Navistar WorkStar 7400, WorkStar 7500 Operator's Manual

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.
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.
WORKSTAR® Series
CALIFORNIA
7300 • 7400 • 7500 • 7600 Models
NOTICE
Important
The information, specifications, and illustrations contained in this manual are based on data that
was current at the time of publication. International reserves the right to make changes and/or
improvements at any time without notification or liability, or without applying those changes or
improvements to vehicles previously manufactured.
August 2010
Printed in the United States of America
© 2010 Navistar, Inc.
All Rights Reserved
3879634R1
Make sure your use of this completed vehicle conforms to all federal, state
and local requirements and regulations imposed on owners and operators.
Operator’s Manual – WORKSTAR® Series
IMPORTANT
IT IS IMPORTANT THAT THE VEHICLE IDENTIFICATION NUMBER (VIN), AND COMPONENT FEATURE CODE AND SERIAL
NUMBERS BE RECORDED. THESE NUMBERS ARE REQUIRED TO OBTAIN INFORMATION PERTINENT TO THIS VEHICLE.
VIN (VEHICLE IDENTIFICATION
NUMBER) LOCATION
®
ENGINE SERIAL NUMBER LOCATION
®
®
LoneStar , 9000i, ProStar®+, TranStar ,
®
®
®
PayStar , WorkStar , DuraStar , and
TerraStar™ Series: Located left door
opening, rear post
COMPONENT IDENTIFICATION
NUMBERS
Component Feature Codes appear on the
vehicle line set ticket.
Component serial numbers appear on the
components.
Feature Code:
Serial Number:
FRONT AXLE
REAR AXLE
TRANSFER CASE
TRANSMISSION
ENGINE
MAXXFORCE : Stamped on pad – right side
of the crankcase, below cylinder head
WORLD HEADQUARTERS
Navistar, Inc.
4201 Winfield Road
Warrenville, Illinois 60555 USA
INTERNATIONAL INTERNET SITE
internationaltrucks.com
SALES REGIONS
MIDWEST
Navistar, Inc.
4201 Winfield Road
PO Box 1488
Warrenville, Illinois 60555
630-753-5900
NORTHEAST
Navistar, Inc.
Cherry Tree Corporate Center
535 Route 38 East, Suite 300
Cherry Hill, New Jersey 08002
856-486-2300
SOUTHEAST
Navistar, Inc.
2400 Commerce Avenue
Building 1100, Suite 100
Duluth, Georgia 30096
678-584-2700
SOUTHWEST
Navistar, Inc.
2595 Dallas Parkway, Suite 203
Frisco, Texas 75034
972-377-1200
WEST
Navistar, Inc.
3017 Douglas Boulevard, Suite 300
Roseville, California 95661
916-774-7526
CANADA
Navistar Canada, Inc.
5500 North Service Road – 4th Floor
Box 5337
Burlington, Ontario L7L 5H7
905-332-3323
MEXICO
Navistar Mexico SA DE CV
Ejército Nacional 904 – 8° Piso
Col, Palmas Polanco 11510 Mexico D.F.
525-262-6666
BRAZIL
International Caminhões do Brasil
Av. Carlos Gomes, 466 conj 1002
Bairro Auxiliadora – CEP 90480-000Porto Alegre/RS
55 51 4009-5800
CUSTOMER ASSISTANCE CENTER
1-800-448-7825 (1-800-44-TRUCK)
Navistar, International, the International Diamond logo, with and without endorsement, WorkStar, and MaxxForce
are registered trademarks of Navistar, Inc., or its subsidiaries, in the United States and other countries.
All other trademarks are the property of their respective owners.
3879634R1
Operator’s Manual – WorkStar® Series
Service Publications
WorkStar® Series
An Operator’s Manual is shipped with this vehicle for
customer use. Information on the purchase of other available
service publications for this vehicle can be found on the
internationaltrucks.com Web site, or by contacting your local
International dealer.
Operator’s Manual – WorkStar® Series
It is the policy of Navistar, Inc. to improve its products whenever
it is possible and practical to do so. We reserve the right to make
changes or add improvements at any time without incurring any
obligation to make such changes on products sold previously.
Operator’s Manual
Form No. 3879634R1
© 2010 Navistar, Inc. All rights reserved.
3879634R1
Printed in the United States of America
Operator’s Manual – WorkStar® Series
Printed in the United States of America
3879634R1
Table of Contents
Section 1 – Foreword
Preface. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
Cautions and Warnings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
Assistance Guide. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
Component Code Numbers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Line Set Ticket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Vehicle Storage Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Storage Duration - One Month or Less. . . . . . . . . . . . . . . . . . . . . . .2
Storage Duration - Over One Month . . . . . . . . . . . . . . . . . . . . . . . . .3
Storage Facilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Exterior Noise Emissions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Tampering with Noise Control System Prohibited. . . . . . . . . . . . . . . .4
Emission Control Systems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Maintenance Record – Noise Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Reporting Safety Defects. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
U.S. Registered Vehicles. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Canadian Registered Vehicles. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Safety Recalls and Authorized Field Changes. . . . . . . . . . . . . . . . . . .5
Customer Security Guide for International Trucks. . . . . . . . . . . . . . .6
Optional Diamond Logic® Electronic Application Solutions. . . . .8
Section 2 – Model Description
Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Available Models. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Available Cabs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Standard Cab. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Extended Cab. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Crew Cab. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Vehicle Identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Vehicle Identification Number (VIN). . . . . . . . . . . . . . . . . . . . . . . . .12
Feature Codes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
3879634R1
Engine Serial Number. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Line Set Ticket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Exterior Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Cab Entry and Exit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Tilt Hood. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Raising the Hood. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Lowering the Hood. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Section 3 – Inspection Guide
Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
General Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
Vehicle Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Preparation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Exterior Lights Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Left Side Cab Area. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
Left Engine Compartment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
Left Front of Vehicle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
Front of Vehicle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
Right Front of Vehicle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
Right Engine Compartment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
Right Side of Cab. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
Right Side Under Vehicle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
Right Rear of Vehicle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
Rear of Vehicle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
Left Rear of Vehicle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
Fifth Wheel and Coupling Area. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
Cab Interior Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
Section 4 – Controls/Features
Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
i
Table of Contents
Electrical. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
Electrical System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
Dash Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
Overhead Console. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
Main Instrument/Control Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
Instrument Panel Gauge Cluster. . . . . . . . . . . . . . . . . . . . . . . . . . . .39
Warning Indicators. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
Gauges. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
Instrument Panel Gauge Cluster Alarms. . . . . . . . . . . . . . . . . . .45
Direct Drive Warning Indicators. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47
Integral Digital Display. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47
Switches. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49
Headlights. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49
Daytime Running Lights (DRL). . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49
Lights on with Wipers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49
Park Lights. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49
Marker Interrupt. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50
Panel Lighting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50
Dome Lighting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50
Courtesy Lights. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50
Optional Instrument panel gauge cluster Compass
Calibration Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52
Compass Declination Zone Set Procedure. . . . . . . . . . . . . . . . .52
Compass Directional Calibration Procedure. . . . . . . . . . . . . . .55
Integral Digital Display Detailed Information. . . . . . . . . . . . . . .56
Steering Wheel Controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .69
Cruise Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .69
Basic Functions of Steering Wheel Controls. . . . . . . . . . . . . . .70
Operational Procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70
Throttle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70
Stationary Variable Speed Control (12VXT). . . . . . . . . . . . . . . .71
Stationary Pre-Set Speed Control (12VXU). . . . . . . . . . . . . . . .71
ii
Mobile Variable Speed Control (12VXV). . . . . . . . . . . . . . . . . . . .71
Steering Column and Switches. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .72
Center Dash Panel/Wing Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .74
Switches. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .75
Auxiliary Gauge/Switch Package (AGSP) (Optional). . . . . . . . . .78
Panel Component Arrangements (Optional). . . . . . . . . . . . . . .78
Climate Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .80
Air Conditioning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .82
Dehumidification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .83
Door and Window Controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .83
Door Lock/Unlock. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .83
Cab Doors and Locks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .83
Remote Keyless Entry Operation (Optional). . . . . . . . . . . . . . .84
Door Opening/Unlock. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .85
Lock/Unlock from Interior. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .85
Automatic Door Lock Function. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .86
Windows. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .86
Manual Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .86
Power Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .86
Window Lockout Function. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .86
Mirror Controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .86
Vent Window. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .87
Driver Reward. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .87
Section 5 – Operation
Operation Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .89
Cab Controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90
Seat Belts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .91
General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .91
Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .92
Care of Seat Belts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .93
3879634R1
Table of Contents
Seats. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .93
Extended Cab Bunk (Optional). . . . . . . . . . . . . . . . . . . . . . . . . . . . . .93
Starting Procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .94
Engine Starting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .94
After the Engine Starts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .95
Engine ShutDown. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .95
Shut-Down Warning Indicator Or Beeper. . . . . . . . . . . . . . . . . . .95
Engine Idle Shutdown Timer (Optional). . . . . . . . . . . . . . . . . . . . .96
System Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .96
Theft Deterrent System (Optional). . . . . . . . . . . . . . . . . . . . . . . . . .96
Theft Deterrent Code Entry Procedures. . . . . . . . . . . . . . . . . . . .97
Emergency Starting Using Jumper Cables. . . . . . . . . . . . . . .100
Cold Weather. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .100
Cold Weather Starting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101
Cold Weather Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101
Winter/Engine Intake Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . .101
Engine Idling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101
Winter Front Usage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .102
Hot Weather Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .102
Starting A Turbocharged Vehicle On A Grade. . . . . . . . . . . .102
Proper Starting Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .102
Operating Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .103
Steering. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .103
Tilt Steering Column. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .103
Adjustable Tilt/Telescoping Steering Column. . . . . . . . . . . . .104
General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .104
Electrical. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .105
Electrical System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .105
Alternator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .106
Ammeter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .106
Battery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .106
Battery Disconnect Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .107
3879634R1
Circuit Breakers, Fuses, and Fusible Links. . . . . . . . . . . . . . .107
Engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .108
Charge Air Cooler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .108
Engine Brake, Retarder (Optional). . . . . . . . . . . . . . . . . . . . . . . . .108
Engine Brake System Operation. . . . . . . . . . . . . . . . . . . . . . . . . . .109
Operational Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .109
MaxxForce® 11 and 13 Engine Brake With Eaton
AutoShift®/UltraShift®
Transmissions
Special
Driver Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .109
Automatic Transmission Operation. . . . . . . . . . . . . . . . . . . . . . . .110
ABS Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .110
MaxxForce® Engine Features. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .110
Certified Clean Idle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .111
Self Diagnostics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .111
Engine Warning/Protection System (EWPS). . . . . . . . . . . . . .111
Optional Coolant Warning Level System – 3 Way
(08WWJ). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .112
Optional Engine Protection System – 3 Way (08WPP). . .112
Air Compressor Cycling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .112
Cooling System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .113
Antifreeze. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .114
Engine Oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .114
Engine Performance Problems. . . . . . . . . . . . . . . . . . . . . . . . . . . . .115
Fuel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .115
Ultra Low Sulfur Diesel Fuel Requirements. . . . . . . . . . . . . . .115
Unacceptable Fuel Blends. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .115
Hazards of Diesel Fuel/Gasoline Blends. . . . . . . . . . . . . . . . . .115
Additional Unsafe Practices. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .115
Fuel and Lubricant Additives. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .116
Fueling Procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .116
Fueling Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .116
Reserve Fuel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .116
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Table of Contents
Exhaust Diesel Particulate Filter Regeneration. . . . . . . . . . .117
Parked Regeneration Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . .119
Regeneration Inhibit Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .119
Two-Position Regeneration Inhibit Switch. . . . . . . . . . . . . . . . .120
Three-Position Regeneration Inhibit Switch. . . . . . . . . . . . . . .120
Transmission. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .120
Manual Transmissions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .120
Engaging the Clutch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .120
Clutch Brake (Vehicles with Nonsynchronized
Transmission) – Vehicle Not Moving. . . . . . . . . . . . . . . . . . . . . . .121
Double Clutch Procedures, Nonsynchronized. . . . . . . . . . . .121
Clutch Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .122
Shifting with Synchronized Transmission. . . . . . . . . . . . . . . . .122
Shifting with Nonsynchronized Transmission. . . . . . . . . . . . .122
Operation of the Eaton AutoShift® Transmission
and Shifter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .122
Eaton UltraShift® Transmissions (Optional). . . . . . . . . . . . . .123
Automatic Transmissions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .123
Allison Transmissions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .123
Allison Transmission with “P” – (Park) Park Pawl
Mechanism or “PB” – Parking Brake Position. . . . . . . . . . . .123
Parking The Vehicle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .124
Preparing to Drive the Vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . .125
Manual Parking Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .125
Air Parking Brake or Power Parking Brake. . . . . . . . . . . . . . .125
Operation of the Allison Generation IV Gearshift
Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .125
Allison Generation IV T-Bar Gearshift Control. . . . . . . . . . . .126
Torque Lock. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .126
Operation of the Allison Generation IV Push-button
Shift Selector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .127
Operation of the Column-Mounted Shifter. . . . . . . . . . . . . . . .128
iv
Main Transmission Controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .128
Backup Alarm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .129
Auto Neutral. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .129
Power Take Off Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .131
Automatic Transmission Operating Temperature. . . . . . . . .131
Rear Drive Axles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .132
Locking Differentials. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .132
Tandem Axle Power Divider Lock (PDL) Control. . . . . . . . .132
Driver-Controlled Differential Lock. . . . . . . . . . . . . . . . . . . . . . . . .133
Controlled Traction Differential. . . . . . . . . . . . . . . . . . . . . . . . . . . . .134
Locking Differential (Optional). . . . . . . . . . . . . . . . . . . . . . . . . . . . . .134
Two Speed Rear Axle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .135
Axle Shift Only. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .135
Split Shifting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .136
Axles and Suspensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .136
Gross Weight (Axle – Vehicle). . . . . . . . . . . . . . . . . . . . . . . . . . . . . .136
Axle Operating Temperature. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .136
Front Axle (4X4, 6X6). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .136
Transfer Case. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .137
Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .137
International® Ride Optimized Suspension (IROS)
(Optional). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .139
Air Suspension Dump (ASD) Switch (Optional). . . . . . . . . .139
Air Suspension System Faults. . . . . . . . . . . . . . . . . . . . . . . . . . . . .140
Axle and Suspension Conversions. . . . . . . . . . . . . . . . . . . . . . . .140
Lift Axle Options. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .140
Lift Axle Locations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .141
Lift Axle Types. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .141
Lift Axle Controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .142
Lift Axle System Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .145
Brakes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .147
Downhill Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .147
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Air Brakes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .148
Air Gauge, Low Air Pressure Beeper and Warning
Indicator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .149
Brake Application. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .149
Parking Brake. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .149
Parking Brake Reset. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .150
Reservoir Moisture Draining. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .151
Air Dryer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .151
Trailer Brake Hand Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .151
Trailer Air Supply and Parking Brake Modular Controls. . .152
Parking Brake Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .153
Parking Brake Alarm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .153
Antilock Brake System (ABS). . . . . . . . . . . . . . . . . . . . . . . . . . . . . .153
ABS Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .154
ABS Self-Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .154
Antilock Driving Tips. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .155
Air Brake Bendix® ABS-6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .155
Core ABS Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .155
Traction Control (If Equipped). . . . . . . . . . . . . . . . . . . . . . . . . . . . . .156
ATC System Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .156
ATC OFF ROAD or MUD/SNOW Switch. . . . . . . . . . . . . . . . . .156
Stability Control Systems – Bendix® ESP. . . . . . . . . . . . . . . .157
Bobtail Proportioning System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .158
Towing Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .158
Towing Vehicle with Front Wheels Suspended. . . . . . . . . . .159
Towing Vehicles with Driver Controlled Differential
Lock. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .160
Removing Axle Shafts Before Towing. . . . . . . . . . . . . . . . . . . . .160
Installing Axle Shafts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .160
Towing Vehicle with Rear Wheels Suspended. . . . . . . . . . . .161
Tractor-Trailer Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .161
3879634R1
Connecting/Disconnecting a Trailer to a Vehicle with
Air Suspension. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .162
Fifth Wheel Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .162
Fifth Wheel Slide Switch (Optional). . . . . . . . . . . . . . . . . . . . . . . .162
Hook-Up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .163
Un-Hook. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .163
Section 6 – Maintenance Instructions
Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .165
Maintenance Guidelines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .165
Supporting Your Vehicle for Service. . . . . . . . . . . . . . . . . . . . . . . . . . . .167
Chassis Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .167
Air Conditioning Service Checks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .168
HVAC Filters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .168
Side Access HVAC Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .168
Front Access HVAC Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .169
Recirculation Filters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .169
Axles. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .170
Front Axle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .170
Inspection and Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .170
Normal Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .170
Alignment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .171
Front Drive Axle and Transfer Case (Optional) . . . . . . . . . .171
Inspection and Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .171
Rear Axle – Inspection and Lubrication. . . . . . . . . . . . . . . . . . .171
Lift Axle System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .171
Brakes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .172
General Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .172
Air Brakes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .173
Inspection and Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .173
Air Dryer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .174
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Table of Contents
General Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .174
Desiccant Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .175
Purge Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .175
Heater. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .175
Air Reservoir/Tanks Moisture Draining. . . . . . . . . . . . . . . . . . . .175
ABS Connections and Sensors. . . . . . . . . . . . . . . . . . . . . . . . . . . .176
Cab. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .176
Care of Vehicle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .176
Washing and Waxing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .176
Bright Metal Care. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .176
Upholstery Care. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .176
Exposed Rubber and Unpainted Plastic Parts. . . . . . . . . . . .176
Clutch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .177
Pedal Free-Travel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .177
Electrical. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .177
Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .177
Battery Cables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .178
Electrical Charging and Starting System Test. . . . . . . . . . . .178
Terminal Inspection-Cleaning-Corrosion Protection. . . . . .178
Accessory Feed Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .179
Fuses and Relays. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .179
Engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .179
General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .179
Engine fluids and contaminated material. . . . . . . . . . . . . . . . . .180
Scheduled Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .180
Air Induction System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .180
Air Restriction Gauge. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .181
Air Cleaner Element Service. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .182
Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .184
Charge Air Cooler And Radiator Core Inspection
And Cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .185
Inspection and Cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .185
vi
Cooling System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .185
Coolant Level. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .185
Filling Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .186
Filling Instructions (MaxxForce® 11 and 13 Engines). . .187
Coolant and Optional Coolant Filter. . . . . . . . . . . . . . . . . . . . . . .188
AntiFreeze. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .189
Fan Clutch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .189
Fuel System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .189
Fuel Tank Draining and Cleaning. . . . . . . . . . . . . . . . . . . . . . . . . .189
Frame. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .190
Tow Hooks, Tow Pins, and Pintle Hooks. . . . . . . . . . . . . . . . . .190
Noise Emissions – Exterior. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .190
Instructions for Proper Maintenance. . . . . . . . . . . . . . . . . . . . . . .190
Air Intake System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .190
Body. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .190
Cooling System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .190
Engine Noise Shields/Blankets. . . . . . . . . . . . . . . . . . . . . . . . . . . . .191
Exhaust System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .191
Diesel Particulate Filter (DPF). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .191
Regeneration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .191
Cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .191
Transmission. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .191
Neutral Start Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .191
Manual/Automated Manual Transmissions. . . . . . . . . . . . . . .191
Automatic Transmissions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .192
Drive Shafts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .192
Suspension (Air and Steel Springs). . . . . . . . . . . . . . . . . . . . . . . . . . . .192
Steering. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .192
General Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .192
Tightening Steering Intermediate Shaft Joint Bolts. . . . . . .193
Lubrication Points. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .193
Power Steering. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .194
3879634R1
Table of Contents
Tires. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .194
Tire Warnings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .194
Tire Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .195
Checking Inflation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .196
Underinflation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .196
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .196
Loads. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .197
Dual Tires Matching. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .197
Dual Tires Mixing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .197
Rotation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .197
Rotation Is Advisable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .197
Tire Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .198
Wheel and Tire Balancing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .198
Wear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .198
Irregular Wear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .199
Use of Tire Chains. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .199
Wheels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .199
Wheel and Wheel Nut Maintenance and Installation. . . . .199
Wheel Nut Torque Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . .200
Hub-Piloted Wheel Installation Procedures. . . . . . . . . . . . . . .200
Unit Refill Capacities. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .214
Front Drive Axles. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .214
Rear Axle Unit Refill Capacities. . . . . . . . . . . . . . . . . . . . . . . . . . . .214
Cooling System Refill Capacities. . . . . . . . . . . . . . . . . . . . . . . . . .216
Crankcase and Oil Filters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .216
Power Steering Systems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .216
Transfer Case. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .216
Transmission. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .217
Tire and Rim Combinations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .218
Approved Tire and Rim Combinations. . . . . . . . . . . . . . . . . . . . .218
Lift Axle System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .219
Torque Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .219
Disc Wheel Torque Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .219
U-Bolt Nut Torque Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .221
Spring U-Bolt Checks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .223
Lift Axle Torque Charts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .223
Fuse Charts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .224
WorkStar® Series Light Information. . . . . . . . . . . . . . . . . . . . . . . . . . . .225
Filter List. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .225
Section 8 – Customer Assistance
Section 7 – Maintenance Intervals And
Specifications
Lubrication and Maintenance Intervals . . . . . . . . . . . . . . . . . . . . . . . .203
Maintenance Intervals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .203
Lubrication and Fluids Charts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .211
Components Requiring Lubrication. . . . . . . . . . . . . . . . . . . . . . . .212
Components Requiring Fluid Check and Fill. . . . . . . . . . . . . .213
3879634R1
Service Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .227
International Truck Warranty Program. . . . . . . . . . . . . . . . . . . . . . . . .227
Section 9 – Index
Index. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .229
vii
Table of Contents
viii
3879634R1
Foreword
SECTION 1 — FOREWORD
Preface
Your vehicle has been engineered and manufactured so that it
can provide economical and trouble-free service. However, it is
the owner’s responsibility to see that the vehicle receives proper
care and maintenance.
Making modifications to various parts, components, and
systems of your vehicle, such as brake, suspension, and
steering systems, can adversely affect the quality and reliability
of your vehicle. Such modifications must be avoided.
Cautions and Warnings
Throughout this manual, you will find Cautions and Warnings:
WARNING
Warnings advise you of hazards,
the
consequences, and what to do to prevent
them, not only to prevent damage to your vehicle
or property, but to help prevent situations and
occurrences, which could result in personal
injury or death.
CAUTION
Cautions will advise you of the proper care to
be taken to prevent damage to your vehicle or
property.
3879634R1
Study this manual carefully. Do not operate your vehicle until you
are completely familiar with the contents of this manual. Always
retain this manual in your vehicle for reference. If you sell the
vehicle, make sure the manual goes with it.
Assistance Guide
When parts are required, always provide the unit code number,
vehicle model, and vehicle serial number.
Request the
salesperson to assist you in obtaining this information upon
delivery.
For information not given in this manual, or if you require
services of trained service personnel, we urge you to contact a
nearby International dealer or phone 1-800-44-TRUCK (87825)
for assistance.
Every customer is entitled to the best service, both from the
product itself and from the firm that sells and services that
product.
If, for any reason, you do not feel you are receiving these
services in connection with the operation of your vehicle or
the sales transaction, you should return to your selling dealer,
so that these matters can be corrected to your satisfaction. If
the matter is not resolved at that time, it is suggested that the
following steps be taken:
Contact a Member of Management at the Dealer.
Discuss the details of the difficulty. In most instances, any
problem can be resolved to your satisfaction by the owner or
manager in charge.
1
Foreword
Contact Closest Navistar, Inc. Regional Sales Office.
Line Set Ticket
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:
Each vehicle is provided with a Line Set Ticket (code sheet),
which lists identification code numbers of component units used
to build the vehicle.
•
Name under which new vehicle was purchased, address,
and telephone number of purchaser
•
Vehicle model, year, vehicle identification
component code, and serial number
•
Vehicle delivery date and present mileage
•
Location where purchased
•
Details of the problem
number,
Component Code Numbers
Code numbers are the basis for identifying the components used
on International trucks. They are used by sales personnel to
order the truck, by manufacturing to build that truck, and by parts
personnel to service the truck. Many items in this manual are
identified by codes.
Code numbers are a combination of numbers and/or letters.
These codes are listed on the Line Set Ticket, which is
sometimes known as the vehicle specification card or code
sheet.
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.
2
3879634R1
Foreword
NOTE: Washing Instructions - Wash the vehicle with warm water
and mild soap, then wipe wet surfaces with a chamois or soft
cloth. DO NOT use hot water or strong soaps or detergents. DO
NOT wash the vehicle in direct sun, or when the sheet metal is
hot to the touch. This will streak the finish. DO NOT wipe dirt off
dry surfaces, as this will scratch the finish.
8. Check state of charge eye in batteries and re-charge if
open circuit voltage is below 12.6 volts. Disconnect battery
ground cables to prevent accidental starting, or parasitic
electrical loads from discharging the battery.
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.
Units in storage longer than one month should be driven until the
engine reaches operating temperature:
Storage Duration - Over One Month
1. Insure all tires are inflated properly, remove vertical exhaust
stack covers and reconnect batteries.
2. Check all vehicle fluid levels and fill as required.
NOTE: For vehicles exposed to ultraviolet rays of the sun, apply
a coating of Bon-Ami® soap, or similar product, to the inside
surfaces of the windshield and windows, to shade the interior
and prevent fading of the interior trim.
2. Inspect painted surfaces; touch up all exposed primed or raw
metal areas to prevent rust.
3. a thick coat of wax to prevent discoloration from the
elements; wax all chrome and stainless steel metal parts.
4. Check the radiator coolant for proper level and adequate
freeze protection [-20°F (-29°C) is standard for medium duty
models and bus chassis, -40°F (-40°C) is standard for heavy
duty models].
5. Cover open ends of vertical exhaust stack(s).
3. Start and run the vehicle at fast idle, until it reaches operating
temperature. To remove surface charge from the battery,
built up from previous start-ups and short idle periods,
operate the heater and/or air conditioner, headlights and
other accessories for several minutes.
4. Turn off heater and/or air conditioner and any other
accessories; shut off the headlights. Park the vehicle and
shut off the engine.
5. Perform the procedure for Storage Duration - One Month
or Less, if returning the vehicle to storage.
NOTE: After every 30 additional days of storage, perform Items
1 through 5.
6. Drain air brake reservoirs and close the drain cocks.
7. Lubricate all exposed transmission, auxiliary transmission
and PTO shift rails.
3879634R1
3
Foreword
Storage Facilities
A. Whenever possible, store vehicles indoors, protected
from sunlight, in a dry, well ventilated area. If indoor
storage is not available, select storage lots to eliminate
conditions that cause deterioration.
B. Park away from transformers and/or electrical motors,
because when the protective wax in tire compound
cracks, ozone in the air attacks the exposed areas.
C. Park away from trees, high weeds and/or grass to
prevent damage from tree or weed sap, and to minimize
bird and insect stains.
D. Park away from railroad tracks, paint shops, smoky
industrial areas, and locations of possible road splash
contact.
E. If a vehicle is parked on an incline, block the wheels.
Exterior Noise Emissions
Many operators and owners of the type of vehicles described
herein are subject to Federal Motor Carrier Safety Regulations
and Noise Emission Requirements. All owners and operators
are urged to obtain a copy and comply with these regulations.
Copies of these regulations can be purchased from:
Superintendent of Documents
U.S. Government Printing Office
Washington, D.C. 20402
Navistar, Inc. warrants to the first person who purchases this
vehicle for purposes other than resale and to each subsequent
4
purchaser that this vehicle, as manufactured by Navistar, Inc.,
was designed, built, and equipped to conform at the time it left
Navistar, Inc. control with all applicable U.S. Environmental
Protection Agency Noise Control Regulations.
This warranty covers this vehicle as designed, built, and
equipped by Navistar, Inc. and is not limited to any particular
part, component, or system of the vehicle manufactured by
Navistar, Inc. Defects in design, assembly, or in any part,
component, or system of the vehicle as manufactured by
Navistar, Inc., which at the time it left Navistar, Inc. control,
that cause noise emissions to exceed Federal standards are
covered by this warranty for the life of the vehicle.
Tampering with Noise Control System Prohibited
Federal law prohibits the following acts or the causing thereof:
(1) The removal or rendering inoperative by any person, other
than for purposes of maintenance, repair, or replacement, of
any device or element of design incorporated into any new
vehicle for the purpose of noise control prior to its sale or
delivery to the ultimate purchaser or while it is in use, or (2) The
use of the vehicle after such device or element of design has
been removed or rendered inoperative by any person. Among
those acts presumed to constitute tampering are the acts listed
as follows: A. Air Intake System: Removal of air cleaner,
intake silencer, or piping. B. Acoustical Shielding (Body):
Removal of wheel well splash shields, cab shields, or acoustical
(underhood) insulation. C. Cooling System: 1. Removal or
rendering inoperative the fan clutch. 2. Removal of fan shrouds.
D. Engine and Driveline System: 1. Removal or rendering
engine speed governor inoperative so as to allow engine speed
to exceed manufacturer specifications. 2. Removal of engine
3879634R1
Foreword
block shield, oil sump shield, or transmission enclosures. E.
Exhaust System: Removal or rendering inoperative exhaust
system components, including muffler, resonator, or tailpipe.
Use the following Maintenance Record – Noise Control form to
log Noise Emission Maintenance of, at a minimum, the above
systems.
Emission Control Systems
NOTE: Federal and California emission system warranties are
found in your Engine Operation and Maintenance Manual.
Maintenance Record – Noise Control
(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
Chassis Model:
Maintenance
Performed
Vehicle Identification Number:
Maintainer
(Name)
Location
Date
If you believe that your vehicle has a defect, which could cause
a crash or could cause injury or death, you should immediately
contact Navistar, Inc. Canada and then Transport Canada.
To contact Navistar, Inc.
Canada, you may either call
the Regional Service Manager (Canadian Sales Region)
905-332-2357 or write to: Navistar, Inc. Canada, 5500 North
Service Road, Box 5337, Burlington, Ontario L7L 5H7.
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
3879634R1
To contact Transport Canada, Defect Investigations and Recalls,
you may call 1-800-333-0510 or write to: Transport Canada,
ASFAD, Place de Ville Tower C, 330 Sparks Street, Ottawa,
Ontario K1A 0N5.
Safety Recalls and Authorized Field Changes
Safety Recalls and Authorized Field Changes are two
campaigns that are used to notify owners of modifications
5
Foreword
that may involve 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.
Add Layers of Protection
Customer Security Guide for International Trucks
This guide has been prepared to help you protect your vehicle
investment from theft. We realize the financial commitment you
have made is significant, and that you depend on that vehicle
to generate profits and a livelihood. Vehicle theft can be more
than an economic crime. Protecting your vehicle from theft
or hijacking can be crucial to the safety and security of the
country and economy. While no system or device is 100 percent
effective, our intention is to provide some tips that you or your
drivers can use to reduce the risk of theft.
If you suspect vehicle theft activity, take a minute to tell the
National Insurance Crime Bureau (NICB) at 1-800-TEL-NICB.
You can make the free call anonymously, and you might
be eligible for a reward. To learn more about vehicle theft
and how you can protect yourself, visit the NICB’s Web site,
www.nicb.org.
6
Four layers of protection are recommended for your vehicle - the
more layers of protection on your vehicle, the more difficult it is
to steal.
Layer 1: Common Sense
•
Lock your doors.
•
Remove your keys from the ignition.
•
Close your windows completely.
•
Park in well-lit areas.
•
Drop a business card with your name on it between the glass
and doorframe. This can aid in identifying the truck when it’s
recovered.
•
Keep a copy of the lineset ticket in a location other than your
truck for reporting purposes and a copy of the VIN in your
wallet.
•
Photograph the interior and exterior of your truck from
various angles and keep these photographs in a safe
nontruck location or send them to your insurance agent.
•
Report a theft as soon as it’s discovered to the local police
and to your insurance company.
•
Post a driver has no cash sign on your door to discourage a
robbery.
•
Permanently mount your CB radio or remove it when you will
be away from your truck.
3879634R1
Foreword
•
Do not discuss where your vehicle is located when you are
not on the road.
•
Do not share information about your specific destination or
the load you are hauling.
•
Be conscious of other vehicles that may be following you
over long distances - call the police.
•
Be suspicious of motorists that are signaling you to stop or
pull over. Call the police, report the incident, and let the
police respond.
Layer 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:
Layer 2: Visible or Audible Device
License Number:
•
Audible alarm system
Insurance Company:
•
Steering wheel locks
•
Steering column collars
•
Theft deterrent decals
•
Wheel locks
•
Window etching
•
Mechanical or electronic steering locks that restrict the
steering shaft U-joint are easy to use and provide a very
high level of affordable theft protection.
Policy Number:
Phone Number:
Other:
Layer 3: Vehicle Immobilizer
A. Fuse cutoffs
B. Kill switches
C. Starter, ignition, and fuel disablers
D. Fuel cutoff switch
3879634R1
7
Foreword
Optional Diamond Logic® Electronic Application
Solutions
WARNING
This vehicle may be equipped from the factory
with electrical switches intended to operate
equipment that was installed by a truck
equipment manufacturer (TEM). Instructions,
Cautions, and Warnings for this additional
equipment will NOT be found in this manual.
Read and understand the appropriate manual
for the specific equipment in question before
operating. Failure to observe this warning may
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.
8
3879634R1
Model Description
SECTION 2 — MODEL DESCRIPTION
Introduction
Available Models
The WorkStar® Series Truck is available in a variety of models,
including the WorkStar® Series Deluxe and the WorkStar®
Series Premium. The WorkStar® Series is available in three
cab models, including the standard cab, extended cab, and the
crew cab.
4x2
This operator’s manual covers all versions. Illustrations in this
manual are used for reference only, and may differ slightly from
the actual vehicle. However, key components addressed in
the manual are represented as accurately as possible. Models
covered are shown on the following pages.
The 4x2 configuration includes these models 7300, 7400, 7500,
7600.
3879634R1
9
Model Description
6x6
4x4
The 6x6 configuration includes these models 7400, 7500.
The 4x4 configuration includes these models 7300, 7400, 7500.
6x4
The 6x4 configuration includes these models 7400, 7500, 7600.
10
3879634R1
Model Description
Available Cabs
Extended Cab
The WorkStar® Series Truck is available with a standard cab,
extended cab, or crew cab. Each cab has its own unique
features and uses.
Standard Cab
Crew Cab
3879634R1
11
Model Description
Vehicle Identification
personnel to service the truck. Many items in this manual are
identified by codes.
Feature Codes are a combination of numbers and/or letters.
These codes are listed on the Line Set Ticket, which is
sometimes known as the vehicle specification card or code
sheet.
Engine Serial Number
The engine dataplate provides the engine serial number as
well as other engine information. For the location of this plate
and more information about engine components and engine
identification, refer to the Engine Operation and Maintenance
Manual.
Line Set Ticket
NOTE: Be sure to return the Line Set Ticket to the vehicle after
obtaining parts.
Vehicle Identification Number (VIN)
The Vehicle Identification Number (VIN) is located on the driver
side door. The VIN and model description are necessary when
ordering replacement parts or service manuals.
Feature Codes
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.
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
12
3879634R1
Model Description
Exterior Components
1. Headlight
2. Door Latch
3. Fuel Cap
4. Side Marker/Turn Light
5. Bumper
6. Fog Light
1. Glad Hand Storage Bracket
2. Work Light
3. Side Marker/Turn Light
4. Fuel Cap
5. Taillights
3879634R1
13
Model Description
Tilt Hood
Cab Entry and Exit
WARNING
WARNING
Do not step or climb upon any vehicle surface
unless it is slip-resistant and a handhold is
provided. Failure to follow this warning could
cause you to slip or fall and could result in
personal injury or death.
WARNING
A three-point stance should be used (three out
of four extremities should be in contact with
the vehicle climbing system) at all times. Face
inward towards the cab when entering and
exiting. Always keep steps and handholds in
continuous good repair. Make sure all attaching
bolts and hardware are tight, thus eliminating
any movement of steps and handholds. Keep
steps, grab handles and shoes free of grease,
mud, dirt, fuel, ice and snow. Use extra care
during inclement weather. Failure to follow this
warning could cause you to slip or fall and could
result in personal injury or death.
To prevent personal injury or death, never put
any part of your body beneath a raised hood
unless the hood is all the way forward in its
range of motion and is fully settled in the over
center position.
Raising the Hood
1. Before opening the hood, make sure that there is enough
room in front of the vehicle for the hood to open completely
without pinning or pinching yourself between the hood and
any other structures.
2. Release the latches on both sides of the cowl.
3. Grasp the hood handle and pull the hood forward over center
and allow it to settle into the raised position.
4. Make certain that hood is resting in the open position before
releasing hood.
Lowering the Hood
1. Make sure that the hood has no tools/parts/people in its path
of motion.
2. Grasp the hood handle and push the hood backward over
center and allow it to settle into lowered position.
3. Engage latches at both sides of cowl.
14
3879634R1
Inspection Guide
SECTION 3 — INSPECTION GUIDE
Introduction
WARNING
General Information
WARNING
To prevent property damage, personal injury or
death when servicing the vehicle, park on a flat
level service, set the parking brakes, turn the
engine off, and chock the wheels.
WARNING
Exercise care when 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.
3879634R1
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.
15
Inspection Guide
Vehicle Inspection
Preparation
NOTE: Perform the following procedures prior to conducting the
pre-trip inspection.
•
Apply parking brakes.
•
Turn on parking lights and hazard lights.
•
Unhook the hood latches and raise the hood.
•
Check under the vehicle for oil, fuel, coolant leaks, or other
signs of damage.
•
Use pull cables or open drain cocks to allow air tanks to expel
any existing water. Release pull cables or close drain cocks.
•
Chock wheels on tractor and trailer, if attached.
•
Start the engine and allow the air pressure to build up to
normal operating pressure of 115 to 130 psi (793 to 896
kPa). Stop engine.
Exterior Lights Check
The optional LMP check switch is used to perform the exterior
lights check in the following manner:
2. Press the optional LMP check switch to activate the
system.
3. The exterior light check will now cycle all vehicle lights
except the back-up light(s). The test flashes the exterior
lights ON and OFF in three, 2-second cycles. The
first 2-second period illuminates park lights (clearance,
identification, side marker and license plate lights),
turn signal lights, low beam headlights, fog lights.
The second 2-second period illuminates park lights
(clearance, identification, side marker and license plate
lights), high beam headlights, brake lights, work lights.
The third 2-second period turns OFF all lights. This
cycle repeats until deactivated by the operator.
4. Walk around vehicle and inspect illumination of lights.
5. To cancel this feature, do one of the following: either
press the brake pedal, manually turn ON any external
light, turn the ignition switch to OFF or CRANK,
depress the exterior light check switch, or release
the parking brake.
The feature will automatically
cancel approximately 10 minutes after activation if not
deactivated by the operator.
6. Checking the backup lights requires two people and
the engine running. Depress the clutch (if applicable)
and select reverse while the second person observes
backup light operation.
1. Place the ignition switch in the ON or ACC position,
place the transmission in (N) Neutral, and apply the
Parking Brake.
16
3879634R1
Inspection Guide
Left Side Cab Area
1. Cab Structure: Check body panels such as doors,
air shield, sunshade, and cab for signs of breaks or
damage. Check condition of cab mounting brackets
and tilt hood latches.
2. Wipers: Check windshield wiper arms for proper spring
tension and wiper blades for damage.
3. Windshield: Check for damage to windshield and clean
if dirty.
4. Battery Box: Inspect for damage and secure mounting
of battery box. Remove battery box cover.
5. Batteries and Cables: Check that batteries are secured
and cases are not broken or leaking. Ensure cables are
free from damage. Tops of batteries and terminals must
be clean and free from foreign material. Replace battery
box cover.
6. Fuel Tank: Check to see that the fuel tank(s) and cap(s)
are secured and make sure there is no damage or leaks
at the tank(s) or fuel lines. Insure mounting straps are
secure and not chafing tank.
3879634R1
17
Inspection Guide
Left Engine Compartment
3. Brake Fluid Level (if equipped): During normal vehicle
operation and servicing, the fluid level will vary between
the “MIN” and “MAX” lines on the master cylinder
mounted “front” reservoir. Do not fill the master cylinder
to the top of the reservoir. Over filling may lead to
overflow. DO NOT add fluid above MAX line.
4. Oil Level: Use dipstick to verify that the oil level is
between the full and add marks.
5. Windshield Washer Fluid Level: Inspect the reservoir
and verify that the fluid level is not empty and has
enough fluid to accomplish the upcoming mission. If
additional fluid is required, see Lubricant and Sealer
Specifications chart, in the Specification section, for
the correct fluid type before filling. Do not use water in
freezing climates.
1. Power Steering Fluid: Verify that the fluid level is
between the Cold or Hot (as applicable) MIN and MAX
marks.
2. Coolant Level: Do not remove pressure cap unless
coolant is cool. Ensure fluid level is between the
minimum and maximum fluid level range as marked on
the plastic translucent reservoir or sight glass .
18
6. Radiator and Charge Air Cooler: Check for loose
mounting and damage. Inspect condition of all hoses
for damage, cracks, and leaks. Inspect for foreign
material on face of cooling package. Carefully brush
away collected materials without bending cooling fins to
maintain proper airflow through cooling package.
3879634R1
Inspection Guide
•
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. Check for
leaks.
•
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.
Left Front of Vehicle
Check that the air dryer heater activates at temperatures
below freezing. With the vehicle in a cold environment and
before the engine is started, turn on the ignition and touch
the air dryer housing. It 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.
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.
3879634R1
19
Inspection Guide
WARNING
Do not operate vehicle if any of the following
conditions are evident. Loss of steering or
suspension could cause loss of vehicle control
and result in property damage, personal injury,
or death.
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.
CAUTION
Retread tires are not recommended for use on
steering axles of trucks.
20
1. Steering Gear: Look for missing or loose fasteners,
power steering fluid leaks, and damage to power
steering hoses.
2. Brake Chamber and Hoses: Check to see that the
brake chambers are not cracked or damaged, and are
securely mounted. Check for broken, loose, or missing
parts. Check for cracked, worn or frayed hoses, and for
secure couplings.
3. 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.
4. 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.
5. 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.
6. Shock Absorber: Check for cracks, leaks, and missing
or broken mounting bolts or bushings.
3879634R1
Inspection Guide
7. Air Suspension (if equipped): Check for air leaks, loose
components, and damage to air bag. Inspect stabilizer
bar for worn, loose, or damaged components.
8. Tires: Check tread depth and 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, mounted on the same wheel
end, are evenly separated and that tire sidewalls are not
touching one another.
10. Hub: Check for obvious leaks on outside or inside of
wheel. Verify correct oil level in hub.
11. Frame: Check for cracks or bends in frame. Make sure
there are no loose, cracked, bent, broken, or missing
crossmembers or fasteners.
12. Steering Linkage: Inspect connecting links, arms, rods,
and steering intermediate shaft for worn, damaged,
loose, or missing components.
9. Wheel and Wheel Nuts: Check for damaged or bent
wheel. Check to see that all wheel nuts are present and
not loose (look for rust trails around nuts). Ensure that
no cracks or damage are present at wheel mount holes.
3879634R1
21
Inspection Guide
Front of Vehicle
1. Bumper: Inspect for damage and security.
2. Grille: Inspect for damage and security. Check bug
screen for damage and cleanliness.
3. Headlights: Lenses should be clean. If equipped, check
daytime running lights.
4. Hood and Fenders: Check hood panels and fenders for
signs of breaks or damage. Ensure hood opens and
closes properly.
5. Lighting System: Lower hood and inspect parking,
clearance, identification lights, turn signals, fog lights,
and reflectors on hood, bumper, and cab. They should
be clean, operational and the proper color Inspect for
damage and security.
22
3879634R1
Inspection Guide
Right Front of Vehicle
WARNING
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.
WARNING
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 fire
which could cause property damage, personal
injury, or death.
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.
3879634R1
23
Inspection Guide
4. Frame: Check for cracks or bends in frame. Make sure
there are no loose, cracked, bent, broken, or missing
crossmembers or fasteners.
5. 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.
6. 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.
7. 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.
24
8. Hub: Check for obvious leaks on outside or inside of
wheel. Verify correct oil level in hub.
9. Wheel and Wheel Nuts: Check for damaged or bent
wheel. Check to see that all wheel nuts are present and
not loose (look for rust trails around nuts). Ensure that
no cracks or damage are present at wheel mount holes.
10. Tires: Check tread depth and 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, mounted on the same wheel
end, are evenly separated and that tire sidewalls are not
touching one another.
11. Steering Linkage: Inspect connecting links, arms, and
rods for worn, damaged, loose, or missing components.
3879634R1
Inspection Guide
Right Engine Compartment
2. Air Cleaner: Check air cleaner element, housing, and
hoses for loose connections or damage. Check filter
minder gauge for restriction reading. For element
replacement, see Air Cleaner Element Service in the
Maintenance section.
3. 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
4. Radiator and Charge Air Cooler: Check for loose
mounting and damage. Inspect condition of all hoses
for damage, cracks, and leaks. Inspect for foreign
material on face of cooling package. Carefully brush
away collected materials without bending cooling fins to
maintain proper airflow through cooling package.
1. Cowl Vent: Ensure air inlet cover is free of dirt and
debris.
3879634R1
•
Air Lines and Wiring: Check air Lines and electrical wiring
for proper security, damage, and chafing. Listen for audible
air leaks.
•
Leaks: Check for signs of fluid puddles under vehicle, or wet
components in the engine compartment.
25
Inspection Guide
Right Side of Cab
CAUTION
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.
1. Cab Structure: Check body panels such as doors,
fenders, and cab for signs of breaks or damage. Check
condition of cab mounting brackets and tilt hood latches
and where the torsion bars are mounted to hood.
2. 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, fuel lines, or tank mounting hardware is secure
.
26
3879634R1
Inspection Guide
Right Side Under Vehicle
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 may cause vehicle
malfunction that could result in property damage,
personal injury, or death.
1. Frame: Check for cracks or bends in frame. Make sure
there are no loose, cracked, bent, broken, or missing
crossmembers or fasteners.
2. Exhaust System: Check to see that all component parts
are securely mounted and no cracks, holes, or severe
dents are visible. 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.
3. Transmission: Inspect for leaks.
4. Drive Shaft: Ensure that all shaft couplings are secure.
•
3879634R1
Air Lines and Wiring: Check air Lines and electrical wiring
for proper security, damage, and chafing. Listen for audible
air leaks.
27
Inspection Guide
1. 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.
Right Rear of Vehicle
2. Slack Adjuster: Check slack adjuster and chamber
push rod travel. When pulled by hand, push rod
should not move more than approximately one inch.
Angle between push rod and adjuster arm should be
approximately 90 degrees when brakes are applied.
3. Brake Lining and Drum: With brakes released, check
to see that brake linings (where visible) are not
worn excessively thin [less than 1/4 inch (6mm)] or
contaminated by lubricant.
WARNING
4. Wheel and Wheel Nuts: Check for damaged or bent
wheel. Check to see that all wheel nuts are present and
not loose (look for rust trails around nuts). Ensure that
no cracks or damage are present at wheel mount holes.
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.
28
3879634R1
Inspection Guide
8. 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.
5. Tires: Check tread depth and 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, mounted on the same wheel
end, are evenly separated and that tire sidewalls are not
touching one another.
6. 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.
7. Spring Suspension: Check condition of spring for
cracks, breaks, or shifting. Inspect spring hanger
fasteners, shackles, U-bolts, and nuts for wear, damage,
and tightness.
3879634R1
9. Air Suspension (if equipped): Check for air leaks, loose
components, and damage to air bag. Inspect ride height
valve and linkage for damage.
10. Frame: Check for cracks or bends in frame. Make sure
there are no loose, cracked, bent, broken, or missing
crossmembers or fasteners.
•
Air Lines and Wiring: Check air lines and electrical wiring for
proper security, damage, and chafing. Listen for audible air
leaks.
29
Inspection Guide
Rear of Vehicle
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 fasteners.
3. Mud flaps: Inspect rear mud flaps and mountings for
damage and proper security.
•
30
Air Lines and Wiring: Check air Lines and electrical wiring
for proper security, and for damage, and chafing. Listen for
audible air leaks.
3879634R1
Inspection Guide
Left Rear of Vehicle
WARNING
Due to tire manufacturers re-marking tires to
conform to the SI (metric) system, tires marked
with old and new loads or inflation pressures
could be placed on the same vehicle. For 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.
1. 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.
2. Slack Adjuster: Check slack adjuster and chamber
push rod travel. When pulled by hand, push rod
should not move more than approximately one inch.
Angle between push rod and adjuster arm should be
approximately 90 degrees when brakes are applied.
3. Brake Lining and Drum: With brakes released, check
to see that brake linings (where visible) are not
worn excessively thin [less than 1/4 inch (6mm)] or
contaminated by lubricant.
4. Frame: Check for cracks or bends in frame. Make sure
there are no loose, cracked, bent, broken, or missing
crossmembers or fasteners.
3879634R1
31
Inspection Guide
5. Wheel and Wheel Nuts: Check for damaged or bent
wheel. Check to see that all wheel nuts are present and
not loose (look for rust trails around nuts). Ensure that
no cracks or damage are present at wheel mount holes.
8. 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.
6. 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.
9. 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.
7. 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.
32
10. Air Suspension (if equipped ) Check for air leaks, loose
components, and damage to air bag. Inspect ride height
valve and linkage for damage.
•
Air Lines and Wiring: Check air Lines and electrical wiring
for proper security, damage, and chafing. Listen for audible
air leaks.
3879634R1
Inspection Guide
Fifth Wheel and Coupling Area
1. Trailer Coupling Cords: Inspect air lines and coupling
gaskets, electrical cord for cuts, chafing, damage, and
proper security. Check air lines for audible air leaks .
2. Work Light(s): Check operation and clean as needed.
3. Lubrication: Make sure that top surface (face) of the 5th
wheel has a coat of grease.
4. Mounting Bolts and Release Handle: Look for loose
or missing mounting brackets, clamps, bolts, or nuts.
All locking pins must be in place and free of damage.
Ensure that release handle is in the engaged position
and the safety latch is functioning and free of damage.
5. 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.
3879634R1
33
Inspection Guide
Cab Interior Inspection
1. Safety/Emergency Equipment:
Prior to entering
cab, verify that vehicle is equipped with 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.
2. Doors: Check door latches for positive closing, latching
and locking.
3. 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.
4. 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.
34
7. Voltmeter: Check the gauge to see if the alternator is
charging between 12.5 and 14.5 volts.
8. Steering Play: Check for smooth operation. Check
for excessive looseness in the steering linkages. The
steering wheel should have less than 10 degrees free
play (approximately 2 inches at rim of 18 inch steering
wheel).
9. 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.
10. Horn(s): Check to see that horn(s) operate properly.
11. Mirrors: Check mirrors for proper adjustment, damage,
cleanliness, and proper mounting. Check (optional)
power mirrors and (optional) heated mirrors for proper
operation.
5. 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 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).
12. Doors: Ensure windows are clean and operate properly
and smoothly in both doors.
6. 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.
15. 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.
13. Windshield and Wipers: Check windshield for cracks,
dirt, illegal stickers or other obstructions to view. Ensure
wipers and windshield washer are functioning properly.
14. Lighting Indicators: Check to see that dash indicators
illuminate when corresponding lights are turned on.
3879634R1
Inspection Guide
16. Air Brake Check: Check the air brakes in the following
manner:
a. Chock wheels if necessary. Push in parking
brake and start engine.
b. Check for air compressor or governor cutout 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 hold.
c.
Shut off engine and TURN IGNITION BACK
ON.
d. Without brake pedal applied, note air
pressure drop for one minute. It should
be less than 2 psi (14 kPa).
e. Depress and hold brake pedal and make
sure there is no more than a 3 psi (21 kPa)
per minute pressure drop. For combination
vehicles, there should be no more than 4 psi
(28 kPa) per minute pressure drop.
f.
Step on and off brake pedal and check that
warning light and alarm come on at about
60 or 76 psi (414 or 524 kPa).
g. 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).
3879634R1
35
Inspection Guide
36
3879634R1
Controls/Features
SECTION 4 — CONTROLS/FEATURES
Introduction
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, and
Vehicle Information Display.
Electrical
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.
3879634R1
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.
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 provides interfaces to a majority of vehicle switches
and sensors and communicates with the standard and optional
system controllers and modules in the vehicle.
37
Controls/Features
Dash Components
Overhead Console
This vehicle is equipped with an overhead console that provides
both dome lighting and storage facilities. The overhead storage
capacity consists of two netted storage bins large enough to
place many items (one for the driver and one for the passenger).
1. Instrument Panel Gauge Cluster
2. Center Dash Panel/Wing Panel
3. Fuse Panel Cover
4. Ashtray
5. Cup Holder
6. Ignition Switch
7. Lower Panel Switches
1. Storage pockets
2. Sun Visors
3. Dome Lamp Switch
4. Optional Compass/Temperature Display
38
3879634R1
Controls/Features
Main Instrument/Control Panel
Instrument Panel Gauge Cluster
The instrument panel gauge cluster includes the instrument
gauges, warning indicators, and an Integral Digital Display, that
3879634R1
provide odometer, transmission gear indication, and compass
heading and outside temperature displays. This instrument
panel gauge cluster displays the crucial operational functions
of the vehicle. The following are descriptions and illustrations
of the gauges, warning indicators, and integral digital display
options.
39
Controls/Features
40
3879634R1
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.
Item
No.
1
2
3
3879634R1
Item
4
Illuminates Yellow. Used in conjunction
with other Warning Indicators or General
Text and Warning Messages to indicate
an Alert condition to the operator.
5
Illuminates Red Used in conjunction with
other Warning Indicators or General Text
and Warning Messages to indicate a red
STOP alert.
6
Illuminates Red when a failure in the
service brake system has occurred. If
the Brake Pressure warning indicator
illuminates, safely stop the vehicle as
soon as possible and seek service
immediately.
7
Illuminates Red when the parking brake
is applied. If the brake warning indicator
does not illuminate, or if it stays on with
the parking brake not engaged, seek
service immediately.
8
Illuminates Green to assist operators
in determining when it is appropriate to
shift the transmission to a higher gear in
order to maximize driving fuel economy.
9
Illuminates Yellow when the
transmission is not engaged in the
selected gear. The warning indicator
goes out when the gearshift lever is
adjusted to the appropriate gear. Refer
to the Transmission Operator’s Manual
for more information.
10
Not used.
Description
Illuminates Yellow when the intake
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.
Illuminates Yellow to alert driver that
vehicle idle shutdown timer will turn
engine off in 30 seconds.
Illuminates Yellow. Used in conjunction
with other Warning Indicators or General
Text and Warning Messages and may
be accompanied by an audible alarm
to indicate an Alert condition to the
operator.
41
Controls/Features
11
Illuminates Yellow when the traction
control system is turned off. It also
illuminates momentarily when the
traction control system is on and is
limiting wheel spin. Indicator blinks if
slippery road conditions exist. If this
happens, adjust your driving accordingly.
Refer to the Operation section for more
information.
12
Not used.
13
Illuminates Yellow when exhaust system
components are operating under normal
conditions and exhaust gases are at
extremely high temperatures.
14
Diesel Particulate Filter (DPF) status
indicator. Illuminates Yellow (Solid
or Flashing) to indicate the need to
regenerate the Diesel Particulate Filter.
(See Exhaust Regen in the Vehicle
Operation Section).
15
16
Illuminates Red when a parking brake
system malfunction has been detected.
If the Service Parking Brake indicator
stays illuminated, have the system
serviced immediately.
17
Optional indicator illuminates Red
immediately after ignition is turned on to
remind operator to fasten seat belt.
Optional Seat Belt Reminder with Seat
Belt Monitoring causes initial visual
indication, then flashes with audible
alarm when ignition is on, parking brake
is released, and seat belt is not fastened.
18
Illuminates Red when the brake fluid
falls below the safe operating level.
19
Not used.
20
Not used.
21
Illuminates Yellow when an antilock
brake system malfunction has been
detected. If the ABS indicator stays
illuminated or continues to flash, have
the system serviced immediately.
22
Illuminates Yellow when transmission
Economy Mode is selected. Refer to
the Transmission Operator’s Manual for
more information.
Engine Emissions Control System
Malfunction Indicator Lamp (MIL)
Illuminates Yellow when an emissions
problem has occurred.
42
3879634R1
Controls/Features
23
24
25
Flashes Green when the left turn signal
or the hazard lights are turned on.
There are six standard and four optional 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-range 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.
Description
Transmission Oil Temperature Gauge:
Indicates the transmission lubricant
temperature in degrees Fahrenheit or
Celsius.
27
Optional Engine Oil Temperature
Gauge: Indicates the engine lubricant
temperature in degrees Fahrenheit or
Celsius.
27
Optional Ammeter: Indicates the rate
of charge of electric current supplied by
the alternator to the battery, or the rate
of discharge from the battery.
28
Coolant Temperature Gauge:
Indicates engine coolant temperature.
Flashes Green when the right turn signal
or the hazard lights are turned on.
Gauges
Item
26
Illuminates Blue when the high beam
head lamps are turned on.
NOTE: If the MIL is illuminated, it is the vehicle owner’s
responsibility to have the engine repaired or face fines.
3879634R1
Item
No.
The warning indicator indicates the
engine coolant temperature has
exceeded 230° F when equipped
with a 10 psi de-aeration tank, and
235° F when equipped with a 15 psi
de-aeration tank. If the warning indicator
is activated, stop the vehicle as soon as
safely possible, turn off the engine and
let the engine cool.
43
Controls/Features
Item
No.
29
Item
Description
Item
No.
Engine Oil Pressure Gauge: Indicates
engine oil pressure. If the needle falls
below the normal range (20–65 psi) at
normal operating temperature, stop the
vehicle as soon as safely possible, and
check the engine oil level. Add oil if
needed. If the oil level is correct, have
your vehicle checked by a qualified
technician.
32
Tachometer: Indicates the engine
speed in revolutions per minute.
Speedometer: Indicates vehicle speed.
Fuel Level Gauge: Indicates the
approximate fuel level in the fuel tank. If
your vehicle is equipped with dual fuel
tanks, the fuel gauge reads the fuel level
only from the primary (draw) fuel tank.
(Optional) Special fuel warning: the
warning indicator will light when gauge
falls below 1/3, and alarm continuously
when below 1/10 (close to ”E”).
33
31
Description
When the fuel level reaches 1/8 full, the
gauge warning indicator will illuminate
and an audible alarm will sound (5
beeps).
The warning indicator indicates low
engine oil.
30
Item
Battery Voltage Gauge: Indicates the
voltage when the key is in the ON or
ACCESSORY position.
The warning indicator illuminates when
the battery voltage is too high or low.
44
3879634R1
Controls/Features
Item
No.
Item
Description
34
Air Pressure Gauge 1: Provides
indication of air pressure available for
the primary air brakes. LED and audible
under-limit (less than 57 psi) warning
indicators.
35
Air Pressure Gauge 2: Provides
indication of air pressure available for
the secondary air brakes. LED and
audible under-limit (less than 57 psi)
warning indicators.
The Instrument Panel Gauge Cluster will sound an audible alarm
that accompanies out of range gauge readings along with the
particular gauge warning indicators. The 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:
Instrument Panel Gauge Cluster Alarms
WARNING
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
Fuel Level Gauge low (alarms on each ignition turn-on and
low fuel occurrence)
5 BEEPS
Voltmeter Gauge out of range reading
5 BEEPS
Engine Oil Pressure Gauge out of range reading
5 BEEPS
3879634R1
Additional Comments
Instrument Panel Gauge Cluster warning indicator
illuminates.
45
Controls/Features
Alarm Conditions
Audible Alarm Pattern
Additional Comments
Engine Oil Temperature Gauge out of range reading
5 BEEPS
Instrument Panel Gauge Cluster warning indicator
illuminates.
Engine Coolant Temperature Gauge out of range reading
5 BEEPS
Instrument Panel Gauge Cluster warning indicator
illuminates.
Transmission Oil Temperature Gauge out of range reading
5 BEEPS
Instrument Panel Gauge Cluster warning indicator
illuminates.
Rear-Rear Axle Oil Temperature Gauge out of range reading
5 BEEPS
Instrument Panel Gauge Cluster warning indicator
illuminates.
Forward-Rear Axle Oil Temperature Gauge out of range
reading
5 BEEPS
Instrument Panel Gauge Cluster warning indicator
illuminates.
Auxiliary Air Pressure Gauge out of range reading
5 BEEPS
Instrument Panel Gauge Cluster warning indicator
illuminates.
Gauge Sensor Faults
3 BEEPS
Gauge pointer goes to 6 o’clock position and
Instrument Panel Gauge Cluster warning indicator
illuminates.
Primary Air Pressure Gauge out of range and air pressure
sensor fault
REPEATING SINGLE
BEEP
Instrument Panel Gauge Cluster warning indicator
illuminates.
Secondary Air Pressure Gauge out of range and air pressure
sensor fault
REPEATING SINGLE
BEEP
Instrument Panel Gauge Cluster warning indicator
illuminates.
Red Stop Warning indicator illuminates
REPEATING SINGLE
BEEP
Instrument panel warning indicator 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.
Low Coolant Alarm
46
REPEATING SINGLE
BEEP
Gauge warning indicator illuminates.
3879634R1
Controls/Features
Direct Drive Warning Indicators
Item
No.
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 indicators installed at those locations.
Item
No.
Item
Color
Yellow
WINTER/ENGINE INTAKE
is set to the Winter position.
37
Yellow
Front rear axle differential
is locked.
38
Yellow
Rear rear axle differential is
locked.
39
Yellow
FRONT AXLE/ON switch is
in the ON position.
40
BLANK
Not used
40
BLANK
Not used
41
BLANK
Not used
41
BLANK
Not used
3879634R1
Yellow
AUTO NEUTRAL function
enabled.
Color
Description
43
Yellow
Optional Transmission
Retarder switch is in the ON
position.
43
Yellow
Illuminates in conjunction
with the (Optional)
Qualcomm satelite
communication system
– see Qualcomm system
owner’s manual.
Description
36
42
Item
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
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.
47
Controls/Features
48
Item No.
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.
45
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
3879634R1
Controls/Features
Item No.
Quadrant Number and Message Function
Message Description
46
Quadrant 2: General Text and Warning
Messages
Displays a variety of messages ranging in priority necessary for vehicle
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 section in Vehicle Operations)
47
Quadrant 3: Compass Heading/Outside
Temperature
(Optional) Displays compass heading when vehicle is equipped with a compass
module.
Displays outside temperature (reading is obtained from the temperature sensor).
48
Display Control
Toggles the information display from one screen to the next when pressed
and released.
Switches
Daytime Running Lights (DRL)
Six switches are located on the lower left and right side of the
main instrument/control panel. Configurations are optional.
Blank cover plates will be used in spaces that do not have
switches installed at those locations.
The daytime running lights feature provides for low beam
headlights at 75 percent 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.
Headlights
Lights on with Wipers
The headlights will be at 100 percent brightness with the
headlight switch activated. The park lights, tail lights, markers,
and clearance lights will be on as well.
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.
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
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:
3879634R1
Park Lights
The park lights, taillights, markers, and clearance lights will turn
ON when the headlight switch is in the park or headlight position.
49
Controls/Features
Marker Interrupt
Dome Lighting
The marker interrupt function is an optional feature that toggles
the park lights and markers when the operator activates the
spring-loaded marker interrupt switch. When park lights are
ON, activating the interrupt switch will cause the park lights and
markers to be turned OFF until the interrupt switch is released.
If park lights are OFF, activating the interrupt switch will cause
the park lights and trailer markers to be turned ON until the
switch is released.
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 its Unlock button is pressed and turns OFF the
light (dims gradually to OFF) when its Lock button is pressed.
Panel Lighting
Courtesy Lights
The panel lighting brightness is controlled by the Panel rocker
switch. To increase the brightness of the instrument panel
lighting, continually press the upper portion of the rocker switch.
To dim the instrument panel lighting, continually press the lower
portion of the rocker switch.
50
The optional driver courtesy lights are located under the
instrument panel ends for door lighting. This feature is provided
with the optional Premium trim package. An optional rear
courtesy light can also be provided with the travel crew cab.
3879634R1
Controls/Features
Item
No.
Item
49
Configured
by
Customer
Request
Description
52
Panel Dimmer
Adjusts the panel lights brightness.
50
Switch options for this position include:
MIR, Fog Light Switch, and Plow Light switch.
54
NOTE: Refer to switch table in this section for
switch functions.
LMP Check
Activates the optional exterior lamp check.
51
53
Configured
by
Customer
Request
Switch options for this position include:
Lift Gate, Work Light, Mirror Heat, Fog Light,
Plow Light, Fan Override, Two Speed Axle,
Air Suspension Dump, Auxiliary, Parked
Regeneration, Inhibit Regen
NOTE: Refer to switch table in this section for
switch functions.
Headlight/Park Lamp Switch
Activates the headlight or parking lights, and
illuminates the instrument panel. This switch
functions even when ignition switch is turned
OFF (a warning will sound when this switch is
ON and the ignition switch is OFF).
3879634R1
51
Controls/Features
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 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”.
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 display 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.
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.
52
3879634R1
Controls/Features
Declination Zone Map
3879634R1
53
Controls/Features
Step
1
2
3
Procedure
Displayed Message
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.
Press and hold the display control knob until any Declination Zone number (0 – 10) is
displayed.
Turn the display control knob clockwise or counterclockwise until the desired Declination
Zone number is displayed. Refer to Declination Zone Map to determine the proper
number for the current geographic location.
4
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.
5
54
Press and HOLD the display control knob until the Compass Declination message
appears (this indicates that the new Declination Zone number has been programmed
into the compass).
3879634R1
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:
Step
1
2
Procedure
Displayed Message
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.
Press and hold the display control knob until the End Calibration command is displayed.
3
NOTE: IF the End Calibration command will not show up, turn OFF the vehicle, restart it,
and return to Step 1.
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.
4
3879634R1
Immediately following the End Calibration command being displayed, drive the vehicle in
3 complete circles (during this time the compass display will go blank or have dashed
lines present).
55
Controls/Features
5
Stop the vehicle and wait shortly. The End Calibration message should reappear on
the display.
6
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.
7
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 a circle 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, restart 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.
Integral Digital Display Detailed Information
Quadrant 1: Informational Displays
NOTE: The available display screens are dependant on the
configuration of the vehicle.
56
3879634R1
Controls/Features
Quadrant 1 – Display Messages
Description
Odometer
The odometer displays the total distance traveled.
Display Format:
100,000.0
MILES
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
Trip Hours
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
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57
Controls/Features
Quadrant 1 – Display Messages
Description
Machine PTO A or B Hours
This display will provide a record of the total accumulated Machine PTO hours, while PTO function A
or B is engaged.
Display Format:
100,000.0
PTO HOURS A
PTO HOURS B
Machine Trip PTO A or B Hours
This display will provide a record of the total accumulated Machine Trip PTO hours, while PTO function A
or B is engaged.
Display Format:
100,000.0
PTO TRP HOURS A
PTO TRP HOURS B
Engine PTO Hours
This display will provide a record of the Engine PTO hours sent from engine.
Display Format:
100,000.0
ENG PTO HOURS
Engine PTO Trip Hours
This display will provide a record of the Engine PTO Trip hours sent from engine.
Display Format:
100,000.0
ENG PTO TRP HOURS
58
3879634R1
Controls/Features
Quadrant 1 – Display Messages
Description
Instantaneous Fuel Economy
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
Trip Average Fuel Economy
The display value shall be the average fuel economy value since the last reset of the trip odometer.
The display shall be in miles per 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
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 L A
PTO L B
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59
Controls/Features
Quadrant 1 – Display Messages
Description
Machine PTO Trip Fuel Used A and B
The display value shall be the calculated Machine PTO Trip Fuel Used.
Display Format:
100,000.0
PTO TRP GAL A
PTO TRP GAL B
PTO TRP L A
PTO TRP L B
Engine PTO Fuel Used
The display value shall be the calculated Engine PTO Fuel Used.
Display Format:
100,000.0
ENG PTO GAL
PTO TRP L
Engine PTO Trip Fuel Used
The display value shall be the 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
60
3879634R1
Controls/Features
Quadrant 1 – Display Messages
Description
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
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:
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 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
3879634R1
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:
61
Controls/Features
Quadrant 2 – Display
Messages
Description
Flash (Yes/No)
Warning Indicator
Association
PARKD REGEN ACTIVE
Message is displayed during a parked regeneration.
No
No
Load Shedding
Message is displayed when electrical load control and
shedding feature is implemented.
Yes
No
Washer Fluid Low
Indicates low washer fluid level.
Yes
No
Electrical Fault
When instrument panel gauge cluster’s ability to display
diagnostic codes is enabled, this message is displayed
when there are active diagnostic codes.
Yes
No
Check A/C
Indicates a fault in the HVAC System.
Yes
No
PARKD REGEN INHIBITED
Message is displayed when parked regeneration has been
requested, but is not performed due to a vehicle interlock
or an engine fault.
No
No
Air Filter Restriction
Message displayed indicates restricted air flow to the
engine.
Yes
No
Exterior Lamp Check Active
Message displayed indicates Exterior Lamp Check is in
progress.
Yes
No
HVAC Temp Setting
Bar graph displayed show temperature setting in low to
high increments.
No
No
Activate HVAC Front Blower
Bar graph displayed show blower speed setting in Off and
low to high increments.
No
No
62
3879634R1
Controls/Features
Quadrant 2 – Display
Messages
HVAC Sleeper Blower Speed
Description
Flash (Yes/No)
Warning Indicator
Association
Bar graph displayed show blower speed setting in Off and
low to high increments.
No
No
Yes
No
Air Pressure Diagnostic
Cruise
Indicates that the Cruise Control System is turned On.
No
No
Fuel Filter
Indicates that the fuel filter is clogged.
Yes
No
Check Brake Switch
Yes
No
Check Pupil Warning Indicator
Yes
No
Check Stop Arm/Crossing Gate
Yes
No
Check Exterior Lamps
Yes
No
Engine Control Shutdown
Yes
No
Check Trailer Lights
Yes
No
Engine Control System Error
Yes
No
PARKD REGEN REQUIRED
Indicates parked regeneration is necessary.
No
No
PARKD REGEN INHIBITED
ENG TMP
Message is displayed when engine coolant temperature is
below 170° F (76.6°C).
No
No
REGEN INHIBIT SWITCH
ACTIVE
Message is displayed when Regen Inhibt Switch is “On”
and regeneration Is disabled.
No
No
No
No
Yes
No
PARKED REGEN AVAILABLE
Low Coolant Level
3879634R1
Message is displayed when coolant level is less than or
equal to 80%.
63
Controls/Features
Quadrant 2 – Display
Messages
Description
Flash (Yes/No)
Warning Indicator
Association
Stop Engine
Message is displayed when Red Stop indicator is
illuminated. MaxxForce® engine only.
Yes
Red warning indicator
Warn Engine (Priority 1 or 2)
(1) Message is displayed when MaxxForce, or MaxxForce®
11/13 ECM turn on the Red warning indicator.
Yes
(1) Red warning indicator
(2) Yellow warning
indicator
(2) Message is displayed when MaxxForce, or MaxxForce®
11/13 ECM requests the Yellow warning indicator and not
the Red warning indicator.
Stop Hybrid
Message is displayed when Hybrid system turns on and
requests the Red warning indicator.
Yes
Red warning indicator
Check Engine
Message is displayed when ECM requests the Yellow
warning indicator and not the Red warning indicator.
Yes
Yellow warning indicator
HV Batt Off-Line
Message is displayed when Hybrid system battery is off
line.
Yes
No
Check Hybrid
Message is displayed when Hybrid system turns on the
Yellow warning indicator while conditions for “HV Batt
Off-Line” message are not met.
Yes
Yellow warning indicator
Low Engine Oil Level
Message is displayed when engine oil level is less than
or equal to 80%.
Yes
No
Change Engine Oil
Message is displayed when engine oil change is detected
as necessary.
Yes
No
Water in Fuel
Message is displayed when water in fuel is present.
Yes
No
Refuel
Message is displayed when fuel level is low. MaxxForce®
11 and 13 engines only.
Yes
No
High Fuel Temp
Message is displayed when fuel temp is high. MaxxForce®
11 and 13 engines only.
Yes
No
64
3879634R1
Controls/Features
Quadrant 2 – Display
Messages
Electrical Fault (Priority 1 or 2)
Description
Flash (Yes/No)
Warning Indicator
Association
(1) Message is displayed when EGC requests the Red
warning indicator.
Yes
(1) Red warning indicator
(2) Yellow warning
indicator
(2) Message is displayed when EGC requests the Yellow
warning indicator.
Check Trans
Message is displayed when transmission needs to be
serviced.
Yes
Yellow warning indicator
Trans Temp
Message is displayed when transmission turns on
the Yellow warning indicator. Not available with all
transmissions.
Yes
Yellow warning indicator
Gen Trns Flt
Message is displayed when transmission turns on Red
Stop, MIL, or PROTECT, or the Yellow Warning indicator
without the conditions to display Check Trans, Trans Temp,
Trans Oil Life, Trans Oil Filter, or Trans Service. Not
available with all transmissions.
Yes
Yes (see description)
Trans Oil Life
Message is displayed when transmission oil needs
changed. Not available with all transmissions.
Yes
No
Trans Oil Filter
Message is displayed when transmission oil filter needs
changed. Not available with all transmissions.
Yes
No
Trans Service
Message is displayed when transmission needs service.
Not available with all transmissions.
Yes
No
DPF Ash Service Required
Message is displayed when diesel particulate filter ash
level requires service/cleaning.
Yes
No
See Visor For Info
Message is displayed indicates the particulate trap
indicator must be on or must flash.
Yes
Yes (see description)
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65
Controls/Features
Quadrant 2 – Display
Messages
Description
Flash (Yes/No)
Warning Indicator
Association
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
Message is displayed when a module other than the
engine requests the red stop warning indicator.
Yes
Red warning indicator
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
Message is displayed when a module other than the
engine requests the Yellow warning indicator.
Yes
Yellow warning indicator
Retarder Temp
Message is displayed when instrument panel gauge cluster
receives signal from the Retarder – Driveline requesting
the Yellow warning indicator.
Yes
Yellow warning indicator
Gen Rtrd Flt
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..
Yes
Yes (see description)
DRV Reward Expected
No
No
DRV Reward Good
No
No
DRV Reward Excellent
No
No
DRV Reward Penalty
No
No
66
3879634R1
Controls/Features
Quadrant 2 – Display
Messages
Description
Flash (Yes/No)
Warning Indicator
Association
DRV Reward Increasing
No
No
DRV Reward Decreasing
No
No
VSL Ovrd Active
No
No
VSL Ovrd Expiring
No
No
Blank screen, available only when engine rpm less than
or equal to 325 RPM, 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.
No
No
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.
No
No
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.
No
No
Declination Zone
Message is displayed only when vehicle speed is less than
2 mph (3 km/h).
No
No
Warning Messages
Red Stop indicator: Stop Engine message
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:
The following chart provides the warning messages that are
displayed along with corresponding Instrument panel gauge
cluster indicators.
Yellow Warning indicator: WARN ENGINE message
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67
Controls/Features
MaxxForce® Engines
Outside Temperature Reading
Quadrant 3: Display Messages
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).
Outside Temperature and Compass Displays (Optional)
The display will be in °F or °C, depending on the units selected
while in the odometer mode.
Warning indicator
Warning Message
Red Stop
Stop Engine
Yellow Warning
Warn Engine
The optional Outside Temperature and Compass Heading is
displayed in Quadrant 3. Typical displays for Temperature and
Compass Heading are listed in the following table. The display
provides both the outside ambient temperature and the relative
direction of the vehicle within a particular geographical zone.
Vehicle must be moving to acquire an accurate temperature.
Quadrant 3 –
Display Messages
Description
Outside
Temperature and
Compass Heading
Display Format:
68
Quadrant 4: Transmission Gear Displays
Quadrant 4 – Transmission Gear Indications
Allison P-R-N-D-L gear
display
Eaton® Transmission display
3879634R1
Controls/Features
Steering Wheel Controls
3
CRUISE/THROTTLE - ON/OFF - Turns
the speed control feature ON or OFF.
Engine speed does not change when
you press the ON position. This control
just activates/deactivates the feature.
When the OFF position is pressed, the
system will be turned OFF.
4
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.
The steering wheel contains the Electric (city) horn, Optional Air
horn control, and Cruise/Throttle controls.
Cruise Control
The cruise control systems for all electronic engines function in
a very similar manner. The biggest difference is the minimum
and maximum allowable cruise control speeds that will vary from
vehicle to vehicle.
WARNING
1
AIR HORN - Used to activate the air
horn.
2
HORN - Used to activate the city horn.
3879634R1
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.
69
Controls/Features
Basic Functions of Steering Wheel Controls
The CRUISE/THROTTLE - ON/OFF control turns the
speed control feature ON or OFF. Engine speed does not
change when you press the ON position. This control just
activates/deactivates the feature. When the OFF position is
pressed, the system will be turned OFF.
The left side CRUISE/THROTTLE switch has different labels,
depending on which feature was ordered. However, they all
perform the same function: to turn ON the basic feature.
The two available options are:
•
Throttle - used when only throttle or an engine speed control
is ordered;
•
Cruise/Throttle - used when cruise control and either a hand
throttle or an engine speed control are ordered.
The right switch (SET/COAST - RESUME/ACCEL) actually sets
and controls the engine speed. But if the left switch has not been
activated, nothing will happen when pushing on this right switch.
This switch has the same label in all applications.
2. Bring the vehicle to the desired operating speed (above
35 MPH), and then push the SET/CRUISE position of
the steering wheel control.
3. Once in the cruise mode the right side SET/CRUISE
– RESUME/ACCEL switch can be used to increase or
decrease vehicle speed by pressing and holding the
RESUME/ACCEL to increase or the SET/CRUISE to
decrease vehicle speed.
4. A slight tap on the brake or clutch pedal will deactivate
the cruise but holds the selected speed in memory. To
return to this speed, just press RESUME/ACCEL.
5. When you press the OFF (left) position of the
CRUISE/THROTTLE - ON/OFF switch, or if the vehicle
is shut off, the selected speed setting is canceled.
Throttle
This feature is ordered to provide variable engine speed control
primarily for operation of PTO powered equipment. It uses the
same Cruise controls as described below.
Operational Procedures
1. Press the CRUISE/THROTTLE - ON/OFF steering
wheel control to ON.
The following steps will activate and enable each of the four
engine speed control features.
2. Press SET/CRUISE on the steering wheel control.
Cruise Control – operates like an automotive cruise control.
1. Press the ON position of the CRUISE/THROTTLE ON/OFF steering wheel control.
70
3. Press and hold RESUME/ACCEL to increase engine
speed until the desired engine speed is obtained. Or,
you can repeatedly press and release RESUME/ACCEL
to increase the speed in small increments.
3879634R1
Controls/Features
4. To change from this initial setting, use the appropriate
control to raise or lower the engine speed as you would
in the cruise control mode. SET/CRUISE reduces
engine speed and RESUME/ACCEL increases engine
speed.
5. Press the OFF position of the ON/OFF control to turn
the throttle off and return the engine to idle.
Stationary Variable Speed Control (12VXT)
This feature is ordered to provide variable engine speed control
primarily for operation of PTO powered equipment. It operates
the same as the Cruise/ Throttle controls discussed above.
Stationary Pre-Set Speed Control (12VXU)
3. First, press the switch that selects one of the desired
speeds.
4. To select the other speed, press the other switch. The
engine will immediately return to idle.
5. You must push the switch a second time to go to the
second speed. This is done to protect equipment from
being inadvertently operated at the wrong speed.
Mobile Variable Speed Control (12VXV)
Operates the same as cruise control, except the engine speed is
accurately controlled instead of vehicle speed. The truck could
be operated in one of several gears but the truck is limited to
a maximum of 20 MPH, or any pre-set lower speed down to 3
MPH.
1. To activate this feature, press the ON position on the left
side CRUISE/THROTTLE - ON/OFF switch.
2. When ordered, this feature can provide two different
predetermined speeds, which are selected with the
SET/CRUISE or RESUME/ACCEL positions. You need
to know which position to use for your specific operation.
Press the right side SET/CRUISE or RESUME/ACCEL
switch for the desired pre-set speed.
3879634R1
71
Controls/Features
Steering Column and Switches
2. 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. On some models
the switch will automatically cancel if the steering wheel is turned
a large enough degree. On other models 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 to movement is felt. The turn
signal lever will return to the OFF position when released.
3. 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.
The steering column contains switches and levers to aid in the
comfort of the operator and to assist the operator while driving
the vehicle.
1. 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.
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.
Multi-function Switch - The multi-function turn signal switch
is mounted on the left side of the steering column below the
steering wheel.
72
3879634R1
Controls/Features
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 anti-freeze in the
windshield washer reservoir. Radiator coolant
in the washer reservoir can severely reduce
visibility when sprayed on the windshield.
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.
5. 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.
Keep the fluid reservoir filled with Fleetrite® Windshield Washer
Solvent or equivalent.
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.
4. Low/High Beam - When the turn signal stalk is pulled past
the “click” position, lights will switch to Hi-Beam position. When
pulled again they will revert to Lo-Beam.
6. Tilting Adjustment Lever (Optional) - Allows the steering
wheel placement to be adjusted for driver comfort. Pull up to
adjust, push down to lock.
Headlight Flash-To-Pass - When the turn signal lever is pulled
with the headlights OFF, the Hi-Beam lights will come on and stay
7. Trailer Brake Lever - This lever is used to apply and release
the brakes to the trailer.
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73
Controls/Features
Center Dash Panel/Wing Panel
1. Radio
The Center Control Switch Panel consists of the switches
that start the vehicle, control the vehicle’s normal operations,
vehicle lights, and special mechanical functions. The panel also
includes control of the interior comfort levels (HVAC controls),
optional parking brake controls and auxiliary electrical power
source (see Vehicle Operation for operational details). Refer
to the Radio Operator’s Manual provided with the vehicle for
instructions on operating the radio installed in this Vehicle.
2. Fan Speed Control
3. Temperature Control
4. Mode Control
5. Storage Compartment/Optional Switch Pack Location
6. Parking Brake
7. Optional Component Panel
8. Trailer Air Supply
9. Optional Switch Pack Location
10. Ignition Switch
11. Switch Pack
74
3879634R1
Controls/Features
Switches
Transmission Retarder – RTARDR ON
Up to 25 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.
Item
Description
Turns ON transmission retarder to slow down drivetrain.
Transmission Retarder – HI/LOW
Selects the percentage of Transmission Retarder
capability. HI = 66%; LOW = 33%.
Marker Interrupt – MKR INTR
A momentary switch that turns all trailer marker lights
ON or OFF, depending on park light switch position.
Heated Mirror – ON/OFF
A momentary switch that, when pushed and released,
turns the mirror heating element ON or OFF.
ENG BRAKE – ON/OFF
FOG LIGHT – ON/OFF
Turns ON Fog Lights when the switch is in the ON
position, ignition switch is in the “Ignition” or “Start”
position, and the headlights are ON and in low beam
mode.
TRAC ENAB/DISAB
This switch enables or disables the ABS traction feature.
Turns engine compression brake ON/OFF.
OFF ROAD ENABLE
ENG BRAKE 1/2/3
A three position switch that selects the amount of
engine braking (1 = Low, 2 = Medium. 3 = High)
3879634R1
As part of the automatic traction control system, this
switch, when enabled, allows for greater engine power
and more wheel spin on soft road surfaces.
75
Controls/Features
MUD/SNOW ENABLE
2 Speed Axle – 2 SPD LO/ 2 SPD HI
As part of the automatic traction control system, this
switch, when enabled, allows for greater engine power
and more wheel spin on soft road surfaces.
A 2 speed switch that allows the operator to select
either high or low rear axle ratio.
PLOW LIGHT ON/OFF
Power Divider lock – LOCK/PDL
With this feature, the ON position selects the high
mounted Plow lights whenever the headlights are ON. If
the operator shuts OFF the vehicle with the plow lights
ON, they will remain ON.
This switch is used to lock together the front and rear
axle of a tandem.
LIFT GATE – ON
This switch provides power to the lift gate system.
This optional feature provides battery protection and/or
programmable time out.
AUTO NEUTL – ON
When the ON position is selected and the parking
brake is applied (vehicle speed is near zero mph), the
transmission goes into (auto) neutral.
FAN OVRD – ON
This switch allows the operator to release the air from
or reinflate the air bags of the air suspension system.
PTO OFF/ON
Engages Power Take Off when switch is in ON position
or disengages Power Take Off when switch is in PTO
OFF position.
5TH WHEEL SLIDE ON/OFF
With the switch in the ON position, the fan mode is
switched from “auto” to the constant “on”.
This switch, when set to ON, releases the sliding 5th
wheel (when ignition switch is in “Run” and vehicle
speed is less than 2 mph).
The switch indicator will be ON when the ON position
is selected.
Differential Lock – DIFF/LOCK
WORK LIGHT – ON
This switch is used to turn the back of cab work light
ON or OFF.
76
SUSP/DUMP
This switch, when set to LOCK, engages the locking
differential which locks the right and left side tires (only if
vehicle is below maximum differential lock engagement
speed of 25 mph (40 km).
3879634R1
Controls/Features
Forward Rear Tandem Axle Differential Lock – DIF FR
AXLE LOCK
This switch, when set to LOCK, engages the forward
rear locking differential for improved traction on poor
surfaces (only if vehicle is below maximum differential
lock engagement speed of 25 mph (40 km).
Engine Shutdown Override – ENG OVRD/ON
This momentary switch, when pushed to the ON
position, will allow the vehicle to be restarted in the
event of an automatic engine shutdown.
AC Power Enable – ON 120V AC
Rear Rear Tandem Axle Differential Lock – DIF RR
AXLE LOCK
This switch, when set to the ON position, will provide
AC output from the Power Pack 3 inverter.
This switch, when set to LOCK, engages the rear
rear locking differential for improved traction on poor
surfaces (only if vehicle is below maximum differential
lock engagement speed of 25 mph (40 km).
WINTER/ENGINE INTAKE
Front Axle Differential Lock – FRONT AXLE/ON
Used to change engine intake air from “outside air” to
engine compartment air.
Engages Front Axle for 4X4 operation.
PARKD REGEN – ON
Transfer Case – XFER HI/XFER LOW
DPF regeneration activation when parked switch is
used for engine after-treatment. Manually initiates DPF
regeneration.
Selects Transfer Case high or low gear ratio.
AIR ASSIST – (OFF) ON
Provides inflation or deflation of auxiliary air bag.
INHIBT REGEN – ON
The Regeneration Inhibit switch is used to prevent
the Active Regeneration or Parked Regeneration
processes.
ENAB/DATA LOG
When enabled, allows the driver to log the last five
seconds of data group’s operational parameter values
into ECM memory.
3879634R1
77
Controls/Features
Auxiliary Gauge/Switch Package (AGSP)
(Optional)
Optional Gauge
Function
Ammeter Gauge
The Auxiliary Gauge/Switch Package provides locations for
three additional gauges and six switches for optional customer
requirements. The following lists the gauges that are approved
for this location.
Provides reading of battery and alternator
current in Amps.
Rear–rear Axle
Temperature Gauge
Provides monitoring of temperature of
axle lubricant. Warning indication at
230°F.
Front–rear Axle
Temperature Gauge
Provides monitoring of temperature of
axle lubricant. Warning indication at
230°F.
Load Indicating Gauge
Provides reading of rear axle load. *
* Gauge reading is for reference only. DO NOT base legal
loading criteria on this gauge reading.
Refer to Switches in this section for optional auxiliary switches.
Panel Component Arrangements (Optional)
1. Auxiliary Gauge Locations
2. Auxiliary Switch Locations
Optional Gauge
Function
Air Application Gauge
Provides readings of brake application
air pressure. Max pressure of 150 psi.
78
Item
Component Description
1
Two Post Power Socket
3879634R1
Controls/Features
Item
Component Description
Item
Component Description
2
Cigar Type Power Socket
5
Telematics No Data Logged Switch
3
Optional Filter Minder
6
Telematics Driver Alert Switch
4
Three Switch Pack
7
Cigar Lighter
3879634R1
a.
Optional Winter/Engine Intake
Switch
b.
Optional Air Horn Switch
c.
Optional Ether Start Switch
d.
Optional Engine Start Switch
e.
Optional Axle Enable Switch
f.
Optional Axle Up/Down Switch
g.
Optional Roof Auxiliary Switch
79
Controls/Features
Climate Control
WARNING
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.
CAUTION
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 optional heater shut off valve(s) to prevent hot coolant from circulating through the heater core(s). Closing
the valve(s) during hot weather operation will improve A/C system performance. If the valves are shut off, in-cab temperature adjustment may become
limited. In addition, when shut off valves are closed, defrosters will only produce cold air.
Item No.
Item
Description
36
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 (and the A/C compressor if A/C is selected), but does not prevent outside air from entering
the vehicle. On vehicles equipped with A/C, moving the mode knob to the MAX A/C position, with
the fan ON, will close the fresh air door eliminating outside air from entering the vehicle.
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:
80
3879634R1
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 recirculation mode may make the inside air stuffy. Use of this mode
for longer than fifteen minutes without a window slightly open 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 OFFautomatically as needed when in this mode.
Bi-Level Air Conditioning Mode
In this mode 75 percent of the airflow is directed to the panel air outlets and 25 percent 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.
3879634R1
81
Controls/Features
Mix Mode
In this mode 50 percent of the airflow is directed to the defrost and side demist air outlets and
50 percent 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
humidity levels and help reduce moisture buildup on the windshield.
Defrost
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.
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
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.
keeps all the mechanical parts of your air conditioner in good
operating condition.
Air Conditioning
CAUTION
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.
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.
At least once or twice a month, turn ON the air conditioner for a
few minutes while the engine is running. This periodic operation
82
3879634R1
Controls/Features
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 debris in both the cab and sleeper HVAC
intake filters that may reduce airflow.
NOTE: The air conditioning system incorporates a low-pressure
switch, which disengages the compressor clutch if evaporator
outlet pressure falls below a certain set point. To restart the air
conditioning system after an automatic shutdown has occurred,
the operator must do one of the following:
1. Set A/C control to OFF and then back to ON. Fan speed
control knob MUST NOT be in the OFF position.
2. Place fan speed control knob in OFF position and then
back to the desired speed setting. A/C system must be
ON.
NOTE: If the system continues to shut down automatically, have
the system checked.
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.
Door and Window Controls
Door Lock/Unlock
Cab Doors and Locks
The cab 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 dealer. Record the key code and keep it in a
secure place. A new key can be made if the keys are lost.
NOTE: The vehicle may be equipped with optional Heater Shut
Off Valve(s) to prevent hot coolant from circulating through the
heater core(s). Closing the valve(s) during hot weather operation
will improve A/C system performance. If 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.
3879634R1
83
Controls/Features
1. Door Handle
Remote Keyless Entry Operation (Optional)
2. Key Lock
3. Interior Lock
4. Interior Door Handle
To open any door from inside,
pull out on interior door
handle.
To open any door from
outside, grab door handle
and pull downward.
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.
If equipped with a crew cab, the rear door locks, when engaged,
must be unlocked using the mechanical lock release or the
switch for electric locks. The rear interior door handle will not
disengage the door locks.
The remote keyless entry key fob is used to lock and unlock all
doors from a distance of 30 feet (9 m) or less. Whenever the
doors are locked or unlocked using the key fob, the city horn
sounds momentarily (chirps). Also, the remote keyless entry key
fob turns ON the interior 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. 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.
The auxiliary button will be used to toggle the optional work light
ON or OFF (if OFF, it will be turned ON, and if ON, it will be turned
OFF).
84
3879634R1
Controls/Features
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 undesirable
operation.
Changes or modifications not expressly approved by the party
responsible for compliance could void the user’s authority to
operate the equipment.
Door Opening/Unlock
Enter or exit the vehicle by manually pulling on the exterior
or interior door handles. To open the door from the interior, if
locked, the front door will unlock when the door handle is pulled.
If equipped with a crew cab, the rear door locks, when engaged,
must be unlocked using the mechanical lock release.
1. Lock/Unlock Button
2. Door Control Panel
3. Driver Side Power Window Control
Lock/Unlock from Interior
4. Passenger Side Power Window Control
WARNING
To help reduce the risk of personal injury in the
event of an accident, keep doors locked when
vehicle is in motion.
3879634R1
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.
85
Controls/Features
Unlocking the Door
To unlock, push the lock/unlock 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.
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
Automatic Door Lock Function
The driver also has the ability to prevent passenger window
up/down operation by pressing the WINDOW LOCK control.
The automatic lock function automatically locks the doors at a
predetermined speed.
Mirror Controls
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.
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.
86
1. Mirror Select Switch
2. Mirror Direction Control Switch
3879634R1
Controls/Features
These controls provide 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.
The following driver reward visual indications appear in the form
of text messages in the gauge cluster digital display:
•
Expected – Reward indication which results in higher vehicle
speed limits.
Vent Window
•
Good – Reward indication which results in higher vehicle
speed limits.
Vehicles are equipped with either a fixed or opening vent window.
The opening vent window can be opened and closed to allow
additional airflow into the cab.
•
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.
Driver Reward
The driver reward feature is designed to give the operator
incentives for driving more efficiently. This is accomplished by
measuring the driver’s habits based on fuel economy, time at
idle, or both. Rewards include higher maximum vehicle speed
and higher cruise control speed limit. Lower maximum vehicle
speed or cruise control speed limits may result as a penalty for
failing to meet the standards.
3879634R1
87
Controls/Features
88
3879634R1
Operation
SECTION 5 — OPERATION
Operation Safety
WARNING
WARNING
Operation of a 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.
3879634R1
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 operated. 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.
89
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.
WARNING
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.
90
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.
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 operating this vehicle.
3879634R1
Operation
Seat Belts
NOTE: Periodically inspect the seat belts for wear and function.
Replace any parts whose performance is in doubt.
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
General
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 need
any adjustment.
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.
3879634R1
91
Operation
Operation
To operate the seat belt follow these steps:
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.
2. 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.
3. 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.
4. 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.
5. 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.
6. 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.
1. Three-Point Seat Belt
2. Retractor
3. Buckle
4. Tongue
Nonretracting Adjustable Seat Belts for Center Passenger
– Bench Seat
To adjust: Tip the buckle end downward and pull the buckle
until the ends can be joined. Insert tongue into the open end of
buckle and snap together. Give it a tug to ensure it is latched.
5. Clip
92
3879634R1
Operation
Shorten the belt after it is connected by pulling on the loose end
until the belt is snug and comfortable.
To release: Push in the button release latch to release the seat
belt.
Care of Seat Belts
WARNING
Do not bleach or re-dye seat belt webbing.
Bleaching or re-dying may cause a weakening
of the webbing, 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.
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.
Ensure that head clearance will be maintained
during all road conditions, as the seat may move
up and decrease the available space.
Bench or bucket type seats have fore and aft adjustment only.
Adjust while sitting in seat. Push seat adjustment lever to release
mechanism and move seat to desired position. Be sure seats
are firmly engaged to avoid forward or rearward movement when
vehicle is started or stopped.
The vehicle may be equipped with a suspension type seat. For
suspension type seat adjustment refer to the booklet or decal
attached to seat frame as supplied by the seat manufacturer.
Seats
WARNING
Do not adjust driver’s 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.
3879634R1
WARNING
Extended Cab Bunk (Optional)
International provides an optional bunk for second driver sleep
accommodations. The bunk is a full 72” long and, when raised
up, provides luggage storage under the mattress. Ventilation is
provided by swing out side windows in the bunk area. The Air
Ride suspension cushions the cab for a ride that is comfortable
for both driver, cab passenger as well as bunk passenger.
93
Operation
Starting Procedures
Engine Starting
WARNING
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.
The ignition switch has four key
positions as follows:
1. ACC (Accessory)
2. OFF
3. ON
4. START
CAUTION
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.
1. Apply the parking brake and place the transmission in
the (N) Neutral position. If equipped with a clutch pedal,
the clutch pedal must be depressed.
2. Turn OFF the headlights and all accessories.
NOTE: Before starting the engine:
•
Read and understand the Controls/Features section of this
manual.
•
Perform the left and right engine compartment inspections
outlined in the Inspection Guide section of this manual.
•
If your vehicle has an optional battery disconnect switch, be
sure that it is in the on position. This switch is cab mounted,
or mounted on the battery box.
NOTE: Automated manual transmissions must be in (N) Neutral
and vehicles with a clutch pedal require the clutch pedal to be
depressed before the starter will engage.
94
3. Turn the key clockwise to the ON position. If the WAIT
TO START indicator comes on (the glow plugs or the air
intake warmer are warming up), wait until the indicator
goes out and then proceed.
4. Turn the key to the START position.
5. When the engine starts, release the key.
6. The key will return to the ON position and the engine will
continue to run.
7. To stop the engine, rotate the key counterclockwise to
the OFF position.
3879634R1
Operation
8. To place the ignition switch in ACC (Accessory) position,
rotate key counterclockwise to the ACC position.
Accessory features can now be used without engine
operation.
9. To terminate ACC (Accessory) operation, rotate the key
clockwise to the OFF position.
After the Engine Starts
follow the size of the engine in order to avoid seals or like
features of an engine being damaged by rising heat.
1. Place the transmission in the (N) Neutral position.
2. Apply the parking brake.
3. Turn OFF the headlights and all accessories.
4. Idle a hot engine for 2 to 5 minutes to allow the
turbocharger to cool.
•
Do not increase engine speed until the oil pressure gauge
indicates normal pressure.
•
Make sure the engine oil pressure is indicated on the gauge
within 20 seconds after starting.
Shut-Down Warning Indicator Or Beeper
•
Operate the engine for three to five minutes before operating
at full power.
WARNING
•
Try to limit engine idle to 10 minutes. Excessive idling
reduces fuel economy, and may decrease oil life.
•
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
and of course, the length of the idling period should somewhat
3879634R1
5. Rotate the key counterclockwise to the OFF position,
and remove key from the ignition switch.
In the event engine shutdown occurs, make
certain that vehicle is safely off the roadway,
the 4-way emergency flashers are on, and traffic
warning devices are properly placed. Failure to
remove vehicle from roadway could cause an
accident and result in property damage, personal
injury, or death.
Vehicles may be equipped with an automatic shutdown system
that stops the engine in the event of high coolant temperature,
low engine oil pressure, or low coolant level. A warning indicator
on the instrument panel along with a beeper or bell will indicate
high coolant temperature or low oil pressure. If the temperature
and/or pressure continue to change beyond the warning point to
a predetermined level, the engine will automatically shut down.
Vehicles are equipped with an override feature that will allow the
95
Operation
engine to be restarted so that the vehicle can be moved. The
engine should be run no longer than absolutely necessary. A
decal located in front of the operator provides instructions on
how the override should be operated.
NOTE: After the engine is restarted, it will operate in a derated
mode for an additional 30 seconds while conditions causing the
shut down are still present.
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 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 SHUT DOWN indicator in the instrument panel
gauge cluster will turn ON 30 seconds before engine
shutdown. This indication will continue until the
engine shuts down or the system is reset.
96
System Operation
The Vehicle Shutdown system operates in the following manner:
1. Bring the vehicle to a stop, place transmission in (N)
Neutral or Park position, and apply the parking brake.
This starts the Vehicle Idle Shutdown system timer.
2. After a minimum of 90 seconds (or whatever the
customer specifies), power is shut off to the engine,
transmission, ABS, HVAC, and any other vehicle
accessories fed by ignition power.
3. When vehicle is ready to be operated, turn the ignition
switch to the START position until the engine starts and
then release the ignition switch.
NOTE: If your vehicle is equipped with the Theft Deterrent
System, the theft deterrent code must be entered before the
vehicle can be safely operated (See the Theft Deterrent System
description).
Theft Deterrent System (Optional)
The optional Theft Deterrent System provides a means to
prevent unauthorized vehicle drive-away, once the vehicle is
started. The driver is required to enter a predetermined code
each time the vehicle is started, or when driving is resumed
after the vehicle was at idle with the parking brake set. The
theft deterrent feature is effective in preventing a vehicle from
being driven by unauthorized individuals - whether the vehicle
has been hot wired or whether it is parked at a location with the
engine idling.
3879634R1
Operation
Theft Deterrent Code.
The theft deterrent code is any
combination of one to eight digits between 0 and 99999999,
obtained from the dealer, and kept in a secured location.
Six switches, located in the instrument panel gauge cluster,
provide the functions of the Theft Deterrent System. Five
of the switches are code digit switches (3-position, center
stable momentary switches) numbered 0 to 9. The remaining
switch is the ENGINE STOP/CLEAR ENTRY switch, which is a
combination switch indicator and a standard momentary switch
(see the illustration below).
The red ENGINE STOP indicator portion of the ENGINE
STOP/CLEAR ENTRY switch flashes to alert the driver that the
theft deterrent code must be entered (within the preprogrammed
time delay or the engine will shut down). The momentary CLEAR
ENTRY position is pressed whenever the driver needs to clear
a failed code entering sequence so that the correct code can
be reentered.
NOTE: The vehicle must be stopped and the parking brake must
be set/engaged before the system will clear the previous theft
deterrent code entry.
Theft Deterrent Code Entry Procedures
Engine Start/Theft Deterrent Code Entry Sequence. The
correct engine start and theft deterrent code entry sequence is
as follows:
1. Driver starts vehicle with parking brake set.
2. The driver enters a code supplied by dealer by pressing
the switch positions for that code (read from left to
right). For example, if the code is 54321, the driver
should press switch positions 5–4–3–2–1 in that order.
If an error is made, while entering the code, the driver
presses the CLEAR ENTRY position of ENGINE
STOP/CLEAR ENTRY switch and enters the entire
code.
3. When the code is entered, an alarm will sound one
short beep and, at the same time, the ENGINE STOP
indicator will flash once. If the wrong code is entered,
an alarm will sound one long beep and the ENGINE
STOP indicator will be illuminated for ~1.5 seconds.
4. Parking brake is released.
5. Vehicle may be driven without interruption.
NOTE: The theft deterrent code must be reentered every time
the parking brake is set/engaged or when the ignition switch is
cycled from the run position.
3879634R1
97
Operation
The following table provides a summary of all the possible
system responses to various driver attempts to start and drive
the vehicle.
#
98
Driver Action
System Alerts
Engine Operating
Status
1.
Engine started with parking brake set
No system alerts
Engine runs without
interruption
2.
Correct theft deterrent code entered (vehicle
stopped and parking brake set).
An alarm will sound one short beep and, at the same time, the
ENGINE STOP indicator will flash once
Engine runs without
interruption
3.
Engine started with parking brake released
Warning sequence is begun; an alarm will beep continuously
and the red ENGINE STOP indicator will flash slowly
Engine will shut down
unless theft deterrent
code is entered within
programmed delay time
4.
Engine started and driven greater than 3
mph
Warning sequence is begun; an alarm will beep continuously
and the red ENGINE STOP indicator will flash slowly
Engine will shut down
unless theft deterrent
code is entered within
programmed delay time
5.
Parking brake is released with engine
running
Warning sequence is begun; an alarm will beep continuously
and the red ENGINE STOP indicator will flash slowly
Engine will shut down
unless correct theft
deterrent code is entered
within programmed delay
time
3879634R1
Operation
#
Driver Action
6.
Correct theft deterrent code is entered after
the warning sequence has begun (within the
programmable delay time)
The continuous alarm beeps and ENGINE STOP indicator
flashes and stops after the alarm sounds once and the
ENGINE STOP indicator flashes once
Engine runs without
interruption
7.
Inadvertent incorrect theft deterrent code is
entered
Alarm activated for one long beep and ENGINE STOP indicator
turns on for ~ 1.5 second
Engine runs without
interruption
8.
Clear switch is depressed with parking brake
set
No system alerts. Theft deterrent code must be entered before
driving vehicle
Engine runs without
interruption
9.
Clear switch is depressed with parking brake
released (assumes correct code previously
entered.)
No action. Previously entered theft deterrent code is not
cleared
Engine runs without
interruption
10.
With vehicle stopped while in warning mode,
set parking brake (within the programmable
delay time)
The ENGINE STOP indicator stops flashing and the alarm
stops beeping. The theft deterrent code must be entered
before driving vehicle
Engine runs without
interruption
3879634R1
System Alerts
Engine Operating
Status
99
Operation
Emergency Starting Using Jumper Cables
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.
CAUTION
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
use batteries connected so as to provide 12 volts.
Never use an electric welder.
1. To prevent shorting of the electrical system, remove metal
rings or watches and do not allow metal tools to contact
positive terminal of battery.
2. Place transmission in (N) Neutral and set parking brake in
both vehicles.
3. Shut off lights, heater, air conditioner and any other electrical
loads in both vehicles.
4. Eye protection should be worn if available. If not available,
shield eyes when near either vehicle’s batteries.
6. Connect one end of the first jumper cable to positive (+)
terminal of the dead battery or (+) terminal of jump start
stud and then the other end to the positive (+) terminal of
the booster battery.
7. Connect one end of the second jumper cable to 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.
8. Reverse above procedure when removing the jumper
cables.
Cold Weather
WARNING
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.
CAUTION
If vehicle is equipped with the optional heated
windshield function, do not scrape the inside
of the windshield. Failure to comply may result
in permanent damage to the heated windshield
components.
5. Vehicle bodies or bumpers must not be in contact.
100
3879634R1
Operation
Cold Weather Starting
Winter/Engine Intake Operation
For vehicles frequently operating in cold climates an optional
engine block heater is available. The block heater utilizes an
external 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.
When the WINTER position is selected, the optional
yellow Snow Valve warning indicator in the instrument
panel gauge cluster turns on. When the intake valve
is fully opened, the yellow warning indicator turns off
and the green indicator, on the switch, turns on. When
the switch is moved from the WINTER position to the
ENGINE INTAKE position, the green indicator on the switch
goes out and the yellow Snow Valve warning indicator in the
instrument panel gauge cluster turns on as soon as the valve
begins to close. When the intake valve is fully closed, the yellow
warning indicator turns off.
Cold Weather Operation
In order to operate the engine in temperatures of 32°F (0°C) or
lower, observe the following instructions:
•
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 anti-freeze 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 -4°F (-20°C) and below, it is
recommended that you use a crankcase mounted coolant
heater to improve cold starting.
•
If operating in arctic temperatures of -20°F (-29°C) or lower,
consult your International dealer for information about
special cold weather equipment and precautions.
3879634R1
Engine Idling
CAUTION
Because diesel engines are highly efficient, they
use very little fuel while idling. As a result, idling
in cold weather will not heat the engine to its
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.
•
Use a minimum 45 Cetane diesel fuel or utilize Cetane Index
improvers from a reputable manufacturer.
101
Operation
•
Maintain a minimum of 1250 RPM idle by use of the hand
throttle. Always make sure that parking brake is applied and
transmission is in (N) Neutral before applying hand throttle.
•
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 in the
exhaust DPF.
•
Consider use of engine block heaters, approved
winter-fronts, and/or radiator shutters where conditions
warrant.
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 vehicles 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
anti-freeze solution to protect against damage by
overheating.
102
2. Fill fuel tank at end of daily operation to prevent
condensation in tank.
3. Keep external surface of engine, radiator, charge air
cooler, AC condenser, and accessories clean to avoid
dirt build-up.
Excessive coolant temperature could be experienced while
driving in a 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.
Starting A Turbocharged Vehicle On A Grade
Once the clutch is engaged on a turbocharged diesel engine,
the RPM falls off significantly. This is due to the emission control
device that controls the fuel input during first gear acceleration.
When engine RPM first falls off, do not disengage the clutch and
try to increase engine RPM. Doing so may damage driveline
components. After the initial drop in speed, the engine will
recover and accelerate in a normal manner.
Proper Starting Procedure
Set the spring brakes or hand brake, if equipped, bring the RPM
up slightly and begin to engage the clutch while, at the same
time, releasing the spring brakes.
As the RPM begins to fall off, DO NOT disengage the clutch. The
RPM will quickly come back and the vehicle will move steadily
up the grade.
3879634R1
Operation
Operating Instructions
WARNING
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.
3879634R1
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.
CAUTION
Do not lubricate the tilt or tilt/telescoping steering
mechanism.
Tilt Steering Column
The optional tilt steering column has infinite positions allowing
adjustment toward or away from the driver through a 20 degree
range. The tilt handle is located on the left side of the column.
To tilt the column, pull the lever towards the driver and move the
steering wheel to the desired position. Release the lever to lock
the column in position.
103
Operation
Adjustable Tilt/Telescoping Steering Column
•
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
1. Steering Wheel
2. Release Handle
If equipped with the optional tilting and telescoping steering
column, the steering wheel can be adjusted as follows:
•
104
•
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 overspeeding of the engine when going down
long and steep grades. The governor has no control over
engine speed when it is being pushed by the loaded vehicle.
Operate in a gear that will permit an engine speed below
the maximum governed speed or high-idle RPM (no load).
Grasp the steering wheel with your right hand and unlock the
release handle with your left hand by pushing forward on the
release handle.
3879634R1
Operation
Electrical
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.
3879634R1
NOTE: 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.
Additional detailed information on
these optional features may be found in the CT-471 Body
Builder Manual, Electrical System Component Section, and
the Body Builder Electrical Guide, both available through the
internationaltrucks.com Web site (Body Builder option, under
Customer Support menu).
Electrical System
The Electrical System provides a means to distribute the
electrical power and provide the driver with controls and
indications of vehicle performance.
This system uses
multiplexing for connecting to major functional areas of the
truck with much less wiring. The system provides interfaces
to a majority of vehicle switches and sensors. The system
also communicates with the standard and optional system
controllers and modules in the vehicle. These include: the
Body Controller (BC), the Electronic Gauge Cluster (EGC),
the engine Electronic Control Module (ECM), a Transmission
Control Module (TCM), the ABS Electronic Control Unit (ECU),
panel-mounted switches, and door pods.
105
Operation
Battery
Alternator
CAUTION
Before connecting a fast charger or booster
battery, or installing a new battery, make sure
that the ground polarities of the fast charger,
booster battery, or alternator (when installing a
battery) are matched to the ground polarity of the
vehicle battery. Improper usage of fast charger,
hook-up of booster battery, or installing battery
can cause damage to the electrical system or
to the alternator. Do not attempt to polarize the
alternator.
Many alternators used in International® 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
or ammeter for charging indication before leaving the vehicle.
Ammeter
The optional ammeter indicates the rate of charge of electric
current supplied by the alternator to the battery, or the rate of
discharge from the battery. At low engine speeds, the ammeter
indicator may show a negative or discharge reading. When the
battery is fully charged, a very slight charge is indicated during
normal vehicle operation.
106
WARNING
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.
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.
WARNING
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 damage,
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.
3879634R1
Operation
WARNING
Do not check battery condition by shorting
(flashing) across terminals. Failure to observe
this warning could result in personal injury
and/or damage to the vehicle.
When working around the terminals and battery, use extra care
to avoid shorting. A good practice is to use insulated pliers and
screwdrivers.
Battery Disconnect Switch
Circuit Breakers, Fuses, and Fusible Links
WARNING
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 fire,
which could cause property damage, personal
injury, or death.
This optional switch is used to prevent the batteries from
discharging. When a vehicle is not going to be operated for
several days, this switch can be used to shut off the system
so the electrical components on the vehicle, if left on, will not
discharge the batteries.
Electrical circuits are protected either by the body 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 Specification section of this
manual.
These features have options that provide a key or lever
operated battery disconnect switch, which may be cab mounted
or mounted on the battery box. There are also options that
completely disconnect the batteries or disconnect everything
except the charging circuits.
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 splicing
in a new fusible link with the same gauge wire as the opened
fusible link.
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 Virtual Fusing
system. Type II circuit breakers will reset if the short is removed
from the circuit.
The various electrical units in the cab and engine compartments
are protected by either fuses or circuit breakers. The power
3879634R1
107
Operation
distribution center is located behind a hand-removable cover on
the instrument panel on the passenger side of the vehicle.
Engine
The engine for this vehicle is an electronically controlled diesel
engine. A separate electronic control module (ECM) monitors
and controls all engine functions. This ECM also communicates
with the body electrical system, which will generate or activate
the necessary indicators to alert the driver of out-of-range
operating conditions.
For complete information on the engine in this vehicle and
its optional features, refer to the Engine Operation and
Maintenance Manual supplied with this 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.
Engine Brake, Retarder (Optional)
WARNING
Do not use the vehicle retarder, 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.
WARNING
Before operating the Engine brake feature, study
the following descriptions and instructions as
well as the engine Operator’s manual. Failure to
do so could result in property damage, personal
injury, or death.
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 slowing system.
Service brakes are always used to bring vehicle to a complete
stop.
Engine braking features are used for traffic conditions that
require frequent use of the service brake and therefore
shortening 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.
The optional braking features are controlled by the driver using
the ENGINE BRAKE ON/OFF switch, and ENGINE BRAKE
108
3879634R1
Operation
SELECTOR 1/2/3 switches that are located in the center
control switch panel. The following paragraphs provide a brief
description of these optional braking features.
NOTE: The engine brake feature will automatically
deactivate if either the accelerator or the clutch is
pushed, or when the engine speed falls to 1000 RPM.
Engine Brake System Operation
Operational Modes
Vehicles, with MaxxForce® DT, 9, or 10 engines, utilize either the
optional Diamond Logic® Engine Brake for additional braking in
various operating conditions.
The optional Diamond Logic® Engine
Brake is a compression style brake that
utilizes the injection control system pressure
and the closed vanes of the turbocharger for
maximum braking power. The Engine brake
is controlled by the switch panel switches:
ENGINE BRAKE ON/OFF, and ENGINE BRAKE SELECTOR
1/2/3. To activate the engine brake, place the ENGINE BRAKE
ON/OFF to the ON position (the switch indicator will turn on).
The ENGINE BRAKE SELECTOR 1/2/3 switch is used to adjust
the amount of braking applied.
The engine brake will operate in one of these two modes.
Changes must be reprogrammed, in the engine controller, by
an authorized International dealer.
NOTE: The ECM will not allow the Diamond Logic® Engine
Brake to operate until the engine oil has reached the acceptable
minimum temperature, therefore, do not attempt to activate
the engine brake until the engine has reached full operating
temperature.
3879634R1
Coast Mode. In the coast mode, with the brake enabled, the
brake will activate when the driver hits the service brake (at or
above 1200 RPM). The brake will deactivate if the driver releases
the brake pedal, or if the engine speed drops below 1200 RPM.
Latched Mode. In the latched mode, with the brake enabled,
the braking will activate when the driver’s foot is lifted from the
accelerator pedal (at or above 1200 RPM). If, however, the
cruise ON/OFF switch is in the ON position (with or without
a cruise set speed), engine brake function defaults to Coast
Mode and braking is activated by pressing the brake pedal and
deactivated by releasing the brake pedal.
MaxxForce® 11 and 13 Engine Brake With Eaton
AutoShift®/UltraShift® Transmissions Special Driver
Instructions
Low or manual transmission mode can be used to maximize
engine brake performance.
•
Keep engine speed as close to 2250 rpm as possible.
•
Maintain brake pedal application until any desired
downshifts are completed. Failure to do so may cause
missed shifts.
109
Operation
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 shift
is completed.
The engine brakes will deactivate when the transmission shifts
from converter lock-up to normal torque converter operation.
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
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.
When an ABS event occurs, the engine brake will turn OFF and
will automatically be turned back ON when the ABS conditions
are no longer present.
•
Automatic Transmission Operation
With the Allison transmission, when the engine brake is
activated, the transmission is programmed to perform shift
schedules that maximize braking effects.
The Allison transmission control module is programmed with a
pre-selected 4th gear as a default. This means that when the
driver selects “D” or Drive, the engine brake will operate down
to 4th gear (at or above 1,200 RPM). If the driver manually
selects 3rd or 2nd gear, the engine brake will operate down to
the manually selected gear (at or above 1200 RPM).
NOTE: Manually selecting 3rd or 2nd gear during braking with
no load or during slippery driving conditions could result in a
loss of traction, as indicated in the above warning. Manually
selecting 3rd gear or 2nd gear will not cause damage to the
engine or transmission. The manually selected gear is only for
driver intent. The transmission will only downshift according to
the pre-programmed shift schedules.
110
ABS Operation
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:
•
Engine Warm-Up Control - (ECM) adjust injector operation
as required.
•
Cold Ambient Protection (CAP) - to aid engine warm up and
maintain engine temperature.
•
Cruise Control - provides vehicle speed control.
3879634R1
Operation
Some Optional Features:
•
Engine Warning System - this system illuminates the Red
“Engine” indicator and actuates a beeper when warning
thresholds for coolant temperature, engine coolant level,
and/or low engine oil pressure are exceeded.
•
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.
•
Throttle Control for PTO Operation.
•
Road Speed Limiting/Governor - programmable maximum
speed.
•
Idle Shutdown Timer - shuts down engine after 5 minutes of
idle time.
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.
Engine Warning/Protection System (EWPS)
The engine provides three distinct levels of protection:
•
Standard Engine Warning System 2-Way
•
Optional Engine Warning System 3-Way (08WWJ)
•
Optional Engine Protection System 3-Way (08WPP)
Standard Engine Warning System 2-Way
Certified Clean Idle
MaxxForce® 11 and 13 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
3879634R1
The ECM monitors engine operating conditions for excessive
engine speed, low oil pressure, and coolant temperature. If
these conditions occur, a fault code will be set, but the Yellow
Engine Warning indicator or the Red Engine Warning Indicator
are not turned ON. Standard instrumentation includes an oil
pressure and engine coolant temperature gauge.
CAUTION
Allowing water to stay in the fuel system
could result in extensive damage to the fuel
injection system. Refer to the appropriate Engine
Operation and Maintenance Manual for more
information.
111
Operation
NOTE: If the Oil/Water Warning Indicator comes ON, bring the
vehicle to a safe stop and shut the engine OFF before shutdown
occurs.
and will operate in a de-rated mode for an additional 30 seconds
if the conditions causing the shutdown are still present (See
Automatic Engine Shut-Down and Restarting procedure).
Optional Coolant Warning Level System – 3 Way (08WWJ)
Air Compressor Cycling
This option provides a warning if the coolant is below the safe
operating level.
The MaxxForce® 11 and 13 Liter engines can be equipped with
one of two different types of air compressor and may have one
or two cylinders.
NOTE: If the RedEngine Warning Indicator comes ON, bring the
vehicle to a safe stop and shut the engine OFF.
•
Direct Line Unloaded (DLU) Air Compressor: This
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 pumped to the atmosphere via the
muffler equipped, frame- mounted unloader valve. This
system provides relatively lower air compressor cylinder
temperatures verses head-unloaded compressors during
the unloaded cycle. It is normal to hear a small amount of
compressor-created sound during the unloaded cycle.
•
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. This system provides relatively higher cylinder
temperatures verses head-unloaded compressors during
the unloaded cycle, but does not require the plumbing and
complexity of the DLU compressor. It is relatively quieter
during the unloaded cycle than the DLU.
Optional Engine Protection System – 3 Way (08WPP)
WARNING
In the event engine shutdown occurs, make
certain that vehicle is safely off the roadway,
the 4-way emergency flashers are on, and the
warning devices are properly placed. Failure to
remove vehicle from roadway could result in an
accident, personal injury or death.
This system includes the 3-way engine warning system. In
addition, if engine oil pressure, excessive engine speed, engine
coolant temperature or engine coolant level conditions exceed
the warning limits, the appropriate fault codes are set and the
Red Engine Warning Indicator is turned ON. If the engine oil
pressure, engine coolant temperature or engine coolant level
conditions exceed the preset critical limit, the engine is shut
down. After an automatic shutdown, the engine can be restarted
112
3879634R1
Operation
•
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 120 psi (827 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 105 psi (724
kPa), the governor signals the air compressor to resume
pumping pressurized air to the air system. During normal
engine operation, this cycle will be evident by the fluctuation of
the primary air tank pressure gauge.
3879634R1
Cooling System
WARNING
To prevent personal injury or death from hot
coolant or steam, use only the following
procedure to remove the pressure cap from
the deaeration tank. Allow the engine to cool
first. Wrap a thick, heavy cloth around the
cap. Depending on the type of cap, push down,
loosen cap slowly to its first notch position, or
unscrew cap slowly; then pause a moment to
allow pressure to release through the overflow
tube. After the pressure has been released, the
pressure cap may be removed.
WARNING
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
no advance warning. Failure to observe these
precautions could result in vehicle damage,
personal injury, or death.
113
Operation
WARNING
Do not exceed the pressure rating on the
deaeration tank cap. Ensure that the pressure
rating of the deaeration tank cap matches that
listed on the side of the tank, or the tank may
burst, causing property damage, personal injury,
or death.
CAUTION
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 cylinder block. Never use
water alone.
Antifreeze
The cooling system of your new vehicle is filled at the factory
with either a Type II Fully-Formulated (purple) or Type III ELC Extended Life Coolant (red). The type of coolant depends upon
the engine manufacturer and the preference of the purchaser if
optional coolants are allowed.
The Type II coolant must meet Type ll specs, such as the
Fleetrite® Premium 50/50 with SCA (P/N ZJJSCA5550). The
Type III coolant must meet Type IlI specs, such as the Shell
Rotella® ELC - Extended Life Coolant (P/N 94042). Refer to
the label on the deaeration tank to determine the coolant type.
114
Consult the Engine Operation and Maintenance Manual for
coolant service life details.
For vehicles with MaxxForce® 11 and 13 engines, the cooling
system of your new vehicle will be filled at the factory with
nitrite-free Shell Rotella® Ultra ELC (YELLOW) coolant.
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.
Engine Oil
For maximum fuel economy and engine protection, keep oil
level between the ADD and FULL marks on the dipstick. Never
operate an engine with oil level above the FULL mark or below
the ADD mark.
When checking the oil level, the dipstick must be withdrawn and
wiped clean, then inserted all the way in and again withdrawn for
a true check.
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.
Use only recommended viscosity engine oil. Refer to the Engine
Operation and Maintenance Manual for engine oil specifications.
3879634R1
Operation
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.
Engine Performance Problems
•
•
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.
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.
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.
3879634R1
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
WARNING
Never add gasoline, gasohol 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
space, which will pose an extreme fire/explosion hazard during
refueling or engine operation.
Additional Unsafe Practices
CAUTION
To prevent engine damage, do not mix propane
with diesel fuel. Warranty claims will not be
honored against engines that have used propane.
115
Operation
CAUTION
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.
Therefore, when refueling, be sure that both tanks are filled
completely, as it is sometimes difficult to determine which tank
is the draw tank and which is the reserve tank.
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.
2. Do not smoke or expose any open flame in the vicinity
of a vehicle being fueled.
Fueling Procedures
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.
NOTE: If your vehicle is equipped with dual fuel tanks, be sure
to read and understand the following information before refueling
the vehicle.
4. Do not permit any other person to engage in such
activities as would be likely to result in fire or explosion.
A dual tank system contains a primary and a secondary fuel tank.
Reserve Fuel
With dual fuel tanks, the vehicle will be equipped with a fuel
transfer pump system that will pump fuel from the secondary
(reserve) fuel tank and send it to the primary (draw) fuel tank.
The draw fuel tank must have fuel in it at all times, otherwise the
vehicle may stall and may be difficult to restart (the fuel gauge
reads the fuel level only from the draw fuel tank).
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.
116
3879634R1
Operation
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 Regeneration. 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.
3879634R1
WARNING
Failure to perform a Parked Regeneration when
exhaust filter indicator is ON will cause the engine
to lose power and eventually 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).
117
Operation
2010 Federal Emissions Label
Level
Indication
1
Audible Alarm
None
Exhaust filter
regeneration required.
None
Scrolls between
See Visor for info
and Parked Regen
Required.
Exhaust filter is full.
An alarm will beep
continuously while
ignition is on.
Scrolls between
See Visor for info
and Parked Regen
Required.
Exhaust filter is full.
Engine performance is
LIMITED.
(Flashing)
3
(Flashing)
Vehicle
Conditions/Operation
Scrolls between
See Visor for info
and Parked Regen
Required.
(Solid)
2
LCD Text Message
Action Required
Drive on highway at highway speeds or start Parked
Regeneration to prevent loss of power.
Pull vehicle safely off roadway and start Parked
Regeneration to prevent loss of engine power.
WARNING
Pull vehicle safely off roadway and
start Parked Regeneration to prevent
engine stopping.
Exhaust System Temperature is HOT
WARNING
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.
118
3879634R1
Operation
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
available
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 170° F (76.6°
C).
NOTE: The engine coolant temperature must be above 170°
F (76.6° C) 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
3879634R1
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.
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 REGEN 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
inhibit switch: the two-position and the three-position
switch. Therefore, it’s necessary to verify which version is
installed in this vehicle. Both versions have the same switch
labels.
119
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.
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.
Engaging the Clutch
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 manual transmissions have a clutch pedal that is
used to engage or disengage the clutch or for connecting or
disconnecting the engine from the transmission and rear wheels.
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!
Almost every early clutch failure can be traced to excessive
friction heat. Do not ride or slip the clutch. Once a clutch is
120
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, increase the engine speed
and fully engage the clutch. Increasing the engine speed before
fully engaging the clutch can damage the clutch and drive train.
Do not shift until vehicle has reached proper speed.
Upshifting before the vehicle has reached the right speed is
almost as bad as starting off in too high a gear. When the
difference between the vehicle speed and the engine speed is
too great, the clutch is forced to slip. The result is extra heat
and wear.
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.
Never coast with the clutch disengaged. This can cause
clutch failure by the very high RPM encountered when coasting
in gear with the clutch released. In this situation, the rear wheels
3879634R1
Operation
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.
Never engage the clutch while coasting. Reengaging 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
when the vehicle is at a standstill and the engine running at idle
speed. Clutch brake application occurs in the last 1 inch (25mm)
of pedal travel.
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, 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 1
inch (25mm) of pedal travel.
1. Driver must start vehicle in first gear.
2. While operating a ceramic clutch, the driver has to engage
the clutch before giving the engine any fuel (at idle).
3. The driver should not try to slip the ceramic clutch by raising
engine RPMs 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).
Clutch Brake (Vehicles with Nonsynchronized Transmission) –
Vehicle Not Moving
Double Clutch Procedures, Nonsynchronized
In order to properly upshift or downshift be sure to do the
following:
•
Depress the clutch pedal to disengage the clutch.
•
Shift the transmission into neutral.
•
Release the clutch pedal.
•
If upshifting, wait until the engine speed matches the
transmission speed of the gear you desire to shift into.
•
If downshifting, accelerate the engine until the engine speed
matches the input speed of the gear you desire to shift into.
A clutch brake is used to stop transmission input shaft rotation so
that the initial first or reverse gear selection can be accomplished
3879634R1
121
Operation
•
Depress the clutch pedal immediately and shift into the
desired gear.
•
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
becomes necessary.
To avoid needless delay and expense, allow only competent and
experienced mechanics to perform these operations.
Shifting with Synchronized Transmission
With the clutch released (pedal depressed), use second speed
gear synchronizer to stop clutch disc rotation. This will allow
smooth engagement of first or reverse gear selection. In order
to complete gear engagement, it may be necessary to apply
light pressure to the shift lever during initial engagement of
the clutch. It takes one to two seconds to match gear speeds.
122
Steady pressure on shift lever will help the synchronizer perform
its job quicker. If the shift lever is forced into gear it is possible to
override a blocker and defeat the purpose of the synchronizer,
causing gear clash.
Shifting with Nonsynchronized Transmission
Refer to Clutch Brake (vehicles with nonsynchronized
transmission) and Double Clutch Procedures in this section
(above).
Operation of the Eaton AutoShift® Transmission and Shifter
WARNING
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” or “D” button. If you do not hold the brake
pedal down, your vehicle may move unexpectedly
and cause property damage, personal injury, or
death.
3879634R1
Operation
To shift the Eaton® transmission into Reverse (R) or Drive (D),
first place foot on the brake and optional clutch pedal. When
in Drive (D), the transmission selects the starting gear and
automatically selects the proper gears for operating loads. To
select a higher or lower gear, first press the Hold button and use
either the up arrow or down arrow shift buttons. If LO is selected
while the vehicle is stopped, the transmission will remain in LO
gear until another gear is selected. If selected while in motion,
the transmission will downshift when it is safe to do so. To place
the transmission in Neutral, press the (N) button.
Eaton UltraShift® Transmissions (Optional)
1. Reverse Button
The optional Eaton UltraShift® transmission is an automatic
transmission that can automatically select and engage the
proper transmission gears.
Vehicles equipped with this
transmission do not have a clutch pedal.
For operating
instructions, refer to the Transmission Manual.
2. Neutral Button
Automatic Transmissions
3. Forward Gear Selector Button
4. Hold Button
5. Low Gear Button
6. Downshift Button
Allison Transmissions
NOTE: For a complete description of the Allison Automatic
Transmissions, refer to the Allison Transmission Operator’s
Manual, supplied with this vehicle.
7. Upshift Button
8. Service Indicator
The Eaton AutoShift® is a partially automated transmission
that automatically selects and engages the proper transmission
gears. Some vehicles are equipped with an optional clutch
pedal that must be used when starting and stopping the vehicle.
3879634R1
Allison Transmission with “P” – (Park) Park Pawl Mechanism or
“PB” – Parking Brake Position
“P” – Park Pawl. A park pawl transmission effectively grounds
the output shaft, thereby preventing rotation of the driveline.
If the vehicle is stationary, selecting the “P” (Park) position on
123
Operation
the shift selector places the transmission in “N” (Neutral) and
engages the park pawl (always use with the Parking brake).
NOTE: If you attempt to engage “P” position while vehicle is in
motion (1 mph, 2 km/hr) or higher, the park pawl mechanism will
ratchet, and will not hold the vehicle.
Parking The Vehicle
The following WARNINGS provide the methods of parking the
vehicle using the various transmission shift selectors.
WARNING
“PB” – Parking Brake.
For the transmissions with the
Auto-Apply Parking Brake – “PB” position, selecting PB places
the transmission in “N” (Neutral) and automatically engages the
Air or Hydraulic parking brake.
To prevent sudden,
unexpected vehicle
movement and property damage, personal
injury or death, always use the parking brake
IN ADDITION TO leaving the transmission in
gear.
CAUTION
Do not apply the parking brake with the vehicle
in motion. Transmission and/or driveline damage
can result. In the event of a dynamic brake apply,
recheck the torque of all brake mounting bolts to
verify the integrity of the mount.
To prevent sudden,
unexpected vehicle
movement and possible property damage,
personal injury or death, perform the following:
•
Bring the vehicle to a complete stop.
•
Put transmission selector in “P” – Park Pawl, “PB” Auto Apply Parking Brake , or N – Neutral.
CAUTION
Sustained use of the parking brake with the
engine running and the transmission in range can
cause an overheating failure of the transmission.
The instrument panel gauge cluster contains a
Parking Brake indicator that illuminates when
the ignition switch is “ON”, the parking brake
is applied, and the transmission selector is in
range.
124
For the park pawl (P – Park) transmissions, slowly lift
foot from brake pedal to engage transmission park pawl
mechanism.
•
Apply the parking brake (either lever or Parking Brake
dash control) and ensure that it is holding properly. (For
the “P” – Park Pawl transmissions, do not rely solely
upon the parking mechanism of the transmission).
3879634R1
Operation
WARNING
•
For the Auto Apply Parking Brake (“PB” transmissions),
make sure that the “PB” selection has applied the
Parking Brake (Parking Brake indicator should be
turned On) by slowly releasing the service brake and
verifying that the vehicle will not roll.
•
Chock the wheels and take any other steps necessary
to keep the vehicle from moving.
•
Turn off engine anytime you leave the vehicle. Never
leave the vehicle unattended with the engine running.
Preparing to Drive the Vehicle
WARNING
To prevent unexpected vehicle movement, hold
the brake pedal down while you move the
gearshift from position to position. Failure to
follow this warning could result in property
damage, personal injury, or death.
Read and perform the following steps for the particular vehicle
Parking brake whenever you prepare to drive away.
Parking Brake Interlock. To shift from P (Park) or PB (Parking
Brake), the shifter is equipped with a Parking brake Interlock.
The ignition switch must be in the ON position and brake pedal
depressed before the gear selector can be moved from the P
(Park) or PB (Parking Brake) position into the desired operational
position.
3879634R1
Manual Parking Brake
After starting the engine, place foot firmly on brake pedal.
With foot still on brake pedal, select the desired transmission
operating position.
With foot still on brake pedal, push manual Parking Brake lever
down to release, then lift foot from brake pedal to allow the
vehicle to move.
Air Parking Brake or Power Parking Brake
After starting the engine, place foot firmly on brake pedal.
With foot still on brake pedal, push and hold shift selector
button and move selector to the desired transmission operating
position.
With foot still on brake pedal, push in on Parking Brake control
knob to release parking brake (Air Brake) or push and release
the control knob (Power Parking Brake), then lift foot from brake
pedal to allow the vehicle to move.
Operation of the Allison Generation IV Gearshift Controls
WARNING
To prevent unexpected vehicle movement, hold
the brake pedal down while you move the
gearshift from position to position. Failure to
follow this warning could result in property
damage, personal injury, or death.
125
Operation
Both the T-Bar gearshift control and the Push-button gearshift
control are available with the Allison automatic transmissions.
They provide the same gear shift functions and control the
transmission in the same manner.
Allison Generation IV T-Bar Gearshift Control
When the vehicle is started, the transmissions are designed
to operate in the standard performance mode. Pressing the
Mode button on the shift tower will switch the transmission
to Economy mode and illuminate Mode ON in the shift tower
display. Economy mode provides operation at a lower engine
RPM while maintaining adequate performance.
If the engine speed is above idle when a gear is selected with the
shift tower, the vehicle will not move. To move the vehicle, the
shift tower must be moved to re-select a gear after the engine
comes down to idle.
For further information on the Allison transmission, refer to
the separate Allison vocational transmission model Operator’s
Manual.
Torque Lock
If the vehicle is parked on an incline and P (Park) is properly
engaged, the weight of the vehicle may generate an excessive
amount of torque on the park pawl in the transmission. In this
situation, it may be difficult to shift the transmission out of the
P (Park) position. To drive the vehicle out of the torque lock,
perform the following:
1. Hold Override Button
•
Push the vehicle uphill a small amount to release the
pressure on the park pawl and permit the shift out of P
(Park). At this point, place foot on brake pedal.
•
Hold foot on brake pedal while shifting the transmission out
of P (Park).
•
Release the parking brake.
2. Mode Indicator (Led)
3. Mode Button
4. Mode Id
5. Digital Display
6. Display Mode Diagnostic Button
126
3879634R1
Operation
Operation of the Allison Generation IV Push-button Shift
Selector
1. Digital Display
2. Mode Id
3. Mode Button
4. Range Selector Buttons
To shift the Allison transmission into Reverse (R) or Drive (D),
first place foot on brake pedal. With foot on brake pedal, press
either R or D, release the Parking Brake, and then release the
brake pedal. When in Drive, to select a lower range press and
release the down arrow button. To select a higher range, press
and release the up arrow button. To place the transmission in
Neutral, press the (N) button.
3879634R1
127
Operation
Operation of the Column-Mounted Shifter
A Column-mounted shifter is used with some Allison
transmissions. The selected gear positions will be indicated, on
the instrument panel gauge cluster’s LCD display, by a dash
directly under R, N, or gear number.
NOTE: When using the column-mounted shifter, while the
transmission is not in “P” – Park or “PB” – Parking Brake, the
LCD display will indicate the selected gear at all times, even if
the ignition switch is in the OFF position. With the ignition switch
in the OFF position, when the transmission is shifted to the park
position, the dash indicator shall disappear and the instrument
panel gauge cluster will complete its shutdown.
To shift the transmission out of “P” – Park or “PB” – Parking
Brake, first read and then perform the following:
•
128
First press foot on service brake pedal (see Park Position
Interlock section).
•
For reverse, pull on shift control lever and move lever to
“R” position (as indicated on LCD display), and then release
column shift lever.
•
Release the Parking Brake.
•
Lift foot from service brake pedal to allow the vehicle to move
backward.
•
To select a forward gear (while holding service brake pedal
down), pull on shift lever and move down thru “N” - Neutral
and stop at “D” – Drive or any of the available gears as
indicated on the LCD display.
•
Release service brake pedal and allow vehicle to move
forward.
Main Transmission Controls
Main transmission, auxiliary transmission, transfer case, and
power take off control shift patterns can be found on a placard
or decal on the driver’s visor door, on the instrument panel, or
on the shift control itself. In certain cases, the shift pattern,
for a component added by a Body Builder, will be in the Body
Builder’s manual.
The main transmission control is used to select the various gear
ratios or speeds provided within the transmission.
Selection of the D (direct drive) gear does not change the gear
ratio provided by the main transmission but is used where the
gear ratios in the main transmission are adequate to handle the
vehicle operation.
3879634R1
Operation
Selection of the OD (overdrive) gear in the auxiliary transmission
permits increased road speeds in the various transmission
ratios.
A loaded vehicle should not be operated with the auxiliary
transmission in OD (overdrive) with the main transmission in
either of the two lowest speed gears. Doing so could cause
damage to either the transmission or propeller shaft.
WARNING
Before backing up, check to see that area behind
vehicle is clear of people, animals and objects.
Use a spotter whenever possible and always
keep that person in sight. Failure to do so may
result in property damage, personal injury, or
death. If so desired, backup alarms are available
through your International dealer. However, they
are never a substitute for the above procedures.
Backup Alarm
An optional backup alarm feature is available and provides
an audible warning signal whenever the vehicle is operated in
reverse gear.
3879634R1
Auto Neutral
WARNING
When using the AUTO NEUTRAL feature, always
hold the brake pedal down when releasing
the parking brake since the transmission will
automatically return to forward gear. Failure to
follow this warning could result in unexpected
vehicle movement causing property damage,
personal injury, or death.
The optional Auto Neutral feature is available for applications
involving frequent starts and stops that also require exiting the
vehicle, such as refuse and concrete truck operations.
This feature is activated by placing the AUTO NEUTRAL
switch in the UP position. When activated, the transmission
automatically shifts to Neutral when the parking brake is applied,
and the AUTO NEUTRAL indicator is illuminated. This feature
also causes the transmission to automatically shift into the
forward gear when the parking brake is released.
The mode, that is installed in your vehicle, is identified by a decal,
located near the shifter. There are TWO possible Auto Neutral
modes that are available for this vehicle. The two modes are
described below.
129
Operation
3. The transmission shifter’s digital display shows a
blinking “N”, indicating the transmission is in Neutral,
and the instrument panel gauge cluster LCD display will
indicate Neutral gear.
When the parking brake is released, the transmission
will go back to the gear originally selected, the shifter’s
digital display will show that gear, the LCD display
will also indicate that gear, and the AUTO NEUTRAL
indicator will go off.
Note: The Auto Neutral switch indicator will still be
On – indicating that the Auto Neutral function is
still enabled – and will remain on until the switch is
placed in the Off position.
Temporary Neutral – 13AAZ. To activate this Auto Neutral
feature, perform the following:
1. To enable Auto Neutral , place the AUTO NEUTL/ON
switch in the ON position (the switch indicator will then
turn On).
2. When the Parking Brake is applied, the transmission
automatically shifts to Neutral, and the AUTO NEUTRAL
indicator in the instrument panel gauge cluster will turn
on.
130
4. Repeat these steps as long as the Auto Neutral mode
is desired. To turn off the Auto Neutral mode, place
the AUTO NEUTL/ON switch to the off (AUTO NEUTL)
position. This will turn Off the switch indicator.
Neutral gear Remains (Hard Neutral) – 13WUA. To activate
this Auto Neutral feature, perform the following:
1. To enable Auto Neutral feature , place the AUTO
NEUTL/ON switch in the ON position (the switch
indicator will turn On).
2. When the Parking Brake is applied, the transmission
automatically shifts to Neutral, and the AUTO NEUTRAL
indicator in the instrument panel gauge cluster will turn
on.
3879634R1
Operation
3. The transmission shifter’s digital display will show
a non-blinking “N”, indicating the transmission is in
Neutral.
T-Bar shifter: when the parking brake is released, the shift
lever has to be moved to Neutral and then back to the
desired forward gear. The AUTO NEUTRAL indicator will
go off.
Pushbutton shifter: when the parking brake is released,
press the shifter button for the desired transmission
gear.
Note: The Auto Neutral switch indicator will still be On –
indicating that the Auto Neutral function is still enabled
– and will remain on until the switch is placed in the Off
position. The AUTO NEUTRAL indicator will go off.
Power Take Off Control
If your vehicle is equipped with a power take off (PTO), refer to
the PTO equipment manufacturer’s instructions.
If vehicle is equipped with an Allison Automatic Transmission,
refer to separate Allison Transmission Operator’s Manual.
Automatic Transmission Operating Temperature
For the Allison transmissions, the sump/fluid reservoir
temperatures (indicated by optional gauge or warning indicator)
should not exceed 250°F (121°C). The converter temperature
(indicated by optional gauge or warning indicator) should not
exceed 300°F (149°C). For the transmissions with retarder, the
converter temperature (indicated by optional gauge or warning
indicator) should not exceed 330°F (166°C).
4. Repeat these steps as long as the Auto Neutral mode
is desired. To turn off the Auto Neutral mode, place
the AUTO NEUTL/ON switch to the off (AUTO NEUTL)
position. This will turn Off the switch indicator.
3879634R1
131
Operation
Tandem Axle Power Divider Lock (PDL) Control
Rear Drive Axles
Locking Differentials
CAUTION
WARNING
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 slip. 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.
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.
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 interaxle
differential action, when backing under a trailer with a tractor,
starting on a slippery surface (poor traction), operating off
highway in mud, (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. If you
encounter wheel spin conditions, the PDL switch should be
moved to the LOCK position.
CAUTION
Engage the PDL only when stopped or moving at
low speed. Never try to engage the PDL while the
wheels are spinning, as this may result in shock
damage to the power divider components.
When encountering slippery highway conditions (poor traction),
the PDL can be engaged at a low, even speed. Momentarily
letting off the accelerator will engage the differential lock.
A warning indicator on the instrument panel gauge cluster
indicates when the inter-axle differential is locked.
132
3879634R1
Operation
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 interaxle
differential.
Tandem axle power dividers or interaxle differentials
in the forward rear axle are controlled by the
dash-mounted power divider lock (PDL LOCK)
switch.
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.
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 interaxle
differential wear due to unequally worn or mismatched tires, etc.
Driver-Controlled Differential Lock
The differential lock feature locks together the axle’s
left and right axle shafts for improved traction on
reduced traction surfaces.
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,
3879634R1
mounted on the instrument panel gauge cluster, the driver can
lock or unlock the rear axle differential(s) when the vehicle is
moving or stopped.
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 manually shifted from the
vehicle cab. By actuating the switches,
mounted on the instrument panel gauge cluster, 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
understeer 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
must be limited to low vehicle 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.
133
Operation
The vehicle may need to be decelerated or turned once or twice
for the differential lock to fully disengage.
Controlled Traction Differential
Some Eaton drive axles are equipped with a controlled traction
differential. This is a differential assembly incorporating a friction
plate assembly designed to transfer torque to both rear wheels.
The unit is basically a multiple disc clutch designed to slip
above predetermined torque values. This controlled slipping
characteristic at higher torque values enables the vehicle to
negotiate turns in a normal manner. Resistance to slippage
at lower torque values enables the vehicle to maintain an
appreciable amount of tractive effort when one wheel encounters
relatively poor traction.
A control valve in the cab is actuated by the driver to engage and
disengage the controlled traction feature.
Disengaged, the axle has differential action all the time. One
wheel will spin independently of the other, if slippery conditions
are encountered.
Engaged, wheel slippage and spin-out are minimized.
CAUTION
Tire sizes on both rear wheels should be the same
on axles equipped with a traction equalizer. If
not, excessive wear may occur to the traction
equalizer.
134
Locking Differential (Optional)
WARNING
Axles equipped with locking differentials can
deliver power to both wheels even when only one
wheel is on the ground. To prevent unexpected
vehicle movement when servicing wheels, tires,
or brakes, turn engine off and raise all driving
wheels of locking differential equipped axle.
Failure to observe this warning could cause
the vehicle to move unexpectedly resulting in
property damage, personal injury, or death.
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.
The optional locking (limited slip) differential is designed to
function as a conventional differential during normal driving
conditions, and, when a loss of traction occurs at one wheel,
it will provide transfer of power to prevent that wheel from
spinning.
3879634R1
Operation
NOTE: These differentials require a certain amount of resistance
in order to start the power transfer. If the spinning wheel is off
the ground, transfer may not begin. If spinning occurs, often a
light application of the brakes, while carefully applying power,
will slow the spinning wheel enough to allow the differential to
transfer power to the other wheel.
Two Speed Rear Axle
WARNING
The performance of a vehicle equipped with locking differential
is somewhat different from that of a vehicle equipped with a
conventional differential.
Never attempt to shift a two-speed axle when
descending a hill as the axle may not complete
the shift, remain in neutral, and cause a loss
of vehicle speed control and result in property
damage, personal injury, or death.
For example: Light noise and mild shuddering may be evident
while turning the vehicle on high coefficient of friction surfaces
(i.e., concrete). Vehicle and operating conditions can add to the
level of this noise and vibration:
Do not attempt to shift a Two-Speed rear axle
when the rear tires are spinning as this could
cause a loss of vehicle control and result in
property damage, personal injury, or death.
•
Tight slow continuous turns, as encountered in tight
parking/delivery areas.
The two-speed rear axle switch permits selection of either the
high or low axle ratio.
•
Higher axle ratios as compared to lower axle ratios.
Axle Shift Only
•
Uneven tire air pressure and/or uneven tire wear.
•
Heavy vehicle loads and/or uneven side-to-side distribution
of load.
Anything that improperly causes a difference in individual wheel
speeds, such as mismatched tire diameters (due to differences
in tire wear or tire pressure), unbalanced loading of the vehicle,
or operating the vehicle on a side slope, may cause the locking
differential to deliver power to only one side of the vehicle,
thus affecting directional stability. Always maintain matched tire
sizes, pressures, and balanced loads and avoid operation on
side slopes.
3879634R1
TO DOWN SHIFT: Select lower ratio position, release and
depress accelerator pedal as quickly as possible, or while
holding the accelerator down, disengage and re-engage clutch
as quickly as possible.
NOTE: Clutch method recommended for slower speeds.
TO UPSHIFT: Keep accelerator down, select a faster ratio
position, release accelerator pedal and pause until axle shifts.
NOTE: De-clutch for smoother axle upshifts at slow speed.
135
Operation
Split Shifting
Axle Operating Temperature
Combined Axle and Transmission Shift
Normally, axle operating temperature will not exceed more than
100ºF (38ºC) above ambient temperature. However, intermittent
operation (5 percent of time) at higher temperatures under
extreme loads (long pulls) will not harm the axle. Operating
temperatures above 230ºF (110ºC) significantly increase the
rate of lubricant oxidation and shorten the effective life of the
lubricant and seals, making more frequent changes necessary.
Extreme Pressure (EP) lubricants should not be run consistently
at temperatures above 230ºF (110ºC).
To Downshift the axle to a slower ratio and upshift or downshift
the transmission, shift the transmission and just before the
clutch is re-engaged, move the control switch to the slower ratio
position.
To Upshift the axle and downshift or upshift the transmission,
move the control switch to a faster ratio position and make the
transmission shift in the usual manner.
NOTE: In all axle upshifts, move the control switch to position
first. When split shifting to a slower axle ratio, do not move the
control switch until just before re-engaging the clutch.
Axles and Suspensions
Gross Weight (Axle – Vehicle)
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.
136
Front Axle (4X4, 6X6)
WARNING
To prevent vehicle damage, personal injury or
death, pay strict attention to the following:
Should it be necessary to operate the rear wheels
(with engine power) with the vehicle stationary
and the rear wheels raised from the ground,
first disengage the front axle, otherwise the front
wheels will pull the vehicle off its support. Always
chock front wheels under these conditions.
3879634R1
Operation
CAUTION
Do not keep the front axle engaged when
operating on dry, hard surfaced roads. Operating
on hard, dry surfaces with both the front and
rear axle engaged creates a build-up of torque
between the axles resulting in excessive tire wear
and strain on the entire drive unit.
When operating with both the transmission and
transfer case in low gear, the front axle must be
engaged to prevent excessive torque loads on the
rear axle.
When front axle is engaged and the transmission
is in low gear, the transfer case must be in low
gear to provide wheel slip protection.
Transfer Case
The transfer case transmits power to the front driving axle for
operation over rough terrain, steep grades, or slippery surfaces
(i.e., mud, gravel, snow, etc.) where improved traction is
required.
In-Switch Indicator
The ON/FRONT AXLE switch contains an indicator that
will be lit steadily when switch is in the ON position and
the front axle has been safely engaged. When the driver
attempts to engage or disengage the front axle at speeds
faster than 10 mph with the ON/FRONT AXLE switch in
the ON position, the indicator will blink until the proper
speed is reached. When the driver attempts to engage
or disengage the front axle when the tires are slipping and the
ON/FRONT AXLE switch is in the ON position, the indicator will
blink until the tires regain proper traction.
Front Axle Engagement when Vehicle is in Motion
To engage the front axle, the following steps are required:
NOTE: Ensure that the wheels are not slipping while performing
these steps, and that there are no error conditions or indicators
displayed.
1. The vehicle must be operating on a level surface.
2. Slow the vehicle to a speed below 10 miles per hour.
3. Place the ON/FRONT AXLE switch in the ON position.
Operation
The transfer case is actuated by control switches on the center
control panel. The ON/FRONT AXLE switch, containing an
in-switch indicator, is used to toggle the solenoid that causes the
air-actuated transfer case to engage or disengage the front axle
from the drive train. The XFER HI/XFER LOW switch controls
either of two solenoids that cause the air-actuated transfer case
to operate in either the high or low gear ratio.
3879634R1
4. The front axle will be engaged and the indicator will be
lit.
Front Axle Disengagement when Vehicle is in Motion
To disengage the front axle, the following steps are required:
137
Operation
NOTE: Ensure that the wheels are not slipping while performing
these steps, and that there are no error conditions or indicators
displayed.
1. The vehicle must first be operating on a level surface.
2. Slow the vehicle to a speed below 10 miles per hour.
The transfer case gear ratio can be selected and the front axle
can be engaged at the same time by performing the following
steps:
NOTE: Ensure that there are no error conditions or indicators
displayed.
3. Place the ON/FRONT AXLE switch in the FRONT AXLE
(Off) position.
1. The vehicle must be stopped and the parking brake
applied (Ignition switch still in the ‘run’ position).
4. The front axle will disengage and the indicator will go
out.
2. Place the transmission in Neutral.
Shifting Transfer Case From High to Low or Low to High
Gear Ratio
The system will only allow the transfer case to be shifted
to the low gear ratio if the following steps are performed:
NOTE: Ensure that there are no error conditions or
indicators displayed.
1. The vehicle must be stopped and the parking
brake applied (Ignition switch still in the ‘run’
position).
2. Place the transmission in Neutral.
3. Place the XFER HI/XFER LOW switch in the XFER HI
position for the high gear ratio or XFER LOW position
for the low gear ratio.
Front Axle Engagement and Transfer Case Gear Ratio
Shifting with Vehicle Stopped
3. Place the ON/FRONT AXLE switch in the ON position.
4. The front axle will be engaged and the indicator will be
lit.
5. Place the XFER HI/XFER LOW switch in the position
required for the desired gear ratio.
Vehicles with Transfer Case Oil Temp(erature) Sender
CAUTION
To prevent damage to transfer case, pull vehicle
off the road immediately when overheating
condition is detected.
If the transfer case lubricant exceeds its maximum allowable
temperature, damage to the transfer case may result. If this
occurs, the transfer case overheat indicator will be lit, alerting
the driver. In the event of a transfer case overheating condition,
proceed with the following:
1. Pull off the highway as soon as possible.
2. Inspect the transfer case and cooling system for leaks.
138
3879634R1
Operation
3. If no leaks are found, resume driving at 15 mph slower
than when the indicator came on.
4. Resume safe speed if indicator stays off.
International® Ride Optimized Suspension (IROS) (Optional)
CAUTION
The vehicle must not be operated on the road
without air in the suspension bags.
This
will prevent suspension damage and ride
degradation. Failure to observe this may cause
property damage.
The International® Ride Optimized Suspension (IROS) is a
variable rate suspension system that automatically adjusts to
different loads to maintain constant frame height. The system
provides improved vehicle ride and increased driver comfort.
This feature also allows the rear of the vehicle to lower several
inches for cargo loading and unloading.
The system may be controlled by an optional two-position
SUSP/DUMP switch with an indicator in the DUMP position. This
switch controls solenoids, which directs air to the suspension
dump and height valve.
NOTE: To lower the suspension (dump operation), the vehicle
speed must be less than 5 mph (8 km/h).
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 air suspension is released, lowering the
frame for loading.
Placing the switch in the SUSP position causes air to fill
or remain in 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 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.
The following is the operation of the optional air suspension
dump (SUSP/DUMP) switch in controlling the vehicle ride
height:
Air Suspension Dump (ASD) Switch (Optional)
NOTE: The suspension will dump when the ignition switch is
in either ACC or ON position, but will only fill when the ignition
switch is in the ON position.
3879634R1
139
Operation
NOTE: The system will automatically switch from DUMP to
SUSP if, while the system is commanding a DUMP operation,
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 (8 km/h) and recycle the SUSP/DUMP switch
to the DUMP position.
•
When the SUSP/DUMP switch is pushed to the DUMP
position, the system releases air from the air suspension
bag. The switch indicator comes on and remains on while
the suspension is being lowered.
•
When the SUSP/DUMP switch is pushed to the SUSP
position, the system fills the air suspension bag, which
raises the vehicle. The switch indicator will then turn off.
Air Suspension System Faults
•
•
•
140
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).
The SUSP/DUMP switch indicator will blink rapidly in the
event of a system component failure or a bad system
signal status when the SUSP/DUMP switch is in the DUMP
position.
The SUSP/DUMP switch indicator will blink slowly in the
event of a system command fault, regardless of the position
of the SUSP/DUMP switch.
Axle and Suspension Conversions
WARNING
When operating a loaded vehicle, always keep all
adjustable axles in the down position supporting
their share of the load. Failure to do so can
overload other axles, tires, wheels, springs,
brakes, and frames, causing early component
failure and loss of vehicle control, which could
result in property damage, personal injury, or
death.
Axle and suspension conversions are not recommended or
approved; however, on occasion, aftermarket add-on axles
and suspensions are installed by others on International truck
chassis, which allow operator control for weight transfer from
other axles (i.e., air lift axles).
Lift Axle Options
WARNING
To prevent the unintentional lowering of a lift
axle(s), set all UP/DOWN switches to the UP
position before turning system on. Be aware,
lift axle(s) will automatically rise to the UP
position when the key is turned off. Ensure lift
axle(s) are clear of people, animals and objects
before turning system on, or turning ignition off.
Failure to follow this warning may cause property
damage, personal injury, or death.
3879634R1
Operation
NOTE: The “Down” indicator on the UP/DOWN switch signals
that the axle, controlled by that switch, is in the lowered position,
and is operational.
NOTE: The use of International Truck installed Lift Axles
provides improved vehicle load-carrying capability. However,
the lift axles do not increase the vehicle’s GVWR. The lift axle
system is made up of two axle types and the lift axle system
controls.
Lift Axle Locations
The vehicle can be equipped with as many as three lift axles.
The two lift axle designations are either a “pusher” or “Tag” axle,
as determined by its location. The “pusher” axle is one that is
mounted ahead of the rear driving axle(s), and a “tag” axle is
one that is mounted behind the last rear drive axle.
Lift Axle Types
WARNING
On systems with self-steering lift axles, the axle
will automatically rise to the UP position any
time the transmission is shifted into reverse, and
back down when the transmission is shifted out
of reverse. Before backing up, check to see that
area behind vehicle is clear of people, animals
and objects. Use a spotter whenever possible
and always keep that person in sight. Failure to
do so may result in property damage, personal
injury, or death.
3879634R1
The two lift axle designs are (1) “Fixed” (Rigid) and (2)
“Self-Steering” lift axles.
Fixed lift axle. The fixed lift axle design provides 20,000 pounds
maximum load carrying capacity. The design does not allow the
wheels to steer when cornering, thereby causing increased tire
wear due to tire scrubbing while cornering. The advantage of
this design is its simplicity, less components, which requires less
maintenance.
Self-Steering Lift Axle. The self-steering lift axle design
contains a spring-loaded self-centering mechanism that keeps
the axle tires tracking straight ahead with the vehicle’s straight
ahead movement. When the vehicle is turned, the drag on
the tires, caused by cornering, causes the tires to steer in the
direction that creates the least rolling resistance. As the vehicle
direction straightens out, the self-centering mechanism returns
the tires to their straight ahead position. The advantage of this
design is the reduction in tire wear. The self-steering lift axle
provides 13,000 pounds of load carrying capacity.
The self-steering lift axles can only operate properly while the
vehicle is moving forward. Placing the truck in reverse while
the lift axle(s) is in the down position, will cause the axle to
automatically raised to the lifted (up) position. The axle will
immediately return to the down position when the transmission
is shifted out of reverse.
141
Operation
Lift Axle Controls
Instrument Panel Controls
The lift axle system controls consist of all the controls, regulators,
and gauges needed to raise and lower the lift axle(s) and to
monitor the load air bag pressures for each axle. These controls
are available in three possible configurations and are the same
for all configurations. The three configurations are “Instrument
Panel”, “In-cab”, and “Mixed” controls. These are the same for
both lift axle types. The system controls are as follows:
1. The one AXLE ENABLE system switch, which is used to
activate all of the controls for any lift axles that are installed
on the vehicle (NOTE: The ignition switch must be in the ON
or RUN position).
1. Optional Location For Lift Axle Switches
2. The UP/DOWN switch is used to raise and lower the lift axle
(one control for each lift axle installed).
3. The Air Pressure Regulator is used to control the amount
of air pressure supplied to the load air bag for the lift axle
(one regulator for each lift axle installed).
4. The Air Pressure Gauge indicates the air pressure in the
load air bags for the lift axle (one gauge per lift axle installed
for in-cab control arrangement; two gauges per lift axle
installed for mixed control arrangement).
NOTE: When lift axle switches are installed in the instrument
panel, the Air Pressure Gauge and Air Pressure Regulators are
located outside of the cab, as shown in the “Mixed Controls”
configuration.
142
3879634R1
Operation
In-Cab Controls
seat. This system’s controls consist of one AXLE ENABLE
system switch, an UP/DOWN switch, an air Pressure Regulator
control, and an air Pressure Gauge for each lift axle.
Mixed Controls
1. Axle Enable System Switch
2. UP/DOWN Switch
3. Air Pressure Regulator
4. Air Pressure Gauge
In this configuration, all lift axle controls are located and
accessible from the floor-mounted pedestal next to the driver’s
3879634R1
1. Axle Enable System Switch
2. UP/DOWN Switch
3. Air Pressure Gauge
143
Operation
1. Air Pressure Gauge
2. Air Pressure Regulator
In this configuration, the lift axle controls are located on the
floor-mounted pedestal and on a panel that is mounted externally
on the rear of the cab. The controls on the floor-mounted
pedestal are the AXLE ENABLE system switch, an UP/DOWN
switch, and an Air Pressure Gauge for each axle. The controls
on the external panel are an Air Pressure Regulator, and a
second Air Pressure Gauge for each lift axle.
1. UP/DOWN Switch – Axle 1
2. UP/DOWN Switch – Axle 2
3. UP/DOWN Switch – Axle 3
Lift Axle Control Identification
Each lift axle has its own set of controls labeled “1” thru “3”
counting the axles from the front of the truck. See the illustrations
below:
144
3879634R1
Operation
Lift Axle System Operation
WARNING
1. Air Pressure Regulator – Axle 1
2. Air Pressure Regulator – Axle 2
3. Air Pressure Regulator – Axle 3
To prevent the unintentional lowering of a lift
axle(s), set all UP/DOWN switches to the UP
position before turning system on. Be aware,
lift axle(s) will automatically rise to the UP
position when the key is turned off. Ensure lift
axle(s) are clear of people, animals and objects
before turning system on, or turning ignition off.
Failure to follow this warning may cause property
damage, personal injury, or death.
Enabling the Lift Axle System
NOTE: Before pressing the AXLE ENABLE switch, ensure that
all UP/DOWN switches are in the UP position.
1. Axle 1
2. Axle 2
The ignition switch must be in the “Run” or “On” position in
order to enable the lift axle system. After this is done, the
lift axle system is enabled by momentarily pressing the AXLE
ENABLE switch. This will cause the indicator for this switch to
be illuminated. The Axle Enable switch need only to be pressed
once after ignition on operation. If the lift axle(s) will not be
used, there will be no need to press the AXLE ENABLE switch.
The only way to disable the system is to turn the ignition switch
to the “off” position. When the ignition switch is turned to the
“Off” position, the axle(s) will go to the “up” position, regardless
of the position of any Lift Axle switches.
3. Axle 3
3879634R1
145
Operation
Lowering the Lift Axles
With the lift axle system enabled, when the DOWN position of
the UP/DOWN switch is selected, air is vented from the lift bags,
thus causing the axle to be lowered. At the same time, air is
applied to the axle load bags through the air pressure regulator
for adjustment of the proper axle load carrying capacity. The
amount of air pressure applied to the load bags is monitored by
the air pressure gauge. The switch DOWN indicator will be lit
indicating that the axle is in the operational position. Refer to the
load capacity charts to determine the air pressure needed
for the desired load capacity for both axle designs.
Raising the Lift Axles
WARNING
On systems with self-steering lift axles, the axle
will automatically rise to the UP position any
time the transmission is shifted into reverse, and
back down when the transmission is shifted out
of reverse. Before backing up, check to see that
area behind vehicle is clear of people, animals
and objects. Use a spotter whenever possible
and always keep that person in sight. Failure to
do so may result in property damage, personal
injury, or death.
When the UP position of the UP/DOWN switch is selected, air
is vented from the axle load air bag and, at the same time,
pressurized air is routed to the lift bag, raising the axle.
For system with self-steering axles, when the transmission is
shifted into Reverse, +12 VDC is removed from the air solenoid,
146
venting air from the axle load air bag and supplying air to the
lift bag. This lifts the axle (s) regardless of the position of the
UP/DOWN switch.
Load Capacity Chart for 20,000 Pound Fixed Lift Axle
Mounting Height
Ground Axle
Load
9 in.
10 in.
11 in.
5,000 lbs
15 psi
15 psi
15 psi
10,000 lbs
36 psi
36 psi
36 psi
15,000 lbs
58 psi
58 psi
58 psi
20,000 lbs
79 psi
79 psi
79 psi
1. This table is approximate. To obtain an accurate load vs. air
pressure reading, it is necessary that the unit be calibrated over a
flat and accurate scale.
2. This table assumes 1500 lbs ground weight with 0 psi air
pressure.
Load Capacity Chart for 13,200 Pound Steerable Lift Axle
Mounting Height
Ground Axle
Load
10 in.
11 in.
12 in.
5,000 lbs
29 psi
31 psi
34 psi
6,000 lbs
37 psi
39 psi
43 psi
7,000 lbs
44 psi
47 psi
52 psi
3879634R1
Operation
Brakes
Mounting Height
Ground Axle
Load
10 in.
11 in.
12 in.
8,000 lbs
52 psi
56 psi
60 psi
9,000 lbs
60 psi
64 psi
69 psi
10,000 lbs
67 psi
72 psi
78 psi
11,000 lbs
75 psi
80 psi
87 psi
12,000 lbs
82 psi
88 psi
96 psi
13,000 lbs
90 psi
97 psi
105 psi
14,000 lbs
98 psi
105 psi
114 psi
WARNING
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.
Downhill Operation
WARNING
1. This table is approximate. To obtain an accurate load vs. air
pressure reading, it is necessary that the unit be calibrated over a
flat and accurate scale.
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.
2. These values are approximations and will vary, especially with
different mounting heights and or bag heights.
3. These Run Heights are based on units with no axle/bag shim
and a 3.50 in offset axle.
4. The values above are based on the standard axle assemblies
with bag heights of 12 in, 13 in, and 14 in respectively.
5. These weights are based on the axle and wheel equipment
weighing 1200 lbs ground weight with no (0 psi) air pressure.
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:
•
3879634R1
Never coast downhill. Service brakes alone should not be
used to control speed on major downgrades. Brakes will
fade from overuse.
147
Operation
•
•
•
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 brakes. 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.
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.
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
WARNING
Stopping distance may increase under the failed
condition since only one section of the brake
system is operating. Reduce speed and employ
safe driving practices.
Have brake system
repaired immediately. Loss of braking capability
could cause an accident and result in property
damage, personal injury, or death.
NOTE: The function of the air compressor is to provide and
maintain air under pressure to supply the air brake system and
other air powered devices. Certain air compressors in vehicles
with MaxxForce® 11 and 13 engines, while in operation, may
cause fluctuation of the needle in the air pressure gauge.
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
occurs in one system, the remaining system continues to
provide braking action.
When a failure is detected, the air dryer is provided with a limp
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.
148
3879634R1
Operation
Air Gauge, Low Air Pressure Beeper and Warning Indicator
WARNING
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 70 psi [483 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 70 ± 6 psi (483 ± 41 kPa) the warning beeper will
sound and the red BRAKE PRESSURE warning indicator on the
instrument panel gauge cluster will glow. Also, the air gauge(s)
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 is sufficient
(approximately 70 psi [483 kPa]) to operate the vehicle.
Should the red indicator and beeper not shut off soon after
startup, the air pressure gauge(s) should also indicate at least
one section of the split system has low air pressure.
3879634R1
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. In the event of primary pressure system
loss, the spring brakes will assist the front brakes in stopping
the vehicle. However, the distance required to stop the vehicle
will be increased.
Brake Application
Rapid successive 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
WARNING
Failure to comply with the following may result in
property damage, personal injury, or death.
Under no circumstances should the spring brake
chamber be disassembled. Disassembly will
release a powerful spring which could result in
property damage, personal injury, or death.
149
Operation
WARNING
Always chock the wheels when manually
releasing the spring brakes, or the vehicle could
roll causing property damage, personal injury, or
death.
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 spring brakes.
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 and to assist in bringing it to an emergency stop. The
parking brake should not be used to brake the vehicle during
normal driving.
To apply the parking brake, pull out control. To release the
parking brake, push in control.
On single-unit trucks and tractors with independent parking
and trailer controls: if air pressure is reduced to approximately
20 to 45 psi (138 to 310 kPa) in both the primary and secondary
systems, the parking brakes will automatically apply.
On tractors with the modular control system: if air pressure is
reduced to approximately 20 to 45 psi (138 to 310 kPa) in both
the primary and secondary systems, the parking brake control
will automatically apply. For the exact air pressure set points,
refer to the Service Manual.
150
It should be noted that upon loss of air pressure, partial spring
brake application will occur prior to automatic application of the
control valve.
To release, recharge system to 70 psi (483 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 manually
released (caged).
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 and
cage the spring and release the brake.
Remove release stud assembly from carrying pocket.
Apply a light coat of antiseize compound 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 plate. 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
3879634R1
Operation
reinstall the access plug in the chamber opening. Reinstall the
release stud and nut in the carrying pocket on the brake chamber
housing.
a replaceable desiccant cartridge and oil blocking filter that is
periodically serviced. It also may include a heater to prevent the
discharge valve from freezing in cold weather.
Reservoir Moisture Draining
Trailer Brake Hand Control
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
ensure 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.
Air Dryer
The function of the air dryer is to collect and remove moisture
and contaminants before the compressed air reaches the air
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.
WARNING
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
is manually moved. To release the trailer brakes, move handle
counterclockwise (up) until trailer moves freely.
The air dryer is installed in the discharge line between the air
compressor and the air system reservoirs. The air dryer includes
3879634R1
151
Operation
Trailer Air Supply and Parking Brake Modular Controls
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:
•
TRAILER AIR SUPPLY (red octagonal knob)
•
PARKING BRAKE (yellow diamond knob)
The PARKING 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,
152
Red Valve
(Trailer Air Supply)
Yellow Valve
(Parking Brake)
Function (Mode)
Out
Out
System Park
In
Out
Trailer Charge
In
In
Normal Running
Out
In
Bobtail/Sliding
Fifth Wheel
Adjustment/Sliding
Trailer Tandems
Adjustment
The PARKING BRAKE valve (yellow knob) controls the spring
brakes on the tractor and when pulled out 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
knob) in.
The TRAILER AIR SUPPLY valve (red knob) 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 points, refer to the Service
Manual.
3879634R1
Operation
NOTE: When attempting to readjust/slide the position of the
tractor fifth wheel or the trailer’s tandem axles with the tractor
and trailer fully connected, leave the tractor’s PARKING BRAKE
pushed in and pull the TRAILER AIR SUPPLY out. This will
apply the trailer’s parking brakes and keep it stationary while
the tractor is moved forward or reverse.
To turn off the alarm, press the service brake pedal. Then, after
turning the ignition switch to the RUN or ACC position, make
sure that the parking brake is set.
Antilock Brake System (ABS)
WARNING
Parking Brake Indicator
WARNING
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.
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.
WARNING
Parking Brake Alarm
The parking brake alarm is used to alert drivers when they have
failed to set the parking brake when exiting the vehicle. The
alarm is a continuous sounding of the electric (city) horn. The
conditions that allow this to occur are:
1. The ignition switch is in the OFF position.
2. The parking brake is not set.
3. The driver’s door (any cab) is opened.
3879634R1
Do not rely on the ABS system to interrupt vehicle
retarder, 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.
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
153
Operation
is imminent. The standard air brake system controls normal
braking when the ABS is not engaged.
ABS Operation
WARNING
If the ABS warning indicator comes on, stopping
distances may increase under certain braking
conditions.
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.
The antilock brake system electronically monitors vehicle
wheel speed at all times and only engages when wheel lock is
imminent. The standard hydraulic brake system controls normal
braking when the ABS is not engaged.
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 overbrake 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 mph (6 km/h). 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
154
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 on the chassis frame. The control
unit monitors and compares all wheel speed inputs to determine
if any wheel(s) is about to lock. If wheel lockup is about to occur,
the control unit commands the appropriate modulator valve to
adjust air pressure delivery to prevent wheel lockup.
ABS Self-Check
A yellow warning indicator on the instrument panel gauge cluster
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 indicator does not
come on with ignition, does not flash, fails to go off, or comes on
again at any other time.
3879634R1
Operation
If overbraking causes wheel lockup on the rear drive axles while
retarding devices are in operation, the ABS will interrupt and
disable the retarder until the lockup situation has stopped.
If the ABS warning indicator is lit, consult your nearest
International truck service center for further assistance in
maintaining and repairing your ABS.
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 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, double, or triple: 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 tractor’s 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.
3879634R1
Air Brake Bendix® ABS-6
WARNING
Vehicles equipped with Stability Control cannot
be used to pull double or triple trailers. Failure
to follow this warning could result in property
damage, personal injury, or death.
WARNING
Stability Control systems are designed to
enhance overall vehicle safety 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.
ABS-6 advanced with RSP provides the core ABS function
as well as Automatic (ATC) and Roll Stability Program (RSP)
functions.
Core ABS Functions
The core ABS system prevents wheel lockup to help drivers
maintain steering control while braking. Bendix® Antilock
Braking Systems (ABS) use wheel speed sensors, ABS
pressure modulator valves, and an Electronic Control Unit
(ECU) to control either four or six wheels of a vehicle. Bendix®
ECUs optimize slip between the tire and the road surface by
155
Operation
monitoring individual wheel turning motion during braking. For
a complete description of the core ABS system, see the ABS
section above.
Traction Control (If Equipped)
WARNING
Traction Control systems are designed to
enhance overall vehicle safety when a vehicle is
driven within its safe operating limits. Traction
Control cannot compensate for a vehicle which
is being driven beyond the physical limits of
control. Drivers operating a Traction Control
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.
Your vehicle may be equipped with an optional traction control
system, which helps you maintain the stability and steerability
of your vehicle, especially on snow or ice-covered roads and
gravel roads. It reduces engine power and/or selectively applies
the rear brakes. The system allows your vehicle to make better
use of available traction in these conditions by also limiting the
engine RPM when you push farther on the accelerator, which
limits wheel spin. The traction control indicator will illuminate
steadily if the system is malfunctioning.
NOTE: The traction control braking (ATC action) to limit wheel
spin does not occur at vehicle speeds above approximately 31
mph (50 km/h). Therefore, at speeds above 31 mph (50 km/h),
all ATC events are controlled only by engine power limiting.
156
The Traction Control switch for Air Brake-equipped
vehicles. If the system is enabled (traction control
switch in the TRAC ENAB position), the traction control
indicator on the instrument panel gauge cluster will
flash during a Traction Control event, and the engine
may not increase RPMs when you push farther on
the accelerator. If the traction control switch is in the
DISAB position, the traction control system is disabled.
ATC System Check
At ignition turn-on, the traction control indicator will illuminate
steadily for 2.5 seconds and then turn off. If not, the system
is defective or inoperative.
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 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
been selected and will flash rapidly whenever ATC is
operating to control excessive wheel spin.
3879634R1
Operation
Stability Control Systems – Bendix® ESP
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.
WARNING
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.
CAUTION
Modification to vehicles equipped with ESP
require prior approval thru Navistar’s Tech
Services # 1-(800)-336-4500.
Unapproved
modifications may result in diminished stability
control performance.
The optional stability control system provides the core ABS
function as well as Automatic Traction Control (ATC) and roll
stability functions.
3879634R1
Core ABS Functions: The core ABS system reduces wheel
lockup to help drivers maintain steering control while braking.
Antilock Braking Systems (ABS) use wheel speed sensors,
ABS pressure modulator valves, and an Electronic Control
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.
Advanced Stability Functions: 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: This sensor enables the advanced
stability system to capture the driver’s steering input and
intervene if a yaw correction is needed. The sensor also
provides the earliest indication of an increase in lateral
acceleration that might cause a potential roll event. A steering
angle sensor provides a greater stability margin than a vehicle
that is not equipped with this sensor.
Brake Demand Sensors: The stability control system was
designed to supplement the driver’s 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
157
Operation
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.
Towing Instructions
WARNING
ABS/Stability System Interaction: With the ABS–based
stability control system, the ABS system is given priority at the
wheel ends to manage wheel slip for optimal braking. The ABS
system functions similarly whether the stability system or the
driver applies the brakes.
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.
Failure to follow this warning could result in
property damage, personal injury, or death.
Bobtail Proportioning System
Bobtail proportioning is available with tractor air brake systems
(for export only with code 04092) with or without ABS or
ABS/systems. The proportioning valve senses when trailer
brakes are not connected to the vehicle air brake system
and automatically adjusts 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.
•
Always chock the wheels when manually releasing the
parking brakes, or the vehicle can roll.
•
It should be noted that there is a noticeably different brake pedal
feel on tractors with this feature while operating in the bobtail
mode. Higher brake pedal efforts will be experienced by the
driver than in a brake system without bobtail proportioning.
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.
158
WARNING
Failure to comply with the following may result in
property damage, personal injury, or death:
3879634R1
Operation
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
Before moving the towed vehicle, check for adequate road
clearance of vehicle components. Unload the towed vehicle
prior to towing to reduce any abnormal loads to the vehicle
components resulting from the towing procedures. 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 Brake section.
Towing Vehicle with Front Wheels Suspended
CAUTION
To prevent vehicle, engine, or 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
components.
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.
3879634R1
159
Operation
Towing Vehicles with Driver Controlled Differential Lock
Removing Axle Shafts Before Towing
CAUTION
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 remove the axle shafts before
the vehicle is towed.
CAUTION
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.
160
2. Remove cap screws and washers or stud nuts and
washers from flanges of both axle shafts.
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 (engaged) 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.
3879634R1
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 farther 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
CAUTION
To prevent damage to cab roof or air deflector
when towing the vehicle backwards (rear wheels
suspended) the air deflector must be removed.
3879634R1
Whenever possible, it is preferable to tow a disabled vehicle from
the rear by raising the rear of the chassis by the rear axles.
When towing a vehicle with rear of the chassis suspended, the
front wheels must be locked in the straight ahead position.
Vehicles with manual shift transmissions must have at least one
(1) pint of transmission lubricant drained from the case. This will
prevent transmission lubricant from entering the clutch housing
and lubricant saturating the clutch discs. Make sure that the
transmission lubricant is replaced before the vehicle is returned
to service.
Tractor-Trailer Connections
WARNING
Whenever possible, make trailer connections
while standing on the ground. Provide adequate
lighting of working areas. Inclement weather and
accumulated road contamination deposits on
hand holds 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 hand
holds. Use a three-point stance when climbing
up and down from a deck plate. Do not jump from
vehicle.
161
Operation
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
loading the trailer. The vehicle speed must be below 5 mph
before the switch will operate the valve.
When connecting to a trailer, switch the SUSP/DUMP switch,
located on the instrument panel gauge cluster, 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.
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
WARNING
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.
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.
WARNING
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
162
3879634R1
Operation
allow it to be moved forward or backward and re-lock it once
the desired position is attained.
To unlock the fifth 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). 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.
NOTE: A fast flashing (twice per second) switch indicator
signifies a problem in the fifth wheel lock system.
5. 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.
6. 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 connecting and disconnecting
trailer.
7. 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.
8. Be sure the coupler release lever is in the locked
position.
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.
1. Fifth wheel jaws must be opened fully.
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.
2. Tilt fifth wheel back to prevent body damage when
tractor is backed under trailer.
11. Check operation of all trailer lights and correct faulty
lights.
Hook-Up
3. Block trailer wheels and be sure trailer spring brakes are
adjusted and applied. Never chase a trailer.
4. Make sure brake hoses and light cords are clear of the
fifth wheel.
3879634R1
Un-Hook
1. Try to keep tractor and trailer in straight line.
2. Apply tractor and trailer parking brakes.
163
Operation
3. 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.
6. Pull coupler release lever to disengage fifth wheel jaws.
7. Release tractor parking brakes.
8. Pull out from trailer slowly, allowing landing gear to take
load gradually.
5. Disconnect brake hoses and light cords. Be sure hoses
and cords are clear.
164
3879634R1
Maintenance Instructions
SECTION 6 — MAINTENANCE INSTRUCTIONS
Introduction
about performing some service, consult your International dealer
or have the service done by a skilled technician.
WARNING
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 manual.
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 the vehicle receives proper care and maintenance to
ensure high performance.
Quality International truck service parts are available through
your International dealer. If International truck service parts are
not used, the owner must make sure that the parts used are
equivalent to International truck service parts.
As with any vehicle, care should be taken to avoid being injured
when performing maintenance or repairs or making any checks.
Improper or incomplete service 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
3879634R1
Maintenance Guidelines
WARNING
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.
165
Maintenance Instructions
CAUTION
WARNING
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.
WARNING
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. Turn off the ignition switch, unless the procedure calls for a
running engine.
2. Set the parking brake and chock the wheels.
3. Use support stands, not a jack, whenever you must be under
a raised vehicle.
4. Do not smoke.
5. Wear safety glasses for eye protection.
6. Operate engine only in a well-ventilated area.
7. Do not work on brakes or clutch unless proper precautions
are taken to avoid inhaling friction material dust.
8. Do not wear loose clothing, hanging jewelry, watches or
rings. Tie up long hair and avoid rotating machinery.
9. Avoid contact with hot metal parts; allow hot components to
cool before working on them.
166
3879634R1
Maintenance Instructions
10. Correct any problems that were revealed during inspection
prior to operating the vehicle.
Supporting Your Vehicle for Service
WARNING
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.
3879634R1
Chassis Lubrication
New vehicles are lubricated at the factory and again during the
predelivery inspection. 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 ensure Outstanding
Life Cycle Value and will reduce overall operating expense.
In some types of operation, and where operating conditions are
extremely severe (such as road salt or corrosive chemical
environments, in deep water, mud, or unusually dusty
conditions), the vehicle may require relubrication 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.
The use of Fleetrite® lubricants and OEM original equipment
parts is recommended.
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 7 — MAINTENANCE
INTERVALS AND SPECIFICATIONS
167
Maintenance Instructions
Air Conditioning Service Checks
Side Access HVAC Filter
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
performance.
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
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.
NOTE: There are two possible cab HVAC filter configurations;
side access and front access HVAC filter housings.
3. Install new filter by sliding filter into air intake housing.
4. Install filter access door and latch in place.
168
3879634R1
Maintenance Instructions
Front Access HVAC Filter
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.
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.
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.
3. Install new filter into air intake housing.
4. Close and secure filter access door by turning screws
clockwise one quarter turn.
3879634R1
169
Maintenance Instructions
Axles
Front Axle
•
Inspect, lubricate and adjust the wheel bearings at regular
intervals.
Refer to SECTION 7 — MAINTENANCE
INTERVALS AND SPECIFICATIONS for the correct
intervals, lubricants, and torques.
Inspection and Lubrication
Normal Maintenance
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:
•
Kingpin wear inspection requires that no weight is on the
tires.
•
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.
•
•
170
Kingpin thrust bushing lubrication requires that the vehicle
weight is resting on the tires. Therefore, add additional
grease to the lower kingpin grease zerk after vehicle weight
is once again resting on the tires.
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 axle section
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 window type
hubcaps is from the minimum line to 5/16 inch (7.9 mm) above
the minimum line.
If the lubricant level suddenly drops dramatically below the
minimum level, see the Service Manual for diagnostic procedure.
Power grease guns may be used: however, a hand-pumped
grease gun is recommended for optimal grease distribution
within each component joint.
3879634R1
Maintenance Instructions
Alignment
Maintaining front axle alignment is very important to achieving
maximum tire life and vehicle control. Inspecting steer axle tires
daily will generally show if tires are wearing normally.
•
Rapid outside shoulder wear on both tires indicates too
much toe-in.
•
Rapid inside shoulder wear on both tires indicates too much
toe-out.
•
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.
•
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.
Front Drive Axle and Transfer Case (Optional)
Inspection and Lubrication
In addition to the checks outlined for the non-drive front axle,
proper lubrication and inspections of the front drive components
must be followed. Both the front drive axle and the transfer case
oil level must be checked periodically and also inspected for
possible oil loss. The proper lubrication level is to the bottom
of the ’oil fill hole’ with the vehicle on level ground.
Make sure the axle mounting U-bolt nuts, attaching or mounting
bolts and nuts, are securely tightened. Loose or misaligned rear
axles will affect vehicle alignment, front tire wear, and handling.
3879634R1
Re-torque the U-bolt nuts after the first 1,000 miles (1,600 km)
and every 36,000 miles (58,000 km) thereafter. Refer to the
LUBRICATION AND MAINTENANCE INTERVAL CHART for
recommended service intervals.
Rear Axle – Inspection and Lubrication
Make sure the axle mounting U-bolt nuts, attaching or mounting
bolts and nuts, are securely tightened. Loose or misaligned
rear axles will affect vehicle alignment, tire wear, and handling.
Refer to AXLE U-BOLT NUT TORQUE CHART for torque
specifications.
Check the rear axle oil level. Proper oil level minimizes gear
wear, heat, and damage to the wheel bearings and seals. The
oil level should be at the lower edge of the oil fill hole when the
vehicle is on level ground. Add oil as necessary.
Refer to the LUBRICATION AND MAINTENANCE INTERVAL
CHART and the LUBRICANT AND SEALER SPECIFICATIONS
CHART for additional information.
Lift Axle System
WARNING
Always lower lift axles before servicing the
axle, controls, or air lines. Failure to follow this
warning may cause a sudden loss of air pressure
and the unintentional lowering of the lift axle
resulting in property damage, personal injury, or
death.
171
Maintenance Instructions
The mechanical items of the lift axle system require periodic
maintenance to maintain reliable operation. Drain cocks, in the
bottom of each air tank, are installed to provide a convenient
means of periodically draining condensation from the tank.
Refer to the Lift Axle System maintenance chart SECTION 7
— MAINTENANCE INTERVALS AND SPECIFICATIONS for
periodic maintenance information.
Brakes
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, carefully 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.
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.
WARNING
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.
172
3879634R1
Maintenance Instructions
Air Brakes
WARNING
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.
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.
Brake Automatic Slack Adjusters (ASA’s) should
not need to be manually adjusted in service.
ASA’s should not routinely have to be adjusted
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.
3879634R1
173
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 and 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.
174
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 disengaged and
wheels chocked.
4. Hose or pipes for rust, damage, deterioration.
5. 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
3879634R1
Maintenance Instructions
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
generally 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.
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 air tanks. The wet tank is the first tank to receive
air from the air drier and therefore collects most of the remaining
moisture 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.
Heater
Check that the air dryer heater activates at temperatures below
freezing. With the vehicle in a cold environment and before the
3879634R1
175
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 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
176
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°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 (pH) 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.
3879634R1
Maintenance Instructions
Clutch
Electrical
Pedal Free-Travel
Batteries
Each time the vehicle chassis is lubricated, check clutch pedal
free-travel. If clutch pedal free-travel is outside the 1 to 1 1/2
inch (25 to 38 mm) range, the clutch must be adjusted to ensure
that the clutch is fully engaging and the clutch brake will activate.
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, 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.
NOTE: Proper clutch pedal free-travel adjustment will provide
adequate release yoke fingers-to-release bearing clearance, as
well as release bearing-to-clutch brake clearance.
New International® vehicles use nonasbestos clutch linings.
However, exposure to excessive amounts of clutch material
dust (whether asbestos or nonasbestos, fiberglass, mineral
wool, aramid, ceramic, or carbon) may be a potentially serious
health hazard.
WARNING
To prevent personal injury or death, prevent
breathing clutch lining fiber dust. Always wear a
respirator when doing clutch lining maintenance.
Persons who handle clutch linings should follow the same
precautions as outlined for handling brake linings.
3879634R1
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.
177
Maintenance Instructions
CAUTION
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 clamped
tightly and that the battery is clamped securely in the battery
box.
For best results:
•
Do not mix and match battery models/manufacturers in the
same battery pack.
•
Do not use batteries with differing CCA ratings in the same
battery pack.
•
Do not use batteries with more than one year difference in
the installed age of batteries in the same battery pack.
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 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
Battery Cables
CAUTION
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
178
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.
3879634R1
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
WARNING
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 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 panel gauge clusters, 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 s 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.
3879634R1
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 7 — MAINTENANCE INTERVALS AND
SPECIFICATIONS of this manual for fuse or relay replacement.
Engine
CAUTION
To prevent damage to the Engine Control Module
it should never be spray-washed directly. Never
spray any connector.
NOTE: Information in this section pertains to MaxxForce®
engines only.
For complete operation and maintenance
information pertaining to your MaxxForce® engine, refer to
the MaxxForce® Engine Operation and Maintenance Manual
provided with the vehicle. Information pertaining to other
engines will be found in separate manuals provided with the
vehicle.
General
For effective emission control and low operating cost, it is
important that maintenance operations be performed at the
specified periods or mileage intervals indicated (kilometers,
miles, hours, gallons of fuel, or months, whichever occurs first)
in the Engine Operation and Maintenance manual.
179
Maintenance Instructions
Service intervals are based upon average operating conditions.
In certain environments and vocations, more frequent servicing
will be required.
Any replacement parts used for required maintenance services
or repairs should be genuine International® service parts. Use
of inferior replacement parts hinders operations of engine and
emission controls and can reduce engine life and/or jeopardize
the warranty.
and inspection and adjustment of items such as valve lash, etc.,
refer to the Engine Operation and Maintenance Manual supplied
with the vehicle.
Air Induction System
WARNING
To prevent property damage, 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. Order protective shield
J-26554 for MaxxForce® engines from your local
International dealer.
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
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.,
180
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 and cloth to clean the inside of
the pipes and rubber/plastic pipes.
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.
•
Check for loose hoses and clamps.
3879634R1
Maintenance Instructions
•
Check for ruptured, bulging, or collapsed pipes.
•
Check air cleaner housing and air restriction gauge for
cracks.
Air Restriction Gauge
on air cleaner mounted gauge is on the end of the gauge. See
illustrations below.
It is recommended that the operator NOT reset the gauge until
after it has been determined if the air filter element must be
replaced.
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. 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.
1. Low Restriction
2. High Restriction
3. Reset Button
Both gauges have a push type reset button. The reset on the
dash panel mounted gauge is in the face of the gauge. The reset
3879634R1
NOTE: If the yellow indicator is at its maximum reading,
replace the air filter element and reset the gauge (refer to the
Troubleshooting table).
181
Maintenance Instructions
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 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.
Your vehicle has either a round or square type air cleaner, refer
to the following for air cleaner element service.
182
1. Air Cleaner Housing Cover
2. Tab
3879634R1
Maintenance Instructions
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
the mentioned conditions exist, obtain and install an
alternate new air filter element from your International®
dealer.
1. Inlet Lid
2. Holddown Latch
3. Air Cleaner Housing
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. For round air cleaner housings, lift the tab on the
air cleaner housing cover and rotate the cover
counterclockwise to unlatch and remove the cover.
For square air cleaner housings, unhook the holddown
latches and remove the inlet lid from air cleaner housing.
Remove the filter element carefully and slowly, then
discard the old element.
5. Carefully install the new air filter element into the air
cleaner housing.
6. For round air cleaner housings, install the air cleaner
end cover onto air cleaner housing, making sure that
the cover seats squarely on housing, and rotate cover
clockwise and latch tabs. For square air cleaner
housings, seat and install the inlet lid squarely onto air
cleaner housing, hook and latch inlet lid to air cleaner
housing with holddown latches.
7. 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.
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!
3879634R1
183
Maintenance Instructions
Troubleshooting
Problem: No Restriction Reading
POSSIBLE CAUSES
HOW TO CHECK
Plugged fitting or vacuum line
Apply vacuum to gauge until locked up at red zone. Re-connect line and hold in 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 air tight.
Hold in reset button. Indicator will drop slightly and then not move unless vacuum line has a leak.
Leak in gauge
Repeat above except close gauge connection airtight.
Engine air flow too low to generate a
restriction reading after being reset
Rev engine from idle to full RPM multiple times to increase air flow enough to create an initial reading.
Air cleaner element split open
Visually inspect element.
Problem: High Restriction Reading
POSSIBLE CAUSES
EXPLANATION
Plugged main air filter element
Normal operation will cause particles to collect in the air filter element. If observed, replace main
air filter element.
Plugged inner element (if equipped)
Normal operation will cause particles to collect in the air filter element. If observed, replace inner
air filter element.
Plugged inlet screens or ducts
Check system upstream from air filter restriction gauge port for debris, damage or improper
installation.
Heavy snow or rain
Temporary high restriction can occur during a rain or snow storm and it disappears after the air filter
element dries out. COLD AIR MAY BE SO DENSE THAT HIGH RESTRICTION MAY NOT REDUCE
ENGINE POWER BEFORE ELEMENTS ARE DAMAGED FROM HIGH VACUUM. If gauge is locked
up at red zone, check elements for damage.
184
3879634R1
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.
NOTE: A visual inspection of the area between the condenser
and radiator should also be done at this time. Remove debris as
necessary.
Cooling System
The cooling system of your new vehicle is filled at the factory
with either a Type II Fully-Formulated Coolant (Purple), Type III
ELC - Extended Life Coolant (Red), or nitrite-free Shell Rotella®
Ultra ELC (YELLOW) coolant. The type of coolant depends upon
the engine manufacturer and the preference of the purchaser, if
optional coolants are allowed.
The Type II coolant must meet International® Type ll
specifications, such as the Fleetrite® Premium 50/50 with
SCA (P/N: ZJJSCA5550). The Type III coolant must meet
International® Type IlI specifications such as the Shell Rotella®
3879634R1
ELC - Extended Life Coolant (P/N 94042). Refer to the label
on the deaeration tank to determine the coolant type. If no
label is present, use Type II Fully-Formulated Coolant (Purple)
and maintain the Supplemental Coolant Additives (SCA’s)
accordingly. Consult the Engine Operation and Maintenance
Manual for coolant service life details.
Coolant Level
WARNING
To prevent personal injury or death from
hot coolant or steam use only the following
procedure to remove the pressure cap from
the deaeration tank. Allow the engine to cool
first. Wrap a thick, heavy cloth around the
cap. Depending on the type of cap, push down,
loosen cap slowly to its first notch position, or
unscrew cap slowly; then pause a moment to
allow pressure to release through the overflow
tube. After the pressure has been released, the
pressure cap may be removed.
WARNING
Do not exceed the pressure rating on the
deaeration tank. Ensure that the pressure rating
of the deaeration tank cap matches that listed
on the side of the tank, or the tank may burst,
causing property damage, personal injury, or
death.
185
Maintenance Instructions
CAUTION
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 cylinder block. Never use
water alone.
NOTE: If excessive amounts of coolant must be added and
coolant system is equipped with bleeder valves, contact an
International® dealer for special instructions on filling the
coolant system.
•
If coolant level is above MAX mark, remove coolant until
coolant level is between ADD and MAX marks on tank.
For vehicles equipped with a translucent deaeration tank with
engine HOT:
•
Assure coolant level is above the ADD mark on the tank. It
may exceed the MAX mark.
•
Add a 50/50 coolant concentrate/water mixture if low. Hot
coolant needs room to expand. Do not overfill.
Filling Instructions
For vehicles equipped with an opaque deaeration tank and two
sight glasses with engine COLD:
•
Ensure coolant level fully covers lower sight glass, but
covers none or only part of upper sight glass.
•
If coolant level fully covers upper sight glass, remove coolant
until top of coolant level can be seen in upper sight glass.
For vehicles equipped with an opaque deaeration tank and two
sight glasses with engine HOT:
•
Assure coolant level fully covers lower sight glass.
•
Coolant covers part or all of upper sight glass. Do not add
additional coolant if coolant is visible in upper sight glass.
For vehicles equipped with a translucent deaeration tank with
engine COLD:
•
186
Assure coolant level is between ADD and MAX marks on
tank.
1. Coolant Make-up Tank
2. Coolant Deaeration Tank
3879634R1
Maintenance Instructions
To function properly, the system must be completely filled with
coolant and all air must be expelled. To accomplish this, the
following procedures should be carefully completed:
4. After adding coolant over a period of two minutes and
keeping the coolant deaeration tank full, replace the coolant
deaeration tank cap tightly.
1. Fully open the heater shut-off valves and coolant system
pipe vent (if present).
5. With the system filled, operate the engine at various speeds
until coolant reaches normal operating temperature. Let
engine completely cool.
2. Pour a 50/50 mixture of the proper (ethylene glycol based)
coolant concentrate and demineralized or distilled water into
the deaeration tank. A 50/50 coolant mixture will achieve
a -34°F (-37°C) freeze point. A 53/47 coolant mixture will
achieve a -40°F (-40°C) freeze point.
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 (60 to 66%) of coolant
concentrate is advised in order to achieve a final mixture close
to 50/50.
3. Start the engine, and continue to add enough coolant to keep
the coolant deaeration tank completely full.
NOTE: Do not add any coolant to the coolant make-up
tank, as that volume will be necessary to adjust the coolant
concentration/freeze point later.
3879634R1
6. Slowly open the (pressurized) coolant deaeration tank cap
and measure the coolant concentration/freeze point. Top off
as needed with the correct top-off fluid (coolant concentrate,
50/50 coolant pre-mix, or demineralized water) necessary to
achieve a -34°F to -40°F (-37°C to -40°C) freeze point. Make
sure the coolant deaeration tank is completely full and the
coolant make-up tank (on the opposite side of the vehicle) is
at or within ¼ inch (6 mm) over the “MAX” line.
Filling Instructions (MaxxForce® 11 and 13 Engines)
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.
187
Maintenance Instructions
1. Turn on ignition without starting the vehicle. This opens the
electrically actuated LTR coolant flow valve.
2. Fully open cab heater coolant shut-off valves and coolant
system vent valve.
3. Remove fill cap and pour a 50/50 mixture (75/25 if it has
been flushed with water) of the proper (Nitrite-Free Shell®
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.
4. Because the radiator fills slowly, it is important to continue to
top off the system for two minutes following the initial fill.
5. 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.
1.
Coolant System Vent Valve
2.
Vented Fill Cap
3.
Deaeration Tank
4.
COLD MIN and COLD MAX Lines
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:
188
6. Run engine at governed speed until engine fan has fully
engaged for 5 minutes. Do not exceed 220° F (104° C).
7. 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.
Coolant and Optional Coolant Filter
The cooling system in vehicles with MaxxForce® 11 and 13
engines, is filled at the factory with Nitrite-free Shell Rotella®
3879634R1
Maintenance Instructions
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.
AntiFreeze
For cooling system capacities coolant part numbers, and
other information, refer to SECTION 7 — 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.
3879634R1
Fuel System
GOVERNMENT REGULATION: Diesel fuel sold for
use in 2007 and later highway vehicles must be 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.
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
189
Maintenance Instructions
all microbes, fuel tank draining alone will not eliminate the
problem. For vehicle operators experiencing microbe growth in
their fuel, the following is recommended:
Noise Emissions – Exterior
Instructions for Proper Maintenance
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 International
dealer) or have your local International dealer perform
the service for you.
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:
2. Treat your vehicle fuel tanks and bulk tanks regularly
with a biocide from a reputable vendor.
Air Intake System
•
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.
Body
•
Frame
International truck chassis are manufactured with frame rails
of either mild carbon steel or HSLA (High Strength Low Alloy)
steel, and each must be handled in a specific manner to
ensure maximum service life. Before attempting frame repair or
modification, consult the Service Manual or your International
dealer.
Tow Hooks, Tow Pins, and Pintle Hooks
Permanent or removable tow hooks as well as pintle hooks (if
present) should be inspected for functionality, damage, or a
loose mounting. Removable tow hooks and or pins should be
stored in such a way that they will not be lost, dislodged, or
damaged.
190
Air Cleaner – should be inspected and its location should
not be altered. Do not alter inlet and outlet piping.
Wheel Well – splash shields, cab shields, and underhood
insulation should be inspected for deterioration, dislocation,
and orientation and repaired or replaced as necessary.
Cooling System
•
Check fan for damage to blades. Replace, if damaged,
with manufacturer’s recommended parts.
Inspect for
fan-to-shroud interference and any damage to shroud, such
as cracks and holes.
•
Fan speed ratio should not be changed and fan spacer
dimensions and position should not be altered.
•
Inspect for proper operation of fan clutch, making sure that
the fan is disengaged when cooling of engine is not required.
3879634R1
Maintenance Instructions
Engine Noise Shields/Blankets
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.
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
•
•
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.
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 normal 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 5 — OPERATION.
3879634R1
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.
Transmission
Check fluid level.
For manual or automated manual
transmissions, during the PM schedule, ensure that the
fluid level is at the bottom of the fill hole. For Allison Automatic
Transmissions, check the fluid level on a daily basis using the
transmission dipstick.
Check gear shift/shift linkage for proper operation.
Refer to the LUBRICATION AND MAINTENANCE INTERVAL
CHART and the LUBRICANT AND SEALER SPECIFICATIONS
chart for information on transmission fluids and fluid and filter
change intervals.
Neutral Start Switch
Manual/Automated Manual Transmissions
Check operation of the safety start switch. The starter should
ONLY operate when the clutch pedal is depressed.
191
Maintenance Instructions
Automatic Transmissions
Periodically:
Check operation of the transmission neutral safety switch. Try to
start the vehicle in all shift selector positions. The starter should
ONLY operate when the shift selector is in Neutral or Park (if
equipped).
•
Check condition of spring leaves for evidence of fatigue,
bending, or breakage.
•
Check condition of suspension mounting brackets and
bushings.
Drive Shafts
•
Check that suspension mounts (brackets,
fasteners, etc.) are tight.
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.
•
Check that torque rod mounting fasteners are tight.
•
Check U-bolts as follows:
Suspension (Air and Steel Springs)
CAUTION
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 axle air suspension height at the PM interval.
See the appropriate Service Manual for suspension height
specifications.
NOTE: Suspension alignment must be maintained at all times.
192
bushings,
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 retorqued.
2. Thereafter, the U-bolt nuts must be retorqued every
36,000 miles (58,000 km).
NOTE: See U-Bolt Nut Torque Chart in the Maintenance
Intervals and Specifications section.
Steering
General Information
WARNING
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.
3879634R1
Maintenance Instructions
Ask your service technician to examine the steering mechanism.
Minor adjustments could head off further problems.
Check tie rod ends, drag link ends, and kingpins. 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.
Repair any concerns at once.
PM interval or annually, whichever occurs first. Tighten bolts to
torque specified in the Torque Specification chart at the end of
this section. DO NOT OVERTIGHTEN.
Lubrication Points
The steering shaft is lubricated at the three points shown in
the illustration below. For the correct maintenance interval,
refer to SECTION 7 – MAINTENANCE INTERVALS AND
SPECIFICATIONS.
Maintain proper steering gear and power steering pump fluid
levels.
CAUTION
To prevent power steering fluid overflow when
hot, be sure to utilize the appropriate HOT or
COLD fluid temperature-specific level marks if
displayed on power steering reservoir.
Regularly inspect steering column joint bolts and steering
linkage, particularly for body-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, it is recommended that steering
intermediate shaft joint bolts be checked for tightness every “B”
3879634R1
193
Maintenance Instructions
Power Steering
Tires
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.
Tire Warnings
Consult your International dealer for proper procedures of filling
and bleeding the system.
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.
Refer to SECTION 7 — MAINTENANCE INTERVALS AND
SPECIFICATIONS for the fluid and filter replacement intervals.
WARNING
Due to tire manufacturers re-marking tires to
conform to the SI (metric) system, tires marked
with old and new loads or inflation pressures
could be placed on the same vehicle. For 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.
WARNING
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.
194
3879634R1
Maintenance Instructions
WARNING
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
tires. 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.
WARNING
•
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 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.
WARNING
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 pressure may result in
sudden tire destruction, improper vehicle handling, and may
cause rapid and irregular tire wear.
Therefore, inflation
3879634R1
195
Maintenance Instructions
pressures should be checked daily and always before
long-distance trips.
tire components (i.e., ply and tread separation and reduced
retreadability).
Follow the tire manufacturer’s 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.)
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.
Checking Inflation
Inspection
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.
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.
•
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.
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.
•
Any cut that reaches to the belt or ply cords or any cut that
is large enough to grow in size and depth.
•
Any nail or puncturing object.
Underinflation
•
If any stone or object is held by a tread groove and is starting
to drill into the tread base, remove the object.
Tires should 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
Proper tire inflation, toe-in adjustment, loads, and road
speeds are important factors governing tire life, steering
ease, maneuverability, fuel economy, and ride quality.
196
3879634R1
Maintenance Instructions
Dual Tires Mixing
Loads
WARNING
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 resulting 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.
3879634R1
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
•
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
position 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.
•
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.
•
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.
197
Maintenance Instructions
2. In a dual assembly, reverse the position of the tires if
one tire wears much faster than its mate.
3. On the 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
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.
NOTE: Retread tires are not recommended for use on steering
axles of trucks.
Wear
•
Radial tires can exhibit three types of normal wear patterns,
even, erosion, or chamfer.
•
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.
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 axle positions:
•
Front (Steering) Axle - Replace tires at front wheels when
tread is worn to 4/32 inch (3 mm) or less.
•
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.
198
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 axle.
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.
3879634R1
Maintenance Instructions
Irregular Wear
Wheels
If irregular wear is present, check the axle alignment, tire
pressure, wheel balance, shock and suspension component
condition, and wheel bearing end play.
Wheel and Wheel Nut Maintenance and Installation
WARNING
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:
To prevent personal injury or death, always
follow these instructions when mounting tires on
wheels:
•
Only personnel that 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
tires. 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 anti-freeze, 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.
Irregular wear can be minimized by:
•
Using the right inflation pressure for the load being carried.
•
Maintaining proper front wheel alignment - especially toe-in
- to specifications.
•
Maintaining proper tire and wheel balance.
•
Maintaining shock absorbers and suspension components.
•
Maintain proper wheel bearing adjustment .
Use of Tire Chains
Refer to chain manufacturer’s recommendation for correct tire
chain usage, installation, and removal.
3879634R1
199
Maintenance Instructions
WARNING
•
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 in property damage, personal injury,
or death.
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.
200
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
WARNING
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.
2. Lubricate, the two-piece wheel nuts by putting two drops
of oil in the slot between the nut and washer and spin the
washer to spread the oil around the nut-to-washer contact
surface.
3. Carefully lubricate the wheel stud threads by wiping them
with a freshly oiled cloth. Do not get the oil on any other
3879634R1
Maintenance Instructions
surfaces or the wheel clamping effectiveness will be
reduced!
4. 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.
5. 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.
6. Hand-start all wheel nuts to avoid cross-threading.
1. Flange Nut Mount – 8 Stud
7. 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.
2. Flange Nut Mount – 10 Stud
8. Use a calibrated torque wrench to apply the specified torque
to each wheel nut in the sequence specified in the wheel
nuts torque sequence diagram above. Refer to SECTION
7 — MAINTENANCE INTERVALS AND SPECIFICATIONS
for proper torque values.
3879634R1
9. 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.
10. 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.
201
Maintenance Instructions
202
3879634R1
Maintenance Intervals And Specifications
SECTION 7 — 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® recommends the use of Fleetrite® lubricants for
optimum performance.
Maintenance Intervals
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 and Maintenance Manual maximum
intervals (based on the actual operating conditions
specified in that manual) must never be exceeded.
Maintenance intervals provided in this manual are for normal
highway and environmental service conditions.
3879634R1
203
Maintenance Intervals And Specifications
Lubrication and Maintenance Interval Chart Symbols Key
Lubrication and Maintenance Interval Chart Notes
Symbol
NOTE 1: A hand-pumped grease gun should be used for optimal
grease distribution within the component joint.
A
B
204
Interval Definition
Severe Service
< 20,000 mi/yr
City < 59,000
mi/yr
Highway
> 60,000 mi/yr
5,000 miles
(8,000 km)
135 hours
3 months
10,000 miles
(16,000 km)
300 hours
6 months
15,000 miles
24,000 km)
450 hours
9 months
10,000 miles
(16,000 km)
300 hours
6 months
20,000 miles
(32,000 km)
600 hours
12 months
30,000 miles
(48,000 km)
900 hours
18 months
NOTE 2: Kingpin thrust washers must be lubricated with vehicle
weight on tires. Kingpins and kingpin bushings must be lubricated
with weight off of the wheels and tires.
NOTE 3: Certain services are performed at Special Intervals or in
addition to A or B Service when the interval dictates.
3879634R1
Maintenance Intervals And Specifications
Lubrication and Maintenance Interval — Recommended Synchronized Intervals
System
Item
Intervals
Pre-Trip
Inspection
Pre-trip Inspection Items listed in Section 3 – Check All
Front Axle
Wheel Bearing-Oil Type – Check Level
A, B
Suspension Fasteners / Components – Check
A, B
Tie Rod Ends – Lubricate (1)
A, B
Drag Link – Lubricate (1)
A, B
King Pins and Bushings – Lubricate (1,2)
A, B
Shock Absorbers – Inspect
A, B
Wheel Bearing-Oil Type (including synthetic) – Change Oil
Severe Service and City:
60,000 miles (96,000 km)/–/6
On-Highway: 100,000 miles (160,000 km)/–/12
Wheel Bearing-Grease Type – Repack
Severe Service and City:
30,000 miles (48,000 km)/–/6
On-Highway: 30,000 miles (48,000 km)/–/12
Wheel Bearings – Check End-play
Axle U-bolts – Retorque
B
At first 1,000 miles (1,600 km) then every
36,000 miles (58,000 km) thereafter.
Drive Axle (4X4 and 6X4 vehicles) – Check Oil Level
5,000(8,000)/–/1
Drive Axle with Petroleum (4X4 and 6X4 vehicles) –
Change Oil (clean magnetic plug and breather)
25,000(40,000)/–/12
Drive Axle with Synthetic (4X4 and 6X4 vehicles) – Change
Oil (clean magnetic plug and breather)
3879634R1
Special Interval (3) : miles (km) / hours / months
50,000(80,000)/–/12
205
Maintenance Intervals And Specifications
Lubrication and Maintenance Interval — Recommended Synchronized Intervals (cont.)
System
Rear Axle
Item
Intervals
Suspension Fasteners/Components – Check
A, B
Axle Flange Nuts – Retorque
B
Ride Height – Check
B
Axle U-bolts – Retorque
Rear Axle with Petroleum Change Oil
(clean magnetic plug and breather as necessary)
Rear Axle Wheel Ends – inspect for leaks, lube
level/condition, and check end play with dial indicator.
Special Interval (3) : miles (km) / hours / months
At first 1,000 miles (1,600 km) then every
36,000 miles (58,000 km) thereafter.
60,000(96,000)/–/12
100,000(160,000)/–/12. Also at brake
lining service.
If wheel end play is found to be outside the 0.001
in. to 0.005 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 Change Oil
(clean magnetic plug and breather as necessary)
Rear Axle Wheel Ends – Full tear down inspection of all
wheel end components, regardless of condition of lube and
wheel bearing end play.
206
120,000(192,000)/–/12
500,000 miles (800,000km)/–/5 Years
3879634R1
Maintenance Intervals And Specifications
Lubrication and Maintenance Interval — Recommended Synchronized Intervals (cont.)
System
Electrical
Steering
Item
Engine Start and Gauge/Warning Indicators – Check
A, B
Instrument Readings Proper – Check
A, B
ABS Wiring Connections & Sensors – Reseat
A, B
Alternator-Starter-Battery – Check
A, B
Electrical lines routing and clipping (lines are not tangled,
crimped or pinched or rubbing against surfaces); not
spliced or taped; insulation not cut, cracked, chafed or
worn – Inspect
A, B
Power Steering Fluid – Check Level
A, B
Steering System – Check Tightness
A, B
Steering Gear – Lubricate
Steering Intermediate Shaft U-Joints/Slip Joint – Lubricate
A, B
Special Interval (3) : miles (km) / hours / months
ATTN: Install grease slowly at low pressure.
Power grease guns may blow out seals.
A, B
Steering Intermediate Shaft U-Joints – Retorque
60,000(96,000)/1,500/24
Power Steering Fluid – Change
100,000(160,000)/3000/12
Power Steering Filter – Replace
500,000(800,000)/15,000/60
Drive Shaft
“SPL”
U-Joints – Lubricate; Slip Joint Boot – Inspect
Drive Shaft
“Non-booted
Slip Joint”
U-Joints and Slip Joint – Lubricate
3879634R1
Intervals
B
5,000(8,000)/–/3
207
Maintenance Intervals And Specifications
Lubrication and Maintenance Interval — Recommended Synchronized Intervals (cont.)
System
Air Brakes
Item
Intervals
Air Wet Tank – Drain Water
A, B
Service Brakes Operation – Check
A, B
Parking Brakes Operation – Check
A, B
Governor Cut-in/Cut-out Pressure – Check
A, B
Low Air Pressure Warning Alarm – Check
A, B
Air Tanks (all) – Drain Water
A, B
S-Cam Bushings – Lubricate
A, B
Shoes – Check for wear and drag
A, B
Drums, Chambers, Hoses, etc. – Check for wear/damage
A, B
Brake Chamber Rod Travel – Check
A, B
Air Dryer Desiccant-Replace
AD-IP: 1 year; AD-9: 2 Years
Air Dryer Heater & Purge Valve – Check
AD-IP: 1 year; AD-9: 2 Years
Air Compressor Discharge Line – Check Blockage
Cooling
System
208
Special Interval (3) : miles (km) / hours / months
50,000 miles (80,000 km)/1,500/24
Coolant – Check Level
A, B
Radiator & CAC Fins – Check for Blockage
A, B
Fan Clutch – Check
A, B
Fan Blade/Shroud – Check Damage/Contact
A, B
Coolant Filter (if equipped) – Replace
B
Extended Life Coolant – Replace
Refer to Engine Operation and Maintenance Manual.
3879634R1
Maintenance Intervals And Specifications
Lubrication and Maintenance Interval — Recommended Synchronized Intervals (cont.)
System
Engine
Item
Intervals
Engine Oil Level – Inspect
A, B
Fan Belt – Inspect
A, B
Air Filter – Check Restriction
A, B
Air Induction System – Check looseness/leaks
A, B
Air Filter – Replace
Special Interval (3) : miles (km) / hours / months
At Restriction Indication or 60 months.
Engine Oil and Filter(s) – Replace
Refer to Engine Operation and Maintenance Manual.
Fan Belt Auto Tensioner – Inspect
Refer to Engine Operation and Maintenance Manual.
Fuel Filter – Drain Separated Water
Refer to Engine Operation and Maintenance Manual.
Fuel Filter – Replace
Fuel Tank
Refer to Engine Operation and Maintenance Manual.
Fuel Tank(s) – Drain and Flush (Note 3)
100,000(160,000)/–/12
Fuel Sender, Hose Connections – Check for Loose
Connectors
Exhaust
System
Clutch
3879634R1
Pipes/Muffler – Inspect for leakage/looseness
Diesel Particulate Filter (DPF) – Clean out ash
Release Bearing/Shafts/Fork – Lubricate
12 months
A, B
Refer to Engine Operation and Maintenance Manual
Highway – 10,000 miles (16,000 km)/–/1
City/Severe Service: – /250/1
209
Maintenance Intervals And Specifications
Lubrication and Maintenance Interval — Recommended Synchronized Intervals (cont.)
System
Transmission
Item
Trans Fluid, Automated/Manual – Check Level
Intervals
Special Interval (3) : miles (km) / hours / months
A, B
Shift Selector/Linkage – Check Function
A, B
Neutral Start Switch – Check Function
Transfer Case
(4X4 only)
A, B
Manual Trans, Petroleum Oil – Replace
Refer to Transmission Operators Manual.
Manual Trans, Synthetic Oil – Replace
Refer to Transmission Operators Manual.
Automated/Manual Trans Fluid/Filter – Replace
Refer to Transmission Operators Manual.
Change Oil
A
Meritor Synthetic Oil Change
Initial Oil Change at 5000 miles (9000 km)
Initial Oil Change at 2,500 miles (4,000 km) or
125 hours whichever comes first.
Thereafter 25,000 miles (40,000 km), 1,250 hours
or 12 months, which ever comes first.
Tires/Wheels
Air Pressure – Check
A, B
Wear and Condition – Check
A, B
Wheel Stud Nuts – Retorque
A, B
Spin Balance
Cab
Components
210
At time of tire mounting or as needed.
Door Hinges/Latches/Strikers – Lubricate, Check Link (Use
Multi-purpose lithium grease or light engine oil. Do Not
use silicone lubricant).
A, B
Door Lock Cylinders – Lubricate
A, B
Seat Adjuster Slides – Lubricate
A, B
3879634R1
Maintenance Intervals And Specifications
Lubrication and Fluids Charts
Fluid Check and Fill Notes
NOTE: The components requiring lubrication and fluid check
shown in this manual are typical representations.
CAUTION
Use only recommended viscosity engine oil.
Refer to the Engine Operation and Maintenance
Manual for engine oil specifications.
Lubrication Notes
CAUTION
Unapproved lubricants can cause premature
component failure. Refer to the Lubricants and
Sealer Specification table for proper lubricants.
•
•
Wipe clean 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. If a 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.
3879634R1
•
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
cause excessive pressure in the axle and create leaks.
211
Maintenance Intervals And Specifications
Components Requiring Lubrication
212
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. Fifth Wheel Pivot Points and Top Plate (If Equipped)
5. Tie Rod Ends
10. Rear S-Cams and Slack Adjusters
3879634R1
Maintenance Intervals And Specifications
Components Requiring Fluid Check and Fill
1. Coolant Make-up Tank
6. Drive Axle Oil Fill/Level Check Plug
2. Coolant Deaeration Tank
7. Manual Transmission Oil Fill/Level Check Plug
3. Engine Oil Dipstick
8. Automatic Transmission Dipstick/Fluid Fill
4. Front Axle Oil-Filled Hubs
9. Windshield Washer Fluid Bottle
5. Transfer Case (if equipped)
10. Power Steering Fluid Reservoir
3879634R1
213
Maintenance Intervals And Specifications
Unit Refill Capacities
Forward
Front Drive Axles
Model
Liters
Quarts
Meritor MX-10–120, MX-12–120,
MX-14–120
7.6
8
Meritor MX-16–120
17
18
Rear Axle Unit Refill Capacities
Forward
Axle Model No.
Liters
Pints
Meritor
MS-21-14X-4DCR
15.9
33.6
Dana Spicer® 17060S,
19060S, 21060S,
21060D, 21060T
13
Meritor RS-19-224
14.7
31
Meritor RS-21-145,
RS–17–144,
RS–19–144
15
32.3
Meritor RS-19-145,
RS-21-162
16
Meritor RS-17-145
28
Rear
Liters
Pints
Axle Model No.
Liters
Pints
Meritor RS-21-160,
RS-21-230, RS-23-160
18.5
39
Meritor RS-21-162
18.7
39.5
Dana Spicer® S23-170,
S23-170D, S23-190,
S23-190D, S26-190,
S26-190D
17.5
37
Meritor RS-23-161
18
37.5
Meritor PRC-674
19
40
Meritor RH-23-186
27.9
59
Meritor RS-26-185
22.2
47
Meritor RS-30-185
22
46.5
Meritor RS-30-185
25
53.5
Meritor RS-30-380
28
58.5
Meritor RS-38-380
22.5
47.5
Rear
Liters
Pints
Tandem
{Dana Spicer®
DS344/RS344
15
31
13
28
33.5
Meritor RT-34-144
14
30.2
12
25.8
14.7
31
13
28
16
34
Dana Spicer®
DS405/RS405
Dana Spicer® 19060T
16.6
35
Meritor RT-40-145
14
30.2
12
25.8
Dana Spicer® 23082T
17.5
37
214
3879634R1
Maintenance Intervals And Specifications
Forward
Axle Model No.
Rear
Forward
Rear
Liters
Pints
Liters
Pints
Axle Model No.
Liters
Pints
Liters
Pints
Dana Spicer®
DS405P/RS405
14.7
31
13
28
Dana Spicer®
D46-170DHP/R46-170DH
18.5
39
17.5
37
Dana Spicer®
DS405/RD405
14.7
31
13
28
Dana Spicer®
D46-170P/R46-170
18.5
39
17.5
37
Dana Spicer®
DD405/RD405
14.7
31
13
28
Dana Spicer®
D46-170P/R46-170D
18.5
39
17.5
37
Dana Spicer®
DD405P/RD405
14.7
31
13
28
Dana Spicer®
D46-170D/R46-170D
18.5
39
17.5
37
Dana Spicer®
DS405P/RD405
14.7
31
13
28
Dana Spicer®
D46-170/R46-170
18.5
39
17.5
37
Dana Spicer®
DST41/RST41
14.7
31
17
36
Meritor RT-46-160,
RT-46-160P
18.5
39
16.3
34.4
Dana Spicer®
DST41P/RST41
14.7
31
17
36
Meritor RT-46-164EH
18
38.1
15.7
33.2
Meritor RT-46-164P
18
38.1
15.7
33.2
{Dana Spicer® DT402P
17.5
37
16
34
Meritor RT-52-185
26.5
56
17
36
Dana Spicer®
D46-170HP/R46-170H
18.5
39
17.5
37
Meritor RT-52-185P
26.5
56
17
36
Dana Spicer®
D46-170HP/R46-170DH
18.5
39
17.5
37
3879634R1
215
Maintenance Intervals And Specifications
Cooling System Refill Capacities
Cooling system refill capacities vary considerably due to
differences in engine models, variations in chassis, and body
options, in addition to the amount of coolant remaining in the
system after draining. Total capacity may range from 6 to 22
gallons (23 to 83 liters).
If system has been drained, fill with fresh 50/50 diluted
concentrate coolant or 50/50 premixed 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 (60 to 66 percent) of
coolant concentrate is advised in order to achieve a final mixture
close to 50/50.
Fill the system and run the vehicle until the thermostat opens.
Check the coolant concentration and add additional water or
concentrated undiluted coolant to adjust the concentration. Run
the vehicle and retest.
Crankcase and Oil Filters
For specific engine crankcase capacities, refer to separate
Engine Operation and Maintenance Manual provided with
vehicle.
216
Power Steering Systems
Steering Gear
Power Steering Fluid Volume
(in³/pints/liters)
TAS-85
240/8.4/3.9*
M-100
240/8.4/3.9*
M-100/ M-80
346/12/5.7*
M110
240/8.4/3.9*
M110/M100
346/12/5.7*
M-110/M-90
346/12/5.7*
* Approximate refill quantity, refer to power steering
reservoir for proper fill marks.
Transfer Case
Model
Liters
Pints
Dana Spicer® 792
5.2
11
Meritor T-4208,
T-4210, and T-4213
4.3
9
Fabco® TC-38
6.6
14
3879634R1
Maintenance Intervals And Specifications
Transmission
Model
Liters
Pints
Manual
Fuller® 5 Speed: 6305A
8.8*
18.5*
Fuller® 6 Speed: FS-5406N; FS-6406N; FSO-8406
9*
19.5*
International® 7 Speed: ES 56–7B; ESO 66
10*
22*
Spicer® 7 Speed: PS110-7B
23*
48*
Fuller® FR—11210B —10 Speed — wet clutch
11*
23.5*
Fuller® 10 Speed: FR-9210B; FRO-11210C; FRO-12210B;
FRO-13210B; FR–9210B; FRO–11210B; FRO-12210B;
FRO-13210B ; FRO-14210B; FRO–12210C; FRO–13210C;
FRO–14210C; FRO–15210C; FRO–16210C
11*
23.5*
Fuller® 10 Speed: RTO(F)–11908L; RTO(F)–14908LL;
RTO(F)–16908LL;
13*
28*
Fuller® 10 Speed: RT-8908LL;
13*
28*
Fuller® 10 Speed: RTO–12910B–AS3; RTO–16910B–AS3;
RTO–14910B–AS3;
12.8*
27*
Fuller® 10 Speed:RTO-14910C-AS3; RTO-16910C-AS3
12*
26*
Fuller® 11 Speed: RTO(F)–11909ALL; RTO(F)–14909ALL;
RTO(F)–16909ALL
13*
28*
Fuller® 13 Speed: RTLO(F)–12913A; RTLO(F)–14913A;
RTLO(F)–16913A; RTLO–18913A
13*
28*
Fuller® 15 Speed: RTO(F)-16915
13*
28*
Fuller® 18 Speed: RTLO(F)–14918B; RTLO(F)–16918B
13*
28*
RTLO-1898A-AS3
13*
28*
3879634R1
217
Maintenance Intervals And Specifications
Model
Liters
Pints
Automatic
Allison Automatic: 2500_HS, RDS P 5 Speed **
18*
38*
Allison Automatic: 3000_HS, EVS P, RDS P 5 & 6 Speed; **
27*
58*
Allison Automatic: 3500_ EVS P, RDS P 5 & 6 Speed; **
27*
58*
Allison Automatic: 4000_HS, EVS P, RDS P 5 & 6 Speed **
47*
100*
Allison Automatic: 4500_HS, EVS P, RDS P 5 & 6 Speed **
47*
100*
* Approx. refill quantity; less than initial fill and fluids remain in external circuits and transmission cavities.
** Check at operating temperature and topped off as required.
*** See Lubricant and Sealer specifications for these transmission lubes.
Tire and Rim Combinations
Approved Tire and Rim Combinations
Tubeless
218
Tire Size
Rim Width
Tire Size
Rim Width
Tire Size
Rim Width
9R22.5
6.75, 7.50
225/70R19.5
6.75
265/70R19.5
6.75, 7.50, 8.25
10R22.5
6.75, 7.50
235/80R22.5
6.75, 7.50
275/80R22.5
7.50, 8.25
11R22.5
7.50, 8.25
245/70R19.5
6.75, 7.50
295/75R22.5
8.25, 9.00
12R22.5
8.25, 9.00
255/70R22.5
7.50, 8.25
315/80R22.5
9.00
3879634R1
Maintenance Intervals And Specifications
Lift Axle System
Maintenance Chart
Procedure
Interval
Check for proper brake operation
Daily/Per operation
Inspect for signs of structural damage, cracks or wear in all components of
suspension parts (arms, hangers, axle seats, etc.)
Daily
Check for air leaks
Daily/Per operation
Check bushings for excessive wear or movement
Every 30 days
Drain condensation from tank
Dry climate – Monthly
Wet climate – Daily
Torque U-bolts and all fasteners (see lift axle Torque charts)
Every 6 months
Drain interior of axle-mounted air tank
Same as other vehicle air tanks
Torque Specifications
DISC WHEEL TORQUE CHART
DISC WHEELS
Size
11/16 Inch
22 mm
3879634R1
Nut Mounting
Torque
lbf – ft
N•m
Flange
350-400
475–542
Flange: Motor Wheel - 37.5 mm Across Flats
450-500
610-678
219
Maintenance Intervals And Specifications
DISC WHEELS
22 mm
Flange: International®/Budd - 33 mm Across
Flats
450-500
610-678
NOTE: Do not use lubrication on dry threads. Where excessive corrosion exists, a light coat of lubricant on first three threads of stud on bolt is
permitted. Keep lubricant away from:
•
hex nut and rim clamp contact surfaces;
•
flange nut washer surface and flat on disc wheel.
220
3879634R1
Maintenance Intervals And Specifications
U-BOLT NUT TORQUE CHART
Torque
Feature Code
Rear Suspension Capacity and Type
lbf - ft
N • m
14SAB
23,000-lb Capacity, RR, Spring, Single, with 3 Torque Rods
400-425
542-576
14SAH
18,500-lb Capacity, RR, Spring, Single Vari-Rate
370-400
502-542
14SAL
31,000-lb Capacity, RR, Spring, Single Vari-Rate, with 4,500-lb Auxiliary Multileaf
Springs
370-400
502-542
14SAM
20,000-lb Capacity, RR, Springs, Vari-Rate
370-400
502-542
14SAN
23,500-lb Capacity, RR, Spring, Single, Vari-Rate
370-400
502-542
14SBM
31,000-lb Capacity, RR, Spring, Single with 3 Torque Rods
400-425
542-576
14SZB
4,500-lb Capacity, Rear Auxiliary Multileaf Springs
370-400
502-542
14TBJ
20,000-lb Capacity, International Air Suspension (IROS)
370-400
502-542
14TBZ
23,000-lb Capacity, Single, Air (Hendrickson PRIMAAX EX)
350-400
475-542
46,000-lb Capacity, Tandem, Air (Hendrickson PRIMAAX EX), with 72 inch, 55
inch, and 60 inch axle spacing.
350-400
475-542
40,000-lb Capacity, International 4-Spring, Multileaf
260-300
353-407
40,000-lb Capacity, International Air Suspension (IROS)
370-400
502-542
14VAD
18,500-lb Capacity, RR, Springs, Vari-Rate, with 4,500-lb Auxiliary Rubber Spring
370-400
502-542
14VAG
20,000-lb Capacity, RR, Springs, Vari-Rate, with 4,500-lb Auxiliary Rubber Spring
370-400
502-542
14VAH
23,500-lb Capacity, RR, Springs, Vari-Rate, with 4,500-lb Auxiliary Rubber Spring
370-400
502-542
14VAJ
31,000-lb Capacity, RR, Springs, Vari-Rate, with 4,500-lb Auxiliary Rubber Spring
370-400
502-542
14UNW, 14UNX, and 14UNY
14UNA
14UNL, 14UNM, 14UNN,
14UNS, 14UNT, and 14UNU
NOTE: For all other vendor supplied suspensions, refer to vendor’s website for proper torque specifications.
3879634R1
221
Maintenance Intervals And Specifications
Torque
Feature Code
Front Suspension Capacity and Type
N • m
3ACP
12,000-lb Capacity, Multileaf , Shackle Type
260-300
353-407
3ACR
18,000-lb Capacity, Multileaf , Shackle Type
260-300
353-407
3ACS
20,000-lb Capacity, Multileaf , Shackle Type
260-300
353-407
20,000-lb Capacity, Multileaf , Shackle Type, (with SBA and CAT Engine)
325-400
441-542
10,000-lb Capacity, Parabolic Taper Leaf
260-300
353-407
10,000-lb to 20,000-lb Capacity, Parabolic Taper Leaf, (with SBA and CAT Engine)
325-400
441-542
3ADC
12,000-lb Capacity, Parabolic Taper Leaf
260-300
353-407
3ADD
14,000-lb Capacity, Parabolic Taper Leaf
260-300
353-407
3ADE
16,000-lb Capacity, Parabolic Taper Leaf
260-300
353-407
3ADG
18,000-lb Capacity, Parabolic Taper Leaf
260-300
353-407
3AGA
20,000-lb Capacity, Parabolic Taper Leaf
260-300
353-407
20,000-lb Capacity, Parabolic Taper Leaf, (with Set Back Axle and CAT Engine)
325-400
441-542
3AGU
14,000-lb Capacity, Multileaf , Shackle Type
260-300
353-407
3AHL
22,000-lb Capacity, Parabolic Taper Leaf
325-400
441-542
3WAJ
Auxiliary Air Bag Springs (Right Side)
260-300
353-407
3WAK
Auxiliary Air Bag Springs (Left Side)
260-300
353-407
3ADB
For vehicles with Hendrickson suspension (14UHK only), the
torque value of the four suspension saddle bolts, if applied at the
head, are 500 ft-lbs.(678 N•m). If applied at the nut, the torque
value is 400 ft-lbs.(543 N•m).
222
lbf - ft
See Lubrication and Maintenance Interval Chart, Axle U-bolts –
Retorque, for maintenance retorque interval.
3879634R1
Maintenance Intervals And Specifications
SPRING U-BOLT CHECKS
Lift Axle U-Bolt Nut Torque Chart
Check U-Bolt Nuts and re-torque every 36,000 miles (57, 936
km) after initial 1,000 mile re-torque.
U-Bolt Size
(UNF – Grade 8)
Size in inches
3/8
1/2
5/8
3/4
7/8
1
1 1/8
Min. Torque
(lbf-ft)
15
40
120
200
400
650
800
Max. Torque
(lbf-ft)
20
60
150
250
450
750
900
LIFT AXLE TORQUE CHARTS
NOTE: Torque values DO NOT apply to air springs or lower
grade fasteners.
The following chart applies to both Steerable and Fixed Lift
Axles.
Capscrew/Bolt Torque Chart
Fixed Axle U-Bolt Torque
The U-Bolts must be tightened and torqued using the following
cross pattern sequence and illustration. The U-Bolt Torque chart
applies only to Fixed lift axles.
1. Tighten 1 and 4 to partial torque.
2. Tighten 2 and 3 to partial torque.
3. Repeat steps 1 and 2 tightening all four bolts to full torque.
CapscrewBolts (UNF –
Grade 8) Size
in inches
3/8
1/2
5/8
3/4
7/8
1
1 1/8
Min. Torque
(lbf-ft)
25
50
150
300
500
700
900
Max. Torque
(lbf-ft)
35
75
200
350
550
800
1000
NOTE: Torque values DO NOT apply to U-BOLTS.
3879634R1
223
Maintenance Intervals And Specifications
Fuse Charts
The following fuse illustrations represent the fuse panel layouts.
The actual vehicle fuse panels will vary depending on the vehicle
options.
224
3879634R1
Maintenance Intervals And Specifications
WorkStar® Series Light Information
Lamp Description
Candlepower or Watt
Bulb P/N
Cab Dome Light
12 Watts
211-2
Cab Mount Clearance/Marker Light
3 CP
GE193
Headlight
65 Watts
GE9007
Fog Light
56 Watts
VH550
Front Park/Marker/Turn Light
2356
Side Marker Light
2548
Tail/Brake/Turn Light
32/3 CP
1157
Back-up Light
32 CP
GE1156
Ashtray Light
N/A
N/A
Filter List
Filter part numbers and/or specifications may change during the
life-cycle of this vehicle. Current information on the appropriate
3879634R1
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 at internationaltrucks.com.
225
Maintenance Intervals And Specifications
226
3879634R1
Customer Assistance
SECTION 8 — 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 purchase 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,
3879634R1
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 Service Contracts.
227
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
•
Extends warranty protection to specified length and
component coverage to suit individual needs
•
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% parts and labor with NO
DEDUCTIBLES .
•
Customized warranty programs are offered to suit your
needs - your specification - your vocation
228
•
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
most 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 <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!
3879634R1
Index
SECTION 9 — INDEX
A
ABS Connections and Sensors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .176
ABS Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .110, 154
ABS Self-Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .154
Accessory Feed Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .179
Additional Unsafe Practices. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .115
Adjustable Tilt/Telescoping Steering Column. . . . . . . . . . . . . . . . . .104
After the Engine Starts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .95
Air Brake Bendix® ABS-6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .155
Air Brakes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .148, 173
ABS Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .154
ABS Self-Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .154
Air Brake Bendix® ABS-6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .155
Air Dryer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .151
Air Gauge, Low Air Pressure Beeper and Warning
Indicator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .149
Antilock Brake System (ABS). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .153
Antilock Driving Tips. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .155
Brake Application. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .149
Core ABS Functions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .155
Inspection and Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .173
Parking Brake. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .149
Parking Brake Alarm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .153
Parking Brake Indicator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .153
Parking Brake Reset. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .150
Reservoir Moisture Draining. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .151
Trailer Air Supply and Parking Brake Modular Controls. . .152
Trailer Brake Hand Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .151
Air Cleaner Element Service. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .182
Air Compressor Cycling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .112
3879634R1
A (CONT.)
Air Conditioning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .82
Air Conditioning Service Checks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .168
Front Access HVAC Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .169
HVAC Filters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .168
Recirculation Filters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .169
Side Access HVAC Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .168
Air Dryer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .151, 174
Desiccant Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .175
Heater. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .175
Purge Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .175
Air Gauge, Low Air Pressure Beeper and Warning
Indicator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .149
Air Induction System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .180
Air Intake System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .190
Air Parking Brake or Power Parking Brake. . . . . . . . . . . . . . . . . . . .125
Air Reservoir/Tanks Moisture Draining. . . . . . . . . . . . . . . . . . . . . . . . .175
Air Restriction Gauge. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .181
Air Suspension Dump (ASD) Switch (Optional). . . . . . . . . . . . . . .139
Air Suspension System Faults. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .140
Alignment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .171
Allison Generation IV T-Bar Gearshift Control. . . . . . . . . . . . . . . . .126
Allison Transmission with “P” – (Park) Park Pawl Mechanism or
“PB” – Parking Brake Position. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .123
Allison Transmissions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .123
Alternator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .106
Ammeter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .106
Antifreeze. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .114
AntiFreeze. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .189
Antilock Brake System (ABS). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .153
229
Index
A (CONT.)
Antilock Driving Tips. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .155
Approved Tire and Rim Combinations. . . . . . . . . . . . . . . . . . . . . . . . .218
Assistance Guide. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
ATC OFF ROAD or MUD/SNOW Switch. . . . . . . . . . . . . . . . . . . . . . .156
ATC System Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .156
Auto Neutral. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .129
Automatic Door Lock Function. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .86
Automatic Transmission Operating Temperature. . . . . . . . . . . . .131
Automatic Transmission Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . .110
Automatic Transmissions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .123, 192
Air Parking Brake or Power Parking Brake. . . . . . . . . . . . . . . . . .125
Allison Generation IV T-Bar Gearshift Control. . . . . . . . . . . . . .126
Allison Transmission with “P” – (Park) Park Pawl Mechanism
or “PB” – Parking Brake Position. . . . . . . . . . . . . . . . . . . . . . . . . . .123
Allison Transmissions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .123
Auto Neutral. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .129
Automatic Transmission Operating Temperature. . . . . . . . . . .131
Backup Alarm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .129
Main Transmission Controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .128
Manual Parking Brake. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .125
Operation of the Allison Generation IV Gearshift
Controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .125
Operation of the Allison Generation IV Push-button Shift
Selector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .127
Operation of the Column-Mounted Shifter. . . . . . . . . . . . . . . . . .128
Parking The Vehicle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .124
Power Take Off Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .131
Preparing to Drive the Vehicle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .125
Torque Lock. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .126
Auxiliary Gauge/Switch Package (AGSP) (Optional). . . . . . . . . .78
Panel Component Arrangements (Optional). . . . . . . . . . . . . . . . .78
230
A (CONT.)
Available Cabs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Crew Cab. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Extended Cab. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Standard Cab. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Available Models. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Axle and Suspension Conversions. . . . . . . . . . . . . . . . . . . . . . . . . . . . .140
Axle Operating Temperature. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .136
Axle Shift Only. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .135
Axles. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .170
Front Axle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .170
Alignment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .171
Inspection and Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .170
Normal Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .170
Front Drive Axle and Transfer Case (Optional). . . . . . . . . . . . .171
Inspection and Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .171
Rear Axle – Inspection and Lubrication. . . . . . . . . . . . . . . . . . . . .171
Axles and Suspensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .136
Air Suspension Dump (ASD) Switch (Optional). . . . . . . . . . . .139
Air Suspension System Faults. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .140
Axle and Suspension Conversions. . . . . . . . . . . . . . . . . . . . . . . . . . .140
Axle Operating Temperature. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .136
Front Axle (4X4, 6X6). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .136
Gross Weight (Axle – Vehicle). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .136
International® Ride Optimized Suspension (IROS)
(Optional). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .139
Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .137
Transfer Case. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .137
B
Backup Alarm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .129
Basic Functions of Steering Wheel Controls. . . . . . . . . . . . . . . . . . . .70
3879634R1
Index
B (CONT.)
Batteries. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .177
Battery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .106
Battery Cables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .178
Battery Disconnect Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .107
Bobtail Proportioning System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .158
Body. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .190
Brake Application. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .149
Brakes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .147, 172
ABS Connections and Sensors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .176
Air Brakes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .148, 173
ABS Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .154
ABS Self-Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .154
Air Brake Bendix® ABS-6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .155
Air Dryer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .151
Air Gauge, Low Air Pressure Beeper and Warning
Indicator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .149
Antilock Brake System (ABS). . . . . . . . . . . . . . . . . . . . . . . . . . . . . .153
Antilock Driving Tips. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .155
Brake Application. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .149
Core ABS Functions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .155
Inspection and Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .173
Parking Brake. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .149
Parking Brake Alarm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .153
Parking Brake Indicator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .153
Parking Brake Reset. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .150
Reservoir Moisture Draining. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .151
Trailer Air Supply and Parking Brake Modular
Controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .152
Trailer Brake Hand Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .151
Air Dryer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .174
Desiccant Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .175
3879634R1
B (CONT.)
Brakes (cont.)
Heater. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .175
Purge Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .175
Air Reservoir/Tanks Moisture Draining. . . . . . . . . . . . . . . . . . . . . .175
ATC OFF ROAD or MUD/SNOW Switch. . . . . . . . . . . . . . . . . . . .156
ATC System Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .156
Downhill Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .147
Stability Control Systems – Bendix® ESP. . . . . . . . . . . . . . . . . .157
Traction Control (If Equipped). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .156
Bright Metal Care. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .176
C
Cab. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .176
Care of Vehicle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .176
Bright Metal Care. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .176
Exposed Rubber and Unpainted Plastic Parts. . . . . . . . . . .176
Upholstery Care. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .176
Washing and Waxing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .176
Cab Controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90
Cab Doors and Locks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .83
Cab Entry and Exit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Cab Interior Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
Canadian Registered Vehicles. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Capscrew/Bolt Torque Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .223
Care of Seat Belts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .93
Care of Vehicle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .176
Bright Metal Care. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .176
Exposed Rubber and Unpainted Plastic Parts. . . . . . . . . . . . . .176
Upholstery Care. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .176
Washing and Waxing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .176
Cautions and Warnings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
231
Index
C (CONT.)
Center Dash Panel/Wing Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .74
Switches. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .75
Certified Clean Idle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .111
Charge Air Cooler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .108
Charge Air Cooler And Radiator Core Inspection And
Cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .185
Inspection and Cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .185
Chassis Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .167
Checking Inflation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .196
Circuit Breakers, Fuses, and Fusible Links. . . . . . . . . . . . . . . . . . . .107
Cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .191
Climate Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .80
Air Conditioning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .82
Dehumidification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .83
Clutch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .177
Pedal Free-Travel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .177
Clutch Brake (Vehicles with Nonsynchronized Transmission) –
Vehicle Not Moving. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .121
Clutch Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .122
Cold Weather. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .100
Cold Weather Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101
Cold Weather Starting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101
Engine Idling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101
Winter Front Usage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .102
Winter/Engine Intake Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101
Cold Weather Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101
Cold Weather Starting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101
Compass Declination Zone Set Procedure. . . . . . . . . . . . . . . . . . . . . .52
Compass Directional Calibration Procedure. . . . . . . . . . . . . . . . . . . .55
Component Code Numbers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Line Set Ticket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
232
C (CONT.)
Components Requiring Fluid Check and Fill. . . . . . . . . . . . . . . . . .213
Components Requiring Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . .212
Connecting/Disconnecting a Trailer to a Vehicle with Air
Suspension. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .162
Controlled Traction Differential. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .134
Coolant and Optional Coolant Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . .188
Coolant Level. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .185
Cooling System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .113, 185
Antifreeze. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .114
AntiFreeze. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .189
Coolant and Optional Coolant Filter. . . . . . . . . . . . . . . . . . . . . . . . .188
Coolant Level. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .185
Fan Clutch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .189
Filling Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .186
Filling Instructions (MaxxForce® 11 and 13 Engines). . . . .187
Cooling System Refill Capacities. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .216
Core ABS Functions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .155
Courtesy Lights. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50
Crankcase and Oil Filters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .216
Crew Cab. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Cruise Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .69
Basic Functions of Steering Wheel Controls. . . . . . . . . . . . . . . . .70
Mobile Variable Speed Control (12VXV). . . . . . . . . . . . . . . . . . . . . .71
Operational Procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70
Stationary Pre-Set Speed Control (12VXU). . . . . . . . . . . . . . . . . .71
Stationary Variable Speed Control (12VXT). . . . . . . . . . . . . . . . . .71
Throttle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70
Customer Security Guide for International Trucks. . . . . . . . . . . . . . .6
D
Dash Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
3879634R1
Index
D (CONT.)
Daytime Running Lights (DRL). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49
Dehumidification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .83
Desiccant Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .175
Diesel Particulate Filter (DPF). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .191
Cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .191
Regeneration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .191
Direct Drive Warning Indicators. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47
Disc Wheel Torque Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .219
Dome Lighting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50
Door and Window Controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .83
Door Lock/Unlock. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .83
Automatic Door Lock Function. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .86
Cab Doors and Locks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .83
Door Opening/Unlock. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .85
Lock/Unlock from Interior. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .85
Remote Keyless Entry Operation (Optional). . . . . . . . . . . . . . .84
Windows. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .86
Manual Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .86
Mirror Controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .86
Power Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .86
Vent Window. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .87
Window Lockout Function. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .86
Door Lock/Unlock. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .83
Automatic Door Lock Function. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .86
Cab Doors and Locks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .83
Door Opening/Unlock. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .85
Lock/Unlock from Interior. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .85
Locking the Door. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .85
Unlocking the Door. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .86
Remote Keyless Entry Operation (Optional). . . . . . . . . . . . . . . . .84
Door Opening/Unlock. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .85
3879634R1
D (CONT.)
Double Clutch Procedures, Nonsynchronized. . . . . . . . . . . . . . . . .121
Downhill Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .147
Drive Shafts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .192
Driver Reward. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .87
Driver-Controlled Differential Lock. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .133
Dual Tires Matching. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .197
Dual Tires Mixing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .197
E
Eaton UltraShift® Transmissions (Optional). . . . . . . . . . . . . . . . . . .123
Electrical. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .105, 177
Accessory Feed Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .179
Alternator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .106
Ammeter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .106
Batteries. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .177
Battery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .106
Battery Cables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .178
Battery Disconnect Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .107
Circuit Breakers, Fuses, and Fusible Links. . . . . . . . . . . . . . . . .107
Electrical Charging and Starting System Test. . . . . . . . . . . . . .178
Electrical System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .105
Fuses and Relays. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .179
Terminal Inspection-Cleaning-Corrosion Protection. . . . . . . .178
Electrical Charging and Starting System Test. . . . . . . . . . . . . . . . .178
Electrical System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37, 105
Emergency Starting Using Jumper Cables. . . . . . . . . . . . . . . . . . . .100
Emission Control Systems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Enabling the Lift Axle System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .145
Engaging the Clutch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .120
Engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .108, 179
Air Cleaner Element Service. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .182
233
Index
E (CONT.)
Engine (cont.)
Air Induction System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .180
Air Restriction Gauge. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .181
Charge Air Cooler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .108
Charge Air Cooler And Radiator Core Inspection And
Cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .185
Inspection and Cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .185
Cooling System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .185
AntiFreeze. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .189
Coolant and Optional Coolant Filter. . . . . . . . . . . . . . . . . . . . . . .188
Coolant Level. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .185
Fan Clutch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .189
Filling Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .186
Filling Instructions (MaxxForce® 11 and 13 Engines). . .187
Engine fluids and contaminated material. . . . . . . . . . . . . . . . . . . .180
Frame. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .190
Fuel System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .189
Fuel Tank Draining and Cleaning. . . . . . . . . . . . . . . . . . . . . . . . . .189
Scheduled Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .180
Tow Hooks, Tow Pins, and Pintle Hooks. . . . . . . . . . . . . . . . . . . .190
Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .184
Engine Brake System Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .109
Engine Brake, Retarder (Optional). . . . . . . . . . . . . . . . . . . . . . . . . . . . .108
ABS Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .110
Automatic Transmission Operation. . . . . . . . . . . . . . . . . . . . . . . . . . .110
Engine Brake System Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . .109
MaxxForce® 11 and 13 Engine Brake With Eaton
AutoShift®/UltraShift® Transmissions Special Driver
Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .109
Operational Modes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .109
Engine fluids and contaminated material. . . . . . . . . . . . . . . . . . . . . .180
234
E (CONT.)
Engine Idle Shutdown Timer (Optional). . . . . . . . . . . . . . . . . . . . . . . . .96
System Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .96
Engine Idling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101
Engine Noise Shields/Blankets. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .191
Engine Oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .114
Engine Performance Problems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .115
Engine Serial Number. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Engine ShutDown. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .95
Shut-Down Warning Indicator Or Beeper. . . . . . . . . . . . . . . . . . . . .95
Engine Starting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .94
Engine Warning/Protection System (EWPS). . . . . . . . . . . . . . . . . . .111
Standard Engine Warning System 2-Way. . . . . . . . . . . . . . . . . . .111
Exhaust Diesel Particulate Filter Regeneration. . . . . . . . . . . . . . . .117
Parked Regeneration Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . .119
Regeneration Inhibit Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .119
Three-Position Regeneration Inhibit Switch. . . . . . . . . . . . . . . . .120
Two-Position Regeneration Inhibit Switch. . . . . . . . . . . . . . . . . . .120
Exhaust System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .191
Exposed Rubber and Unpainted Plastic Parts. . . . . . . . . . . . . . . .176
Extended Cab. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Extended Cab Bunk (Optional). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .93
Exterior Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Exterior Lights Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Exterior Noise Emissions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
F
Fan Clutch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .189
Feature Codes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Fifth Wheel and Coupling Area. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
Fifth Wheel Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .162
Fifth Wheel Slide Switch (Optional). . . . . . . . . . . . . . . . . . . . . . . . . .162
3879634R1
Index
F (CONT.)
Fifth Wheel Operation (cont.)
Hook-Up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .163
Un-Hook. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .163
Fifth Wheel Slide Switch (Optional). . . . . . . . . . . . . . . . . . . . . . . . . . . . .162
Filling Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .186
Filling Instructions (MaxxForce® 11 and 13 Engines). . . . . . . .187
Filter List. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .225
Frame. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .190
Front Access HVAC Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .169
Front Axle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .170
Alignment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .171
Inspection and Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .170
Normal Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .170
Front Axle (4X4, 6X6). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .136
Front Drive Axle and Transfer Case (Optional). . . . . . . . . . . . . . . .171
Inspection and Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .171
Front Drive Axles. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .214
Front of Vehicle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
Fuel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .115
Additional Unsafe Practices. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .115
Fuel and Lubricant Additives. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .116
Fueling Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .116
Fueling Procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .116
Hazards of Diesel Fuel/Gasoline Blends. . . . . . . . . . . . . . . . . . . .115
Reserve Fuel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .116
Ultra Low Sulfur Diesel Fuel Requirements. . . . . . . . . . . . . . . . .115
Unacceptable Fuel Blends. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .115
Fuel and Lubricant Additives. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .116
Fuel System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .189
Fuel Tank Draining and Cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . .189
Fuel Tank Draining and Cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .189
3879634R1
F (CONT.)
Fueling Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .116
Fueling Procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .116
Fuse Charts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .224
Fuses and Relays. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .179
G
Gauges. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
Gross Weight (Axle – Vehicle). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .136
H
Hazards of Diesel Fuel/Gasoline Blends. . . . . . . . . . . . . . . . . . . . . . .115
Headlights. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49
Heater. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .175
Hook-Up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .163
Hot Weather Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .102
Hub-Piloted Wheel Installation Procedures. . . . . . . . . . . . . . . . . . . .200
HVAC Filters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .168
I
In-Cab Controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .143
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .196
Inspection and Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .173
Inspection and Cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .185
Inspection and Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .170–171
Installing Axle Shafts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .160
Instructions for Proper Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . .190
Instrument Panel Controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .142
Instrument Panel Gauge Cluster. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
Instrument Panel Gauge Cluster Alarms. . . . . . . . . . . . . . . . . . . . . . . .45
Integral Digital Display. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47
Integral Digital Display Detailed Information. . . . . . . . . . . . . . . . . . . .56
235
Index
I (CONT.)
Integral Digital Display Detailed Information (cont.)
Outside Temperature and Compass Displays (Optional). . .68
Outside Temperature Reading. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68
Quadrant 1: Informational Displays. . . . . . . . . . . . . . . . . . . . . . . . . . .56
Quadrant 2 Text and Warning Messages. . . . . . . . . . . . . . . . . . . . .61
Quadrant 3: Display Messages. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68
Quadrant 4: Transmission Gear Displays. . . . . . . . . . . . . . . . . . . .68
Warning Messages. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67
International Truck Warranty Program. . . . . . . . . . . . . . . . . . . . . . . . .227
International® Ride Optimized Suspension (IROS)
(Optional). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Available Cabs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Crew Cab. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Extended Cab. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Standard Cab. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Available Models. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Cab Entry and Exit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Electrical System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
Exterior Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Tilt Hood. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Lowering the Hood. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Raising the Hood. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Vehicle Identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Engine Serial Number. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Feature Codes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Line Set Ticket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Vehicle Identification Number (VIN). . . . . . . . . . . . . . . . . . . . . . . .12
Irregular Wear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .199
236
L
Left Engine Compartment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
Left Front of Vehicle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
Left Rear of Vehicle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
Left Side Cab Area. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
Lift Axle Control Identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .144
Lift Axle Controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .142
In-Cab Controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .143
Instrument Panel Controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .142
Lift Axle Control Identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .144
Mixed Controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .143
Lift Axle Locations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .141
Lift Axle Options. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .140
Lift Axle Controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .142
Lift Axle Locations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .141
Lift Axle System Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .145
Lift Axle Types. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .141
Lift Axle System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .171, 219
Maintenance Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .219
Lift Axle System Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .145
Enabling the Lift Axle System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .145
Load Capacity Chart for 13,200 Pound Steerable Lift
Axle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .146
Load Capacity Chart for 20,000 Pound Fixed Lift Axle. . . .146
Lowering the Lift Axles. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .146
Raising the Lift Axles. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .146
Lift Axle Torque Charts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .223
Capscrew/Bolt Torque Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .223
Lift Axle U-Bolt Nut Torque Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . .223
Lift Axle Types. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .141
Lift Axle U-Bolt Nut Torque Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .223
Lights on with Wipers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49
3879634R1
Index
L (CONT.)
Line Set Ticket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2, 12
Load Capacity Chart for 13,200 Pound Steerable Lift Axle. . .146
Load Capacity Chart for 20,000 Pound Fixed Lift Axle. . . . . . .146
Loads. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .197
Lock/Unlock from Interior. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .85
Locking the Door. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .85
Unlocking the Door. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .86
Locking Differential (Optional). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .134
Locking Differentials. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .132
Locking the Door. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .85
Lowering the Hood. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Lowering the Lift Axles. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .146
Lubrication and Fluids Charts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .211
Components Requiring Fluid Check and Fill. . . . . . . . . . . . . . . .213
Components Requiring Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . .212
Lubrication and Maintenance Interval — Recommended
Synchronized Intervals Table. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .205
Lubrication and Maintenance Interval Chart Notes. . . . . . . . . . .204
Lubrication and Maintenance Interval Chart Symbols Key. . .204
Lubrication and Maintenance Intervals . . . . . . . . . . . . . . . . . . . . . . . .203
Maintenance Intervals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .203
Lubrication Points. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .193
M
Main Instrument/Control Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
Direct Drive Warning Indicators. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47
Gauges. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
Instrument Panel Gauge Cluster. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
Instrument Panel Gauge Cluster Alarms. . . . . . . . . . . . . . . . . . . . . .45
Integral Digital Display. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47
Integral Digital Display Detailed Information. . . . . . . . . . . . . . . . . .56
3879634R1
M (CONT.)
Main Instrument/Control Panel (cont.)
Optional Instrument panel gauge cluster Compass Calibration
Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52
Compass Declination Zone Set Procedure. . . . . . . . . . . . . . . .52
Compass Directional Calibration Procedure. . . . . . . . . . . . . . .55
Switches. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49
Courtesy Lights. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50
Daytime Running Lights (DRL). . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49
Dome Lighting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50
Headlights. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49
Lights on with Wipers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49
Marker Interrupt. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50
Panel Lighting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50
Park Lights. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49
Warning Indicators. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
Main Transmission Controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .128
Maintenance Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .219
Maintenance Guidelines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .165
Maintenance Intervals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .203
Lubrication and Maintenance Interval — Recommended
Synchronized Intervals Table. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .205
Lubrication and Maintenance Interval Chart Notes. . . . . . . . .204
Lubrication and Maintenance Interval Chart Symbols
Key. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .204
Maintenance Record – Noise Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Manual Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .86
Manual Parking Brake. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .125
Manual Transmissions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .120
Manual/Automated Manual Transmissions. . . . . . . . . . . . . . . . . . . .191
Marker Interrupt. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50
237
Index
M (CONT.)
MaxxForce® 11 and 13 Engine Brake With Eaton
AutoShift®/UltraShift® Transmissions Special Driver
Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .109
MaxxForce® Engine Features. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .110
Air Compressor Cycling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .112
Certified Clean Idle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .111
Engine Warning/Protection System (EWPS). . . . . . . . . . . . . . . .111
Standard Engine Warning System 2-Way. . . . . . . . . . . . . . . . .111
Optional Coolant Warning Level System – 3 Way
(08WWJ). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .112
Optional Engine Protection System – 3 Way (08WPP). . . .112
Self Diagnostics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .111
Mirror Controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .86
Mixed Controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .143
Mobile Variable Speed Control (12VXV). . . . . . . . . . . . . . . . . . . . . . . .71
N
Neutral Start Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .191
Automatic Transmissions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .192
Manual/Automated Manual Transmissions. . . . . . . . . . . . . . . . .191
Noise Emissions – Exterior. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .190
Air Intake System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .190
Body. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .190
Engine Noise Shields/Blankets. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .191
Exhaust System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .191
Instructions for Proper Maintenance. . . . . . . . . . . . . . . . . . . . . . . . .190
Nonretracting Adjustable Seat Belts for Center Passenger –
Bench Seat. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .92
Normal Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .170
238
O
Operating Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .103
Automatic Transmissions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .123
Air Parking Brake or Power Parking Brake. . . . . . . . . . . . . . .125
Allison Generation IV T-Bar Gearshift Control. . . . . . . . . . .126
Allison Transmission with “P” – (Park) Park Pawl
Mechanism or “PB” – Parking Brake Position. . . . . . . . . .123
Allison Transmissions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .123
Auto Neutral. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .129
Automatic Transmission Operating Temperature. . . . . . . .131
Backup Alarm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .129
Main Transmission Controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .128
Manual Parking Brake. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .125
Operation of the Allison Generation IV Gearshift
Controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .125
Operation of the Allison Generation IV Push-button Shift
Selector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .127
Operation of the Column-Mounted Shifter. . . . . . . . . . . . . . . .128
Parking The Vehicle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .124
Power Take Off Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .131
Preparing to Drive the Vehicle. . . . . . . . . . . . . . . . . . . . . . . . . . . . .125
Torque Lock. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .126
Axles and Suspensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .136
Air Suspension Dump (ASD) Switch (Optional). . . . . . . . . .139
Air Suspension System Faults. . . . . . . . . . . . . . . . . . . . . . . . . . . . .140
Axle and Suspension Conversions. . . . . . . . . . . . . . . . . . . . . . . .140
Axle Operating Temperature. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .136
Front Axle (4X4, 6X6). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .136
Gross Weight (Axle – Vehicle). . . . . . . . . . . . . . . . . . . . . . . . . . . . .136
International® Ride Optimized Suspension (IROS)
(Optional). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .139
Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .137
3879634R1
Index
O (CONT.)
Operating Instructions (cont.)
Transfer Case. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .137
Cooling System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .113
Antifreeze. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .114
Eaton UltraShift® Transmissions (Optional). . . . . . . . . . . . . . . .123
Electrical. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .105
Alternator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .106
Ammeter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .106
Battery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .106
Battery Disconnect Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .107
Circuit Breakers, Fuses, and Fusible Links. . . . . . . . . . . . . . .107
Electrical System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .105
Engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .108
Charge Air Cooler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .108
Engine Brake, Retarder (Optional). . . . . . . . . . . . . . . . . . . . . . . . . . .108
ABS Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .110
Automatic Transmission Operation. . . . . . . . . . . . . . . . . . . . . . . .110
Engine Brake System Operation. . . . . . . . . . . . . . . . . . . . . . . . . .109
MaxxForce® 11 and 13 Engine Brake With Eaton
AutoShift®/UltraShift® Transmissions Special Driver
Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .109
Operational Modes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .109
Engine Oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .114
Engine Performance Problems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .115
Exhaust Diesel Particulate Filter Regeneration. . . . . . . . . . . . .117
Parked Regeneration Procedure. . . . . . . . . . . . . . . . . . . . . . . . . .119
Regeneration Inhibit Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .119
Three-Position Regeneration Inhibit Switch. . . . . . . . . . . . . .120
Two-Position Regeneration Inhibit Switch. . . . . . . . . . . . . . . .120
Fuel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .115
Additional Unsafe Practices. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .115
3879634R1
O (CONT.)
Operating Instructions (cont.)
Fuel and Lubricant Additives. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .116
Fueling Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .116
Fueling Procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .116
Hazards of Diesel Fuel/Gasoline Blends. . . . . . . . . . . . . . . . . .115
Reserve Fuel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .116
Ultra Low Sulfur Diesel Fuel Requirements. . . . . . . . . . . . . .115
Unacceptable Fuel Blends. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .115
MaxxForce® Engine Features. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .110
Air Compressor Cycling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .112
Certified Clean Idle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .111
Engine Warning/Protection System (EWPS). . . . . . . . . . . . .111
Optional Coolant Warning Level System – 3 Way
(08WWJ). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .112
Optional Engine Protection System – 3 Way (08WPP). . .112
Self Diagnostics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .111
Rear Drive Axles. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .132
Controlled Traction Differential. . . . . . . . . . . . . . . . . . . . . . . . . . . . .134
Driver-Controlled Differential Lock. . . . . . . . . . . . . . . . . . . . . . . . .133
Locking Differential (Optional). . . . . . . . . . . . . . . . . . . . . . . . . . . . .134
Locking Differentials. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .132
Tandem Axle Power Divider Lock (PDL) Control. . . . . . . .132
Steering. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .103
Adjustable Tilt/Telescoping Steering Column. . . . . . . . . . . .104
Tilt Steering Column. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .103
Transmission. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .120
Clutch Brake (Vehicles with Nonsynchronized
Transmission) – Vehicle Not Moving. . . . . . . . . . . . . . . . . . . . .121
Clutch Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .122
Double Clutch Procedures, Nonsynchronized. . . . . . . . . . .121
Engaging the Clutch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .120
239
Index
O (CONT.)
Operating Instructions (cont.)
Manual Transmissions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .120
Operation of the Eaton AutoShift® Transmission and
Shifter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .122
Shifting with Nonsynchronized Transmission. . . . . . . . . . . .122
Shifting with Synchronized Transmission. . . . . . . . . . . . . . . . .122
Two Speed Rear Axle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .135
Axle Shift Only. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .135
Split Shifting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .136
Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .92, 137
Nonretracting Adjustable Seat Belts for Center Passenger –
Bench Seat. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .92
Operation of the Allison Generation IV Gearshift Controls. . .125
Operation of the Allison Generation IV Push-button Shift
Selector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .127
Operation of the Column-Mounted Shifter. . . . . . . . . . . . . . . . . . . . .128
Operation of the Eaton AutoShift® Transmission and
Shifter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .122
Operation Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .89
Cab Controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90
Operational Modes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .109
Operational Procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70
Optional Coolant Warning Level System – 3 Way
(08WWJ). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .112
Optional Diamond Logic® Electronic Application Solutions. . . . .8
Optional Engine Protection System – 3 Way (08WPP). . . . . . .112
Optional Instrument panel gauge cluster Compass Calibration
Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52
Compass Declination Zone Set Procedure. . . . . . . . . . . . . . . . . . .52
Compass Directional Calibration Procedure. . . . . . . . . . . . . . . . . .55
Outside Temperature and Compass Displays (Optional). . . . . .68
240
O (CONT.)
Outside Temperature Reading. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68
Overhead Console. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
P
Panel Component Arrangements (Optional). . . . . . . . . . . . . . . . . . . .78
Panel Lighting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50
Park Lights. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49
Parked Regeneration Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .119
Parking Brake. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .149
Parking Brake Alarm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .153
Parking Brake Indicator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .153
Parking Brake Reset. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .150
Parking The Vehicle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .124
Pedal Free-Travel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .177
Power Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .86
Power Steering. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .194
Power Steering Systems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .216
Power Take Off Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .131
Preface. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
Preparation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Preparing to Drive the Vehicle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .125
Problem: High Restriction Reading Table. . . . . . . . . . . . . . . . . . . . . .184
Problem: No Restriction Reading Table. . . . . . . . . . . . . . . . . . . . . . . .184
Proper Starting Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .102
Purge Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .175
Q
Quadrant 1: Informational Displays. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56
Quadrant 2 Text and Warning Messages. . . . . . . . . . . . . . . . . . . . . . . .61
Quadrant 3: Display Messages. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68
Quadrant 4: Transmission Gear Displays. . . . . . . . . . . . . . . . . . . . . . .68
3879634R1
Index
R
Raising the Hood. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Raising the Lift Axles. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .146
Rear Axle – Inspection and Lubrication. . . . . . . . . . . . . . . . . . . . . . . .171
Rear Axle Unit Refill Capacities. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .214
Rear Drive Axles. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .132
Controlled Traction Differential. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .134
Driver-Controlled Differential Lock. . . . . . . . . . . . . . . . . . . . . . . . . . .133
Locking Differential (Optional). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .134
Locking Differentials. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .132
Tandem Axle Power Divider Lock (PDL) Control. . . . . . . . . . .132
Rear of Vehicle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
Recirculation Filters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .169
Regeneration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .191
Regeneration Inhibit Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .119
Remote Keyless Entry Operation (Optional). . . . . . . . . . . . . . . . . . . .84
Removing Axle Shafts Before Towing. . . . . . . . . . . . . . . . . . . . . . . . . .160
Reporting Safety Defects. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Canadian Registered Vehicles. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
U.S. Registered Vehicles. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Reserve Fuel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .116
Reservoir Moisture Draining. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .151
Right Engine Compartment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
Right Front of Vehicle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
Right Rear of Vehicle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
Right Side of Cab. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
Right Side Under Vehicle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
Rotation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .197
Rotation Is Advisable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .197
Tire Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .198
Rotation Is Advisable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .197
3879634R1
S
Safety Recalls and Authorized Field Changes. . . . . . . . . . . . . . . . . . .5
Scheduled Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .180
Seat Belts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .91
Care of Seat Belts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .93
Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .92
Seats. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .93
Extended Cab Bunk (Optional). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .93
Self Diagnostics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .111
Service Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .227
Shifting with Nonsynchronized Transmission. . . . . . . . . . . . . . . . . .122
Shifting with Synchronized Transmission. . . . . . . . . . . . . . . . . . . . . .122
Shut-Down Warning Indicator Or Beeper. . . . . . . . . . . . . . . . . . . . . . . .95
Side Access HVAC Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .168
Split Shifting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .136
Spring U-Bolt Checks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .223
Stability Control Systems – Bendix® ESP. . . . . . . . . . . . . . . . . . . . .157
Standard Cab. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Standard Engine Warning System 2-Way. . . . . . . . . . . . . . . . . . . . . .111
Starting A Turbocharged Vehicle On A Grade. . . . . . . . . . . . . . . . .102
Proper Starting Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .102
Starting Procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .94
After the Engine Starts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .95
Cold Weather. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .100
Cold Weather Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101
Cold Weather Starting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101
Engine Idling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101
Winter Front Usage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .102
Winter/Engine Intake Operation. . . . . . . . . . . . . . . . . . . . . . . . . . .101
Emergency Starting Using Jumper Cables. . . . . . . . . . . . . . . . . .100
Engine Idle Shutdown Timer (Optional). . . . . . . . . . . . . . . . . . . . . . .96
System Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .96
241
Index
S (CONT.)
Starting Procedures (cont.)
Engine ShutDown. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .95
Shut-Down Warning Indicator Or Beeper. . . . . . . . . . . . . . . . . .95
Engine Starting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .94
Hot Weather Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .102
Starting A Turbocharged Vehicle On A Grade. . . . . . . . . . . . . .102
Proper Starting Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .102
Theft Deterrent System (Optional). . . . . . . . . . . . . . . . . . . . . . . . . . . . .96
Theft Deterrent Code Entry Procedures. . . . . . . . . . . . . . . . . . . .97
Stationary Pre-Set Speed Control (12VXU). . . . . . . . . . . . . . . . . . . . .71
Stationary Variable Speed Control (12VXT). . . . . . . . . . . . . . . . . . . . .71
Steering. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .103, 192
Adjustable Tilt/Telescoping Steering Column. . . . . . . . . . . . . . .104
Lubrication Points. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .193
Power Steering. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .194
Tightening Steering Intermediate Shaft Joint Bolts. . . . . . . . .193
Tilt Steering Column. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .103
Steering Column and Switches. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .72
Steering Wheel Controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .69
Cruise Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .69
Basic Functions of Steering Wheel Controls. . . . . . . . . . . . . . .70
Mobile Variable Speed Control (12VXV). . . . . . . . . . . . . . . . . . .71
Operational Procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70
Stationary Pre-Set Speed Control (12VXU). . . . . . . . . . . . . . .71
Stationary Variable Speed Control (12VXT). . . . . . . . . . . . . . .71
Throttle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70
Storage Duration - One Month or Less. . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Storage Duration - Over One Month. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Storage Facilities. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Supporting Your Vehicle for Service. . . . . . . . . . . . . . . . . . . . . . . . . . . .167
Suspension (Air and Steel Springs). . . . . . . . . . . . . . . . . . . . . . . . . . . .192
242
S (CONT.)
Switches. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49, 75
Courtesy Lights. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50
Daytime Running Lights (DRL). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49
Dome Lighting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50
Headlights. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49
Lights on with Wipers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49
Marker Interrupt. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50
Panel Lighting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50
Park Lights. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49
System Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .96
T
Tampering with Noise Control System Prohibited. . . . . . . . . . . . . . . .4
Tandem Axle Power Divider Lock (PDL) Control. . . . . . . . . . . . . .132
Terminal Inspection-Cleaning-Corrosion Protection. . . . . . . . . .178
Theft Deterrent Code Entry Procedures. . . . . . . . . . . . . . . . . . . . . . . . .97
Theft Deterrent System (Optional). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .96
Theft Deterrent Code Entry Procedures. . . . . . . . . . . . . . . . . . . . . .97
Three-Position Regeneration Inhibit Switch. . . . . . . . . . . . . . . . . . .120
Throttle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70
Tightening Steering Intermediate Shaft Joint Bolts. . . . . . . . . . .193
Tilt Hood. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Lowering the Hood. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Raising the Hood. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Tilt Steering Column. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .103
Tire and Rim Combinations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .218
Approved Tire and Rim Combinations. . . . . . . . . . . . . . . . . . . . . . .218
Tire Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .195
Checking Inflation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .196
Underinflation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .196
Tire Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .198
3879634R1
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T (CONT.)
Tire Warnings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .194
Tires. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .194
Dual Tires Matching. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .197
Dual Tires Mixing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .197
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .196
Loads. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .197
Rotation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .197
Rotation Is Advisable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .197
Tire Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .198
Tire Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .195
Checking Inflation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .196
Underinflation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .196
Tire Warnings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .194
Use of Tire Chains. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .199
Wear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .198
Irregular Wear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .199
Wheel and Tire Balancing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .198
Torque Lock. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .126
Torque Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .219
Disc Wheel Torque Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .219
Lift Axle Torque Charts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .223
Capscrew/Bolt Torque Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .223
Lift Axle U-Bolt Nut Torque Chart. . . . . . . . . . . . . . . . . . . . . . . . . .223
Spring U-Bolt Checks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .223
U-Bolt Nut Torque Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .221
Tow Hooks, Tow Pins, and Pintle Hooks. . . . . . . . . . . . . . . . . . . . . . .190
Towing Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .158
Towing Vehicle with Front Wheels Suspended. . . . . . . . . . . . .159
Towing Vehicle with Rear Wheels Suspended. . . . . . . . . . . . . .161
Towing Vehicles with Driver Controlled Differential Lock. . .160
Installing Axle Shafts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .160
3879634R1
T (CONT.)
Towing Instructions (cont.)
Removing Axle Shafts Before Towing. . . . . . . . . . . . . . . . . . . . .160
Towing Vehicle with Front Wheels Suspended. . . . . . . . . . . . . . . .159
Towing Vehicle with Rear Wheels Suspended. . . . . . . . . . . . . . . .161
Towing Vehicles with Driver Controlled Differential Lock. . . . .160
Installing Axle Shafts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .160
Removing Axle Shafts Before Towing. . . . . . . . . . . . . . . . . . . . . . .160
Traction Control (If Equipped). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .156
Tractor-Trailer Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .161
Connecting/Disconnecting a Trailer to a Vehicle with Air
Suspension. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .162
Fifth Wheel Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .162
Fifth Wheel Slide Switch (Optional). . . . . . . . . . . . . . . . . . . . . . .162
Hook-Up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .163
Un-Hook. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .163
Trailer Air Supply and Parking Brake Modular Controls. . . . . .152
Trailer Brake Hand Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .151
Transfer Case. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .137, 216
Transmission. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .120, 217
Clutch Brake (Vehicles with Nonsynchronized Transmission)
– Vehicle Not Moving. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .121
Clutch Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .122
Double Clutch Procedures, Nonsynchronized. . . . . . . . . . . . . .121
Engaging the Clutch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .120
Manual Transmissions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .120
Neutral Start Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .191
Automatic Transmissions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .192
Manual/Automated Manual Transmissions. . . . . . . . . . . . . . .191
Operation of the Eaton AutoShift® Transmission and
Shifter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .122
Shifting with Nonsynchronized Transmission. . . . . . . . . . . . . . .122
243
Index
T (CONT.)
Transmission (cont.)
Shifting with Synchronized Transmission. . . . . . . . . . . . . . . . . . .122
Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .184
Problem: High Restriction Reading Table. . . . . . . . . . . . . . . . . . .184
Problem: No Restriction Reading Table. . . . . . . . . . . . . . . . . . . . .184
Two Speed Rear Axle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .135
Axle Shift Only. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .135
Split Shifting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .136
Two-Position Regeneration Inhibit Switch. . . . . . . . . . . . . . . . . . . . .120
U
U-Bolt Nut Torque Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .221
U.S. Registered Vehicles. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Ultra Low Sulfur Diesel Fuel Requirements. . . . . . . . . . . . . . . . . . . .115
Un-Hook. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .163
Unacceptable Fuel Blends. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .115
Underinflation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .196
Unit Refill Capacities. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .214
Cooling System Refill Capacities. . . . . . . . . . . . . . . . . . . . . . . . . . . . .216
Crankcase and Oil Filters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .216
Front Drive Axles. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .214
Power Steering Systems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .216
Rear Axle Unit Refill Capacities. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .214
Transfer Case. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .216
Transmission. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .217
Unlocking the Door. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .86
Upholstery Care. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .176
Use of Tire Chains. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .199
V
Vehicle Identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
244
V (CONT.)
Vehicle Identification (cont.)
Engine Serial Number. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Feature Codes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Line Set Ticket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Vehicle Identification Number (VIN). . . . . . . . . . . . . . . . . . . . . . . . . . .12
Vehicle Identification Number (VIN). . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Vehicle Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Cab Interior Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
Exterior Lights Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Fifth Wheel and Coupling Area. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
Front of Vehicle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
Left Engine Compartment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
Left Front of Vehicle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
Left Rear of Vehicle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
Left Side Cab Area. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
Preparation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Rear of Vehicle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
Right Engine Compartment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
Right Front of Vehicle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
Right Rear of Vehicle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
Right Side of Cab. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
Right Side Under Vehicle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
Vehicle Storage Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Storage Duration - One Month or Less. . . . . . . . . . . . . . . . . . . . . . . . .2
Storage Duration - Over One Month. . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Storage Facilities. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Vent Window. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .87
W
Warning Indicators. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
Warning Messages. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67
3879634R1
Index
W (CONT.)
Washing and Waxing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .176
Wear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .198
Irregular Wear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .199
Wheel and Tire Balancing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .198
Wheel and Wheel Nut Maintenance and Installation. . . . . . . . .199
Hub-Piloted Wheel Installation Procedures. . . . . . . . . . . . . . . . .200
Wheel Nut Torque Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .200
Wheel Nut Torque Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .200
Wheels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .199
Wheel and Wheel Nut Maintenance and Installation. . . . . . .199
Hub-Piloted Wheel Installation Procedures. . . . . . . . . . . . . .200
Wheel Nut Torque Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . .200
3879634R1
W (CONT.)
Window Lockout Function. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .86
Windows. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .86
Manual Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .86
Mirror Controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .86
Power Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .86
Vent Window. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .87
Window Lockout Function. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .86
Winter Front Usage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .102
Winter/Engine Intake Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101
WorkStar® Series Light Information. . . . . . . . . . . . . . . . . . . . . . . . . . . .225
245
Index
246
3879634R1
">