Navistar ProStar+ User manual

ProStar®+0000663250
4328311R1
EPA10,2013HD-OBD-US,Canada,MexicoJune2015
ProStar®+
OperationandMaintenanceManual
Navistar,Inc.
2701NavistarDrive,Lisle,IL60532USA
©2015Navistar,Inc.Allrightsreserved.Allmarksaretrademarksoftheirrespectiveowners.

IMPORTANT
Theinformation,specications,andillustrationscontainedinthismanualarebasedondatathatwascurrentatthetimeof
publication.Navistar,Inc.reservestherighttomakechangesand/orimprovementsatanytimewithoutnotication,liability,
orwithoutapplyingthosechangesorimprovementstovehiclespreviouslymanufacturedand/orsold.
NOTICE
Beadvisedthatthismotorvehiclemaybeequippedwith
computer/recordingdevices.Theirfunctionistoallowan
authorizedindividualtodownloaddataorinformationrelating
totheoperationorperformanceofthisvehicle.
Thestoreddataorinformationmaybeneitherdownloaded
norretrievedexceptbythevehicle’sregisteredowner,or,in
thealternative,byanotherindividualorentityauthorizedby
theregisteredowner,(e.g.,InternationalDealer)whomay
needthisdataorinformationtoproperlyserviceordiagnose
thisvehicleforrepairorfollowinganaccident.
Anyaccesstothisinformationwithouttheowner’sconsent
maybeinviolationoflawandmaysubjectthatpersonor
entitytocriminalpenalties.
CALIFORNIA
Proposition65Warning
Dieselengineexhaustandsomeofitsconstituentsare
knowntotheStateofCaliforniatocausecancer,birth
defects,andotherreproductiveharm.
Batteryposts,terminalsandrelatedaccessoriescontain
leadandleadcompounds,chemicalsknowntotheState
ofCaliforniatocausecancerandreproductiveharm.
Washhandsafterhandling.

IMPORTANT
Itisimportantthattheapplicablevehicleidenticationnumber(VIN),engineserialnumberandorcomponentfeaturecodesare
recorded.Thesenumbersarerequiredtoobtainpertinentinformationforthisvehicleorengine.
VEHICLEIDENTIFICATIONNUMBER(VIN)
ENGINE
FeatureCode:SerialNumber:
FRONTAXLE
FeatureCode:SerialNumber:
REARAXLE
FeatureCode:SerialNumber:
TRANSMISSION
FeatureCode:SerialNumber:
TRANSFERCASE
FeatureCode:SerialNumber:
CUSTOMERASSISTANCECENTER
1-800-44-TRUCK(1-800-448-7825)
Navistar,Inc.
2701NavistarDrive
Lisle,IL60532USA
www.navistar.com

TableofContents
Section1–Foreword
Preface...............................................................1
CautionsandWarnings.............................................1
AssistanceGuide....................................................2
ComponentCodeNumbers........................................2
LineSetTicket..................................................3
VehicleStorageInstructions........................................3
StorageDuration-OneMonthorLess.......................3
StorageDuration-OverOneMonth.........................4
StorageFacilities...............................................4
DieselExhaustFluid(DEF)Storage..............................5
ExteriorNoiseEmissions...........................................5
NoiseEmissionsWarranty.........................................5
TamperingwithNoiseControlSystemProhibited................6
EmissionControlSystems..........................................6
HD-OBDForeword.............................................6
SupplementalFederalEmissionControlSystem
Warranty.........................................................7
ReportingSafetyDefects...........................................8
U.S.RegisteredVehicles......................................8
CanadianRegisteredVehicles................................8
SafetyRecallsandAuthorizedFieldChanges...................9
CustomerSecurityGuideforInternational®Trucks..............9
OptionalDiamondLogic®ElectronicApplicationSolutions....11
Section2–ModelDescription
Introduction.........................................................13
AvailableModels...................................................13
VehicleIdentication...............................................16
VehicleIdenticationNumber(VIN).........................16
FeatureCodes.................................................16
EngineSerialNumber........................................16
LineSetTicket.................................................17
ExteriorComponents..............................................18
FrontView:ProStar®+NotEquippedwithSelective
CatalyticReduction(SCR)System..........................18
FrontView:ProStar®+EquippedwithSelective
CatalyticReduction(SCR)System..........................19
BackView:IdenticalforAllProStar®+Models.............20
CabEntryandExit.................................................21
Hood.................................................................21
RaisingtheHood..............................................21
LoweringtheHood............................................22
LuggageBoxAccess..............................................23
DriverandPassengerSide...................................23
ChassisSkirts......................................................23
ChassisSkirtRemoval........................................24
ChassisSkirtInstallation.....................................25
ExtendedChassisSkirts.....................................25
Section3–InspectionGuide
Introduction.........................................................27
GeneralInformation...........................................27
TractorInspection..................................................28
Preparation....................................................28
ExteriorLightsCheck........................................28
LeftSideCabArea(forVehiclesNotEquippedwith
SelectiveCatalyticReduction(SCR)System).............29
LeftSideCabArea(forVehiclesEquippedwith
SelectiveCatalyticReduction(SCR)System).............30
LeftEngineCompartment....................................31
LeftFrontofTractor...........................................32
i

TableofContents
FrontofTractor................................................34
RightFrontofTractor.........................................35
RightEngineCompartment..................................37
RightSideofCab.............................................38
RightSideUnderVehicle.....................................39
RightRearofTractor..........................................40
RearofTractor................................................42
LeftRearofTractor...........................................43
FifthWheelandCouplingArea..............................44
CabInteriorInspection........................................45
Section4–Controls/Features
Introduction.........................................................47
GeneralInformation...........................................47
Electrical.......................................................47
ElectricalSystem..............................................47
DashComponents.................................................48
OverheadConsole.................................................48
InstrumentPanelGaugeCluster............................49
WarningIndicators............................................50
Gauges.........................................................53
InstrumentPanelGaugeClusterAlarms...................55
DirectDriveWarningIndicators..............................57
IntegralDigitalDisplay........................................58
GeneralTextandWarningMessages.......................60
OptionalInstrumentPanelGaugeClusterCompass
CalibrationProcedure.........................................61
CompassDeclinationZoneSetProcedure.................61
CompassDirectionalCalibrationProcedure...............64
IntegralDigitalDisplayDetailedInformation...............66
Switches........................................................80
Headlights......................................................80
DaytimeRunningLights(DRL)..............................80
LightsOnWithWipers........................................80
ParkLights.....................................................80
PanelLighting.................................................80
DomeLighting.................................................81
CourtesyLights................................................81
SteeringWheelControls..........................................82
CruiseControl.................................................83
SteeringColumnandSwitches...................................84
CenterDashPanel/WingPanel.................................86
Gauges.........................................................87
Switches........................................................87
ClimateControl................................................92
AirConditioning...............................................95
Dehumidication...............................................95
ElectronicTouchscreen............................................95
VehicleInfotainmentSystem.................................95
SmartWave®Display...............................................96
DoorandWindowControls.......................................96
DoorLock/Unlock............................................96
CabDoorsandLocks.........................................96
RemoteKeylessEntryOperation(Optional)...............97
Lock/UnlockFromInterior..................................98
AutomaticDoorLockFunction...............................98
Driver/PassengerWindows.................................99
ManualOperation.............................................99
PowerOperation..............................................99
WindowLockoutFunction....................................99
MirrorControls.................................................99
VentWindow...................................................99
Bendix®Wingman®Advanced®CollisionWarningSystem...100
ii

TableofContents
Bendix®Wingman®Fusion®System............................102
Bendix®DriverInterfaceUnit....................................103
MeritorWabco®OnGuard™CollisionSafetySystem.........104
DriverReward.....................................................105
Section5–SleeperFeatures
Introduction........................................................107
GeneralInformation.........................................107
MainFeatures................................................107
Lighting............................................................109
DomeLight...................................................109
ReadingLights...............................................109
FloorLights...................................................109
AccentLights.................................................109
SleeperControlPanel............................................110
GeneralInformation.........................................110
AccentLightDimmerSwitch................................111
AccentLightSwitch..........................................111
SleeperDome/FloorLightSwitch.........................111
EngineControlSwitch.......................................111
AutoStart/StopSystem....................................112
ManualClimateControls....................................114
No-IdleHeating..............................................115
PowerReceptacle...........................................115
RadioRemoteControl.......................................115
RemotePowerInverterPanel..............................115
Windows...........................................................116
GeneralInformation.........................................116
BunkRestraintSystem...........................................117
GeneralInformation.........................................117
AdjustableBelts..............................................117
RestraintWebbingSystem..................................117
LowerBunk........................................................119
GeneralInformation.........................................119
UpperBunk.......................................................120
GeneralInformation.........................................120
EnteringtheUpperBunk....................................121
ExitingtheUpperBunk......................................122
Cabinets/Storage................................................123
GeneralInformation.........................................123
Cabinets...........................................................124
RefrigeratorCabinet.........................................124
HorizontalRefrigerator......................................125
DresserCabinet..............................................125
TowerWardrobeCabinet...................................127
RearWardrobeCabinet.....................................128
AirlineCabinets..............................................129
ConvenienceFeatures...........................................130
GeneralInformation.........................................130
SleeperCurtain..............................................130
TelevisionMount.............................................130
PowerInverter...............................................130
PowerSockets...............................................130
Speakers.....................................................130
FloorCovering...............................................130
SleeperFan..................................................130
Section6–Operation
OperationSafety..................................................131
GeneralInformation.........................................131
CabControls.................................................133
SeatBelts.........................................................133
iii

TableofContents
GeneralInformation.........................................133
GeneralInformation.........................................134
Operation.....................................................135
CareofSeatBelts...........................................136
Seats...............................................................137
GeneralInformation.........................................137
StartingProcedures..............................................139
GeneralInformation.........................................139
EngineStarting...............................................139
AftertheEngineStarts......................................140
EngineShutdown............................................141
EmergencyStarting.........................................141
ColdWeather.................................................142
GeneralInformation.........................................142
ColdWeatherStarting.......................................142
ColdWeatherOperation....................................143
EngineIdling.................................................143
EngineIdleShutdownTimer(Optional)...................144
WinterFrontUsage..........................................144
HotWeatherOperation......................................144
OperatingInstructions............................................145
GeneralInformation.........................................145
Steering.......................................................145
AdjustableSteeringColumn................................146
GeneralInformation.........................................146
Electrical......................................................147
Alternator.....................................................147
Battery........................................................147
BATTERYONIndicator.....................................148
CircuitBreakers,FusesandFusibleLinks................149
ElectricalLoadControlandShedding(ELCS)............149
Engine........................................................149
ChargeAirCooler...........................................150
ElectronicEngineController................................150
EngineBrake.................................................150
EngineBrakeWithAllisonTransmissions.................151
EngineBrakeWithEaton®AutoShift®/UltraShift®
TransmissionsSpecialDriverInstructions................151
EngineFeatures.............................................152
HD-OBDOverview..........................................153
SelfDiagnostics..............................................153
AirCompressorCycling.....................................154
CoolingSystem..............................................154
EngineOil....................................................155
EnginePerformanceProblems.............................155
Fuel............................................................156
UltraLowSulfurDieselFuelRequirements...............156
UnacceptableFuelBlends..................................156
HazardsofDieselFuel/GasolineBlends................156
AdditionalUnsafePractices................................156
FuelandLubricantAdditives...............................156
FuelingProcedures..........................................156
FuelingPrecautions.........................................157
ReserveFuel.................................................157
Transmission.................................................157
TransmissionFluid...........................................157
TransmissionFluidTemperature..........................158
ManualTransmissions......................................158
EngagingtheClutch.........................................160
HydraulicClutchActuationSystem........................161
DoubleClutchProcedures..................................162
ClutchBrake..................................................162
ClutchPrecautions..........................................162
Eaton®AutoShift®Transmissions...........................162
iv

TableofContents
Eaton®UltraShift®Transmissions(Optional)..............162
Eaton®Cummins®AllianceTransmissions................163
Eaton®Navistar®AllianceTransmissions..................163
AllisonTransmissions.......................................163
HillStartAid/HillBrake(Optional)........................163
PowerTake-offControl......................................163
RearAxles...................................................163
LockingorLimitedSlipDifferentials.......................163
TandemAxlePowerDividerLock(PDL)Control.........164
DriverControlledDifferentialLock.........................165
RearSuspension............................................166
RearAirRideSuspension..................................166
RearAirSuspensionAirDump.............................166
AirSuspensionSystemFaults.............................166
ExhaustAftertreatment..........................................167
SelectiveCatalyticReductionSystem(IfEquipped).....167
Introduction...................................................167
DieselExhaustFluid.........................................167
DEFTank.....................................................167
LowDEFLevel...............................................168
DEFContaminationorSCRSystemFault................172
ExhaustDieselParticulateFilterRegeneration...........178
ParkedRegenerationProcedure...........................181
RegenerationInhibitSwitch................................181
Two-PositionRegenerationInhibitSwitch.................182
Three-PositionRegenerationInhibitSwitch...............182
Brakes.............................................................182
GeneralInformation.........................................182
DownhillOperation..........................................182
AirBrakes....................................................183
GeneralInformation.........................................183
AirGauge,LowAirPressureBeeperandWarning
Indicator.......................................................183
ReservoirMoistureDraining................................184
BrakeApplication............................................184
ParkingBrake................................................184
ParkingBrakeReset........................................185
ParkingBrakeAlarm........................................185
AirDryer......................................................186
TrailerBrakeHandControl.................................186
TrailerAirSupplyandParkingBrakeModularControls...186
ParkingBrakeIndicator....................................188
BobtailProportioningSystem...............................188
AntilockBrakeSystem(ABS)..............................188
GeneralInformation.........................................188
ABSOperation...............................................189
ABSSelfCheck..............................................189
AntilockDrivingTips.........................................190
AutomaticTractionControl(ATC)System....................190
GeneralInformation.........................................190
ATCSystemCheck..........................................190
ATCOFFROADorMUD/SNOWSwitch................191
StabilityControlSystems–Bendix®RSP/WABCO®
RSC/Bendix®ESP..........................................191
TowingInstructions...............................................193
TowHooks....................................................194
TowingVehicleWithFrontWheelsSuspended...........195
TowingVehiclesWithDriverControlledDifferential
Lock...........................................................195
RemovingAxleShaftsBeforeTowing.....................195
InstallingAxleShafts........................................196
TowingVehicleWithRearWheelsSuspended...........196
Tractor-TrailerConnections.....................................197
v

TableofContents
Connecting/DisconnectingaTrailertoaVehicle
withAirSuspension.........................................197
FifthWheelOperation.......................................198
FifthWheelSlideSwitch(Optional)........................198
Hook-Up......................................................198
Un-Hook......................................................199
FifthWheelJawUnlockControl...........................199
FifthWheelJawMonitoring................................200
Section7–MaintenanceInstructions
Introduction........................................................201
MaintenanceGuidelines.........................................201
SupportingYourVehicleforService............................203
ChassisLubrication..............................................203
AirConditioningServiceChecks................................203
HVACFilters..................................................204
SideAccessHVACFilter....................................204
FrontAccessHVACFilter...................................205
RecirculationFilters.........................................205
SleeperHVACFilter.........................................206
Axles...............................................................206
FrontAxle.....................................................206
InspectionandLubrication..................................206
NormalMaintenance........................................207
Alignment.....................................................207
RearAxle....................................................207
InspectionandLubrication..................................207
LockingDifferential..........................................207
Brakes.............................................................208
GeneralInformation.........................................208
AirBrakes....................................................208
InspectionandAdjustment.................................208
AirDryer......................................................210
GeneralInformation.........................................210
DesiccantFilter..............................................210
PurgeValve..................................................210
Heater.........................................................211
AirReservoir/TanksMoistureDraining...................211
ABSConnectionsandSensors.............................211
Cab.................................................................211
CareofVehicle...............................................211
WashingandWaxing........................................211
BrightMetalCare............................................212
UpholsteryCare..............................................212
ExposedRubberandUnpaintedPlasticParts............212
Clutch..............................................................212
PedalFreeTravel............................................212
HydraulicClutch.............................................214
Electrical...........................................................215
Batteries.....................................................215
AutoStart/StopSystemBatteryCables..................216
HighCurrentRelay..........................................217
ElectricalChargingandStartingSystemTest............217
TerminalInspection-Cleaning-CorrosionProtection......217
AccessoryFeedConnections..............................218
FusesandRelays...........................................218
Engine.............................................................218
GeneralInformation.........................................218
EngineFluidsandContaminatedMaterial................219
ScheduledMaintenance....................................219
AirInductionSystem........................................219
AirRestrictionGauge........................................219
AirCleanerElementService...............................220
vi

TableofContents
Troubleshooting..............................................223
ChargeAirCoolerandRadiatorCoreInspectionand
Cleaning......................................................224
InspectionandCleaning....................................224
CoolingSystem..............................................224
CoolantLevelCheck........................................224
FillingInstructions...........................................224
CoolantandOptionalCoolantFilter.......................227
CoolantConcentrationFreezePoint.......................227
Antifreeze.....................................................227
FanClutch....................................................227
FuelSystem..................................................228
FuelTankDrainingandCleaning..........................228
CrankcaseVentilationFilter................................228
Frame..............................................................228
NoiseEmissions–Exterior......................................229
InstructionsforProperMaintenance.......................229
AirIntakeSystem............................................229
Body...........................................................229
CoolingSystem..............................................229
EngineNoiseShields/Blankets...........................229
ExhaustSystem..............................................229
MaintenanceRecord–NoiseControl..........................230
DEFTankFilling..................................................232
DieselParticulateFilter(DPF)..................................232
Regeneration.................................................232
Cleaning......................................................232
DriveShafts.......................................................232
Suspension(AirandSteelSprings)............................233
FrontSuspension............................................233
RearSuspension............................................233
Steering............................................................234
GeneralInformation.........................................234
TighteningSteeringIntermediateShaftJointBolts.......234
LubricationPoints............................................234
PowerSteering...............................................235
Tires................................................................235
TireWarnings................................................235
TireMaintenance............................................237
CheckingInation............................................237
Underination................................................237
SmartWave®TirePressureMonitoringSystem
(TPMS)........................................................237
Inspection.....................................................238
Loads.........................................................238
DualTiresMatching.........................................239
DualTiresMixing............................................239
Rotation.......................................................239
RotationIsAdvisable........................................239
TireReplacement............................................240
WheelandTireBalancing..................................240
Wear..........................................................240
IrregularWear................................................240
UseofTireChains...........................................241
Wheels.............................................................241
WheelandWheelNutMaintenanceandInstallation.....241
WheelNutTorqueMaintenance............................242
Hub-PilotedWheelInstallationProcedures...............242
Transmission.................................................244
Section8–MaintenanceIntervalsand
Specications
LubricationandMaintenanceIntervals........................245
vii

TableofContents
MaintenanceIntervals.......................................245
LubricationandFluidsCharts...................................254
ComponentsRequiringLubrication........................255
ComponentsRequiringFluidCheckandFill..............256
UnitRellCapacities.............................................257
CoolingSystemRellCapacities..........................257
DieselExhaustFluidTank..................................257
CrankcaseandOilFilters...................................257
HydraulicClutchSystem....................................257
PowerSteeringSystems....................................257
Transmission.................................................258
RearAxleUnitRellCapacities............................260
LubricantandSealerSpecications............................261
TorqueSpecications............................................266
U-BoltNutTorqueChart....................................266
DiscWheelNutTorqueChart..............................267
FuseCharts.......................................................267
TypicalInteriorFusePanelLayout.........................268
TypicalLuggageCompartmentFusePanelLayout......269
TypicalUnder-HoodPowerDistributionModule
(PDM)FusePanelLayout..................................269
ProStar®+SeriesLightInformation........................272
FilterList......................................................273
Section9–CustomerAssistance
ServiceInformation...............................................275
InternationalTruckWarrantyProgram.........................275
Section10–Index
Index...............................................................277
viii

Foreword
SECTION1—FOREWORD
Preface
Yourvehiclehasbeenengineeredandmanufacturedsothatit
canprovideeconomicalandtrouble-freeservice.However,itis
theowner'sresponsibilitytoseethatthevehiclereceivesproper
careandmaintenance.
Makingmodicationstovariousparts,components,and
systemsofyourvehicle,suchasbrake,suspension,and
steeringsystems,canadverselyaffectthequalityandreliability
ofyourvehicle.Suchmodicationsmustbeavoided.
CautionsandWarnings
Throughoutthismanual,youwillndCautionsandWarnings:
WARNING
Warningsadviseyouofhazards,the
consequences,andwhattodotopreventthem,
notonlytopreventdamagetoyourvehicleor
property,buttohelppreventsituationsand
occurrencesthatcouldresultinpersonalinjury
ordeath.
CAUTION
Cautionswilladviseyouofthepropercareto
betakentopreventdamagetoyourvehicleor
property.
Studythismanualcarefully.Donotoperateyourvehicleuntilyou
arecompletelyfamiliarwiththecontentsofthismanual.Always
retainthismanualinyourvehicleforreference.Ifyousellthe
vehicle,makesurethemanualgoeswithit.
1

Foreword
AssistanceGuide
Whenpartsarerequired,alwaysprovidetheunitcodenumber,
vehiclemodel,andvehicleserialnumber.Requestthe
salespersontoassistyouinobtainingthisinformationupon
delivery.
Forinformationnotgiveninthismanual,orifyourequire
servicesoftrainedservicepersonnel,weurgeyoutocontacta
nearbyInternationaldealerorphone1-800-44-TRUCK(87825)
forassistance.
Everycustomerisentitledtothebestservice,bothfromthe
productitselfandfromthermthatsellsandservicesthat
product.
Foranyreason,ifyoudonotfeelyouarereceivingthese
servicesinconnectionwiththeoperationofyourvehicleor
thesalestransaction,youshouldreturntoyoursellingdealer,
sothatthesematterscanbecorrectedtoyoursatisfaction.If
thematterisnotresolvedatthattime,itissuggestedthatthe
followingstepsbetaken:
ContactaMemberofManagementattheDealer.
Discussthedetailsofthedifculty.Inmostinstances,any
problemcanberesolvedtoyoursatisfactionbytheowneror
managerincharge.
ContactClosestNavistar,Inc.RegionalSalesOfce.
AddressesofRegionalSalesOfcesarefoundinthefront
ofthismanual.Shouldyoudesiretocontactanyofthese
ofces,itisimportanttoincludethefollowinginformationinyour
communication:
•Nameunderwhichnewvehiclewaspurchased,address,
andtelephonenumberofpurchaser
•Vehiclemodel,year,vehicleidenticationnumber,
componentcode,andserialnumber
•Vehicledeliverydateandpresentmileage
•Locationwherepurchased
•Detailsoftheproblem
ComponentCodeNumbers
Codenumbersarethebasisforidentifyingthecomponentsused
onInternationaltrucks.Theyareusedbysalespersonnelto
orderthetruck,bymanufacturingtobuildthattruck,andbyparts
personneltoservicethetruck.Manyitemsinthismanualare
identiedbycodes.
Codenumbersareacombinationofnumbersand/orletters.
ThesecodesarelistedontheLineSetTicket,whichis
sometimesknownasthevehiclespecicationcardorcode
sheet.
2

Foreword
LineSetTicket
EachvehicleisprovidedwithaLineSetTicket(codesheet),
whichlistsidenticationcodenumbersofcomponentunitsused
tobuildthevehicle.
OnecopyoftheLineSetTicketisincludedintheliterature
providedwiththevehicle.Whenreplacementpartsarerequired,
takethiscopywithyoutopositivelyidentifyvehiclecomponents
tobesureofgettingthecorrectparts.
BeSureToReturnLineSetTicketToVehicleAfterObtaining
Parts.
VehicleStorageInstructions
Whenavehicleisnotusedforanextendedperiodoftime,
precautionsmustbetakentopreventdeteriorationofvehicle
components.Vehiclesthatareoutofserviceforextended
periodsoftimecanexperiencecorrosionandotherundesirable
effects.Drivevehiclemonthlytoexercisethebrakes,driveline,
andsteering.Runthevehiclelongenoughfortheengineto
reachoperatingtemperature.
NOTE:Lossesoccurringtoaunitwhileitisinstoragewill
notbeconsideredforwarrantyreimbursement.
StorageDuration-OneMonthorLess
1.Washvehiclesasnecessary.Alwayswashvehiclesthat
havebeenexposedtoroadsalt.
NOTE:WashingInstructions-Washthevehiclewithwarm
waterandmildsoap,thenwipewetsurfaceswithachamois
orsoftcloth.DONOTusehotwaterorstrongsoapsor
detergents.DONOTwashthevehicleindirectsun,orwhen
thesheetmetalishottothetouch.Thiswillstreakthenish.
DONOTwipedirtoffdrysurfaces,asthiswillscratchthe
nish.
NOTE:Whenvehiclesarestoredoutside,particularlyin
coastalareas(saltwaterandhighhumidityatmosphere)
orotherareasofcorrosiveenvironment,paintandbright
metalmayrequirefrequentwashingandwaxingtoprevent
deterioration.Determiningwashingfrequencyisthe
customer’sresponsibility.
NOTE:Forvehiclesexposedtoultravioletraysofthesun,
applyacoatingofBon-Ami®soap,orsimilarproduct,tothe
insidesurfacesofthewindshieldandwindows,toshadethe
interiorandpreventfadingoftheinteriortrim.
2.Inspectpaintedsurfaces;touchupallexposedprimedorraw
metalareastopreventrust.
3.Applyathickcoatofwaxtopreventdiscolorationfromthe
elements;waxallchromeandstainlesssteelmetalparts.
4.Checktheradiatorcoolantforproperlevelandadequate
freezeprotection.20°F(-29°C)isstandardformedium-duty
modelsandbuschassis;-40°F(-40°C)isstandardfor
heavy-dutymodels.
5.Coveropenendsofverticalexhauststack(s).
6.Drainairbrakereservoirsandclosethedraincocks.
3

Foreword
7.Lubricateallexposedtransmission,auxiliarytransmission
andPTOshiftrails.
8.Checkstateofchargeeyeinbatteriesandrechargeif
opencircuitvoltageisbelow12.6volts.Disconnectbattery
groundcablestopreventaccidentalstartingorparasitic
electricalloadsfromdischargingthebattery.
StorageDuration-OverOneMonth
Unitsinstoragelongerthanonemonthshouldbedrivenuntilthe
enginereachesoperatingtemperature.
1.Ensurealltiresareinatedproperly,removeverticalexhaust
stackcovers,andreconnectbatteries.
2.Checkallvehicleuidlevelsandllasrequired.
3.Startandrunthevehicleatfastidleuntilitreachesoperating
temperature.T oremovesurfacechargefromthebattery,
builtupfrompreviousstartupsandshortidleperiods,
operatetheheaterand/orairconditioner,headlights,and
otheraccessoriesforseveralminutes.
4.Turnoffheaterand/orairconditionerandanyother
accessories;shutofftheheadlights.Parkthevehicleand
shutofftheengine.
5.PerformtheprocedureforStorageDuration-OneMonth
orLess,ifreturningthevehicletostorage.
NOTE:Afterevery30additionaldaysofstorage,perform
Items1through5.
StorageFacilities
•Wheneverpossible,storevehiclesindoors,protected
fromsunlight,inadry,wellventilatedarea.Ifindoor
storageisnotavailable,selectstoragelotstoeliminate
conditionsthatcausedeterioration.
•Parkawayfromtransformersand/orelectricalmotors,
becausewhentheprotectivewaxintirecompound
cracks,ozoneintheairattackstheexposedareas.
•Parkawayfromtrees,highweedsand/orgrassto
preventdamagefromtreeorweedsap,andtominimize
birdandinsectstains.
•Parkawayfromrailroadtracks,paintshops,smoky
industrialareas,andlocationsofpossibleroadsplash
contact.
•Ifavehicleisparkedonanincline,Installwheelchocks.
4

Foreword
DieselExhaustFluid(DEF)Storage
DEFhasalimitedshelflife,bothinthevehicle'sDEFtankand
instoragecontainers.
ThefollowingconditionsareidealformaintainingDEFquality
andshelflifeduringprolongedtransportationandstorage:
•Storagetemperaturebetween23°Fand77°F(-5°Cand
25°C)
•Storageinsealedcontainerstoavoidcontamination
•Avoidanceofdirectsunlight
Long-term,in-vehiclestorage(inexcessof6months)isnot
recommended.Iflongtermstorageisnecessary,periodic
testingoftheDEFisrecommendedtoensureproperDEF
concentration.
ExteriorNoiseEmissions
Manyoperatorsandownersofthetypeofvehiclesdescribed
hereinaresubjecttoFederalMotorCarrierSafetyRegulations
andNoiseEmissionRequirements.Allownersandoperators
areurgedtoobtainacopyandcomplywiththeseregulations.
Copiesoftheseregulationscanbepurchasedfrom:
SuperintendentofDocuments
U.S.GovernmentPrintingOfce
Washington,D.C.20401
http://gpo.gov
NoiseEmissionsWarranty
Navistar,Inc.warrantstotherstpersonwhopurchasesthis
vehicleforpurposesotherthanresaleandtoeachsubsequent
purchaserthatthisvehicle,asmanufacturedbyNavistar,
wasdesigned,built,andequippedtoconformatthetimeit
leftNavistarcontrolwithallapplicableU.S.Environmental
ProtectionAgencyNoiseControlRegulations.
Thiswarrantycoversthisvehicleasdesigned,built,and
equippedbyNavistarandisnotlimitedtoanyparticularpart,
component,orsystemofthevehiclemanufacturedbyNavistar.
Defectsindesign,assembly,orinanypart,component,or
systemofthevehicleasmanufacturedbyNavistaratthetime
thevehicleleftNavistar’scontrol,whichcausenoiseemissions
toexceedFederalstandards,arecoveredbythiswarrantyfor
thelifeofthevehicle.
5

Foreword
TamperingwithNoiseControlSystemProhibited
Federallawprohibitsthefollowingactsorthecausingthereof:
1.Removingorrenderinginoperativebyanyperson,
otherthanforpurposesofmaintenance,repair,
orreplacement,anydeviceorelementofdesign
incorporatedintoanynewvehicleforthepurposeof
noisecontrolpriortoitssaleordeliverytotheultimate
purchaserorwhileitisinuse.
2.Usingthevehicleaftersuchdeviceorelementofdesign
hasbeenremovedorrenderedinoperativebyany
person.
Amongthoseactspresumedtoconstitutetamperingaretheacts
listedasfollows:
1.AirIntakeSystem:Removingaircleaner,intake
silencer,orpiping.
2.AcousticalShielding(Body):Removingwheelwell
splashshields,cabshields,oracoustical(underhood)
insulation.
3.CoolingSystem:Removingorrenderinginoperativethe
fanclutchand/orfanshrouds.
4.EngineandDrivelineSystem:Removingorrendering
enginespeedgovernorinoperativesoastoallowengine
speedtoexceedmanufacturerspecications,and/or
engineblockshield,oilsumpshield,ortransmission
enclosures.
5.Changesinhardware,software,calibration,or
programmableparametersthatincreaseengine
operatingspeedorhorsepowerotherthanthose
providedbyNavistar,Inc.
6.ExhaustSystem:Removingorrenderinginoperative
exhaustsystemcomponents,includingmufer,
resonator,exhaustaftertreatmentcomponents,or
tailpipe.
NOTE:RefertoSection7–MaintenanceInstructionsfor
propermaintenance,use,andrepairofnoiseemission
items.
EmissionControlSystems
NOTE:FederalandCaliforniaemissionsystemwarranties
arefoundinyourEngineOperationandMaintenance
Manual.
HD-OBDForeword
HeavyDutyOn-BoardDiagnostics(HD-OBD)isaU.S.
Governmentmandatedstandardforall2013andlaterClass4
andabovevehicleswithaGrossVehicleWeightRating(GVWR)
of14,001poundsormore.TheHD-OBDsystemmonitorsthe
engineandaftertreatmentsystemstoverifytheyareoperating
withinemissionslimits.Ifanemissionsfaultislogged,the
MalfunctionIndicatorLamp(MIL)willilluminateandoneormore
faultcodeswillbeset.
TheHD-OBDsystemoperatessimilarlytopreviouspowertrain
controlsystemsbystoringfaultcodesandturningontheMIL.If
theproblemthatcausedthefaultgoesaway,thecodewillclear
6

Foreword
andtheMILwillgooutaftercertainoperatingconditionshave
beenmet.Thismaytakeseveraltimesoperatingthevehicle.
SupplementalFederalEmissionControlSystemWarranty
TheUnitedStatesEnvironmentalProtectionAgencyadopted
newheavy-dutyGreenhouseGas(GHG)vehicleregulationson
15September2011.ThisvehiclemaybecertiedtotheGHG
regulations.Forcertiedvehicles,additionalGHGemissions
controlsystemwarrantycoverscertainvehiclecomponents.
ThisSupplementalGHGFederalEmissionControlSystem
Warrantycoverageforthesevehiclecomponentswillbe
managedaccordingtocurrentFederalEmissionControlSystem
Warrantyprocess.TheGHGemissioncontrolsystemwarranty
appliestothebelowlistedvehiclecomponentssuchthatthey
meetthefollowingtwoconditions:
1.Thevehicleand/orGHGemissioncontrolsystem
componentisdesigned,built,andequippedsoit
conformsatthetimeofsaletotheultimatepurchaser
withtherequirementsoftheGHGregulationsandsuch
componentisanemissioncontrolandappearsonthe
GHGvehicleemissioncerticationlabel,and
2.Thevehicleand/orGHGemissioncontrolsystem
componentisfreefromdefectsinmaterialsand
workmanshipthatcausethevehicletofailtoconform
totheGHGrequirementsduringtheapplicable
supplementalwarrantyperiod.
GHGEmissionControlSystemWarrantyPeriod
TheGHGemissioncontrolsystemwarrantyperiodbeginson
thedatethenewGHGcertiedvehicleisdeliveredtoyou.
Theperiodofcoverageisthegreaterofthebasemechanical
warrantyor:
•Five(5)yearsor50,000miles,whichevercomesrst,
forspark-ignitionandlightheavy-dutydieselvehicleswith
GVWRbelow19,500pounds.
•Five(5)yearsor100,000miles,whichevercomesrst,
formediumandheavyheavy-dutyvehicleswithGVWR
equaltoorgreaterthan19,500pounds.
•Two(2)yearsor24,000miles,whichevercomesrst,for
tires.
AdditionalComponentsCovered
Appliestoallcertiedmodels:
TheGHGemission-relatedwarrantycoversthefollowing
componentssuchthattheymeetthetwoconditionslistedabove
•Hybridsystemcomponents(whereapplicable)
•Componentswhosefailurewouldincreaseavehicle’s
evaporativeemissions(forvehiclessubjectto
evaporativeemissionstandards)
•Tires
Appliesonlytocertaincertiedffthwheelequipped
ProStar®,LoneStar®,TranStar®,DuraStar®,and9900models:
TheGHGemission-relatedwarrantycovers1)Vehiclespeed
limiters,2)Idleshutdownsystems,and3)Fairingstothe
extentsuchemission-relatedcomponentsareincludedin
thecertiedemissioncontrolsandarelistedonthevehicle
GHGcerticationlabel.TheGHGemission-relatedwarranty
7

Foreword
coversallcomponentswhosefailurewouldincreaseavehicle’s
emissionsofairconditioningrefrigerantsforvehiclessubjectto
airconditioningleakagestandards.
Appliesonlytocertiedvehiclesequippedwithinnovative
technologies
TheGHGemission-relatedwarrantycoverscomponents
certiedasinnovativetechnologieswhicharepartofthecertied
emissioncontrols.PleasecontactyourauthorizedInternational
Dealerforfurtherinformation.
SupplementalFederalEmissionControlSystem
Maintenance,Repair,andReplacement
YourvehiclemaycomplywiththeGreenhouseGas(GHG)
regulationsadoptedbytheEnvironmentalProtectionAgency
on15September2011.AsowneroroperatorofaGHG
compliantvehicle,yourvehicleandGHGemissionscontrol
systemcomponentsshouldbeproperlymaintainedingood
workingorder.
RepairandreplacementofGHGemissioncontrolsystem
componentsshouldbedonetooriginalvehiclemanufacturers’
specicationstoensureproperfunctionofthevehicle.Tire
replacementshouldbetotireswithGHGemissionperformance
asgood,orbetter,thantiresoriginallyequippedonthevehicle.
Consultwiththetiremanufacturerfortirespecications.
TheUnitedStatesEnvironmentalProtectionAgencyallows
limitedmodicationofyourvehicleanditsGHGemissioncontrol
systemcomponents.Pleaserefertoapplicableregulationsfor
allowableandprohibitedmodications.
ReportingSafetyDefects
U.S.RegisteredVehicles
Ifyoubelievethatyourvehiclehasadefectthatcouldcausea
crashorcouldcauseinjuryordeath,youshouldimmediately
informtheNationalHighwayTrafcSafetyAdministration
(NHTSA)inadditiontonotifyingNavistar,Inc.T onotifyNavistar
seethecontactinformationlistedinthefrontofthemanual.
IfNHTSAreceivessimilarcomplaints,itmayopenan
investigationand,ifitndsthatasafetydefectexistsinagroupof
vehicles,itmayorderarecallandremedycampaign.However,
NHTSAcannotbecomeinvolvedinindividualproblemsbetween
you,yourdealer,orNavistar.
TocontactNHTSA,youmayeithercalltheAutoSafety
Hotlinetoll-freeat1-800-424-9393(or202-366-0123in
Washington,D.C.area)orwriteto:NHTSA,U.S.Departmentof
Transportation,Washington,D.C.20590.Youcanalsoobtain
otherinformationaboutmotorvehiclesafetyfromthehotline.
CanadianRegisteredVehicles
Ifyoubelievethatyourvehiclehasadefectthatcouldcause
acrashorcouldcauseinjuryordeath,youshouldimmediately
contactNavistarCanadaandthenTransportCanada.
TocontactNavistarCanada,youmayeithercalltheRegional
ServiceManager(CanadianSalesRegion)905-332-2357or
writeto:NavistarCanada,5500NorthServiceRoad,Box5337,
Burlington,OntarioL7L5H7.
TocontactTransportCanada,DefectInvestigationsandRecalls,
youmaycall1-800-333-0510orwriteto:TransportCanada,
8