Navistar WorkStar Series User manual

Printed in the United States of America
© 2010 Navistar, Inc. All Rights Reserved
NOTICE CALIFORNIA
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.
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.
Make sure your use of this completed vehicle conforms to all federal, state
and local requirements and regulations imposed on owners and operators.
WORKSTAR®Series 3879634R1 7300 • 7400 • 7500 • 7600 Models August 2010

Operator’s Manual – WORKSTAR®Series
3879634R1
IMPORTANT
IT IS IMPORTANT THAT THE VEHICLE IDENTIFICATION NUMBER (VIN), AND COMPONENT FEATURE CODE AND SERIAL
NUMBERS BE RECORDED. THESE NUMBERS ARE REQUIRED TO OBTAIN INFORMATION PERTINENT TO THIS VEHICLE.
VIN (VEHICLE IDENTIFICATION
NUMBER) LOCATION
LoneStar®, 9000i, 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
ENGINE SERIAL NUMBER LOCATION
MAXXFORCE®: Stamped on pad – right side
of the crankcase, below cylinder head
WORLD HEADQUARTERS
Navistar, Inc.
4201 Winfield Road
Warrenville, Illinois 60555 USA
INTERNATIONAL INTERNET SITE
internationaltrucks.com
SALES REGIONS
MIDWEST
Navistar, Inc.
4201 Winfield Road
PO Box 1488
Warrenville, Illinois 60555
630-753-5900
NORTHEAST
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 90480-000-
Porto Alegre/RS
55 51 4009-5800
CUSTOMER ASSISTANCE CENTER
1-800-448-7825 (1-800-44-TRUCK)
Navistar, International, the International Diamond logo, with and without endorsement, 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.

Operator’s Manual – WorkStar® Series
Service Publications
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.
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.
WorkStar® Series
Operator’s Manual – WorkStar® Series
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
CautionsandWarnings.............................................1
AssistanceGuide....................................................1
ComponentCodeNumbers........................................2
LineSetTicket..................................................2
VehicleStorageInstructions........................................2
StorageDuration-OneMonthorLess.......................2
StorageDuration-OverOneMonth.........................3
Storage Facilities ...............................................4
ExteriorNoiseEmissions...........................................4
TamperingwithNoiseControlSystemProhibited................4
EmissionControlSystems..........................................5
MaintenanceRecord–NoiseControl.............................5
ReportingSafetyDefects...........................................5
U.S.RegisteredVehicles......................................5
CanadianRegisteredVehicles................................5
SafetyRecallsandAuthorizedFieldChanges...................5
CustomerSecurityGuideforInternationalTrucks...............6
Optional Diamond Logic® Electronic Application Solutions.....8
Section 2 – Model Description
Introduction...........................................................9
AvailableModels................................................9
AvailableCabs.................................................11
StandardCab..................................................11
ExtendedCab..................................................11
CrewCab.......................................................11
Vehicle Identification..........................................12
Vehicle IdentificationNumber(VIN).........................12
FeatureCodes.................................................12
EngineSerialNumber........................................12
LineSetTicket.................................................12
ExteriorComponents.........................................13
CabEntryandExit............................................14
TiltHood........................................................14
RaisingtheHood..............................................14
LoweringtheHood............................................14
Section 3 – Inspection Guide
Introduction.........................................................15
GeneralInformation...........................................15
VehicleInspection..................................................16
Preparation....................................................16
ExteriorLightsCheck........................................16
LeftSideCabArea............................................17
LeftEngineCompartment....................................18
LeftFrontofVehicle...........................................19
FrontofVehicle................................................22
RightFrontofVehicle.........................................23
RightEngineCompartment..................................25
RightSideofCab.............................................26
RightSideUnderVehicle.....................................27
RightRearofVehicle.........................................28
RearofVehicle................................................30
LeftRearofVehicle...........................................31
FifthWheelandCouplingArea..............................33
CabInteriorInspection........................................34
Section 4 – Controls/Features
Introduction.........................................................37
3879634R1 i

Table of Contents
Electrical.......................................................37
ElectricalSystem..............................................37
DashComponents.................................................38
OverheadConsole.................................................38
MainInstrument/ControlPanel...................................39
InstrumentPanelGaugeCluster............................39
WarningIndicators............................................41
Gauges.........................................................43
InstrumentPanelGaugeClusterAlarms...................45
DirectDriveWarningIndicators..............................47
IntegralDigitalDisplay........................................47
Switches........................................................49
Headlights......................................................49
DaytimeRunningLights(DRL)..............................49
LightsonwithWipers.........................................49
ParkLights.....................................................49
MarkerInterrupt...............................................50
PanelLighting.................................................50
DomeLighting.................................................50
CourtesyLights................................................50
Optional Instrument panel gauge cluster Compass
CalibrationProcedure.........................................52
CompassDeclinationZoneSetProcedure.................52
Compass Directional Calibration Procedure...............55
Integral Digital Display Detailed Information...............56
SteeringWheelControls..........................................69
CruiseControl.................................................69
BasicFunctionsofSteeringWheelControls...............70
OperationalProcedures......................................70
Throttle.........................................................70
StationaryVariableSpeedControl(12VXT)................71
StationaryPre-SetSpeedControl(12VXU)................71
Mobile Variable Speed Control (12VXV)....................71
SteeringColumnandSwitches...................................72
CenterDashPanel/WingPanel..................................74
Switches........................................................75
Auxiliary Gauge/Switch Package (AGSP) (Optional)..........78
PanelComponentArrangements(Optional)...............78
ClimateControl.....................................................80
AirConditioning...............................................82
Dehumidification...............................................83
DoorandWindowControls.......................................83
DoorLock/Unlock.............................................83
CabDoorsandLocks.........................................83
RemoteKeylessEntryOperation(Optional)...............84
DoorOpening/Unlock.........................................85
Lock/UnlockfromInterior.....................................85
AutomaticDoorLockFunction...............................86
Windows.......................................................86
ManualOperation.............................................86
PowerOperation..............................................86
WindowLockoutFunction....................................86
MirrorControls.................................................86
VentWindow...................................................87
DriverReward......................................................87
Section 5 – Operation
OperationSafety...................................................89
CabControls...................................................90
SeatBelts...........................................................91
General.........................................................91
Operation.......................................................92
CareofSeatBelts.............................................93
ii 3879634R1

Table of Contents
Seats................................................................93
ExtendedCabBunk(Optional)..............................93
StartingProcedures................................................94
EngineStarting................................................94
AftertheEngineStarts........................................95
EngineShutDown.............................................95
Shut-DownWarningIndicatorOrBeeper...................95
EngineIdleShutdownTimer(Optional).....................96
SystemOperation.............................................96
TheftDeterrentSystem(Optional)..........................96
TheftDeterrentCodeEntryProcedures....................97
EmergencyStartingUsingJumperCables...............100
ColdWeather.................................................100
ColdWeatherStarting.......................................101
ColdWeatherOperation....................................101
Winter/EngineIntakeOperation............................101
EngineIdling.................................................101
WinterFrontUsage..........................................102
HotWeatherOperation......................................102
Starting A Turbocharged Vehicle On A Grade............102
ProperStartingProcedure..................................102
OperatingInstructions............................................103
Steering.......................................................103
TiltSteeringColumn.........................................103
AdjustableTilt/TelescopingSteeringColumn.............104
General.......................................................104
Electrical......................................................105
ElectricalSystem............................................105
Alternator.....................................................106
Ammeter......................................................106
Battery........................................................106
BatteryDisconnectSwitch..................................107
CircuitBreakers,Fuses,andFusibleLinks...............107
Engine........................................................108
ChargeAirCooler...........................................108
EngineBrake,Retarder(Optional).........................108
EngineBrakeSystemOperation...........................109
OperationalModes..........................................109
MaxxForce® 11 and 13 Engine Brake With Eaton
AutoShift®/UltraShift® Transmissions Special
DriverInstructions...........................................109
AutomaticTransmissionOperation........................110
ABSOperation...............................................110
MaxxForce®EngineFeatures..............................110
CertifiedCleanIdle...........................................111
SelfDiagnostics..............................................111
Engine Warning/Protection System (EWPS)..............111
Optional Coolant Warning Level System – 3 Way
(08WWJ)......................................................112
Optional Engine Protection System – 3 Way (08WPP)...112
AirCompressorCycling.....................................112
CoolingSystem..............................................113
Antifreeze.....................................................114
EngineOil.....................................................114
EnginePerformanceProblems.............................115
Fuel............................................................115
Ultra Low Sulfur Diesel Fuel Requirements...............115
UnacceptableFuelBlends..................................115
HazardsofDieselFuel/GasolineBlends..................115
AdditionalUnsafePractices.................................115
FuelandLubricantAdditives...............................116
FuelingProcedures..........................................116
FuelingPrecautions.........................................116
ReserveFuel.................................................116
3879634R1 iii

Table of Contents
Exhaust Diesel Particulate Filter Regeneration...........117
ParkedRegenerationProcedure...........................119
RegenerationInhibitSwitch.................................119
Two-PositionRegenerationInhibitSwitch.................120
Three-PositionRegenerationInhibitSwitch...............120
Transmission.................................................120
ManualTransmissions......................................120
EngagingtheClutch.........................................120
Clutch Brake (Vehicles with Nonsynchronized
Transmission)–VehicleNotMoving.......................121
DoubleClutchProcedures,Nonsynchronized............121
ClutchPrecautions..........................................122
ShiftingwithSynchronizedTransmission.................122
ShiftingwithNonsynchronizedTransmission.............122
Operation of the Eaton AutoShift® Transmission
andShifter...................................................122
EatonUltraShift®Transmissions(Optional)..............123
AutomaticTransmissions...................................123
Allison Transmissions.......................................123
Allison Transmission with “P” – (Park) Park Pawl
Mechanismor“PB”–ParkingBrakePosition............123
ParkingTheVehicle.........................................124
PreparingtoDrivetheVehicle.............................125
ManualParkingBrake......................................125
AirParkingBrakeorPowerParkingBrake...............125
Operation of the Allison Generation IV Gearshift
Controls......................................................125
Allison Generation IV T-Bar Gearshift Control............126
TorqueLock..................................................126
Operation of the Allison Generation IV Push-button
ShiftSelector................................................127
OperationoftheColumn-MountedShifter................128
MainTransmissionControls................................128
BackupAlarm................................................129
AutoNeutral..................................................129
PowerTakeOffControl.....................................131
Automatic Transmission Operating Temperature.........131
RearDriveAxles............................................132
LockingDifferentials.........................................132
TandemAxlePowerDividerLock(PDL)Control.........132
Driver-ControlledDifferentialLock.........................133
ControlledTractionDifferential.............................134
LockingDifferential(Optional)..............................134
TwoSpeedRearAxle.......................................135
AxleShiftOnly...............................................135
SplitShifting..................................................136
AxlesandSuspensions.....................................136
GrossWeight(Axle–Vehicle)..............................136
AxleOperatingTemperature................................136
FrontAxle(4X4,6X6).......................................136
TransferCase................................................137
Operation.....................................................137
International® Ride Optimized Suspension (IROS)
(Optional).....................................................139
Air Suspension Dump (ASD) Switch (Optional)..........139
AirSuspensionSystemFaults.............................140
AxleandSuspensionConversions........................140
LiftAxleOptions..................................................140
LiftAxleLocations...........................................141
LiftAxleTypes...............................................141
LiftAxleControls.............................................142
LiftAxleSystemOperation.................................145
Brakes.............................................................147
DownhillOperation..........................................147
iv 3879634R1

Table of Contents
AirBrakes....................................................148
Air Gauge, Low Air Pressure Beeper and Warning
Indicator.......................................................149
BrakeApplication............................................149
ParkingBrake................................................149
ParkingBrakeReset........................................150
ReservoirMoistureDraining................................151
AirDryer......................................................151
TrailerBrakeHandControl.................................151
TrailerAirSupply andParkingBrakeModularControls...152
ParkingBrakeIndicator....................................153
ParkingBrakeAlarm........................................153
AntilockBrakeSystem(ABS)..............................153
ABSOperation...............................................154
ABSSelf-Check..............................................154
AntilockDrivingTips.........................................155
AirBrakeBendix®ABS-6..................................155
CoreABSFunctions........................................155
TractionControl(IfEquipped)..............................156
ATCSystemCheck..........................................156
ATCOFFROADorMUD/SNOWSwitch..................156
Stability Control Systems – Bendix® ESP................157
BobtailProportioningSystem...................................158
TowingInstructions...............................................158
Towing Vehicle with Front Wheels Suspended...........159
Towing Vehicles with Driver Controlled Differential
Lock...........................................................160
RemovingAxleShaftsBeforeTowing.....................160
Installing Axle Shafts........................................160
Towing Vehicle with Rear Wheels Suspended............161
Tractor-TrailerConnections.....................................161
Connecting/DisconnectingaTrailertoaVehiclewith
AirSuspension...............................................162
FifthWheelOperation.......................................162
FifthWheelSlideSwitch(Optional)........................162
Hook-Up......................................................163
Un-Hook......................................................163
Section 6 – Maintenance Instructions
Introduction........................................................165
MaintenanceGuidelines.........................................165
SupportingYourVehicleforService............................167
ChassisLubrication..............................................167
AirConditioningServiceChecks................................168
HVACFilters..................................................168
SideAccessHVACFilter....................................168
FrontAccessHVACFilter...................................169
RecirculationFilters.........................................169
Axles...............................................................170
FrontAxle.....................................................170
InspectionandLubrication..................................170
NormalMaintenance........................................170
Alignment.....................................................171
FrontDriveAxleandTransferCase(Optional)..........171
InspectionandLubrication..................................171
RearAxle–InspectionandLubrication...................171
LiftAxleSystem..................................................171
Brakes.............................................................172
GeneralInformation.........................................172
AirBrakes....................................................173
InspectionandAdjustment.................................173
AirDryer......................................................174
3879634R1 v

Table of Contents
GeneralInformation.........................................174
DesiccantFilter..............................................175
PurgeValve..................................................175
Heater.........................................................175
AirReservoir/TanksMoistureDraining....................175
ABSConnectionsandSensors............................176
Cab.................................................................176
CareofVehicle...............................................176
WashingandWaxing........................................176
BrightMetalCare............................................176
UpholsteryCare..............................................176
Exposed Rubber and Unpainted Plastic Parts............176
Clutch..............................................................177
PedalFree-Travel............................................177
Electrical...........................................................177
Batteries.....................................................177
BatteryCables...............................................178
ElectricalChargingandStartingSystemTest............178
Terminal Inspection-Cleaning-Corrosion Protection......178
AccessoryFeedConnections..............................179
FusesandRelays...........................................179
Engine.............................................................179
General.......................................................179
Engine fluidsandcontaminatedmaterial..................180
ScheduledMaintenance....................................180
AirInductionSystem........................................180
AirRestrictionGauge........................................181
AirCleanerElementService...............................182
Troubleshooting..............................................184
Charge Air Cooler And Radiator Core Inspection
AndCleaning.................................................185
InspectionandCleaning....................................185
CoolingSystem..............................................185
CoolantLevel................................................185
Filling Instructions...........................................186
Filling Instructions (MaxxForce® 11 and 13 Engines)...187
CoolantandOptionalCoolantFilter.......................188
AntiFreeze....................................................189
FanClutch....................................................189
FuelSystem..................................................189
FuelTankDrainingandCleaning..........................189
Frame.........................................................190
TowHooks,TowPins,andPintleHooks..................190
NoiseEmissions–Exterior......................................190
InstructionsforProperMaintenance.......................190
AirIntakeSystem............................................190
Body...........................................................190
CoolingSystem..............................................190
EngineNoiseShields/Blankets.............................191
ExhaustSystem..............................................191
DieselParticulateFilter(DPF)..................................191
Regeneration.................................................191
Cleaning......................................................191
Transmission......................................................191
NeutralStartSwitch.........................................191
Manual/AutomatedManualTransmissions...............191
AutomaticTransmissions...................................192
DriveShafts.......................................................192
Suspension(AirandSteelSprings)............................192
Steering............................................................192
GeneralInformation.........................................192
TighteningSteeringIntermediateShaftJointBolts.......193
LubricationPoints............................................193
PowerSteering...............................................194
vi 3879634R1

Table of Contents
Tires................................................................194
TireWarnings................................................194
TireMaintenance............................................195
Checking Inflation............................................196
Underinflation................................................196
Inspection.....................................................196
Loads.........................................................197
DualTiresMatching.........................................197
DualTiresMixing............................................197
Rotation.......................................................197
RotationIsAdvisable........................................197
TireReplacement............................................198
WheelandTireBalancing..................................198
Wear..........................................................198
IrregularWear................................................199
UseofTireChains...........................................199
Wheels.............................................................199
Wheel and Wheel Nut Maintenance and Installation.....199
WheelNutTorqueMaintenance............................200
Hub-PilotedWheelInstallationProcedures...............200
Section 7 – Maintenance Intervals And
Specifications
LubricationandMaintenanceIntervals........................203
MaintenanceIntervals.......................................203
LubricationandFluidsCharts...................................211
ComponentsRequiringLubrication........................212
Components Requiring Fluid Check and Fill..............213
Unit RefillCapacities.............................................214
FrontDriveAxles............................................214
Rear Axle Unit RefillCapacities............................214
Cooling System RefillCapacities..........................216
CrankcaseandOilFilters...................................216
PowerSteeringSystems....................................216
TransferCase................................................216
Transmission.................................................217
TireandRimCombinations.....................................218
ApprovedTireandRimCombinations.....................218
LiftAxleSystem..................................................219
Torque Specifications............................................219
DiscWheelTorqueChart...................................219
U-BoltNutTorqueChart....................................221
SpringU-BoltChecks.......................................223
LiftAxleTorqueCharts......................................223
FuseCharts.......................................................224
WorkStar®SeriesLightInformation............................225
FilterList...........................................................225
Section 8 – Customer Assistance
ServiceInformation...............................................227
InternationalTruckWarrantyProgram.........................227
Section 9 – Index
Index...............................................................229
3879634R1 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.
Studythismanualcarefully. Donotoperateyourvehicleuntilyou
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.
3879634R1 1

Foreword
Contact Closest Navistar, Inc. Regional Sales Office.
Addresses of Regional Sales Offices are found in the front
of this manual. Should you desire to contact any of these
offices, it is important to include the following information in your
communication:
• Name under which new vehicle was purchased, address,
and telephone number of purchaser
• Vehicle model, year, vehicle identification number,
component code, and serial number
• Vehicle delivery date and present mileage
• Location where purchased
• Details of the problem
Component Code Numbers
Code numbers are the basis for identifying thecomponents 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.
Line Set Ticket
Each vehicle is provided with a Line Set Ticket (code sheet),
which lists identification code numbers of component units used
to build the vehicle.
One copy of the Line Set Ticket is included in the literature
provided with the vehicle. When replacement parts are
required, take this copy with you to positively identify vehicle
components to be sure of getting the correct parts.
Be Sure To Return Line Set Ticket To Vehicle After Obtaining
Parts.
Vehicle Storage Instructions
When a vehicle is not used for an extended period of time,
precautions must be taken to prevent deterioration of vehicle
components. Vehicles that are out of service for extended
periods of time can experience corrosion and other undesirable
effects. Drive vehicle monthly to exercise the brakes, driveline
and steering. Run the vehicle long enough for the engine to
reach operating temperature.
NOTE: Losses occurring to a unit while it is in storage will not be
considered for warranty reimbursement.
Storage Duration - One Month or Less
1. Wash vehicles as necessary. Always wash vehicles that
have been exposed to road salt.
23879634R1

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 ordetergents. 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.
NOTE: When vehicles are stored outside, particularly in coastal
areas (salt water and high humidity atmosphere) or other
areas of corrosive environment, paint and bright metal may
require frequent washing and waxing to prevent deterioration.
Determining washing frequency is the customers responsibility.
NOTE: For vehicles exposed to ultraviolet rays of the sun, apply
a coating of Bon-Ami® soap, or similar product, to the inside
surfaces of the windshield and windows, to shade the interior
and prevent fading of the interior trim.
2. Inspectpainted surfaces; touch upall exposedprimedor 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).
6. Drain air brake reservoirs and close the drain cocks.
7. Lubricate all exposed transmission, auxiliary transmission
and PTO shift rails.
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.
Storage Duration - Over One Month
Units in storage longer than one month should be driven untilthe
engine reaches operating temperature:
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.
3. Startandrunthevehicleatfastidle, untilitreachesoperating
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.
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
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
thoseactspresumedtoconstitutetamperingaretheactslisted
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
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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
Chassis Model: Vehicle Identification Number:
Maintenance
Performed Maintainer (Name) Location Date
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
(NHTSA) in addition to notifying Navistar, Inc. To notify Navistar,
Inc., see regional numbers listed in the front of the manual.
If NHTSA receives similar complaints, it may open an
investigation and, if it finds that a safety defect exists in a
group of vehicles, it may order a recall and remedy campaign.
However, NHTSA cannot become involved in individual
problems between you, your dealer, or Navistar, Inc.
To contact NHTSA, you may either call the Auto Safety
Hotline toll-free at 1-800-424-9393 (or 202-366-0123 in
Washington, D.C. area) or write to: NHTSA, U.S. Department of
Transportation, Washington, D.C. 20590. You can also obtain
other information about motor vehicle safety from the hotline.
Canadian Registered Vehicles
If you believe that your vehicle has a defect, which could cause
a crash or could cause injury or death, you should immediately
contact Navistar, Inc. Canada and then Transport Canada.
To contact Navistar, Inc. Canada, you may either call
the Regional Service Manager (Canadian Sales Region)
905-332-2357 or write to: Navistar, Inc. Canada, 5500 North
Service Road, Box 5337, Burlington, Ontario L7L 5H7.
To contact Transport Canada, Defect Investigations and Recalls,
you may call 1-800-333-0510 or write to: Transport Canada,
ASFAD, Place de Ville Tower C, 330 Sparks Street, Ottawa,
Ontario K1A 0N5.
Safety Recalls and Authorized Field Changes
Safety Recalls and Authorized Field Changes are two
campaigns that are used to notify owners of modifications
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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.
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.
Add Layers of Protection
Four layers of protection are recommended for your vehicle - the
more layers of protection on your vehicle, the more difficult it is
to steal.
Layer 1: Common Sense
• Lock your doors.
• Remove your keys from the ignition.
• Close your windows completely.
• Park in well-lit areas.
• Dropabusinesscardwithyournameonitbetweentheglass
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.
•Postadriver 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.
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• 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 2: Visible or Audible Device
• Audible alarm system
• 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.
Layer 3: Vehicle Immobilizer
A. Fuse cutoffs
B. Kill switches
C. Starter, ignition, and fuel disablers
D. Fuel cutoff switch
Layer 4: Tracking System
The final layer is a tracking system that emits a signal to the
police or a monitoring service when the vehicle is reported
stolen. If your vehicle has a tracking system and is stolen, it can
oftentimes be recovered faster and with less damage.
VIN:
Model/Year:
Engine Serial Number:
License Number:
Insurance Company:
Policy Number:
Phone Number:
Other:
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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, personalinjury, 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
ontheLineSetTicket. IfinstalledbyaTEM,youshould
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.
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