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
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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