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International Trucks ProStar+ Series User Manual

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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.
PROSTAR
®
+ Series 3878859R2
ProStar+ Models December 2010

Table of Contents

Questions and Answers:

International Trucks ProStar+ Series Specifications

General IconGeneral
BrandInternational Trucks
ModelProStar+ Series
CategoryTrucks
LanguageEnglish

Summary

Vehicle Information and Warnings

Notice Regarding Vehicle Recording Devices

Advises that the vehicle may be equipped with computer/recording devices for data download.

California Proposition 65 Warning

Warns about cancer and reproductive harm from diesel exhaust and battery lead.

Vehicle Identification and Component Information

VIN and Component Identification Locations

Specifies where to find the Vehicle Identification Number and component identification numbers.

Engine Serial Number Location

Indicates the location of the engine serial number on the crankcase.

Navistar Sales Regions and Customer Assistance

Lists Navistar's World Headquarters, sales regions, and customer assistance contact.

Service Publications Information

Section 1 – Foreword

Preface and Cautions

Introduces the manual, explains warning symbols, and owner responsibilities for vehicle care.

Assistance and Component Identification

Provides guidance on obtaining assistance and explains component code numbers and the Line Set Ticket.

Vehicle Storage Instructions

Outlines precautions to prevent component deterioration during extended periods of non-use.

Noise Emission Regulations and Tampering

References federal regulations on exterior noise emissions and prohibits tampering with noise control systems.

Section 2 – Model Description

Model Introduction and Available Models

Introduces the ProStar®+ Series truck models and illustrates available configurations.

Vehicle Identification and Component Codes

Explains the VIN, Feature Codes, and their importance for identifying vehicle components.

Exterior Components Overview

Illustrates and lists various exterior components of the vehicle.

Cab Entry, Exit, and Hood Operation

Provides safety warnings for cab entry/exit and details hood raising/lowering procedures.

Bumper and Chassis Skirt Operation

Explains tilt-away bumper operation and the function and removal/installation of chassis skirts.

Section 3 – Inspection Guide

Inspection Introduction and General Information

Introduces the section on pre-trip inspections and emphasizes safety and vehicle readiness.

Tractor Inspection Preparation and Exterior Lights

Lists procedures before inspection and details the exterior lights check process.

Cab Area and Engine Compartment Inspections

Details inspection items for the left side cab area and left engine compartment.

Front and Rear of Tractor Inspections

Covers inspection points for the left and right front sections, and the left and right rear sections of the tractor.

Engine Compartment and Cab Side Inspections

Details inspection items for the right engine compartment and the right side of the cab.

Under Vehicle and Fifth Wheel Inspections

Covers inspection points for the underside of the vehicle and the fifth wheel area.

Cab Interior Inspection Procedures

Lists inspection items for the vehicle's cab interior and details the air brake check procedure.

Section 4 – Controls/Features

Introduction and Electrical System

Introduces the section and describes the vehicle's electrical system.

Dash Components Overview

Illustrates and labels various components located on the dash, steering column, and center panels.

Overhead Console Features

Describes the overhead console, which contains storage and comfort items for the operator.

Instrument Panel Gauge Cluster Overview

Details the instrument gauges, warning indicators, and digital display that show vehicle operational functions.

Warning Indicators and Gauges

Explains the function and illumination of warning indicators and describes the vehicle's gauges.

Direct Drive Warning Indicators and Integral Digital Display

Explains warning indicators and the integral digital display, its quadrants, and control functions.

Integral Digital Display Detailed Information

Details informational, text, and warning messages displayed in Quadrants 1 and 2.

Compass Calibration Procedures

Details procedures for calibrating the compass, setting declination zones, and testing.

Steering Wheel Controls and Cruise Control

Details steering wheel controls for vehicle operation and cruise control usage.

Steering Column Adjustments and Wiper Controls

Describes steering column adjustments and wiper/washer controls.

Center Dash Panel Components and Switches

Illustrates center dash panel components and describes various switches.

Climate Control System Operation

Introduces the climate control system and details manual and electronic operations.

Air Conditioning System Maintenance

Provides guidance on servicing the air conditioning system and cleaning filters.

Electronic Vehicle Monitoring and SmartWave® Display

Describes electronic monitoring displays and the SmartWave® tire pressure system.

Door and Window Controls

Explains door lock/unlock functions, remote entry, and window operations.

Eaton VORAD Collision Warning System

Explains the Eaton VORAD system, its warnings, and driver reward features.

Section 5 – Sleeper Features

Sleeper Features Introduction and Main Features

Introduces sleeper features and lists main components like duct work and cabinets.

Sleeper Compartment Lighting

Describes dome, reading, floor, and accent lighting systems in the sleeper.

Sleeper Control Panel and Engine Controls

Details the sleeper control panel and the engine control switch for remote starting.

Climate Control and Power Systems

Describes electronic climate control and power inverter panel functions.

Sleeper Compartment Windows and Curtains

Provides information on sleeper compartment windows and privacy curtains.

Bunk Restraint Systems

Explains occupant restraint systems for sleeper berths, including installation and removal.

Lower Bunk Features and Components

Details the standard lower bunk, its features, and associated components like storage and HVAC.

Upper Bunk Operation

Describes the optional upper bunk, its mounting, and procedures for entering/exiting.

Cabinets and Storage Configurations

Introduces cabinets and describes various configurations for storage in the sleeper compartment.

Refrigerator and Dresser Cabinet Details

Details the refrigerator and dresser cabinets, their features, and components.

Tower Wardrobe and Rear Wardrobe Cabinets

Describes tower and rear wardrobe cabinets, their storage, and components.

Convenience Features Overview

Introduces convenience features like sleeper curtains, TV mounts, and power outlets.

Section 6 – Operation

Operation Safety Warnings

Provides critical safety warnings regarding engine operation, weight ratings, and restraints.

Seat Belts Usage and Maintenance

Discusses mandatory seat belt use, inspection, care, and operation procedures.

Seats and Adjustment Controls

Details seat options, general information, and specific controls for seat adjustments.

Starting Procedures and Engine Operation

Provides procedures for starting the engine, after-start guidance, and shutdown.

Cold Weather and Hot Weather Operation

Covers operating instructions for cold weather starting/operation and hot weather conditions.

Steering System and Driving Information

Provides general information and warnings about steering system maintenance and driving.

Clutch Operation and Transmission Systems

Details manual transmission shifting, clutch operation, and optional automated transmissions.

Rear Axle Differential Locks

Provides warnings and precautions for vehicles equipped with locking or limited slip differentials.

Towing Instructions and Connections

Covers towing instructions, differential locks, air suspension, and tractor-trailer connections.

Antilock Brake System (ABS) and Traction Control

Introduces ABS and ATC systems, their operation, warnings, and driving tips.

Brake System Checks and Operation

Covers downhill operation, air brakes, parking brakes, and trailer brake controls.

Section 7 – Maintenance Instructions

Introduction and Maintenance Guidelines

Introduces maintenance section and provides essential guidelines and safety warnings.

General Maintenance and Battery Safety

Provides general safety precautions for maintenance and critical warnings for battery handling.

Electrical System Maintenance

Details battery maintenance, charging tests, and terminal inspection/cleaning.

Engine and Air Induction System Maintenance

Covers engine information, air cleaner service, and fluid handling regulations.

Air Restriction Gauge and Cleaner Service

Explains the air restriction gauge and provides procedures for servicing the air cleaner element.

Troubleshooting Air Restriction Issues

Provides troubleshooting steps for air restriction reading problems.

Cooling System Inspection and Filling

Details inspection and cleaning of cooling system cores and filling procedures.

Coolant and Filter Specifications

Discusses coolant types, optional filters, freeze points, and antifreeze.

Fuel System and Tank Maintenance

Covers fuel system inspection, fuel/water separators, and fuel tank draining.

Exhaust System and DPF Regeneration

Details exhaust system inspection and DPF regeneration procedures.

Drive Shafts and Suspension Systems

Covers inspection of drive shafts and air/steel spring suspension components.

Steering System Maintenance

Provides general information, checks, lubrication points, and tightening procedures for the steering system.

Tire Maintenance and Warnings

Covers tire warnings, maintenance practices, and inflation checks.

Tire Inspection, Wear Patterns, and Rotation

Details tire inspection for wear, damage, and rotation programs.

Tire Replacement and Wheel Balancing

Specifies when to replace tires and explains wheel and tire balancing.

Irregular Tire Wear and Wheel Maintenance

Discusses causes of irregular tire wear and wheel/nut maintenance.

Torque Specifications: U-Bolt Nuts and Disc Wheels

Provides torque specifications for U-bolt nuts and disc wheel nuts.

Section 8 – Maintenance Intervals and Specifications

Lubrication and Maintenance Intervals Overview

Explains the importance of regular lubrication and maintenance intervals.

Interval Chart Symbols Key and Notes

Defines symbols and provides notes for the lubrication and maintenance interval charts.

Recommended Synchronized Intervals: Front Axle

Lists maintenance intervals for pre-trip inspections and front axle components.

Recommended Synchronized Intervals: Rear Axle and Electrical

Lists maintenance intervals for rear axles and the electrical system.

Recommended Synchronized Intervals: Steering, Drive Shaft, and Air Brakes

Lists maintenance intervals for steering, drive shaft, and air brake systems.

Recommended Synchronized Intervals: Cooling System and Engine

Lists maintenance intervals for cooling system and engine components.

Recommended Synchronized Intervals: Fuel System and Transmission

Lists maintenance intervals for fuel system and transmission components.

Recommended Synchronized Intervals: Tires/Wheels

Lists maintenance intervals for tires and wheels, including wear checks.

Components Requiring Lubrication Diagrams

Illustrates components requiring lubrication for steering, drive shaft, and clutch.

Components Requiring Fluid Check and Fill Diagrams

Illustrates components requiring fluid checks and fills for engine, power steering, and axles.

Unit Refill Capacities: Cooling System

Provides refill capacities for the cooling system and cautions regarding coolant mixtures.

Unit Refill Capacities: Transmission Oil

Details transmission oil types, viscosities, and applicable temperatures for various transmissions.

Unit Refill Capacities: Rear Axle

Lists refill capacities for various rear axle models, including 4x2 and 6x4 tandem axles.

Lubricant and Sealer Specifications: Front Axle

Specifies lubricant types and applicable temperatures for front axle components.

Lubricant and Sealer Specifications: Steering and Drive Shaft

Specifies lubricants for steering system components and drive shaft U-joints.

Lubricant and Sealer Specifications: Clutch and Cooling System

Specifies lubricants for clutch components and coolant types.

Lubricant and Sealer Specifications: Rear Drive Axle and Electrical

Specifies lubricants for rear drive axles and electrical terminals.

Fuse Panel Layouts

Shows typical interior and luggage compartment fuse panel layouts.

ProStar®+ Series Light Information

Lists lamp descriptions and corresponding bulb part numbers for the ProStar®+ Series.

Filter List Information

Explains that filter part numbers may change and how to obtain current information.

Section 9 – Customer Assistance

Service Information Resources

Discusses servicing through dealers, service publications, and online resources.

International Truck Warranty Program Overview

Introduces the warranty program, standard warranty, and optional service contracts.

Customer Service Contracts and Warranty Advantages

Describes custom service contracts, performance PM service, and warranty benefits.

Obtaining International Truck Warranties

Explains how to obtain standard and optional warranty programs through dealers.

Section 10 – Index

Index Topics A-B

Lists index entries for topics starting with 'A' and 'B'.

Index Topics B-C

Lists index entries for topics starting with 'B' and 'C'.

Index Topics C-D

Lists index entries for topics starting with 'C' and 'D'.

Index Topics D-E

Lists index entries for topics starting with 'D' and 'E'.

Index Topics E-F

Lists index entries for topics starting with 'E' and 'F'.

Index Topics F-G

Lists index entries for topics starting with 'F' and 'G'.

Index Topics G-H

Lists index entries for topics starting with 'G' and 'H'.

Index Topics H-I

Lists index entries for topics starting with 'H' and 'I'.

Index Topics I-L

Lists index entries for topics starting with 'I' and 'L'.

Index Topics L

Lists index entries for topics starting with 'L'.

Index Topics M

Lists index entries for topics starting with 'M'.

Index Topics N-O

Lists index entries for topics starting with 'N' and 'O'.

Index Topics O-P

Lists index entries for topics starting with 'O' and 'P'.

Index Topics P-Q

Lists index entries for topics starting with 'P' and 'Q'.

Index Topics Q-R

Lists index entries for topics starting with 'Q' and 'R'.

Index Topics R-S

Lists index entries for topics starting with 'R' and 'S'.

Index Topics S

Lists index entries for topics starting with 'S'.

Index Topics S-T

Lists index entries for topics starting with 'S' and 'T'.

Index Topics T

Lists index entries for topics starting with 'T'.

Index Topics T-U

Lists index entries for topics starting with 'T' and 'U'.

Index Topics U

Lists index entries for topics starting with 'U'.

Index Topics U-V

Lists index entries for topics starting with 'U' and 'V'.

Index Topics V-W

Lists index entries for topics starting with 'V' and 'W'.

Index Topics W

Lists index entries for topics starting with 'W'.

Index Topics W (cont.)

Lists index entries for topics starting with 'W'.

Index Topics W (cont. 2)

Lists index entries for topics starting with 'W'.

Index Topics W (cont. 3)

Lists index entries for topics starting with 'W'.

Index Topics W (cont. 4)

Lists index entries for topics starting with 'W'.