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Navistar ProStar+ User Manual
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ProStar
®
+
0000663250
432831
1R1
EP
A
10,
2013
HD-OBD
-
US,
Canada,
Mexico
June
2015
ProStar
®
+
Operation
and
Maintenance
Manual
Navistar
,
Inc.
2701
Navistar
Drive,
Lisle,
IL
60532
USA
©
2015
Navistar
,
Inc.
All
rights
reserved.
All
marks
are
trademarks
of
their
respective
owners.
2
Table of Contents
Table of Contents
5
Cautions and Warnings
13
Preface
13
Section 1 - Foreword
13
Assistance Guide
14
Component Code Numbers
14
Line Set Ticket
15
Vehicle Storage Instructions
15
Storage Duration - One Month or Less
15
Storage Duration - over One Month
16
Storage Facilities
16
Diesel Exhaust Fluid (DEF) Storage
17
Exterior Noise Emissions
17
Noise Emissions Warranty
17
Emission Control Systems
18
HD-OBD Foreword
18
Warranty
19
Supplemental Federal Emission Control System
20
Tampering with Noise Control System Prohibited
18
Reporting Safety Defects
20
U.S. Registered Vehicles
20
Canadian Registered Vehicles
20
Customer Security Guide for International
21
Safety Recalls and Authorized Field Changes
21
Trucks
21
Optional Diamond Logic Electronic Application Solutions
23
Section 2 - Model Description
25
Available Models
25
Introduction
25
Vehicle Identification
28
Vehicle Identification Number (VIN)
28
Feature Codes
28
Engine Serial Number
28
Line Set Ticket
29
Exterior Components
30
Front View: Prostar
30
Not Equipped with Selective
30
Catalytic Reduction (SCR) System
30
Front View: Prostar
31
Equipped with Selective
31
Catalytic Reduction (SCR) System
31
Back View: Identical for All Prostar + Models
32
Cab Entry and Exit
33
Hood
33
Raising the Hood
33
Lowering the Hood
34
Chassis Skirts
35
Chassis Skirt Removal
36
Chassis Skirt Installation
37
Extended Chassis Skirts
37
Section 3 - Inspection Guide
39
Luggage Box Access
35
Driver and Passenger Side
35
Introduction
39
General Information
39
Tractor Inspection
40
Preparation
40
Exterior Lights Check
40
Left Side Cab Area (for Vehicles Not Equipped with Selective Catalytic Reduction (SCR) System)
41
Left Side Cab Area (for Vehicles Equipped with Selective Catalytic Reduction (SCR) System)
42
Left Engine Compartment
43
Left Front of Tractor
44
Front of Tractor
46
Right Front of Tractor
47
Right Engine Compartment
49
Right Side of Cab
50
Right Side under Vehicle
51
Right Rear of Tractor
52
Rear of Tractor
54
Left Rear of Tractor
55
Fifth Wheel and Coupling Area
56
Cab Interior Inspection
57
Section 4 - Controls / Features
59
Introduction
59
General Information
59
Electrical
59
Electrical System
59
Dash Components
60
Overhead Console
60
Instrument Panel Gauge Cluster
61
Warning Indicators
62
Gauges
65
Instrument Panel Gauge Cluster Alarms
67
Direct Drive Warning Indicators
69
Integral Digital Display
70
General Text and Warning Messages
72
Optional Instrument Panel Gauge Cluster Compass
73
Calibration Procedure
73
Compass Declination Zone Set Procedure
73
Compass Directional Calibration Procedure
76
Integral Digital Display Detailed Information
78
Switches
92
Headlights
92
Daytime Running Lights (DRL)
92
Lights on with Wipers
92
Park Lights
92
Panel Lighting
92
Dome Lighting
93
Courtesy Lights
93
Steering Wheel Controls
94
Cruise Control
95
Steering Column and Switches
96
Center Dash Panel / Wing Panel
98
Gauges
99
Switches
99
Climate Control
104
Air Conditioning
107
Dehumidification
107
Electronic Touchscreen
107
Vehicle Infotainment System
107
Door and Window Controls
108
Door Lock / Unlock
108
Cab Doors and Locks
108
Remote Keyless Entry Operation (Optional)
109
Lock / Unlock from Interior
110
Automatic Door Lock Function
110
Driver / Passenger Windows
111
Manual Operation
111
Power Operation
111
Window Lockout Function
111
Mirror Controls
111
Vent Window
111
Smartwave ® Display
108
Bendix Wingman Advanced ® Collision Warning System
112
Bendix Wingman Fusion
114
System
114
Driver Interface Unit
115
Meritor Wabco Onguard™ Collision Safety System
116
Driver Reward
117
Section 5 - Sleeper Features
119
Introduction
119
General Information
119
Main Features
119
Lighting
121
Dome Light
121
Reading Lights
121
Floor Lights
121
Accent Lights
121
Sleeper Control Panel
122
General Information
122
Accent Light Dimmer Switch
123
Accent Light Switch
123
Sleeper Dome / Floor Light Switch
123
Engine Control Switch
123
Auto Start / Stop System
124
Manual Climate Controls
126
No-Idle Heating
127
Power Receptacle
127
Radio Remote Control
127
Remote Power Inverter Panel
127
Windows
128
General Information
128
Bunk Restraint System
129
General Information
129
Adjustable Belts
129
Restraint Webbing System
129
Lower Bunk
131
General Information
131
Upper Bunk
132
General Information
132
Entering the Upper Bunk
133
Exiting the Upper Bunk
134
Cabinets / Storage
135
General Information
135
Cabinets
136
Refrigerator Cabinet
136
Horizontal Refrigerator
137
Dresser Cabinet
137
Tower Wardrobe Cabinet
139
Rear Wardrobe Cabinet
140
Airline Cabinets
141
Convenience Features
142
General Information
142
Sleeper Curtain
142
Television Mount
142
Power Inverter
142
Power Sockets
142
Speakers
142
Floor Covering
142
Sleeper Fan
142
Section 6 - Operation
143
Operation Safety
143
General Information
143
Cab Controls
145
Seat Belts
145
General Information
145
General Information
146
Operation
147
Care of Seat Belts
148
Seats
149
General Information
149
Starting Procedures
151
General Information
151
Engine Starting
151
After the Engine Starts
152
Engine Shutdown
153
Emergency Starting
153
Cold Weather
154
General Information
154
Cold Weather Starting
154
Cold Weather Operation
155
Engine Idling
155
Engine Idle Shutdown Timer (Optional)
156
Winter Front Usage
156
Hot Weather Operation
156
Operating Instructions
157
General Information
157
Steering
157
Adjustable Steering Column
158
General Information
158
Electrical
159
Alternator
159
Battery
159
BATTERY on Indicator
160
Circuit Breakers, Fuses and Fusible Links
161
Electrical Load Control and Shedding (ELCS)
161
Engine
161
Charge Air Cooler
162
Electronic Engine Controller
162
Engine Brake
162
Engine Brake with Allison Transmissions
163
Engine Brake with Eaton Autoshift / Ultrashift Transmissions Special Driver Instructions
163
Engine Features
164
HD-OBD Overview
165
Self Diagnostics
165
Air Compressor Cycling
166
Cooling System
166
Engine Oil
167
Engine Performance Problems
167
Additional Unsafe Practices
168
Fuel
168
Fuel and Lubricant Additives
168
Fueling Procedures
168
Hazards of Diesel Fuel / Gasoline Blends
168
Ultra Low Sulfur Diesel Fuel Requirements
168
Unacceptable Fuel Blends
168
Fueling Precautions
169
Reserve Fuel
169
Transmission
169
Transmission Fluid
169
Manual Transmissions
170
Transmission Fluid Temperature
170
Engaging the Clutch
172
Hydraulic Clutch Actuation System
173
Clutch Brake
174
Clutch Precautions
174
Double Clutch Procedures
174
Eaton Autoshift ® Transmissions
174
Eaton Ultrashift Transmissions (Optional)
174
Eaton Cummins Alliance Transmissions
175
Eaton Navistar ® Alliance Transmissions
175
Allison Transmissions
175
Hill Start Aid / Hill Brake (Optional)
175
Power Take-Off Control
175
Rear Axles
175
Locking or Limited Slip Differentials
175
Tandem Axle Power Divider Lock (PDL) Control
176
Driver Controlled Differential Lock
177
Rear Suspension
178
Rear Air Ride Suspension
178
Rear Air Suspension Air Dump
178
Air Suspension System Faults
178
Exhaust Aftertreatment
179
Selective Catalytic Reduction System (if Equipped)
179
Introduction
179
Diesel Exhaust Fluid
179
DEF Tank
179
Low DEF Level
180
DEF Contamination or SCR System Fault
184
Exhaust Diesel Particulate Filter Regeneration
190
Parked Regeneration Procedure
193
Regeneration Inhibit Switch
193
Two-Position Regeneration Inhibit Switch
194
Three-Position Regeneration Inhibit Switch
194
Brakes
194
General Information
194
Downhill Operation
194
Air Brakes
195
General Information
195
Air Gauge, Low Air Pressure Beeper and Warning
195
Indicator
195
Reservoir Moisture Draining
196
Brake Application
196
Parking Brake
196
Parking Brake Reset
197
Parking Brake Alarm
197
Air Dryer
198
Trailer Brake Hand Control
198
Trailer Air Supply and Parking Brake Modular Controls
198
Parking Brake Indicator
200
Bobtail Proportioning System
200
Antilock Brake System (ABS)
200
General Information
200
ABS Operation
201
ABS Self Check
201
Antilock Driving Tips
202
Automatic Traction Control (ATC) System
202
General Information
202
ATC System Check
202
ATC off ROAD or MUD / SNOW Switch
203
Stability Control Systems - Bendix RSP / WABCO RSC / Bendix ESP
203
Towing Instructions
205
Tow Hooks
206
Towing Vehicle with Front Wheels Suspended
207
Towing Vehicles with Driver Controlled Differential
207
Lock
207
Removing Axle Shafts before Towing
207
Installing Axle Shafts
208
Towing Vehicle with Rear Wheels Suspended
208
Tractor-Trailer Connections
209
Connecting / Disconnecting a Trailer to a Vehicle
209
With Air Suspension
209
Fifth Wheel Operation
210
Fifth Wheel Slide Switch (Optional)
210
Hook-Up
210
Un-Hook
211
Fifth Wheel Jaw Unlock Control
211
Fifth Wheel Jaw Monitoring
212
Section 7 - Maintenance Instructions
213
Introduction
213
Maintenance Guidelines
213
Air Conditioning Service Checks
215
HVAC Filters
216
Side Access HVAC Filter
216
Front Access HVAC Filter
217
Recirculation Filters
217
Sleeper HVAC Filter
218
Chassis Lubrication
215
Supporting Your Vehicle for Service
215
Axles
218
Front Axle
218
Inspection and Lubrication
218
Normal Maintenance
219
Alignment
219
Rear Axle
219
Inspection and Lubrication
219
Locking Differential
219
Brakes
220
General Information
220
Air Brakes
220
Inspection and Adjustment
220
Air Dryer
222
General Information
222
Desiccant Filter
222
Purge Valve
222
Heater
223
Air Reservoir / Tanks Moisture Draining
223
ABS Connections and Sensors
223
Cab
223
Care of Vehicle
223
Washing and Waxing
223
Bright Metal Care
224
Upholstery Care
224
Exposed Rubber and Unpainted Plastic Parts
224
Clutch
224
Pedal Free Travel
224
Hydraulic Clutch
226
Electrical
227
Batteries
227
Auto Start / Stop System Battery Cables
228
High Current Relay
229
Electrical Charging and Starting System Test
229
Terminal Inspection-Cleaning-Corrosion Protection
229
Accessory Feed Connections
230
Fuses and Relays
230
Engine
230
General Information
230
Engine Fluids and Contaminated Material
231
Scheduled Maintenance
231
Air Induction System
231
Air Restriction Gauge
231
Air Cleaner Element Service
232
Troubleshooting
235
Charge Air Cooler and Radiator Core Inspection and Cleaning
236
Inspection and Cleaning
236
Cooling System
236
Coolant Level Check
236
Filling Instructions
236
Coolant and Optional Coolant Filter
239
Coolant Concentration Freeze Point
239
Antifreeze
239
Fan Clutch
239
Fuel System
240
Fuel Tank Draining and Cleaning
240
Crankcase Ventilation Filter
240
Frame
240
Noise Emissions - Exterior
241
Instructions for Proper Maintenance
241
Air Intake System
241
Body
241
Cooling System
241
Engine Noise Shields / Blankets
241
Exhaust System
241
Maintenance Record - Noise Control
242
DEF Tank Filling
244
Diesel Particulate Filter (DPF)
244
Regeneration
244
Cleaning
244
Drive Shafts
244
Suspension (Air and Steel Springs)
245
Front Suspension
245
Rear Suspension
245
Steering
246
General Information
246
Tightening Steering Intermediate Shaft Joint Bolts
246
Lubrication Points
246
Power Steering
247
Tires
247
Tire Warnings
247
Tire Maintenance
249
Checking Inflation
249
Underinflation
249
Smartwave Tire Pressure Monitoring System
249
(Tpms)
249
Inspection
250
Loads
250
Dual Tires Matching
251
Dual Tires Mixing
251
Rotation
251
Rotation Is Advisable
251
Tire Replacement
252
Wheel and Tire Balancing
252
Wear
252
Irregular Wear
252
Use of Tire Chains
253
Wheels
253
Wheel and Wheel Nut Maintenance and Installation
253
Wheel Nut Torque Maintenance
254
Hub-Piloted Wheel Installation Procedures
254
Transmission
256
Section 8 - Maintenance Intervals and Specifications
257
Lubrication and Maintenance Intervals
257
Maintenance Intervals
257
Lubrication and Fluids Charts
266
Components Requiring Lubrication
267
Components Requiring Fluid Check and Fill
268
Unit Refill Capacities
269
Cooling System Refill Capacities
269
Diesel Exhaust Fluid Tank
269
Crankcase and Oil Filters
269
Hydraulic Clutch System
269
Power Steering Systems
269
Transmission
270
Rear Axle Unit Refill Capacities
272
Lubricant and Sealer Specifications
273
Torque Specifications
278
U-Bolt Nut Torque Chart
278
Disc Wheel Nut Torque Chart
279
Fuse Charts
279
Typical Interior Fuse Panel Layout
280
Typical Luggage Compartment Fuse Panel Layout
281
Typical Under-Hood Power Distribution Module
281
(PDM) Fuse Panel Layout
281
Prostar + Series Light Information
284
Filter List
285
Section 9 - Customer Assistance
287
International Truck Warranty Program
287
Service Information
287
Index
289
5
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Navistar ProStar+ Specifications
General
Brand
Navistar
Model
ProStar+
Category
Trucks
Language
English
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