Navistar ProStar+

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IMPORTANT

Itisimportantthattheapplicablevehicleidenticationnumber(VIN),engineserialnumberandorcomponentfeaturecodesare

recorded.Thesenumbersarerequiredtoobtainpertinentinformationforthisvehicleorengine.

VEHICLEIDENTIFICATIONNUMBER(VIN)

ENGINE

FeatureCode:SerialNumber:

FRONTAXLE

FeatureCode:SerialNumber:

REARAXLE

FeatureCode:SerialNumber:

TRANSMISSION

FeatureCode:SerialNumber:

TRANSFERCASE

FeatureCode:SerialNumber:

CUSTOMERASSISTANCECENTER

1-800-44-TRUCK(1-800-448-7825)

Navistar,Inc.

2701NavistarDrive

Lisle,IL60532USA

www.navistar.com

Main Page

Table of Contents5
Cautions and Warnings13
Preface13
Section 1 - Foreword13
Assistance Guide14
Component Code Numbers14
- Line Set Ticket15
Vehicle Storage Instructions15
- Storage Duration - One Month or Less15
- Storage Duration - over One Month16
- Storage Facilities16
Diesel Exhaust Fluid (DEF) Storage17
Exterior Noise Emissions17
Noise Emissions Warranty17
Emission Control Systems18
- HD-OBD Foreword18
- Warranty19
- Supplemental Federal Emission Control System20
Tampering with Noise Control System Prohibited18
Reporting Safety Defects20
- U.S. Registered Vehicles20
- Canadian Registered Vehicles20
Customer Security Guide for International21
Safety Recalls and Authorized Field Changes21
Trucks21
Optional Diamond Logic Electronic Application Solutions23
- Section 2 - Model Description25
Available Models25
Introduction25
Vehicle Identification28
- Vehicle Identification Number (VIN)28
- Feature Codes28
- Engine Serial Number28
- Line Set Ticket29
Exterior Components30
- Front View: Prostar30
- Not Equipped with Selective30
- Catalytic Reduction (SCR) System30
- Front View: Prostar31
- Equipped with Selective31
- Catalytic Reduction (SCR) System31
- Back View: Identical for All Prostar + Models32
Cab Entry and Exit33
Hood33
- Raising the Hood33
- Lowering the Hood34
Chassis Skirts35
- Chassis Skirt Removal36
- Chassis Skirt Installation37
- Extended Chassis Skirts37
- Section 3 - Inspection Guide39
Luggage Box Access35
- Driver and Passenger Side35
Introduction39
- General Information39
Tractor Inspection40
- Preparation40
- Exterior Lights Check40
- 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 Compartment43
- Left Front of Tractor44
- Front of Tractor46
- Right Front of Tractor47
- Right Engine Compartment49
- Right Side of Cab50
- Right Side under Vehicle51
- Right Rear of Tractor52
- Rear of Tractor54
- Left Rear of Tractor55
- Fifth Wheel and Coupling Area56
- Cab Interior Inspection57
- Section 4 - Controls / Features59
Introduction59
- General Information59
- Electrical59
- Electrical System59
Dash Components60
Overhead Console60
- Instrument Panel Gauge Cluster61
- Warning Indicators62
- Gauges65
- Instrument Panel Gauge Cluster Alarms67
- Direct Drive Warning Indicators69
- Integral Digital Display70
- General Text and Warning Messages72
- Optional Instrument Panel Gauge Cluster Compass73
- Calibration Procedure73
- Compass Declination Zone Set Procedure73
- Compass Directional Calibration Procedure76
- Integral Digital Display Detailed Information78
- Switches92
- Headlights92
- Daytime Running Lights (DRL)92
- Lights on with Wipers92
- Park Lights92
- Panel Lighting92
- Dome Lighting93
- Courtesy Lights93
Steering Wheel Controls94
- Cruise Control95
Steering Column and Switches96
Center Dash Panel / Wing Panel98
- Gauges99
- Switches99
- Climate Control104
- Air Conditioning107
- Dehumidification107
Electronic Touchscreen107
- Vehicle Infotainment System107
Door and Window Controls108
- Door Lock / Unlock108
- Cab Doors and Locks108
- Remote Keyless Entry Operation (Optional)109
- Lock / Unlock from Interior110
- Automatic Door Lock Function110
- Driver / Passenger Windows111
- Manual Operation111
- Power Operation111
- Window Lockout Function111
- Mirror Controls111
- Vent Window111
Smartwave ® Display108
Bendix Wingman Advanced ® Collision Warning System112
Bendix Wingman Fusion114
- System114
Driver Interface Unit115
Meritor Wabco Onguard™ Collision Safety System116
Driver Reward117
- Section 5 - Sleeper Features119
Introduction119
- General Information119
- Main Features119
Lighting121
- Dome Light121
- Reading Lights121
- Floor Lights121
- Accent Lights121
Sleeper Control Panel122
- General Information122
- Accent Light Dimmer Switch123
- Accent Light Switch123
- Sleeper Dome / Floor Light Switch123
- Engine Control Switch123
- Auto Start / Stop System124
- Manual Climate Controls126
- No-Idle Heating127
- Power Receptacle127
- Radio Remote Control127
- Remote Power Inverter Panel127
Windows128
- General Information128
Bunk Restraint System129
- General Information129
- Adjustable Belts129
- Restraint Webbing System129
Lower Bunk131
- General Information131
Upper Bunk132
- General Information132
- Entering the Upper Bunk133
- Exiting the Upper Bunk134
Cabinets / Storage135
- General Information135
Cabinets136
- Refrigerator Cabinet136
- Horizontal Refrigerator137
- Dresser Cabinet137
- Tower Wardrobe Cabinet139
- Rear Wardrobe Cabinet140
- Airline Cabinets141
Convenience Features142
- General Information142
- Sleeper Curtain142
- Television Mount142
- Power Inverter142
- Power Sockets142
- Speakers142
- Floor Covering142
- Sleeper Fan142
- Section 6 - Operation143
Operation Safety143
- General Information143
- Cab Controls145
Seat Belts145
- General Information145
- General Information146
- Operation147
- Care of Seat Belts148
Seats149
- General Information149
Starting Procedures151
- General Information151
- Engine Starting151
- After the Engine Starts152
- Engine Shutdown153
- Emergency Starting153
- Cold Weather154
- General Information154
- Cold Weather Starting154
- Cold Weather Operation155
- Engine Idling155
- Engine Idle Shutdown Timer (Optional)156
- Winter Front Usage156
- Hot Weather Operation156
Operating Instructions157
- General Information157
- Steering157
- Adjustable Steering Column158
- General Information158
- Electrical159
- Alternator159
- Battery159
- BATTERY on Indicator160
- Circuit Breakers, Fuses and Fusible Links161
- Electrical Load Control and Shedding (ELCS)161
- Engine161
Charge Air Cooler162
Electronic Engine Controller162
Engine Brake162
Engine Brake with Allison Transmissions163
Engine Brake with Eaton Autoshift / Ultrashift Transmissions Special Driver Instructions163
Engine Features164
HD-OBD Overview165
Self Diagnostics165
Air Compressor Cycling166
Cooling System166
Engine Oil167
Engine Performance Problems167
Additional Unsafe Practices168
Fuel168
Fuel and Lubricant Additives168
Fueling Procedures168
Hazards of Diesel Fuel / Gasoline Blends168
Ultra Low Sulfur Diesel Fuel Requirements168
Unacceptable Fuel Blends168
Fueling Precautions169
Reserve Fuel169
Transmission169
Transmission Fluid169
Manual Transmissions170
Transmission Fluid Temperature170
Engaging the Clutch172
Hydraulic Clutch Actuation System173
Clutch Brake174
Clutch Precautions174
Double Clutch Procedures174
Eaton Autoshift ® Transmissions174
- Eaton Ultrashift Transmissions (Optional)174
- Eaton Cummins Alliance Transmissions175
- Eaton Navistar ® Alliance Transmissions175
- Allison Transmissions175
- Hill Start Aid / Hill Brake (Optional)175
- Power Take-Off Control175
- Rear Axles175
- Locking or Limited Slip Differentials175
- Tandem Axle Power Divider Lock (PDL) Control176
- Driver Controlled Differential Lock177
- Rear Suspension178
- Rear Air Ride Suspension178
- Rear Air Suspension Air Dump178
- Air Suspension System Faults178
Exhaust Aftertreatment179
- Selective Catalytic Reduction System (if Equipped)179
- Introduction179
- Diesel Exhaust Fluid179
- DEF Tank179
- Low DEF Level180
- DEF Contamination or SCR System Fault184
- Exhaust Diesel Particulate Filter Regeneration190
- Parked Regeneration Procedure193
- Regeneration Inhibit Switch193
- Two-Position Regeneration Inhibit Switch194
- Three-Position Regeneration Inhibit Switch194
Brakes194
- General Information194
- Downhill Operation194
- Air Brakes195
- General Information195
- Air Gauge, Low Air Pressure Beeper and Warning195
- Indicator195
- Reservoir Moisture Draining196
- Brake Application196
- Parking Brake196
- Parking Brake Reset197
- Parking Brake Alarm197
- Air Dryer198
- Trailer Brake Hand Control198
- Trailer Air Supply and Parking Brake Modular Controls198
- Parking Brake Indicator200
- Bobtail Proportioning System200
- Antilock Brake System (ABS)200
- General Information200
- ABS Operation201
- ABS Self Check201
- Antilock Driving Tips202
Automatic Traction Control (ATC) System202
- General Information202
- ATC System Check202
- ATC off ROAD or MUD / SNOW Switch203
- Stability Control Systems - Bendix RSP / WABCO RSC / Bendix ESP203
Towing Instructions205
- Tow Hooks206
- Towing Vehicle with Front Wheels Suspended207
- Towing Vehicles with Driver Controlled Differential207
- Lock207
- Removing Axle Shafts before Towing207
- Installing Axle Shafts208
- Towing Vehicle with Rear Wheels Suspended208
Tractor-Trailer Connections209
- Connecting / Disconnecting a Trailer to a Vehicle209
- With Air Suspension209
- Fifth Wheel Operation210
- Fifth Wheel Slide Switch (Optional)210
- Hook-Up210
- Un-Hook211
- Fifth Wheel Jaw Unlock Control211
- Fifth Wheel Jaw Monitoring212
- Section 7 - Maintenance Instructions213
Introduction213
Maintenance Guidelines213
Air Conditioning Service Checks215
- HVAC Filters216
- Side Access HVAC Filter216
- Front Access HVAC Filter217
- Recirculation Filters217
- Sleeper HVAC Filter218
Chassis Lubrication215
Supporting Your Vehicle for Service215
Axles218
- Front Axle218
- Inspection and Lubrication218
- Normal Maintenance219
- Alignment219
- Rear Axle219
- Inspection and Lubrication219
- Locking Differential219
Brakes220
- General Information220
- Air Brakes220
- Inspection and Adjustment220
- Air Dryer222
- General Information222
- Desiccant Filter222
- Purge Valve222
- Heater223
- Air Reservoir / Tanks Moisture Draining223
- ABS Connections and Sensors223
Cab223
- Care of Vehicle223
- Washing and Waxing223
- Bright Metal Care224
- Upholstery Care224
- Exposed Rubber and Unpainted Plastic Parts224
Clutch224
- Pedal Free Travel224
- Hydraulic Clutch226
Electrical227
- Batteries227
- Auto Start / Stop System Battery Cables228
- High Current Relay229
- Electrical Charging and Starting System Test229
- Terminal Inspection-Cleaning-Corrosion Protection229
- Accessory Feed Connections230
- Fuses and Relays230
Engine230
- General Information230
- Engine Fluids and Contaminated Material231
- Scheduled Maintenance231
- Air Induction System231
- Air Restriction Gauge231
- Air Cleaner Element Service232
- Troubleshooting235
- Charge Air Cooler and Radiator Core Inspection and Cleaning236
- Inspection and Cleaning236
- Cooling System236
- Coolant Level Check236
- Filling Instructions236
- Coolant and Optional Coolant Filter239
- Coolant Concentration Freeze Point239
- Antifreeze239
- Fan Clutch239
- Fuel System240
- Fuel Tank Draining and Cleaning240
- Crankcase Ventilation Filter240
Frame240
Noise Emissions - Exterior241
- Instructions for Proper Maintenance241
- Air Intake System241
- Body241
- Cooling System241
- Engine Noise Shields / Blankets241
- Exhaust System241
Maintenance Record - Noise Control242
DEF Tank Filling244
Diesel Particulate Filter (DPF)244
- Regeneration244
- Cleaning244
Drive Shafts244
Suspension (Air and Steel Springs)245
- Front Suspension245
- Rear Suspension245
Steering246
- General Information246
- Tightening Steering Intermediate Shaft Joint Bolts246
- Lubrication Points246
- Power Steering247
Tires247
- Tire Warnings247
- Tire Maintenance249
- Checking Inflation249
- Underinflation249
- Smartwave Tire Pressure Monitoring System249
- (Tpms)249
- Inspection250
- Loads250
- Dual Tires Matching251
- Dual Tires Mixing251
- Rotation251
- Rotation Is Advisable251
- Tire Replacement252
- Wheel and Tire Balancing252
- Wear252
- Irregular Wear252
- Use of Tire Chains253
Wheels253
- Wheel and Wheel Nut Maintenance and Installation253
- Wheel Nut Torque Maintenance254
- Hub-Piloted Wheel Installation Procedures254
- Transmission256
- Section 8 - Maintenance Intervals and Specifications257
Lubrication and Maintenance Intervals257
- Maintenance Intervals257
Lubrication and Fluids Charts266
- Components Requiring Lubrication267
- Components Requiring Fluid Check and Fill268
Unit Refill Capacities269
- Cooling System Refill Capacities269
- Diesel Exhaust Fluid Tank269
- Crankcase and Oil Filters269
- Hydraulic Clutch System269
- Power Steering Systems269
- Transmission270
- Rear Axle Unit Refill Capacities272
Lubricant and Sealer Specifications273
Torque Specifications278
- U-Bolt Nut Torque Chart278
- Disc Wheel Nut Torque Chart279
Fuse Charts279
- Typical Interior Fuse Panel Layout280
- Typical Luggage Compartment Fuse Panel Layout281
- Typical Under-Hood Power Distribution Module281
- (PDM) Fuse Panel Layout281
- Prostar + Series Light Information284
- Filter List285
- Section 9 - Customer Assistance287
International Truck Warranty Program287
Service Information287
Index289

Navistar ProStar+ - Page 3

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