Navistar International Truck 7300 7400 7500 7600 WORKSTAR Series Operator Manual

Description

Navistar International Truck 7300 7400 7500 7600 WORKSTAR Series Operator Manual – PDF DOWNLOAD

FILE DETAILS:

Navistar International Truck 7300 7400 7500 7600 WORKSTAR Series Operator Manual – PDF DOWNLOAD

Language :English
Pages :258
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

DESCRIPTION:

Navistar International Truck 7300 7400 7500 7600 WORKSTAR Series Operator Manual – PDF DOWNLOAD

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.

Preface

SECTION 1 — FOREWORD

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.

TABLE OF CONTENTS:

Navistar International Truck 7300 7400 7500 7600 WORKSTAR Series Operator Manual – PDF DOWNLOAD

Table of Contents
Section 1 – Foreword
Preface 1
Cautions and Warnings 1
Assistance Guide 1
Component Code Numbers 2
Line Set Ticket 2
Vehicle Storage Instructions 2
Storage Duration – One Month or Less 2
Storage Duration – Over One Month 3
Storage Facilities 4
Exterior Noise Emissions 4
Tampering with Noise Control System Prohibited 4
Emission Control Systems 5
Maintenance Record – Noise Control 5
Reporting Safety Defects 5
US Registered Vehicles 5
Canadian Registered Vehicles 5
Safety Recalls and Authorized Field Changes 5
Customer Security Guide for International Trucks 6
Optional Diamond Logic® Electronic Application Solutions 8
Section 2 – Model Description
Introduction 9
Available Models 9
Available Cabs 11
Standard Cab 11
Extended Cab 11
Crew Cab 11
Vehicle Identification 12
Vehicle Identification Number (VIN) 12
Feature Codes 12
Engine Serial Number 12
Line Set Ticket 12
Exterior Components 13
Cab Entry and Exit 14
Tilt Hood 14
Raising the Hood 14
Lowering the Hood 14
Section 3 – Inspection Guide
Introduction 15
General Information 15
Vehicle Inspection 16
Preparation 16
Exterior Lights Check 16
Left Side Cab Area 17
Left Engine Compartment 18
Left Front of Vehicle 19
Front of Vehicle 22
Right Front of Vehicle 23
Right Engine Compartment 25
Right Side of Cab 26
Right Side Under Vehicle 27
Right Rear of Vehicle 28
Rear of Vehicle 30
Left Rear of Vehicle 31
Fifth Wheel and Coupling Area 33
Cab Interior Inspection 34
Section 4 – Controls/Features
Introduction 37
Table of Contents
Electrical 37
Electrical System 37
Dash Components 38
Overhead Console 38
Main Instrument/Control Panel 39
Instrument Panel Gauge Cluster 39
Warning Indicators 41
Gauges 43
Instrument Panel Gauge Cluster Alarms 45
Direct Drive Warning Indicators 47
Integral Digital Display 47
Switches 49
Headlights 49
Daytime Running Lights (DRL) 49
Lights on with Wipers 49
Park Lights 49
Marker Interrupt 50
Panel Lighting 50
Dome Lighting 50
Courtesy Lights 50
Optional Instrument panel gauge cluster Compass
Calibration Procedure 52
Compass Declination Zone Set Procedure 52
Compass Directional Calibration Procedure 55
Integral Digital Display Detailed Information 56
Steering Wheel Controls 69
Cruise Control 69
Basic Functions of Steering Wheel Controls 70
Operational Procedures 70
Throttle 70
Stationary Variable Speed Control (12VXT) 71
Stationary Pre-Set Speed Control (12VXU) 71
Mobile Variable Speed Control (12VXV) 71
Steering Column and Switches 72
Center Dash Panel/Wing Panel 74
Switches 75
Auxiliary Gauge/Switch Package (AGSP) (Optional) 78
Panel Component Arrangements (Optional) 78
Climate Control 80
Air Conditioning 82
Dehumidification 83
Door and Window Controls 83
Door Lock/Unlock 83
Cab Doors and Locks 83
Remote Keyless Entry Operation (Optional) 84
Door Opening/Unlock 85
Lock/Unlock from Interior 85
Automatic Door Lock Function 86
Windows 86
Manual Operation 86
Power Operation 86
Window Lockout Function 86
Mirror Controls 86
Vent Window 87
Driver Reward 87
Section 5 – Operation
Operation Safety 89
Cab Controls 90
Seat Belts 91
General 91
Operation 92
Care of Seat Belts 93
Table of Contents
Seats 93
Extended Cab Bunk (Optional) 93
Starting Procedures 94
Engine Starting 94
After the Engine Starts 95
Engine ShutDown 95
Shut-Down Warning Indicator Or Beeper 95
Engine Idle Shutdown Timer (Optional) 96
System Operation 96
Theft Deterrent System (Optional) 96
Theft Deterrent Code Entry Procedures 97
Emergency Starting Using Jumper Cables 100
Cold Weather 100
Cold Weather Starting 101
Cold Weather Operation 101
Winter/Engine Intake Operation 101
Engine Idling 101
Winter Front Usage 102
Hot Weather Operation 102
Starting A Turbocharged Vehicle On A Grade 102
Proper Starting Procedure 102
Operating Instructions 103
Steering 103
Tilt Steering Column 103
Adjustable Tilt/Telescoping Steering Column 104
General 104
Electrical 105
Electrical System 105
Alternator 106
Ammeter 106
Battery 106
Battery Disconnect Switch 107
Circuit Breakers, Fuses, and Fusible Links 107
Engine 108
Charge Air Cooler 108
Engine Brake, Retarder (Optional) 108
Engine Brake System Operation 109
Operational Modes 109
MaxxForce® 11 and 13 Engine Brake With Eaton
AutoShift®/UltraShift® Transmissions Special
Driver Instructions 109
Automatic Transmission Operation 110
ABS Operation 110
MaxxForce® Engine Features 110
Certified Clean Idle 111
Self Diagnostics 111
Engine Warning/Protection System (EWPS) 111
Optional Coolant Warning Level System – 3 Way
(08WWJ) 112
Optional Engine Protection System – 3 Way (08WPP) 112
Air Compressor Cycling 112
Cooling System 113
Antifreeze 114
Engine Oil 114
Engine Performance Problems 115
Fuel 115
Ultra Low Sulfur Diesel Fuel Requirements 115
Unacceptable Fuel Blends 115
Hazards of Diesel Fuel/Gasoline Blends 115
Additional Unsafe Practices 115
Fuel and Lubricant Additives 116
Fueling Procedures 116
Fueling Precautions 116
Reserve Fuel 116
Table of Contents
Exhaust Diesel Particulate Filter Regeneration 117
Parked Regeneration Procedure 119
Regeneration Inhibit Switch 119
Two-Position Regeneration Inhibit Switch 120
Three-Position Regeneration Inhibit Switch 120
Transmission 120
Manual Transmissions 120
Engaging the Clutch 120
Clutch Brake (Vehicles with Nonsynchronized
Transmission) – Vehicle Not Moving 121
Double Clutch Procedures, Nonsynchronized 121
Clutch Precautions 122
Shifting with Synchronized Transmission 122
Shifting with Nonsynchronized Transmission 122
Operation of the Eaton AutoShift® Transmission
and Shifter 122
Eaton UltraShift® Transmissions (Optional) 123
Automatic Transmissions 123
Allison Transmissions 123
Allison Transmission with “P” – (Park) Park Pawl
Mechanism or “PB” – Parking Brake Position 123
Parking The Vehicle 124
Preparing to Drive the Vehicle 125
Manual Parking Brake 125
Air Parking Brake or Power Parking Brake 125
Operation of the Allison Generation IV Gearshift
Controls 125
Allison Generation IV T-Bar Gearshift Control 126
Torque Lock 126
Operation of the Allison Generation IV Push-button
Shift Selector 127
Operation of the Column-Mounted Shifter 128
Main Transmission Controls 128
Backup Alarm 129
Auto Neutral 129
Power Take Off Control 131
Automatic Transmission Operating Temperature 131
Rear Drive Axles 132
Locking Differentials 132
Tandem Axle Power Divider Lock (PDL) Control 132
Driver-Controlled Differential Lock 133
Controlled Traction Differential 134
Locking Differential (Optional) 134
Two Speed Rear Axle 135
Axle Shift Only 135
Split Shifting 136
Axles and Suspensions 136
Gross Weight (Axle – Vehicle) 136
Axle Operating Temperature 136
Front Axle (4X4, 6X6) 136
Transfer Case 137
Operation 137
International® Ride Optimized Suspension (IROS)
(Optional) 139
Air Suspension Dump (ASD) Switch (Optional) 139
Air Suspension System Faults 140
Axle and Suspension Conversions 140
Lift Axle Options 140
Lift Axle Locations 141
Lift Axle Types 141
Lift Axle Controls 142
Lift Axle System Operation 145
Brakes 147
Downhill Operation 147
Table of Contents
Air Brakes 148
Air Gauge, Low Air Pressure Beeper and Warning
Indicator 149
Brake Application 149
Parking Brake 149
Parking Brake Reset 150
Reservoir Moisture Draining 151
Air Dryer 151
Trailer Brake Hand Control 151
Trailer Air Supply and Parking Brake Modular Controls 152
Parking Brake Indicator 153
Parking Brake Alarm 153
Antilock Brake System (ABS) 153
ABS Operation 154
ABS Self-Check 154
Antilock Driving Tips 155
Air Brake Bendix® ABS-6 155
Core ABS Functions 155
Traction Control (If Equipped) 156
ATC System Check 156
ATC OFF ROAD or MUD/SNOW Switch 156
Stability Control Systems – Bendix® ESP 157
Bobtail Proportioning System 158
Towing Instructions 158
Towing Vehicle with Front Wheels Suspended 159
Towing Vehicles with Driver Controlled Differential
Lock 160
Removing Axle Shafts Before Towing 160
Installing Axle Shafts 160
Towing Vehicle with Rear Wheels Suspended 161
Tractor-Trailer Connections 161
Connecting/Disconnecting a Trailer to a Vehicle with
Air Suspension 162
Fifth Wheel Operation 162
Fifth Wheel Slide Switch (Optional) 162
Hook-Up 163
Un-Hook 163
Section 6 – Maintenance Instructions
Introduction 165
Maintenance Guidelines 165
Supporting Your Vehicle for Service 167
Chassis Lubrication 167
Air Conditioning Service Checks 168
HVAC Filters 168
Side Access HVAC Filter 168
Front Access HVAC Filter 169
Recirculation Filters 169
Axles 170
Front Axle 170
Inspection and Lubrication 170
Normal Maintenance 170
Alignment 171
Front Drive Axle and Transfer Case (Optional) 171
Inspection and Lubrication 171
Rear Axle – Inspection and Lubrication 171
Lift Axle System 171
Brakes 172
General Information 172
Air Brakes 173
Inspection and Adjustment 173
Air Dryer 17
Table of Contents
General Information 174
Desiccant Filter 175
Purge Valve 175
Heater 175
Air Reservoir/Tanks Moisture Draining 175
ABS Connections and Sensors 176
Cab 176
Care of Vehicle 176
Washing and Waxing 176
Bright Metal Care 176
Upholstery Care 176
Exposed Rubber and Unpainted Plastic Parts 176
Clutch 177
Pedal Free-Travel 177
Electrical 177
Batteries 177
Battery Cables 178
Electrical Charging and Starting System Test 178
Terminal Inspection-Cleaning-Corrosion Protection 178
Accessory Feed Connections 179
Fuses and Relays 179
Engine 179
General 179
Engine fluids and contaminated material 180
Scheduled Maintenance 180
Air Induction System 180
Air Restriction Gauge 181
Air Cleaner Element Service 182
Troubleshooting 184
Charge Air Cooler And Radiator Core Inspection
And Cleaning 185
Inspection and Cleaning 185
Cooling System 185
Coolant Level 185
Filling Instructions 186
Filling Instructions (MaxxForce® 11 and 13 Engines) 187
Coolant and Optional Coolant Filter 188
AntiFreeze 189
Fan Clutch 189
Fuel System 189
Fuel Tank Draining and Cleaning 189
Frame 190
Tow Hooks, Tow Pins, and Pintle Hooks 190
Noise Emissions – Exterior 190
Instructions for Proper Maintenance 190
Air Intake System 190
Body 190
Cooling System 190
Engine Noise Shields/Blankets 191
Exhaust System 191
Diesel Particulate Filter (DPF) 191
Regeneration 191
Cleaning 191
Transmission 191
Neutral Start Switch 191
Manual/Automated Manual Transmissions 191
Automatic Transmissions 192
Drive Shafts 192
Suspension (Air and Steel Springs) 192
Steering 192
General Information 192
Tightening Steering Intermediate Shaft Joint Bolts 193
Lubrication Points 193
Power Steering 1
Table of Contents
Tires 194
Tire Warnings 194
Tire Maintenance 195
Checking Inflation 196
Underinflation 196
Inspection 196
Loads 197
Dual Tires Matching 197
Dual Tires Mixing 197
Rotation 197
Rotation Is Advisable 197
Tire Replacement 198
Wheel and Tire Balancing 198
Wear 198
Irregular Wear 199
Use of Tire Chains 199
Wheels 199
Wheel and Wheel Nut Maintenance and Installation 199
Wheel Nut Torque Maintenance 200
Hub-Piloted Wheel Installation Procedures 200
Section 7 – Maintenance Intervals And
Specifications
Lubrication and Maintenance Intervals 203
Maintenance Intervals 203
Lubrication and Fluids Charts 211
Components Requiring Lubrication 212
Components Requiring Fluid Check and Fill 213
Unit Refill Capacities 214
Front Drive Axles 214
Rear Axle Unit Refill Capacities 214
Cooling System Refill Capacities 216
Crankcase and Oil Filters 216
Power Steering Systems 216
Transfer Case 216
Transmission 217
Tire and Rim Combinations 218
Approved Tire and Rim Combinations 218
Lift Axle System 219
Torque Specifications 219
Disc Wheel Torque Chart 219
U-Bolt Nut Torque Chart 221
Spring U-Bolt Checks 223
Lift Axle Torque Charts 223
Fuse Charts 224
WorkStar® Series Light Information 225
Filter List 225
Section 8 – Customer Assistance
Service Information 227
International Truck Warranty Program 227
Section 9 – Index
Index 229

S.M 23/2/2025