¢> INTERNATIONAL Medium 1000 4000CALIFORNIA 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. Notice The information, specifications and illustrations in this manual are based on information that was current at the time of publication. Navistar International Transportation Corp. reserves the right to make changes or improvements without notification, or applying these changes or improvements to vehicles previously manufactured. Make sure your use of this completed vehicle conforms with all federal, state and local requirements and regulations imposed on owners and operators. Sexvice PemticarionsIMPORTANT IIS IMPORTANT THAT VEHICLE IDENTIFICATION NUMBER (VIN), COMPONENT CODE AND SERIAL NUMBERS BE RECORDED. THESE NUMBERS ARE REQUIRED TO OBTAIN INFORMATION PERTINENT TO THIS VEHICLE. \VENICLE IDENTIFICATION NUMBER (VM) oD SERES US Supe elt a et ‘Hn, S00, M00: Sage on plate ‘ere post ‘COMPONENT IDENTIFICATION NUMBERS (Geepags A). Component sv numbers pen he compares FRONT AXLE copes, senaue REAR ANE TANSFER CASE "TRANSMISSION a | Se ENGINE SERIAL NUMBER LOCATION CATERPILLAR, Spel nite seo Eas spent ee pc Sot DDETROFT DIESEL: Sump on pte, side flock INTERNATIONALS: Sung opal edo SALES REGION NoRTHEAST ‘Nua erator Taapoaton Comp {000 Aatun Way Sue 01 Mow Lar Ne ey O80 eo 7m2. 006 Sourmeast avs tan Tampon Cop Seen Fea coat souriwest £080 Seca Deve SLOW Datu eum 20h PRINTED IN THE UNITED STATES OF AMERICA copy ©2000 Nout emabonalTarepoason CoD. owest avatar tear Transporation Cop 19015 Meyers Ra (coe 0 WesTERN ‘vata eatin Tasgoraon Cap 268 atop Die Sate 10k PO. Boxstos Sin Raen Califo 94585 (Sioa ccaNaoa evita ern Caporin, Cad Box araton, Omar L385 (on sa 700 (CUSTOMER ASSISTANCE CENTERCONTENTS SECTION TITLE SECTION TAB LOCATOR| | VEHICLE INSPECTION GUIDE ‘To be sure your vehicle is ready to operate, conduct a pre-trip inspection atthe beginning of each work period. Follow the steps below and check them off to assure a proper vehicle inspection procedure. The pages in this section may be reproduced locally and used on a regular basis. LEngine Compartment — with the engine stopped, check the following: (OF Level — Use dip stick to verify that the ol level is between the full and refill mark Coolant Level — Look through the plastic reservoir and make sure the Aud level is within the minimum and maximum Muid level range as marked on the reservot. Do Not Remove Radiator Cap Until Radiator Has Cooled. See Cooling System in Section B. Power Steering Fluid — Use the dip sick to verify hat the Muid level is between the fll and refill mark Water Pump — With engine off, touch or press belt to test that itis snug. Check for fray, cracks, loose fibers, or visible signs of wear. IF it defect more than 1/2 1 3/4 ofan inch, slippage is probably excessive. Alternator — Check belts the same as for Water Pump. [Air Compressor — Check belts (if so equipped) the same as for Water Pump. Refrigerant Compressor — Check belts (if 90 equipped) the same as for Water Pump. ‘Any Leaks — Check for signs of fuid puddles, or dripping fuids onthe ground under the engine, or the underside of the engine.VEHICLE INSPECTION GUIDE 2LEngine Start Satety/Emergency Equipment — Prior to entering cab, verify that vehicle is equipped with electrical fuses (if used); 3 red reflective triangles; and a properly charged and rated fire extinguisher, and wheel chocks. When entering cab, verify that grab ‘handles and steps are tight and clean; use extreme caution and maintain 3 point contact at all times. (Cluteh/Gearshift — Depress clutch (if manual transmission) and verify transmission isin neutral before turning on staner; Keep depressed until engine reaches idling sped. (0 Pressure Builds — Check to see that oil pressure is building to normal. Engine il temperature gauge should begin 2 ‘gradual rise to normal operating range. [Air Buzzer Sounds — If the air pressure is low, the low air pressure waring should sound immediately after the engine starts but before the air compressor has built up pressure. Let the air pressure build to governed cut-out pressure, which should coeur between 100-125 psi. The low air pressure waming should stop when the air pressure gets to 60 psi or mee. ‘Accelerator — Depress accelerator pedal and verify that it operates smoothly without any binding or imegular feel. Remove foot from accelerator and make sure engine returns to idle immediatly. ‘Ammeter/Volimeter — Check the gauge 10 see ifthe altemator is charging. Steering Play — Check for excessive looseness in the steering linkages. The steering wheel should have less than 10 degrees fee play (approximately 2 inches at rim of 20 inch steering wheel. Hlorn(#) — Check to see that hor works. Mirrors, Windshield — Check mimors for proper adjusunent, check for cracks or loose fitings. Make sure the mis are clean, Check the windshield for cracks, dit, illegal stickers or other obstuctions to view. Wipers — Check the following: worn rubber on blades, blades securely mounted on wiper arms, and that wipers work. Lighting Indicators — Check to see that indicators laminate when comesponding lights are tumed on. HeaterfDetroster — Check to be sure hesteddefroter is working,VEHICLE INSPECTION GUIDE “Hydraulic Brake Check — Pump the brake pedal thee times. Then apply firm pressure to the pedal and hold for five sec- ‘nds. The pedal should not move. If it does, there may be a leak or other problem. Do not dive vehicle until problem is fixed. Parking Brake — Check that parking brake wil hold vehicle by gently tying to pull forward with parking brake on. ‘Air Brake Check — Check the air brakes inthe following manner. 1. Chock wheels if necessary. Push in parking brake and Tractor Protection Valve (TPV) knobs. 2. Check the air compressor or governor cut-out pressure (approximately 120 PSH, 3. Shut off engine and TURN KEY BACK ON. 4 ‘Without brake pedal applied, note air pressure drop for one minut, It should be less than 2 PSI for single vehicles, 3 PSI foc combinations. Depress and hold brake pedal and make sure there is no more than a 4 PSI per minute leak. 6. Step on and off brake pedal and check for waming light and buzzer to come on at about 60 PSI. 7. Step on and off brake pedal and check to make sure the tractor protection and parking brake knobs pop out between 20 to 45 psi (138 to 310 kPa), 4. Restart engine, shift into alow gear, and gently pull against brakes to make sue they will hol 3.Frront of Vehicle Lights — Check to sce that all lights illuminate and are clean. Make sure headlighis function on both high and low beams. ‘Check 10 see that reflectors are clean and unbroken and of proper color (red on ear, amber elsewhere). Make sue that run- ‘ing lights are also clean and unbroken. Rear runing lights must be checked separately fom signal, flasher and brake lights Steering Gear — Look for: missing of loose fasteners, power steering Mui leaks, and damage to power steering hoses Steering Linkage — Check to see that connecting Tink, arms, rods are not wor or cracked; joints, sockets and boot seals are not wom oF lose; that there are no loose oF missing cotter Keys, nus of botVEHICLE INSPECTION GUIDE AF ront Suspension —— Spring — Look for missing, broken or shifted leaves, or ones that rein contactor neatly in contact with is, rim, brake ‘drum, frame or body. —— Spring Mount — Chec\/nspect spring hanger, bolts, bushings, axle mounting U-bolts and nuts for: cracks, breaks, wear, damage, tightness, and correct component quantity —— _ Shock Absorber — Check for cracks, leaks, and missing or broken mounting bolts or bushings, 5.Front Broke —— Hoses — Check for cracked, worn or frayed hoses; and for secure couplings. —— Chamber — Check to see that the brake chambers are not cracked or dented and that they ae securely mounted. —— _ Stack Adjuster — Check for broken, loose or missing pars; angle between push rod and adjuster arm should be approxi- mately 90 degrees when brakes are applied. When pulled by hand, push rod should not move more than approximately 1 inch, —— _Drum — Check to see there are no cracks, dents or holes; no loose or missing bolts. Check to see that brake linings (where visible) are not worn dangerously thin oF contaminated by lubricant. 6.Front Wheel —— _Trres — Check trad depth and tre inflation and note if tread is evenly worn, Look for cuts, of other damage tothe tread walls. See If valve caps and stem are missing broken or damaged, Make sure retread is not separating from tie. Reteads are ot allowed on font axles of school buses, nor are they recommended on front axles of trucks. NOTE: Minimum tread depth {is 432 inch on front ties, and 232 inch on other ties, Rims — Check for damaged or bent sims. Rims should not have welding repairs and no rst wails tha indicate it is loose on the wheel.VEHICLE INSPECTION GUIDE [Lug Nuts — Check to see that all lug aus are present and not loose (lok for rust wails around nus), There should be no cracks radiating from lug bot oles nor distonion ofthe bolt holes. "Hub OU! Seal — Check whee! hub oil seal for leaks, and, i sight glass is present, that ol level is adequate (O11 Lubricated Front Whee! Bearings — If hubcap has a transparent window, check lube for proper level. If hubcap does ‘ot have a transparent window, remove rubber fill plug and check for prope level 'TDrivertPuel Area Door, Mirror — Check for proper adjustment. Check for cracks of locke fitings. Make sure visibility i not impaired due to diny mirrors. Fuel Tank — Check to see that tank is secure and that caps are secure, Make sure there is no damage to the tank [Leaks — Check for any fuel leaks from tanks. B.Under Vehicle — Rear of Tractor Drive Shaft — Check to see that shaft i not bent or cracked. Shaft couplings should be socue Exhaust System — Check to soe that outside visible parts are securely mounted. Check to see there are no cracks, holes or severe dents, Frame — Check for cracks or bends in longitudinal frame members. Make sure there are no Toose, cracked, bent, broken or missing cross members.VEHICLE INSPECTION GUIDE Polit dt dt | 9.Tractor Only ‘AirfBlectric Lines — Check to see that air hoses are not cut, cracked, chafed or wor (stel braid should not show dough) Listen for audible air leaks. Make sure air and electrical lines are not tangled, crimped or pinched of being dragged against tmactor parts. Electrical line insulation should not be eut, cracked, chafed or wom. None of the ai or electrical lines should be spliced or taped. Deck Plate — Check to see if deck plate is clean, securely bolted to tractor frame, and clear of lose objects. Lights, Reflectors — Check to see that reflectors are clean. Make sure none are missing or broken. Check for proper color red on rear, amber elsewhere. Rear runing lights shouldbe clean, not broken, and the proper color, Rear running lights ‘must be checked separaely from signal flasher and brake lights. ‘Coupling System Mounting Bolts — Look for loose or missing mounting brackets, clamps, bolts or nuts. Both fith whee! and slide mounting should be solidly atached. Platform — Check for cracks or breaks inthe platform structure. Safety Latch — Check to seo if sfey latch is engaged. Release Arm — Check to see if release arm is in the engaged position and that any sfery latch is in plac. Kingpin/Apron — Check to see that kingpin is not bent. Make sure that apron lies flat on fifth wheel skid plate, and that visible part of apron is not bent, cracked or broken Sliding 6th Wheel Locking Pins — Check for loose o missing pins inthe slide mechanism of sliding fith wheels. Ifa powered, check for sir leaks, Make sure that fifth wheel isnot so far forward that tractor frame will strike landing gear during tus,VEHICLE INSPECTION GUIDE 1O.Trractor Only — Springs ‘Springs — Check for broken leaves, leaves that have shifted and are in, or nearly in, contact with the res, rim, brake drum, frame or body, Check for missing or broken leaves inthe leaf spring. For coll spring, check for broken or distoned sping. Spring Mounts — Check for cracked or broken spring hangers; broken, missing or loose bolts; missing or damaged bushings: broken, locke oF missing axle mounting pars. ‘Torsion, Shocks — Check to see that torsion bar assembly or torque arm is not cracked, broken or missing. Check shock sbsorber for cracks or leaks. There should be no missing or broken mounting bolts or worm bushings. L1.Rear Wheels ‘Tires — Check tread depth and tire inflation and note if wead is evenly worn. Look for cus, or other damage to the tread walls. See if valve caps and stem are missing, broken or damaged. Make sure revead is not separating from tie. Reteads a ‘ot allowed on front axles of school buses, or are they recommended oa front axles of mucks. NOTE: Minimum tead depth {432 inch 0a font tires, and 2/32 inch on other tres. Spacers — Check to see that dual wheels are evenly separated, and that tres are not touching one another Lights, Reflectors — Check to see that reflectors are clean. Make sure none are missing or broken. Check for proper color ~ red on reer, amber elsewhere. Reat running lights should be clean, not broken and proper color. Rear running Hights must be checked separately from signal, flasher and brake lights Rims — Check for damaged or beat rims, Rims should not have welding repairs and no rust wails that indicate itis loose on the wheel [Lug Nuts — Check to see that all lug nuts ae present and not lose (Jook for rust tls around nuts). Thre should be m0 ‘racks radiating from lug bolt holes nor distortion ofthe bolt holes.VEHICLE INSPECTION GUIDE 12.Rear of Vehicle —— _SignatBrake Lights — Check to see that both brake lighs come on when brakes are applid. Make sue each signal light ashes; and check that four-way flashers work. 13.Traiter —— _Tyou are operating a tractor with taller attached, an inspection of the trallr similar to that of the tractor should be one. Such an inspection should fellow traller manufacturer recommendations and should inclade at a minimum: gen ‘eral condition, landing gear, doors, sides, light, reflectors, suspension, brakes, tres and wheels.Section A: To The Owner CAUTIONS AND WARNINGS ASSISTANCE GUIDE COMPONENT CODE NUMBERS . LINE SET TICKET . VEHICLE STORAGE INSTRUCTIONS . EXTERIOR NOISE EMISSIONS. TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED EMISSION CONTROL SYSTEMS .. ‘SAFETY CHECKS AND PRECAUTIONS Accelerator ‘Axte - Front. t 1 1 2 2 3 3 3 4 4 4 4 8 5 5 6 6 8 7 7 7 7 7 DDDDDDDDDDDDDEDDD>> > > >> >>> >>‘Section A: To The Owner REPORTING SAFETY DEFECTS US. Registered Vehicies Canadian Registered Vehicles Safety Recalls and Authorized Field Changes NAVISTAR CUSTOMER SECURITY GUIDE ‘A-10 A-10 SA=10 + A=10 aanTo The Owner CAUTIONS AND WARNINGS ‘Throughout this manual you will find Cautions and Warnings: CAUTION Cautions will advise you of the proper care to be taken to avoid damage to your vehicle or property. Ay warning ‘Warnings will advise you of the proper care to be taken, not only to avoid damage to your vehicle or property, but to help prevent situations ‘and occurrences which could result in personal injury or death. ‘Study this manual carefully. Do not operate your vehicle until you are completely familiar withthe cootents ofthis man- tal, Always retain this manual in your vehicle for reference. If you sell the vehicle, make sure the manual goes with it ASSISTANCE GUIDE ‘When parts are required, always provide the unit code number, vehicle model and vehicle serial number. Request the salesperson to asist you in obtaining this information upon delivery For information not given in this manual, or if you require services of trained service personnel, we urge you to contact 1 nearby Interational® dealer. [Navistar believes that every customer is ented to the best service, both from the product itself and from the fmm who sells and services that product. If, for any reason, you do not feel you are receiving these services in connection with the operation of your vehicle or Ant‘Section A: To The Owner the sales transaction, you should retum to your selling dealer so that these maters can be corrected 1 your satisfaction. I the matter is oot resolved at that time, itis suggested thatthe following steps be taken: Contact a Member of Management at the Dealer. Discuss the details ofthe difficulty. In most instances any problem can be resolved to your satisfaction by the owner or ‘manager in charge Contact Closest Navistar International Sales Region Office or the Customer Relations Manager. ‘Addresses of Region Sales Offices and the Customer Relations Manager are found on the first page of this manual. ‘Should you desire to contact any ofthese offices, iti important to inclode the fllowing information in your communi- cation. 1. Name under which new vehicle was purchased, adds and telephone number of purchaser 2 Vehicle model, year, vehicle identification number, component code an serial numbers 3. Vehicle delivery date and present mileage 4, Location where purchased 5. Details of the problem ‘We sincerely appreciate your purchase of an Intemational® vehicle. Remember, you ae entitled to and shall recsive every consideration and complete service involving your vehicle. Thank you for favoring us with your business! COMPONENT CODE NUMBERS Code numbers are the basis for identifying the components used oa Tntematonal® trucks. They ate used by sales person- rel to ofder the tuck, by manufacturing to build that ruck and by pars personnel to service the truck. Many items in this manual ae idenfed by codes. Code numbers are a combination of numbers andor alphabetical letters. These codes are listed on the Vehicle Line Set- ting Ticket which is sometimes known asthe vehicle specification card or code sheet. LINE SET TICKET Each vehicle is provided with a Line Set Ticket (code sheet) which lists idenieation code numbers of component units ‘sed to build the vehicle, (One copy of the Tne set ticket is included in the lierature provided with the vehicle. When replacement parts are required, take this copy with you 1 positively identify vehicle components to be sure of geting the comect pas.Section A: To The Owner ‘Be Sure To Retur Line Set Ticket To Vehicle Afler Obtaining Pans. VEHICLE STORAGE INSTRUCTIONS ‘When a vehicle is not used for an extended period of time, certain precautions must be taken to prevent deterioration of some components. Contact your dealer for avice on vehicle storage, as well as proper procedures to follow when you returm the Vehicle to service EXTERIOR NOISE EMISSIONS “Many operators and owners of the type of vehicles described herein are subject to Federal Motor Carier Safety Regu- lations and Noise Emission Requirements. All owners and operators ae uged to obtain a copy and comply with these regulations. Copies of these regulations can be purchased from: Superintendent of Documents US. Goverament Printing Office ‘Washington, D.C, 20402 [Navistar Intemational Transportation Corp. warrants to the first person who purchases this vehicle for purposes otber chan resale and to each subsequent purchaser that this vehicle, as manufactured by Navistar, was designed, built and equipped to conform atthe time it left Navisar's contol with all applicable US. Enviroamental Protection Agency Noise Cootrol Regulations ‘This warramy covers this vehicle as designed, built and equipped ty Navistar, and is not limited to any particular part, component of system of the vehicle manufactured by Navistar. Defects in design, assembly or in any pat, component or system of the vehicle as manufactured by Navistar, which at the time it lft Navisa’s contol, cause noise emissions 10 exceed Federal standards are covered by this warranty forthe life ofthe vehicle. TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED Federal law prohibits the following acts or the causing thereof: (1) The removal or rendering inoperative by any person ‘ther than for purposes of maintenance, repair, o replacement, of any device or element of design incorporated into any ‘ew vehicle forthe purpose of noise control prior tn its sale or delivery to the ultimate purchaser or while iti in use, oF (2) The use of the vehicle ater such device or element of design has been removed or rendered inoperative by any person, Among those acts presumed to constitute tampering are the acts listed as follows: A. Air Intake System: Removal of air cleaner, intake silencer of piping. B. Acoustical Shielding (Body): Removal of wheel well splash shields, cab shields or acoustical (undethood) insulation. C. Cooling System: 1, Removal or rendering inoperative the fan clutch, 2. a3Section A: To The Owner Removal of fan shrouds. D. Engine and Driveline System: 1. Removal or rendering engine speed governor inoperative 50 1s to allow engine speed to exceed manufacturer specifications. 2. Removal of engine block shield, oil sump shield or ‘transmission enclosures, E. Exhaust System: Removal or rendering inoperative exhaust system components including muf- ‘er, resonator or tilpipe. EMISSION CONTROL SYSTEMS NOTE: Federal and California Emision sytem warranties are found in your Engine Operator's Manual, SAFETY CHECKS AND PRECAUTIONS Every effort has been made to assure that your new vehicle has been engineered and manufactured to provide continued trouble-free service. Materials selected to manufacture the many pans which make up the vehicle undergo exhaustive test- ing and research to make certain that acceptable, safe service life is realized, ‘Ther is, however, an area in which the vehicle owner plays an important part and which determines in large measure the extent of continued, trouble-free service to be realized from the owes iavestment in the vehicle, This has to do with the owner's responsibility in seeing thatthe vehicle receives proper care by following the periodic lubricating proce- dares and arranging the regular inspection interval to assure that pars that normally wear out are replaced or repaired. In addition, ask your Intemational® dealer to make an inspection of your vehicle atleast once a year AA general vehicle check by an experienced technician will give you assurance that your vehicle is sill in a safe condl- ‘ion. ‘The hbrication intervals present a good opportunity to inspect the vehicle, and we suggest the following points be checked at these intervals. NOTE: Refer to the Vehicle Inspection Guide atthe front of this manual for 2 recommended dally inspection rutin. ACCELERATOR (Check to assure that accelerator system is smooth, does not bind, and returns engine to idle properly. AXLE — FRONT ‘Mainaining proper front axle alignment specifications is of great importance and should only be performed by a quali fied mechanic. Check to assure that axle mounting U-bolt aus, attaching or mounting bolts and outs are securely tight ened, Regularly check front axle for damaged, binding or worm pars, and adequate lubrication.‘Section A: To The Owner ‘AXLE — REAR (Check to assure that axle mounting U-bolt nuts, attaching oF mounting bolts and nuts are securely tightened. Regularly check rear ale for damaged, binding or wor pat. BRAKE SYSTEM Brake Lining Adjustment - Always maintain proper lining adjustment [Brake Lining Inspection - Inspect brake linings for wear. Refer to MAINTENANCE, BRAKES, Air ot Hydraulic for inspection interval Parking Brake Adjustment - Always maintain proper parking brake lever adjustment. Where vehicles are used in severe service or in considerable stop-and-go service, more frequent inspections should be scheduled. (On a periodic basis or at least once a year inspect entre brake system for: 1. Brake contols (Refer to RUBBER PARTS, inthis scion) 2. Condition of drums, bake chambers, lack adjusters, dies and calipers. 3. Air Teas, hydraulic Mud leaks, 4. Hose or pipe damage. 5, Operation of service and parking brakes. Detrosters - Operate defor contos to deemine i suicient iris being directed exist winds Door Latches ~ Check laches for postive closing, latching and locking Glass ~ Check for cracked, broken, scraiched or diny gas nln rearview mors. ‘Mirrors ~ Check to be certain all mirrors are clean, properly adjusted and in good condition. Seats Be sre manly opeaed seals re fmly engaged 1 avoid forward or rearward movement whe staring oF stopping. Seat Belts ~ Check the entire seat bel asembly for wear and proper operon. Make cerain anchor mountings ae sake Steps and Grabhandles - Check to make sre all spe and grabandes ae tight and undamagedSection A: To The Owner Upper Sleeper Bunks ~ Check lach for positive latching and locking In addition to the above, check condition of cab mounting brackets, sheet metal, rubber mountings and safety prop when euipped CLUTCH Maintain specified cluch pedal adjustment. Regularly inspect clutch control linkage for tighmess. Refer to MAINTE: NANCE, CLUTCH for more detail COOLING Ay _WARNING Exercise great caution when working on vehicles equipped with an auto- matic fan clutch. The fan starts in motion only after engine coolant reaches a predetermined temperature or the refrigerant pressure (if ‘equipped with air conditioning) reaches a predetermined setting. ‘The fan will start in motion at these points with no advance waming. ‘Never reach or permit objects to protrude into the fan blade radius while the engine is running, as it could result in vehicle damage, personal injury or death. ELECTRICAL Horn - Occasionally blow the hom (ar or electric) to check for satisfactory operation, Instruments - Check operation ofall instruments and gauges. Lights - Be sure lights, regardless of type or where they are located, wil iuminate at all times. Wiring - Replace loose, weathered, cracked or broken wires to safeguard against breakdown on the road or possible shoas. Balteries - Check charge level. Bateies should be kept at full chargeSection A: To The Owner EXHAUST SYSTEM Inspect heat shields for proper installation or location. Maintain exhaust sytem (mufflers, pipes, tail pipes, joints) img ‘ity to assure no exhaust fumes can enter cab ara. Ay_Warning Maintain adequate clearance between all parts of the exhaust system and all hoses, wires and lines for engine cooling, brake system, fuel system, power steering system and electrical system. Heat damage to hoses, Wires or lines may cause vehicle malfunction that could result in property ‘damage, personal injury or death. FRAME Because Internatonal® chassis ae manufactured with frame rails of either cold rolled steel or heat-reated steel, or alumi- ‘mum alloy, each must be handled in a specific manner w assure maximum service life, ‘Specific instructions ae published conceming proper repair of frame rails and can be obtained from your nearest Intema- tional® dealer. FUEL SYSTEM Froquenily check throttle linkage for proper operation. Inspect for leaks and general condition of fuel tanks, fuel lines, clips and routing. PROPELLER SHAFT [At the regular lubrication interval, check universal joins for wear Should propeller shaft vibrations occur, stop the vehi- le immedisiely io avoid possible hizardous consequences or damage 10 other components RUBBER PARTS Rubber pans ae subject to deterioration. Brake components should be considered for periodic replacement once each year based upon the severity and length of service. Usualy careful inspection by experienced mechanics will disclose the eed for ation,Section A: To The Owner ‘SPRINGS Maintain specified torque on spring U-bolt nus. Periodically check condition of spring leaves for evidence of fatigue, ending of breakage CAUTION Never apply grease to spring pads. STEERING Be alert to any change (fee) in steering when driving. This change or feel would include increased steering efforts, ‘unusual sounds when turing, excessive wheel play oF pulling to either side. (Check te rod and drag lnk end clamp bolts. They must be tight. Ask a service technician to examine the steering mech: anism, Minor adjustments could head off further problems. (Check power stering system for leaks or hose chafing. Repair at once. Maintain proper stering gear and power stering ‘pump lubricant levels. Regularly inspect all steering linkage, particularly for body or chasis clearance. ‘SUSPENSIONS (Check conttion of suspension mounting brackets or bushings. Suspension alignment must be maintained at all tmes Ay _WARNING Do not operate vehicle if any of the above conditions are evident. Loss of steering or suspension could result in property damage, personal Injury or death. TOW HOOKS Front and rear tow hooks should be inspected for damage or a loose mounting. Tis is of great importance, particularly on vehicles used in operations where the tow hooks are frequently required,Section A: To The Owner If vehicle is equipped with an automatic transmission, have a qualified techniclan occasionally check operation of transmission neutral start switch. I unit starts in gear, the vehicle may inadvertently move, which could result in property damage, personal injury or death. WHEELS ‘Check condition and maintain recommended toque on wheel and rim mounting bolts and nuts. Check condition of tres for abnormal wear pate, and proper inflation pressures. Cut or broken tire casing must be repaired Dy _Warning fa wheel must be changed, obtain expert tire service help. Mounting and demounting of tires should only be performed by qualified personnel using necessary safety procedures and equipment, otherwise the result ‘could be property damage, personal injury or death. Wheel bearings must be properly lubricated and adjusted at regular intervals.Section A: To The Owner REPORTING SAFETY DEFECTS A-10 U.S. REGISTERED VEHICLES If you believe that your vehicle has a defect which could cause a crash or could cause injury or death, you should immediately inform the National Highway Traffic Safety Adminisvation (NHTSA) in addition wo notifying Navistar Ine. ‘ational Transportation Corp. If NHTSA receives similar complaints, it may open an investigation, and if it finds that a safety defect exists in a group of vehicles, it may order a recall and remedy campaign. However, NHTSA cannot become involved in individual prob- Jems between you, your dealer, or Navistar Imemational Transportation Corp. ‘To contact NHTSA, you may ether call the Auto Safety Hotline toll fee at 1-800-424-9393 (or 366.0123 in Washington, DC. area) or write to: NHTSA, U.S. Department of Transportation, Washington, D.C. 20590. You can also obtain other information about motor vehicle safety from the Hodine CANADIAN REGISTERED VEHICLES If you believe that your vehicle has a defect which could cause a crash or could cause injury or death, you should immediately contact Navistar International Corporation Canada and then Transport Canad. ‘To contact Navistar Intemational Corporation Canada, you may either call 416-528-7700 o write to: Navistar Intemational Corporation Canada, 120 King Suet West, PO Box 2020, Hamilton, Ontario L8N 385. ‘To contact Transport Canada, write to: ‘Transport Canada, Motor Vehicle Defect Investigation, PO Box 8880, Ottawa, Ontario KIG 312, SAFETY RECALLS AND AUTHORIZED FIELD CHANGES ‘Safety Recalls and Authorized Field Changes are two campaigns that are used to notify owners of modifications that may involve their vehicle. If you receive such notification, PLEASE FOLLOW ALL INSTRUCTIONS PROVIDED IN ‘THE CUSTOMER LETTERIT your vehicle is part of & Safety Recall campaign, the recall service procedure rust be completed to assure safe operation of your vehicle. As a vehicle owner, you mist provide Navisar dealers with address corrections and changes to ensure that you receive all notifications. Please verify that your local dealer has your corect tures. Dealers will also have a record of any outstanding campaigns that affect your vehicle.Section A: To The Owner NAVISTAR CUSTOMER SECURITY GUIDE [Navistar has prepared this guide to help you protect your tuck/investment from theft. We realize the financial commit ‘ment you have made is significant, and that you depend on that vehicle to generate profits and a livelihood. While no system or device is 100% effective, our intention isto provide some tps that you of your divers can use 10 reduce the fikk of thet ‘+ Bich your Vehicle Identification Number on one of your side windows, Contact yout Intemational® dealer for information ‘+ Drop a business card with your name on it between the glass and door frame. This can aid in identifying the ‘ouck when it's recovered. ‘+ Keep a copy of the lineset ticket in a locaton other than your tuck for reporting purposes and a copy of the VAN. in your wallet. + Photograph the interior and exterior of your tuck from various angles and Keep these photographs in 2 safe now-tuck location, of send them to your insurance agent. ‘= Whenever posible, park your truck in well lit areas where it can be seen + Lock all doors when unatended. + Steering locks that slide into the stering shaft u-joint are easy to use and provide a very high level of afford- able theft protection, ‘+ High quality whoe! locks can help prevent tre and whee! thet ‘+ Trllers can be protected by using filth wheel and tile locks. Install hidden ignition cutof switch or fuel cutoff switch Report a theft as soon as i's discovered to the local police and to your insurance company. Post a driver has no cash sign on your door to discourage a robbery. Permanently mount your C:B. radio or remove it when you will be away from your truck. * Do not discuss where your rig is located when you are not on the road. + Do not share information about your specific destination, or te load you are hauling, + Exercise caution and good judgement when asked numerous questions by people you do not know concerning your business activites.‘Section A: To The Owner Ani ‘The following information block Figure 1 can assist you in reporting a theft when completely filled out. Put a copy of this Information in your wallet. Fig. 4. Information BlockBae | Section B: Operation PREFACE VEHICLE ENTRY AND EXIT ‘OCCUPANT RESTRAINT SYSTEM. ‘SEAT ADJUSTMENT . ‘Bench or Bucket Type Seat with Single Lever Adjustment ‘SUSPENSION TYPE SEATS SEAT BELTS . ‘Adjustable Lap and Shoulder (Three Point) Belts. Komfort-Clip Adjustment . Non-Retracting Adjustable Seat Belts for Center Passenger ~ Bench Seat. Care of Seat Belts . INSTRUMENT PANEL AND CONTROLS 1000/4000. Series Instrumentation . 1652 SC Series Instrumentation 4000 Series Control Panels AXLES . 7 ‘Axle Operating Temperature . Front Axle (4x4, 6x6) . Front Wheel Locking Hubs (4x4, 6x6) «.. ‘Two Speed Rear Axle ‘Tandem Axle Power Divider (Inte-Axie Differential) Rear Axles (With Locking or Limited Slip Diferentiale) ‘Axle and Suspension Conversions ...Contents: Section B Downhill Operation Alr Brakes | ‘lr Brake: rake System (ABS) . Hydraulic Brake: Antilock Brake System (ABS) . ‘Air Suspension (Connect and Disconnect Trailer) Hydraulic Brakes. Brake Burnishing (Driveline Type w/Orschein Lever). CAB... 7 Cargo Area Occupancy CLUTCH AND TRANSMISSION .. Cluteh Tranemiesion - Transter Caso. Power Take Off Control... Automatic Transmission Operating Temperature CRUISE CONTROL, . CCrulse Control Systems for International Engines Novistar International Electronically Controlled Engines . DOOR CONTROL AND LOCK .. To Lock/Unlock From Inside - To Lock/Unlock From Outside ‘To Open From Inside/Outside DOOR WINDOW REGULATOR ...... POWER WINDOWS (OPTIONAL) ELECTRICAL .. ‘Accessory Feed Connections Alternator. ‘Ammeter (Not Standard, Opiona BatteryELECTRICAL (CONT) Voltmeter Circuit Breakers, Fuses and Fusible Links Horn .....-- : as Hour Meter Lighting Switches . il Pressure Warning Light, High Water Temperate faring Light. Pyrometer Speedometer and Odometer. Low Fue! Waring Light .. ‘Tachometer . Data Link Driven instrument Cluster ~ 1000 rough ‘2000 - ‘Turn Signal Switch ‘Tratle Hazard Warning Light Switch - Glow Plug Wait Light (T 444E Diesel Engine) Warning Lights ... ‘Starting Switches . ENGINE ‘Operation of Engine in Fuel Rich Aimosphere Air Restriction Gauge . ‘Troubleshooting Diesel Engines...... Charge Alr Cooler - . Engine Performance Problems . Emergency Starting Using Jumper Cables « Operating Instructions .. : ‘Staring a Turbocharged Vehicle on a Grade ‘Shut-Down . ‘Shut-Down Warning Light or Buzzer . Parking Cooling SystemContents: Section B ENGINE (CONT) Engine Olt FUEL . eee Hazards of Diesel Fuel/Gasoline Blends. Fuel and Lubricant Additives ....... Fueling Precautions GROSS WEIGHT (AXLE - VEHICLE) HEATING, DEFROSTING, VENTILATION, AIR CONDITIONING - HOOD Tit Hood ‘SMOKING ‘STEERING .. [ADJUSTABLE STEERING COLUMN ‘TOWING INSTRUCTIONS. ‘Towing Vehicle with Front Wheels Suspended .. ‘Towing Vehicles with Driver Controlled Ditferentisi Lock. ‘Towing Vehicle with Rear Wheels Suspended .. ‘TRACTOR-TRAILER CONNECTIONS . Connect and Disconnect Traller with Air Suspension Fith Wheel Operation .. Silding Fit Wheel WINDSHIELD WIPER CONTROL. WINDSHIELD WASHERS .Operation PREFACE ‘Your vehicle has been en itis the owner's respons yeeted and manufactured so that it can provide economical and trouble-free service. However, to see that the vehicle receives proper care and maintenance. Making modifications to various pris, components and systems of your vehicle, such as brake and stern systems, adversely affect the quality and reliabiliy of your vehicle. Such modifications must be avoided Ad _WARNING This vehicle has many parts dimensioned in the metric system as well as the English system. Some fasteners are metric and are very close in dimension to well-known English fasteners in the inch system. Mis- ‘matched or Incorrect fasteners could result in vehicle damage, personal injury oF death. VEHICLE ENTRY AND EXIT Ay _wanninc Do not step or climb upon any vehicle surtace unless it is slip resistant ‘and handholds are provided. Failure to follow this warning could result in Personal injury or death.‘Do not use side mounted fairing (wind deflector) brackets and braces as steps or grab handles. They are not intended for that purpose; they could fail and result in personal injury or death. By wannine Certain steps may be of a folding or pivoting design. Be certain that ‘such steps are firmly engaged in the weight bearing position before plac- ing full weight on the step. Failure to follow these procedures could result in personal injury or death. By warning Failure to exercise due care when entering and exiting vehicles can result in personal injury or death. {A three-point stance should be used (three out of four extemitis should be in contact with the vehicle a all times), Face inward toward steps and handholds when entering and exiting. Alvays keep sept and handholds in continuous good repair. Make sure all asching bots and hardware are Gght, thus eliminating any movement of steps and handhold, Keep steps, grab handles and shoes fre of grease, mud, dit, fel, ice and snow. Use extra care during inclement weather.‘Section 8: Operation OCCUPANT RESTRAINT SYSTEM Ay _WARNING ‘Always use occupant restraint system when vehicle is being operated. Any location in the vehicle not equipped with a seat belt, bunk restraint bolts or sleeper berth restraint webbing is not intended to be occupied when the vehicle is being operated. In the event of a vehicle accident or sudden unexpected movement, fellure to properly use an occupant restraint system could result In personal injury or death, ‘SEAT ADJUSTMENT Ay warning Do not adjust driver’s seat while vehicle Is moving. The seat could sud- denly or unexpectedly move causing the driver to lose control of vehicle, which could result in property damage, personal injury or death. Ay_Wanning ‘Operating this vehicle over rough roads or surfaces can result in per- ‘sonal injury. Use caution and reduce speed. Properly adjusted seats and ‘seating systems may not compensate completely for severe road condi- tlons. BENCH OR BUCKET TYPE SEAT WITH SINGLE LEVER ADJUSTMENT ‘These seats have fore and aft adjustment only, Adjust while siting in seat, Push seat adjustment lever to release mecha- nism and move seat to desired position. Be sure seats are firmly engaged to avoid forward or rearward movement when vehicle is started oF stoppedSection B: Operation ‘SUSPENSION TYPE SEATS Ay _WARNING SEAT BELTS ‘A replacement seat should be of the same specification as the original ‘equipment, accident resulting in personal injury or death. ‘The vehicle may be equipped with suspension type seat. For suspension type Scat adjustment refer to the booklet or decal atached 10 seat frame as supplied by the seat manufacture, Fallure to obtain proper replacement parts could cause an Fallure to properly inspect and maintain seat belts could result in per- ‘sonal injury or death. 7 diately. All ‘Any seat belt severely strained in an accident should be replaced imme- belts should be replaced at least every five years. Belt failure could result In personal injury or death. Ay _WARNING ‘The seat belt in a commercial truck application should be considered to have a finite life and must be replaced as needed throughout the life of the vehicle. Belt must be inspected for needed maintenance every 20,000 miles or more often if exposed to severe environmental or vocational conditions. . Belt failure could result in personal injury or death.Section B: Operation Za_warwne H replacement of any part of the seat belt is required, the entire belt must be replaced, both retractor and buckle side. Belt failure could result in personal injury or death. Seat belts should be worn at all times the vehicle is in motion to avoid personal injury. Before fastening a front seat belt, always adjust the driver's seat to the position in which you will rive. Lap and shoulder (dree-point seat belts with retractor are standard for driver and door-side passenger. An adjustable belt that does not retract is provided forthe center passenger with full and two-man bench seats ADJUSTABLE LAP AND SHOULDER (THREE-POINT) BELTS ‘To fasen the belt Figure 2, bring belt across hips and chest and insert tongue into buckle. The web is free to slide through tongue, allowing the belt tension to equalize across hips and chest. The retractor isa locking type which allows webbing to come out to adjust for body movement 1. BELT TONGUE 2, BUCKLE A. PRESS TO UNFASTEN, Fig. 2. Adjustable Lap And Shoulder (Three-Point) Belts‘Section 8: Operation ‘The webbing will return to the retractor Figure 3 as the body returns to its original postion. The retractor wil retain moderate tension across the body in its operator made. ‘To release, push the buton release latch on the buckle. Give the belt a tg 10 insure it will retract, KOMFORT-CLIP ADJUSTMENT ‘The Komfor-Clip is located over the shoulder under the wall mounted O-ring. The clip can be engaged by pulling on webbing of belts shoulder strap, permitting only enough slack in the shoulder belt to allow slight pressure on shoulder ‘and chest (maximum amount of slack should not exceed 1 inch when measured from chest to belt. While holding this slack lift levertop of Komfor latch mechanism upward, clamping webbing in place. Belt tension will be removed across the ches. If you try to lean forward, the clip wll hold unless a moderate force is applied causing the clip 0 dit ‘engage. At this point the Komfor-clip would have to be reset as mentioned above. ONLY ENGAGE THE KOMFORT: (CLIP WHILE THE TRUCK IS AT REST. NON-RETRACTING ADJUSTABLE SEAT BELTS FOR CENTER PASSENGER — BENCH SEAT ‘To adjast: Figure 4 Tip the buckle end downward and pull the buckle ntl the ends can be joined. Insert tongue into ‘open end of buckle and snap together. Shorten the belt afer itis connected by pulling on the loose end until the belt is snug and comforable. ‘To Release: Figure 4 Push in the button release latch to release the seat belt y 1. INSERT To CONNECT 3. PULL TO SHORTEN WITH BELT 4, PULL TO LENGTHEN WITH BUCKLE 2. PUSH BUTTON TO RELEASE CONNECTED IN VERTICAL POSITION Fig. 4. Non-Retracting Adjustable Seat Belts For Center Passenger — Bench Seat‘Section B: Operation CARE OF SEAT BELTS ‘Clean the belts occasionally with mild soap; do not use cleaning solvents or abrasives Do not bleach or re-dye color webbing. Bleaching or re-dying may cause a severe loss of belt strength. This loss of strength could allow the seat belt to break under stress, and could result in personal injury or death. ‘The entre seat belt assembly should be inspected periodically for corosion, wear, fraying or weak spots. The retractor, latch, and buckle should be checked for proper function, and all seatbelt mounting bolts should be tight at all ines.‘Section 8: Operation INSTRUMENT PANEL AND CONTROLS 1000/4000 SERIES INSTRUMENTATION Figure 5 Fig. 5. 1000/4000 Series InstrumentationSection 8: Operation ENGINE OIL TEMPERATURE GAUGE (OPTIONAL) ‘TRANSMISSION OIL. TEMPERATURE GAUGE (OPTIONAL) EXHAUST TEMPERATURE GAUGE OR AMMETER (OPTIONAL) WARNING UGHTS: 2) OLWATER, ) BRAKE PRESSURE ©) COOLANT LEVEL, 1) STOP ENGINE-RED LIGHT/CHANGE OIL-AMBER LIGHT ©) ENGINE WARNING 1) TRACTION CONTROL 9) CHECK TRANS, 5. LEFT TURN INDICATOR 6. ANTILOCK BRAKE WARNING LIGHT 7. ENGINE COOLANT TEMPERATURE GAUGE 8, ENGINE OIL PRESSURE GAUGE 9, WARNING LIGHTS: RETARD ON ) CHANGE TRANSMISSION FILTER ¢) RETARD OVERHEAT 1) ALTERNATOR, 10. TACHOMETER 11, HOURMETER (OPTIONAL) 12, SPEEDOMETER, 13, ODOMETER 14, HIGH BEAM INDICATOR 15. RIGHT TURN INDICATOR 16. FUEL GAUGE 17, VOLTMETER 18, WARNING LIGHTS: '@) WATER IN FUEL ) FUEL FILTER, PTO. 1d) LOW BRAKE FLUID 19. WARNING LIGHTS: '8) WATT TO START ) POL (NOT BUS) ©) PARKING BRAKE ‘| WINDSHIELD WASHER FLUID ©) FRONT AXLE (NOT BUS) 1) DIFF LOCK ENGAGED 9) SUSPENSION LOW AIR 20. DUAL AIR PRESSURE GAUGE 21. FORWARD REAR AXLE TEMPERATURE GAUGE (OPTIONAL — ‘Nor BUS) 22, REAR REAR AXLE TEMPERATURE GAUGE (OPTIONAL — NOT Bus)Section B: Operation 1652 SC SERIES INSTRUMENTATION Figure 6 o 1. TURN SIGNAL INDICATOR, 2. WATER IN FUEL 8, WAIT TO START 4, HEADUGHT HEBEAM 5. CHANGE Ol 6. FUEL FILTER, 7. SUSP LOW AIR 8, WARN ENGINE 9. O1L WATER 10. BRAKE PRESS 11, PARK BRAKE: 12. LOW BATT 18. TOGGLE SW (MIHRS) 14, PANEL LIGHT DIMMER NOTE: All ofthe actwe warning lights for this cister are noted shove, Fig. 6. 1652 SC Series InstrumentationSection B: Operation 4000 SERIES CONTROL PANELS Refer tothe 4000 Series Control Panel Rocker Switch Figure 7, and 4000 Series Control Panel Other Controls Figure 8‘Section B: Operation 1. RIGHT POWER MIRROR 2. HEATED MIRROR 3. CRUISE ONOFF 4, FUEL-TACH ONOFF/RESET OR CRUISE/SETRESUME 5. ENGINE BRAKE ONOFF 6. ENGINE BRAKE SELECTOR 7. NOT USED 18 NOT USED ‘8, HEADLIGHT SWITCH (OIMMER SWITCH ON TURN SIGNAL LEVER) 10. PANEL LIGHTS SWITCH 11, FOG UGHT SWITCH 12. MARKER INTERRUPT SWITCH 13. ENGINE PUSH BUTTON START 14. KEY SWITCH (START) 15. ENGINE SHUTDOWN SWITCH 16. HANO THROTTLE 17, AUTOMATIC TRANSMISSION SELECTOR 18. SWITCH IDLE DIAGNOSTIC 18. SWITCH DIAGNOSTIC ONOFF 20. ETHER START OR AIR WIPERS (BOTH OPTIONAL) 21. PUSH BUTTON START (OPTION) 22. DATA LINK CONNECTOR (6-WAY DEUTSCH) 23, FUSE PANEL‘Section B: Operation 1. BRAKE CONTROLS (PUSH-PULL) ‘9, POWER DIVIDER Lock OUT 2. ANTILOCK BRAKE SYSTEM (ABS) WARNING LIGHT 10. STH WHEEL CONTROL 13. FLOOR AIRHEAT (AIC ONLY) 11, HEATER AIG UNIT ‘4 RADIO 12. AIR SUSPENSION 5. CIGAR LIGHTER 18, DIFFERENTIAL LOCKOUT 6. AIR RESTRICTION GAUGE 14 0B POWER CONNECTION 7. CAUTION NOTE 15, LOWER AIC OUTLET {8 FRONT AXLE LOCK-OUT NOTE: STANDARD HEADLIGHT DIMMER SWITCH ON TURN SIGNAL CONTROL B-14‘Section 8: Operation AXLES AXLE OPERATING TEMPERATURE Normally, axle operating temperature will not exceed more than 100*F (38°C) above ambient temperature. However, inermitent operation (5% of time) a higher temperatures under extreme loads (long pulls) will not harm the axle. Oper. ting temperatures above 230°F (110°C) significantly increase the rate of lubricant oxidation and shorten the effective life (ofthe lubricant, making more frequent changes necestary. EP lubricants should not be run consistently at temperatures above 230°F (110°C). FRONT AXLE (4X4, 6X6) ‘With different configurations of transfer cases and types of contols, such as manually operated or sir operated, it is important thatthe front axle control instructions provided on the vehicle be followed. Most vehicles have a front axe indicator light to alert the driver thatthe front axle is engaged. Ay _Wannine ‘To avoid property damage, personal injury or death, pay strict attention to the following: ‘Should it be necessary to operate the rear wheels (with engine power) with the vehicle stationary and the rear wheels raised from the ground, firet disengage the front axle; otherwise the driving front axle will pull the vehicle off its support. Parking brakes should be applied when the transmission and the transfer case have been left in the neutral position with the engine running or not running. IMPORTANT: Do not keep the front axle engaged when operating on dry, hard surfaced roads except where it ‘absolutely necessary to operate with the transfer case in low range. Operating on hard, dry surfaces with both the front ‘and rear asle engaged creates a bulld-up of torque between the axes resulting in excessive tire wear and strain on the entire drive unit B15Section B: Operation ‘When necessary to operate with the transfer casein low range, the froat axe drive must be engaged to avoid excesive torque load on the rear axle. CAUTION B-16 Use extreme caution when backing up on a steep grade. Weight transfer to the front will reduce traction on the rear axle while increasing the load demands on the front axle. This can make the front drive components, subject to overloading and damage. Front Axle Disengagement (4x4, 6x6) “The torque build-up between the font and rear axles sometimes makes it ficult to disengage the front axle wrile the ‘vehicle ts in motion. To disengage the frot ale with the vehicle in motion, slack off abruptly on the accelerator andor release the clutch while pressure is applied to the font axle conto. In some instances it may be necessary 10 stop the ‘ehicle and move it slightly inthe revere direction to complete disengagement ofthe font axe Front Axle Engagement Locking Hubs in Lock Position or Axles Without Locking Hubs ‘The front axle can be engaged with the vehicle in motion by pushing the front axe contol to the IN position. 1 isnot necessary 10 stop the vehicle of to disengage the clutch when engaging the font axle. It is recommended thatthe accel cerator be released while engaging the front axle wo release torgue on the driven Locking Hubs in Free Position Vehicle must be stopped to engage the front ane. I dificlty is encountered in engaging the font axle when the vehicle is notin motion, it means the splines on the engaging clutch are not matched. Using forcing action or kicking the con- tel wil not make it engage but may damage the control linkage. Shift the transmission into low gear and rol the vehi- cle forward, Keeping pressure on the conto. When the spines are matched, they will engage. ‘With an automatic transmission, it may be necessary to use a special procedure to shift out of neutral positon in the transfer case. The input shaft to the tansfr case must be stopped citer by shifting between forward and reverse or by stopping the engine. Keep ressre on the tansfer case lever asthe input shat approaches zero speed. Stopping the engine will isre that the transfer case is not damaged.‘Section B: Operation FRONT WHEEL LOCKING HUBS (4X4, 6X6) Locking hubs contol the engagement of the front wheels with the front drive axle. When the hubs are engaged, ful power is transmited to both wheels. Disengagement with front axle not diving allows the front wheels to free whee, snd the axle shaft and differential gears to remain ide, saving unnecessary wear. IMPORTANT: For the frst 200 miles (320 kilometers) operate your new vehicle with locking hubs in LOCK postion to asset in Intnl break-in of the driving axle. IMPORTANT: Be sure tat both hubs are in ether FREE position (turn counterlockwise to FREE) oF LOCK post tion (turn clockwise to LOCK). Arrow in center of controls must always point directly to one of the dots on the rim of ‘he hub. You can fee! the control “seat” iself when itis properly set. If arrow does not point to one of the dots it will not seat Both hubs must always be set the same! Use fingers only o turn controls, If contro do not turn frely with your fingers, move vehicle slightly either way in trroowheel drive, standard gear range, and try agai. Do not fore controls with tools. ‘When to use FREE or LOCK postion: Use FREE for all driving that does not requlre foursheel drive power and trac- ‘Hon. Use LOCK whenever fourheel drive is used. ‘To avoid excessive torque loads on the rear axle, do not drive vehide in low range of transfer case with locking hubs set ln FREE poston. TWO SPEED REAR AXLE. ‘The two-speed rear axle switch permits selection of either the high or low axle rato. Axle Shift Only ‘TO DOWN SHIFT: Select lower ratio position, release and depress accelerator pedal as quickly as possible, or while holding the accelerator down, disengage and re-ngage clutch as quickly as posible NOTE - Clutch method recommended for slower speeds. ‘TO UPSHIFT: Keep accelerator down, select a faster ratio position, release accelerator pedal and pause until ale shit NOTE - De-cutch for smoother axle upshifs at slow speed. B17‘Section 8: Operation Split Shifting Combined Axle and Transmission Shift TO DOWNSHIFT the axle to a slower ratio and upsit or downshift the transmission, sift the tansmision and just before the clutch is re-engaged. move the control switch to the slower ratio positon. ‘TO UPSHIFT the aule and downshift or upsift the wansmisson, move the contol switch to a faster ratio position and snake the transmission shift inthe usual manner. NOTE - In all axe upshift, move the control switch to position first. When split siting to slower axle ratio, do not move the control switch uni just before engaging the clutch Ay WARNING ‘Never attempt to shift a two-speed axle when descending a hill as It could cause a loss of vehicle control and resutt In property damage, per- ‘sonal injury of death, ‘TANDEM AXLE POWER DIVIDER (INTER-AXLE DIFFERENTIAL) LOCK CONTROL ‘Tandem axle power dividers of interale differentials in the forward rear axle are controlled by the dash mounted power divider lock switch POWER DIVIDER LOCK HP Fig. 9. Power Divider Lock B18‘Section B: Operation Under normal highway conditions (good iection) the power divider Iock switch should be inthe OUT postion which allows differential action between the forward, rear axle and the rear, rear axle preventing inter axle differential wear due to unequally worn or mismatched tres, ete “The power divider lock switch shouldbe in the IN postion, which prevents interasle diferenal action, when backing nde a trailer with a uacter, starting on a slippery surface (poor traction). operating off highway in mud, et. (poor tac tion), or when traveling on slippery highways (poor traction). Failure to lock the power divider IN under these conditions ‘may result in power divider differential spin-out failures and costly repairs. If you encounter wheel spin conditions, your power divider lock should be IN. ‘CAUTION “Switch the power divider lock to IN only when stopped or moving at low ‘speed. Never try to go in the IN position while your wheels are spinning ‘a8 this may result in shock damage to the power divider components. and costly repairs. ‘When encountering slippery highway conditions (poor traction) the power divider lock can be moved to IN at a low, even speed and momentanly ling off the accelerator will engage the difereatal lock. A warning light on the instru- ‘ment panel indicates when the inter axle differentia i locke, ‘When highway conditions improve (goad traction) the power divider lock can be moved to OUT at a low, even speed. Letting up on the accelerator momentarily will unlock the inter axle differentia ‘CAUTION ‘Do not operate with the power divider lock in the IN position on dry pavement (good traction) continuously. This will result in excessive tire ‘wear and premature axle wear. CAUTION ‘Never shift a two-speed tandem axle from one range to another with the power divider lock switch to the IN position. This may cause shock dam- age to the inter axle differential and result in costly repairs.Section B: Operation REAR AXLES (WITH LOCKING OR LIMITED SLIP DIFFERENTIALS) Ay_WARNING ‘To avoid property damage, personal injury or death, pay strict attention to the following: lf your vehicle is equipped with any type of locking or limited slip differ- ‘ential, power will be transmitted to the opposite wheel should one of the wheels slip. Both wheels must be raised free of the ground should it be Necessary to operate one wheel with the vehicle stationary; otherwise the ‘whee! that is not raised will pull the vehicle off its support. ‘As with any vehicle, care should be taken to avoid sudden accelerations ‘when both drive wheels are on a slippery surface. This could cause both drive wheels to spin, and allow the vehicle to slide sideways on the crowned surface of a road or in a turn, and possibly result in loss of vehicle control. ‘Traction Equalizer Some Meritor drive axles are equipped with a uaction equalizer It will maintain an appreciable amount of wheel end traction in all operating conditions while stil allowing the vehicle to negotiate turns smoothly. This is accomplished with the ability of the taction equalizer to slip above a ceri torque value, and remain rigid below this torque value. CAUTION Tire sizes on both rear wheels should be the same on axles equipped with a traction equalizer. if not, excessive wear may occur to the traction equalizer.Section B: Operation NoSPIN Detroit Locker Positive Locking Differential ‘The following is a brief summary of operational guidelines for Dewoit Locker posi tory thatthe owneroperatr efer to the separate NoSPIN owner's manual provided instructions, warnings, and required operational tess The NoSPIN differential is designed to deliver 100 percent of the avilable power to either or both drive wheels, yet UNLOCK as required t0 allow wheel speed differentiation, automaticaly “The performance of a vehicle equipped with a NoSPIN diffrenal is somewhat different from that of a vehicle equipped with a conventional differential FFor example: when turing a corer, the sound of gear disengagement and re-engagement may be audible, and the wans- fer of driving torque from both wheels to one whee! may be noticeable. ‘When going from drive (acceleration) t0 coast (deceleration) in a turn, a metallic sound may be heard as torque flow is reversed (inside wheel engaged during acceleration; ouside wheel engaged during deceleration). ‘These characerscs area result of necessary backlash designed into the NoSPIN differentia, which is of a fixed amount {one to two inches of rotation at the tire tread) [Anything that improperly causes a difference in individual wheel speeds, such as mismatched tire diameters due to differ ‘ences in tie wear oF tire pressure, unbalanced loading of the vehicle, oF when the vehicle is operated on aside slope, ‘can cause the NoSPIN differential to deliver power to only one side ofthe vehicle, which may affect directional sa ‘Always maintain matched tre sizes and pressures and balanced loads, and avoid operation on side slopes. locking diferentals. It is manda- th the vehicle for adtioa iy. Ad_WARNING To prevent the vehicle trom moving when servicing wheels, tires, or brakes, turn engine off and raise all driving wheels of locker differential equipped axle. Axles equipped with NoSPIN Detroit Locker Differentials, deliver power to both wheels even when only one wheel Is on the ‘ground. Failure to observe this warning could cause the vehicle to move Unexpectedly resulting in property damage, personal injury, or death.‘Section 8: Operation ‘As with any vehicle, care should be taken to avoid sudden accelerations when both drive wheels are on a slippery surface. This could cause both drive wheels to spin, and allow the vehicle to slide sideways on the erowned surface of a road or in a turn, and could cause loss of vehicle control, resulting in property damage, personal injury or death. Driver Controlled Differential Lock Some MeritofEaton drive axles have a driver controled differential lock. The air actuated traction device that can be ‘manually shifted from the vehicle cab. By actuating a switch, mounted on the instrument panel, the driver can lock oF unlock the differential when the vehicle is moving oF stoped, IMPORTANT: When the differential is fully Iocked, the vehicle wil have 2 sight “understeer” condition. This will Increase the turning radius of the vehicle, ‘The driver must limit the use of the differential lock to low vehicle speeds, under 25 MPH. Also, the differential must not be locked when the vehicle is traveling down steep grades and traction is minimal, 1 is mandatory that the Owner/Operator refer to the separate driver contlled main differential lock owner's manual pro- ied with the vehicle for additonal instructions, warnings, and required operational tess AXLE AND SUSPENSION CONVERSIONS Navistar Intemational Transporation Corporation does not recommend or approve axle and suspension conversions; how- ‘ever, i is aware that on occasion aftermarket add-on axles and suspensions are installed by others on Intemational truck ‘chasis which allow operator control for weight transfer from other axles (ie, air it axles), Ay _WaRNInG ‘When operating a loaded vehicle, the driver must keep all adj axles on the ground at all times, supporting their share of the load. Fall- ture to do so can overioad other axle, tires, wheels, springs, steering, brakes and frames, which could caue early component failure, loss of Vehicle control and resutt In property damage, personal injury or death.Section B: Operation BRAKES By_WaRnine Fallure to maintain brakes in proper condition and adjustment could cause reduced braking ability and result in property damage, personal injury, oF death. DOWNHILL OPERATION ‘Always descend hills with exteme care, relying on the engine braking effect to control vehicle speed. Heed warning ‘signs posted for any grade. Stop and check brakes for condition and adjustment at available pull off areas before staring a descent ‘Observe the following precautions: Never coast downhill, Service brakes alone should not be used to contol speed on major downgrades. Brakes will fade from overuse, Downhill speed is controlled by removing one’s foot from the accelerator pedal (engine running with closed throtle) and putting the ransmission/ear axle in reduced gear. I the transmissiowrear axle is in a gear that results in more than the ‘esied acceleration or speed, a proper downshift should be made to avoid overuse ofthe brakes. If the proper gear Selection was not made and the brakes were overused, then stop the vehicle and wait for the brakes t0 coo. After the brakes have cooled, continue down rage in a lower gear range. ADx_warning DO NOT ATTEMPT to gear down if the engine has reached maximum ‘speed (RPM) in any gear range since it will be impossible to shift into a lower gear and could cause vehicle runaway, resulting in property dam- ‘age, personal injury, or death. “The common rue to follow in using the engine and transmission/ear axle to control vehicle speed is to select a lower gear going down the hill than would be required to ascend the hil. There are some exceptions, such as going down a short hill with good visibility and no hazards‘Section 8: Operation “The service brakes should be used to supplement available vehicle retardation. When descending long grades requiring use ofthe brakes, snub applications (five to tem seconds duration) should be made rather than long, cominuous applica- tions. This minimizes temperature rise, brake fade and air consumption of ait brake system, AIR BRAKES All air brake equipped vehicles 10 which this manual applies have a spit brake system. ‘The purpose of this split system isto provide a means of stopping the vehicle should a failure occur in citer the pri rary oF secondary brake sytem. Tn the event air pressure loss occurs in one system, the remaining system continues 10 provide baking action. ‘Even though there will be enough braking capability for emergency stopping, the vehicle must not be operated when a failure is indicated, as there is no means of replenishing air pressure, If vehicle has been parked for an extended peri in cold weather, always check to be sure all wheels re rolling free (brakes are not frozen) when stating out. Always clean accumulate ice and snow from brake linkage. ‘Some vehicles are equipped with color-coded si brake lines, The color coding is as follows ‘+ GREEN — Primary Supply and Delivery System ‘+ ORANGE — Secondary Supply and Delivery System ‘+ YELLOW — Spring Brake System ‘+ RED — Taller Emergency ‘+ GRAY — Power Divider Lockout ‘+ BLUE — Tractor Protection Valve Service ‘+ BLACK — Other Systems ‘Air Gauge, Low Air Pressure Buzzer and Indicator Light ‘Should air pressure in either section of the split ar brake system be reduced 10 70+6 psi (483341 kPa) the warning buzzer will sound and a re light on the instrument panel will glow. Also, the air gauge/gauges will indicate low air pressure in atleast one of the independent systems, ‘The warning buzzer and red light will automatically shu off when the sir pressure in both systems is sufficient (approxi: rately 70 psi (483 KPal) to operate the vehicleSection B: Operation ‘Should the red Hight and buzzer not shutoff soon ater sar-up, the ar pressure gauge/gauges should also indicate at least one section of the split system has low air pressure. If the red light, buzzer and gauge indicate loss of pressure while diving, the vehicle sill has a portion of the braking capabily, in that either one-half of the spit system or the spring brake system braking capability is retained. However, the distance required to stop the vehicle will be increased. Ay _WARNING To avold loss of vehicle control resuiting in possible property damage, personal injury or death, never operate the vehicle when insufficient air pressure (less than 70 pel [483 kPal) Is indicated for elther system since ‘the volume of air required to stop the vehicle may be greater than that avallable. Have the brake system checked and repaired before returning the vehicle to service. Brake Application Rapid successive brake applications and release, sometimes refered to as fanning or pumping the pedal, should be avoided. This is an inefficient way of slowing or stopping a vehicle and inefficient use of air pressure. Parking Brake All vehicles with ait brakes are equipped with spring brake chambers for parking. The parking system is operated manu- ally by a single valve, which in the case of a actor also controls the parking system on the trier. Ay_WARNING Under no circumstances should the spring section of the spring and ser- vice chamber assembly be disassembled. Disassembly will release a pow- erful spring, which could result in pereonal injury or death. “The purposes of this brake is to hold the vehicle ina parked position and to assist in bringing it to an emergency stop. ‘The parking brake should not be used w brake the vehicle during normal diving,‘Section 8: Operation ‘To apply te parking brake, pull out contol. To release the parking brake, push in on contol ‘On single unt trucks and tractors with independent parking and trailer controls: if air pressure is reduced to approximately 20 1 45 psi (138 to 310 KPa) in both the primary and secondary systems, the parking brakes will auto- matically apply. ‘On tractors with the modular control system: if sr pressure is reduced to approximately 20 to 45 pai (138 to 310 Pa) in both the primary and secondary systems, the parking brake contol will automatically apply. For the exact aie pressure set-point, refer to the Service Manusl 1k should be noted that upon los of air pressure partial spring brake aplication wil occur prior to automatic application of the contol valve. ‘To release, recharge system to 70 psi (483 kPa) and push inthe parking bake conuol. Ifthe system cannot be recharged and the vehicle must be moved, he spring brake must be manually released (caged). Ay warning ‘When manually releasing the spring brakes, be sure to block the wheels ‘80 that vehicle cannot move when the brakes are released. Failure to do ‘80 could resutt in property damage, personal injury or death. For towing, make sure the disabled vehicle is securely connected to tow vehicle and tow vehicle parking brakes are applied before releasing the disabled vehicle's parking brakes. Release After Emergency Application In the event itis necessary to move the vehicle after an emergency application (before air pressure can be restored), the parking spring can be compressed mechanically to release the brake. A release stud spring caging fool is furnished with the brake chamber assembly. The release stud engages in the spring pressure plate and its nut is tightened to compress, ‘age, the spring and release the bake. Remove release stud assembly from carrying pocket Apply a light coat of Never Seeze to the threads of the releate stud to avoid any unnecessary wear of the threads Remove the acess plug from the end of the spring chamber, Insert the release stud through the opening in the chamber and into the sping pressure plateSection B: Operation Release After Emergency Application Fig. 10. Mechanical Release ‘Tum the release stad one-quarter tum to engage the tangs on the release stud into the slot in the pressure plate. Install the nut on the release stud. Be sure tang on release stud stays engaged with slot on pressure plate while insaling the fut. Tighten the nut with @ wrench to compress the spring. Parking Brake Reset ‘Charge spring brake chambers with air pressure. Loosen nut and remove the release stud and nut from the spring hous: ing and re-install the acess plugin the chamber opening. Reinstall the release stud and nut in the carying pocket on the brake chamber housing. Reservoir Moisture Draining Moisture taken in with the air through the compressor inlet valves collects in the reservoirs and necessitates draining ‘each reservoir daily in cold weather and once a week in warm weather by opening the drain cock located either on the bottom of the tank or inthe end of the tank. If in the end ofthe tank, there must be some air pressure inthe system {0 assure proper drainage. Be sure to close the drain cocks afer all moisture has been expelled. (On vehicles so equipped, the reservoir automatic drain valve ejects moisture and contaminants from the reservoir in which itis connected. It operates automatically and requires 90 manual assistance or contol lines from other sources. ‘The reservoir should be drained and the valve should be examined periodically to ensure thatthe drain passage is not ‘obstructed.