Service Publications

5000i, 9000i
An Operators Manual is shipped with this vehicle for customer Operators Manual
use. Additional service publications are available for these
vehicles and can be purchased by contacting International Form No. 3628504R1
Printing and Distribution Services, c/o Moore Wallace North
America, 1750 Wallace Avenue, St. Charles, Illinois 60174.
It is the policy of International Truck and Engine Corporation to
improve its products whenever it is possible and practical to do
so. We reserve the right to make changes or add improvements
at any time without incurring any obligation to make such
changes on products sold previously.

02/21/2006

Form No. 3628504R1

Printed in the United States of America
 Form No. 3628504R1
Printed in the United States of America
 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. . .. . . .. . . . .. . . .. . . .. . . . .. . . .. . . .. . . . .. . . .. . . .. . . .. . . . .. . . .. . . .. . . . .. . . .. . . .. . . . ..3
Exterior Noise Emissions. .. . .. . .. . .. .. . .. . .. . .. .. . .. . .. . .. .. . .. . .. . .. . .. .. . .. . .. . .. .. . .. . .. . .. .. . .. . .. . .. . .. ..3
Tampering With Noise Control System Prohibited. . . . .. . . .. . . .. . . .. . . .. . . .. . . . .. . . .. . . .. . . .. . . .. . . . .. . . ..3
Emission Control Systems. . .. . . . .. . . . .. . . .. . . . .. . . . .. . . .. . . . .. . . . .. . . .. . . . .. . . . .. . . .. . . . .. . . . .. . . .. . . . .. . . . ..4
Verification of Inspection Noise Emissions. . .. .. . .. .. .. . .. .. . .. .. .. . .. .. . .. .. .. . .. .. . .. .. .. . .. .. . .. .. ..4
Reporting Safety Defects. . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . .. .5
U.S. Registered Vehicles. . .. .. . .. .. . .. .. .. . .. .. . .. .. . .. .. . .. .. .. . .. .. . .. .. . .. .. . .. .. .. . .. .. . .. .. . .. .. . .. .. ..5
Canadian Registered Vehicles.. . .. .. .. .. .. .. .. .. .. . .. .. .. .. .. .. .. .. . .. .. .. .. .. .. .. .. .. . .. .. .. .. .. .. .. .. .. . .5
Safety Recalls and Authorized Field Changes. . .. . .. . .. .. . .. . .. . .. . .. . .. .. . .. . .. . .. . .. .. . .. . .. . .. . .. .. . ..5
International Customer Security Guide. . . . .. . . . . . . . . . . .. . . . . . . . . . . .. . . . . . . . . . . .. . . . . . . . . . . .. . . . . . . . . . .. . . . .5
Optional Diamond Logic Electronic Application Solutions. . .. . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . .. . . . . . .8

SECTION 2 VEHICLE INSPECTION GUIDE

Description.. .. . .. . .. . .. . .. .. . .. . .. . .. .. . .. . .. . .. . .. .. . .. . .. . .. .. . .. . .. . .. . .. .. . .. . .. . .. .. . .. . .. . .. . .. .. . .. . .. . .. 9
Engine Compartment.. .. .. .. .. .. .. . .. .. .. .. .. .. .. .. .. .. . .. .. .. .. .. .. .. .. .. .. .. . .. .. .. .. .. .. .. .. .. .. . .. .. .. .. ..10
Engine Start with Parking Brake(s) Applied.. .. .. .. .. .. .. .. .. .. .. .. .. . .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ..11
Transmission.. . . .. . .. . . .. . . .. . . .. . . .. . . .. . .. . . .. . . .. . . .. . . .. . . .. . .. . . .. . . .. . . .. . . .. . . .. . .. . . .. . . .. . . .. . . .. . . .. .14
Front of Vehicle.. . . . .. . . . . .. . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . .. . . . . .. . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . .. . . .14
Front Suspension.. .. . .. .. . .. .. . .. .. . .. . .. .. . .. .. . .. .. . .. .. . .. . .. .. . .. .. . .. .. . .. .. . .. . .. .. . .. .. . .. .. . .. .. . .. . ..15
Front Brakes. .. . .. . .. . .. . .. . .. . .. . .. . .. . .. .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. .. . .. . .. . .. . .. . .. . .. . .. . .. . .. .. . .. . .. .15
Front Wheel.. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. .16
Driver/Fuel Area.. . .. . .. .. . .. . .. .. . .. . .. .. . .. . .. .. . .. . .. .. . .. . .. .. . .. . .. .. . .. . .. .. . .. . .. .. . .. . .. .. . .. . .. .. . .. .. .17

Form No. 3628504R1

Printed in the United States of America
 TABLE OF CONTENTS

Under Vehicle Rear of Tractor. . .. . .. . .. . .. .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .18

Truck/Tractor.. .. .. .. .. .. .. .. .. .. .. .. .. . .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. . .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. . .. .. .. .. .18
Trailer. .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . ..19
Rear Springs. . .. . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . .. . . . . .. . . . .. . . . . ..20
Rear Brakes.. . .. . .. .. . .. . .. .. . .. .. . .. . .. .. . .. .. . .. . .. .. . .. .. . .. . .. .. . .. .. . .. . .. .. . .. . .. .. . .. .. . .. . .. .. . .. .. . .. . .20
Rear Wheels. .. . . . .. . . . .. . . . .. . . . .. . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . .. . . . .. . . . .. . . . ..21
Rear of Vehicle. . . .. . . .. . . . .. . . .. . . .. . . . .. . . .. . . . .. . . .. . . .. . . . .. . . .. . . . .. . . .. . . .. . . . .. . . .. . . .. . . . .. . . .. . . . .. . . ..21

SECTION 3 VEHICLE CONTROLS

Introduction.. .. . .. . .. .. . .. . .. .. . .. .. . .. . .. .. . .. . .. .. . .. .. . .. . .. .. . .. . .. .. . .. .. . .. . .. .. . .. . .. .. . .. .. . .. . .. .. . .. . .23
5000 and 9000i Overhead Panel . . . .. . . .. . . . .. . . .. . . . .. . . .. . . . .. . . .. . . .. . . . .. . . .. . . . .. . . .. . . . .. . . .. . . . .. . . ..23
Instrument Panel and Controls.. . .. .. . .. . .. .. . .. .. . .. . .. .. . .. . .. .. . .. . .. .. . .. . .. .. . .. .. . .. . .. .. . .. . .. .. . .. . .24
5000i Controls.. . . . . .. . . . .. . . . . .. . . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . . ..24
9000i Controls.. . . . . .. . . . .. . . . . .. . . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . . ..25
5000i and 9000i Series Instrument Panel.. .. . .. .. . .. . .. .. . .. . .. .. . .. .. . .. . .. .. . .. . .. .. . .. .. . .. . .. .. . .. . .26
Sleeper controls. . . . .. . . . . .. . . . .. . . . .. . . . . .. . . . .. . . . .. . . . . .. . . . .. . . . .. . . . . .. . . . .. . . . .. . . . . .. . . . .. . . . .. . . . . ..32
Caterpillar CAT Messenger and Cummins Roadrelay. . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . ..32
Transmission Shifters. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . ..33

SECTION 4 VEHICLE OPERATION

Cab Air Suspension. . . .. . . .. . . .. . .. . . .. . . .. . . .. . .. . . .. . . .. . . .. . .. . . .. . . .. . . .. . .. . . .. . . .. . . .. . .. . . .. . . .. . .. . . ..35
Cargo Area Occupancy. . .. . .. . . .. . .. . .. . . .. . .. . .. . . .. . .. . .. . . .. . .. . .. . . .. . .. . .. . . .. . .. . .. . . .. . .. . .. . . .. . .. . ..35
Vehicle Entry and Exit. .. . .. .. .. .. . .. .. .. . .. .. .. .. . .. .. .. .. . .. .. .. . .. .. .. .. . .. .. .. .. . .. .. .. . .. .. .. .. . .. .. .. .. . .35
Sleeper Upper Bunk Entry/Exit Instructions (Optional). .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . ..36
9000i Series Conventional 51 (130 cm) Hi-Rise Pro Sleeper Upper Bunk Entry. . . . . . . . . . . . . . . .36
9000i Series Conventional 51 (130 cm) Hi-Rise Pro Sleeper Upper Bunk Exit. . .. . .. . .. . .. . .. . .37
9000i Series Conventional Sky-Rise and 72 (183 cm) Hi-Rise Pro Sleeper Upper Bunk
Entry. .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . . .. . . .. . . .. . . .. . . .. . . .. . . ..38

Form No. 3628504R1

Printed in the United States of America
 TABLE OF CONTENTS

9000i Series Conventional Sky-Rise and 72 (183 cm) Hi-Rise Pro Sleeper Upper Bunk Exit. ..38
Occupant Restraint System. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. . .. .. . .. .. . .. .. . ..39
Seat Belts. .. . . . .. . . . .. . . . .. . . . . .. . . . .. . . . .. . . . .. . . . .. . . . . .. . . . .. . . . .. . . . .. . . . .. . . . . .. . . . .. . . . .. . . . .. . . . . .. . .39
Adjustable Lap And Shoulder (Three-Point) Belts. . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40
Seat Belt Tether.. .. . .. .. .. . .. .. .. .. . .. .. .. . .. .. .. . .. .. .. . .. .. .. . .. .. .. . .. .. .. . .. .. .. . .. .. .. . .. .. .. . .. .. .. . ..41
Non-Retracting Adjustable Seat Belts For Center Passenger Bench Seat. . . . . . . . . . . . . . . . . . . . . . .43
Komfort-Clip Adjustment.. . .. . .. .. . .. . .. . .. .. . .. . .. . .. . .. .. . .. . .. . .. .. . .. . .. . .. .. . .. . .. . .. . .. .. . .. . .. . .. .. .43
Care Of Seat Belts. .. . . . . .. . . . . .. . . . . . .. . . . . .. . . . . . .. . . . . .. . . . . .. . . . . . .. . . . . .. . . . . . .. . . . . .. . . . . .. . . . . . .. . . .44
Upper and Lower Bunk Restraint Systems. . . . . . . . .. . . . . . . . . .. . . . . . . . .. . . . . . . . .. . . . . . . . .. . . . . . . . . .. . . . . .44
Seat Adjustment. .. . . . .. . . . . .. . . . .. . . . .. . . . .. . . . . .. . . . .. . . . .. . . . .. . . . . .. . . . .. . . . .. . . . .. . . . . .. . . . .. . . . .. . . . . .. . .45
Seats With Single Lever Adjustment. . . . . .. . . . . . . .. . . . . . . . .. . . . . . . .. . . . . . . .. . . . . . . .. . . . . . . .. . . . . . . .. . . . . .46
Swivel Seats (Optional).. . . .. . .. . . .. . .. . .. . . .. . .. . .. . . .. . .. . .. . . .. . .. . .. . . .. . .. . .. . . .. . .. . . .. . .. . .. . . .. . .. .46
Seat Storage. . .. . .. . .. . . .. . .. . .. . .. . . .. . .. . .. . .. . . .. . .. . .. . .. . . .. . .. . .. . .. . . .. . .. . .. . .. . . .. . .. . .. . . .. . .. . .. .46
Sleeper Cabinet and Storage Shelf Features. . . . . . . . . . . .. . . . . . . . . . . . .. . . . . . . . . . . . .. . . . . . . . . . . . . .. . . . . . . . .46
Pull-out desk with Work Surface. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . .. . .47
Twist and Pull Latch Instructions. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. . .. .. . .. .. . ..47
Microwave Cabinet. . .. . .. . .. . . .. . .. . .. . .. . . .. . .. . .. . .. . . .. . .. . .. . .. . .. . . .. . .. . .. . .. . . .. . .. . .. . .. . . .. . .. . .. .48
Refrigerator Cabinet.. . .. .. . .. .. .. . .. .. .. . .. .. . .. .. .. . .. .. .. . .. .. .. . .. .. . .. .. .. . .. .. .. . .. .. . .. .. .. . .. .. .. . ..49
TV/VCR Cabinet.. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. .50
Dresser Cabinets (Optional). . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . ..50
Rear Wall Wardrobe Cabinet (Used Only with Single Bunk).. . .. . . .. . .. . .. . . .. . .. . .. . . .. . .. . .. . . .. . .. .51
Airline-Style Corner Overhead Cabinets (Both Corners). . .. . . . . .. . . . .. . . . . .. . . . . .. . . . . .. . . . .. . . . . .. . . .51
Airline-Style Overhead Cabinets (Right/Left Hand). . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . . .. . . . .. . .51
Tower Wardrobe Cabinet.. . . . . .. . . . . .. . . . . .. . . . . .. . . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . . .. . . . . .. . . . . .. . . . . .. . . .52
Storage Shelf.. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ..52
Storage Shelf With DVD Player (optional) . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . .52
Lift-up Bunk with Storage System. . . . .. . . . . . . . . .. . . . . . . . . .. . . . . . . . . .. . . . . . . . . .. . . . . . . . . .. . . . . . . . . .. . . . . . .53
Footlocker Cabinet. . . .. . . . .. . . . .. . . .. . . . .. . . . .. . . . .. . . . .. . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . .. . . . .. . . . .. . . . .. . .54
Sleeper Controls For 9000i Pro Sleeper Models. .. . .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ..54
Standard Temperature Control System. . . . . .. . . . . . . . . . . . .. . . . . . . . . . . .. . . . . . . . . . . . .. . . . . . . . . . . . .. . . . . . . . .54

Form No. 3628504R1

Printed in the United States of America
 TABLE OF CONTENTS

Automatic Temperature Control (Optional). .. .. . .. .. .. .. .. .. .. . .. .. .. .. .. .. . .. .. .. .. .. .. . .. .. .. .. .. .. . .. .54

Sleeper Radio Control Module (Optional). . .. .. . .. . .. .. . .. .. . .. . .. .. . .. . .. .. . .. . .. .. . .. . .. .. . .. . .. .. . .. . .55
Inverter Remote Control, RC8 (Optional). . . . . . .. . . . . .. . . . . .. . . . . .. . . . . .. . . . . . .. . . . . .. . . . . .. . . . . .. . . . . .. .56
Cab Controls.. .. .. . .. .. .. . .. .. .. . .. .. .. .. . .. .. .. . .. .. .. . .. .. .. .. . .. .. .. . .. .. .. . .. .. .. .. . .. .. .. . .. .. .. . .. .. .. .. . .57
Overhead Panel . . .. .. .. .. . .. .. .. . .. .. .. .. . .. .. .. . .. .. .. .. . .. .. .. . .. .. .. .. . .. .. .. . .. .. .. .. . .. .. .. . .. .. .. .. . .57
Door Lock and Unlock Control. .. . . . .. . . . .. . . . . .. . . . .. . . . .. . . . .. . . . .. . . . . .. . . . .. . . . .. . . . .. . . . .. . . . . .. . . . ..57
Door Window Regulator. . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. .58
Power Windows (Optional).. . . . .. . . .. . . . .. . . .. . . . .. . . . .. . . .. . . . .. . . .. . . . .. . . .. . . . .. . . . .. . . .. . . . .. . . .. . . . ..59
Cruise Control.. .. .. .. .. . .. .. .. .. .. .. . .. .. .. .. .. . .. .. .. .. .. . .. .. .. .. .. . .. .. .. .. .. .. . .. .. .. .. .. . .. .. .. .. .. . .. .59
Smoking. . . .. . . .. . .. . . .. . . .. . .. . . .. . . .. . .. . . .. . . .. . . .. . .. . . .. . . .. . .. . . .. . . .. . . .. . .. . . .. . . .. . .. . . .. . . .. . . .. . ..63
Engine Ignition Switch. . .. . .. .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .64
Ignition Switches And Starting The Engine.. . . . . .. . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . .. . . . . .. . . . .. . . . . ..64
Electrical. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. . .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. . .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. . .. .. .. .. .66
Accessory Feed Connections. . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . ..66
Sleeper Inverter/Battery Charger (Optional). . . .. . . .. . .. . . .. . . .. . . .. . .. . . .. . . .. . . .. . .. . . .. . . .. . . .. . .. . . ..66
Phone And Cable TV Communication Ports (Optional). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67
Alternator. . .. . .. . . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . . .. . .. . .. . .. . .. . .. . .. . .. . .. . ..67
Ammeter (Optional). . . . . .. . . . . .. . . . . .. . . . . .. . . . . . .. . . . . .. . . . . .. . . . . .. . . . . .. . . . . . .. . . . . .. . . . . .. . . . . .. . . . . .. .67
Antennas: 5000i And 9000i. .. .. .. .. .. . .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. . .. .. .. .. .. .. .. .. .67
Battery. . .. . .. . .. . . .. . .. . .. . . .. . .. . .. . . .. . .. . .. . . .. . .. . .. . . .. . .. . .. . . .. . .. . .. . . .. . .. . .. . .. . . .. . .. . .. . . .. . .. . ..68
Circuit Breakers, Fuses And Fusible Links. . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . .69
Windshield Wiper And Washer Controls.. . . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . . .. . . . . ..70
Horn.. .. . .. .. . .. .. . .. .. .. . .. .. . .. .. . .. .. .. . .. .. . .. .. . .. .. . .. .. .. . .. .. . .. .. . .. .. .. . .. .. . .. .. . .. .. . .. .. .. . .. .. . .71
Mirrors. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . .. . . .. . . .. . . .. . . ..71
Lighting Switches.. . .. . .. .. . .. . .. . .. . .. . .. . .. . .. . .. .. . .. . .. . .. . .. . .. . .. . .. . .. . .. .. . .. . .. . .. . .. . .. . .. . .. . .. . .72
Audible Alarm. .. . .. . .. . .. . .. . . .. . .. . .. . .. . .. . . .. . .. . .. . .. . .. . . .. . .. . .. . .. . .. . . .. . .. . .. . .. . .. . . .. . .. . .. . .. . ..72
Data Link Driven Instrument Cluster.. . .. .. .. . .. .. .. .. . .. .. .. .. . .. .. .. . .. .. .. .. . .. .. .. . .. .. .. .. . .. .. .. .. . .73
Oil Pressure Warning Light, High Water Temperature Warning Light. . . . . .. . . . . .. . . . . . .. . . . . .. . . . . .. .73
Speedometer .. .. . .. . .. . .. .. . .. . .. . .. . .. .. . .. . .. . .. .. . .. . .. . .. .. . .. . .. . .. .. . .. . .. . .. .. . .. . .. . .. . .. .. . .. . .. . .73
Tachometer. . .. .. .. . .. .. .. . .. .. .. . .. .. .. . .. .. .. . .. .. .. .. . .. .. .. . .. .. .. . .. .. .. . .. .. .. . .. .. .. . .. .. .. .. . .. .. .. . .74

Form No. 3628504R1

Printed in the United States of America
 TABLE OF CONTENTS

Pyrometer. . .. . . . .. . . .. . . .. . . .. . . .. . . . .. . . .. . . .. . . .. . . . .. . . .. . . .. . . .. . . . .. . . .. . . .. . . .. . . .. . . . .. . . .. . . .. . . .. . .74
Voltmeter. .. . . . .. . . .. . . .. . . . .. . . .. . . .. . . . .. . . .. . . .. . . .. . . . .. . . .. . . .. . . . .. . . .. . . .. . . . .. . . .. . . .. . . . .. . . .. . . .. . .74
Electronic Digital Odometer. . . .. . . . . .. . . . . .. . . . . .. . . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . . .. . . . . .. . . . . .. . . . . .. . . .74
Warning Lights. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. .. . .. . .. . .. . .. . .. .76
Turn Signal Switch. .. .. .. .. . .. .. .. .. .. .. .. .. . .. .. .. .. .. .. .. .. .. . .. .. .. .. .. .. .. .. . .. .. .. .. .. .. .. .. .. . .. .. .. ..77
American Technology Compass and Outside Temperature System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .78
Heating, Defrosting, Ventilation, Air Conditioning.. . . .. . .. . . .. . .. . .. . . .. . .. . . .. . .. . . .. . .. . . .. . .. . .. . . .. .79
HVAC Central Control Panel. . . .. . . . . . .. . . . . .. . . . . .. . . . . .. . . . . . .. . . . . .. . . . . .. . . . . . .. . . . . .. . . . . .. . . . . . .. . . .79
Pro Sleeper Climate Control: . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. .. . .. . .. .81
Eaton VORAD EVT-300 Collision Warning System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .82
SmartCruise.. . .. .. . .. .. . .. .. . .. .. . .. . .. .. . .. .. . .. .. . .. .. . .. . .. .. . .. .. . .. .. . .. .. . .. . .. .. . .. .. . .. .. . .. .. . .. . ..86
Electronically Controlled Engines. . . .. . . .. . . .. . . . .. . . .. . . .. . . .. . . .. . . . .. . . .. . . .. . . .. . . .. . . . .. . . .. . . .. . . .. . .88
Caterpillar Engines . . . .. . . . . .. . . . . .. . . . . .. . . . . .. . . . . .. . . . . . .. . . . . .. . . . . .. . . . . .. . . . . .. . . . . .. . . . . . .. . . . . .. . . .88
Cummins Engines. .. . .. . .. . . .. . .. . .. . . .. . .. . .. . . .. . .. . .. . . .. . .. . .. . .. . . .. . .. . .. . . .. . .. . .. . . .. . .. . .. . . .. . .. .94
Axles and Suspensions.. . . .. . . .. . . .. . . .. . .. . . .. . . .. . . .. . . .. . .. . . .. . . .. . . .. . . .. . .. . . .. . . .. . . .. . . .. . . .. . .. . . .101
Gross Weight (Axle Vehicle). .. . .. . .. .. . .. . .. .. . .. . .. .. . .. . .. .. . .. . .. .. . .. . .. .. . .. . .. .. . .. . .. .. . .. . .. .101
Axle Operating Temperature. .. . .. . .. . . .. . .. . .. . . .. . .. . .. . .. . . .. . .. . .. . .. . . .. . .. . .. . . .. . .. . .. . .. . . .. . .. . .102
Front Axle (4X4, 6X6).. . .. .. .. .. .. . .. .. .. .. .. . .. .. .. .. .. . .. .. .. .. . .. .. .. .. .. . .. .. .. .. .. . .. .. .. .. .. . .. .. .. .102
Two Speed Rear Axle. . . .. . . . . . .. . . . . . .. . . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . . .. . . . . . .. . . . . . .. . . . . . . .. . . . . . .103
Tandem Axle Power Divider (Inter-Axle Differential) Lock Control.. . . . .. . . .. . . . .. . . . .. . . . .. . . . .. . . . .105
Rear Axles (With Locking Or Limited Slip Differentials). .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .107
Axle And Suspension Conversions. .. .. .. . .. .. . .. .. .. . .. .. .. . .. .. . .. .. .. . .. .. .. . .. .. . .. .. .. . .. .. .. . .. .. .110
Brakes. . .. . .. . . .. . .. . . .. . .. . .. . . .. . .. . . .. . .. . . .. . .. . . .. . .. . . .. . .. . . .. . .. . .. . . .. . .. . . .. . .. . . .. . .. . . .. . .. . . .. . .. . .111
Downhill Operation.. . .. . .. .. . .. . .. . .. . .. . .. .. . .. . .. . .. . .. .. . .. . .. . .. . .. . .. .. . .. . .. . .. . .. . .. .. . .. . .. . .. . .. .111
Air Brakes. .. . .. . . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . . .. . .. . .. . .. . .. . .. . .. . .. . .. . .111
Bobtail Proportioning System. . .. . .. . .. . .. . . .. . .. . .. . .. . .. . . .. . .. . .. . .. . .. . . .. . .. . .. . .. . .. . .. . . .. . .. . .. . .121
Air Antilock Brake System (ABS).. . .. . .. . .. . .. .. . .. . .. . .. . .. . .. .. . .. . .. . .. . .. . .. .. . .. . .. . .. . .. . .. . .. .. . .122
Automatic Traction Control System (ATC). . .. .. . .. .. . .. .. . .. .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .124
Bendix ABS-6 Advanced with RSP (Roll Stability Program).. .. .. .. . .. .. .. .. .. . .. .. .. .. .. .. . .. .. .. .. .125
Transmission. . .. .. . .. .. . .. .. .. . .. .. . .. .. . .. .. . .. .. .. . .. .. . .. .. . .. .. . .. .. . .. .. .. . .. .. . .. .. . .. .. . .. .. .. . .. .. . .. .127

Form No. 3628504R1

Printed in the United States of America
 TABLE OF CONTENTS

Manual Transmissions.. .. .. . .. .. .. . .. .. .. . .. .. . .. .. .. . .. .. .. . .. .. .. . .. .. .. . .. .. .. . .. .. .. . .. .. . .. .. .. . .. ..127

Automatic Transmissions.. .. . .. .. .. .. .. .. . .. .. .. .. .. . .. .. .. .. .. . .. .. .. .. .. . .. .. .. .. .. .. . .. .. .. .. .. . .. .. ..134
Transfer Case. . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . .139
Engine. . .. . .. . .. . .. . .. . .. . .. .. . .. . .. . .. . .. . .. . .. . .. . .. .. . .. . .. . .. . .. . .. . .. . .. . .. . .. .. . .. . .. . .. . .. . .. . .. . .. . .. . ..140
Governed Engine Speed. .. . .. . . .. . . .. . .. . . .. . . .. . .. . . .. . . .. . .. . . .. . . .. . . .. . .. . . .. . . .. . .. . . .. . . .. . .. . . .. .140
Hazards of Operation Near Flammable Vapors. .. . .. . .. .. . .. .. . .. . .. .. . .. . .. .. . .. .. . .. . .. .. . .. .. . .. . ..141
Air Restriction Gauge. .. . .. . .. . .. . .. . .. . .. . .. .. . .. . .. . .. . .. . .. . .. . .. . .. . .. .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . ..141
Troubleshooting.. . . .. . . .. . . .. . . .. . .. . . .. . . .. . . .. . . .. . .. . . .. . . .. . . .. . . .. . .. . . .. . . .. . . .. . . .. . . .. . .. . . .. . . .. .143
Diesel Engines. . .. . . . . .. . . . .. . . . . .. . . . .. . . . .. . . . . .. . . . .. . . . .. . . . . .. . . . .. . . . .. . . . . .. . . . .. . . . .. . . . . .. . . . .. . .144
Charge Air Cooler. .. . .. .. . .. . .. . .. .. . .. . .. . .. .. . .. . .. . .. . .. .. . .. . .. . .. .. . .. . .. . .. .. . .. . .. . .. . .. .. . .. . .. . ..144
Engine Performance Problems. .. . . .. . .. . . .. . . .. . .. . . .. . . .. . .. . . .. . . .. . . .. . .. . . .. . . .. . .. . . .. . . .. . .. . . .. .144
Emergency Starting Using Jumper Cables.. . .. . .. . .. .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . ..145
Operating Instructions. . . .. . . .. . . .. . . .. . . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . . .. . . .. . . .. . . .. .146
Starting A Turbocharged Vehicle On A Grade. . . . .. . . . . . . . .. . . . . . . . .. . . . . . . . . .. . . . . . . . .. . . . . . . . .. . . . . .148
Shut-Down. . .. . .. . .. . .. .. . .. . .. . .. . .. . .. . .. . .. . .. . .. .. . .. . .. . .. . .. . .. . .. . .. . .. .. . .. . .. . .. . .. . .. . .. . .. . .. . ..149
Engine Shut-Down and Restarting Procedure. .. . . . . .. . . . . . .. . . . . .. . . . . . .. . . . . .. . . . . .. . . . . . .. . . . . .. . . .149
Parking.. . .. . .. . . .. . .. . .. . .. . .. . .. . . .. . .. . .. . .. . .. . .. . . .. . .. . .. . .. . .. . .. . . .. . .. . .. . .. . .. . . .. . .. . .. . .. . .. . .. .150
Cooling System.. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. . .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. . .. .. .. .. .. .. .. .. .. .. ..150
Engine Oil.. .. . .. .. . .. . .. .. . .. .. . .. . .. .. . .. .. . .. . .. .. . .. .. . .. . .. .. . .. .. . .. . .. .. . .. .. . .. . .. .. . .. .. . .. . .. .. . ..151
Fuel. . .. . . .. . . .. . . .. . . .. . . .. . . . .. . . .. . . .. . . .. . . .. . . .. . . . .. . . .. . . .. . . .. . . .. . . .. . . . .. . . .. . . .. . . .. . . .. . . .. . . . .. . . .. .151
Hazards Of Diesel Fuel/Gasoline Blends. . .. .. . .. .. . .. . .. .. . .. .. . .. .. . .. . .. .. . .. .. . .. .. . .. . .. .. . .. .. . ..151
Fuel and Lubricant Additives. . .. .. . .. .. .. . .. .. .. . .. .. .. . .. .. .. . .. .. . .. .. .. . .. .. .. . .. .. .. . .. .. .. . .. .. . .. ..152
Fueling Procedures.. . . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. .152
Fueling Precautions. . .. .. .. . .. .. .. . .. .. .. . .. .. .. .. . .. .. .. . .. .. .. . .. .. .. . .. .. .. . .. .. .. .. . .. .. .. . .. .. .. . .. ..152
Hood.. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. .153
Tilt Hood. .. . .. .. .. .. .. .. .. .. .. .. . .. .. .. .. .. .. .. .. .. .. . .. .. .. .. .. .. .. .. .. .. . .. .. .. .. .. .. .. .. .. .. . .. .. .. .. .. ..153
5000i Series With Butterfly Hood. . .. . .. .. . .. . .. . .. . .. . .. .. . .. . .. . .. . .. . .. .. . .. . .. . .. . .. .. . .. . .. . .. . .. . ..154
Steering. . .. . .. . . .. . . .. . .. . . .. . . .. . .. . . .. . . .. . .. . . .. . . .. . .. . . .. . . .. . . .. . .. . . .. . . .. . .. . . .. . . .. . .. . . .. . . .. . .. . . .. .154
Adjustable Steering Column. . . .. . . . .. . . . . .. . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . .154
Towing Instructions. .. . .. . .. . .. . .. .. . .. . .. . .. .. . .. . .. . .. . .. .. . .. . .. . .. . .. .. . .. . .. . .. .. . .. . .. . .. . .. .. . .. . .. . ..155

Form No. 3628504R1

Printed in the United States of America
 TABLE OF CONTENTS

Towing Vehicle With Front Wheels Suspended. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .156

Towing Vehicles With Driver Controlled Differential Lock. . . .. . . . . .. . . . . .. . . . . .. . . . . .. . . . .. . . . . .. . . . . .157
Towing Vehicle With Rear Wheels Suspended. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . .159
Tractor-Trailer Connections. .. . . . .. . . . .. . . . .. . . . . .. . . . .. . . . .. . . . .. . . . .. . . . . .. . . . .. . . . .. . . . .. . . . . .. . . . .. . . . .160
Connecting And Disconnecting Trailers Using Air Suspension Dump Valve Feature. . .. . . .. . .. . . .160
Fifth Wheel Operation. . . .. . . . .. . . . .. . . . .. . . . . .. . . . .. . . . .. . . . .. . . . .. . . . . .. . . . .. . . . .. . . . .. . . . .. . . . . .. . . . .. . . . .161
Hook-Up. .. . .. .. .. .. .. .. . .. .. .. .. .. . .. .. .. .. .. .. . .. .. .. .. .. .. . .. .. .. .. .. .. . .. .. .. .. .. . .. .. .. .. .. .. . .. .. .. .. .161
Un-Hook. .. . .. .. .. .. .. .. . .. .. .. .. .. . .. .. .. .. .. .. . .. .. .. .. .. .. . .. .. .. .. .. .. . .. .. .. .. .. . .. .. .. .. .. .. . .. .. .. .. .162
Sliding Fifth Wheel. . .. . .. . .. . .. . . .. . .. . .. . .. . .. . .. . .. . . .. . .. . .. . .. . .. . .. . . .. . .. . .. . .. . .. . .. . .. . . .. . .. . .. . .. . .162

SECTION 5 VEHICLE MAINTENANCE INSTRUCTIONS

Preface. . . .. . .. . . .. . . .. . . .. . .. . . .. . . .. . . .. . .. . . .. . . .. . . .. . .. . . .. . . .. . . .. . . .. . .. . . .. . . .. . . .. . .. . . .. . . .. . . .. . .. . . .165
Maintenance Guidelines.. .. .. . .. .. .. . .. .. .. . .. .. .. . .. .. .. . .. .. .. . .. .. .. . .. .. .. . .. .. .. . .. .. .. . .. .. .. . .. .. .165
Supporting Your Vehicle for Service.. .. .. .. .. .. .. .. .. .. .. .. . .. .. .. .. .. .. .. .. .. .. .. .. . .. .. .. .. .. .. .. .. .. .167
Chassis Lubrication. .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .167
Air Conditioning Service Checks. .. . .. . .. . .. .. . .. . .. . .. .. . .. . .. . .. .. . .. . .. . .. . .. .. . .. . .. . .. .. . .. . .. . .. .. . .168
Axles. . .. .. .. . .. .. . .. .. .. . .. .. . .. .. .. . .. .. . .. .. .. . .. .. . .. .. .. . .. .. . .. .. .. . .. .. . .. .. .. . .. .. . .. .. . .. .. .. . .. .. . .. .. .168
Front Axle. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. .. . .. . .. . .. . .. . .. . .168
Rear Axle .. .. .. . .. .. .. . .. .. .. . .. .. .. . .. .. .. . .. .. .. . .. .. .. . .. .. .. . .. .. .. .. . .. .. .. . .. .. .. . .. .. .. . .. .. .. . .. .. .170
NoSpin Detroit Locker Positive Locking Differential. . . .. . . . .. . . . . .. . . . .. . . . .. . . . .. . . . .. . . . . .. . . . .. . . . .170
Brakes. .. . .. . .. . .. . .. . .. .. . .. . .. . .. . .. . .. . .. . .. . .. . .. .. . .. . .. . .. . .. . .. . .. . .. . .. .. . .. . .. . .. . .. . .. . .. . .. . .. .. . .. . .170
General Information. .. .. .. . .. .. .. . .. .. .. . .. .. .. . .. .. .. .. . .. .. .. . .. .. .. . .. .. .. . .. .. .. . .. .. .. .. . .. .. .. . .. .. .170
Air Brakes. .. .. . .. . .. .. . .. . .. .. . .. .. . .. . .. .. . .. .. . .. . .. .. . .. .. . .. . .. .. . .. .. . .. . .. .. . .. .. . .. . .. .. . .. .. . .. . .. .171
Cab.. .. . .. .. . .. .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .174
Care Of Vehicle. .. .. .. .. .. .. .. .. .. . .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. . .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .174
Clutch. .. .. .. . .. .. .. .. .. .. .. . .. .. .. .. .. .. . .. .. .. .. .. .. .. . .. .. .. .. .. .. .. . .. .. .. .. .. .. .. . .. .. .. .. .. .. .. . .. .. .. .. .. .175
Pedal Free Travel. .. . . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . . .. . .175
Electrical.. . .. . .. . . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . . .. . .. . .. . .. . .. . .. . .. . .. . .176
Alternator-Starter-Battery Test.. . .. . .. . .. . .. . .. . . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . . .. . .. . .. . .. . .. . .. . .. . .176

Form No. 3628504R1

Printed in the United States of America
 TABLE OF CONTENTS

Terminal Inspection-Cleaning-Corrosion Protection. . .. . . .. . . . .. . . . .. . . .. . . . .. . . .. . . . .. . . .. . . . .. . . .. . .176

Accessory Feed Connections.. . .. .. .. .. . .. .. .. . .. .. .. . .. .. .. .. . .. .. .. . .. .. .. . .. .. .. . .. .. .. .. . .. .. .. . .. ..177
Engine. . .. . .. . .. . .. . .. . .. . .. .. . .. . .. . .. . .. . .. . .. . .. . .. .. . .. . .. . .. . .. . .. . .. . .. . .. . .. .. . .. . .. . .. . .. . .. . .. . .. . .. . ..177
General. . .. .. .. .. .. . .. .. .. .. . .. .. .. .. .. . .. .. .. .. .. . .. .. .. .. . .. .. .. .. .. . .. .. .. .. .. . .. .. .. .. . .. .. .. .. .. . .. .. ..178
Scheduled Maintenance . . .. . .. . .. . .. . .. . .. . .. . .. . . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. .178
Catalytic Converter.. .. .. .. .. .. .. .. .. . .. .. .. .. .. .. .. .. .. . .. .. .. .. .. .. .. .. .. . .. .. .. .. .. .. .. .. .. . .. .. .. .. .. ..178
Air Induction System. .. . .. . .. .. . .. .. . .. .. . .. . .. .. . .. .. . .. .. . .. . .. .. . .. .. . .. .. . .. . .. .. . .. .. . .. .. . .. . .. .. . ..179
Air Cleaner Element Service.. . .. . .. .. . .. . .. . .. .. . .. . .. . .. .. . .. . .. . .. . .. .. . .. . .. . .. .. . .. . .. . .. .. . .. . .. . ..179
Chassis Mounted Charge Air Cooler.. . .. .. . .. .. . .. .. . .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . ..180
Cooling System.. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. . .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. . .. .. .. .. .. .. .. .. .. .. ..181
Frame And Tow Hooks.. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . .183
Fuel System.. . . .. . .. . . .. . . .. . . .. . . .. . . .. . . .. . .. . . .. . . .. . . .. . . .. . . .. . .. . . .. . . .. . . .. . . .. . . .. . . .. . .. . . .. . . .. . . .. .183
Noise Emissions Exterior.. . .. .. .. .. .. .. .. .. .. .. . .. .. .. .. .. .. .. .. .. .. .. . .. .. .. .. .. .. .. .. .. .. . .. .. .. .. .. ..184
Air Intake System:. .. .. .. .. . .. .. .. .. .. .. . .. .. .. .. .. .. .. . .. .. .. .. .. .. .. . .. .. .. .. .. .. . .. .. .. .. .. .. .. . .. .. .. ..184
Body:. . . .. . . .. . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . .. . . .. . . .. . . .. . . .. . . .. .184
Cooling System:.. . .. .. . .. .. . .. .. . .. .. . .. .. . .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. . .. .. . .. .. . .. .. . .. .. . ..184
Engine and Driveline System:. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . . .. . . . . . .. . . .184
Exhaust System:. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. .184
Drive Shaft. . .. . .. .. . .. .. . .. . .. .. . .. . .. .. . .. .. . .. . .. .. . .. .. . .. . .. .. . .. . .. .. . .. .. . .. . .. .. . .. .. . .. . .. .. . .. . .. .. . ..185
Suspension (Air And Steel Springs). . . . .. . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . .. . . . .. . . . .. . . . .. . . . .. . . .. . . . .. . .185
Steering. . .. . .. . . .. . . .. . .. . . .. . . .. . .. . . .. . . .. . .. . . .. . . .. . .. . . .. . . .. . . .. . .. . . .. . . .. . .. . . .. . . .. . .. . . .. . . .. . .. . . .. .185
General. . .. .. .. .. .. . .. .. .. .. . .. .. .. .. .. . .. .. .. .. .. . .. .. .. .. . .. .. .. .. .. . .. .. .. .. .. . .. .. .. .. . .. .. .. .. .. . .. .. ..185
Tightening Steering Intermediate Shaft Joint Bolts. . . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . . .. . . .. . . .. .186
Lubrication Points.. . .. . .. . .. . .. . . .. . .. . .. . .. . .. . . .. . .. . .. . .. . . .. . .. . .. . .. . .. . . .. . .. . .. . .. . .. . . .. . .. . .. . .. .186
Power Steering.. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . ..186
Tires. .. .. .. .. .. .. .. .. . .. .. .. .. .. .. .. .. .. .. .. .. . .. .. .. .. .. .. .. .. .. .. .. .. . .. .. .. .. .. .. .. .. .. .. .. .. . .. .. .. .. .. .. .. ..187
Inflation. .. .. .. . .. .. . .. .. . .. .. . .. .. . .. .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. .. . .. .. . .. .. . .. .. . .. .. . .. .. .. . .. .. . ..187
Inspection. .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . ..190
Loads. .. . .. .. . .. .. . .. .. . .. . .. .. . .. .. . .. .. . .. .. . .. . .. .. . .. .. . .. .. . .. .. . .. . .. .. . .. .. . .. .. . .. .. . .. . .. .. . .. .. . ..191
Matching. . . .. . . .. . . .. . . . .. . . .. . . .. . . .. . . . .. . . .. . . .. . . .. . . .. . . . .. . . .. . . .. . . .. . . .. . . . .. . . .. . . .. . . .. . . .. . . . .. .191

Form No. 3628504R1

Printed in the United States of America
 TABLE OF CONTENTS

Mixing.. . . . .. . . .. . . . .. . . .. . . . .. . . . .. . . .. . . . .. . . .. . . . .. . . . .. . . .. . . . .. . . .. . . . .. . . . .. . . .. . . . .. . . .. . . . .. . . . .. . . .191
Rotation. . .. . .. . . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . . .. . .191
Wheel And Tire Balancing.. . .. .. .. .. .. .. .. .. . .. .. .. .. .. .. .. . .. .. .. .. .. .. .. .. . .. .. .. .. .. .. .. . .. .. .. .. .. .. .192
Wear. . .. .. .. . .. .. . .. .. .. . .. .. . .. .. . .. .. .. . .. .. . .. .. . .. .. .. . .. .. . .. .. . .. .. .. . .. .. . .. .. .. . .. .. . .. .. . .. .. .. . .. .192
Use Of Tire Chains. .. .. . .. .. .. .. . .. .. .. .. . .. .. .. .. . .. .. .. . .. .. .. .. . .. .. .. .. . .. .. .. . .. .. .. .. . .. .. .. .. . .. .. .193
Transmission. . .. .. . .. .. . .. .. .. . .. .. . .. .. . .. .. . .. .. .. . .. .. . .. .. . .. .. . .. .. . .. .. .. . .. .. . .. .. . .. .. . .. .. .. . .. .. . .. .194
Automatic Transmissions. .. . .. .. .. .. .. . .. .. .. .. .. . .. .. .. .. .. .. . .. .. .. .. .. . .. .. .. .. .. . .. .. .. .. .. . .. .. .. .. .194
Wheels.. .. .. .. .. . .. .. .. .. .. .. .. .. .. . .. .. .. .. .. .. .. .. .. .. . .. .. .. .. .. .. .. .. .. . .. .. .. .. .. .. .. .. .. .. . .. .. .. .. .. .. .. .194
General. .. .. .. .. . .. .. .. .. .. . .. .. .. .. .. . .. .. .. .. . .. .. .. .. .. . .. .. .. .. .. . .. .. .. .. . .. .. .. .. .. . .. .. .. .. .. . .. .. .. .194
Grease Lubricated Front Wheel Bearings. . . .. . . .. . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . .. . . .. . . .. . . .195
Oil Lubricated Front Wheel Bearings. . . . . . . . .. . . . . . . . . . . . . .. . . . . . . . . . . . . . .. . . . . . . . . . . . . .. . . . . . . . . . . . . ..196
Installation, Tightening And Alignment.. .. . .. .. . .. . .. .. . .. . .. .. . .. .. . .. . .. .. . .. . .. .. . .. . .. .. . .. .. . .. . .. .196
Proper Torque. .. . . . .. . . .. . . .. . . . .. . . .. . . .. . . . .. . . .. . . .. . . . .. . . .. . . .. . . . .. . . .. . . .. . . . .. . . .. . . .. . . .. . . . .. . . .203
Changing Wheel Types. .. . .. .. .. . .. .. . .. .. .. . .. .. .. . .. .. . .. .. .. . .. .. . .. .. .. . .. .. .. . .. .. . .. .. .. . .. .. . .. .. .203
Tire And Rim Combinations. . .. . .. . . .. . .. . . .. . .. . . .. . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . .204
Torque Specifications. .. . . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . . .205
Disc Wheel Torque Chart.. . .. .. .. . .. .. .. .. . .. .. .. . .. .. .. .. . .. .. .. .. . .. .. .. . .. .. .. .. . .. .. .. . .. .. .. .. . .. .. .205
U-Bolt Nut Torque Chart. .. .. . .. . .. .. . .. . .. . .. .. . .. . .. .. . .. . .. .. . .. . .. .. . .. . .. .. . .. . .. .. . .. . .. . .. .. . .. . .. .206
Spring U-Bolt Checks. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .206
Fuse Charts.. .. .. .. .. .. .. .. .. .. .. . .. .. .. .. .. .. .. .. .. .. .. .. .. . .. .. .. .. .. .. .. .. .. .. .. .. .. .. . .. .. .. .. .. .. .. .. .. .. .206
Power Distribution Center Fuse and Circuit Breaker Layout. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .207
Pro-Sleeper Fuse Index. .. . . .. . .. . . .. . . .. . . .. . . .. . . .. . .. . . .. . . .. . . .. . . .. . . .. . .. . . .. . . .. . . .. . . .. . .. . . .. . . .207

SECTION 6 LUBRICATION, SEALERS AND MAINTENANCE INTERVALS

Description. .. . . . .. . . . .. . . . .. . . . .. . . . . .. . . . .. . . . .. . . . .. . . . .. . . . . .. . . . .. . . . .. . . . .. . . . .. . . . . .. . . . .. . . . .. . . . .. . . . .209
Engine Oil Specifications.. . . . .. . . . .. . . . .. . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . .209
Engine Oil. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .209
Crankcase Oil Specifications. . . . . . . .. . . . . . .. . . . . . . .. . . . . . .. . . . . . . .. . . . . . . .. . . . . . .. . . . . . . .. . . . . . .. . . . . . . .210
Grease Specifications. . . . .. . . . .. . . . . .. . . . .. . . . .. . . . .. . . . . .. . . . .. . . . .. . . . . .. . . . .. . . . .. . . . .. . . . . .. . . . .. . . . .210

Form No. 3628504R1

Printed in the United States of America
 TABLE OF CONTENTS

Lubrication Interval Tables. . . .. . . . . . .. . . . . .. . . . . .. . . . . .. . . . . .. . . . . .. . . . . .. . . . . .. . . . . .. . . . . .. . . . . .. . . . . .. . . .211

Front Axle. .. . .. . .. . .. . .. . .. .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . ..212
Springs.. . .. . .. . . .. . .. . .. . .. . .. . .. . . .. . .. . .. . .. . .. . .. . . .. . .. . .. . .. . .. . .. . . .. . .. . .. . .. . .. . . .. . .. . .. . .. . .. . .. .216
Brakes. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . ..217
Steering.. . .. . . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. .218
Drive Shaft. . .. . .. . .. . .. .. . .. . .. . .. . .. . .. . .. . .. . .. . .. .. . .. . .. . .. . .. . .. . .. . .. . .. .. . .. . .. . .. . .. . .. . .. . .. . .. . ..220
Front End Sheet Metal.. .. .. . .. .. .. .. .. .. . .. .. .. .. .. .. .. . .. .. .. .. .. .. . .. .. .. .. .. .. .. . .. .. .. .. .. .. . .. .. .. ..221
Clutch. .. .. .. .. .. .. .. . .. .. .. .. .. .. .. .. .. .. .. .. . .. .. .. .. .. .. .. .. .. .. .. . .. .. .. .. .. .. .. .. .. .. .. .. . .. .. .. .. .. .. ..221
Engine.. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . ..223
Transmission. .. . . . .. . . . .. . . . .. . . . . .. . . . .. . . . .. . . . .. . . . . .. . . . .. . . . .. . . . .. . . . . .. . . . .. . . . .. . . . .. . . . . .. . . . .. . .223
Rear Axle. . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . .228
Cab. .. . . .. . .. . . .. . .. . . .. . .. . . .. . .. . . .. . .. . . .. . .. . . .. . .. . . .. . .. . .. . . .. . .. . . .. . .. . . .. . .. . . .. . .. . . .. . .. . . .. . .. .231
Special Instructions.. . . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . . .. . .. . . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. .232
Unit Refill Capacities. .. .. .. .. .. .. .. . .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. . .. .. .. .. .. .. .. .. .. .. .. .. .. ..245
Front Drive Axle Capacities.. . . .. . .. . .. . . .. . .. . . .. . .. . .. . . .. . .. . . .. . .. . . .. . .. . .. . . .. . .. . . .. . .. . .. . . .. . .. .245
Rear Axle Refill Capacities. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . ..246
Cooling System Refill Capacities. .. . .. . .. . .. . .. . .. .. . .. . .. . .. . .. . .. .. . .. . .. . .. . .. . .. . .. .. . .. . .. . .. . .. . ..249
Bypass Filter Capacity: (If So Equipped). .. . .. .. . .. . .. .. . .. . .. .. . .. . .. .. . .. . .. .. . .. . .. .. . .. . .. .. . .. . ..250
Power Steering Gear Refill Capacities.. .. . .. .. .. . .. .. .. . .. .. . .. .. .. . .. .. .. . .. .. . .. .. .. . .. .. .. . .. .. . .. ..250
Transmission (Main) Refill Capacities. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ..250
Transmission (Auxiliary) Refill Capacities. . .. . . . . . .. . . . . . . .. . . . . . . .. . . . . . . .. . . . . . . .. . . . . . .. . . . . . . .. . . . .256
Transfer Case Refill Capacities. . .. .. . .. .. . .. .. .. . .. .. . .. .. .. . .. .. . .. .. . .. .. .. . .. .. . .. .. .. . .. .. . .. .. .. . ..257
Air Conditioning Refill Capacities.. .. . .. .. . .. .. . .. .. .. . .. .. . .. .. .. . .. .. . .. .. .. . .. .. . .. .. .. . .. .. . .. .. .. . ..258
Sealers. . . .. . . .. . . . .. . . .. . . . .. . . .. . . . .. . . .. . . . .. . . .. . . . .. . . .. . . . .. . . .. . . . .. . . .. . . . .. . . .. . . . .. . . .. . . . .. . . .. . . .. . .258
Special Instructions.. . . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . . .. . .. . . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. .261

SECTION 7 CUSTOMER ASSISTANCE

Service Information.. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. .265
International Warranty Program. . . . . .. . . . . . .. . . . . .. . . . . .. . . . . .. . . . . . .. . . . . .. . . . . .. . . . . . .. . . . . .. . . . . .. . . .265

Form No. 3628504R1

Printed in the United States of America
 SECTION 1 FOREWORD
Preface
Your vehicle has been engineered and manufactured so that it
can provide economical and trouble-free service. However, it is
the owners 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 and steering systems,
can adversely affect the quality and reliability of your vehicle.
Such modifications must be avoided.
Optional Features. This manual describes many optional
features that may not be installed in this vehicle.
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.
Form No. 3628504R1
Printed in the United States of America
WARNING: Warnings advise you of hazards, the
consequences, and what to do to avoid them, 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 with the contents of this manual. 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 assist 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 a nearby
International dealer, or phone 1-800-44-TRUCK (87825) for
assistance.
International believes that every customer is entitled to the best
service, both from the product itself and from the firm who sells
and services that product.
Page 1
 SECTION 1 FOREWORD
Assistance Guide (cont.)
If, for any reason, you do not feel you are receiving these
services in connection with the operation of your vehicle or
the sales transaction, you should return to your selling dealer
so that these matters can be corrected to your satisfaction. If
the matter is not resolved at that time, it is suggested that the
following steps be taken:
Contact a Member of Management at the Dealer.
Discuss the details of the difficulty. In most instances any
problem can be resolved to your satisfaction by the owner or
manager in charge.
Contact Closest 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 of these offices, it is important to include
the following information in your communication.
Name under which new vehicle was purchased, address and
telephone number of purchaser
Vehicle model, year, vehicle identification number,
component code and serial numbers
Vehicle delivery date and present mileage
Location where purchased
Details of the problem.
Form No. 3628504R1
Page 2 Printed in the United States of America
Component Code Numbers
Code numbers are the basis for identifying the components used
on International trucks. They are used by sales personnel to
order the truck, by manufacturing to build that truck and by parts
personnel to service the truck. Many items in this manual are
identified by codes.
Code numbers are a combination of numbers and/or
alphabetical letters. These codes are listed on the Vehicle
Line Set Ticket which is sometimes known as the vehicle
specification card or code sheet.
Line Set Ticket
Each vehicle is provided with a Line Set Ticket (code sheet)
which lists identification code numbers of component units used
to build the vehicle.
One copy of the line set ticket is included in the literature
provided with the vehicle. When replacement parts are
required, take this copy with you to positively identify vehicle
components to be sure of getting the correct parts.
Be Sure To Return Line Set Ticket To Vehicle After Obtaining
Parts.
 SECTION 1 FOREWORD
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 advice on vehicle
storage, as well as proper procedures to follow when you return
the vehicle to service.
Exterior Noise Emissions
Many operators and owners of the type of vehicles described
herein are subject to Federal Motor Carrier Safety Regulations
and Noise Emission Requirements. All owners and operators
are urged to obtain a copy and comply with these regulations.
Copies of these regulations can be purchased from:
Superintendent of Documents
U.S. Government Printing Office
Washington, D.C. 20402
International Truck and Engine Corporation warrants to the
first person who purchases this vehicle for purposes other than
resale and to each subsequent purchaser that this vehicle,
as manufactured by International, was designed, built and
equipped to conform at the time it left Internationals control
with all applicable U.S. Environmental Protection Agency Noise
Control Regulations.
This warranty covers this vehicle as designed, built and
equipped by International Truck and Engine Corporation, and
is not limited to any particular part, component or system
Form No. 3628504R1
Printed in the United States of America
of the vehicle manufactured by International. Defects in
design, assembly or in any part, component or system of the
vehicle as manufactured by International, which at the time it
left Internationals control, cause noise emissions to exceed
Federal standards, are covered by this warranty for the life of
the 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 other
than for purposes of maintenance, repair, or replacement, of any
device or element of design incorporated into any new vehicle
for the purpose of noise control prior to its sale or delivery to
the ultimate purchaser or while it is in use, or (2) The use of
the vehicle after 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 or piping. B. Acoustical Shielding (Body): Removal of
wheel well splash shields, cab shields or acoustical (underhood)
insulation. C. Cooling System: 1. Removal or rendering
inoperative the fan clutch. 2. Removal of fan shrouds. D.
Engine and Driveline System: 1. Removal or rendering engine
speed governor inoperative so as 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 muffler, resonator or tailpipe.
Page 3
 SECTION 1 FOREWORD

Tampering With Noise Control System Prohibited

(cont.)
Use the following Verification Of Inspection forms to log Noise Emission inspections of, at a minimum, the above systems.

Emission Control Systems

NOTE: Federal and California Emission system warranties are found in your Engine Operators Manual.

Verification of Inspection Noise Emissions

Form No. 3628504R1

Page 4 Printed in the United States of America
 SECTION 1 FOREWORD
Reporting Safety Defects
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 Administration
(NHTSA) in addition to notifying International Truck and Engine
Corporation. To notify International, see regional numbers,
listed in the front of the manual.
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
problems between you, your dealer, or International Truck and
Engine Corporation.
To contact NHTSA, you may either call the Auto Safety Hotline
toll-free at 1-800-424-9393 (or 366-0123 in Washington, D.C.
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 Hotline.
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 International Truck and Engine Corporation Canada and
then Transport Canada.
Form No. 3628504R1
Printed in the United States of America
To contact International Truck and Engine Corporation Canada,
you may either call the Regional Service Manager (Canadian
Sales Region) 905-332-2537 or write to: International Truck and
Engine Corporation Canada, 5500 North Service Road, Box
5337, Burlington, Ontario L7L 5H7.
To contact Transport Canada, Defect Investigations and Recalls,
you may call 1-800-333-0510, or write to: Transport Canada,
ASFAD, Place de Ville Tower C, 330 Sparks Street, Ottawa,
Ontario K1A 0N5.
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 LETTER. If your vehicle is part of a Safety Recall
campaign, the recall service procedure must be completed to
assure safe operation of your vehicle. As a vehicle owner, you
must provide International dealers with address corrections and
changes to ensure that you receive all notifications. Please
verify that your local dealer has your correct address. Dealers
will also have a record of any outstanding campaigns that affect
your vehicle.
International Customer Security Guide
International has prepared this guide to help you protect
your vehicle investment from theft. We realize the financial
Page 5
 SECTION 1 FOREWORD

International Customer Security Guide (cont.)

commitment you have made is significant, and that you depend
on that vehicle to generate profits and a livelihood. Vehicle theft
can be more than an economic crime. Protecting your vehicle
from theft or hijacking can be crucial to the safety and security
of the country and economy. While no system or device is 100%
effective, our intention is to provide some tips that you or your
drivers can use to reduce the risk of theft.
If you suspect vehicle theft activity, take a minute to tell the
National Insurance Crime Bureau (NICB) at 1800TEL-NICB.
You can make the free call anonymously and you might be
eligible for a reward. To learn more about vehicle theft and how
you can protect yourself, visit the NICBs website, www.nicb.org
Add Layers of Protection
International recommends four layers of protection for your
vehicle the more layers of protection on your vehicle, the
more difficult it is to steal.
Layer 1: Common Sense
Lock your doors.
Remove your keys from the ignition.
Close your windows completely.
Park in well-lit areas.
Drop a business card with your name on it between the glass
and doorframe. This can aid in identifying the truck when its
recovered.
Keep a copy of the lineset ticket in a location other than your
truck for reporting purposes and a copy of the VIN in your
wallet.
Photograph the interior and exterior of your truck from
various angles and keep these photographs in a safe
non-truck location, or send them to your insurance agent.
Report a theft as soon as its 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 vehicle is located when you are
not on the road.
Do not share information about your specific destination, or
the load you are hauling.
Be conscious of other vehicles that may be following you
over long distances call the police.

Form No. 3628504R1

Page 6 Printed in the United States of America
 SECTION 1 FOREWORD

International Customer Security Guide (cont.)

Be very suspicious of motorists that are signaling the driver Layer 4: Tracking System
to stop or pull over. Call the police, report the incident, and
The final layer is a tracking system that emits a signal to the
let the police respond.
police or a monitoring service when the vehicle is reported
stolen. If your vehicle has a tracking system and is stolen, it
Layer 2: Visible or Audible Device
can oftentimes be recovered faster and with less damage. Put
Audible alarm system your vehicle on the radar screen by installing a tracking system,
such as Internationals AWARE Vehicle Intelligence System.
Steering wheel locks
Steering column collars
Theft deterrent decals
Wheel locks
Window etching
Mechanical or electronic steering locks that restrict the
steering shaft u-joint are easy to use and provide a very
high level of affordable theft protection.

Layer 3: Vehicle Immobilizer

Fuse cut-offs
Kill switches
Starter, ignition and fuel disablers
Fuel cut-off switch

Form No. 3628504R1

Printed in the United States of America Page 7
 SECTION 1 FOREWORD
Optional Diamond Logic Electronic Application
Solutions
WARNING: This vehicle may be equipped from
the factory with electrical switches intended to operate
equipment that was installed by a truck equipment
manufacturer (TEM). Instructions, Cautions, and
Warnings for this additional equipment will NOT
be found in this manual. Read and understand the
appropriate manual for the specific equipment in
question before operating. Failure to observe this
warning may cause property damage, personal injury,
or death.
Form No. 3628504R1
Page 8 Printed in the United States of America
NOTE: This vehicle may be equipped with electronic, application
specific options not described in this Operators Manual. Many
of these features are supplied with rocker switches that have
custom labels applied. The presence of these options as factory
installed can be verified from the Line Set Ticket included with
the vehicle. A truck equipment manufacturer (TEM), however,
may have installed some of these options after production. In
that case, they will not appear on the Line Set Ticket. If installed
by a TEM, you should receive an operating guide and/or training
for the specific functions provided. Familiarize yourself with all
of the switches that control chassis, engine and body equipment
and seek adequate training on the function of all features before
operating this vehicle. Additional more detailed information
on these optional features may be found in the International
CT-471 Body Builder Manual, Electrical System Component
Section and the Body Builder Electrical Guide, both available
through the internationaldelivers.com website (Body Builder
option, under Customer Support menu).
 SECTION 2 VEHICLE INSPECTION GUIDE

Description

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. Mismatched or incorrect
fasteners can loosen and reduce clamping load,
which could result in vehicle damage, personal injury
or death.

To be sure your vehicle is ready to operate, conduct a pre-trip

inspection at the 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.

Form No. 3628504R1

Printed in the United States of America Page 9
 SECTION 2 VEHICLE INSPECTION GUIDE

Engine Compartment
With the engine stopped, check the following:

WARNING: To avoid personal injury or death from hot coolant or steam use only the following procedure to remove the
pressure cap from the radiator or expansion tank. Allow the engine to cool first. Wrap a thick, heavy cloth around the cap. Push
down, loosen cap slowly to its first notch position; then pause a moment to allow pressure to release through the overflow tube.
After the pressure has been released, the pressure cap may be removed.

Oil Level:
Coolant Level:
Windshield Washer Fluid Level:
Filter Minder:
Power Steering Fluid:
Fan, Alternator, Water Pump/Drive
Belt, and Air Compressor:
Refrigerant Compressor:
Any Leaks:
Use dipstick to verify that the oil level is between the full and refill mark.
Look through the plastic reservoir and make sure the fluid is within the minimum and maximum fluid
level range as marked on the reservoir. Do Not Remove Pressure Cap Until Coolant Has Cooled.
Inspect the reservoir and verify that the fluid level is up to the full mark. If additional fluid is required,
see Lubricant and Sealer Specifications chart, in the Maintenance section, for the correct fluid type
before filling.
Inspect gauge, on the air cleaner, for filter element air restriction indication. For element replacement,
See Air Cleaner Element Service in the Maintenance section.
Verify that the fluid level is between the full and refill mark.
With engine off, press belt to test that it is snug. Check for frays, cracks, loose fibers, or visible signs of
wear. If it deflects more than to of an inch, slippage is probably excessive.
Check belts (if so equipped) the same as for Water Pump.
Check for signs of fluid puddles, or dripping fluids on the ground under the engine, or the underside of
the engine.

Form No. 3628504R1

Page 10 Printed in the United States of America
 SECTION 2 VEHICLE INSPECTION GUIDE

Engine Compartment (cont.)

HVAC Air Inlet:
HVAC Fresh Air Filter-Optional:
Air Restriction Gauge (Filter Minder)
Air Brake Reservoir
Check for debris, leaves, etc. that may have collected on the HVAC air inlet grille or inside the exterior
module, which could reduce system performance.
Periodically check the optional HVAC fresh air filter for cleanliness.
Verify that the yellow indicator in gauge is below the maximum restriction mark.
Use petcock to drain air brake reservoir.

Engine Start with Parking Brake(s) Applied

NOTE: Ensure that parking brake is applied before starting

engine.

WARNING: Exercise care when working on vehicles with running engines that are equipped with an automatic fan clutch.
The fan engages when engine coolant reaches a predetermined temperature or the refrigerant pressure (if equipped with air
conditioning) reaches a predetermined setting. The fan will start with no advance warning. Failure to observe these precautions
could result in vehicle damage, personal injury or death.

Safety/Emergency Equipment:
Clutch/Gearshift:
Prior to entering cab, verify that vehicle is equipped with spare electrical fuses (if used), 3 red reflective
triangles, a properly charged and rated fire extinguisher, and wheel chocks. Walk around vehicle and check
that all steps and grab handles, inside and out as well as behind, are tight and clean. Use extreme caution
and maintain 3 point contact at all times. Check door latches for positive closing, latching and locking.
Depress clutch (if manual transmission) and verify transmission is in neutral before turning on starter;
keep depressed until engine reaches idling speed.

Form No. 3628504R1

Printed in the United States of America Page 11
 SECTION 2 VEHICLE INSPECTION GUIDE

Engine Start with Parking Brake(s) Applied

(cont.)
Oil Pressure Builds: Check to see that oil pressure is building to normal. Engine oil pressure gauge should begin a gradual
rise to normal operating range.
Air Beeper Sounds: The low air pressure warning should sound immediately after the engine starts but before the air
compressor has built up pressure. The low air pressure warning should stop when the air pressure
gets to 70 psi or more. Let the air pressure build to governed cut-out pressure, which should occur
between 115 - 130 psi.
Accelerator: Depress accelerator pedal and verify that it operates smoothly without any binding or irregular feel.
Remove foot from accelerator and make sure engine returns to idle immediately.
Ammeter/Voltmeter: Check the gauge to see if the alternator is charging.
Steering Play: Check for smooth operation through complete rotation. Check for excessive looseness in the steering
linkages. The steering wheel should have less than 10 degrees free play (approximately 2 inches at
rim of 18 inch steering wheel).
Seats: Be sure seats are firmly engaged to avoid forward or rearward movement when starting or stopping. Make
sure that anchor mounting fasteners to the floor as well as tether straps to floor or cab-back are tight
(25-35 lbf-ft., 34 47.5 N.m) and straps are not worn.
Seat Belts: Check the entire seat belt assembly for wear and proper operation. Make certain that anchor mountings
are tight.
Horn(s): Check to see that horn works.
Mirrors, Windshield: Check mirrors for proper adjustment; check for cracks or loose fittings. Check (optional) power mirrors
and (optional) heated mirrors for proper operation. Make sure the mirrors are clean.

Check the windshield for cracks, dirt, illegal stickers or other obstructions 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 illuminate when corresponding lights are turned on.

Form No. 3628504R1

Page 12 Printed in the United States of America
 SECTION 2 VEHICLE INSPECTION GUIDE

Engine Start with Parking Brake(s) Applied

(cont.)
Heater/Defroster: Check to be sure that heater/defroster is working. Verify adequate air flow from louvers and vents.
Operate Temperature and Mode controls to verify proper operation.
Parking Brake: Check that parking brake will hold vehicle by gently trying to pull forward with parking brake on.
Air Brake Check: Check the air brakes in the following manner:

1. Chock wheels if necessary. Push in parking brake and Tractor Protection Valve (TPV) knobs. (Tractor
only)

2. Check the air compressor or governor cut-out pressure (approximately 120 PSI).

3. Shut off engine and turn ignition switch back ON.

4. Without brake pedal applied, note air pressure drop for one minute. It should be less than 2 PSI for
single vehicles, 3 PSI for combinations.

5. Depress and hold brake pedal and make sure there is no more than a 3 PSI per pressure drop. For
combination vehicles, there should be no more than 4 PSI per minute pressure drop.

6. Step on and off brake pedal and check for warning light and buzzer to come on at about 70 6 PSI.
7. Step on and off brake and check to make sure the tractor protection and parking brake knobs pop out
between 20 to 45 PSI (138 to 310 kPA).

8. Restart engine, shift into a low gear, and gently pull against service and parking brakes separately
to make sure they will hold.

Form No. 3628504R1

Printed in the United States of America Page 13
 SECTION 2 VEHICLE INSPECTION GUIDE

Transmission

WARNING: If vehicle is equipped with an automatic transmission, have a qualified technician regularly check operation of
transmission neutral start switch. If unit starts in gear, the vehicle may inadvertently move, which could result in property damage,
personal injury or death.

Fluid Level: Check fluid level and shift linkage for proper operation.

Front of Vehicle

Lights: Check to see that all lights illuminate and are clean. Make sure headlights function on both high and low
beams. Check to see that reflectors are clean and unbroken and of proper color (red on rear, amber
elsewhere). Make sure that running lights are also clean and unbroken. Rear running lights must be
checked separately from signal, flasher and brake lights.
Steering Gear: Look for: missing or loose fasteners, power steering fluid leaks, and damage to power steering hoses.
Steering Linkage: Check to see that connecting links, arms, rods are not worn or cracked; joints, sockets and boot seals are
not worn or loose; that there are no loose or missing cotter keys, nuts or bolts.
Tow Hooks: Front and rear tow hooks should be inspected for damage or a loose mounting. This is particularly
important on vehicles where the tow hooks are frequently used.
Eaton VORAD Front Sensor Check to make sure that sensors view is clear of mud, dirt, ice or any material or objects.
(Optional)
Cab Mounting: Check condition of cab mounting brackets, tilt hood latches, sheet metal, rubber mountings.

Form No. 3628504R1

Page 14 Printed in the United States of America
 SECTION 2 VEHICLE INSPECTION GUIDE

Front Suspension

WARNING: Do not operate vehicle if any of the following conditions are evident. Loss of steering or suspension could
cause loss of vehicle control and result in property damage, personal injury or death.

Spring: Look for missing, broken or shifted leaves, or ones that are in contact or nearly in contact with tires,
rim, brake drum, frame or body.
Spring Mount: Check/inspect spring hangers, 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.

Front Brakes

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 are securely mounted.
Slack Adjuster: Check for broken, loose or missing parts. Angle between push rod and adjuster arm should be
approximately 90 degrees when brakes are applied. When pulled by hand, push rod should not move more
than approximately one inch.
Drums and Brake Linings: 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 or contaminated by lubricant.

Form No. 3628504R1

Printed in the United States of America Page 15
 SECTION 2 VEHICLE INSPECTION GUIDE

Front Wheel

WARNING: If wheels or tires must be changed, obtain expert tire service help. Mounting and de-mounting 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.

Tires: Check tread depth and tire inflation and note if tread is evenly worn. Look for cuts, or other damage to
the tread walls. See if valve caps and stem are missing, broken or damaged. Make sure retread is not
separating from tire. Retreads are not recommended on front axles of trucks. NOTE: Minimum tread
depth is 4/32 inch on front tires, and 2/32 inch on other tires.
Rims: Check for damaged or bent rims. Rim should not have welding repairs and no rust trails that indicate it
is loose on the wheel.
Lug Nuts: Check to see that all lug nuts are present and not loose (look for rust trails around nuts). There should be
no cracks radiating from lug bolt holes nor distortion of the bolt holes.
Hub Oil Seal: Check wheel hub oil seal for leaks, and, if sight glass is present, check to see that oil level is adequate.
Oil Lubricated Front Wheel If hubcap has a transparent window, check lube for proper level. If hubcap does not have a transparent
Bearings: window, remove rubber fill plug and check for proper level.

Form No. 3628504R1

Page 16 Printed in the United States of America
 SECTION 2 VEHICLE INSPECTION GUIDE

Driver/Fuel Area

WARNING: Maintain adequate clearance between all parts of the exhaust system and all hoses and wires for the engine cooling
system, brake system, fuel system, power steering system and electrical system. Heat damage to hoses or wires may cause a vehicle
malfunction that could result in property damage, personal injury or death.

Door, Mirror: Check for proper adjustment. Check for cracks or loose fittings. Make sure visibility is not impaired due to dirty mirrors.
Fuel Tank(s): Check to see that tank(s) is secure and that cap(s) are secure. Make sure there is no damage to the tank(s).
Leaks: Check for any fuel leaks from tank(s).
Eaton VORAD Right Check to make sure that sensors view is clear of mud, dirt, ice or any material or objects.
and/or Left Side
Sensors (Optional)

Form No. 3628504R1

Printed in the United States of America Page 17
 SECTION 2 VEHICLE INSPECTION GUIDE

Under Vehicle Rear of Tractor

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.

Drive Shaft: Check to see that shaft is not bent or cracked. Ensure that all shaft couplings are secure.
Exhaust System: Check to see 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 loose, cracked, bent, broken or missing
crossmembers or crossmember fasteners.

Truck/Tractor

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.

Air Lines/Electric Check to see that air hoses are not cut, cracked, chafed or worn (steel braid should not show through). Listen for
Wires audible air leaks. Make sure air lines and electrical wires are not tangled, crimped or pinched or being dragged
against truck/tractor parts. Electrical wire insulation should not be cut, cracked, chafed or worn. None of the air
lines or electrical wires should be spliced or taped. Check for corrosion on pins and in electrical sockets to ensure
continuity and reduced heat build-up potential.

Form No. 3628504R1

Page 18 Printed in the United States of America
 SECTION 2 VEHICLE INSPECTION GUIDE

Truck/Tractor (cont.)
Deck Plate: Check to see if deck plate is clean, securely bolted to tractor frame, and clear of loose 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. All running lights should be clean, not broken, and the proper color. All running lights must be
checked separately from signal flasher and brake lights.
Tractor Coupling System
Mounting Bolts: Look for loose or missing mounting brackets, clamps, bolts or nuts. Both fifth wheel and slide mounting must be
solidly attached.
Platform: Check for cracks or breaks in the platform structure.
Safety Latch: Check to see if safety latch is engaged.
Release Arm: Check to see if release arm is in the engaged position and that any safety latch is in place.
Kingpin/Apron: Check to see that kingpin is not bent or worn. Make sure that apron lies flat on fifth wheel skid plate, and that visible
part of apron is not bent, cracked or broken.
Tractor Sliding 5th Wheel
Locking Pins: Check for loose or missing pins in the slide mechanism of sliding 5th wheel. If air powered, check for air leaks. Make
sure that 5th wheel is not so far forward that tractor frame will strike landing gear during turns.
Lubrication: Make sure that top surface (face) of the wheel has a heavy coat of grease.

Trailer
NOTE: If you are operating a tractor with a trailer attached, an inspection of the trailer similar to that of the tractor should be done. Such an inspection
should follow trailer manufacturer recommendations and should include at a minimum: general condition, landing gear, doors, sides, lights, reflectors,
suspension, brakes, tires and wheels.

Form No. 3628504R1

Printed in the United States of America Page 19
 SECTION 2 VEHICLE INSPECTION GUIDE

Rear Springs

Springs: Check for broken leaves, leaves that have shifted and are in (or nearly in) contact with the tires, rim, brake drum,
frame or body. Check for missing or broken leaves in the leaf spring.
Spring Mounts: Check for cracked or broken spring hangers; broken, missing or loose bolts; missing or damaged bushings;
broken, loose or missing axle mounting parts.
Torque Rod, and Shocks Check to see that torque rod is not cracked, broken or missing. Check shock absorbers for cracks or leaks. There
Absorbers should be no missing or broken mounting bolts or worn bushings. Check that torque rod mounting fasteners
are tight.

Rear Brakes

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 are securely mounted.
Slack Adjuster: Check for broken, loose or missing parts. Angle between push rod and adjuster arm should be approximately 90
degrees when brakes are applied. When pulled by hand, push rod should not move more than approximately one inch.
Drums and Brake Check to see there are no cracks, dents or holes; no loose or missing bolts. Check to see that brake linings (where
Linings: visible) are not worn dangerously thin or contaminated by lubricant.

Form No. 3628504R1

Page 20 Printed in the United States of America
 SECTION 2 VEHICLE INSPECTION GUIDE

Rear Wheels

Tires: Check the tread depth and tire inflation and note if tread is evenly worn. Look for cuts, or other damage to the tread walls. See
if valve caps and stem are missing, broken or damaged. Make sure retread is not separating from tire. NOTE: Minimum tread
depth is 4/32 inch on front tires, and 2/32 inch on other tires.
Spacers: Check to see that dual wheels are evenly separated, and that tires are not touching one another.
Rims: Check for damaged or bent rims. Rims should not have welding repairs and no rust trails that indicate it is loose on the wheel.
Lug Nuts: Check to see that all lug nuts are present and not loose (look for rust trails around nuts). There should be no cracks radiating
from lug bolt holes nor distortion of the bolt holes.

Rear of Vehicle

Signal/Brake Lights:
Lights, Reflectors:
Check to see that both brake lights come on when brakes are applied. Make sure each signal light flashes,
and check that four-way flashers work.
Check to see that reflectors are clean. Make sure none are missing or broken. Check for proper color - red
on rear, amber elsewhere. Rear running lights should be clean, not broken and proper color. Rear running
lights must be checked separately from signal, flasher and brake lights.

Form No. 3628504R1

Printed in the United States of America Page 21
 SECTION 2 VEHICLE INSPECTION GUIDE

Form No. 3628504R1

Page 22 Printed in the United States of America
 SECTION 3 VEHICLE CONTROLS

Introduction
The vehicle controls enable the driver to manage the operation
of the majority of the vehicles functions. This section describes
the Overhead Console, Instrument with Wing Panel, and Glove
Box (that houses the fuse pane and relays).

5000 and 9000i Overhead Panel

The overhead console is provided for storage, Cab lighting,
and optional compass and temperature monitoring functions
(see adjustment procedures in Compass/Temperature section
of Vehicle Operations).

1. RADIO SPEAKER LOCATIONS (2)

2. CAB COURTESY LIGHT SWITCH (CHOOSE DOOR
TO HAVE LIGHTS TURN ON WHEN A DOOR IS
OPENED)
3. SLEEPER LIGHT SWITCH
4. COMPASS/OUTSIDE TEMPERATURE DISPLAY
(OPTIONAL)
5. STORAGE AREAS (2)
6. CB RADIO STORAGE CONSOLE
7. CAB COURTESY LIGHT LOCATIONS (2)

Form No. 3628504R1

Printed in the United States of America Page 23
 SECTION 3 VEHICLE CONTROLS

Instrument Panel and Controls

The Instrument Panel and Controls are designed to provide the
driver with the ability to monitor and control the operation of the
vehicle. This section shows the difference between the location
of the controls in the 5000i and the 9000i vehicles.

5000i Controls

The following are the controls for the 5000i cab. 1. DOOR CONTROL

2. TURN SIGNAL SWITCH

3. ELECTRIC HORN

4. WINDOW REGULATOR

5. CLUTCH PEDAL

6. BRAKE PEDAL

7. ACCELERATOR PEDAL

8. THROTTLE CONTROL

9. TRANSMISSION SHIFT LEVER

10. TRAILER BRAKE HAND CONTROL VALVE

Form No. 3628504R1

Page 24 Printed in the United States of America
 SECTION 3 VEHICLE CONTROLS

Instrument Panel and Controls (cont.)

9000i Controls

The following are the controls for the 9000i cab.

1. AIR HORN

2. DOOR CONTROL

3. TURN SIGNAL SWITCH

4. ELECTRIC HORN

5. TRAILER BRAKE CONTROL

6. WINDOW REGULATOR

7. FLOOR AIR CONTROL

8. DIMMER SWITCH

9. CLUTCH PEDAL

10. BRAKE PEDAL

11. ACCELERATOR PEDAL

12. TRANSMISSION SHIFT LEVER

Form No. 3628504R1

Printed in the United States of America Page 25
 SECTION 3 VEHICLE CONTROLS

Instrument Panel and Controls (cont.)

5000i and 9000i Series Instrument Panel

The 5000i and 9000i models Instrument Panel includes the instrument 1. IGNITION SWITCH STANDARD EQUIPMENT
gauges, warning indicators, and a digital Liquid Crystal Display (LCD),
2. DIAGNOSTIC CONNECTION; ELECTRONIC ENGINES
that provide odometer, and diagnostic message displays. The center
STANDARD EQUIPMENT
panel contains the Tachometer, Speedometer, and the Liquid Crystal
Display (LCD). The right and left panels contains instrument gauge panels 3. CIGARETTE LIGHTER STANDARD EQUIPMENT
that indicate the crucial operational functions of the vehicle. All gauges,
4. HVAC CENTRAL CONTROL PANEL STANDARD
except for the Speedometer and Tachometer, also contain indicators, that,
EQUIPMENT
when illuminated, indicate an out-of-range condition. The Wing Panel
contains various switches and controls used to operate standard and 5. GLOVE BOX WITH STORAGE; ALSO PROVIDES ACCESS
optional functions of the vehicle, including HVAC, and Parking and Trailer TO FUSES AND RELAYS STANDARD EQUIPMENT
brakes. The following illustrations show the gauge and display details.
6. PUSH BUTTON STARTING, AIR STARTER, OR ABS BLINK
CODE OPTIONAL EQUIPMENT

7. EATON TWO SPEED TANDEM REAR AXLE OR TRACTION

DIFFERENTIAL CONTROL OPTIONAL EQUIPMENT

a. FLIPPER WITH EATON

b. PUSH/PULL WITH DANA

8. AIR SUSPENSION DUMP; INCLUDED WITH AIR

SUSPENSION OPTIONAL EQUIPMENT

9. TWO-POST TERMINAL POWER SOURCE OPTIONAL

EQUIPMENT

10. CIGARETTE LIGHTER TYPE POWER SOURCE

OPTIONAL EQUIPMENT

Form No. 3628504R1

Page 26 Printed in the United States of America
 SECTION 3 VEHICLE CONTROLS

Instrument Panel and Controls (cont.)

5000I AND 9000I SERIES INSTRUMENT PANEL (cont.)

CENTER PANEL 1. TACHOMETER

2. SPEEDOMETER

3. ELECTRONIC (LCD) DIGITAL DISPLAY ODOMETER

4. MODE/RESET BUTTON FOR TRIP ODOMETER

Form No. 3628504R1

Printed in the United States of America Page 27
 SECTION 3 VEHICLE CONTROLS

Instrument Panel and Controls (cont.)

5000I AND 9000I SERIES INSTRUMENT PANEL (cont.)

LEFT GAUGE PANEL 1. BRAKE AIR APPLICATION

2. ENGINE COOLANT TEMPERATURE - ELECTRONIC

3. ENGINE EXHAUST TEMPERATURE PYROMETER

(OPTIONAL)

4. ENGINE OIL PRESSURE - ELECTRONIC

5. ENGINE OIL TEMPERATURE (OPTIONAL)

6. VOLTMETER

7. Warning Lights

a. HIGH COOLANT TEMPERATURE WITH BEEPER ALARM

b. COOLANT LEVEL

c. WORK LIGHT FOR FIFTH WHEELS OR CARGO AREA

(OPTIONAL)

d. MESSAGE WAIT LIGHT FOR SATELLITE SYSTEM

(OPTIONAL)

e. LOW ENGINE OIL PRESSURE WITH BEEP ALARM

f. ENGINE WARNING

g. STOP ENGINE

h. SERVICE CHECK ENGINE

i. TRAILER ABS

Form No. 3628504R1

Page 28 Printed in the United States of America
 SECTION 3 VEHICLE CONTROLS

Instrument Panel and Controls (cont.)

5000I AND 9000I SERIES INSTRUMENT PANEL (cont.)

RIGHT GAUGE PANEL 8. AIR BRAKE PRIMARY PRESSURE

9. FORWARD AXLE OIL TEMPERATURE (OPTIONAL)

10. AIR BRAKE SECONDARY PRESSURE

11. REAR AXLE OIL TEMPERATURE (OPTIONAL)

12. FUEL GAUGE

13. OIL TEMPERATURE GAUGE FOR MANUAL TRANSMISSION

14. Warning Lights

a. PARKING BRAKE

b. AIR SUSPENSION DUMP (OPTIONAL)

c. DIFFERENTIAL LOCK FOR 6X4 MODELS

d. POWER DIVIDER LOCKOUT (BUZZER OPTIONAL)

e. LOW AIR WITH BEEPER ALARM

f. TRACTION CONTROL FOR USE WITH BOBTAIL SYSTEM

AND ABS (OPTIONAL)

g. ABS FOR USE WITH CODE 04AZA (TRUCK) AND 04AZC

(TRACTOR) OR ABS TRACTION CONTROL

h. LOW FUEL LEVEL WITH BEEPER ALARM

i. DO NOT SHIFT (OPTIONAL)

Form No. 3628504R1

Printed in the United States of America Page 29
 SECTION 3 VEHICLE CONTROLS

WING PANEL 1. RADIO

2. AIR REGISTER

3. SWITCH: TRAILER LIGHTS

4. HEADLIGHT SWITCH: FLOOR MOUNTED DIMMER SWITCH

5. SWITCH: DIMMER IN COMMAND CENTER

6. SWITCH: WINDSHIELD WIPER/WASHER WITH HI/LOW AND

INTERMITTENT CYCLE CONTROL

7. SWITCH: HEATED MIRROR

8. SWITCH: CRUISE SET/RESUME WITH ELECTRONIC

ENGINES

9. SWITCH: CRUISE ON/OFF WITH ELECTRONIC ENGINES

10. SWITCH: ENGINE BRAKE (OPTIONAL)

11. SWITCH: ENGINE BRAKE ON/OFF ELECTRONIC

(OPTIONAL)

12. OPTIONAL GAUGES (CLOCK, AIR RESTRICTION,

MANIFOLD PRESSURE GAUGE, SUSPENSION PRESSURE
GAUGE (See Note below), FUEL PRESSURE)

13. VALVE: TRAILER BRAKE

14. VALVE: PARKING BRAKE
15. HEATER A/C CENTRAL CONTROL PANEL
16. POWER DIVIDER LOCK (PDL)

Form No. 3628504R1

Page 30 Printed in the United States of America
 SECTION 3 VEHICLE CONTROLS

17. FIFTH WHEEL a. EATON VORAD COLLISION WARNING SYSTEM

DRIVER DISPLAY UNIT
18. OPTIONAL SWITCHES
b. CAT MESSENGER
a. LIGHTED MIRRORS
c. CUMMINS ROADRELAY
b. POWER MIRROR
d. FREEDOMLINE TRANSMISSION DISPLAY
c. FOG LIGHTS
(Illustration not available).
d. COLD STARTING EQUIPMENT (ETHER)
NOTE: The SUSPENSION PRESSURE GAUGE is used for
e. TRAILER AUXILIARY
reference only. Do not base legal loading criteria on this gauge.
f. ELECTRONIC ENGINE DIAGNOSTIC SWITCHES (2
WITH CUMMINS ENGINES)
g. WORK LIGHT SWITCH (W/WIRING)
h. ATC OFF-ROAD
19. OPTIONAL CONTROL PANELS/DISPLAYS

Form No. 3628504R1

Printed in the United States of America Page 31
 SECTION 3 VEHICLE CONTROLS

Sleeper controls Caterpillar CAT Messenger and Cummins Roadrelay

See Vehicle Operations for details of the various sleeper control See Caterpillar MESSENGER and
functions provided in the 9000ivehicle. Cummins ROADRELAY descriptions
within the Electronically Controlled
Engines section and the Eaton
VORAD operational description in the
Eaton VORAD section.

CATERPILLAR CAT MESSENGER

Form No. 3628504R1

Page 32 Printed in the United States of America
 SECTION 3 VEHICLE CONTROLS

CATERPILLAR CAT MESSENGER AND CUMMINS

ROADRELAY (cont.)

CUMMINS ROADRELAY Transmission Shifters

See Vehicle Operations, Transmissions Section for descriptions

of the shifter controls.

ALLISON GENERATION 4 WTEC PUSHBUTTON SHIFTER

EATON VORAD Driver Display Unit

Form No. 3628504R1

Printed in the United States of America Page 33
 SECTION 3 VEHICLE CONTROLS

TRANSMISSION SHIFTERS (cont.)

EATON AUTO-SHIFT/ULTRA-SHIFT PUSHBUTTON SHIFTER MERITOR FREEDOMLINE TRANSMISSION GEARSHIFT

MODULE

Form No. 3628504R1

Page 34 Printed in the United States of America
 SECTION 4 VEHICLE OPERATION

Cargo Area Occupancy

WARNING: All vehicles have blind spots. Make
sure your way is clear in all directions before moving
your vehicle. Failure to follow these procedures could
result in property damage, personal injury or death.
Cab Air Suspension
WARNING: To avoid personal injury or death, do
not ride in the vehicle cargo area or on the outside of
the vehicle. Ride only in designated seating positions
or sleeper berth with seat belts or bunk restraints
fastened and properly adjusted.

NOTE: If your vehicle is equipped with a cab air suspension, it

may have been shipped with a wooden block installed between
the cab suspension track bar assembly and the cab suspension
lower plate as shown in the illustration below. To benefit from the
cab air suspension, this block must be removed.
Vehicle Entry and Exit
WARNING: Do not step or climb upon any vehicle
surface unless it is slip resistant and a handhold is
provided. Failure to follow this warning could cause
you to slip or fall and could result in personal injury or
death.

Form No. 3628504R1

Printed in the United States of America Page 35
 SECTION 4 VEHICLE OPERATION
Vehicle Entry and Exit (cont.)
WARNING: A three-point stance should be used
(three out of four extremities should be in contact
with the vehicle climbing system at all times). Face
inward towards the cab when entering and exiting.
Always keep steps and handholds in continuous good
repair. Make sure all attaching bolts and hardware
are tight, thus eliminating any movement of steps and
handholds. Keep steps, grab handles and shoes free
of grease, mud, dirt, fuel, ice and snow. Use extra
care during inclement weather. Failure to follow this
warning could cause you to slip or fall and could result
in personal injury or death.
Sleeper Upper Bunk Entry/Exit Instructions
(Optional)
WARNING: Failure to exercise due care when
entering and exiting upper bunk area can cause you to
slip or fall and could result in personal injury or death.
Form No. 3628504R1
Page 36 Printed in the United States of America
Entry and exit should be done slowly, deliberately, and carefully.
A three-point stance should be used (three out of four extremities
should be in contact with the bunk rails, grab handles, steps
and/or floor at all times). Keep blankets, pillows and other
materials off the bunk rails while entering or exiting the upper
bunk.
WARNING: Always use occupant restraint
system when vehicle is moving. Any location in the
vehicle not equipped with a seat belt, bunk restraint
belts, or sleeper berth restraint webbing should not
be occupied when the vehicle is being operated. In
the event of a vehicle accident or sudden, unexpected
movement, failure to properly use an occupant
restraint system could result in personal injury or
death.
9000i Series Conventional 51 (130 cm) Hi-Rise Pro Sleeper
Upper Bunk Entry
1. The bunk platform must first be unlatched at the center strap
and rotated down to the horizontal position. Make sure that
the plunger on the drivers side is engaged in the receiver
provided on the side panel support bracket.
 SECTION 4 VEHICLE OPERATION

Sleeper Upper Bunk Entry/Exit Instructions

(Optional) (cont.)
9000I SERIES CONVENTIONAL 51 (130 CM) HI-RISE PRO
SLEEPER UPPER BUNK ENTRY (cont.)

2. Begin by standing with both feet on the floor facing inward
toward the bunk, and as close to the cabinets on the drivers
side as possible. (The bunk area is designed for your head
to be at the drivers side of the bunk.)
3. Grasp the upper front bunk rail with both hands.
4. Step upon the lower bunk rail with your left foot and then
your right foot.
5. Switch your left hand from the front rail to the rear rail.
6. Bring your left leg up and onto the bunk, pull your body up
with your left hand while pushing with your right, and rotate
your body until the right leg can follow onto the bunk. Then
position yourself in the center of the bunk area.
7. Now you can release both your right and left hands.
9000i Series Conventional 51 (130 cm) Hi-Rise Pro Sleeper
Upper Bunk Exit
2. With your left hand, grasp the rear bunk rail; with your right
hand, grasp the front bunk rail.
3. From this position, move to the front portion of the bunk and
swing your right leg over the front edge and rotate your body
until you can position your right foot on the front portion of
the lower bunk.
4. Continue rotating your body around the front rail of the bunk
and place your left foot on the lower bunk.
5. From this position, release your left hand from the rear of the
bunk and grasp the front rail of the bunk with both hands.
6. From this position, step to the floor with your right foot,
followed by your left foot, and then release both hands from
the bunk rail.
7. The upper bunk should now be rotated up to the vertical
position and secured in place with the center strap.

NOTE: Always face inward toward the bunk when exiting the
upper bunk.
1. Position yourself in the center of the bunk on your stomach.

Form No. 3628504R1

Printed in the United States of America Page 37
 SECTION 4 VEHICLE OPERATION
Sleeper Upper Bunk Entry/Exit Instructions
(Optional) (cont.)
9000i Series Conventional Sky-Rise and 72 (183 cm)
Hi-Rise Pro Sleeper Upper Bunk Entry
NOTE: The Sky-Rise is equipped with a dome light to aid
your entry/exit into the upper bunk. A dome light on/off switch
is located at the center of the header panel, just above the
windshield, and on the dome light itself. This allows control of
the light from both the floor and upper bunk.
1. The bunk platform must first be unlatched from the up
position. Locate bunk latch release handle on rear wall of
Step-Wardrobe cabinet. Place right hand on upper bunk to
guide its descent and pull latch release T handle with left
hand. Upper bunk is equipped with an extension shock to
slow the descent of the bunk.
2. Begin by facing the bunk entry steps, placing your right
foot on the bottom step while gripping the grab handle on
the upper bunk with your right hand and the side wall grab
handle with your left hand. (The bunk area is designed for
your head to be at the drivers side of the bunk.)
3. Step up on bottom step and place your left foot on the second
step keeping both hands gripping the two grab handles.
4. Step up on the second step and while keeping both hands
gripping the two grab handles, swing your right hip over onto
the upper bunk.
Form No. 3628504R1
Page 38 Printed in the United States of America
5. Release your left hand from the side wall grab handle and
grip the front edge of the bunk rail along side your left hip
with your left hand.
6. Using your right hand on the upper bunk grab handle and
your left hand on the front edge of the bunk, push your rump
up and back onto the bunk. You are now in a sitting position
on the edge of the upper bunk facing forward in the vehicle.
7. Swing your legs up and to the right, positioning your body in
the center of the bunk.
9000i Series Conventional Sky-Rise and 72 (183 cm)
Hi-Rise Pro Sleeper Upper Bunk Exit
1. Sit up on the bunk positioning your body with your right hip
next to the grab handle mounted on the upper bunk and your
legs hanging over the front edge of the bunk. Keep your right
hand on the grab handle and your left hand on the front edge
of the upper bunk.
2. Look down and locate the upper step on the cabinet.
3. Grab the side wall grab handle with your left hand and pivot
your body to your right swinging your left leg down placing
your left foot on the upper step. Keep hold of both grab
handles.
4. Put your weight on your left foot keeping hold of both grab
handles; step down with your right foot to the bottom step.
 SECTION 4 VEHICLE OPERATION

Sleeper Upper Bunk Entry/Exit Instructions

(Optional) (cont.)
9000I SERIES CONVENTIONAL SKY-RISE AND 72 (183
CM) HI-RISE PRO SLEEPER UPPER BUNK EXIT (cont.)

5. Keeping hold of both grab handles, step down to the cab Occupant Restraint System
floor with your left foot followed by your right foot. You can
now release the grab handles. This section provides the driver seat belt restraint system and
the sleeper bunk restraint system instructions.
6. The upper bunk should now be rotated up to the vertical
position being sure that no bed coverings, clothes or other
objects interfere with the latch engagement to the bunk Seat Belts
striker rod.
7. The upper bunk should be pushed up into the latch
mechanism until the striker rod bottoms out in the latch. You
will hear an audible click indicating the latch is engaged. WARNING: Failure to properly inspect and
maintain seat belts could result in personal injury or
death.

WARNING: Any seat belt in use during an

accident must be replaced. When replacement of any
part of the seat belt is required, the entire belt must be
replaced, both retractor and buckle sides. Belt failure
could result in personal injury or death.

Form No. 3628504R1

Printed in the United States of America Page 39
 SECTION 4 VEHICLE OPERATION

Occupant Restraint System (cont.)

Seat Belts (cont.)

allowing the belt tension to equalize across hips and chest. The
retractor is a locking type which allows webbing to come out to
WARNING: The seat belt in a commercial truck or adjust for body movement.
bus 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
care and maintenance every 20,000 miles (32 000 km)
or more often if exposed to severe environmental or
vocational conditions. All belts should be replaced
at least every 5 years. Failure to maintain the seat
belts can weaken the system resulting in belt failure,
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 drivers seat to the position in which you will
drive. Lap and shoulder (three-point) seat belts with retractor
are standard for driver and door-side passenger. An adjustable,
non-retracting belt is provided for the center passenger position
of bench type seats.
1. BELT TONGUE
2. BUCKLE
Adjustable Lap And Shoulder (Three-Point) Belts
3. PRESS TO UNFASTEN
To fasten the belt, bring belt across hips and chest and insert
tongue into buckle. The web is free to slide through tongue,

Form No. 3628504R1

Page 40 Printed in the United States of America
 SECTION 4 VEHICLE OPERATION

Occupant Restraint System (cont.)

Adjustable Lap And Shoulder (Three-Point) Belts (cont.)

Automatic Webbing Retraction Seat Belt Tether

The webbing will return to the retractor as the body returns to
its original position. The retractor will retain moderate tension
across the body in its operator mode.
To release: Push the button release latch on the buckle. Give
the belt a tug to insure it will retract.
NOTE: The seat belt tether must be checked for proper
adjustment prior to vehicle operation.
Adjustment
1. Adjust the driver seat fore and aft to accommodate driver
comfort.
2. After the seat is adjusted, take weight off the seat to
allow the seat to rise to its highest point.
3. Pull the webbing through the seat belt tether adjuster
until there is no slack (See illustration below).

Form No. 3628504R1

Printed in the United States of America Page 41
 SECTION 4 VEHICLE OPERATION

Occupant Restraint System (cont.)

Seat Belt Tether (cont.)

TETHER_SHORTENING

Lengthening The Tether.To lengthen the tether, squeeze the

Adjuster and, while firmly holding the strap, use the Nub and
Adjusting The Length Of The Tether
wire loop to move the webbing toward the Adjuster.
Perform the following steps to lengthen or shorten the tether
(See the illustration below).
Shortening The Tether. To shorten the tether, squeeze the
Adjuster and, pull the Nub and wire loop to move the webbing
away from the Adjuster (as shown by the arrows).

Form No. 3628504R1

Page 42 Printed in the United States of America
 SECTION 4 VEHICLE OPERATION
Occupant Restraint System (cont.)
Seat Belt Tether (cont.)
Non-Retracting Adjustable Seat Belts For Center
Passenger Bench Seat
To adjust: Tip the buckle end downward and pull the buckle
until the ends can be joined. Insert tongue into open end of
buckle and snap together. Shorten the belt after it is connected
by pulling on the loose end until the belt is snug and comfortable.
Form No. 3628504R1
Printed in the United States of America
Figure 14
1. INSERT TO CONNECT
2. PUSH BUTTON TO RELEASE
3. PULL TO SHORTEN WITH BELT CONNECTED
4. PULL TO LENGTHEN WITH BUCKLE IN VERTICAL POSITION
To Release: Push in the button release latch to release the seat
belt.
Komfort-Clip Adjustment
The Komfort-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
lever/top of Komfort-Clip mechanism upward, clamping webbing
in place. Belt tension will be removed across the chest. If you
try to lean forward, the clip will hold unless a moderate force
Page 43
 SECTION 4 VEHICLE OPERATION

Occupant Restraint System (cont.)

Komfort-Clip Adjustment (cont.)

is applied causing the clip to disengage. At this point the Upper and Lower Bunk Restraint Systems
Komfort-Clip would have to be reset as mentioned above.

NOTE: Only engage the Komfort-Clip while the truck is at rest.

Care Of Seat Belts
Clean the belts occasionally with mild soap; do not use cleaning
solvents or abrasives.
WARNING: Do not bleach or re-dye seat belt
webbing. Bleaching or re-dying may cause a
weakening of the webbing, resulting in personal
injury or death.
The entire seat belt assembly should be inspected periodically
for corrosion, wear, fraying or weak spots. The retractor, latch,
and buckle should be checked for proper function, and all seat
belt mounting bolts should be tight at all times.
WARNING: Always use occupant restraint
system when vehicle is moving. Any location in the
vehicle not equipped with a seat belt, bunk restraint
belts, webbing restraints, or sleeper berth tents,
should not be occupied when the vehicle is being
operated. In the event of a vehicle accident or sudden,
unexpected movement, failure to properly use an
occupant restraint system could result in personal
injury or death.
Three types of sleeper berth occupant restraint systems are
available with sleeper berths supplied by International. If the
bunk of a sleeper berth is not provided with one of these restraint
systems, that bunk is not intended to be occupied when the
vehicle is in motion and must not be used when the vehicle is
being operated. The description and recommended usage of

Form No. 3628504R1

Page 44 Printed in the United States of America
 SECTION 4 VEHICLE OPERATION
Occupant Restraint System (cont.)
Upper and Lower Bunk Restraint Systems (cont.)
the three available restraint systems for sleeper berth areas are
as follows:
Two Sets of Adjustable Belts
To use the two-belt system, the bunk occupant should place
one belt set across the lower body (positioned above the
occupants knees but below the hips), and the other belt set
should be positioned across the upper body (above the hips
but below the shoulders). Slack must be removed from each
belt set after connecting the buckle by pulling the loose end
of each belt set to fit the connected belt set snugly across
the occupants body.
Belt Webbing Closure System (Optional)
To use the webbing closure system, the occupant must
close the buckle in the middle of the webbing system after
entering the sleeper berth area. After the buckle is closed,
the webbing closure must be tightened snugly by pulling on
the loose end of the belt at the buckle.
Tent Style Restraints (Optional)
To use the tent restraint systems, refer to the manufacturers
instruction booklet.
Form No. 3628504R1
Printed in the United States of America
Seat Adjustment
WARNING: Do not adjust drivers seat while
vehicle is moving. The seat could suddenly or
unexpectedly move causing the driver to lose control
of vehicle, which could result in property damage,
personal injury or death.
WARNING: Reckless operation of this vehicle
over rough roads or surfaces can cause loss of vehicle
control and result in property damage, personal
injury, or death. Use caution and reduce speed.
Properly adjusted seats and seating systems may not
compensate completely for severe road conditions.
Ensure that head clearance will be maintained during
all road conditions as the seat may move up and
decrease the available space.
Page 45
 SECTION 4 VEHICLE OPERATION

Seat Adjustment (cont.)

Seats With Single Lever Adjustment
These seats have fore and aft adjustment only. Adjust while
sitting in seat. Push seat adjustment lever to release mechanism
and move seat to desired position. Be sure seats are firmly
engaged to avoid forward or rearward movement when vehicle
is started or stopped.
Swivel Seats (Optional)
Sleeper Cabinet and Storage Shelf Features
WARNING: Always remove all work surfaces
from slide-out trays and store in the seat back pocket
when vehicle is in motion. Falling items can be a
distraction to the driver or a projectile during an
accident which could result in personal injury or
death.

The 9000i Conventional Series vehicles may be equipped with

optional swivel type seats. A lever release on the outboard
side of the seat, under and toward the front, will allow the seat
to swivel around. Be sure the seats are locked in the straight
forward position when operating the vehicle. See the seat
manual for more information.
The current sleepers are now equipped with cabinets that
provide more storage space and added features.
NOTE: The following will describe and illustrate the standard
cabinets and their storage functions for the Hi Rise Pro Sleeper
Eagle. Your vehicle may not have all of these features.

Seat Storage

There are new storage features:

A new storage compartment located in the passenger seat
base for thermos, maps and CDs.
Vinyl storage pockets mounted on both driver and
passenger seat backs of sleeper cabs.

Form No. 3628504R1

Page 46 Printed in the United States of America
 SECTION 4 VEHICLE OPERATION

Sleeper Cabinet and Storage Shelf Features

(cont.)

Pull-out desk with Work Surface

The pull-out desk locks in both extended and retracted positions

and provides either one or two cup holders and removable work
surface for ease of cleaning. Twist and Pull Latch Instructions

The Twist and Pull latches ensure that the cabinet doors
remain closed and secure during normal vehicle movement.
Perform the following instructions to properly close and secure
or unfasten the following sleeper cabinet doors.

Form No. 3628504R1

Printed in the United States of America Page 47
 SECTION 4 VEHICLE OPERATION

Sleeper Cabinet and Storage Shelf Features

(cont.)
TWIST AND PULL LATCH INSTRUCTIONS (cont.)

Unfastening the Door

First flip the latch out from its closed position.
Rotate the latch counter clockwise turn (180 ).
Pull on the latch to open the cabinet.
Reverse to fasten.

Microwave Cabinet

This cabinet provides storage and operation for a microwave

oven and also provides a light fixture for use when using
microwave. It is equipped with a Twist and Pull latch for
consistent reliable door closing.
The cabinet is also equipped with a reading light that illuminates
the work surface. The reading light is mounted on bottom
surface of the cabinet.

Form No. 3628504R1

Page 48 Printed in the United States of America
 SECTION 4 VEHICLE OPERATION

Sleeper Cabinet and Storage Shelf Features

(cont.)
MICROWAVE CABINET (cont.)

and includes a removable work surface. It is equipped with a

Twist and Pull latch for consistent reliable door closing.

Refrigerator Cabinet

This cabinet is used to house and operate one of two

refrigerators with vents for the refrigerators. This cabinet
also supports a pull-out work table with two built-in cupholders

Form No. 3628504R1

Printed in the United States of America Page 49
 SECTION 4 VEHICLE OPERATION

Sleeper Cabinet and Storage Shelf Features

(cont.)
TV/VCR Cabinet Dresser Cabinets (Optional)

This cabinet is located behind the passenger seat and houses
and provides operation of a combination TV/VCR. It is equipped
with a Twist and Pull latch for consistent reliable door closing.
The cabinet is also equipped with a reading light that illuminates
the work surface. The reading light is mounted on bottom
surface of the cabinet.
There are two optional dresser cabinets. One is located behind
the passengers seat, below the TV cabinet and the other is
located behind the drivers seat. They both will be provided
with a pull-out desk with one or two built-in cup holders, and
a removable work surface. They both can be equipped with or
without a latchable door. The cabinet that has a door will also
include two slide-out drawers, and a removable storage bin.

Form No. 3628504R1

Page 50 Printed in the United States of America
 SECTION 4 VEHICLE OPERATION

Sleeper Cabinet and Storage Shelf Features

(cont.)
Rear Wall Wardrobe Cabinet (Used Only with Single Bunk) Airline-Style Corner Overhead Cabinets (Both Corners)

This cabinet is mounted on rear wall and provides hanging These cabinets support both Stereo speakers and contain small
storage for 20 pairs of slacks, two rods for shirts, and 5 storage compartments. They are equipped with Twist and Pull
compartment shelves. It also provides two hanging doors which latches for consistent reliable door closing.
conceal clothing, with one door providing a dressing mirror.

Airline-Style Overhead Cabinets (Right/Left Hand)

These two cabinets provide large storage compartments. They

are equipped with Twist and Pull latches for consistent reliable
door closing.

Form No. 3628504R1

Printed in the United States of America Page 51
 SECTION 4 VEHICLE OPERATION

Sleeper Cabinet and Storage Shelf Features

(cont.)
AIRLINE-STYLE OVERHEAD CABINETS (RIGHT/LEFT
HAND) (cont.)

Tower Wardrobe Cabinet

This cabinet is located on passengers side of vehicle and

provides hanging clothes storage and an optional door to
conceal clothing. It is used when the sleeper is equipped with
an upper as well as a lower bunk. When the upper and lower
bunk are installed, the wardrobe cabinet will be ordered with
optional steps that allow an occupant to climb up to upper bunk.
The cabinet is equipped with a Twist and Pull latch for consistent
reliable door closing.

Storage Shelf

There are two shelves for storing miscellaneous packages and

are provided on both the driver and passenger sides of the
sleeper.

Storage Shelf With DVD Player (optional)

An optional DVD player is mounted under the passenger side

storage shelf. The DVD player features a 10.2 Screen, Wireless
Head Phones, Remote Control, Sound Interfaced with Vehicle
Radio, RCA and S-video type Input/Output. The DVD player
may also be equipped with a tuner that provides available TV
broadcast reception.

Form No. 3628504R1

Page 52 Printed in the United States of America
 SECTION 4 VEHICLE OPERATION

Sleeper Cabinet and Storage Shelf Features

(cont.)
STORAGE SHELF WITH DVD PLAYER (OPTIONAL) (cont.)

Lift-up Bunk with Storage System

The lower bunk raises for access to three basic storage

functions. The middle front compartment houses a removable
storage tray, which sits immediately under the bunk when it is
raised. When the tray is removed, two lock boxes that are used
to store valuables (may be secured with a commercial grade
padlock).

Form No. 3628504R1

Printed in the United States of America Page 53
 SECTION 4 VEHICLE OPERATION
Sleeper Cabinet and Storage Shelf Features
(cont.)
Footlocker Cabinet
The two footlockers are located at the foot of the bunk. They
each include two inner storage shelves and a top shelf and
are used for additional storage of miscellaneous items. An
optional footlocker provides a top shelf for TV/VCR storage and
operation.
Sleeper Controls For 9000i Pro Sleeper Models
The sleeper Control Panel provides control of sleeper
temperature, blower speed, overhead and indirect light switches,
Form No. 3628504R1
Page 54 Printed in the United States of America
a remote radio control module, a 110 VAC inverter control/battery
charger, and an auxiliary 12 VDC power connector.
Standard Temperature Control System
Heating and A/C controls for the front of the cab and the sleeper
bunk operate independently. The BUNK button on the HVAC
Central Control Panel must be pushed (indicator light, to the right
of the button, is lit) to activate the sleeper control panel.
The sleeper blower may be set to High Speed for rapid
heating/cooling of sleeper compartment. Under normal use,
blower speed should be set to Low or Med.
The sleeper temperature control knob is used to control the
damper that lets more or less heated air through the air vents.
NOTE: It is not necessary to turn off the sleeper bunk control
panel if the BUNK control in the HVAC Central Control Panel is
in out (OFF) position.
Automatic Temperature Control (Optional)
The optional automatic temperature control system will maintain
a desired sleeper temperature via the temperature sensor and
thermostat control knob. When the sensor detects that the
selected temperature has been reached, the damper door
will be adjusted to maintain that temperature. Turning the
 SECTION 4 VEHICLE OPERATION

Sleeper Controls For 9000i Pro Sleeper Models

(cont.)
AUTOMATIC TEMPERATURE CONTROL (OPTIONAL)
(cont.)

knob clockwise or counter-clockwise will adjust the sleeper Sleeper Radio Control Module (Optional)
temperature set point, either higher or lower.
The Sleeper Radio Control module provides remote control of
The sleeper blower may be set to High Speed for rapid most of the main cab radio features from a position in the sleeper.
heating/cooling of sleeper compartment. Under normal use,
blower speed should be set to Low or Med.

NOTE: If air is not allowed to flow into the sensor slots, the
automatic temperature control system will not function properly.
Do not block, clog or cover the automatic temperature control
sensor slots on this panel (e.g., pillows, dirt, dust).

Form No. 3628504R1

Printed in the United States of America Page 55
 SECTION 4 VEHICLE OPERATION
Sleeper Controls For 9000i Pro Sleeper Models
(cont.)
SLEEPER RADIO CONTROL MODULE (OPTIONAL) (cont.)
Some of the features available to the radio control module are:
radio power ON/OFF control; radio volume control; audio mode
select (Volume/Bass/Treble/Bal/Fade); manual or automatic
tuning; radio function MODE control; AM/FM or WB (Weather
Band); and clock/alarm set.
Inverter Remote Control, RC8 (Optional)
The RC8 remote control duplicates the ON/OFF power switch
on the inverter and mimics its front panel LED status display.
Form No. 3628504R1
Page 56 Printed in the United States of America
The inverter parameters that are displayed by the RC8 LED are:
Inverter Status (ON/OFF); Inverter/Charger indication; search
mode indication; and error indication. The inverter is mounted
under the lower lift up bunk. The following are operating
instructions for the RC8 control of the inverter.
Operation
1. Press the PUSH ON/OFF portion of the RC8 front panel to
turn the inverter on; press on it again to turn the inverter
off.
2. With the Inverter turned on, the Status LED will be lit as
follows:
Solid: Inverter supplying power to AC load (TV,
Microwave, etc.).
Blinking Slow (3 to 5 flashes @ 1 sec. intervals): No
load connected (Inverter in search mode).
Blinking Fast: The presence of overheating,
over-current, low battery voltage, or high battery
voltage condition.
Erratic Blinking (0 to 3 and 2 to 5 flashes @ 2 sec.
intervals): An error while in search mode (usually by
low or high battery voltage).
 SECTION 4 VEHICLE OPERATION

Sleeper Controls For 9000i Pro Sleeper Models

(cont.)
INVERTER REMOTE CONTROL, RC8 (OPTIONAL) (cont.)

Door Lock and Unlock Control

To Lock/Unlock From Inside/Outside

WARNING: To help reduce the risk of personal

injury in the event of an accident, keep doors locked
when vehicle is in motion.

WARNING: Do not use the door handle as a

handhold during entry and exit. Failure to follow this
warning could cause you to slip or fall and could result
in personal injury or death.

Cab Controls
To open door from inside, pull on handle. To open door from
outside, insert fingertips into control recess and pull handle
Overhead Panel outward.

For the location of the Overhead Panel components, see the

illustration in the Vehicle Controls section.

Form No. 3628504R1

Printed in the United States of America Page 57
 SECTION 4 VEHICLE OPERATION

Cab Controls (cont.)

Door Lock and Unlock Control (cont.)

Power Door Locks (Optional) Illuminated Entry.

Power door locks, controlled by door mounted switches, are The dome light turns on for 1 minute when the UNLOCK button
used to lock and unlock both driver and passenger doors. is pressed. If within 1 minute, the dome light will turn off as soon
as the ignition switch is turned on.

Remote Keyless Entry Operation (Optional)

The Remote Keyless Entry (RKE) is a device that allows the

driver to operate the optional power door locks from a remote
distance. When the RKE is used to unlock doors, the cab dome
light will be turned on for 1 minute or until the ignition switch is
turned on, and the Parking brake is released.

NOTE: The RKE will not respond if the Parking brake is OFF
(released). To use while the truck is running, the Parking brake
must be ON (applied).
Locking Doors.
To lock both doors, press the LOCK button once. Press again
for horn confirmation. Door Window Regulator
Unlocking the Doors.
To lower door glass (left door), turn window regulator handle
To unlock the drivers door, press the UNLOCK button once, or clockwise. To raise glass, turn handle counterclockwise.
press and hold the UNLOCK button (for at least .5 seconds) to Reverse this procedure for opposite door.
unlock both the driver and the passenger door.

Form No. 3628504R1

Page 58 Printed in the United States of America
 SECTION 4 VEHICLE OPERATION

Cab Controls (cont.)

Power Windows (Optional)
9000i Series trucks may have optional electrically operated
windows. The controls are mounted in the doors for driver and
passenger convenience.
speed has been obtained. The cruise control can be manually
disengaged with this switch. The cruise control is automatically
disengaged by depressing the clutch pedal or brake pedal.

Cruise Control

The cruise control systems for all electronic engines function in a

very similar manner. The biggest difference is the minimum and
maximum allowable cruise control speeds which will vary from
vehicle to vehicle.

WARNING: Do not use the cruise control system

when unpredictable driving conditions are present.
Such conditions include heavy traffic, roads that are
winding, icy, snow covered, slippery, or with a loose
surface. These conditions may cause wheel slippage
and loss of vehicle control, resulting in property
damage, personal injury or death.

CRUISE CONTROL

The cruise control will only function with the CRUISE ON/OFF
switch is in the ON position, providing that the minimum vehicle

Form No. 3628504R1

Printed in the United States of America Page 59
 SECTION 4 VEHICLE OPERATION

Cab Controls (cont.)

Cruise Control (cont.)

CRUISE CONTROL (cont.)

1. CRUISE SET/RESUME WITH ELECTRONIC CRUISE SET/RESUME Switch

ENGINES
With the CRUISE ON/OFF switch ON, moving the CRUISE
2. CRUISE ON/OFF WITH ELECTRONIC ENGINES SET/RES(UME) switch to the SET position and releasing it will
engage the system at the speed currently being driven. If the
3. DIAGNOSTIC CONNECTION; ELECTRONIC
cruise control has been disengaged by depressing the clutch
ENGINES

Form No. 3628504R1

Page 60 Printed in the United States of America
 SECTION 4 VEHICLE OPERATION
Cab Controls (cont.)
Cruise Control (cont.)
CRUISE CONTROL (cont.)
pedal or brake pedal, moving the CRUISE SET/RES(UME)
switch to the RESUME position and releasing it will return the
vehicle to the last set speed.
The resume speed may be lost when the vehicle is turned off. It
is not necessary to turn the cruise control OFF during city driving
or when shifting the gears using the clutch.
Accelerate/ Decelerate Function
For the Caterpillar C-11, C-13, and C-15 and Cummins ISX, and
ISM engines, holding the CRUISE SET/RES(UME) switch in the
SET position longer than one second will accelerate the vehicle.
Holding the CRUISE SET/RES(UME) switch in the RESUME
position for more than one second will decelerate (coast) the
vehicle until the switch is released.
Engine Speed Control Systems i
The electronic engine speed controls are also activated by use
of the CRUISE/(THROTTLE) switches located in the cab dash.
These switches are used to control engine speed for PTO
functions and normal vehicle speed control. The variable type
controls bring the engine up to a desired speed and hold it
Form No. 3628504R1
Printed in the United States of America
there. The Pre-Set type controls, when activated, automatically
advance the engine speed to a pre-set speed and hold it there.
These electronic features are: cruise control, hand throttle,
stationary pre-set speed control, stationary variable speed
control, and mobile variable speed control.
Basic Functions of CRUISE/(THROTTLE) Switches
The ON/OFF switch turns the control feature on or off, depending
on which feature was ordered. However, they all perform the
same function: to turn on the basic feature.
The SET/RESUME switch actually sets and controls the engine
speed. But if the ON/OFF switch has not been activated, nothing
will happen when pushing on this switch. This switch has the
same label in all applications.
The three available options are:
Cruise used when only cruise control is ordered;
Throttle used when only hand throttle or an engine speed
control is ordered;
Cruise/Throttle used when cruise control and either hand
throttle or an engine speed control are ordered.
Page 61
 SECTION 4 VEHICLE OPERATION

Cab Controls (cont.)

Cruise Control (cont.)

Engine Speed Control Systems i (cont.)

Operation Procedures Cruise Control (12VVN)
The following steps will activate and enable each of the five
engine speed control features.
Cruise Control (12VVN) operates like an automotive cruise
control:
1. Press the ON (lower) position on the ON/OFF left rocker
switch.
2. Bring the vehicle to the desired operating speed (above 35
MPH), and then push the SET/COAST position on the right
rocker switch.
3. Once in the cruise mode the SET/RES(UME) switch can
be used to increase or decrease vehicle speed by pushing
and holding the CRUISE SET/RES(UME) switch to the SET
position to increase or the CRUISE SET/RES(UME) switch
in the RESUME position to decrease speed.
4. A slight tap on the brake or clutch pedal will deactivate the
cruise but holds the selected speed in memory. To return
to this speed, just press the SET/RES(UME) switch to the
RESUME position.
5. When the left switch is pressed on the OFF position, or if the
vehicle is shut off, the previous speed setting is canceled.
Operation Procedures Hand Throttle (12UGN)
1. Press the ON (lower) position on the ON/OFF switch.
2. Press and release the SET/RES(UME) switch to the
SET position.
3. Press and hold SET/RES(UME) switch in the SET
position on the right switch until the speed desired is
obtained. Or, you can repeatedly press and release this
position and increase the speed in small increments.
4. To change from this initial setting, use the
SET/RES(UME) switch to lower or raise the
engine speed as you would in the cruise control mode.
RESUME position reduces engine speed and SET
position increases engine speed.
5. Press he CRUISE ON/OFF switch is in the OFF position
to turn the throttle off and return engine to idle.
Operation Procedures Stationary Variable Speed Control
(12VVT)
This feature is ordered to provide variable engine speed control
primarily for operation of PTO powered equipment. It operates
the same as the hand throttle discussed above.

Form No. 3628504R1

Page 62 Printed in the United States of America
 SECTION 4 VEHICLE OPERATION

Cab Controls (cont.)

Cruise Control (cont.)

Engine Speed Control Systems i (cont.)

Operation Procedures Stationary Pre-Set Speed Control
(12VVS)
1. Press the ON (lower) position on the ON/OFF left rocker
switch.
2. Press and release the CRUISE SET/RES(UME) switch
to the SET position for the pre-set speed desired.
When ordered, this feature can provide two different
predetermined speeds, which are selected with the
SET or RES(UME) positions. You need to know which
position to use for your specific operation.
3. To go from the first selected speed to the second speed,
you need to be aware that when you press on this other
position, the engine will initially return to idle. You must
push it a second time to go to the second speed. This
is done to protect equipment from being inadvertently
operated at the wrong speed.
Operation Procedures Mobile Variable Speed Control
(12VVU)
Operates the same as cruise control, except the engine speed is
accurately controlled instead of vehicle speed. The truck could
be operated in one of several gears but the truck is limited to 20
MPH, or any pre-set lower speed down to 3 MPH.
Smoking
WARNING: Always use the ashtray(s) provided
for disposing of cigar, cigarette, or pipe ashes and
tobacco. Failure to use an ashtray is a fire hazard and
could result in property damage, personal injury, or
death.

Form No. 3628504R1

Printed in the United States of America Page 63
 SECTION 4 VEHICLE OPERATION
Engine Ignition Switch
WARNING: Never start the engine unless youre
sure the transmission selector is in neutral and the
brake is applied, otherwise accidental movement of
the vehicle can occur which could result in property
damage, personal injury, or death.
WARNING: In the event engine shutdown occurs,
make certain that vehicle is safely off the roadway, the
4-way emergency flashers are on, and traffic warning
devices are properly placed. Failure to remove vehicle
from roadway could cause an accident and result in
property damage, personal injury or death.
Automatic transmissions must be in neutral before the starter
will engage. Manual transmissions require the clutch pedal to
be depressed before the starter will engage.
Form No. 3628504R1
Page 64 Printed in the United States of America
Ignition Switches And Starting The Engine
Ignition Switch with START Position
Set parking brake, place transmission control in the neutral
position and depress clutch pedal. With ignition key in
switch, rotate switch clockwise to the first position, marked
ON. Continued clockwise rotation of the key will activate the
cranking system causing the engine to turn over. As soon as the
engine starts, release key and the switch will return to the ON
position. Engine will continue to run with key in ON position. To
stop the engine, rotate the key counterclockwise to the vertical
position, marked OFF, and remove key from switch. There is
also an ACC (Accessory) position on the switch, allowing use
of accessories during periods when engine operation is not
desired. With ignition key in switch, rotate key counterclockwise
from the OFF position. Switch will stop at the ACC position. To
terminate accessory operation rotate key clockwise to the OFF
position and remove key.
 SECTION 4 VEHICLE OPERATION

Engine Ignition Switch (cont.)

Ignition Switches And Starting The Engine (cont.)

Ignition Switch with Pushbutton Start

NOTE: Pushbutton start is an optional feature on some models.

To engage cranking motor for engine operation:
Set parking brake, place transmission control in neutral position
and depress clutch pedal. Insert key into switch, rotate switch
clockwise to the RUN position and depress start pushbutton
located on instrument panel. When engine starts, release start
pushbutton. Engine will continue to run with switch in the RUN
position. To stop the engine, rotate the switch counterclockwise
to the vertical position, marked OFF, and remove key from
switch. Some engines have separate manual shut-off valves. 1. IGNITION SWITCH
2. KEY POSITIONS
3. STARTER PUSH BUTTON
4. INSTRUMENT PANEL
There is also an ACC (Accessory) position on the switch,
allowing use of accessories during periods when engine
operation is not desired. With key in switch, rotate key
counterclockwise from the OFF position. Switch will stop at
the ACC position. To terminate accessory operation rotate key
clockwise to the OFF position and remove key.

Form No. 3628504R1

Printed in the United States of America Page 65
 SECTION 4 VEHICLE OPERATION

Electrical

Accessory Feed Connections

When connecting owner-installed electrical accessories to the

vehicles electrical system, use only the connection terminals
provided for this purpose.

CAUTION: DO NOT splice or cut into existing vehicle

circuits to connect accessories.

External Accessory Connections There are two primary

access connector ports for communication and 120 VAC
(shore) power. They are mounted on the left rear of the
sleeper cab. See figure below.
For locations of internal accessory feed connectors, refer to the
ELECTRICAL CIRCUIT DIAGRAM MANUAL.
Sleeper Inverter/Battery Charger (Optional)

The inverter located in the sleeper supplies 1100 Watt of 110

VAC to operate any appliances needed by the driver, including
TV/VCR, microwave ovens, hair dryers, fans, etc. While the
inverter is supplying power to its load, the LED will be lit steadily,
indicating normal operation.
The inverter becomes a battery charger when connected to
optional 120 VAC shore power connector. When the inverter

Form No. 3628504R1

Page 66 Printed in the United States of America
 SECTION 4 VEHICLE OPERATION
Electrical (cont.)
Sleeper Inverter/Battery Charger (Optional) (cont.)
is charging the battery, the LED will be lit steadily indicating
normal charging operation.
NOTE: See Inverter Remote Control operation in Sleeper
Control Section.
Phone And Cable TV Communication Ports (Optional)
The vehicle is equipped with two external communications ports
for cable TV and telephone (See illustration). The telephone
connector will provide the driver with the ability to use the Internet
via the phone line and a dial-up modem.
Alternator
Many alternators used in International vehicles are of the
self-energizing type. Some engines may need to be briefly
revved after starting to turn on the alternator. The alternator will
then charge at idle. If the vehicle is to be warmed up prior to
beginning operation, the operator should observe the voltmeter
or ammeter for charging indication before leaving the vehicle.
Form No. 3628504R1
Printed in the United States of America
NOTE: Before connecting a fast charger, booster battery or
installing a new battery, make sure that the ground polarities of
the fast charger, booster battery or alternator (when installing a
battery) are matched to the ground polarity of the vehicle battery.
Improper usage of fast charger, hook-up of booster battery or
installing battery can cause damage to the electrical system or
to the alternator. Do not attempt to polarize the alternator.
Ammeter (Optional)
The ammeter indicates the rate of charge of electric current
supplied by the alternator to the battery, or the rate of discharge
from the battery. At low engine speeds the ammeter indicator
may show a negative or discharge reading. When the battery
is fully charged, a very slight charge is indicated during normal
vehicle operation.
Antennas: 5000i And 9000i
Your vehicle is equipped with one standard dual purpose
antenna or two optional dual purpose antennas. The antenna
cables go into a splitter located behind the radio in the dash.
From the splitter, cables go to the enterntainment radio and
to the CB radio. These antennas were designed to provide
optimal reception in your vehicle and must be replaced with
Page 67
 SECTION 4 VEHICLE OPERATION

Electrical (cont.)
Antennas: 5000i And 9000i (cont.)

original replacement antennas unless you are going to bypass

the splitter and provide one antenna for your entertainment
radio and another antenna for your CB radio.
Battery
WARNING: Always wear eye protection when
working around batteries. Do not attempt to jump-start
a vehicle with a frozen battery because the battery may
rupture or explode. If a frozen battery is suspected,
thaw out battery and recharge.

Do not check battery condition by shorting (flashing)

WARNING: Keep lighted tobacco, flames, sparks
or other ignition sources away from the batteries. Gas
from the battery cells is flammable and can ignite
and/or explode. This is particularly true when jumper
cables are being used. Battery fires or explosions
could cause severe injury to the face, eyes, limbs and
body.
In addition, inhaling the hydrogen gas produced by the
normal operation of the battery could result in partial
or permanent damage to the respiratory system.
Whenever disconnecting battery terminals, always
disconnect ground terminal first. When reconnecting,
always connect ground terminal last. Failure to follow
this procedure could result in a short to ground and
cause property damage, personal injury, or death.
across terminals.
Failure to follow this warning could result in property
damage, personal injury or death.
The solution in each cell should be to the indicator level. When
the solution is below this level, add distilled water, using a clean
syringe. Acid or electrolyte should never be added except
by persons skilled in working with these materials. Some
maintenance-free batteries do not have removable caps for
adding distilled water.
NOTE: Never add special solutions or powders to batteries.
Battery cable terminals must be clean and tight. Use hot water
and common baking soda for removing terminal corrosion and
for cleaning the top of the battery. Brighten the contact surface

Form No. 3628504R1

Page 68 Printed in the United States of America
 SECTION 4 VEHICLE OPERATION

Electrical (cont.)
Battery (cont.)

with steel wool, apply a light coat of lubricant sealing grease such Circuit breakers interrupt the circuit when an overload or short
as Fleetrite 472141C1 or equivalent and reassemble. Be sure occurs. Manual circuit breakers (Type III) can be reset by
the terminals are clamped tightly and that the battery is clamped depressing the reset button on the breaker. Automatic reset
securely in the battery box. breakers (Type I) will reset automatically; they should only be
used in the headlight and wiper motor circuits. Type II circuit
When working around the terminals and battery, use extra care
breakers will reset if the short is removed from the circuit.
to avoid shorting. A good practice is to use insulated pliers and
screwdrivers. Do Not Check Battery Condition By Shorting
(Flashing) Across Terminals.
WARNING: Electrical circuits are designed with
a particular wire gauge to meet the fuse and circuit
Circuit Breakers, Fuses And Fusible Links breaker current rating. Do not increase size of fuse or
circuit breaker or change type of breaker supplied with
The various electrical circuits on these chassis are protected
your truck. To do so could cause wiring to overheat
either by circuit breakers, fuses or fusible links and are
and possibly burn, resulting in a fire which could cause
conveniently located inside the glove box for easy access. For
property damage, personal injury or death.
the size and location of circuit breakers, fuses and fusible links,
please refer to the VEHICLE SPECIFICATIONS SECTION of
this manual. A computer generated listing is also provided there
for each vehicle.
Fusible links consist of a length of lighter gauge wire in a circuit.
In case of a short or overload, the fusible link opens (burns out) to
protect the remainder of the circuit. Repair consists of splicing
in a new fusible link with the same gauge wire as the opened
fusible link.

Form No. 3628504R1

Printed in the United States of America Page 69
 SECTION 4 VEHICLE OPERATION

Electrical (cont.)
Windshield Wiper And Washer Controls

WARNING: Do not use the washers in freezing

weather without first warming the windshield with the
defrosters; otherwise, the washer solution may freeze
on the windshield and obscure your vision and cause
an accident which could result in property damage,
personal injury or death.

Do not use radiator coolant or anti-freeze in the

windshield washer reservoir. Radiator coolant in the
washer reservoir can severely affect visibility when
sprayed on the windshield.

Electric wipers with intermittent settings are standard. The

switch is located on the right side of the dash in the wing panel.
The wiper/washer control has a toggle switch that pushes in like 1. High Constant (highest speed)
a button to turn the wipers ON and OFF and a separate WASH 2. Low Constant
button. The toggle switch controls seven different wiper settings
that can easily be chosen by toggling up or down in speed by 3. Three Second Delayed Cycle
quickly pushing up or down on the toggle switch (holding up or 4. Five Second Delayed Cycle
down less than 1 second).
5. Eight Second Delayed Cycle
Keep the fluid reservoir filled with Fleetrite Windshield Washer
Solvent or an equivalent. 6. Twelve Second Delayed Cycle
7. Seventeen Second Delayed Cycle

Form No. 3628504R1

Page 70 Printed in the United States of America
 SECTION 4 VEHICLE OPERATION
Electrical (cont.)
Windshield Wiper And Washer Controls (cont.)
Wiper and Washer Instructions:
A. To start low speed wiping, push the toggle switch in or
push the toggle switch down quickly (hold down less
than 1 second).
B. To turn off wipers in any speed push the toggle switch
in.
C. To select high speed constant wiping push up on the
toggle switch and hold for 1 second.
D. To make a single dry sweep for mist conditions quickly
press the wash button (hold down for less than 1/2
second).
E. To wash the windshield push and hold the wash button
for more than 1/2 second and release to get a 1 or 2
cycle wash. The wash button may be held in to continue
washing. After washing cycles are complete the wipers
will continue at the prior speed.
F. To operate the intermittent wiping modes step down in
speed by quickly pushing down on the toggle switch to
the desired intermittent speed or hold the toggle down
for more than 1 second to put the wipers in the slowest
intermittent speed.
Form No. 3628504R1
Printed in the United States of America
Horn
Some areas have local Noise Control Laws regulating horn use.
If your vehicle has both an electric and an air horn system, use
the electric horn within city limits and the air horn outside city
limits.
The electric horn control (city horn) is normally located in the
steering wheel. Push horn button down to operate.
The air horn control (country horn) is normally located forward of
the left door opening above the drivers head. Pull control down
to operate.
Mirrors
Heated Mirror Switch
This is an ON/OFF switch which, when turned to the ON position,
will heat the mirror automatically based on ambient temperature.
Mirror Select Switch
This is a Joy Stick type switch with a lever that, when is rotated
left or right, selects the desired mirror. The control lever can then
be pushed up, down, left, or right to the mirror for the best from
that mirror.
Page 71
 SECTION 4 VEHICLE OPERATION

Electrical (cont.)
Lighting Switches

NOTE: Vehicles Equipped With Fog Lights: the electrical circuit

is designed so that the fog lights will operate with the headlights
on low beam mode.
The light control switches are clearly labeled and located on the
wing panel of the instrument panel. The courtesy light switch and
the switch for lights in the sleeper are located on the left side of
the header panel above the drivers seat.

Audible Alarm

The instrument cluster has a multiple function alarm that is

attached to the rear of the speedo/tach module. This alarm
serves to indicate the following alarms.

Form No. 3628504R1

Page 72 Printed in the United States of America
 SECTION 4 VEHICLE OPERATION

Multiple Function Alarm

Alarm Condition Alarm Sound Visual Alarm
Low Air Continuous Beeps Low Air Light
Low Fuel 5 Fast Beeps Low Fuel Light
Low Oil Pressure 5 Fast Beeps Low Oil Press. Light
High Coolant Temp. 5 Fast Beeps High Water Temp. Light
Oil Pressure Sender Fault 3 Long Beeps Gauge Points Down
Water Temp. Sender Fault 3 Long Beeps Gauge Points Down
Fuel Sender Open 3 Long Beeps Gauge Points Down
Tach Sender Fault 3 Long Beeps Gauge Points Down
Speed Sender Fault 3 Long Beeps Gauge Points Down

Data Link Driven Instrument Cluster
The basic six electronic gauges (speedo, tach, oil pressure,
water temperature, voltmeter and fuel) will go through one full
sweep on every power-up before returning to indicating a gauge
parameter. This tells the driver that all electronics, the electronic
gauges and the odometer are functioning properly. Gauges that
are erratic or do not sweep completely should be serviced.
Oil Pressure Warning Light, High Water Temperature
Warning Light
With the ignition switch turned ON the light will glow while the
basic 6 gauges are cycled through one complete sweep. If light
fails to go OUT after starting engine, stop engine and determine
cause of low oil pressure and/or excessive water temperature.

Speedometer

The speedometer indicates the vehicle speed in miles or

kilometers per hour. The speedometer will go through a

Form No. 3628504R1

Printed in the United States of America Page 73
 SECTION 4 VEHICLE OPERATION
Speedometer (cont.)
self-check (full sweep) on every power-up. The odometer
records the total number of miles/kilometers traveled.
Tachometer
The tachometer indicates engine RPM. The engine can be
operated between rated speed and high idle without damage
but should not be allowed to overspeed (such as when going
downhill). Refer to Engine segment of this section for vehicle
operation engine speeds.
Pyrometer
The pyrometer indicates the temperature of the exhaust gases.
Variations in engine load can cause exhaust temperatures to
vary. If the pyrometer reading shows that exhaust temperature
exceeds 1200F (649C), throttle less fuel to the engine until the
exhaust temperature is reduced. Downshift to a lower gear if the
engine is in an overloaded condition.
NOTE: The pyrometer is set to ambient temperature. With
the engine cold, the pyrometer reading should indicate
approximately the outside temperature. Do not attempt to
adjust the pyrometer to 0 (zero) degrees.
Form No. 3628504R1
Page 74 Printed in the United States of America
Voltmeter
The voltmeter gauge indicates the condition of the battery.
The gauge is divided into colored sections.
With the ignition switch ON (before starting engine) the gauge
will show the condition of the battery.
GREEN A well charged battery.
ORANGE (RED) Very low battery charge.
With the engine running at operating speeds the gauge will show
the condition of the generating system.
GREEN Generating system working properly.
ORANGE (RED) Voltage output too low or too high.
Constant reading in either RED area indicates the need for a
complete check of the battery and generating system.
Electronic Digital Odometer
The electronic digital (LCD) odometer provides both vehicle
operating functions as well as diagnostic messages. It may
display as many as seven functions that include total vehicle
miles, trip miles, engine hours, trip hours, (optional) total PTO
hours, (optional) total idle hours, and (optional) instantaneous
fuel economy. Each mode is selected by pressing the
SET/RESET push button switch located outside the lower
 SECTION 4 VEHICLE OPERATION

Electronic Digital Odometer (cont.)

right corner of the speedometer. Each time the switch is Engine Hours and Trip Hours
depressed, the display will advance to the next mode. The last
The Engine Hour display provides a permanent record of the
menu, the diagnostic menu, indicates the presence of a system
number of engine hour operation, and will not operate unless
fault..
the engine is running. This display function cannot be cleared.
The display also provides display of diagnostic messages that
The Trip Hour display provides a record of elapsed time.
can, if a fault exists, assist maintenance personnel in vehicle
Pressing and holding the RESET switch for at least 3 seconds
repair. The following is a brief description of odometer readings.
will clear the display.
Odometer and Trip Odometer
The odometer records the total number of miles/kilometers
traveled. The trip hours and trip miles are independently reset
by pressing and holding the RESET switch for more than 3
seconds. When either the odometer or trip odometer miles are
displayed, pressing and holding the SET/RESET push button
changes miles (MI) to kilometers (KM).

PTO Hours
The PTO Hours display provides a permanent record of the
number of engine hours during PTO operations.

Form No. 3628504R1

Printed in the United States of America Page 75
 SECTION 4 VEHICLE OPERATION

Electronic Digital Odometer (cont.)

Total Idle Hours

The Idle Hours display indicates the total time that the engine
is running without the transmission or PTO drive gear engaged.
As with the Total Engine Hours display, this display cannot be
cleared by using the RESET button.

Warning Lights

All of the warning lights have power applied (turns on) during the
ignition key TURN-ON sequence.
Instantaneous Fuel Economy
Air Brake Pressure Warning Light: This warning light will turn
This display indicates the vehicles fuel economy, at any vehicle
OFF when the pressure in the system rises above 60 psi. When
speed, in either miles per gallon or kilometers per liter. The
the engine is first started, this light will come ON and remain ON
display is toggled (between standard and metric units) by
until the air pressure rises above 60 psi.
pressing and holding the SET/RESET button at least 3 seconds.
Coolant Temperature Warning Light: This warning light will
turn on when the engine coolant temperature rises above 210F
(99C). Selecting the next lower transmission gear range may
help drop the temperature. If the temperature drops the light may
not immediately correspond to the temperature gauge. There
may be a 10 to 15F (6 to 8C) drop on the temperature gauge
before the temperature warning light goes off.

Form No. 3628504R1

Page 76 Printed in the United States of America
 SECTION 4 VEHICLE OPERATION

Warning Lights (cont.)

Engine Oil Pressure Warning Light: The engine oil pressure
warning light will turn on when the engine oil pressure is below
the allowable minimum.
Transfer Case Warning Light: A transfer case overheat
warning light is located on the wing panel to the right of the
heater/AC controls. This light will illuminate if the lubricant
temperature exceeds the maximum range. If the warning light
comes on, pull off the roadway as soon as it is safe to do so.
When stopped, inspect the transfer case, oil cooler and lines for
leaks. If there are no leaks, resume driving 15 mph slower than
when the light came on. Resume safe speed if light stays off.
Low Fuel Warning Light This warning light will turn on when
fuel level begins to drop below 1/8th tank.
Turn Signal Switch
Turn Signal Function.
To signal for a left turn, move lever down until left green
directional indicator comes on. To signal for a right turn, move
lever up until right green directional indicator comes on. (See
illustration)
Traffic Hazard Warning Switch.
The traffic hazard warning flasher system will operate with the
ignition switch in the ON or OFF position. Use the warning
system any time your vehicle becomes a traffic hazard, day or
night.
The traffic hazard warning switch lever is located on the turn
signal switch below the turn signal lever. Pull the switch out to
activate the system. To stop the warning signal, move the turn
signal lever up (right) or down (left), and the switch control will
move to the OFF position.

NOTE: The turn signal system on some models is not self

canceling. After a turn is completed, the driver must manually
shut the system off by returning the switch to the OFF(central)
position.
The turn signal switch is mounted on the left side of the steering
column below the steering wheel. Green directional indicator
lights are located on the instrument panel. The turn signal switch
assembly contains both the turn signal and the traffic hazard
warning switch.

Form No. 3628504R1

Printed in the United States of America Page 77
 SECTION 4 VEHICLE OPERATION

Turn Signal Switch (cont.)

The system utilizes a Vacuum Fluorescent display that provides

current compass heading and temperature readings. The
temperature reading can be toggled between Fahrenheit and
Celsius using the F/C button.
Sleep Mode One Touch Mode. The unit display is blank
whenever the ignition is turned off, but will display temperature
and heading, for 10 seconds, if either MODE or F/C button is
pressed.
Refer to the American Technology Compass and Temperature
System Operation Manual for details of operation and
calibration.

1. TURN SIGNAL LEFT TURN

2. TURN SIGNAL RIGHT TURN
3. HAZARD WARNING ON POSITION
4. HAZARD WARNING OFF POSITION

American Technology Compass and Outside Temperature

System

International makes available the optional Compass/Outside

Temperature system. This system monitors and displays both
the outside ambient temperature and relative direction of vehicle
within the current geographical zone.

Form No. 3628504R1

Page 78 Printed in the United States of America
 SECTION 4 VEHICLE OPERATION

Heating, Defrosting, Ventilation, Air Conditioning HVAC Central Control Panel

WARNING: Never drive the vehicle unless the

windshield and all other windows are clear. A fogged,
ice/snow covered, or dirty windshield or window limits
vision, which could cause an accident, resulting in
property damage, personal injury or death. To improve
defroster efficiency, remove ice and/or snow by hand
from the windshield and windows with a non-metallic
scraper.

CAUTION: To clear system of humid air, operate
blowers for 30 seconds at high speed before moving
the air outlet knob or the mode control knob to the
DEF position. This will prevent fogging of the glass,
which can occur if humid air is blown onto a cool
windshield.
1. FAN SPEED CONTROL KNOB WITH 4 SPEEDS
2. BUNK CONTROL PANEL ON/OFF BUTTON
3. TEMPERATURE CONTROL KNOB FOR FRONT OF
CAB
4. A/C ON/OFF BUTTON FOR FRONT OF CAB A/C
5. MODE CONTROL KNOB TO DIRECT AIR FLOW

Heating:

The temperature, direction, and volume of hot air is easily

controlled by setting the Temperature Control Knob, the Mode
Control Knob, and the Fan Speed Control Knob to the desired

Form No. 3628504R1

Printed in the United States of America Page 79
 SECTION 4 VEHICLE OPERATION

Heating, Defrosting, Ventilation, Air Conditioning

(cont.)
HVAC Central Control Panel (cont.)

Heating: (cont.)
positions. Do not heat the cab with the Mode Control Knob in
the Max position or fogging of the windows may occur.
For maximum heating rotate the Fan Speed Control Knob to 4,
turn the Temperature Control Knob to the hottest setting or fully
clockwise, and direct the air flow to "Panel Only," "Panel and
Floor," "Floor Only," "Defrost and Floor," or "Defrost Only" by
turning the Mode Control Knob. There are two floor air outlets
on the drivers side and one on the passengers side.
The front of the cab and the sleeper bunk may be heated or
cooled independently. To warm the sleeper bunk while the front
of the cab is kept at a lower temperature the air flow deflectors
in the bunk should be set to direct heat downward toward the
floor and lower bunk. Make sure the BUNK Button on the HVAC
Central Control Panel is ON or the bunk control panel will not
function. For bunk control panel instructions see "Pro-Sleeper
Controls" under "Instrument Panel and Controls".
Defrosting:
For maximum defrosting set the Fan Speed Control Knob to 4,
set the Temperature Control Knob fully clockwise, and set the
Mode Control Knob to the "Defrost Only" position by rotating
it fully clockwise. Once the glass is fully defrosted the Mode
Control Knob may be turned to the "Defrost and Floor," "Floor
Only," "Panel and Floor," or "Panel Only" position. To avoid
fogging on the inside of the glass during initial start-up of the
defroster, purge the the moist air out of the heating system by
directing the air flow towards the floor by selecting the Floor
Only position on the Mode Control Knob and then turning the
Fan Speed Control Knob to 4.
Fresh Air Ventilation:
The heating and air conditioning system uses fresh air ventilation
in every mode except for when the Mode Control Knob is in the
"MAX position (see Item 5 in the figure above). The "MAX"
position is used to recirculate the air in the cab. The fresh air
modes should be used regularly while the "MAX" mode should
only be used initially to rapidly lower the cab temperature. The
temperature, direction, and volume of fresh air ventilation is
easily controlled by setting the Temperature Control Knob, the
Mode Control Knob, and Fan Speed Control Knob to the desired
positions.

Form No. 3628504R1

Page 80 Printed in the United States of America
 SECTION 4 VEHICLE OPERATION

Heating, Defrosting, Ventilation, Air Conditioning

(cont.)
HVAC Central Control Panel (cont.)

Air Conditioning:
For maximum cab cooling at initial start-up, push the A/C
button ON and turn the Fan Speed Control Knob to 4, turn the
Temperature Control Knob counterclockwise, and turn the Mode
Control Knob to the "MAX" position. Once the cab reaches
the desired temperature, the Mode Control Knob should be
rotated out of the "MAX" position to allow the HVAC system to
dehumidify the cab air. The "MAX" position is to be used only
long enough to rapidly cool a warm cab.
Always park the vehicle in the shade whenever possible. If your
vehicle has been parked in the sun with the windows up, remove
overheated cab air by driving with the windows down and the air
conditioner ON for one or two city blocks.
Keep radiator area free of bugs, leaves, etc. Do not cover the
condenser with a fine mesh screen.
At least once or twice a month turn on the air conditioner for a
few minutes while the engine is running. This periodic operation
keeps all the mechanical parts of your air conditioner in good
operating condition.
It is normal for small amounts of water to drain out of the air
conditioner. This water is condensed moisture removed from
the air inside the vehicle.
The front of the cab and the sleeper bunk may be heated or
cooled independently. Make sure the BUNK button on the HVAC
Central Control Panel is ON or the bunk control panel will not
function. For bunk control panel instructions see "Pro-Sleeper
Controls" under "Instrument Panel and Controls".
Dehumidification:
The HVAC system can be used to take moisture out of the cab air
by setting the Mode Control Knob to the "Panel Only" position,
the "Panel and Floor" position, or the "Floor Only" position by
pushing the A/C Button ON and setting the Temperature Control
Knob and the Fan Speed Control Knob to the desired positions.
When the Mode Control Knob is in the "Defrost and Floor"
position or the "Defrost Only" position, the A/C will automatically
turn on and it is not necessary to put the A/C button in the ON
position.
Pro Sleeper Climate Control:
Instructions for operating the heating/ventilation and air
conditioning of the Pro Sleeper are found under Pro Sleeper
Controls in the Sleeper Features section. The sleeper bunk
Central Control Panel will not function unless the BUNK Button

Form No. 3628504R1

Printed in the United States of America Page 81
 SECTION 4 VEHICLE OPERATION
Heating, Defrosting, Ventilation, Air Conditioning
(cont.)
Pro Sleeper Climate Control: (cont.)
on the dash mounted HVAC Central Control Panel is pushed
in. If the sleeper bunk Central Control Panel is preset for the
desired climate control then the sleeper bunk may be heated
or cooled prior to stopping the vehicle by pushing the BUNK
Button ON.
Eaton VORAD EVT-300 Collision Warning System
WARNING: Before using this feature, read
and understand the EatonVORAD Collision Warning
Systems Driver Instructions manual, and obtain
proper training. Improper use of this system could
result in property damage, personal injury, or death.
Form No. 3628504R1
Page 82 Printed in the United States of America
Limitations of the EVT-300 Collision Warning System (From
Driver Instructions VODR-0030)
WARNING: The Eaton VORAD Collision Warning
System is intended solely as an aid for an alert and
conscientious professional driver. It is not to be used
or relied upon to operate a vehicle. The system should
be used in conjunction with rear view mirrors and
other instrumentation to maintain safe operation. A
vehicle equipped with the Collision Warning System
should be operated in the same safe manner as if
the Collision Warning System were not installed. The
system is not a substitute for normal safe driving
procedures. It will not compensate for any driver
impairment, such as drugs, alcohol, or fatigue. Failure
to follow this warning could result in property damage,
personal injury, or death.
 SECTION 4 VEHICLE OPERATION

Eaton VORAD EVT-300 Collision Warning System

(cont.)

WARNING: The Eaton VORAD Collision Warning

System may provide little or no warning for some
hazards, such as pedestrians, animals, oncoming
vehicles, and cross traffic. Failure to follow this
warning could result in property damage, personal
injury, or death.

System Description.
The Eaton VORAD EVT-300 Collision Warning System (CWS)
is a high frequency radar system that transmits and receives
radar signals from the front and side of the vehicle, to constantly
monitor areas ahead of and in blind spot of your vehicle. The
system consists of a Front Antenna Assembly, the Driver Display
Unit (DDU), Central Processing Unit (CPU), and an optional
Side Sensor with a Side Sensor Display. The following is a
brief operational summary of the system, however, for complete
operating instructions, see the Eaton VORAD Collision Warning
System manual Driver Instructions manual VODR-0030.
Driver Display Unit (DDU). The Driver Display Unit is the control GEVT300DDU

and monitoring device for the Eaton VORAD EVT-300 CWS. It is

mounted in the Wing Panel and is easily visible and accessible A speaker volume control/system power On/Off knob used
to the driver. The DDU contains the following system control to apply power to the system, and to control the loudness of
knobs, system indicators, and warning level indicators: the warning tones.

Form No. 3628504R1

Printed in the United States of America Page 83
 SECTION 4 VEHICLE OPERATION

Eaton VORAD EVT-300 Collision Warning System

(cont.)
A control knob for range adjustment of the first alert (3 The following is a table of Eaton VORAD EVT-300 alerts (visual
to 2 seconds) and second alert (2 to 1.75 seconds) in and audible).
normal operation, and following intervals when in optional
SmartCruise (see operating description below). DRIVER DISPLAY UNIT

The green system indicator that lights when system power is Lights Beeps () DESCRIPTION (Range
turned on, and blinks continuously when the optional Driver knob full clockwise)
Identification Card has not been installed. Y Proximity Alert within
The red indicator that warns of a system failure. 15 feet (Approaching a
stationary object at < 2
The S/C indicator that comes on whenever the optional mph or vehicle in front
SmartCruise feature is enabled. rolling backwards towards
Three warning level indicators that provide multiple warning you)
levels based upon target vehicle distances and their closing Y Object detected @ 350
interval (in seconds) to your vehicle. feet
A light sensor that automatically increases brightness of Y Or At 2-3 seconds from
indictor lights in the daytime and decreases brightness detected vehicle
during nighttime.
Y Or At 1-2 seconds from
A small speaker is mounted under the top cover of the DDU detected vehicle
that provides audible alert tones whenever appropriate Y Or R At 0-1 second from
hazard conditions occur. It is used by both the DDU and the detected vehicle
Side Sensor Display. The loudness of the tones is adjusted
by the Power/Volume control knob.
A slot at the front bottom edge of the Driver Display Unit to
insert the optional Driver Identification Card.

Form No. 3628504R1

Page 84 Printed in the United States of America
 SECTION 4 VEHICLE OPERATION

Eaton VORAD EVT-300 Collision Warning System

(cont.)
DRIVER DISPLAY UNIT Indicate whether or not the Side Sensor is detecting an object.
The display is mounted on right side A-pillar on the inside of
Lights Beeps () DESCRIPTION (Range
the vehicle, easily seen (usually in the same line of sight of the
knob full clockwise)
side mirror). The Yellow indicator light is lit all the time when
Y Or R At .5 seconds from no blind spot object has been detected by the Side Sensor.
Repeating detected vehicle When the turn signal is activated, and an object is detected, the
Y Or R Detected object moving Red indicator light comes and triple alert tone is heard from the
20% slower than you or Driver Display unit. A light sensor that increases brightness of
a stationary object, within indictor lights in the daytime and decreases brightness during
220 feet At less than 3 nighttime.
seconds away

Front Antenna Assembly. The collision warning system uses a

front-mounted antenna assembly to transmit and receive radar
signals to determine the distance and relative speed between
the vehicle and objects in front of vehicle. The unit can see and
track up to 20 vehicles within a range of 350 feet, even those
in adjacent lanes, but only reports the ones in your own lane
even if the lane curves. The unit is mounted on the front of the
vehicle, usually in the center of the bumper.
Side Sensor (optional). The optional Side Sensor is a device
that is normally mounted on the right side of the vehicle. The
unit detects vehicles or objects 2 to 10 feet from the side of the
vehicle, moving or stationary, which are adjacent to your vehicle.
Side Sensor Display (optional). The optional Side Sensor
GEVT300SSD
Display contains Red and Yellow alert indicator lights that

Form No. 3628504R1

Printed in the United States of America Page 85
 SECTION 4 VEHICLE OPERATION

Eaton VORAD EVT-300 Collision Warning System

(cont.)
SIDE SENSOR DISPLAY SmartCruise
Lights TONES DISTANCE/RANGE
Y No object detected (with or without
right turn signal activated) WARNING: SmartCruise does not replace an
alert, trained driver. SmartCruise will not react to
R When right turn signal is activated,
stationary objects and cannot bring the vehicle to a
and an object is detected and
complete stop. The driver still needs to use good
remains a hazard for more than 1
driving practices to avoid an accident. Failure to
second.
follow this warning could result in property damage,
personal injury, or death.
Central Processing Unit The Central Processing Unit (CPU)
is the electronic control unit for the EVT- 300 Collision Warning
System. It compiles information from the front Antenna
Assembly, Engine Control Module (ECM), Speedometer,
optional Side Sensor, Brake, and Turn Signal Circuits to
produce audible and visual warnings. The warning tones and
alert indicators are produced and displayed in the Driver Display
unit and the optional Side Sensor display.

Form No. 3628504R1

Page 86 Printed in the United States of America
 SECTION 4 VEHICLE OPERATION

Eaton VORAD EVT-300 Collision Warning System

(cont.)
SmartCruise (cont.)

WARNING: Improper use of SmartCruise can
result in property damage, personal injury, or death.
Do not use SmartCruise in:
slippery conditions (wet, snow, ice, mud) or fog.
stop-and-go traffic
winding roads
any situation where your vehicle manual advises
against using Cruise Control.
Check front sensor periodically for alignment and
cleaning. Heed all safety information in your Eaton
VORAD manual and truck operator manual. Failure to
follow this warning could result in property damage,
personal injury, or death.
WARNING: If the host vehicle speed and the
target vehicle speed are drastically different, the driver
may need to apply the service brakes to maintain a
safe distance. If the service brakes is applied, press
the CRUISE SET/RES(UME) switch to the RESUME
position to reactivate cruise (this will also activate
SmartCruise. Failure to follow this warning could
result in property damage, personal injury, or death.
NOTE: Be sure to read the Eaton VORAD EVT-300 Driver
Instruction manual, and obtain proper training for additional
driving situations encountered while using SmartCruise.
The Smart Cruise feature, of the EVT-300 collision warning
system, works along with the vehicles Cruise control system
to control vehicle speed and following intervals between your
vehicle and the target vehicle ahead of you.
Whenever the vehicles Cruise Control system is activated
(switches CRUISE ON/OFF Switch to the ON position
and CRUISE SET/RES(UME) switch to the SET position),
SmartCruise will be activated and the (S/C) indicator light will
come on. When a target vehicle is detected by the EVT300 front

Form No. 3628504R1

Printed in the United States of America Page 87
 SECTION 4 VEHICLE OPERATION

Eaton VORAD EVT-300 Collision Warning System

(cont.)
SmartCruise (cont.)

sensor, SmartCruise will adjust the vehicle speed to maintain Following Intervals
a safe following interval between vehicles. If there are no
target vehicles or the vehicle ahead of you is out of range of the Following Following Following Following Following
EVT300, the vehicle speed will be maintained by the vehicles Interval (In Distance Distance Distance Distance
Cruise Control system. Seconds) (In feet at (In feet at (In feet at (In feet at
50 MPH) 55 MPH) 60 MPH) 65 MPH)
NOTE: Control of following intervals will take precedence over 2.25 165 182 198 214
the vehicles Cruise Control set speed.
2.50 183 202 220 238
Range Control 2.75 202 222 242 262
The following interval provided by SmartCruise are restricted 3.00 220 242 264 286
to 2.25 to 3.25 seconds and are controlled by the Range control
3.25 238 262 286 309
knob. The Following Intervals table shows the following
intervals in seconds versus following distances in feet, at
various speeds.
As your vehicle approaches a target vehicle (in range and in
Electronically Controlled Engines
same lane), SmartCruise will slow your vehicle to match that
of the other vehicle, and will maintain the selected following
Caterpillar Engines
intervals at the two vehicles speeds as listed in the Following
Intervals table. The speed reduction is accomplished by the The Caterpillar ACERT engines are electronically controlled,
engine ECM, that controls fuel injection and engine retarder mechanically actuated unit injector diesel engines. These
operation. engines rely on the ECM (Electronic Control Module) to control

Form No. 3628504R1

Page 88 Printed in the United States of America
 SECTION 4 VEHICLE OPERATION
Electronically Controlled Engines (cont.)
Caterpillar Engines (cont.)
the fuel injection process. Some of the benefits of the system
include:
Cruise Control
Road Speed Limiting
PTO Governing (using the cruise switches)
Engine Protection/Shutdown
Self Diagnosis
Each vehicle built by International with an ACERT engine
contains a Caterpillar manual in the drivers door pocket. Refer
to the Caterpillar manual for detailed information on these
engine control systems.
Since the ACERT engine control system is electronically
programmable, there are several parameters or settings that
may vary from vehicle to vehicle depending on the owners
specifications. The differences may include: the maximum
cruise speed, the maximum road speed, maximum PTO speed,
and shift schedules. A list of all programmable parameter
settings is included with the vehicle upon delivery.
Form No. 3628504R1
Printed in the United States of America
Caterpillar Integral Compression Brake
DESCRIPTION
The optional Cat Compression Brake is integral to the engine
and delivers increased braking power.
The driver can slow vehicle speeds on down grades without
using the service brakes, making brake fade much less likely.
The brake also helps the driver slow the vehicle without using
the service brake when adjusting to ever-changing traffic speeds
on the highway.
The Cat compression braking system provides engine braking
torque by opening the exhaust valves during the compression
stroke of the engine. The electronic control module (ECM)
opens the retarder the cylinders exhaust valves to release
compressed air. Compression braking is available at all times,
provided engine speed is greater than the factory preset
minimum (typically 800 rpm), and no fuel is supplied to the
engine.
The system is enabled with the Brake ON/OFF switch, and
another switch is used to select the three ranges of engine
braking (low, medium, or high).
Page 89
 SECTION 4 VEHICLE OPERATION

Electronically Controlled Engines (cont.)

Caterpillar Engines (cont.)

Caterpillar Integral Compression Brake (cont.)

In the coast and latch modes the Cruise Control function
must be enabled. In the coast mode, the compression brake
automatically activate when the operator applies the foot brake,
and disengages as soon as the foot brake is released. The
latch mode operates the same as the coast mode, except that
compression braking remains on when the operator releases
the foot brake. In the manual mode, the brake system becomes
active when the drivers foot is lifted from the accelerator.
The Cat brake works with the anti-lock braking systems (ABS) by
turning off the compression braking if wheel slippage is detected.
For complete instructions, see the Caterpillar Engine Operation
manual.

Progressive Shift

The ACERT system is capable of being electronically

Compression Brake Switches programmed to govern the shifting of the vehicle. The maximum
RPM of the engine can be limited until certain road speeds or
1. COMPRESSION BRAKE SELECTOR SWITCH gear combinations are attained.
2. COMPRESSION BRAKE ON/OFF SWITCH
The ECM can be programmed, from the factory, to operate
the brake in three different modes: manual, coast and latch.

Form No. 3628504R1

Page 90 Printed in the United States of America
 SECTION 4 VEHICLE OPERATION

Electronically Controlled Engines (cont.)

Caterpillar Engines (cont.)

Engine Protection Shutdown Feature 2. Log a fault code in the ECM. When the ECM has
an active fault the Engine Warning Light (refer to
Diagnostics) will remain ON, blinking every five
seconds. If the engine condition returns to normal,
WARNING: In the event engine shutdown occurs, the code will be inactive and the Engine Warning light
make certain that vehicle is safely off the roadway, the will go out.
4-way emergency flashers are on, and traffic warning
For the engines that have the shutdown feature selected, the
devices are properly placed. Failure to remove vehicle
engine will be derated gradually until the shutdown occurs after
from roadway could cause an accident and result in
30 seconds. The vehicle may be turned off and back on with the
property damage, personal injury or death.
ignition switch for an additional 30 seconds of run time.

Every ACERT engine is programmed to one of the following

settings: PDCC (Power Demand Cruise Control) Optional

Off
Yellow "Oil/Water Warning Light Only (Default if no selection
is made)
Yellow "Oil/Water Warning Light and Engine De-rate
Yellow "Oil/Water" Warning Light, Engine Derate and Engine
Shutdown
The system monitors coolant level, oil pressure and coolant
temperature. If any of these inputs goes outside a limit set by
Caterpillar, the ECM will:
1. Respond as programmed from the list above.
The optional PDCC feature for the ACERT engine provides
higher horsepower capabilities when the vehicle is in cruise
control. Disabling the cruise control via the brakes, clutch or
"Cruise ON/OFF switch will cause the engine to drop back to
the normal rated power. Since cruise control is only available
above a certain road speed, the PDCC feature will only work in
the upper gears.
Idle Timer
The idle shutdown timer stops the engine (not the power to
the cab) after a programmed length of time. If this feature is

Form No. 3628504R1

Printed in the United States of America Page 91
 SECTION 4 VEHICLE OPERATION
Electronically Controlled Engines (cont.)
Caterpillar Engines (cont.)
Idle Timer (cont.)
not enabled or if it is set to a long length of time it will not be
noticeable. The timer will begin counting down if the engine is
up to temperature and the engine is at idle. If these conditions
are met for the appropriate length of time, the yellow Engine
Warning light will start flashing rapidly ninety seconds before
shutdown occurs.
Diagnostics
All vehicles equipped with an ACERT engine have a
yellow "Engine Warning" light located in the cab. This light
communicates engine status to the driver.
During normal vehicle startup, turning the ignition switch to the
START position causes the Engine Warning light to come ON
as a system test. It is on for approximately 6 seconds and goes
off. If the Engine Warning light stays on after the initial startup,
the Electronic Control System has detected a problem with the
engine.
If during vehicle operation the Engine Warning light comes ON,
it indicates that an active fault is present. The light will remain
ON, but blink approximately every five seconds for a brief 1/2
second.
Form No. 3628504R1
Page 92 Printed in the United States of America
NOTE: If your vehicle is equipped with the CAT Messenger
Driver Information Display, when the Engine Warning light
comes on, a fault message will also be displayed on the CAT
Messenger (see a brief description of the CAT Messenger at the
end of this section). For complete operating instructions, see
the CAT Messenger manual, supplied by Caterpillar.
If the Yellow Engine Warning light comes on it is an indication
that the engine needs service. Take your vehicle to a service
center as soon as possible as some features may be lost while
light is on. To determine the fault codes, do one of the following:
see CAT Messenger section below for an explanation on how
to read a fault code, or use the following procedure:
IGNITION SWITCH ON ENGINE OFF
When the ignition switch is turned to the START position, the
warning light comes ON for approximately 6 seconds, then goes
off for several more seconds and then begins to "flash" any
logged flash code numbers. If there are no logged fault codes it
will "flash" a code 55.
WITH ENGINE RUNNING
1. Begin the procedure with the engine off.
 SECTION 4 VEHICLE OPERATION
Electronically Controlled Engines (cont.)
Caterpillar Engines (cont.)
Diagnostics (cont.)
2. Start and allow the engine to run at low idle for about 30
seconds.
3. Ensure that Cruise ON/OFF switch is in the OFF
position.
4. Hold Cruise SET/ACCEL RESUME/COAST switch in
the SET/RESUME position until the codes begin to
"flash" then release.
5. Yellow Engine Warning light will flash first digit.
6. There will be a one to two second pause.
7. Yellow Engine Warning light will flash second digit.
8. There will be a two to three second pause between fault
codes.
NOTE: Caterpillar Fault Codes are all 2 digits.
9. The second and successive fault codes will flash until all
codes have been shown.
10. To stop the diagnostics procedure, do nothing (after the
last fault code, the flashing will stop). To see the fault
codes again, repeat steps 4 to 10.
Form No. 3628504R1
Printed in the United States of America
A flash code example: yellow Engine Warning light flashes
FLASH, FLASH, FLASH, FLASH, FLASH Digit #1 = 5. Then
there is a one to two second pause. FLASH, FLASH, FLASH,
FLASH, FLASH Digit #2 = 5. Another pause. The Fault Code
is 55. This code means that NO faults are logged.
Service
If a problem occurs with the ACERT system, see the nearest
Intemational Dealer for assistance. Every International
Dealer has the electronic service tools needed to diagnose and
monitor your vehicles electronic system. If your vehicle needs
to be re-programmed then consult your nearest authorized
Caterpillar service center.
CAT MESSENGER, DRIVER INFORMATION DISPLAY
The Caterpillar CAT Messenger driver display is available on
vehicles powered by Caterpillar ACERT engines. The display
provides the driver with information on engine operation and
vehicle trip data.
The CAT Messenger is located within the Center Control Switch
Panel. The following is a summary of the types of information
provided by the CAT Messenger.
Page 93
 SECTION 4 VEHICLE OPERATION

Electronically Controlled Engines (cont.)

Caterpillar Engines (cont.)

CAT MESSENGER, DRIVER INFORMATION DISPLAY (cont.)

NOTE: for complete instructions, see CAT Messenger Special
Instructions manual in storage compartment.
Engine Operation Information. The CAT Messenger display
provides information on cruise control set speed, PTO engine
rpm set speed, fuel temperature to the engine, boost and oil
pressure, coolant temperature, and intake manifold temperature.
Vehicle Trip Information. The vehicle trip information that the
CAT Messenger provides includes fuel quantity used on the
trip, fuel economy, average vehicle speed, idle time, PTO time,
percent idle hour, idle fuel, and PTO fuel. The trip information
can be viewed for the entire trip, or for any portion of the trip
(trip segment).
Theft Deterrent. The CAT Messenger also provides the driver
with the ability to prevent vehicle theft by entering a password
that prevents the engine from starting unless that password is
keyed into the display.
should bring the vehicle to a safe stop off the road. If the Check
Engine warning lamp comes on, and the following three codes
are displayed, the engine controller will shut the engine down
within 20 seconds: 100-11 Very Low Oil Pressure, 111-11
Very Low Coolant Level, and 110-11 Very High Coolant
Temperature.
Cummins Engines
The Cummins electronic engine controller is available on both
the ISM and ISX engines. These engines are electronically
controlled, mechanically actuated unit injector diesel engines.
These engines rely on the ECM (electronic control module) to
control the fuel injector process. Some of the benefits of the
system include:
Cruise Control

Diagnostic Data. (NOTE: Service or repairs to the vehicle Road Speed Governor
should only be performed by a qualified maintenance Progressive Shifting
technician). The CAT messenger will automatically display
certain diagnostic codes, and their description, in order to alert Self Diagnosis
the driver of potential serious engine problems. These codes Adjustable Low Engine Idle
will override any current display and, when displayed the driver
Idle Shutdown Timer

Form No. 3628504R1

Page 94 Printed in the United States of America
 SECTION 4 VEHICLE OPERATION
Electronically Controlled Engines (cont.)
Cummins Engines (cont.)
Cummins ICON Idle Control System
Engine Protection System
Each vehicle built by International with a Cummins ISM or ISX
engine contains a Cummins engine manual in the drivers door
pocket. Refer to the Cummins manual for detailed information
on these engine control systems.
Since the Cummins electronic engine control system is
programmable to owner specifications, there are many
operating parameters that may vary from vehicle to vehicle.
These parameters include: maximum cruise speed, maximum
road speed, shift schedules, idle RPM and many others. A list
of all programmable parameter settings is included with the
vehicle upon delivery.
Form No. 3628504R1
Printed in the United States of America
Jacobs Engine Compression Brake (Optional)
WARNING: Do not use the vehicle retarder,
engine or exhaust brake on slippery road surfaces.
Doing so may cause wheel slippage and/or loss
of vehicle control, which could result in property
damage, personal injury or death.
NOTE: The ENGINE OR EXHAUST BRAKE should never be
considered a substitute for the vehicle service brakes. The
service brakes should always be viewed as the primary vehicle
braking system. The Engine or Exhaust brake cannot bring the
vehicle to a complete stop. Only the service brakes can bring
the vehicle to a complete stop.
These engine braking features are used for traffic conditions
that require frequent use of the service brake and therefore
shortening brake lining life. The features also allow the driver
to slow the vehicle down or maintain a constant speed on steep
road grades that would otherwise result in prolonged use of the
service brake that could cause brake fade.
All of the optional braking features are controlled by the driver,
using the ENGINE BRAKE ON/OFF, and ENGINE BRAKE
Page 95
 SECTION 4 VEHICLE OPERATION

Electronically Controlled Engines (cont.)

Cummins Engines (cont.)

Jacobs Engine Compression Brake (Optional) (cont.)

SELECTOR switches that are located in the Instrument Panel. Jacobs Brake Cruise Control Operation
The following paragraphs provide a brief description and
operation of this optional braking features when using Cruise
control. For either the Cummins or Caterpillar engines, refer to
the engine Operators Manual for operational details.

1. ENGINE BRAKE SELECTOR SWITCH

2. ENGINE BRAKE ON/OFF SWITCH
With the cruise control OFF, the Jacobs brake will operate in
the standard manner. In a cruise control mode, the engine

Form No. 3628504R1

Page 96 Printed in the United States of America
 SECTION 4 VEHICLE OPERATION

Electronically Controlled Engines (cont.)

Cummins Engines (cont.)

Jacobs Brake Cruise Control Operation (cont.)

brake operation is electronically tied to the vehicle service
brake system. The engine brake will activate when the Engine
Brake ON/OFF Switch is in the ON position, and when the
service brakes are applied. Applying the service brakes also
disengages the cruise control system.
The customer can specify whether the engine brake will "latch
itself on" and continue to brake the vehicle after the service
brakes are released, or if the engine will "coast" when the
brakes are released. Consult your International Dealer for more
information.
25 RPM. Pressing the "INC/DEC" switch to the DEC position
will lower the idle RPM in increments of 25 RPM.
Idle Shutdown Timer
If the idle shutdown timer is enabled, the engine will shut off after
a period of no activity (no clutching, braking, or throttling). The
length of time is programmable from 3 to 60 minutes.
CUMMINS ICON Idle Control System

Progressive Shifting
The electronic control system is capable of being programmed
to govern the shifting of the vehicle. The maximum RPM of the
engine may be limited until pre-set road speeds are reached.
The Cummins new ICON Idle Control System automatically
turns an engine on and off, maintaining oil temperature as it
eliminates excess idling. For details of this feature, see the
Cummins Engine Operations manual.

Adjustable Low Idle

Every Cummins vehicle from International is equipped with a

switch to adjust the low idle speed. Pressing the switch to the
"INC" position will increase the idle speed in increments of

Form No. 3628504R1

Printed in the United States of America Page 97
 SECTION 4 VEHICLE OPERATION
Electronically Controlled Engines (cont.)
Cummins Engines (cont.)
Engine Protection Feature
WARNING: In the event engine shutdown occurs,
make certain that vehicle is safely off the roadway, the
4-way emergency flashers are on, and traffic warning
devices are properly placed. Failure to remove vehicle
from roadway could cause an accident and result in
property damage, personal injury or death.
Each Cummins engine includes a standard engine protection
system to prevent damage to the engine. This system monitors
the following five inputs:
Coolant Level
Coolant Temperature
Oil Pressure
Oil Temperature
Intake Manifold Temperature
If any of these inputs goes outside of a limit set by Cummins,
the engine will take action to protect itself. It will either derate
or shut down depending on how the engine is programmed. If
the electronic control system is derating the engine, the yellow
Form No. 3628504R1
Page 98 Printed in the United States of America
"Oil/Water" warning light in the instrument cluster will come on.
When the input returns to acceptable limits the engine will return
to full power and the warning light will turn off. If a shutdown
has occurred the engine may be turned off and re-started for an
additional 30 seconds of run time.
Diagnostics
All Cummins vehicles have a Yellow ENGINE warning light and
a Red ENGINE warning light located in the instrument gauge
cluster. Every time the ignition switch is turned to the START
position, the lights will come on for several seconds as a system
self-test and then turn off.
If, during vehicle operation, the Yellow ENGINE warning light
comes on, it is an indication that the engine needs service. Take
your vehicle to a service center as soon as possible as some
features may be lost while light is on.
NOTE: If your vehicle is equipped with the Cummins
RoadRelay 4 Vehicle Monitoring System, when either the
Yellow ENGINE or Red ENGINE warning light comes on, a fault
message will also be displayed on the Cummins RoadRelay
4 (see a brief description of the Cummins RoadRelay 4 at the
end of this section).
 SECTION 4 VEHICLE OPERATION
Electronically Controlled Engines (cont.)
Cummins Engines (cont.)
Diagnostics (cont.)
CAUTION: If the Red ENGINE warning light comes on,
it is an indication of potential engine damage. Pull
over as soon as possible and seek service (see also
Engine Protection Feature).
Diagnostic Check
NOTE: Cummins Engine Diagnostics must be checked with the
engine NOT RUNNING.
A diagnostic check may be performed using the "Idle/Diagnostic
Inc/Dec Switch" and any error codes will be reported with
flashing red and yellow warning lights. If no errors are found,
both lights will stay on while the "Diagnostic Switch" is on. An
explanation of the fault codes is contained in the Cummins
Engine Troubleshooting and Maintenance Manuals.
If both Yellow ENGINE and Red ENGINE warning lights come
on momentarily and then go out, it is an indication that engine
faults are present. If both Yellow ENGINE and Red ENGINE
warning lights come on and stay on, it is an indication that NO
engine faults are present.
Form No. 3628504R1
Printed in the United States of America
To determine the fault codes, use the following procedure:
1. Begin the procedure with the engine off.
2. Place the ignition switch in the OFF position.
3. Turn Diagnostic switch to the ON position.
4. Turn ignition switch to Run position (not Crank).
5. The Yellow ENGINE warning light will flash once before and
after the flash code with a one to two second pause between
each code.
6. The Red ENGINE warning light will flash the code with one
or two seconds between digits.
NOTE: Cummins Fault Codes are all 3 digits.
7. After the Yellow ENGINE warning light flashes, (indicating
the end of the fault code) the same fault code will be
repeated.
8. To go to the second fault code, move the
IDLE/DIAGNOSTIC INC/DEC switch to the INC
position and then release it. The process will then repeat
itself as indicated in Steps 5 through 7.
Page 99
 SECTION 4 VEHICLE OPERATION

Electronically Controlled Engines (cont.)

Cummins Engines (cont.)

Diagnostics (cont.)
9. To move back to the last or previous fault codes, move the
IDLE/DIAGNOSTIC INC/DEC switch to the DEC position
and then release it. The process will then repeat itself as
indicated in Steps 5 through 7.
10. To stop the diagnostics procedure, move the diagnostic
switch to the OFF position, and turn the vehicle ignition
switch to the OFF position.
Flash code example: the Yellow ENGINE warning light flashes
once. The Red ENGINE warning light flashes:
FLASH
Service
If a problem occurs with the Cummins electronic control system,
see the nearest International Dealer for assistance. Every
International Dealer has the electronic service tools needed to
diagnose and monitor your vehicles electronic system. If your
vehicle needs to be re-programmed then consult your nearest
authorized Cummins service center.
The service manuals available from Cummins will be helpful in
resolving problems. Complete information on ordering service
literature is located at the end of this manual.

Digit #1 is 1. Then there is a pause.

CUMMINS ROADRELAY 4 VEHICLE MONITORING
FLASH, FLASH
SYSTEM
Digit #2 is 2. Then there is a pause.
The Cummins RoadRelay 4 is a vehicle monitoring system
FLASH, FLASH, FLASH that provides the drivers, owners, and fleet managers important
Digit #3 is 3. the Yellow ENGINE warning light flashes once. information about the operation and performance of the vehicle
during an entire trip or any portion. It can also be used with
The Fault Code is 123. drivers who are not familiar with the various vehicles in a fleet, to
obtain the best performance from that vehicle. The RoadRelay
4 supports any Cummins electronic engine, including the
Cummins ISM engines. The Cummins RoadRelay 4 is located
within the Center Control Switch Panel (see figure below). The

Form No. 3628504R1

Page 100 Printed in the United States of America
 SECTION 4 VEHICLE OPERATION

Electronically Controlled Engines (cont.)

Cummins Engines (cont.)

CUMMINS ROADRELAY 4 VEHICLE MONITORING

SYSTEM (cont.)

following is a summary of the types of information provided by Preventative Maintenance. The Cummins RoadRelay 4
the Cummins RoadRelay 4. provides reminders of scheduled oil/oil filter change, tire
change/rotation, brake maintenance, and fuel filter change.
NOTE: For complete operating instructions, see the Cummins
Diagnostic Displays. When a fault occurs, a message is
RoadRelay 4 Users Guide, located in the storage
automatically displayed that overrides the current display and
compartment.
contains information and advice on the seriousness of the fault.
Engine Monitoring Data. The driver may select various
Cummins RoadRelay 4 displays that continuously monitor
engine data such as engine RPM, boost pressure, percent Axles and Suspensions
load, oil pressure and temperature, transmission and coolant
temperature, as well as instantaneous fuel economy.
Vehicle Operation mode. The Cummins RoadRelay 4 provides Gross Weight (Axle Vehicle)
display of fuel economy, estimated time of arrival (ETA), average
trip mph, vehicle idle time displays, PTO performance, and total
driving time for the trip. It also provides tips on shift schedules
versus engine RPMs, and warnings for over speed events. WARNING: Do not exceed the trucks gross
axle weight, gross vehicle weight, and gross
Anti-Theft mode. The Cummins RoadRelay 4 display provides combination weight ratings. Exceeding these ratings
a method to lock the engine to prevent unauthorized engine start, by overloading can cause component failure resulting
using a predetermined password. in property damage, personal injury or death.

Form No. 3628504R1

Printed in the United States of America Page 101
 SECTION 4 VEHICLE OPERATION
Axles and Suspensions (cont.)
Axle Operating Temperature
Normally, axle operating temperature will not exceed more than
100F (38C) above ambient temperature. However, intermittent
operation (5% of time) at higher temperatures under extreme
loads (long pulls) will not harm the axle. Operating temperatures
above 230F (110C) significantly increase the rate of lubricant
oxidation and shorten the effective life of the lubricant, making
more frequent changes necessary.
NOTE: EP lubricants should not be run consistently at
temperatures above 230F (110C).
Front Axle (4X4, 6X6)
With different configurations of transfer cases and types of
controls, such as manually operated or air operated, it is
important that the front axle control instructions provided on the
vehicle be followed. Most vehicles have a front axle indicator
light to alert the driver that the front axle is engaged.
Form No. 3628504R1
Page 102 Printed in the United States of America
WARNING: To avoid vehicle 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, first disengage the
front axle, otherwise the front wheels will pull the
vehicle off its support. Always chock front wheels
under these conditions.
NOTE: 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.
NOTE: Do not keep the front axle engaged when operating on
dry, hard surfaced roads except where it is absolutely necessary
to operate with the transfer case in low range. Operating on hard,
dry surfaces with both the front and rear axle engaged creates a
build-up of torque between the axles resulting in excessive tire
wear and strain on the entire drive unit.
When necessary to operate with the transfer case in low range,
the front axle drive must be engaged to avoid excessive torque
load on the rear axle.
 SECTION 4 VEHICLE OPERATION

Axles and Suspensions (cont.)

Front Axle (4X4, 6X6) (cont.)

shaft approaches zero speed. Stopping the engine will assure

CAUTION: Use extreme caution when backing up on that the transfer case is not damaged.
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 Two Speed Rear Axle
drive components subject to overloading and damage.

WARNING: Never attempt to shift a two-speed

Front Axle Disengagement (4x4, 6x6)
The torque build-up between the front and rear axles sometimes
makes it difficult to disengage the front axle while the vehicle is in
motion. Therefore, to disengage the front axle, bring the vehicle
to a complete stop and apply the parking brake. Then apply
the front axle control. In some instances it may be necessary
to move the vehicle slightly in the reverse direction to complete
disengagement of the front axle.
Front Axle Engagement
axle when descending a hill as the axle may not
complete the shift, remain in neutral, and cause a
loss of vehicle speed control and result in property
damage, personal injury or death.
WARNING: Do not attempt to shift a Two-Speed
rear axle when the rear tires are spinning as this could
cause a loss of vehicle control and result in property
damage, personal injury or death.

With an automatic transmission, it may be necessary to use a

special procedure to shift out of neutral position in the transfer
case. The input shaft to the transfer case must be stopped
either by shifting between forward and reverse or by stopping
the engine. Keep pressure on the transfer case lever as the input

Form No. 3628504R1

Printed in the United States of America Page 103
 SECTION 4 VEHICLE OPERATION
Axles and Suspensions (cont.)
Two Speed Rear Axle (cont.)
CAUTION: Use caution when shifting a Two-Speed
rear axle going uphill. It is preferred to make the shift
before starting uphill.
The two-speed rear axle switch permits selection of either the
high or low axle ratio.
NOTE: When the air is lost, a spring will automatically engage
the low range of the Two-Speed rear axle.
Axle Shift Only
Four (4) Speed Through Seven (7) Speed Transmissions or
Ten (10) Speed Through (18) Eighteen Speed Transmissions
with or Without A Transmission Splitter Engaged:
CAUTION: For Axle Shift mode, the Two-Speed rear
axle can only be shifted into the low range when the
vehicle is stopped.
With vehicle stopped, shift Two-Speed rear axle into low range,
shift transmission into desired starting gear, then start moving
Form No. 3628504R1
Page 104 Printed in the United States of America
vehicle, shifting through as many transmission gears as needed
until vehicle reaches the desired operating performance. Then
the Two-Speed rear axle may be shifted into the high range if
desired.
TO DOWN SHIFT: Select lower ratio position then release the
accelerator pedal. Then pause and, when axle shifts, depress
the accelerator pedal and resume vehicle operation.
NOTE: Clutch method recommended for slower speeds.
TO UPSHIFT:Select faster ratio position then release the
accelerator pedal. Then pause and, when axle shifts, depress
the accelerator pedal and resume vehicle operation.
NOTE: De-clutch for smoother axle upshifts at slow speed.
Split Shifting
(Combined Axle and Four (4) Speed Through Seven (7)
Speed Transmission Shifting ONLY)
With vehicle stopped, shift Two-Speed rear axle into low range,
shift transmission into desired starting gear, then start moving
vehicle. Then, when ready, shift the Two-Speed rear axle into
the high range. Then when ready to shift the transmission,
shift the Two-Speed rear axle into low range AND then shift the
 SECTION 4 VEHICLE OPERATION
Axles and Suspensions (cont.)
Two Speed Rear Axle (cont.)
Split Shifting (cont.)
transmission into the next gear. Continue this sequence until
the vehicle reaches the desired operating performance.
TO DOWNSHIFT the axle to a slower ratio and upshift or
downshift the transmission, shift the transmission and just
before the clutch is re-engaged, move the control switch to the
slower ratio position.
TO UPSHIFT the axle and downshift or upshift the transmission,
move the control switch to a faster ratio position and make the
transmission shift in the usual manner.
NOTE: In all axle upshifts, move the control switch to position
first. When split shifting to a slower axle ratio, do not move the
control switch until just before engaging the clutch.
Recommended vehicle speed for Two-Speed rear axle
range shifting
For Axle Shifting only, the Two-Speed rear axle can be shifted
into the high range at any prudent vehicle speed, but into the
low range when the vehicle is stopped. For Split Shifting, the
Two-Speed rear axle can be shifted into either the low or high
range at any prudent vehicle speed. Many road conditions will
determine what the actual prudent speed will be.
Form No. 3628504R1
Printed in the United States of America
NOTE: The maximum vehicle speed that a Two-Speed rear axle
may be shifted into high range is 68 mph.
Tandem Axle Power Divider (Inter-Axle Differential) Lock
Control
Tandem axle power dividers or interaxle differentials in the
forward rear axle are controlled by the dash mounted POWER
DIVIDER LOCK switch.
Under normal highway conditions (good traction) the power
divider lock switch should be in the OUT position 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 tires, etc.
The power divider lock switch should be in the IN position,
which prevents interaxle differential action, when backing under
a trailer with a tractor, starting on a slippery surface (poor
traction), operating off highway in mud, etc. (poor traction), 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.
Page 105
 SECTION 4 VEHICLE OPERATION

Axles and Suspensions (cont.)

Tandem Axle Power Divider (Inter-Axle Differential) Lock
Control (cont.)

Power Divider Lock

CAUTION: Never move the power divider lock to the IN
position when your wheels are spinning.
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 as
this may result in shock damage to the power divider CAUTION: Never shift a two-speed tandem axle from
components and costly repairs. one range to another with the power divider lock
switch to the IN position. This may cause shock
damage to the inter axle differential and result in
costly repairs.
CAUTION: The Power Divider Lock switch will not
engage or will disengage when or if the Parking brake
is set.

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.

Form No. 3628504R1

Page 106 Printed in the United States of America
 SECTION 4 VEHICLE OPERATION

Axles and Suspensions (cont.)

Tandem Axle Power Divider (Inter-Axle Differential) Lock
Control (cont.)

When encountering slippery highway conditions (poor traction)

the power divider lock can be moved to IN at a low, even
speed and momentarily letting off the accelerator will engage
the differential lock. A warning light on the instrument panel
indicates when the inter axle differential is locked.
When highway conditions improve (good 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
differential.
WARNING: To avoid vehicle damage, personal injury
or death, pay strict attention to the following:
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.

Rear Axles (With Locking Or Limited Slip Differentials)

Traction Equalizer
WARNING: To avoid vehicle damage, personal injury
or death, pay strict attention to the following:
CAUTION: Tire sizes on both rear wheels should be
the same on axles equipped with a traction equalizer.
If your vehicle is equipped with any type of locking or limited
If not, excessive wear may occur to the traction
slip differential, power will be transmitted to the opposite
equalizer.
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 wheel Some Meritor drive axles are equipped with a traction equalizer.
that is not raised will pull the vehicle off its support. It will maintain an appreciable amount of wheel end traction
in all operating conditions while still allowing the vehicle to

Form No. 3628504R1

Printed in the United States of America Page 107
 SECTION 4 VEHICLE OPERATION

Axles and Suspensions (cont.)

Rear Axles (With Locking Or Limited Slip Differentials)
(cont.)

Traction Equalizer (cont.)

negotiate turns smoothly. This is accomplished with the ability
of the traction equalizer to slip above a certain torque value,
and remain rigid below this torque value.
Controlled Traction Diffential
A control valve in the cab is actuated by the driver to engage and
disengage the controlled traction feature.
Disengaged, the axle has differential action all the time. One
wheel will spin independently of the other, if slippery conditions
are encountered.
Engaged, wheel slippage and spin-out are minimized.

CAUTION: Tire sizes on both rear wheels should be

the same, especially on axles equipped with traction NoSPIN Detroit Locker Positive Locking Differential
controlled differentials. If not, excessive wear may
occur to the differential.

WARNING: To prevent vehicle damage, personal

Some EATON drive axles are equipped with a controlled traction
differential. This is a differential assembly incorporating a friction
plate assembly designed to transfer torque to both rear wheels.
The unit is basically a multiple disc clutch designed to slip
above predetermined torque values. This controlled slipping
characteristic at higher torque values enables the vehicle to
negotiate turns in a normal manner. Resistance to slippage
at lower torque values enables the vehicle to maintain an
appreciable amount of tractive effort when one wheel encounters
relatively poor traction.
injury or death, pay strict attention to the following:
If your vehicle is equipped with any type of locking
or limited slip differential, 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 wheel that is not raised will
pull the vehicle off its support.

Form No. 3628504R1

Page 108 Printed in the United States of America
 SECTION 4 VEHICLE OPERATION

Axles and Suspensions (cont.)

Rear Axles (With Locking Or Limited Slip Differentials)
(cont.)

NoSPIN Detroit Locker Positive Locking Differential (cont.)

WARNING: To prevent vehicle damage, personal
injury or death, pay strict attention to the following:
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, resulting in loss of vehicle
control.
The following is a brief summary of operational guidelines for
Detroit Locker positive locking differentials. It is mandatory
that the owner/operator refer to the separate NoSPIN owners
manual provided with the vehicle for additional instructions,
warnings, and required operational tests.
The NoSPIN differential is designed to deliver 100 percent of the
available power to either or both drive wheels, yet UNLOCK as
required to allow wheel speed differentiation, automatically.
The performance of a vehicle equipped with a NoSPIN
differential is somewhat different from that of a vehicle equipped
with a conventional differential.
For example: when turning a corner, the sound of gear
disengagement and re-engagement may be audible, and the
transfer of driving torque from both wheels to one wheel may
be noticeable.
When going from drive (acceleration) to coast (deceleration)
in a turn, a metallic sound may be heard as torque flow is
reversed (inside wheel engaged during acceleration; outside
wheel engaged during deceleration).
These characteristics are a result of necessary backlash
designed into the NoSPIN differential, 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 differences
in tire wear or tire pressure, unbalanced loading of the vehicle,
or when the vehicle is operated on a side slope, can cause
the NoSPIN differential to deliver power to only one side of the
vehicle, which may affect directional stability. Always maintain
matched tire sizes and pressures and balanced loads, and avoid
operation on side slopes.

Form No. 3628504R1

Printed in the United States of America Page 109
 SECTION 4 VEHICLE OPERATION

Axles and Suspensions (cont.)

Rear Axles (With Locking Or Limited Slip Differentials)
(cont.)

Driver Controlled Differential Lock Axle And Suspension Conversions

Some Meritor/Eaton drive axles have a driver controlled

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 or unlock
the differential when the vehicle is moving or stopped.
NOTE: When the differential is fully locked, the vehicle will have
a slight 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.
It is mandatory that the Owner/Operator refer to the separate
driver controlled main differential lock owners manual provided
with the vehicle for additional instructions, warnings, and
required operational tests.
WARNING: When operating a loaded vehicle, the
driver must keep all adjustable axles on the ground at all
times, supporting their share of the load. Failure to do so
can overload other axle, tires, wheels, springs, steering,
brakes and frames, resulting in early component failure
and loss of vehicle control, which could result in property
damage, personal injury or death.
International Truck and Engine Corporation does not
recommend or approve axle and suspension conversions;
however, it is aware that on occasion aftermarket add-on axles
and suspensions are installed by others on International truck
chassis which allow operator control for weight transfer from
other axles (i.e., air lift axles).

Form No. 3628504R1

Page 110 Printed in the United States of America
 SECTION 4 VEHICLE OPERATION
Brakes
WARNING: Always check and maintain brakes in
proper condition and adjustment. Out of adjustment
brakes could cause reduced braking ability and result
in property damage, personal injury, or death.
Downhill Operation
Always descend hills with extreme care, relying primarily 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 starting a
descent.
Observe the following precautions:
Never coast downhill. Service brakes alone should not be used
to control speed on major downgrades. Brakes will fade from
overuse.
Downhill speed is controlled by removing ones foot from the
accelerator pedal (engine running with closed throttle) and
putting the transmission/rear axle in reduced gear. If the
transmission/rear axle is in a gear that results in more than
the appropriate speed, a proper downshift should be made to
avoid overuse of the brakes. If the proper gear selection was
not made and the brakes were overused, then stop the vehicle
Form No. 3628504R1
Printed in the United States of America
and wait for the brakes to cool. After the brakes have cooled,
continue down grade in a lower gear range.
WARNING: DO NOT ATTEMPT to gear down
if the engine is at or near maximum speed (RPM).
Under these conditions it will be impossible to shift
into a lower gear and could result in possible vehicle
runaway, resulting in property damage, personal
injury, or death.
The common rule to follow in using the engine and
transmission/rear axle to control vehicle speed is to select a
lower gear going down the hill than would be required to ascend
the hill. There are some exceptions, such as going down a
short hill with good visibility and no hazards.
The service brakes should be used to supplement available
vehicle retardation methods. When descending long grades
requiring use of the brakes, short applications (three to five
seconds duration) should be made rather than long, continuous
applications. This minimizes temperature rise, brake fade and
air consumption of air brake system.
Air Brakes
The truck types covered in this manual are equipped with a split
brake system.
Page 111
 SECTION 4 VEHICLE OPERATION

Brakes (cont.)
Air Brakes (cont.)

The purpose of this split system is to provide a means of Color Coding

stopping the vehicle should a failure occur in either the primary
Green Primary Supply and Delivery System
or secondary brake system. In the event air pressure loss
occurs in one system, the remaining system continues to Orange Secondary Supply and Delivery System
provide braking action. Yellow Spring Brake System
Even though there will be enough braking capability for Red Trailer Emergency
emergency stopping, the vehicle must not be operated when
Gray Power Divider Lockout
a failure is indicated, as there is no means of replenishing air
pressure. Blue Trailer Service

If vehicle has been parked for an extended period in cold Brown Air Suspension System
weather, always check to be sure all wheels are rolling free Silver PDL Control, Governor to Dryer
(brakes are not frozen) when starting out. Always clean
accumulated ice and snow from brake linkage. Tan Locking Differential, traction differential,
two-speed axle control
Some vehicles are equipped with color-coded air brake lines.
Black Other systems
The color coding is as follows:

Form No. 3628504R1

Page 112 Printed in the United States of America
 SECTION 4 VEHICLE OPERATION

Brakes (cont.)
Air Brakes (cont.)

Air Gauge, Low Air Pressure Beeper and Warning Light Should the red light and beeper not shut off soon after start-up,
the air pressure gauge/gauges should also indicate at least one
section of the split system has low air pressure.
If the red light, beeper and gauge indicate a loss of pressure
WARNING: To avoid loss of vehicle braking or
while driving, the vehicle still has a portion of the braking
control resulting in property damage, personal injury
capability, because one-half of the split system braking capability
or death, never operate the vehicle when insufficient
is retained. In the event of primary pressure system loss, the
air pressure (less than 70 psi [483 kPa]) is indicated
spring brakes will assist the front brakes in stopping the vehicle.
for either the primary or secondary air system. The
However, the distance required to stop the vehicle will be
volume of air required to stop the vehicle may be
increased.
greater than that available. Have the brake system
checked and repaired before returning the vehicle to
service.
Brake Application

Should air pressure in either section of the split air brake system
be reduced to 70 6 psi (483 41 kPa) the warning beeper
will sound and the Red BRAKE PRESSURE warning light, on
the instrument panel, will glow. Also, the air gauge/gauges
will indicate low air pressure in at least one of the independent
systems.
The warning beeper and red light will automatically shut off when
the air pressure in both systems is sufficient (approximately 70
psi [483 kPa]) to operate the vehicle.
Rapid successive brake applications and release, sometimes
referred 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 air brakes are equipped with spring brake
chambers for parking. The parking system is operated manually
by a single valve, which in the case of a tractor also controls the
parking system on the trailer.

Form No. 3628504R1

Printed in the United States of America Page 113
 SECTION 4 VEHICLE OPERATION

Brakes (cont.)
Air Brakes (cont.)

Parking Brake (cont.)

WARNING: Under no circumstances should the
spring brake section of the spring and service brake
chamber be disassembled. Disassembly will release
a powerful spring, which could result in property
damage, personal injury or death.
The purpose of this brake is to hold the vehicle in a parked
position and to assist in bringing it to an emergency stop. The
parking brake should not be used to brake the vehicle during
normal driving.
To apply the parking brake, pull out control. To release the
parking brake, push in control.
On single unit trucks and tractors with independent parking
and trailer controls: if air pressure is reduced to approximately
20 to 45 psi (138 to 310 kPa) in both the primary and secondary
systems, the parking brakes will automatically apply.
On tractors with the modular control system: if air pressure is
reduced to approximately 20 to 45 psi (138 to 310 kPa) in both
the primary and secondary systems, the parking brake control
will automatically apply. For the exact air pressure set-points,
refer to the Service Manual.
It should be noted that upon loss of air pressure partial spring
brake application will occur prior to automatic application of the
control valve.
To release, recharge system to 70 psi (483 kPa) and push in the
parking brake control. If the system cannot be recharged and
the vehicle must be moved, the spring brake must be manually
released (caged).
WARNING: Always chock the wheels when
manually releasing the spring brakes, or the vehicle
could roll causing property damage, personal injury,
or death.
For towing, make sure the vehicle is securely
connected to tow vehicle and tow vehicle parking
brakes are applied before releasing the disabled
vehicles spring brakes.

Form No. 3628504R1

Page 114 Printed in the United States of America
 SECTION 4 VEHICLE OPERATION
Brakes (cont.)
Air Brakes (cont.)
Parking Brake (cont.)
In the event it is 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 tool is furnished with
the brake chamber assembly. The release stud engages in the
spring pressure plate and its nut is tightened to compress, cage,
the spring and release the brake.
Remove release stud assembly from carrying pocket.
Apply a light coat of Never Seeze to the threads of the release
stud to avoid any unnecessary wear of the threads. Remove
the access plug from the end of the spring chamber. Insert the
Form No. 3628504R1
Printed in the United States of America
release stud through the opening in the chamber and into the
spring pressure plate.
Turn the release stud one-quarter turn 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 installing the nut. Tighten the
nut with a 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 housing and
re-install the access plug in the chamber opening. Re-install the
release stud and nut in the carrying 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. This is done by opening the drain cock located either
on the bottom of the tank or in the end of the tank. If the drain
cock is opened in the end of the tank, there must be some air
Page 115
 SECTION 4 VEHICLE OPERATION

Brakes (cont.)
Air Brakes (cont.)

Reservoir Moisture Draining (cont.)

pressure in the system to assure proper drainage. Be sure to air cools in the expansion chamber both water and oil vapors
close the drain cocks after all moisture has been expelled. are condensed out. This condensation collects on the walls of
the expansion chamber and runs down into the collection area
On vehicles so equipped, the reservoir automatic drain valve
where it is automatically discharged.
ejects moisture and contaminants from the reservoir in which it
is connected. It operates automatically and requires no manual
assistance or control lines from other sources. The reservoir
Rear Chassis Brake Hand Control
should be drained and the valve should be examined periodically
to ensure that the drain passage is not obstructed. The rear chassis brake hand control is used to apply the rear
chassis (rear axle) service brakes, independently of the front
service brakes. The rear chassis brake hand control operates
Air Dryer a valve that provides gradual control of air pressure applied to
the rear chassis service brakes. The rear chassis service brakes
The function of the air dryer is to collect and remove moisture
can be fully or partially applied, but when in a partial position, can
and contaminants before air reaches the first reservoir, thus
be overridden by pressing fully on the brake pedal.
providing lower moisture air for the air brake system. Daily
draining of the air system reservoirs is no longer necessary. To apply the rear chassis brakes utilizing the hand control, move
(See Maintenance Section.) the lever clockwise (down). The further the handle is moved
clockwise, the greater the air pressure that is applied to the rear
The air dryer is installed in the discharge line between the air
chassis brakes. The hand brake handle will remain in place with
compressor and supply reservoir. The air dryer can be a unit
the desired brake pressure applied until the handle is manually
with desiccant cartridge and a paper oil filter that is serviced as
moved. To release the rear chassis brakes, move handle full
an assembly. An air dryer can also be an aftercooler in which the
counterclockwise (up).
hot compressed air enters the expansion chamber; the sudden
drop in pressure cools the air. The heat is carried away through
the external fins that are an integral part of the body. As the

Form No. 3628504R1

Page 116 Printed in the United States of America
 SECTION 4 VEHICLE OPERATION

Brakes (cont.)
Air Brakes (cont.)

Rear Chassis Brake Hand Control (cont.)

Trailer Air Supply and Parking Brake Modular Controls

The PARKING BRAKE valve B (yellow

control) controls the spring brakes on the
tractor and when pulled out simultaneously
causes the trailer supply valve to pop
out, thus applying both tractor and trailer
parking brakes. The trailer brakes may
be independently released by pushing
only the TRAILER AIR SUPPLY valve (red
control) in.

The TRAILER AIR SUPPLY valve A (red

control) delivers air to the trailer supply
and will automatically pop out, shutting off
the trailer supply if pressure decreased to
approximately 35 psi (241 kPa). For exact
air pressure set-points, refer to the Service
Manual.

Form No. 3628504R1

Printed in the United States of America Page 117
 SECTION 4 VEHICLE OPERATION

Brakes (cont.)
Air Brakes (cont.)

Trailer Air Supply and Parking Brake Modular Controls

(cont.)

Initial Charge

With air system completely discharged, both controls A and B will be out. When air system
pressure reaches 70 psi (483 kPa) the TRAILER AIR SUPPLY (red control) A may be pushed
in and should stay in charging the trailer air system and releasing the trailer brakes.

The PARKING BRAKE (yellow control) B may now be pushed in and supply air to the tractor
spring brakes, releasing them.

Form No. 3628504R1

Page 118 Printed in the United States of America
 SECTION 4 VEHICLE OPERATION

Brakes (cont.)
Air Brakes (cont.)

Trailer Air Supply and Parking Brake Modular Controls

(cont.)

System Park

With both controls pushed in (normal driving position), the parking brakes on
both tractor and trailer are applied by pulling the parking control B (yellow)
out, exhausting air from the tractor spring brakes and simultaneously causing
the trailer supply valve (red control) to pop out, applying the trailer brakes.

Trailer Charge

If both controls are out (both tractor and trailer brakes applied), and it is desired to
recharge the trailer while leaving the tractor spring brakes applied, the red control
A may be pushed in to re-pressurize the trailer supply line. This mode may also
be used to park a combination vehicle with tractor spring brakes.

Form No. 3628504R1

Printed in the United States of America Page 119
 SECTION 4 VEHICLE OPERATION

Brakes (cont.)
Air Brakes (cont.)

Trailer Air Supply and Parking Brake Modular Controls

(cont.)

Automatic Application

If, with both controls in (normal operating position), the brake system air pressure is reduced
to approximately 35 psi (241 kPa) the red control A will pop out, applying the emergency or
parking brakes on the trailer. If the red control A is manually held in and the pressure is
further reduced to approximately 30 psi (207 kPa) a tripper piston within the valve will move,
exhausting the trailer air supply, thus applying the trailer brakes. Further reduction of pressure,
while holding in the red knob, will cause yellow knob to pop at 25 psi (172 kPa). For exact air
pressure set points refer to the Service Manual.
Normal Run Position

With both controls pushed in, air is then supplied to both trailer and tractor spring brakes
and all brakes are released.

Actuation of Trailer Park (Emergency) or Tractor Bobtail Position

To actuate the trailer brakes only, the red control A is pulled out, exhausting the trailer air
supply. The trailer brakes are now applied whether emergency or spring brakes are used on
the trailer. This mode is also used when the tractor is used during bobtail operation.

Form No. 3628504R1

Page 120 Printed in the United States of America
 SECTION 4 VEHICLE OPERATION

Brakes (cont.)
Air Brakes (cont.)

Park Brake Indicator Light
WARNING: Driving with the parking brakes
applied can lead to excessive heat build up and fire
resulting in property damage, personal injury, or
death.
shorter stopping distances, particularly on wet and slippery road
surfaces.
It should be noted that there is a noticeably different brake pedal
feel on tractors with this feature while operating in the bobtail
mode. Higher brake pedal efforts will be experienced by the
driver than in a brake system without bobtail proportioning.

The Park Brake indicator is operated in conjunction with the

parking brake. With the ignition switch on and the Park brake
set, the PARK light will illuminate. If the light does not illuminate
with the Park brake set, the indicator may be inoperative.

Bobtail Proportioning System

Bobtail proportioning is available with tractor air brake systems

(for export only with code 04092) with or without ABS or
ABS/Traction Control Systems. The proportioning valve
senses when trailer brakes are not connected to the vehicle
air brake system, and automatically adjusts braking power
when operating in the bobtail mode, then returns full braking
power when a trailer is attached. When operating in the bobtail
mode, bobtail proportioning provides more braking control and

Form No. 3628504R1

Printed in the United States of America Page 121
 SECTION 4 VEHICLE OPERATION
Brakes (cont.)
Air Antilock Brake System (ABS)
WARNING: Antilock brake systems are designed
to enhance overall vehicle safety when a vehicle is
driven within its safe operating limits. ABS cannot
compensate for a vehicle that is being driven beyond
the physical limits of control. Drivers operating an
ABS equipped vehicle should employ safe driving
practices and assume no additional driving risks.
Failure to do so could result in property damage,
personal injury or death.
WARNING: Do not rely on the ABS system to
interrupt vehicle retarder, engine or exhaust brake
on slippery road surfaces. Turn these devises off
during hazardous driving conditions. Failure to follow
this warning may cause wheel slippage and/or loss
of vehicle control, which could result in property
damage, personal injury or death.
The Antilock Brake System is a mandated feature added to the
standard air brake system. It electronically monitors vehicle
Form No. 3628504R1
Page 122 Printed in the United States of America
wheel speed at all times, and only engages when wheel lock
is imminent. The standard air brake system controls normal
braking when the ABS is not engaged.
ABS Operation
WARNING: If the ABS warning light comes on,
your stopping distances may increase under certain
braking conditions. Have the ABS system repaired
immediately. Take every precaution to avoid wheel
lockup, which could result in loss of vehicle control
causing property damage, personal injury or death.
The Antilock Brake System electronically monitors vehicle
wheel speed at all times, and only engages when wheel lock is
imminent. The standard hydraulic brake system controls normal
braking when the ABS is not engaged.
ABS requires no changes in driving practices. For the best
stopping performance with or without ABS, modulate - do
not pump - the brake pedal until the vehicle slows to desired
speed or stops. Be aware that ABS on a towing vehicle does
not control brakes on towed vehicles. Towed vehicles may
or may not have ABS. ABS will prevent lockup of controlled
wheels if you over brake for existing road conditions. Optimum
 SECTION 4 VEHICLE OPERATION

Brakes (cont.)
Air Antilock Brake System (ABS) (cont.)

ABS Operation (cont.)

vehicle control for existing road conditions will be provided as on, then flashes twice and remains on for several seconds
a result of the ABS preventing wheel lockup at speeds above before going out.
approximately 4 miles per hour. The ABS cannot provide any
During the self-checkout, the modulator valves will cycle around
better braking and steering capability than the available road
the vehicle twice in the following pattern
traction will permit. If the road is slippery it will take longer
to stop than on a dry road. Steering maneuverability will be A. Right Front
similarly limited. Vehicle speed must be reduced to compensate
B. Left Front
for the extended time and distance required to stop or slow the
vehicle on slippery roads. C. Right Rear
The wheel hubs carry exciter rings used by axle mounted D. Left Rear
sensors to transmit wheel speed information to the ABS
A fault has been detected in the ABS if the warning indicator
electronic control unit located on the chassis frame. The control
does not come on with ignition, does not flash, fails to go off or
unit monitors and compares all wheel speed inputs to determine
comes on again at any other time.
if any wheel(s) are about to lock. If wheel lockup is about to
occur, the control unit commands the appropriate modulator If over-braking causes wheel lockup on the rear drive axles while
valve to adjust air pressure delivery to prevent wheel lockup. retarding devices are in operation, the ABS will interrupt and
disable the retarder until the lockup situation has stopped.
ABS Self Check
If the ABS warning light on the instrument panel is lit, consult
Bendix ABS Checkout: A yellow warning light on the instrument your nearest International service center for further assistance
panel indicates the antilock system status. The indicator in maintaining and repairing your ABS system.
comes on and the system goes through an ABS self-checkout
sequence each time the ignition is turned on. The system is
working normally when: ignition is turned on, indicator comes

Form No. 3628504R1

Printed in the United States of America Page 123
 SECTION 4 VEHICLE OPERATION
Brakes (cont.)
Air Antilock Brake System (ABS) (cont.)
Antilock Driving Tips
Brake just the way you always have.
Apply brakes as normal to stop in time. The ABS monitors the
brake application electronically and automatically controls the
brakes, much faster than a driver could do by pumping the brake
pedal.
Always remember that you are the most important factor to
safe operation of your vehicle.
Steer clear of traffic, pedestrians, animals or other obstacles
while you are in an emergency braking situation. The Antilock
tractor and truck brake system will allow you to steer the vehicle
during braking while it comes to a full stop. ABS is not an excuse
to take unnecessary risks. Always drive carefully and stay a safe
distance away from the vehicle in front of you.
When driving with a single trailer, doubles, or triples:
Brake as necessary and watch your trailer(s) through your
mirrors and correct steering as necessary to keep in straight
lines.
If only your tractor has ABS:
Use your tractors ABS brakes. Steer clear of obstacles and
watch the trailer through your mirrors to make sure it follows your
Form No. 3628504R1
Page 124 Printed in the United States of America
tractor properly. Tractor ABS will help prevent tractor jackknife
but will not prevent trailer swing out.
Automatic Traction Control System (ATC)
The automatic traction control (ATC) feature is an available
option on some models. Automatic Traction Control is an
integrated addition to the Antilock Brake System. This system
utilizes input from the individual wheel sensors to determine if
drive axle wheel slip is occurring during vehicle acceleration.
If drive axle wheel slippage is occurring, the Controller Relay
initiates action to reduce engine power and/or to selectively
apply rear brakes to transfer power from the slipping wheel to
the opposite wheel to enable the vehicle to gain momentum
and move to road surfaces providing more traction. The system
instantly blinks a dash indicator lamp to advise the driver that
wheel spin is occurring.
If wheel spin occurs at speeds above 25 mph, the dash indicator
lamp blinks, and, using its link to the engine control module, the
ATC reduces engine RPM to a level suitable for the available
traction. The brakes are not applied, even slightly, at any speed
above 25 mph.
Both Antilock and Traction Control are features added to the
basic air brake system and the loss of either or both should
in no way affect the basic system. ABS and ATC require no
 SECTION 4 VEHICLE OPERATION
Brakes (cont.)
Automatic Traction Control System (ATC) (cont.)
changes in driving style and it is best not to change your usual,
careful driving habits. Other than during initial start-up, when
the Traction lamp flashes and then goet exchangs out, the ATC
system should not be noticed until its needed. Routine operation
of the brakes and accelerator are unchanged.
ATC System Check At ignition turn-on, the ATC warning
indicator will illuminate steadily for 2.5 seconds and then turns
off. If not, the system is defective or inoperative.
Bendix ABS-6 Advanced with RSP (Roll Stability Program)
WARNING: Vehicles equipped with Stability
Control cannot be used to pull double or triple trailers.
Failure to follow this warning could result in property
damage, personal injury, or death.
Form No. 3628504R1
Printed in the United States of America
WARNING: Stability Control systems are
designed to enhance overall vehicle safety by
automatically reducing vehicle speed under certain
conditions. Drivers operating a Stability Control
equipped vehicle should employ safe driving practices
and assume no additional driving risks. Failure to
follow this warning could result in property damage,
personal injury, or death.
ABS-6 Advanced with RSP provides the core ABS function
as well as Automatic Traction Control (ATC) and Roll Stability
Program (RSP) functions.
Core ABS Functions
The core ABS sysem prevents wheel lock-up to help drivers
maintain steering control while braking. Bendix Antilock
Braking Systems (ABS) use wheel speed sensors, ABS
pressure modulator valves, and an Electronic Control Unit
(ECU) to control either four or six wheels of a vehicle. Bendix
ECUs optimize slip between the tire and the road surface by
monitoring individual wheel turning motion during braking.
Page 125
 SECTION 4 VEHICLE OPERATION

Brakes (cont.)
Bendix ABS-6 Advanced with RSP (Roll Stability Program)
(cont.)

Basic Automatic Traction Control (ATC) Functions
The Basic Automatic Traction Control (ATC) works to control
wheel spin during vehicle acceleration. In such cases, the ATC
system will automatically intervene and apply braking pressure
to a spinning wheel transferring engine power to other drive
wheels that have better traction.
If all of the drive wheels begin to spin, the ATC will reduce engine
throttle to improve traction at all drive wheels.
ATC Off-Road Switch
The function of this switch is to allow greater engine power and
more wheel spin. When operating on soft road surfaces, place
the switch in the ATC Off-Road position. The switch indicator
will flash slowly to indicate that this function has been selected,
and will flash rapidly whenever ATC is operating to control wheel
spin.
NOTE: Be sure to turn the ATC Off-Road switch to the OFF
position when you return to a firm surface.
Smart ATC.
Smart ATC monitors the accelerator pedal position to help
provide optimum traction and vehicle stability. Smart ATC uses
throttle position and adjusts the drive wheel behavior to allow
higher wheel slip within preset driving parameters. In addition,
Smart ATC decreases wheel slip when driving through a curve
for improved vehicle stability.
Roll Stability Program Functions
The Roll Stability Program (RSP) helps to mitigate rollovers
through advanced sensing and automatic application of the
vehicle brakes. The Roll Stability Program (RSP), is an all-axle
ABS solution that helps reduce vehicle speed by applying all
vehicle brakes as needed, reducing the tendency to roll over.
RSP focuses on reducing the vehicles speed below the critical
roll threshold during direction-changing maneuvers, (such as at
exit ramps) lane changing, cornering, or obstacle avoidance. It
is most often used on dry, high-friction surfaces.
RSP Vehicle Speed Reduction
In the case of a potential roll event, the Bendix Advanced ABS
RSP will remove the throttle and quickly apply brake pressure
at all wheel ends to slow the vehicle combination below the
threshold.

Form No. 3628504R1

Page 126 Printed in the United States of America
 SECTION 4 VEHICLE OPERATION
Brakes (cont.)
Bendix ABS-6 Advanced with RSP (Roll Stability Program)
(cont.)
Roll Stability Program Functions (cont.)
Steering Angle Sensor
This sensor enables the Bendix Advanced stability system
to capture the drivers steering input and intervene if a yaw
correction is needed. The sensor also provides the earliest
indication of an increase in lateral acceleration that might cause
a potential roll event. A steering angle sensor provides a greater
stability margin than a vehicle that is not equipped with this
sensor.
Brake Demand Sensors
Bendix RSP was designed to supplement the drivers actions.
By directly measuring driver brake demand, the system
can transition seamlessly between driver-intended and
system-intended braking pressure. For example, if in a
certain maneuver, the system calculates that 40 psi (276 kPa)
is needed and the driver is only applying 20 psi (138 kPa), the
system compensates automatically to deliver the needed 40 psi
(276 kPa). If, however, during the same maneuver the driver
steps on the brake pedal quickly to apply a higher [above 40 psi
(276 kPa)] braking level, the drivers braking input overrides the
temporary change made by the system.
Form No. 3628504R1
Printed in the United States of America
ABS / stability System Interaction
With the Bendix ABS-6 Advanced, the ABS system is given
priority at the wheel ends to manage wheel slip for optimal
braking. The ABS system functions similarly whether the
stability system or the driver applies the brakes.
Transmission
Manual Transmissions
Vehicles with manual transmissions have a clutch pedal that
is used to engage or disengage the clutch, connecting or
disconnecting the engine from the transmission and rear
wheels. With the clutch pedal released (extended) the clutch is
engaged, driving the transmission and rear wheels. Depressing
the clutch pedal releases the clutch, permitting transmission
gear changes.
Clutches will last many thousands of miles if properly used and
maintained. EXCESS HEAT IS A CLUTCHS WORST ENEMY!
Almost every early clutch failure can be traced to excessive
friction heat. Do not ride or slip the clutch. Once a clutch is
Page 127
 SECTION 4 VEHICLE OPERATION
Transmission (cont.)
Manual Transmissions (cont.)
fully engaged, there is no heat generated and little or no wear.
However, during the brief period when the clutch is picking up
the load, considerable heat is generated. By riding or slipping
the clutch, the period of partial engagement is lengthened,
causing unnecessary heat and wear.
Engaging the Clutch
Always start in the proper gear: An empty vehicle can be
started in a higher gear than a fully loaded one. But starting in a
gear too high for the load can cause too much clutch slippage,
generating excessive heat and unnecessary wear. A gear that
will start the vehicle moving with the engine at idle speed is
usually correct. If the engine must be revved up to prevent
stalling, the gear selection is too high. As the clutch pedal is
released and the clutch begins to engage, the engine speed will
drop slightly. When this happens, increase the engine speed
and fully engage the clutch. Increasing the engine speed before
fully engaging the clutch can damage the clutch and drive train.
Do not shift until vehicle has reached proper speed.
Upshifting before the vehicle has reached the right speed is
almost as bad as starting off in too high a gear. When the
difference between the vehicle speed and the engine speed is
too great, the clutch is forced to slip. The result is extra heat
and wear.
Form No. 3628504R1
Page 128 Printed in the United States of America
When approaching a hill, depress accelerator smoothly to start
the upgrade at full power, then shift down as needed to maintain
vehicle speed.
Never hold a vehicle on a hill with the clutch. To hold on a hill
with the clutch requires that the clutch be purposely slipped. By
doing this enough heat can be generated to burn up the clutch.
Never coast with the clutch disengaged. This can cause
clutch failure by the very high RPM encountered when coasting
in gear with the clutch released. In this situation, the rear wheels
are driving the disc through the multiplication of the rear axle and
transmission ratios. This can result in over 10,000 RPM, which
is beyond the burst strength of the facing material. Something as
simple as coasting down an unloading ramp can burst a driven
disc.
Never engage the clutch while coasting. Re-engaging a
clutch after coasting causes tremendous shock to the clutch and
the whole drive train. It can result in internal engine damage
and/or clutch and flywheel failure. Always report unusual clutch
operation promptly. Proper maintenance, performed on time,
will greatly extend the life of the clutch. The driver should report
any change in free pedal (free travel), slippage or any strange
feel to the clutch operation.
 SECTION 4 VEHICLE OPERATION

Transmission (cont.)
Manual Transmissions (cont.)

Engaging the Clutch (cont.)

Helpful Hints to Operate Vehicles with Ceramic Clutch
Facings
1. Driver must start vehicle in first gear.
2. While operating a ceramic clutch the driver has to engage
the clutch before giving the engine any fuel (at idle).
3. The driver should not try to slip the ceramic clutch by raising
engine RPMs and riding or feathering clutch pedal since the
vehicle will experience erratic engagement.
Erratic engagement can cause engine stalling and potential
serious damage to your vehicles drive train components (i.e.,
clutch, transmission, driveshaft(s), rear axle).
When using the clutch brake, fully depress the clutch pedal and
shift the transmission into either first or reverse gear. If the
transmission does not go into first gear or reverse, toothbutting
may be occurring. Slowly release the clutch pedal while applying
light pressure on the shift lever until the transmission goes into
gear. This will provide for a smooth shift into either first or reverse
gear.
NOTE: After engagement of first gear DO NOT use the clutch
brake for upshifting and downshifting. To do so will shorten the
service life of the clutch brake and gear selection shift efforts
may be increased. Clutch brake application occurs in the last 1
inch (25mm) of pedal travel.

Clutch Brake (Vehicles with Non-Synchronized Double Clutch Procedures, Non-Synchronized

Transmission) Vehicle Not Moving
In order to properly upshift or downshift be sure to do the
A clutch brake is used to stop transmission input shaft rotation so following:
that the initial first or reverse gear selection can be accomplished
Depress the clutch pedal to disengage the clutch.
when the vehicle is at a standstill and the engine running at idle
speed. Clutch brake application occurs in the last 1 inch (25mm) Shift the transmission into neutral.
of pedal travel.
Release the clutch pedal.

Form No. 3628504R1

Printed in the United States of America Page 129
 SECTION 4 VEHICLE OPERATION

Transmission (cont.)
Manual Transmissions (cont.)

Double Clutch Procedures, Non-Synchronized (cont.)

If upshifting, wait until the engine speed matches the
transmission speed of the gear you desire to shift into.
If downshifting, accelerate the engine until the engine speed
matches the input speed of the gear you desire to shift into.
Depress the clutch pedal immediately and shift into the
desired gear.
Release the clutch pedal to engage the clutch.
Clutch Precautions
Maintain specified clutch adjustment. Regularly inspect clutch
control linkage for tightness.
When adjustment of the clutch is necessary, it is extremely
important that the work be properly performed; otherwise, early
failure of the clutch will result and a costly clutch overhaul
becomes necessary.
Shifting with Synchronized Transmission
With the clutch released (pedal depressed) use second speed
gear synchronizer to stop clutch disc rotation. This will allow
smooth engagement of first or reverse gear selection. In order
to complete gear engagement, it may be necessary to apply
light pressure to the shift lever during initial engagement of
the clutch. It takes one to two seconds to match gear speeds.
Steady pressure on shift lever will help the synchronizer perform
its job quicker. If the shift lever is forced into gear it is possible to
override a blocker and defeat the purpose of the synchronizer,
causing gear clash.
Shifting with Non-Synchronized Transmission
Refer to Clutch Brake (vehicles with non-synchronized
transmission) and Double Clutch Procedures in this section
(above).

To avoid needless delay and expense, allow only competent and

experienced mechanics to perform these operations.

Form No. 3628504R1

Page 130 Printed in the United States of America
 SECTION 4 VEHICLE OPERATION

Transmission (cont.)
Manual Transmissions (cont.)

Eaton AutoShift and UltraShift Transmissions and automatic transmission, with the efficiency of a manual
Shifters transmission. For complete operating instructions, see the
EatonFuller AutoShift driver instruction manual.
The UltraShift Transmission provides fully automatic operation
WARNING: To avoid unexpected vehicle (no clutch pedal) using an Eaton Fuller manual transmission
movement, hold the brake pedal down while you coupled with electronic modules that automate the shifts. The
move the gearshift from position to position. Hold electronics provide automatic shifting (automatic reverse and
down both brake and clutch pedal (AutoShift only) forward vehicle starts with no clutch) eliminating mechanical
while pushing the R and D button. If you do not lever shifting, permitting the driver to keep both hands on the
hold the brake pedal down, your vehicle may move steering wheel. For complete operating instructions, see the
unexpectedly and cause property damage, personal EatonFuller UltraShift driver instruction manual.
injury or death.
Eaton AutoShift and UltraShift Transmission Shifter
Both the Eaton AutoShift and UltraShift Transmissions use
The Eaton AutoShift and UltraShift are automated
the shifter controls that are shown in the following illustrations.
transmissions that automatically select and engage the
proper manual transmission gears. The Eaton AutoShift
transmission uses a clutch pedal that must be used when
starting and stopping the vehicle.
The AutoShift transmission is an advanced shift-by-wire
system consisting of an Eaton Fuller heavy-duty transmission
communicating with an electronic engine utilizing the SAE-J1939
protocol for precise control of the engine and transmission
functions. The clutch is used only for starting and stopping.
Once the vehicle is in motion, AutoShift operates like an

Form No. 3628504R1

Printed in the United States of America Page 131
 SECTION 4 VEHICLE OPERATION

Transmission (cont.)
Manual Transmissions (cont.)

Eaton AutoShift and UltraShift Transmissions and

Shifters (cont.)
Eaton Cobra Shift Lever
The Eaton AutoShift transmission also utilizes a Cobra style
shift lever for the drivers that are used to the conventional shift
handle.

Form No. 3628504R1

Page 132 Printed in the United States of America
 SECTION 4 VEHICLE OPERATION

Transmission (cont.)
Manual Transmissions (cont.)

ZF Meritor FreedomLine Transmission
WARNING: To avoid the vehicle from rolling
backwards on a hill or grade at a stop, place foot
firmly on service brake.
drivers seat. The shift module replaces the standard shift lever,
shift tower and shift knob. The joystick is moved FORWARD
to upshift and BACKWARD to downshift. The FreedomLine
transmissions two-pedal system completely eliminates driver
clutch pedal operation.
Shift Module

When starting from a stop, quickly move your foot The following shows the four components that make up the Shift
from the service brake to the accelerator pedal. Failure module.
to observe these precautions could result in property
damage, personal injury or possible death.

NOTE: Before using the ZF Meritor FreedomLine

transmission, read and thoroughly understand the operator
manual, TP-20170, and obtain proper training.
The ZF Meritor FreedomLine transmission provides a choice
of automatic or manual modes depending on driver preference
or road conditions.
The FreedomLine transmission operates in full automatic
mode, determining the proper starting gear, senses load and
selects the right gear for specific conditions.
If the driver prefers to shift manually, the driver uses the Shift
Module. The shift module, with a joystick, is located next to the

Form No. 3628504R1

Printed in the United States of America Page 133
 SECTION 4 VEHICLE OPERATION

Transmission (cont.)
Manual Transmissions (cont.)

ZF Meritor FreedomLine Transmission (cont.)

3. NEUTRAL Button (On gearshift lever)
Used to shift into Neutral gear at any time
4. Shift Module Display
Illuminates either F (Forward), N (Neutral), or R
(Reverse).
The FreedomLine Transmission also uses an instrument
panel display (optional), mounted in the wing panel. The
instrument panel provides system and shift status, as well as
system malfunction alerts.
For detailed information and instruction, see the FreedomLine
Transmission Operator Manual TP-20170.

1. Gearshift Lever
Used to upshift or downshift in manual Automatic Transmissions

Used to shift into Reverse Low and Reverse High Allison Transmissions
gears.
2. FUNCTION Button (On gearshift lever) NOTE: For Allison Automatic Transmissions refer also to
separate Allison Transmission Operators Manual.
Used to shift between Automatic and Manual
transmission modes
Used to shift into Reverse gear.

Form No. 3628504R1

Page 134 Printed in the United States of America
 SECTION 4 VEHICLE OPERATION

Transmission (cont.)
Automatic Transmissions (cont.)

Allison Transmissions (cont.)

Releasing the Park Brake

WARNING: To avoid sudden, unexpected vehicle

movement and property damage, personal injury or
death, always use the parking brake. Do not leave
transmission in gear instead of using parking brake.
Bring the vehicle to a complete stop using the
service brake pedal.
Put transmission selector in N Neutral.
Apply the Park brake and ensure that it is holding
properly.
Turn off engine when you leave vehicle. NEVER
LEAVE THE VEHICLE UNATTENDED WITH ENGINE
RUNNING.
WARNING: To avoid unexpected vehicle
movement, hold the brake pedal down while you
move the gearshift from position to position. Failure
to follow this warning could result in property damage,
personal injury, or death.
NOTE: Read and perform the following steps whenever you
prepare to drive away.
After starting the engine, place foot firmly on brake pedal.
With foot still on brake pedal, select the desired transmission
operating position.
With foot still on brake pedal, push in on Park Brake control to
release air park brake, then lift foot from brake pedal to allow the
vehicle to move.

Form No. 3628504R1

Printed in the United States of America Page 135
 SECTION 4 VEHICLE OPERATION

Transmission (cont.)
Automatic Transmissions (cont.)

Operation of the PanelMounted Gearshift Controls Allison Generation 4 T-Bar Gearshift Control

WARNING: To avoid unexpected vehicle

movement, hold the brake pedal down while you
select the desired gear positions. Failure to follow this
warning could result in property damage, personal
injury, or death.

Both the T-Bar gearshift control and the Push-button gearshift

control are available with the Allison automatic transmissions.
They provide the same gear shift functions and control the
transmission in the same manner.

When the vehicle is started, the transmissions are designed

to operate in the standard performance mode. Pressing the
Mode button on the shift tower will switch the transmission
to Economy mode and illuminate Mode ON in the shift tower
display. Economy mode provides operation at a lower engine
RPM while maintaining adequate performance.

Form No. 3628504R1

Page 136 Printed in the United States of America
 SECTION 4 VEHICLE OPERATION

Transmission (cont.)
Automatic Transmissions (cont.)

Allison Generation 4 T-Bar Gearshift Control (cont.)

If the engine speed is above idle when a gear is selected with the Operation of the Allison Generation 4 Push-button Shift
shift tower, the vehicle will not launch. To move the vehicle, the Selector
shift tower must be moved to re-select a gear after the engine
comes down to idle.

To shift the Allison transmission into Reverse (R) or Drive (D),

first place foot on brake pedal. With foot on brake pedal, press
either R or D, and release brake pedal. When in Drive, to select a

Form No. 3628504R1

Printed in the United States of America Page 137
 SECTION 4 VEHICLE OPERATION

Transmission (cont.)
Automatic Transmissions (cont.)

Operation of the Allison Generation 4 Push-button Shift

Selector (cont.)

lower range press and release the down arrow button. To select
a higher range, press and release the up arrow button. To place
the transmission in Neutral, press the (N) button.
Main Transmission Controls
Main transmission, auxiliary transmission, transfer case, and
power take off control shift patterns can be found on a placard
or decal on the drivers visor door, on the instrument panel, or
on the shift control itself. In certain cases, the shift pattern,
for a component added by a Body Builder, will be in the Body
Builders manual.
The main transmission control is used to select the various gear
ratios or speeds provided within the transmission.
The auxiliary transmission, used in conjunction with the main
transmission, provides additional gear ratios. The auxiliary
transmission (in addition to the main transmission) must be
placed in one of the driving positions before power can be
transferred to the rear wheels.
Selection of the UD (underdrive) gear in the auxiliary
transmission gives a greater gear reduction than provided
by the main transmission and can be used with any of the
main transmission ratios. This ratio is generally used where the
vehicle is under heavy load and additional torque is required.
The auxiliary transmission should always be in UD (underdrive)
when starting with a load.
Selection of the D (direct drive) gear does not change the gear
ratio provided by the main transmission but is used where the
gear ratios in the main transmission are adequate to handle the
vehicle operation.
Selection of the OD (overdrive) gear in the auxiliary transmission
permits increased road speeds in the various transmission
ratios.
A loaded vehicle should not be operated with the auxiliary
transmission in OD (overdrive) with the main transmission in
either of the two lowest speed gears. Doing so could cause
damage to either the transmission or propeller shaft.

Form No. 3628504R1

Page 138 Printed in the United States of America
 SECTION 4 VEHICLE OPERATION
Transmission (cont.)
Automatic Transmissions (cont.)
Main Transmission Controls (cont.)
WARNING: Before backing up, check to see
that area behind vehicle is clear of people, animals
and objects. Use a spotter whenever possible and
always keep that person in sight. Failure to do so may
result in property damage, personal injury, or death.
If so desired, backup alarms are available through
your International dealer. However, they are never a
substitute for the above procedures.
Power Take Off Control
If your vehicle is equipped with a power take off (PTO), refer to
the PTO equipment manufacturers instructions.
If vehicle is equipped with an Allison Automatic Transmission,
refer to separate Allison Transmission Operators Manual.
Automatic Transmission Operating Temperature
For the Allison transmissions, the sump/fluid reservoir
temperatures (indicated by optional gauge or warning light)
Form No. 3628504R1
Printed in the United States of America
should not exceed 250F (121C). The converter temperature
(indicated by optional gauge or warning light) should not
exceed 300F (149C). For the transmissions with retarder, the
converter temperature (indicated by optional gauge or warning
light) should not exceed 330F (166C).
Transfer Case
NOTE: For warning light description see Warning Lights under
Electrical.
This control ENGAGES or DISENGAGES the front axle and
selects the HIGH or LOW speed range of the transfer case.
Shifting
The transfer case transmits power to the front driving axle for
operation over rough terrain, steep grades or slippery surfaces
(i.e., mud, gravel, snow) where improved traction is required.
Low gear of the transfer case (if so equipped) should be engaged
only when the vehicle is stopped or moving forward slowly. Low
gear is intended for off-highway use only, where additional gear
reduction is occasionally required to pull heavy loads.
Page 139
 SECTION 4 VEHICLE OPERATION

Transmission (cont.)
Transfer Case (cont.)

Shifting (cont.)
NOTE: The vehicle must not be operated on dry, flat, hard Engine
surface roads with the transfer case in low gear. Operating
under these conditions may damage the power train.
Governed Engine Speed

Downhill Operation

For precautions to be observed when operating vehicle on WARNING: Operating an engine beyond the
downgrades, refer to the Brakes section of this manual. maximum governed speed could result in vehicle
damage, personal injury or death.

Prevent over-speeding of the engine when going down long and

steep grades. The governor has no control over engine speed
when it is being pushed by the loaded vehicle. Operate in a gear
that will permit an engine speed not in excess of the Maximum
Governed Speed or High-Idle RPM (no load).

Form No. 3628504R1

Page 140 Printed in the United States of America
 SECTION 4 VEHICLE OPERATION

Engine (cont.)
Hazards of Operation Near Flammable Vapors Air Restriction Gauge

The air restriction gauge indicates how much engine air cleaner
filter capacity has been used and how much filter capacity
WARNING: Operation of a diesel engine near remains. It measures maximum restriction of the filter element
flammable vapors in the air may cause the engine when the engine is operated at full load and locks at that
speed to increase uncontrollably and over speed. point. This feature gives the operator the capability of reading
If this situation occurs, mechanical damage, fire, maximum restriction with the engine shut down.
explosion, personal injury or death could result.
The gauge will be mounted either on the air cleaner or instrument
Turning off the ignition switch will not slow or stop
panel (dash mounted).
the engine due to uncontrollable fueling of the engine
through flammable vapors being drawn into the engine Both gauges have a push type reset button. The reset on the
air inlet. Operation of components such as starter, dash panel mounted gauge is in face of the gauge. The reset
alternator, electric motors, etc. and static electricity on air cleaner mounted gauge is on bottom of gauge. See
could also ignite flammable vapors. illustrations below.
It is recommended that the operator NOT reset gauge until it has
Do not operate the truck in the possible presence
been determined if air cleaner service is required.
of flammable vapors unless both a complete hazard
analysis is performed and necessary additional safety
processes and/or equipment such as vapor testing,
air intake shutoff devices, ventilation, etc. are utilized.
The operator is responsible for using those processes
and/or equipment to ensure that the diesel engine and
all other components on the truck can be operated
safely under the specific conditions and hazards that
may be encountered.

Form No. 3628504R1

Printed in the United States of America Page 141
 SECTION 4 VEHICLE OPERATION

Engine (cont.)
Air Restriction Gauge (cont.)

NOTE: It is not necessary that engine be shut down when NOTE: After starting engine, indicator may be seen in lower part
the yellow indicator in gauge reaches the maximum restriction of window. This is normal and should not be mistaken as a signal
(red) but indicates air cleaner service is required (refer to for element service.
Troubleshooting).

The initial restriction with a new air filter element will vary with air
cleaner design and installation.
After servicing the filter element, reset the yellow indicator by
pushing the reset button and releasing it. The yellow indicator
will drop below the window so the air restriction gauge can be
reused.

Form No. 3628504R1

Page 142 Printed in the United States of America
 SECTION 4 VEHICLE OPERATION

Engine (cont.)
Troubleshooting

No Restriction Reading
POSSIBLE CAUSES
Plugged fitting or vacuum line
Leak in vacuum line
Leak in gauge
Engine air flow too low to generate a
restriction reading
Air cleaner element split open
HOW TO CHECK
Apply vacuum to gauge until locked up at red zone. Re-connect line and hold in reset button.
Indicator will fully return unless line or fitting is plugged. A slow return is normal due to safety
filter in fitting.
Apply vacuum to gauge until locked up at red zone. Re-connect gauge and close end of line air tight.
Hold in reset button. Indicator will drop slightly and then not move unless vacuum line has a leak.
Repeat above except close gauge connection air-tight.
Turbocharged engines must be full load to pull full engine air flow (N.A. engines at full RPM).
Visually inspect element.

High Restriction Reading

POSSIBLE CAUSES EXPLANATION
Plugged elements Ultra fine particles are difficult to remove and cleaning may not sufficiently lower restriction.
Plugged inner element (if equipped) Replace inner element.
Plugged inlet screens or ducts Check system upstream from restriction tap for debris, damage or improper installation.
Heavy snow or rain Temporary high restriction can occur during a rain or snow storm and it disappears after drying
out. COLD AIR MAY BE SO DENSE THAT HIGH RESTRICTION MAY NOT REDUCE ENGINE

Form No. 3628504R1

Printed in the United States of America Page 143
 SECTION 4 VEHICLE OPERATION

Engine (cont.)
Troubleshooting (cont.)

High Restriction Reading (cont.)

POSSIBLE CAUSES EXPLANATION
POWER BEFORE ELEMENTS ARE DAMAGED FROM HIGH VACUUM. If gauge is locked up at
red zone check elements for damage.

Diesel Engines Engine Performance Problems

NOTE: For information pertaining to fuel and requirements refer
to individual engine owners manual provided with the vehicle.
The text herein applies to International engines only.
Refer to Fueling Precautions listed in this section of manual.
Lower fuel viscosity could reduce engine power and fuel
economy, and increases the possibility of excessive fuel system
wear or failure.
Lower cetane number could cause hard starting and slower
warm-up, and could increase engine noise and exhaust
emissions.

Charge Air Cooler

All International engines are equipped with charge air cooling WARNING: Never add gasoline and/or alcohol
system. The function of the charge air cooler is to cool the hot to diesel fuel. This mixture creates an extreme fire
compressed air before it enters the engines intake manifold. and explosion hazard which could result in property
This system uses ambient air as the cooling medium by allowing damage, personal injury, or death.
the intake air to pass through a network of heat exchanging
fins and tubes prior to entering the combustion chamber. The
resulting cooler intake air is denser than uncooled air.

Form No. 3628504R1

Page 144 Printed in the United States of America
 SECTION 4 VEHICLE OPERATION
Engine (cont.)
Engine Performance Problems (cont.)
WARNING: Exhaust gases from engines
contain hazardous compounds. Do not operate
engines in enclosed areas without abundant forced
ventilation (with garage doors and windows wide
open). Maintain exhaust system in good operating
condition. Breathing exhaust gases could result in
personal injury or death.
Emergency Starting Using Jumper Cables
WARNING: The following procedures must be
performed exactly as outlined, otherwise a fire or a
battery explosion could result in property damage,
personal injury or death.
1. To prevent shorting of the electrical system, remove metal
rings or watches and do not allow metal tools to contact
positive terminal of battery.
Form No. 3628504R1
Printed in the United States of America
2. Place transmission in Neutral and set parking brake in both
vehicles.
3. Shut off lights, heater, air conditioner and any other electrical
loads in both vehicles.
4. Eye protection should be worn if available. If not available,
shield eyes when near either battery.
5. Vehicle bodies or bumpers must not be in contact.
6. Connect one end of the first jumper cable to positive (+)
terminal of the dead battery or (+) terminal of jump start
stud and then the other end to the positive (+) terminal of
the booster battery.
CAUTION: To avoid damage to vehicle electronic
components, voltage supplied to a vehicles electrical
system must never exceed 16.0 volts. This voltage
must not be exceeded when the ignition switch is
in the OFF, ACC, or IGN position, or during engine
cranking. The most reliable means for jump starting a
vehicle is to use batteries connected so as to provide
12 volts. Never use an electric welder.
Page 145
 SECTION 4 VEHICLE OPERATION

Engine (cont.)
Emergency Starting Using Jumper Cables (cont.)

7. Connect one end of the second jumper cable to negative (-)
terminal of the booster battery, and the other end to chassis
frame. Do not attach the other end to the negative (-) battery
terminal, because a spark could occur and cause explosion
of gases normally present around the battery.
8. Reverse above procedure when removing the jumper
cables.
When approaching a hill, depress accelerator smoothly to start
the upgrade at full power, then shift down as needed to maintain
vehicle speed.
Prevent over-speeding of the engine when going down long and
steep grades. The governor has no control over engine speed
when it is being pushed by the loaded vehicle. Operate in a gear
that will permit an engine speed not in excess of the Maximum
Governed Speed or High-Idle RPM (no load).

Operating Instructions

General WARNING: Operating an engine beyond the

maximum governed speed could result in engine
Start the vehicle in motion by utilizing the highest gear speed in failure and cause vehicle damage, personal injury or
the transmission that will enable the engine to easily start the death.
load without slipping the clutch. Accelerate smoothly and evenly
to engine rated speed. Rapid acceleration will result in high fuel
consumption with no increase in performance.

WARNING: All vehicles have blind spots. Make

sure your way is clear in all directions before moving
your vehicle. Failure to follow these procedures could
result in property damage, personal injury or death.

Form No. 3628504R1

Page 146 Printed in the United States of America
 SECTION 4 VEHICLE OPERATION
Engine (cont.)
Operating Instructions (cont.)
Cold Weather Operation
WARNING: Explosion Hazard. Do not use volatile
starting aids such as ether, propane, or gasoline in
the engine air intake system. Glow plugs and/or grid
heater will ignite vapors, which can cause severe
engine damage, personal injury, or death.
In order to operate engine in temperatures of 32F (0C) or lower,
observe the following instructions.
1. Make certain that batteries are of sufficient size and in fully
charged condition. Check that all other electrical equipment
is in optimum condition.
2. Use permanent type engine anti-freeze solution to protect
against damage by freezing.
3. At the end of each daily operation, drain water from
fuel-water separator, if equipped. Fill fuel tank at end of
daily operation to prevent condensation.
4. Be sure to use proper cold weather lubricating oil, and be
sure crankcase is at proper level.
Form No. 3628504R1
Printed in the United States of America
5. At temperatures of -4 degrees F (-20 degrees C) and below,
it is recommended that you use a crankcase mounted
coolant heater to improve cold starting.
6. If operating in arctic temperatures of -20 degrees F (-29
degrees C) or lower, consult your International truck dealer
for information about special cold weather equipment and
precautions.
CAUTION: Because diesel engines are highly efficient,
they use very little fuel while idling. As a result,
idling in cold weather will not heat the engine to its
normal operating temperature. This in turn can cause
a build-up of heavy deposits of carbon and rust on
valve stems causing them to stick. Sticking valves can
cause significant valve train damage. The colder the
ambient temperature, the more likely this will occur.
The following cold weather idling guidelines must be
followed:
Avoid extended idling (beyond 10 minutes) whenever
possible.
Use a minimum 45 Cetane diesel fuel or utilize Cetane Index
improvers from a reputable manufacturer.
Page 147
 SECTION 4 VEHICLE OPERATION
Engine (cont.)
Operating Instructions (cont.)
Cold Weather Operation (cont.)
Maintain a minimum of 1250 rpm idle by use of the hand
throttle. Always make sure that parking brake is applied and
transmission is in neutral before applying hand throttle.
Maintain engine cooling system.
Do not shut engine down after extended idling period. Drive
the vehicle under load for several miles at normal operating
temperatures to burn off any accumulated carbon and
varnish.
Consider use of engine block heaters, approved
winter-fronts, and/or radiator shutters where conditions
warrant.
Winter Front Usage
Unless extremely cold conditions exist, the use of winter fronts
or other air restrictive devices mounted in front of the radiator is
not recommended on vehicles equipped with chassis mounted
charge air coolers. Air flow restriction can cause high exhaust
temperatures, power loss, excessive fan usage, and a reduction
in fuel economy. If you insist on using a winter front, the device
should have a permanent opening directly in line with the fan
Form No. 3628504R1
Page 148 Printed in the United States of America
hub. The openings minimum dimension must be at least 120
sq. in.
Hot Weather Operation
1. Keep cooling system filled with clean permanent anti-freeze
solution to protect against damage by overheating.
2. Fill fuel tank at end of daily operation to prevent
condensation in tank.
3. Keep external surface of engine, radiator, CAC AC
condenser and accessories clean to avoid dirt build-up.
Above normal coolant temperature could be experienced while
driving in a transmission gear ratio which would lug the engine.
To correct the problem, engine speed should be increased by
down shifting into the next lower gear to increase engine RPMs
which will increase coolant flow through the radiator.
Starting A Turbocharged Vehicle On A Grade
When starting a loaded vehicle on a grade and the clutch is
engaged, the RPM will fall off significantly. This is due to the
emission control device on the turbocharged engine that controls
 SECTION 4 VEHICLE OPERATION
Engine (cont.)
Starting A Turbocharged Vehicle On A Grade (cont.)
the fuel input during first gear acceleration. When engine RPM
first falls off, do not disengage the clutch and try to increase
engine RPM. Doing so may damage driveline components. After
the initial drop in speed, the engine will recover and accelerate
in a normal manner.
Proper Starting Procedure
Set the spring brakes or hand brake, if equipped, bring the RPM
up slightly and begin to engage the clutch while, at the same
time, releasing the spring brakes.
As the RPM begins to fall off, DO NOT disengage the clutch. The
RPM will quickly come back and the vehicle will move steadily
up the grade.
Shut-Down
Idle the engine for three to five minutes before shutting down.
This few minutes idling allows the lubricating oil and water to
carry heat away from the iron masses.
The larger the engine, the greater the need for this idling period
and of course, the length of the idling period should somewhat
follow the size of the engine in order to avoid seals or like
features of an engine being damaged by rising heat.
Form No. 3628504R1
Printed in the United States of America
Engine Shut-Down and Restarting Procedure
WARNING: In the event engine shutdown occurs,
make certain that vehicle is safely off the roadway, the
4-way emergency flashers are on, and traffic warning
devices are properly placed. Failure to remove vehicle
from roadway could cause an accident and result in
property damage, personal injury or death.
Vehicles may be equipped with an optional automatic shutdown
system that stops the engine in the event of high coolant
temperature or low engine oil pressure or low coolant level. A
warning light on the instrument panel along with a beeper or
bell will indicate high coolant temperature or low oil pressure.
If the temperature and/or pressure continue to change beyond
the warning point to a predetermined level, the engine will
automatically shut down. Vehicles that are equipped with the
ENGINE SHUTDOWN OVERRIDE switch, will allow the engine
to be restarted so that the vehicle can be moved. The engine
should be run no longer than absolutely necessary. A decal
located in front of the operator provides instructions on how the
override should be operated.
Page 149
 SECTION 4 VEHICLE OPERATION
Engine (cont.)
Engine Shut-Down and Restarting Procedure (cont.)
NOTE: After the engine is restarted, it will operate in a de-rated
mode for an additional 30 seconds while conditions causing the
shut-down are still present.
Parking
WARNING: When parking your vehicle, do not
leave transmission in gear; if vehicle rolls, engine
could start by heat of compression. Always use
parking brake. When parking on a grade, chock
wheels and turn front wheels to keep the vehicle
from rolling into the traveled portion of the roadway.
Failure to follow these procedures could cause an
unattended vehicle to move, resulting in property
damage, personal injury or death.
Form No. 3628504R1
Page 150 Printed in the United States of America
Cooling System
WARNING: To avoid personal injury or death
from hot coolant or steam use only the following
procedure to remove the pressure cap from the
radiator or expansion tank. Allow the engine to cool
first. Wrap a thick, heavy cloth around the cap. Push
down, loosen cap slowly to its first notch position;
then pause a moment to allow pressure to release
through the overflow tube. After the pressure has
been released, the pressure cap may be removed.
CAUTION: If the coolant should get extremely low
and the engine very hot, let the engine cool for
approximately 15 minutes before adding coolant;
then, with the engine running, add coolant slowly.
Adding cold coolant to a hot engine may crack the
cylinder head or crankcase. Never use water alone.
 SECTION 4 VEHICLE OPERATION
Engine (cont.)
Cooling System (cont.)
WARNING: Exercise great care when working on
vehicles with running engines that are equipped with
an automatic fan clutch. The fan engages when engine
coolant reaches a predetermined temperature or the
refrigerant pressure (if equipped with air conditioning)
reaches a predetermined setting. The fan will start
with no advance warning. Failure to observe these
precautions could result in vehicle damage, personal
injury or death.
Anti-Freeze (Extended Life Coolant)
The cooling system of your new vehicle is filled at the factory
with either a Type II (Purple) or Type III ELC - Extended Life
Coolant (Red). The type of coolant used depends on the
vehicles engine. Consult the engine manual to determine the
coolant type and its service life details.
Engine Oil
Keep oil level as near the high level mark as possible. Never
operate an engine with oil level below low level mark.
Form No. 3628504R1
Printed in the United States of America
When checking the oil level, the dipstick must be withdrawn and
wiped clean, then inserted all the way and again withdrawn for
a true checking.
Never check the oil level with engine running or immediately after
engine shutdown as an inaccurate reading will be obtained. Most
engines require a 15 to 20 minutes waiting period.
Use only recommended viscosity engine oil. Refer to the Engine
Owners Manual for engine oil specifications.
The lubricating oil in a diesel engine becomes dark in color
after short periods of engine operation. This discoloration is not
harmful to engine parts as long as the oil and oil filter element
changes are performed at recommended intervals.
Fuel
Hazards Of Diesel Fuel/Gasoline Blends
International Truck and Engine Corporation does not
recommend the blending of gasoline, and/or alcohol with diesel
fuel due to the hazards of fire/explosion and the detrimental
effects on engine performance.
Page 151
 SECTION 4 VEHICLE OPERATION
Fuel (cont.)
Hazards Of Diesel Fuel/Gasoline Blends (cont.)
WARNING: Never add gasoline and/or alcohol
to diesel fuel. This mixture creates an extreme fire
and explosion hazard which could result in property
damage, personal injury, or death.
As little as two percent volume gasoline mixed with diesel fuel
will create a flammable/explosive mixture in the fuel tank vapor
space, which will pose an extreme fire/explosion hazard during
refueling or engine operation.
Fuel and Lubricant Additives
International Trucks are designed and built to operate
satisfactorily on fuels and lubricants of good quality marketed
by the petroleum industry. International Truck and Engine
Corporation does not recommend the use of any supplementary
fuel or lubricant additives. Malfunctions attributed to the use of
such additives or failure to follow recommended fuel or lubricant
recommendations may not be covered by any applicable
warranty.
Form No. 3628504R1
Page 152 Printed in the United States of America
Fueling Procedures
NOTE: If your vehicle is equipped with dual fuel tanks, be sure
to read and understand the following information before refueling
the vehicle.
A dual tank system contains a primary and a secondary fuel tank.
With dual fuel tanks, the vehicle will be equipped with a fuel
transfer pump system that will pump fuel from the secondary
(reserve) fuel tank and send it to the primary (draw) fuel tank.
The draw fuel tank must have fuel in it at all times otherwise the
vehicle may stall and may be difficult to re-start (the fuel gauge
reads the fuel level only from the draw fuel tank).
Therefore, when refueling, be sure that both tanks are filled
completely, as it is sometimes difficult to determine which tank
is the draw tank and which is the reserve tank.
Fueling Precautions
According to the Federal Motor Carrier Safety Regulations,
no driver or any employee of a motor carrier shall:
1. Fuel a motor vehicle with the engine running, except
when it is necessary to run the engine to fuel the vehicle.
 SECTION 4 VEHICLE OPERATION

Fuel (cont.)
Fueling Precautions (cont.)

2. Smoke or expose any open flame in the vicinity of a Hood

vehicle being fueled.
3. Fuel a motor vehicle unless the nozzle of the fuel hose
Tilt Hood
is continuously in contact with the intake pipe of the fuel
tank.
4. Permit, insofar as practicable, any other person to
engage in such activities as would be likely to result in WARNING: Never put any part of your body
fire or explosion. beneath a raised hood unless the hood is all the way
forward in its range of motion and is fully settled in
the over center position.
Reserve Fuel

Raising the Hood

WARNING: Never carry extra fuel unless it is in a
properly mounted fuel tank/tanks.
No extra supply of fuel for the propulsion of the vehicle or for the
operation of accessories shall be carried on any motor vehicle
except in a properly mounted fuel tank or tanks.
1. Before opening the hood make sure that there is enough
room in front of the vehicle for the hood to open completely
without pinning or pinching yourself between the hood and
any other structures.
2. Release the latches on both sides of the cowl.
3. Grasp the hood handle and pull the hood forward over center
and allow it to settle into the raised position.
4. Make certain that hood restraining cables are engaged
before releasing hood.

Form No. 3628504R1

Printed in the United States of America Page 153
 SECTION 4 VEHICLE OPERATION

Hood (cont.)
Tilt Hood (cont.)

Lowering the Hood Steering

1. Make sure that the hood has no tools/parts/people in its path
of motion.
2. Grasp the hood handle and push the hood backward over
center and allow it to settle into lowered position.
3. Engage latches at both sides of cowl.
Be alert to any change (feel) in steering when driving. This
change or feel would include increased steering efforts, unusual
sounds when turning, excessive wheel play or pulling to either
side. If any of the above are detected have the vehicle inspected
and repaired at once by a qualified mechanic.

Adjustable Steering Column

5000i Series With Butterfly Hood

Raising the Hood

To raise the hood (right or left side), release the two latches.
Then, raise the hood to permit the ratchet to engage and hold
the hood open.
WARNING: Do not adjust the steering column
while the vehicle is moving. It could suddenly or
unexpectedly move causing the driver to lose control
of vehicle which could result in property damage,
personal injury, or death.

Lowering the Hood

To close the hood, raise the hood sufficiently to permit

disengagement of the ratchet. Lower the hood slowly. Engage CAUTION: Do not lubricate the Tilt mechanism.
the two hold-down latches.

Form No. 3628504R1

Page 154 Printed in the United States of America
 SECTION 4 VEHICLE OPERATION

Steering (cont.)
Adjustable Steering Column (cont.)

Tilt and Telescope Towing Instructions

The Tilt and Telescoping Steering Wheel for the 5000i and
9000i Series has a single lever operation. Pull lever up, toward
steering wheel, to tilt the wheel. Push lever down, away from
steering wheel, to telescope. Let lever go to lock wheel in
desired location.
WARNING: This vehicle may be equipped with
(optional) dual tow hooks. Always use both tow
hooks to avoid possible overloading and breaking of
individual hooks. Failure to follow this warning could
result in property damage, personal injury, or death.

Before moving the towed vehicle, check for adequate road

clearance of vehicle components. International recommends
unloading the towed vehicle prior to towing to reduce any
abnormal loads to the vehicle components resulting from the
towing procedures. Before towing, be sure to fully release the
parking brake. The spring actuated type parking brake can be
reset by recharging the air system with at least 64 lbs. (441 kPa)
of air. If brake system will not retain air pressure, then the spring
brakes must be released manually. SEE PARKING BRAKES.

Form No. 3628504R1

Printed in the United States of America Page 155
 SECTION 4 VEHICLE OPERATION

Towing Instructions (cont.)

Towing Vehicle With Front Wheels Suspended

WARNING: Always chock the wheels when

manually releasing the parking brakes, or the vehicle
can roll causing property damage, personal injury, or
death.
For towing, make sure the vehicle is securely
connected to tow vehicle and tow vehicle parking
brakes are applied before releasing the disabled
vehicles parking brakes.
WARNING: Under no circumstances should a
spring brake chamber be disassembled. Disassembly
will release a powerful spring which could result in
property damage, personal injury, or death.
CAUTION: To avoid transmission damage, vehicles
should not be towed even short distances without
suspending rear wheels or removing the axle shafts
or propeller shaft.
In the event the chassis is equipped with tandem
axle and the vehicle is to be towed from the front,
the forward rear axle may be raised to clear the
road surface and secured to the frame by chains or
U-bolts, allowing only rear rear axle to contact road
surface. Axle shafts must be removed from rear
rear axle assembly. The wheel hub ends must be
covered to avoid loss of axle lubricant and entrance
of contaminants. Use extreme care in securing the
chains or U-bolts to avoid possible damage of brake
lines, hoses or other components.

When it is necessary to tow a vehicle with the front wheels

suspended, extra precautions must be taken to avoid
transmission or differential damage. Proceed as follows.
Remove axle shafts from axle assembly to prevent the wheels
from driving the differential and the transmission. The wheel
hub ends must be covered to avoid loss of axle lubricant and
entrance of contaminants.

Form No. 3628504R1

Page 156 Printed in the United States of America
 SECTION 4 VEHICLE OPERATION

Towing Instructions (cont.)

Towing Vehicle With Front Wheels Suspended (cont.)

If axle shafts are not removed, removal of propeller shafts at rear

axle will be required. CAUTION: Do not use a chisel or wedge to loosen axle
shafts and dowels. The chisel or wedge can damage
hub, axle shafts and oil seals if used.
Towing Vehicles With Driver Controlled Differential Lock

Removing Axle Shafts Before Towing 5. Remove tapered dowels and both axle shafts from axle
assembly.
6. Assemble a cover over openings of both wheel ends to
CAUTION: If the vehicle must be towed to a service avoid loss of lubricant and keep dirt from the wheel bearing
facility with the drive axle wheels on the ground, it is cavities.
necessary to remove the axle shafts before the vehicle
is towed. NOTE: One of the axle shafts has two sets of splines. One set
to engage with differential side gear and one set to engage with
1. Shift main differential to the unlocked (disengaged) position. shift collar for the differential lock. It may be necessary to rotate
Differential lock light in the cab will go out. shaft slightly to align side gear spline teeth with clutch collar teeth
in order to remove axle shaft.
2. Disconnect driveline universal joint from pinion input yoke or
flange on carrier.
3. Remove capscrews and washers or stud nuts and washers
from flanges of both axle shafts.
4. Loosen tapered dowels in flanges of both axle shafts by
holding a 1-1/2 inch diameter brass drift or hammer against
axle shaft center and hitting it with a five to six pound
hammer.

Form No. 3628504R1

Printed in the United States of America Page 157
 SECTION 4 VEHICLE OPERATION

Towing Instructions (cont.)

Towing Vehicles With Driver Controlled Differential Lock
(cont.)

Removing Axle Shafts Before Towing (cont.)

1. SHIFT COLLAR IN LOCKED POSITION

2. ACTUATOR ASSEMBLY AND SHIFT FORK

3. SHAFT, AXLE

4. INTERFERENCE BETWEEN SHIFT COLLAR AND HOUSING

5. SHIFT COLLAR IN UNLOCKED POSITION

6. OUTER SPLINES- AXLE SHAFT TO COLLAR

7. SHIFT COLLAR AND DIFFERENTIAL CASE SPLINES

8. INNER SPLINES, AXLE SHAFT TO SIDE GEAR

9. GEAR, SIDE

10. DIFFERENTIAL (PLAIN) CASE HALF

Installing Axle Shafts a. Place gaskets on wheel hub studs.

1. Remove covers from wheel ends.
2. Shift differential lock to the unlocked (disengaged) position.
3. Install right-hand and left-hand axle shafts.
b. Push right-hand axle shaft and gasket into wheel end
and housing until shaft stops against differential shift
collar.
c. Push down and in on axle shaft flange and rotate shaft
until splines of shaft and shift collar are engaged.

Form No. 3628504R1

Page 158 Printed in the United States of America
 SECTION 4 VEHICLE OPERATION

Towing Instructions (cont.)

Towing Vehicles With Driver Controlled Differential Lock
(cont.)

Installing Axle Shafts (cont.)

d. Push axle shaft further into housing until shaft stops
against differential side gear.
e. Push down on axle shaft flange and rotate shaft until
splines of shaft and side gear are engaged.
f. Push axle shaft completely into housing until axle shaft
flange and gasket are flush against wheel hub.
g. Install left-hand axle shaft and gasket into wheel end.
4. If tapered dowels are required, install them at each stud and
into flange of axle shaft. Use a punch or drift and hammer if
needed.
5. Install fasteners and tighten to correct torque value. Refer
to the appropriate Service Manual Section.
Whenever possible, it is preferable to tow a disabled vehicle from
the rear by raising the rear of the chassis.
When towing a vehicle with rear of the chassis suspended the
front wheels must be locked in the straight ahead position.
Vehicles with manual shift transmissions must have a least one
(1) pint of transmission lubricant drained from the case. This
will avoid transmission lubricant from entering the clutch housing
and lubricant saturating the clutch discs. Make sure that the
transmission lubricant is replaced before the vehicle is returned
to service.

Towing Vehicle With Rear Wheels Suspended

CAUTION: To avoid damage to cab roof or air deflector

when towing the vehicle backwards (rear wheels
suspended) the air deflector must be removed.

Form No. 3628504R1

Printed in the United States of America Page 159
 SECTION 4 VEHICLE OPERATION

Tractor-Trailer Connections Connecting And Disconnecting Trailers Using Air

Suspension Dump Valve Feature

WARNING: Whenever possible make trailer

connections while standing on the ground. Provide
adequate lighting of working areas. Inclement weather
and accumulated road contamination deposits on
handholds and stepping surfaces require extra care
to avoid slips and falls which could cause personal
injury or death.

Do not climb on the back of a tractor unless it has been

equipped with a deck plate and a handhold. Use a three
point stance when climbing up and down from a deck
plate. Do not jump from vehicle.
An optional air suspension dump feature permits raising and
lowering the chassis to aid in connecting and disconnecting
trailers.
This system is controlled by a flipper type control valve located
on or near the instrument panel. To lower the chassis, place the
control valve lever in the Dump position. To raise the chassis,
place the lever in the Run position.
When connecting to a trailer, move the air suspension control
valve to the Dump position, allow time for the chassis to
drop to its lowest position, then slowly back under the trailer.
After completing all necessary air, electrical, and fifth wheel
connections, move the suspension control valve to the Run
position and then raise the trailer landing gear.

Form No. 3628504R1

Page 160 Printed in the United States of America
 SECTION 4 VEHICLE OPERATION
Tractor-Trailer Connections (cont.)
Connecting And Disconnecting Trailers Using Air
Suspension Dump Valve Feature (cont.)
When disconnecting from a trailer, lower the trailer landing
gear, disconnect all necessary air, electrical, and fifth wheel
connections, move the suspension control valve lever to the
Dump position and then slowly pull out from under the trailer.
The air suspension dump valve must always be in the Run
position when operating with a trailer or in a bobtail (tractor only)
mode.
Fifth Wheel Operation
WARNING: Always follow the fifth wheel
manufacturers instructions for hooking and
unhooking as well as sliding the fifth wheel. Failure to
follow this warning could result in property damage,
personal injury or death.
The hand control valve should never be used to
apply the trailer brakes when the tractor and trailer
are parked. Air pressure may leak from the system,
and the vehicle could roll away, resulting in property
damage, personal injury or death.
Form No. 3628504R1
Printed in the United States of America
Hook-Up
1. Fifth wheel jaws must be opened fully.
2. Tilt fifth wheel back to prevent body damage when tractor is
backed under trailer.
3. Block trailer wheels and be sure trailer spring brakes are
adjusted and applied. Never chase a trailer.
4. Make sure brake hoses and light cords are clear of the fifth
wheel.
5. Back tractor squarely under trailer, engaging fifth wheel jaws
on trailer kingpin. Always back slowly, making sure trailer is
neither too high nor too low. Avoid backing under trailer from
an angle.
6. Connect service and emergency brake hoses and trailer light
connector. Refer to Tractor-Trailer Connections adhering
to the WARNING and using the three point stance while
connecting and disconnecting trailer.
7. Inspect fifth-wheel jaws to be sure they have closed on trailer
king pin and the trailer plate is resting securely on the fifth
wheel.
8. Be sure the coupler release lever is in the locked position.
Page 161
 SECTION 4 VEHICLE OPERATION

Fifth Wheel Operation (cont.)

HOOK-UP (cont.)

9. Charge trailer brake system. Set trailer brakes, either with
the hand valve or tractor protection valve. Pull against trailer
for an additional check of hook-up. Do not pull hard enough
to damage or strain the equipment.
10. Set tractor parking brakes and fully raise trailer landing gear.
Refer to Brakes segment of this section for Operation of
Parking Brakes and Trailer Brakes.
11. Check operation of all trailer lights and correct faulty
operational lights.
Un-Hook
1. Try to keep tractor and trailer in straight line.
2. Apply parking brakes.
3. Lower trailer landing gear, making sure it is on solid, level
ground. The weight of trailer is to be on landing gear.
4. Block trailer wheels.
5. Disconnect brake hoses and light cords. Be sure hoses and
cords are clear.
6. Pull coupler release lever to disengage fifth wheel jaws.
7. Release tractor parking brakes.
8. Pull out from trailer slowly, allowing landing gear to take load
gradually.
Sliding Fifth Wheel
WARNING: When using an assistant to
re-position a sliding fifth wheel, the driver must
be ready to stop as soon as the fifth wheel moves to
the desired position. The assistant must keep feet,
hands and body clear of the vehicles tires and other
moving parts to avoid personal injury or death. The
driver must not begin to move the vehicle until the
assistant is clear and signals the driver to move the
vehicle.
The fifth wheel permits the fine tuning of load distribution or the
adjustment of overall tractor/trailer length to meet regulations.
By design, tandem axles will be balanced within 500 lbs. (227
Kg) with the fifth wheel set 12 inches (305 mm) ahead of center.
Severe unbalanced condition can affect inter-axle shaft U-joint
working angles and adversely affect the service life of the
U-joints. Refer to the Service Manual, Springs, Suspension
Alignment Section, Load Equalization.

Form No. 3628504R1

Page 162 Printed in the United States of America
 SECTION 4 VEHICLE OPERATION

Sliding Fifth Wheel (cont.)

For incab control of sliding 5th wheel, the slide mechanism
is locked or unlocked using the 5th WHEEL/SLIDE (ON/OFF)
SWITCH.
For manual operation, the basic precautions for heavy lifting are
applicable to releasing fifth wheel and when moving sliding fifth
wheel.
Be sure of your grip on release lever. Dont jerk the lever
and be sure to wear gloves.
It may be necessary to rock the vehicle to release the fifth
wheel or locking mechanism of sliding fifth wheel.

Form No. 3628504R1

Printed in the United States of America Page 163
 SECTION 4 VEHICLE OPERATION

Form No. 3628504R1

Page 164 Printed in the United States of America
 SECTION 5 VEHICLE MAINTENANCE INSTRUCTIONS

Preface Maintenance Guidelines

WARNING: If the owner/operator of the vehicle is WARNING: Failure to properly perform

a skilled technician and intends to perform the vehicle maintenance and servicing procedures could result in
maintenance and servicing, he/she is strongly urged property damage, personal injury or death.
to purchase and follow the appropriate International
service manual. Ordering information is included at
the back of this manual. Failure to properly perform
maintenance and servicing procedures could result in
property damage, personal injury or death. WARNING: Making any modifications to any part,
component or system of the vehicle, can adversely
affect the quality and reliability of your vehicle and
Your vehicle has been engineered and manufactured to provide must be avoided. Modifications to systems could
economical and trouble-free service. However, it is the owners result in property damage, personal injury or death.
responsibility to see that the vehicle receives proper care and
maintenance.
Quality International service parts are available through your
International dealer. If International service parts are not used,
the owner must make sure that the parts used are equivalent to WARNING: Use only genuine International
International service parts. service parts. The use of inferior parts can adversely
affect the quality and reliability of your vehicle, which
As with any vehicle, care should be taken to avoid being injured could result in property damage, personal injury or
when performing maintenance or repairs or making any checks. death.
Improper or incomplete service could result in the vehicle not
working properly which, in turn, may result in personal injury
or damage to the vehicle or its equipment. If you have any
question about performing some service, have the service done
by a skilled technician.

Form No. 3628504R1

Printed in the United States of America Page 165
 SECTION 5 VEHICLE MAINTENANCE INSTRUCTIONS
Preface (cont.)
Maintenance Guidelines (cont.)
WARNING: To avoid property damage, personal
injury or death, take care when performing any
maintenance or making any check or repair. Some of
the materials in this vehicle may also be hazardous
if used, serviced, or handled improperly. If you have
any questions pertaining to the service, have the work
done by a skilled technician.
WARNING: To avoid property damage, personal
injury or death when servicing the vehicle, park on a
flat level surface, set the parking brake, turn off the
engine, and chock the wheels.
Form No. 3628504R1
Page 166 Printed in the United States of America
CAUTION: To avoid damage to electronic components,
disconnect the ground battery terminal first, then the
positive cable prior to electric welding. Attach the
welder ground cable as close as possible to the part
being welded. If it is necessary to weld close to an
electronic component, it is recommended that the
component be temporarily removed.
When servicing your vehicle always:
1. Turn off the ignition switch unless the procedure calls for a
running engine.
2. Set the parking brake and chock the wheels.
3. Use support stands, not a jack, whenever you must be under
a raised vehicle.
4. Do not smoke.
5. Wear safety glasses for eye protection.
6. Operate engine only in a well ventilated area.
7. Do not work on brakes or clutch unless proper precautions
are taken to avoid inhaling friction material dust.
 SECTION 5 VEHICLE MAINTENANCE INSTRUCTIONS
Preface (cont.)
Maintenance Guidelines (cont.)
8. Do not wear loose clothing, hanging jewelry, watches or
rings. Tie up long hair and avoid rotating machinery.
9. Avoid contact with hot metal parts; allow hot components to
cool before working on them.
10. Correct any problems that were revealed during inspection,
prior to operating the vehicle.
Supporting Your Vehicle for Service
WARNING: Always use floor stands to support
the vehicle before working under it. Using only a jack
could allow the vehicle to fall resulting in property
damage, personal injury or death.
When performing service repairs on a vehicle, first:
1. Park vehicle on level concrete floor.
2. Set parking brake and/or block wheels to prevent vehicle
from moving.
3. Select jack with a rated capacity sufficient to lift the
vehicle.
Form No. 3628504R1
Printed in the United States of America
4. Raise vehicle with jack applied to axle. (DO NOT use
bumper as a lifting point.)
5. Support vehicle with floor stands under axle(s).
If axle or suspension components are to be serviced, support
vehicle with floor stands under frame side members, preferably
between the axles.
Chassis Lubrication
New vehicles are lubricated at the factory. After the vehicle
is placed in operation, regular lubrication and maintenance
intervals, based on the type of service and road conditions,
should be established. The loads carried, speed, road and
weather conditions all contribute to the frequency of lubrication
intervals. Thorough lubrication and maintenance at the specified
intervals will insure Outstanding Life Cycle Value and will reduce
overall operating expense.
In some types of operation, and where operating conditions are
extremely severe (such as in deep water, mud or unusually dusty
conditions), the vehicle may require re-lubrication after every
twenty-four (24) hours of operation.
Only lubricants of superior quality, such as Fleetrite lubricants,
should be used. The use of inferior products will reduce the
service life of the vehicle or result in failure of its components.
Page 167
 SECTION 5 VEHICLE MAINTENANCE INSTRUCTIONS

Preface (cont.)
Chassis Lubrication (cont.)

International Truck and Engine Corporation recommends the Axles

use of Fleetrite lubricants and International Engine original
equipment parts.
The lubrication intervals specified should be performed at
whatever interval occurs first, whether it is miles (kilometers),
hours, or months.
These intervals are provided in the LUBRICATION, SEALERS,
AND MAINTENANCE INTERVALS section.
Air Conditioning Service Checks
Have your air conditioner serviced each spring. The refrigerant
charge, cleanliness of condenser-evaporator cores, proper
belt tension and belt condition are essential to air conditioning
performance.
For 5000i, and 9000i models the Blend-Air system air filter
element should be replaced every year at the beginning of the
cooling season. More frequent replacement may be required
for vehicles operating in dusty areas. The filter is located under
the passenger seat and faces the passenger door. (Refer the
Master Service Manual section Air Conditioning Heater
System.)
Front Axle
Front Axle Inspection and Lubrication
Check to make sure that the front axle mounting U-bolts,
attaching or mounting bolts and nuts are securely tightened.
Observe the following when checking the front axle for damaged,
binding, or worn parts, and adequate lubrication:
Kingpin wear inspection requires that no weight is on the
tires.
Kingpin and Kingpin Bushing lubrication requires that the
vehicle weight is off tires and the front wheels be turned fully
to the left or right prior to installing grease distribution,
Kingpin Thrust Bushing lubrication requires that the vehicle
weight is resting on the tires.
Power grease guns may be used, however, a hand-pumped
grease gun is recommended for optimal grease distribution
within each component joint.

Form No. 3628504R1

Page 168 Printed in the United States of America
 SECTION 5 VEHICLE MAINTENANCE INSTRUCTIONS

Axles (cont.)
Front Axle (cont.)

Front Axle Inspection and Lubrication (cont.)

Inspect, lubricate and adjust the wheel bearings at regular
intervals. Refer to the LUBRICATION, SEALERS, AND
MAINTENANCE INTERVALS Section and the TORQUE
SPECIFICATIONS chart for the correct lubricants and
torques.
If the lube level suddenly drops dramatically below the minimum
level, see the Service Manual for diagnostic procedure.
Front Axle Alignment

Maintaining front axle alignment very important to achieve

Front Axle Normal Maintenance maximum tire life and vehicle control. Inspecting steer axle tires
in the first 3,000 to 10,000 service miles will generally show if
During operation, the air and oil inside the hub/wheel cavity tires are wearing normally.
expands. It is normal for a mist of oil to be present on the
outside of the hubcap around the vent slit or hole. Over time,
if not wiped off, this film may collect dust and appear unsightly. Rapid outside shoulder wear on both tires indicates too
If the entire face and end of the hubcap become wet with oil, much toe-in.
investigate the cause. Refer to the axle Service Manual section
Rapid inside shoulder wear on both tires indicates too much
for repair procedures.
toe-out.
Routinely clean the hubcap to ensure that the lube level can
Excessive wear on the inside or outside of one steer tire
be easily observed through the clear window as intended.
but not the other can indicate a toe-in or toe-out condition
In situations where the window is clean on the outside but
coupled with a misaligned front or rear axle.
discolored on the inside, check the lube level by removing the
rubber fill/vent plug and insert a finger into the hole. Pulling to the right or left can indicate misalignment
of the front or rear axle, unequal tire pressures, or a
The specified lube level for International clear window type
damaged/mismatched tire.
hubcaps is from the minimum line to 5/16 inch above the
minimum line. Refer to the TIRES subsection for additional related information.

Form No. 3628504R1

Printed in the United States of America Page 169
 SECTION 5 VEHICLE MAINTENANCE INSTRUCTIONS

Axles (cont.)
Rear Axle Brakes
Rear Axle Inspection and Lubrication
General Information
Make sure the axle mounting U-bolt nuts, attaching or mounting
bolts and nuts, are securely tightened. Loose or misaligned
rear axles will affect vehicle alignment, front tire wear, and
handling. Refer to AXLE U-BOLT NUT TORQUE CHART for WARNING: Avoid breathing brake lining fiber
torque specifications. dust as it may be hazardous to your health. Always
Check the rear axle oil level. Proper oil level minimizes gear use a respirator while performing brake maintenance.
wear, heat and damage to the wheel bearings and seals. The Follow precautions listed below.
oil level should be at the lower edge of the level inspection hole
when the vehicle is on level ground. Add oil as necessary.
Refer to the LUBRICATION, SEALERS, AND MAINTENANCE
INTERVALS section for additional information. WARNING: Always check and maintain brakes in
proper condition and adjustment. Out of adjustment
brakes could cause reduced braking ability and result
NoSpin Detroit Locker Positive Locking Differential in property damage, personal injury, or death.

Vehicles which have NoSpin Detroit Locker Positive Locking

Differential have the operators manual supplied with the vehicle. All new International vehicles use non-asbestos brake linings.
Refer to this manual for maintenance checks. However, exposure to excessive amounts of brake material dust
may be a potentially serious health hazard.

Form No. 3628504R1

Page 170 Printed in the United States of America
 SECTION 5 VEHICLE MAINTENANCE INSTRUCTIONS

Brakes (cont.)
General Information (cont.)

Follow these precautions: Air Brakes

Always wear a respirator approved by National Institute of
Occupational Studies of Health (NIOSH) or Mine Safety and
Appliance (MSA) during all brake service procedures. Wear
the respirator from removal of the wheels through assembly.
NEVER use compressed air or dry brushing to clean brake
parts or assemblies.
Clean brake parts and assemblies in the open air. During
disassembly, carefully place all parts on the floor to avoid
getting dust into the air. Use an industrial vacuum cleaner
with a HEPA filter system to clean dust from the brake
drums, backing plates, and other brake parts. After using
the vacuum, remove any remaining dust with a rag soaked
in water and wrung until nearly dry.
NEVER use compressed air or dry sweeping to clean the
work area. Use an industrial vacuum cleaner with a HEPA
filter system and rags soaked in water and wrung until nearly
dry. Dispose of used rags with care to avoid getting dust into
the air. Use an approved respirator when emptying vacuum
cleaners and handling used rags.
Worker clean-up. Wash your hands before eating, drinking,
or smoking. Vacuum your work clothes after use and then
launder them separately, without shaking them, to prevent
fiber dust from getting into the air.
Brake Inspection and Adjustment
WARNING: Always chock the wheels when
manually releasing the spring brakes, or the vehicle
could roll causing property damage, personal injury,
or death.
WARNING: Under no circumstances should a
spring brake chamber be disassembled. Disassembly
will release a powerful spring which could result in
property damage, personal injury, or death.
A regular schedule for periodic cleaning, lubrication, adjustment
and inspection should be established, based on the type
of vehicle operation. It is difficult to predetermine an exact
maintenance interval (time or mileage), since vehicles will be
used in a wide variety of applications and conditions. If you
are uncertain of the proper schedule and procedures for your
vehicle, contact your International dealer.

Form No. 3628504R1

Printed in the United States of America Page 171
 SECTION 5 VEHICLE MAINTENANCE INSTRUCTIONS

Brakes (cont.)
Air Brakes (cont.)

Brake Inspection and Adjustment (cont.)

Periodic checking of push rod travel or brake adjustment is
essential for good braking. Push rod travel should be checked
every service interval to determine if adjustment is necessary.
Brake chamber push rods on original equipment chambers now
incorporate a stroke indicator to aid adjustment checks an
orange paint marker near the base of the push rod. If the push
rod is clean and the brakes require adjustment, the orange
marker can be seen protruding from the chamber when the
brakes are applied.
Slack adjusters should also be checked to ensure proper
operation of the adjuster mechanism at the 6 month interval.
Push rod travel should be kept at a minimum without brakes
dragging.
Inspect brake linings every maintenance interval. When brake
lining or blocks are worn to within 1/16 in. (1.6mm) of rivets,
brake lining must be replaced.
This inspection or adjustment should only be performed by
qualified service personnel and must be in accordance with
instructions provided by the International Service Manual.
Do not back off or disconnect front brakes so that they are
less effective, letting the rear brakes do all the stopping of the
vehicle. Do not overlook the brakes on the trailer either. Brake
condition on a trailer is just as important as the tractor. Proper
brake balance on trucks and tractor-trailers is essential for good
braking.
At least once a year, the entire brake system must be inspected.
Check:
1. Rubber as it may deteriorate whenever it is used.
Rubber brake components should be inspected by
a competent mechanic and replaced as necessary.
Replacement intervals will vary according to the severity
and length of service.
2. Condition of drums, brake chambers, and slack
adjusters.
3. For air leaks.
4. Hose or pipes for rust, damage, deterioration.
5. Proper operation of service and parking brake controls.
6. The condition of the ABS wheel speed sensors and
wiring.
7. Proper ABS wheel speed sensor-to-exciter teeth gap.

Form No. 3628504R1

Page 172 Printed in the United States of America
 SECTION 5 VEHICLE MAINTENANCE INSTRUCTIONS
Brakes (cont.)
Air Brakes (cont.)
Brake Inspection and Adjustment (cont.)
Periodically inspect the air brake chamber diaphragm, air
compressor, and air cleaner and replace if considered
unserviceable.
Air Dryer
NOTE: The use of an air dryer does not eliminate the need to
periodically drain the air reservoirs.
The air dryer removes humidity (water), air compressor oil and
dirt from the incoming compressed air, thus protecting the air
system against deterioration and restriction.
The air dryer is installed between the air compressor discharge
line and the Wet Tank. The air dryer has a desiccant cartridge
and a filter which is serviced as an assembly. Moisture from the
air collects on the desiccant and is automatically discharged.
Life and performance of the air dryer depends on usage, air
humidity levels, environmental temperatures, air compressor oil
control and desiccant quantity. Regularly check the desiccant,
purge valve and air dryer heater performance.
Form No. 3628504R1
Printed in the United States of America
Desiccant Air Dryer
Open reservoir drain valves and check for presence of water.
Small amounts of water due to condensation is normal. If the
wet (air) tank and primary or secondary tanks are collecting an
abnormally high amount of water between regular air tank drain
intervals, replace the air dryer desiccant.
The air dryer desiccant replacement interval may vary; it is
generally recommended that the desiccant be replaced every
12 months for small air dryers like the Bendix AD-IP, or every 24
months for large air dryers like the Bendix AD-9. If experience
has shown that extended or shortened life has resulted for a
particular installation, then the interval should be increased or
reduced accordingly.
Air Dryer Purge Valve
Check that the purge valve opens and expels moisture when
the air governor shuts off the air compressor. Air should escape
rapidly and then quickly stop. If the purge valve does not open
or you can hear a slight audible air leakage past the valve for
longer than 30 seconds, the valve may be sticking and should
be rebuilt. Purge valves may also stick if the air dryer heater has
failed and ice is clogging the valve.
Page 173
 SECTION 5 VEHICLE MAINTENANCE INSTRUCTIONS

Brakes (cont.)
Air Brakes (cont.)

Air Dryer Heater
Check that the air dryer heater activates at temperatures below
freezing. With the vehicle in a cold environment and before the
engine is started, turn on the ignition and touch the air dryer
housing. It should be warmer than other metallic items on the
vehicle. If some warmth cannot be felt it may indicate that the
heater element or the wiring powering it should be serviced.
Periodically, manually drain the reservoir and make sure the
drain passage is not plugged.
ABS Connections And Sensors
Periodically push together the ABS wiring connections to assure
they are fully seated. Press the wheel speed sensors into their
mounting collars to assure they are fully seated.

Air Reservoir/Tanks Moisture Draining

Moisture taken in with the air through the compressor inlet valves
collects in the reservoirs. Drain the wet tank reservoir every day
at the end of the trip. Drain the primary and secondary tanks
periodically. Open the drain cock located either on the bottom of
the tank or in the end of the tank. For ease of draining, some or
all tanks may be equipped with optional pull cords. There must
be some air pressure in the system to assure proper drainage.
Close the drain cocks after all moisture has been expelled. If
you are unsure which tank is the wet tank, drain all tanks daily.
On vehicles equipped with automatic drain valve(s), moisture
and contaminants are automatically removed from the reservoir
to which it is connected. It operates automatically and requires
no manual assistance or control lines from other sources.
Cab
Care Of Vehicle
Washing and Waxing
Frequent and regular washing will lengthen the life of your new
vehicles painted finish and bright metal trim.
Wash your vehicle often with warm or cold water to remove dirt
and preserve the original luster of the paint. Never wash the
vehicle in the direct rays of the hot sun or when the sheet metal
is hot to the touch, as this may cause streaks on the finish. Do
not use hot water or strong soaps or detergents or wipe off dirt
when the surface is dry, as this will scratch the paint.

Form No. 3628504R1

Page 174 Printed in the United States of America
 SECTION 5 VEHICLE MAINTENANCE INSTRUCTIONS

Cab (cont.)
Care Of Vehicle (cont.)

Washing and Waxing (cont.)

Always make certain that steps and grab handles are clean and wax or polish on bright metal usually will restore the original
free of road grime, grease, ice, and other debris. brightness.
Prior to using any wax or polish, the vehicle must be thoroughly
washed.
Upholstery Care

Use a whisk broom and vacuum cleaner to remove loose dust

Bright Metal Care and dirt from upholstery and floor. Vinyl and woven plastic
upholstery can be washed with warm water and mild soap.
To preserve the bright look of your vehicles trim (grilles,
Wipe dry. If commercial cleaners are used, follow instructions
bumpers, etc). use only mild detergents and lukewarm water
supplied with cleaner.
for cleaning. Damage to these parts can occur if cleaning
solutions having excessive acidity or alkalinity (pH) are used.
Also, the higher the solution temperature ranges, the more
caustic the cleaners chemical compounds become. However, Clutch
if high pressure washing equipment and washing compounds
are used, satisfactory results can be achieved if the solution
has a pH value between 4 and 8, and the temperature does not Pedal Free Travel
exceed 160 degrees F (71 degrees C). Solutions that are more
acid or more alkaline will attack the anodic coating.
If you are having difficulty with your washing compound, contact WARNING: Avoid breathing clutch lining
your local supplier for the acidity/alkalinity (pH) specification. fiber dust as it may be hazardous to your health.
Always wear a respirator when doing clutch lining
A non-abrasive chrome cleaner may be used sparingly to clean
maintenance.
the bright metal. Do not use steel wool. Use of automobile

Form No. 3628504R1

Printed in the United States of America Page 175
 SECTION 5 VEHICLE MAINTENANCE INSTRUCTIONS

Clutch (cont.)
Pedal Free Travel (cont.)

Each time the vehicle chassis is lubricated, check clutch pedal wool, aramid, ceramic or carbon) may be a potentially serious
free play. If pedal free play is more or less than the dimensions health hazard.
specified in the chart below, the clutch must be adjusted to
Persons who handle clutch linings should follow the same
be assured that the clutch is fully engaged. Before making
precautions as outlined for handling brake linings.
any clutch adjustments, contact your International dealer for
approved clutch adjust procedures.
Electrical
Vehicle Model Pedal Free Travel
5000i 1 1/2 inches (38mm)
Alternator-Starter-Battery Test
9000i 1 1/2 inches (38mm)
The Amps-Volts-Resistance (AVR) test should be performed
NOTE: Proper free pedal adjustment will provide adequate periodically by a qualified technician. The test will check for
clearance between the release yoke fingers and the release Alternator amperage output, Starter current draw, and Battery
bearing. amperage capacity. This type of testing will detect weaknesses
that may not yet be apparent during normal daily operations.
Pull type clutches are adjusted internally for wear. Your
International dealer should be contacted for the proper
adjustment procedure. Terminal Inspection-Cleaning-Corrosion Protection

NOTE: Improper adjustment of pull type clutches may cause
improper clutch operation and may void the clutch warranty.
New International vehicles use non-asbestos clutch linings.
However, exposure to excessive amounts of clutch material
dust (whether asbestos or non-asbestos, fiberglass, mineral
Periodically inspect electrical connectors on the engine,
electrical fuse panel, battery, and frame for corrosion and
tightness. Inspect exposed cables for fraying or signs of
abrasion. Exposed terminals such as fuel sender, cranking
motor, alternator, and feed through studs should be cleaned and
re-coated with a dieletric grease such as Fleetrite 472141C1
or equivalent. The inspection/cleaning/corrosion protection

Form No. 3628504R1

Page 176 Printed in the United States of America
 SECTION 5 VEHICLE MAINTENANCE INSTRUCTIONS

Electrical (cont.)
Terminal Inspection-Cleaning-Corrosion Protection (cont.)

should include feed through connections, power and ground Electrical Circuit Diagram Manuals available from International
cable connections for batteries, engines and the starter stud. (see order form in back of this manual) to assure that any body
lights and accessories are connected to circuits that are both
Connectors that are more subject to corrosion may be
appropriate and not overloaded. No modification should be
disassembled and sprayed internally with a light coating of
made to any vehicle control system without first contacting your
dielectric grease. Use grease sparingly as too much grease
International dealer.
with not allow air to escape from the connection and this
compressed air will push the connection apart.

Accessory Feed Connections

Engine

WARNING: Electrical circuits are designed with CAUTION: To avoid damage to the International Engine
a particular wire gauge to meet the fuse and circuit Control Module it should never be spray-washed
breaker current rating. Do not increase size of fuse or directly. Never spray any connector.
circuit breaker or change type of breaker supplied with
your truck. To do so could cause wiring to overheat
and possibly burn, resulting in a fire which could cause NOTE: Information in this Section pertains to International
property damage, personal injury or death. Engines only. For complete operation and maintenance
information pertaining to your International engine, refer to
the International Engine Operation and Maintenance Manual
Vehicle electrical systems are complex and often include
provided with the vehicle. Information pertaining to engines not
electronic components such as engine and transmission
manufactured by International Truck and Engine Corporation
controls, instrument panels, anti-lock brakes, etc. While most
will be found in separate manuals provided with the vehicle.
systems still operate on battery voltage (12 volts), some systems
can be as high as 90 volts or as low as 5 volts. Refer to the

Form No. 3628504R1

Printed in the United States of America Page 177
 SECTION 5 VEHICLE MAINTENANCE INSTRUCTIONS

Engine (cont.)
General refer to the Engine Operation and Maintenance Manual supplied
with the vehicle.
For effective emission control and low operating cost, it is
important that maintenance operations be performed at the
specified periods or mileage intervals indicated (kilometers, Catalytic Converter
miles, hour, or months, whichever occurs first) in the Engine
Operation and Maintenance manual.
Service intervals are based upon average operating conditions. CAUTION: DO NOT blend waste oil with diesel fuel.
In certain environments and vocations, more frequent servicing Operate only on low sulfur (less than 500 parts per
will be required. million sulfur) diesel fuel. Failure to do so will reduce
Catalytic Converter performance and may render it
The required maintenance operations may be performed at inoperable.
a service establishment. Any replacement parts used for
required maintenance services or repairs should be genuine
International service parts. Use of inferior replacement parts
hinders operations of engine and emission controls and can
CAUTION: If your vehicle is equipped with a vertical
reduce engine life and/or jeopardize the warranty.
exhaust pipe, it is very important to have and maintain
Receipts covering the performance of regular maintenance a rain cap on the exhaust pipe to prevent water from
should be retained in the event questions arise concerning entering the exhaust system and catalytic converter.
maintenance. The receipts should be transferred to each Any water entering the catalytic converter may damage
subsequent owner of the engine (vehicle). the catalyst, and affect the function of the converter.

Scheduled Maintenance It is important to review the maintenance schedule in the Engine

Operation and Maintenance Manual to insure proper functioning
For information regarding routine scheduled maintenance such of the catalytic converter. Also, take precautions not to damage
as replacement of oil, filters, coolant, belts, belt tensioners, etc., the catalytic converter when servicing your engine or storing your
and inspection and adjustment of items such as valve lash, etc. vehicle.

Form No. 3628504R1

Page 178 Printed in the United States of America
 SECTION 5 VEHICLE MAINTENANCE INSTRUCTIONS
Engine (cont.)
Air Induction System
WARNING: To avoid personal injury or death
when performing maintenance and repairs to any
turbocharged engine with engine air inlet piping
disconnected, a turbocharger compressor air inlet
protective shield should be installed over the
turbocharger air inlet. Order protective shield J-26554
for International engines from your local International
dealer.
Once each year perform a complete inspection of the air
induction system. In areas where road salt is used, the
inspection consists of disassembling the joints of each aluminum
component and inspecting for salt build-up, presence of chlorine
that can cause aluminum particles to flake off and enter the
engine combustion chambers.
If evidence of corrosion is found (usually appears at the pipe
connections) use a wire brush to clean the inside of the pipes
and inside the rubber hoses.
If the intake pipes are pitted at the joint ends, use RTV Silicone
to seal the joints. Be certain that no excess material is on the
inside of the pipe that can be pulled into the engine. If the service
Form No. 3628504R1
Printed in the United States of America
condition of the pipes, hoses or clamps is questionable, replace
that part or parts.
Check for loose hoses and clamps.
Check for ruptured or collapsed hoses.
Check air cleaner housing for cracks.
Air Cleaner Element Service
1. Lift the tab on the air cleaner housing cover and rotate
the cover counter-clockwise to unlatch and remove the
cover. Remove the filter element carefully and slowly;
then discard the old element.
NOTE: (Be careful not to bump the filter while in the
housing; this can raise a cloud of dust that can enter
the clean side piping to the turbocharger).
2. Cover the turbocharger inlet piping with a clean rag to
prevent dust from entering the turbocharger. Wipe the
inside of the air cleaner housing with a clean damp cloth.
Be sure to clean the gasket sealing surface. DO NOT
use compressed air for this cleaning!
3. Visually inspect the air cleaner housing for damage or
distortion which could allow unfiltered air to enter the
engine. Inspect to be sure that the rubber dust unloader
valve at bottom of housing is in place and not cracked.
Page 179
 SECTION 5 VEHICLE MAINTENANCE INSTRUCTIONS

Engine (cont.)
Air Cleaner Element Service (cont.)

4. Inspect the new filter element for a damaged or
non-resilient rubber gasket. Inspect the filter element
body for dents or excessive pleat bunching. If any of
the mentioned conditions exist, obtain and install a new
service element from your International dealer.
5. Install the air cleaner end cover onto air cleaner housing,
making sure that cover seats squarely on housing, and
the cover is rotated clockwise and the tabs are fully
latched
6. When servicing is completed, reset air restriction gauge
by pushing and holding the reset button and releasing
it. The yellow indicator will drop below the window. Now
the air restriction gauge is ready for the next operating
cycle.
NOTE: After starting engine, the indicator may be seen in the
lower part of the window. This is NORMAL and should NOT be
mistaken as a signal for element service.
Chassis Mounted Charge Air Cooler
Inspect Charge Air Cooler Daily
1. With the engine off, visually inspect the charge air cooler
core assembly for debris and clogging of external fins.
2. Prior to engine operation, remove any debris blocking the
core.
Inspect Air Intake Piping (8,000 miles, 12 900 km, 200
hours, or 4 months)
1. Check for accumulation of salt deposits. If present,
disassemble and clean the complete air intake piping
system. If the intake piping is pitted use RTV silicone to
seal joints against leakage.
2. Check for loose hoses and clamps.
3. Check for ruptured hoses.
4. Check air cleaner housing for cracks.

Form No. 3628504R1

Page 180 Printed in the United States of America
 SECTION 5 VEHICLE MAINTENANCE INSTRUCTIONS
Engine (cont.)
Cooling System
The cooling system of your new vehicle is filled at the factory
with either a Type II (Purple) or Type III ELC - Extended Life
Coolant (Red). The type of coolant used depends on the
vehicles engine.
The Type II coolant must meet International Type ll specs., such
as the Fleetrite Premium 50/50 with SCA (P/N: ZJJSCA5550).
The Type III coolant must meet International Type IlI specs. such
as the Shell Rotella ELC - Extended Life Coolant (P/N 94042).
Consult the engine manual to determine the coolant type and its
service life details.
Coolant Level
WARNING: To avoid personal injury or death
from hot coolant or steam use only the following
procedure to remove the pressure cap from the
radiator or expansion tank. Allow the engine to cool
first. Wrap a thick, heavy cloth around the cap. Push
down, loosen cap slowly to its first notch position;
then pause a moment to allow pressure to release
through the overflow tube. After the pressure has
been released, the pressure cap may be removed.
Form No. 3628504R1
Printed in the United States of America
WARNING: Do not exceed the pressure rating on
the de-aeration tank cap. Ensure that the pressure
rating of the de-aeration tank cap matches that listed
on the side of the tank, or the tank may burst, causing
property damage, personal injury, or death.
CAUTION: If the coolant should get extremely low
and the engine very hot, let the engine cool for
approximately 15 minutes before adding coolant;
then, with the engine running, add coolant slowly.
Adding cold coolant to a hot engine may crack the
cylinder head or crankcase. Never use water alone.
Keep coolant level between the ADD and MAX levels
indicated on the de-aeration tank. Add a 50/50 coolant
concentrate/water mixture if low. Hot coolant needs room to
expand. Do not overfill.
Filling Instructions
NOTE: Pressure filling is not recommended. Fill rate must not
exceed five gallons per minute.
Page 181
 SECTION 5 VEHICLE MAINTENANCE INSTRUCTIONS
Engine (cont.)
Cooling System (cont.)
Filling Instructions (cont.)
To function properly, the system must be completely filled with
coolant and all air must be expelled. To accomplish this, the
following procedures should be carefully followed:
1. Open all heater cut-off valves fully.
2. Pour a 50/50 mixture of the proper (ethylene glycol based)
coolant concentrate and demineralized or distilled water into
the de-aeration tank. A 50/50 coolant mixture will achieve a
34 deg F (-37 deg C) freeze point. A 53/47 coolant mixture
will achieve a 40 deg F (-40 deg C) freeze point.
3. Because the radiator fills slowly, it is important to continue to
top off the system for two minutes following the initial fill.
4. Start the engine, and continue to add enough coolant to
keep the coolant level between the ADD and MAX levels
marked on the de-aeration tank. Replace the de-aeration
tank cap tightly after adding make-up coolant for two
minutes.
5. With the system filled, operate the engine at various
speeds until coolant reaches normal operating temperature.
Let engine completely cool. Re-check coolant level and
concentration/freeze point and top off as needed to achieve
a coolant level slightly above the ADD line when cold.
Form No. 3628504R1
Page 182 Printed in the United States of America
NOTE: If system has been drained, fill with fresh 50/50
diluted concentrate coolant or 50/50 pre-mixed coolant. If the
system has been flushed with water, a significant amount of
the freshwater flush will remain in the system. In this case
refilling with a mixture with a higher percentage (60 to 66%) of
concentrated coolant concentrate is advised in order to achieve
a final mixture close to 50/50.
Coolant Concentration Freeze point
Cooling systems should be checked twice a year to assure
proper coolant water concentrations. A 53/47 coolant/water
mixture from the factory provides freeze protection down to
minus -40 F as well as excellent corrosion protection. A 50/50
mixture can be easily created in the shop using undiluted
coolant and water and will provide freeze protection down to
34 deg F (-36.7 deg C) if no further dilution is experienced
during installation.
Concentrations greater than 67% are not recommended. The
use of ELC pre-mixed to make up for coolant loss will assure the
glycol/water concentrations stay in balance.
 SECTION 5 VEHICLE MAINTENANCE INSTRUCTIONS

Engine (cont.)
Cooling System (cont.)

Coolant Concentration Freeze point (cont.)

CAUTION: Always use premixed ELC or equivalent to
top off the cooling system. Failure to do so may result
in the loss of extended life properties and will require
testing for SCA levels. Should top off occur with
conventional coolant(s) exceeding 10% of the total
cooling system capacity, either drain and refill with
ELC or maintain as a conventional coolant system
using SCAs at the recommended levels.
Anti-Freeze Capacities
Frame And Tow Hooks
International chassis are manufactured with frame rails of
either mild carbon steel, or HSLA steel and each must be
handled in a specific manner to assure maximum service life.
Before attempting frame repair or modification, consult the
service manual of your International truck dealer.
Specific instructions are published concerning proper repair of
frame rails. See your nearest International dealer.
Front and rear tow hooks should be inspected for damage or
a loose mounting. This is of great importance, particularly on
vehicles where the tow hooks are used frequently.

For cooling system capacities, refer to the Lubrication service

manual section of this manual. For anti-freeze coolant part
numbers and other anti-freeze information, refer to the Engine
Operation and Maintenance Manual.
Fan Clutch
Fuel System
Frequently inspect condition of fuel tanks and mounting
hardware, fuel tank cap and vent, fuel lines, clips and routing.
Periodically drain water and sediment from the fuel tank via the
drain plug on the bottom of the fuel tank.

Inspect for proper operation, secure electrical connections, and

air supply as appropriate. See the Service Manual for details.

Form No. 3628504R1

Printed in the United States of America Page 183
 SECTION 5 VEHICLE MAINTENANCE INSTRUCTIONS

Noise Emissions Exterior Check for proper operation of radiator shutters, if

provided. Shutters should be open during normal operating
Instructions For Proper Maintenance temperatures.
In order to comply with federal exterior noise regulations, your
Engine and Driveline System:
vehicle may be equipped with noise emission items. Depending
upon the vehicle configuration, it may incorporate all or some of Transmission enclosure inspect for cracks, holes, and
the following. tears. Clean any deposits such as oil, dirt, and stones.

Air Intake System: Engine valve covers and block covers are made to damp out
engine mechanical noise and, if needed, should be replaced
Air Cleaner should be inspected and its location should with recommended parts. Check for mechanical isolations.
not be altered. Do not alter inlet and outlet piping.
Exhaust System:
Body:
Inspect for leaks at various joint connections and tighten
Wheel Well splash shields, cab shields and under-hood clamps. Make visual inspection for cracks or holes in
insulation should be inspected for deterioration, dislocation, muffler and tail pipe. Always replace with manufacturer
and orientation. recommended parts. Tail pipe elbow or offset tail pipe
orientation must not be changed from standard position as
Cooling System: originally received.

Check fan for damage to blades; replace, if damaged, with To avoid abnormal changes in vehicle sound level, it
manufacturer recommended parts. Inspect for fan to shroud is necessary for the owner to perform inspections and
interference, and any damage to shroud such as cracks and necessary maintenance at the intervals shown in the
holes. maintenance schedules, and record on the inspection
verification form provided.
Fan ratio should not be changed and fan spacer dimensions
and position should not be altered.
Inspect for proper operation of fan clutch making sure that
the fan is disengaged when cooling of engine is not required.

Form No. 3628504R1

Page 184 Printed in the United States of America
 SECTION 5 VEHICLE MAINTENANCE INSTRUCTIONS
Drive Shaft
At the regular lubrication interval, check universal joints, slip
joints, slip joint boot, and carrier bearings for any evidence of
wear or looseness. Should drive shaft vibrations occur, stop the
vehicle immediately to avoid possible hazardous consequences
or damage to other components.
Suspension (Air And Steel Springs)
CAUTION: Do not adjust air suspension height to any
setting other than the specified setting. Altering the
height setting will change the driveline angle and may
result in unwarrantable component damage, such as
transmission component damage.
Verify drive axle air suspension height and height control
valve performance at engine lube oil change intervals. See
LUBRICATION AND MAINTENANCE INTERVALS CHART.
NOTE: Suspension alignment must be maintained at all times.
Periodically:
Check condition of spring leaves for evidence of fatigue,
bending or breakage.
Check condition of suspension mounting brackets and
bushings.
Form No. 3628504R1
Printed in the United States of America
Check that suspension mounting fasteners (brackets,
bushings, etc.) are tight.
Check that torque rod mounting fasteners are tight.
Check U-Bolts as follows:
1. After the chassis has been operating under load for
1,000 miles (1 600 km) or six months, whichever
comes first, the U-Bolt nuts must be re-torqued.
2. Thereafter, the U-Bolt nuts must be re-torqued every
36,000 miles (57 936 km).
NOTE: See U-Bolt Nut Torquing Chart under Lubrication and
Maintenance Intervals at the end of this section.
Steering
General
WARNING: Always follow recommended
procedures for steering system maintenance. Failure
to maintain the steering system in proper condition
can cause reduced steering ability resulting in
property damage, personal injury or death.
Ask your service technician to examine the steering mechanism.
Minor adjustments could head off further problems.
Page 185
 SECTION 5 VEHICLE MAINTENANCE INSTRUCTIONS

Steering (cont.)
General (cont.)

Check tie rod ends, drag link ends and king pins. Joints Lubrication Points
and fasteners must be tight. Articulating joints must be well
lubricated. The steering shaft is lubricated at the points shown in the
following illustration. For the correct maintenance interval, refer
Check for installation and spread of cotter pins and tightness of to the MAINTENANCE AND LUBRICATION INTERVAL CHART.
nuts at both ends of tie rod and drag link.
Check that pitman arm (steering arm at steering gear) mounting
is tight and locked. Check system for leaks or hose chafing.
Repair at once.
Maintain proper steering gear and power steering pump lubricant
levels.
Regularly inspect steering column joint bolts and steering
linkage, particularly for body-to-chassis clearance.

NOTE: Have any steering problems corrected at once by a

qualified service technician.

Tightening Steering Intermediate Shaft Joint Bolts

As a good maintenance practice, it is recommended that

steering intermediate shaft joint bolts be checked for tightness Power Steering
every 60,000 miles (96 000 km) or annually, whichever occurs
Whenever the hydraulic (power steering) system has been
first. Tighten bolts to torque specified in the Torque Specification
drained and refilled for any reason, air must be bled from
chart at the end of this section. DO NOT OVER-TIGHTEN.
the system before returning the vehicle to service. Failure to

Form No. 3628504R1

Page 186 Printed in the United States of America
 SECTION 5 VEHICLE MAINTENANCE INSTRUCTIONS

Steering (cont.)
Power Steering (cont.)

properly bleed the hydraulic system can result in degradation of Tires

power system performance.
Consult your International dealer who is aware of the proper
Inflation
procedures for filling and bleeding the system.
The Power Steering fluid filter is located inside the power
steering reservoir. To remove the filter, unscrew the large cap
on the power steering reservoir and unscrew the filter. Reverse WARNING: Due to tire manufacturers re-marking
the procedure to iinstall the new filter. tires to conform to the SI (metric) system, tires marked
with old and new loads or inflation pressures could
Refer to the LUBRICATION, SEALERS, AND MAINTENANCE be placed on the same vehicle. For field maintenance,
INTERVALS section for the fluid and filter replacement intervals. only inflate and load tires to the maximum of the
least-rated tire on the axle. Failure to adhere to this
warning could possibly result in tire malfunction,
damage to your vehicle, personal injury, or death.

Form No. 3628504R1

Printed in the United States of America Page 187
 SECTION 5 VEHICLE MAINTENANCE INSTRUCTIONS
Tires (cont.)
Inflation (cont.)
WARNING: Always maintain your tires in good
condition. Frequently check and maintain correct
inflation pressures as specified by tire manufacturers.
Inspect periodically for abnormal wear patterns and
repair/replace cut or broken tire casing. Always use
experienced, trained personnel with proper equipment
and correct procedures to mount or remove tires and
wheels. Failure to adhere to these warnings could
result in wheel or tire malfunction, damage to your
vehicle, personal injury, or death.
Form No. 3628504R1
Page 188 Printed in the United States of America
WARNING: To avoid personal injury or death,
always follow these instructions when mounting radial
tires on wheels:
Only personnel that have had proper training and
experience should mount or remove tires from
rims or wheels.
Use only heavy-duty rims or approved rims for
radial tires. It may be necessary to contact your
wheel and rim distributor to determine if your rims
are approved for radial tires.
If a tube is to be used, make sure special radial tire
tubes are used because of the increased flexing of
the sidewalls on radial tires.
Never use anti-freeze, silicones, or petroleum
based lubricants when mounting radial tires. Only
an approved lubricant should be used as an aid
for mounting tires.
Always inflate tires in a safety cage.
 SECTION 5 VEHICLE MAINTENANCE INSTRUCTIONS
Tires (cont.)
Inflation (cont.)
WARNING:
Do not attempt to mix stud piloted wheels or
fasteners with hub piloted wheels or fasteners. To
do so may cause premature wheel failure resulting
in property damage, personal injury, or death.
Do no mix foreign (not made in North America)
wheel mounting parts with domestic (made in
North America) parts. Many foreign wheel
components look similar to, but not exactly
the same as domestic made components. Mixing
components could cause wheel or fastener failures
and result in property damage, personal injury, or
death.
Do not change from aluminum wheels to steel
wheels or vice-versa without changing the
mounting hardware where required or, in some
cases with flange nut mounting systems, changing
the hub and stud assembly. Mixing components
could cause wheel or fastener failures and result
in property damage, personal injury, or death.
Form No. 3628504R1
Printed in the United States of America
WARNING: Do not mount tube type tires on
tubeless wheels or tubeless tires on tube type wheels.
To do so could result in tire or wheel failure and cause
property damage, personal injury or death.
Preserving proper inflation pressure is a very important
maintenance practice to insure safe vehicle operation and long
life for the tires.
Failure to maintain correct inflation pressure may result in
sudden tire destruction, improper vehicle handling, and may
cause rapid and irregular tire wear. Therefore, inflation
pressures should be checked daily and always before long
distance trips.
Follow the tire manufacturers recommended cold inflation
pressure for the tire size, type, load range (ply rating) and axle
loading typical for your operation. (Each steer axle tire load will
equal 1/2 steer axle loading; each drive tire load will be 1/4 the
axle loading if fitted with four tires).
Checking Inflation
Always check inflation pressure when tires are cold. Never bleed
air from hot tires to relieve normal pressure build-up. Normal
Page 189
 SECTION 5 VEHICLE MAINTENANCE INSTRUCTIONS

Tires (cont.)
Inflation (cont.)

Checking Inflation (cont.)

increases in pressure due to service conditions will be 10 to 15
psi (69 to 103 kPa), which is allowable in truck tires.
It is particularly important to keep moisture from the inside
of tires, and proper selection of air compressor equipment,
proper air line routing, and the use of shop air dryers is strongly
recommended to avoid moisture in the high pressure air used
for tire inflation.
Under Inflation
Tires should not be permitted to become under-inflated.
Increased flexing due to under-inflation causes heat build-up
within the tire components. This leads to reduced strength,
breakdown of the rubber compounds, and possible separation of
the tire components (i.e., ply and tread separation and reduced
retreadability).
Under-inflation is also the primary cause of blowouts. In addition,
low inflation causes an increase in rolling resistance. This results
in reduced fuel mileage, a loss in tread mileage, and uneven
wear due to increased tread movement. To determine proper
inflation refer to the tire inflation range stated on the tire sidewall.
Inspection
Check condition of tires for abnormal wear patterns, and proper
inflation pressures. Cut or broken tire casing must be repaired
or replaced.
Tires should be inspected for the following conditions. If any are
present, the tire should be removed and repaired, retreaded or
scrapped as the condition indicates.
Any blister, bump or raised portion anywhere on the surface
of the tire tread or sidewall (other than a bump made by a
repair). These indicate the start of internal separation.
Any cut that reaches to the belt or ply cords, or any cut that
is large enough to grow in size and depth.
Any nail or puncturing object.
If any stone or object is held by a tread groove and is starting
to drill into the tread base, remove the object.
Proper tire inflation, toe-in adjustment, loads, and road speeds
are important factors governing tire mileage, steering ease and
maneuverability.

Form No. 3628504R1

Page 190 Printed in the United States of America
 SECTION 5 VEHICLE MAINTENANCE INSTRUCTIONS

Tires (cont.)
Loads (19mm) in circumference should not be mounted on the same
dual wheel assembly.

WARNING: Loading tires beyond their rated Mixing

capacity decreases tire life requiring more frequent
replacement of tires. Overloading creates an unsafe
condition that may result in sudden air loss from a
tire failure resulting in an accident that could cause
property damage, personal injury or death.
NOTE: Never mix bias and radial tires on this vehicle.
It is recommended for best overall performance that only radial
tires be used on this vehicle.
Never mix different tire sizes or constructions on the same axle.

NOTE: Your GAW / GVW rating is correct at the time of your

vehicle production, and reflects the exact rating of the tires
specified. When replacing tires be sure that the replacement tire
load rating (listed in pounds and kilograms on the tire sidewall)
is the same or higher than the tire that is removed. Failure to do
so will adversely affect maximum load carrying capacity. Tires
with the same size specification do not always have the same
load specification.
Matching
Dual Tires
Rotation
Rotation Is Always Advisable:
1. If front (steering) axle tires become irregularly worn,
move to rear position.
2. In a dual assembly, reverse the position of the tires if
one tire wears much faster than its mate.
3. On the drive axle, if heel and toe wear or alternate lug
wear occurs, rotating the tires from one end of the axle
to the other end of the axle may help even out this wear.

Dual tires should be matched using tires of equivalent size. Tires

which differ more than 1/4 inch (6mm) in diameter or 3/4 inch

Form No. 3628504R1

Printed in the United States of America Page 191
 SECTION 5 VEHICLE MAINTENANCE INSTRUCTIONS
Tires (cont.)
Rotation (cont.)
Rotation May Not Be Advisable:
Front (Steering) Axle Tires must be removed when tread
is worn to 4/32 inch (3mm) or less. Retread or rotate worn
tires to drive position. Retreaded tires are not recommended
to be used on steering axles.
Rear Axles Tires must be removed when tread is worn
to 2/32 inch (2mm).
If rib tire is used on front axle and lug or off-road type on
rear axle positions:
Front (Steering) Axle Replace tires at front wheels when
tread is worn to 4/32 inch (3mm) or less. These tires may
be moved to trailer positions.
Rear and Trailer Axles Tires must be removed when the
tread is worn to 2/32 inch (2mm) or less. Tires identified
with the word re-groovable molded on the sidewall can be
re-grooved. A minimum of 3/32 of under-tread must be left
at the bottom of the grooves.
Wheel And Tire Balancing
Out-of-round or out-of-balance wheels or tires can cause
vehicle vibration, bounce and shimmy. Replace damaged or
out-of-round wheels. Out-of-round tires and wheel assemblies
Form No. 3628504R1
Page 192 Printed in the United States of America
can be corrected by re-clocking the tire relative to the wheel.
The tire and wheel assembly should then be dynamically
balanced.
Wear
Radial tires can exhibit three types of normal wear patterns: 1)
Even, 2) Erosion, 3) Chamfer.
Even Wear is a sign that the tire is being properly used and
maintained.
Erosion Wear has also been called rolling wear, channel or river
wear. Erosion wear is found more often at free rolling tires. This
is an indication that the tire is being used in a slow wearing
operation. What happens is that the belt plies are held very rigid
and the tread is not allowed to distort as it passes through the
contact area. Wear will only occur at the edge of the tread. No
corrective action required. If erosion gets to be 1/16 inch (2mm)
or more, the tire may be rotated to a drive axle.
Chamfer or Shoulder Wear, with tires inflated properly, is a
normal tendency of most radial tire designs. If both inside and
outside shoulders are wearing evenly around the tire, no further
action is required. Over-inflation is not effective in correcting this
effect.
 SECTION 5 VEHICLE MAINTENANCE INSTRUCTIONS

Tires (cont.)
Wear (cont.)

Tires Irregular Wear Drive axle tires may be placed on the other end of the same
axle so that direction of rotation is reversed. This is often
If irregular wear is present, check the axle alignment, tire helpful if a heel and toe or alternate lug wear pattern has
pressure, wheel balancing, shock and suspension component developed.
condition, and wheel bearing end play.
Irregular wear can be minimized by:
This condition not only shortens tire life, but will adversely affect
the handling of your vehicle, which is dangerous. Using the right inflation pressure for the load being carried.

Rotating tires from one wheel position to another is a way often Maintaining proper front wheel alignment especially
used to even out many types of irregular wear or to avoid it toe-in to specifications.
altogether. Some of the more effective tire rotation programs Maintaining proper tire and wheel balance.
are:
Maintaining shock absorbers and suspension components.
Steer tires that have developed some type of irregular wear
pattern can be rotated to drive axles if rib tires are being
used on all wheel positions. Applying steer tires to a drive Use Of Tire Chains
position will often clean them and they can be moved back to
the steer axles or run out to re-tread stage on the rear axle. Refer to chain manufacturers recommendation for correct tire
chain usage, installation and removal.
Another rotation possibility for fleets with rib tires in all wheel
positions is to break in the new steer tires in the drive axle
positions, then move them to steer axles. This will wear
away tread rubber relatively quickly in the early life of a tire
when it is most likely to develop an unusual wear pattern.

Form No. 3628504R1

Printed in the United States of America Page 193
 SECTION 5 VEHICLE MAINTENANCE INSTRUCTIONS

Transmission Wheels
Check fluid level and shift linkage for proper operation.
General
Automatic Transmissions

For vehicles equipped with automatic transmissions, observe the

following: WARNING: To avoid personal injury or death,
Check operation of transmission neutral safety switch. Try always follow these instructions when mounting radial
to start the vehicle in all shift selector positions. The starter tires on wheels:
should ONLY operate when the shift selector is in Neutral or Only personnel that have had proper training and
Park (if equipped). experience should mount or remove tires from
Refer to the LUBRICATION, SEALERS, AND rims or wheels.
MAINTENANCE INTERVALS section for information Use only heavy-duty rims or approved rims for
on automatic transmission fluids and fluid and filter change radial tires. It may be necessary to contact your
intervals. wheel and rim distributor to determine if your rims
are approved for radial tires.
If a tube is to be used, make sure special radial tire
tubes are used because of the increased flexing of
the sidewalls on radial tires.
Never use anti-freeze, silicones, or petroleum
based lubricants when mounting radial tires. Only
an approved lubricant should be used as an aid
for mounting tires.
Always inflate tires in a safety cage.

Form No. 3628504R1

Page 194 Printed in the United States of America
 SECTION 5 VEHICLE MAINTENANCE INSTRUCTIONS

Wheels (cont.)
General (cont.)

WARNING: WARNING: When installing the tire and rim

Do not mix stud piloted wheels or fasteners
with hub piloted wheels or fasteners. Premature
wheel failure can result causing property damage,
personal injury, or death.
Do not mix foreign (not made in North America)
wheel mounting parts with domestic (made
in North America) parts. Many foreign wheel
components look similar but not exactly the same
as North American made. Mixing components
could cause wheel or fastener failures and result
in property damage, personal injury or death.
Do not change from aluminum wheels to steel
wheels or vice-versa without changing the
mounting hardware where required or, in some
cases with flange nut mounting systems, changing
the hub and stud assembly. Mixing components
could cause wheel or fastener failures and result
in property damage, personal injury or death.
assembly on disc - brake equipped axles, make sure
the tire valve stem clears the brake caliper. The
use of either an International valve stem retainer
or a tire manufacturers stem forming tool is the
only acceptable method of obtaining clearance when
necessary. Failure to obtain proper clearance may
result in rapid tire deflation and cause property
damage, personal injury, or death.
Wheel bearings should be inspected, lubricated and adjusted at
regular intervals. This is especially important if operating in deep
sand, mud, or water. Refer to the Lubrication service manual
section.
Grease Lubricated Front Wheel Bearings
When lubricating front axle wheel bearings, do not mix Lithium
based grease with synthetic grease. Refer to the line set ticket
for the type of grease installed at the factory.

Form No. 3628504R1

Printed in the United States of America Page 195
 SECTION 5 VEHICLE MAINTENANCE INSTRUCTIONS

Wheels (cont.)
Oil Lubricated Front Wheel Bearings
During normal vehicle duty cycle, the lube and air inside the
hub/wheel cavity expands and if not vented, causes pressure
build-up that could cause accelerated seal wear.
Currently there are two popular venting methods (a slit or small
hole in the rubber check vent or window) used on International
trucks to prevent pressure build-up.
As the air and oil expand, it is normal for a mist of oil to be
present on the outside of the hubcap around the slit or hole.
Over a period of time, if not wiped off, this film may collect dust
and appear unsightly. If the entire face and end of the hubcap
become wet with oil, further investigation should be conducted.
See Service Manual for procedure.
Normal Maintenance
The specified lube level for International clear window type
hubcaps is from the minimum line to + 5/16 inch above the
minimum line.
If the lube level should suddenly drop dramatically below the
minimum level, see the Service Manual for diagnostic procedure.
Installation, Tightening And Alignment
WARNING: Use only the same type and style
wheels and mounting hardware to replace original
parts. Failure to do so may result in an assembly,
which looks fine, but does not fit together properly.
This could cause wheel or fastener failures and result
in property damage, personal injury or death.

As previously noted, over a period of time, if not routinely

cleaned, a slight film of oil can collect dirt around the rubber fill
plug and face which could be perceived as a leak. Furthermore,
routine cleaning ensures that the lube level can be easily
observed through the clear window as intended. In a case
where the window is clean on the outside but discolored on the
inside from the lubricant used, its lube level may be checked by
inserting a finger through the rubber check vent hole.
When installing wheels, be certain that the threads on studs and
nuts are clean to permit correct torquing of nuts. the mounting
surfaces of rims, wheels, spacer rings and clamps must be free
of dirt, rust, lubricants or damage.
Use a wire brush to clean mounting contact surfaces. Do not
use lubricant on threads.
After rim or wheel has been properly tightened, it should be
checked for alignment. Rotate the wheel with a piece of chalk

Form No. 3628504R1

Page 196 Printed in the United States of America
 SECTION 5 VEHICLE MAINTENANCE INSTRUCTIONS

Wheels (cont.)
Installation, Tightening And Alignment (cont.)

attached to a steady, firm surface and placed to just barely clear
outside surface of tire bead seat. This procedure will point out
the high spot. Keep in mind, however, that a high spot does not
necessarily mean that lug nuts have been unevenly tightened.
This condition or misalignment could be caused by a bent wheel.
Checking the alignment of the wheel/rim installation is more
important on cast spoke rims since the rims can be drawn out
of alignment when improperly tightened. Use the following
installation procedures.
Cast Spoke Wheels
Tightening procedure for Cast Spoke Wheels:
1. Slide inner rear or front tire and rim assembly over the cast
spoke wheel and push it back into position against tapered
mounting surface. Be sure valve stem faces out and is
centered between two spokes.
2. Slide spacer ring over rear wheel. Check spacer ring for
concentricity by rotating spacer ring around cast spoke
wheel.
3. Slide the outside rear tire and rim assembly on the wheel,
making sure the valve stem faces inboard and is located in
same relative position as inner valve stem.
4. Assemble all rim clamps and nuts. Turn nuts on studs until
each nut is flush with end of stud.
5. Turn top nut 1 until it is snug.
6. Rotate wheel and rim until nut 2 is at top position and turn
nut until snug.
7. Rotate wheel and rim until nut 3 is at top position and turn
nut until snug.
8. Rotate wheel and rim until nuts 4, 5, and 6 are respectively
at top and turn these nuts until snug.
9. Repeat the sequence of tightening the nuts to torque value
listed in Torque Chart.
10. After operating the vehicle approximately 50 miles (80 km)
check the stud nuts for tightness in same sequence shown.
Once each week inspect and re-tighten wheel stud nuts.
Since the entire weight of tire and rim assembly is on top spoke,
the foregoing procedure (criss-cross sequence) will assure even
application of force at all points on the rim, keeping the rim in
proper alignment.

Form No. 3628504R1

Printed in the United States of America Page 197
 SECTION 5 VEHICLE MAINTENANCE INSTRUCTIONS

Wheels (cont.)
Installation, Tightening And Alignment (cont.)

Cast Spoke Wheels (cont.)

Disc Wheels with Ball Seat Nuts (Stud Piloted)
Tightening procedure for disc wheels with ball seat nuts (stud
piloted):
1. Slide inner rear or front tire and wheel in position over studs
and push back as far as possible. Use care to avoid damage
to threads on studs.
2. Install the outer wheel nut on front wheels and inner wheel
nut on rear dual wheels. Run nuts on studs until the nuts
start to contact the wheel. Rotate wheel a half turn to allow
parts to seat naturally.
3. Draw up stud nuts, alternately following the sequence
(criss-cross pattern) illustrated. Do not fully tighten the nuts
at this time. This procedure will allow a uniform seating of
nuts and insure the even face-to-face contact of wheel and
hub.
4. Continue tightening the nuts to the torque specifications in
the Torque Chart using the same alternating (criss-cross)
sequence shown.
5. Install the outer rear wheel and repeat the preceding
method. Be sure that both inner and outer tire valve stems
are accessible.
6. After operating the vehicle approximately 50 miles (80 km)
check the stud nuts for tightness. Some natural seating of
parts may be encountered and the torque on nuts will drop.
Retighten all nuts to specified torque.

Form No. 3628504R1

Page 198 Printed in the United States of America
 SECTION 5 VEHICLE MAINTENANCE INSTRUCTIONS

Wheels (cont.)
Installation, Tightening And Alignment (cont.)

Disc Wheels with Ball Seat Nuts (Stud Piloted) (cont.)

1. INNER WHEEL NUT (11/8 INCH O.D.) 6. WHEEL HUB

2. OUTER WHEEL NUT To check and tighten the inner wheel to proper torque, first
loosen the outer wheel nuts several turns. Then tighten the
3. WHEEL(S)
inner nuts and retighten the outer nuts.
4. BRAKE DRUM
To prevent losing the seating of the outer wheel when checking
5. WHEEL STUD (11/8 INCH FRONT) (3/4 INCH REAR) the inner wheel torque, first loosen alternate outer nuts. Then
tighten the inner nuts and retighten the outer nuts. Then loosen

Form No. 3628504R1

Printed in the United States of America Page 199
 SECTION 5 VEHICLE MAINTENANCE INSTRUCTIONS
Wheels (cont.)
Installation, Tightening And Alignment (cont.)
Disc Wheels with Ball Seat Nuts (Stud Piloted) (cont.)
the remaining outer nuts, tighten the inner nuts and retighten the
outer nuts.
Once each week inspect and retighten wheel stud nuts.
Disc Wheels With Flange Nuts (Hub Piloted)
NOTE: Before mounting wheel(s) ensure that outboard brake
drums, if equipped, remains seated on their pilots.
Tightening procedure for disc wheels with flange nuts (hub
piloted):
Form No. 3628504R1
Page 200 Printed in the United States of America
1. Slide inner rear or front tire and wheel in position over studs
and push back as far as possible. Use care so that the
threads on studs are not damaged.
2. Position outer rear tire and wheel in place over the studs
and push back as far as possible. Again, use care so that
the threads on studs are not damaged.
3. Run the nuts on the studs until nuts contact the wheel or
wheels. Rotate wheel assembly a half turn to permit parts
to seat.
4. Draw up nuts alternately following the (criss-cross)
sequence illustrated. Do not fully tighten nuts at this
time. This will allow uniform seating of nuts and assure
even face to face contact of wheel and hub.
5. Continue tightening the nuts to torque specifications in the
Torque Chart using the same alternating sequence shown.
6. After operating the vehicle approximately 50 miles (80 km)
check the stud nuts for tightness. Some natural seating of
parts may be encountered and the torque on nuts will drop.
Retighten all nuts to specified torque.
Once a week inspect and retighten wheel stud nuts.
 SECTION 5 VEHICLE MAINTENANCE INSTRUCTIONS

Wheels (cont.)
Installation, Tightening And Alignment (cont.)

Disc Wheels With Flange Nuts (Hub Piloted) (cont.)

1. FLANGE NUT Aluminum Rear Disc Wheels With Flange Nuts (Hub
Piloted)
2. WHEEL(S)
3. BRAKE DRUM Prior to re-installing rear aluminum hub-piloted wheels, clean
each wheel locator pad on the hub from all dirt, rust and foreign
4. WHEEL STUD (22MM) material. Apply a light coat of chassis grease, never seize or
5. WHEEL HUB disc brake corrosion control grease.

Form No. 3628504R1

Printed in the United States of America Page 201
 SECTION 5 VEHICLE MAINTENANCE INSTRUCTIONS

Wheels (cont.)
Installation, Tightening And Alignment (cont.)

Aluminum Rear Disc Wheels With Flange Nuts (Hub

Piloted) (cont.)

WARNING: Failure to follow these instructions

could result in property damage, personal injury or
death:

Always loosen rim clamps before complete removal of

nut from stud (cast spoke wheels). With loosened nuts
on stud, strike clamps with a heavy hammer and be
sure each clamp is loose.

Always deflate tires completely before removing locks

or side rings.

Always inflate tires in a safety cage.

Always use a clip-on air chuck with remote control

1. FLANGE NUT valve to inflate tires.
2. WHEEL(S)
Never strike cast spokes of wheel assembly when
3. BRAKE DRUM loosening rim clamps.
4. WHEEL STUD (22MM)
5. WHEEL HUB

Form No. 3628504R1

Page 202 Printed in the United States of America
 SECTION 5 VEHICLE MAINTENANCE INSTRUCTIONS

Wheels (cont.)
Installation, Tightening And Alignment (cont.)

Aluminum Rear Disc Wheels With Flange Nuts (Hub

Piloted) (cont.)

WARNING: Failure to follow these instructions
could result in property damage, personal injury or
death:
Never mix rim side rings or lock rings of different types
or sizes.
Never use cracked, bent or badly rusted parts.
WARNING: When installing the tire and rim
assembly on disc - brake equipped axles, make sure
the tire valve stem clears the brake caliper. The
use of either an International valve stem retainer
or a tire manufacturers stem forming tool is the
only acceptable method of obtaining clearance when
necessary.

Never re-inflate flat tires on vehicle. Use the spare.

Proper Torque
Never add air until each side or lock ring is fully seated.
It is important to tighten and maintain wheel and rim mounting
nuts to the proper torque. Loose nuts or overtightened nuts can
Never hammer side or lock ring on a partially or fully
lead to premature wear and possible failure of the wheel, rim
inflated tire.
and/or mounting hardware. See torque chart at the end of the
section.

Changing Wheel Types

Consult your International dealer or wheel/rim distributor

before attempting any wheel or fastener changes.

Form No. 3628504R1

Printed in the United States of America Page 203
 SECTION 5 VEHICLE MAINTENANCE INSTRUCTIONS

Tire And Rim Combinations

Tubeless
Tire Size Rim Width
9R22.5 6.75, 7.50
10R22.5 6.75, 7.50
11R22.5 7.50, 8.25
12R22.5 8.25, 9.00
16.5-22.5 12.25, 13.00
18-22.5 13.00, 14.00
225/70R19.5 6.75
235/80R22.5 6.75, 7.50
245/70R19.5 6.75, 7.50
255/70R22.5 7.50, 8.25
265/70R19.5 6.75, 7.50, 8.25
275/80R22.5 7.50, 8.25
285/75R24.5 8.25
295/75R22.5 8.25, 9.00
315/80R22.5 9.00
385/65R22.5 11.75, 12.25
425/65R22.5 12.25, 13.00
445/65R22.5 13.00, 14.00

Form No. 3628504R1

Page 204 Printed in the United States of America
 SECTION 5 VEHICLE MAINTENANCE INSTRUCTIONS

Torque Specifications

Disc Wheel Torque Chart

DISC WHEELS
Size Nut Mounting Torque
lbf-ft Nm
11/16 Inch Flange 350-400 475543
22mm Flange: Motor Wheel - 37.5mm Across Flats 450-500 610-678
22mm Flange: International/Budd - 33mm Across Flats 450-500 610-678
Ball Seat (Conical Nut)
3/4 Inch Standard Square Cap: 13/16 inch Across Flats 450-500 610-678
3/4 Inch Standard Hex Cap: 1-1/2 inches Across Flats 450-500 610-678
1-1/8 Inches Standard Hex Cap: 1-3/4 inches Across Flats 450-500 610-678
15/16 Inch Heavy Duty Square Cap: 15/16 inch Across Flats 750-900 1017-1221
1-5/16 Inches Heavy Duty Cap: 1-3/4 inches Across Flats 750-900 1017-1221
Cast Wheels
5/8 Inch Rim Clamp Nut 160175 217237
3/4 Inch Rim Clamp Nut 200-240 271-325
NOTE: Do not use lubrication on dry threads. Where excessive corrosion exists, a light coat of lubricant on first three threads of stud
on bolt is permitted. Keep lubricant away from:

hex nut and rim clamp contact surfaces;

flange nut washer surface and flat on disc wheel.

Form No. 3628504R1

Printed in the United States of America Page 205
 SECTION 5 VEHICLE MAINTENANCE INSTRUCTIONS

Torque Specifications (cont.)

U-Bolt Nut Torque Chart

U-Bolt Diameter (Nominal) Torque

lbf ft N.m
Inch Flanged Lock Nut 260 300 353 407
7/8 Inch Hex Head with Washer (14ADN, 14ADP, axles) 260 300 353 407
14AGA, and 14AGE axles 260 300 353 407
1 Inch Hex Head with Washer 325 400 441 543

Spring U-Bolt Checks

Check U-Bolt Nuts and re-torque every 36,000 miles (57 936 km) after initial 1,000 mile re-torque.

Fuse Charts

A computer generated listing for Fuse, Circuit Breaker and Relay Location is found inside the glove box for easy access.

Form No. 3628504R1

Page 206 Printed in the United States of America
 SECTION 5 VEHICLE MAINTENANCE INSTRUCTIONS

Fuse Charts (cont.)

Power Distribution Center Fuse and Circuit Breaker Layout

Pro-Sleeper Fuse Index

Fuse and Circuit Breakers for the Pro Sleeper are located in the
left sleeper storage compartment.

Form No. 3628504R1

Printed in the United States of America Page 207
 SECTION 5 VEHICLE MAINTENANCE INSTRUCTIONS

Fuse Charts (cont.)

Pro-Sleeper Fuse Index (cont.)

Form No. 3628504R1

Page 208 Printed in the United States of America
 SECTION 6 LUBRICATION, SEALERS AND MAINTENANCE INTERVALS
Description
New vehicles are lubricated at the factory. After the vehicle
is placed in operation, regular lubrication intervals, based on
the type of service and road conditions, should be established.
Thorough lubrication at the specified intervals will improve the
Low Cost of Ownership (LCO) and will reduce overall operating
expense.
Choosing an engine oil of correct quality and proper viscosity,
and following recommended oil change intervals are essential
to Low Cost of Ownership. Using the recommended oil change
intervals will result in dependable engine starting, performance,
and long term durability.
The interval between lubrication periods, oil changes, etc.
depends entirely upon operating conditions. The loads carried,
speed, road and weather conditions all contribute to the
frequency of lubrication periods.
In some types of operation, and where operating conditions
are extremely severe (such as in deep water, mud or unusually
dusty conditions), the vehicle may require lubrication after every
twenty-four (24) hours of operation.
Only lubricants of superior quality, such as Fleetrite lubricants,
should be used. The use of inferior products will reduce the
service life of the vehicle or result in failure of its components.
International recommends the use of Fleetrite lubricants.
The lubrication specifications refer only to the viscosity (SAE)
and type to be applied. The viscosity numbers have been
Form No. 3628504R1
Printed in the United States of America
adopted by the Society of Automotive Engineers to classify
lubricants according to viscosity and do not cover any other
properties.
The lubrication intervals specified should be performed at
whatever interval occurs first, whether it is months, miles
(kilometers) or hours.
Engine Oil Specifications
Engine Oil
Keep oil level as near the high level mark as possible. Never
operate an engine with the oil level above the FULL or
below the LOW (add) level mark on the dipstick.
High oil level may increase oil temperature and lower fuel
economy due to oil interference with crankcase rotation.
When checking the oil level, the dipstick must be withdrawn and
wiped clean, then inserted all the way and withdrawn again for a
true reading.
Never check the oil level with the engine running or immediately
after engine shutdown as an inaccurate reading will be obtained.
International, Caterpillar, and Cummins Engines
Refer to the manufacturers specific engine manual for oil type,
oil change intervals, and filter change intervals.
Page 209
 SECTION 6 LUBRICATION, SEALERS AND MAINTENANCE INTERVALS

Engine Oil Specifications (cont.)

Crankcase Oil Specifications An important property of a grease is its dropping point, the
temperature where it changes from a semi-solid state to a liquid
For specific information on most commercial oil brand names, state. However, the operating temperature of a specific grease
write for the booklet entitled: is not determined solely by the dropping point. Other properties
"LUBRICATING OIL DATA BOOK FOR HEAVY-DUTY such as resistance to change in consistency and chemical
AUTOMOTIVE AND INDUSTRIAL ENGINES" deterioration at high temperatures must be considered.

Engine Manufacturers Association, 111 E. Wacker Drive, NOTE: Grease lubricants are classified by the National
Chicago, Illinois 60601; (312) 644-6610 Lubricating Grease Institute (NLGI) and given grade numbers
based on consistency of the grease. Recently, the NLGI
developed a new specification and classification for automotive
Grease Specifications greases based on application. The NLGI issues licensed
symbols (see the Figure below) designating the application for
Grease lubricants contain three substances: oil, a thickener which the grease is approved.
base and additives.
The oil lubricates, the thickener (base) holds the oil in place
and releases it to provide the necessary lubrication; and the
additives enhance the characteristics of the oil and thickener.
Extreme Pressure (EP) additives help prevent scoring, galling
and welding of moving parts.
The thickener may be simple or complex soap (lithium, calcium,
aluminum, etc.), organic (polyurea) or inorganic (clay).
When mixing different greases, the possibility of incompatibility
exists and should be considered. Mixing incompatible greases
may reduce the lubricating ability of greases. International
vehicles are filled with a lithium grease at the factory.

Form No. 3628504R1

Page 210 Printed in the United States of America
 SECTION 6 LUBRICATION, SEALERS AND MAINTENANCE INTERVALS

Lubrication Interval Tables

The following tables are organized by the Master Service
Manual Service Groups so that the Service Group (section of
the Manual) can be easily accessed when more information is
desired to perform any of the following lubrication services. The
following twelve Service Groups require lubrication: 02: Front
Axles, 03: Suspension, 04: Brakes, 05: Steering, 06: Drive
Shafts, 08: Electrical, 09: Front End, 11: Clutch, 12: Engine,
13: Transmission, 14: Rear Axles, 16: Cab.
Please read the SPECIAL INSTRUCTIONS referenced in
the LUBE TYPE/LUBE NOTES column of the lubrication
tables. The reference letters are defined at the end of the
LUBRICATION INTERVAL TABLES section in this SPECIAL
INSTRUCTIONS section.

Form No. 3628504R1

Printed in the United States of America Page 211
 SECTION 6 LUBRICATION, SEALERS AND MAINTENANCE INTERVALS

Lubrication Interval Tables (cont.)

Front Axle

02 FRONT AXLE: TABLE 021: EATON-SPICER NON DRIVE AXLE LUBE INTERVALS
SERVICE
1-1. WHEEL BEARINGS: OIL TYPE:
CHECK OIL LEVEL
1-2. WHEEL BEARINGS: OIL TYPE:
CHANGE OIL
1-3. WHEEL BEARINGS: REPACK
1-4. TIE ROD ENDS
1-5. DRAG LINKS: 9200, 9400, 9900
MODELS
1-6. DRAG LINKS
1-7. KINGPINS AND BUSHINGS
1-8. BALL STUDS ON STEERING ARM
LUBE TYPE / LUBE INTERVALS: PERFORM THE SERVICE AT WHICHEVER
NOTES INTERVAL COMES FIRST WHEN GIVEN A CHOICE
BELOW.
C 4,000 MILES or 6,500 KILOMETERS
C 100,000 MILES or 160,000 KILOMETERS or 12 MONTHS
A-15 100,000 MILES or 160,000 KILOMETERS or 12 MONTHS
A-15 100,000 MILES or 160,000 KILOMETERS or 12 MONTHS
Q, A-15 18,000 MILES or 29,000 KILOMETERS or 5 MONTHS
Q, A-15 6,000 MILES or 9,500 KILOMETERS or 1 MONTH
A-15 100,000 MILES or 160,000 KILOMETERS or 12 MONTHS
A-15 50,000 MILES or 80,000 KILOMETERS or 12 MONTHS

Form No. 3628504R1

Page 212 Printed in the United States of America
 SECTION 6 LUBRICATION, SEALERS AND MAINTENANCE INTERVALS

Lubrication Interval Tables (cont.)

Front Axle (cont.)

02 FRONT AXLE: TABLE 022: FABCO DRIVE AXLE LUBE INTERVALS

SERVICE LUBE TYPE / LUBE INTERVALS: PERFORM THE SERVICE AT WHICHEVER
NOTES INTERVAL COMES FIRST WHEN GIVEN A CHOICE
BELOW.
2-1. WHEEL BEARINGS: REPACK A-15 AT EACH BRAKE RELINE OR ANNUALLY.
2-2. U-JOINTS: GREASE R, NOT APPLICABLE SEALED AT THE FACTORY, NO LUBE REQUIRED
THROUGHOUT LIFE OF PART
2-3. KINGPIN BEARINGS: GREASE A-15 AT EACH CHASSIS LUBE or 1,000 MILES or 1,600
KILOMETERS
2-4. DIFFERENTIAL CARRIERS: SEE NOTE 4 AT END 10,000 MILES or 16,000 KILOMETERS
CHANGE FLUID OF THIS TABLE.
2-5. STEERING TIE ROD ENDS: A-15 AT EACH CHASSIS LUBE OR AT EVERY 1,000 MILES
GREASE OR 1,600 KILOMETERS
2-6. SPINDLE INNER BEARINGS: A-15 16,000 MILES or 25,600 KILOMETERS or 12 MONTHS
SDA-1200 ONLY, PACK GREASE
NOTE 4: RECOMMENDED GEAR OIL

ABOVE 32 deg F (0 deg C) use MIL-L-2105B, SAE 140, MIL-L-2105C or 80W-140.

BELOW 32 deg F (0 deg C) use MIL-L-2105B, SAE 90, MIL-L-2105C or 80W-90

Form No. 3628504R1

Printed in the United States of America Page 213
 SECTION 6 LUBRICATION, SEALERS AND MAINTENANCE INTERVALS

Lubrication Interval Tables (cont.)

Front Axle (cont.)

02 FRONT AXLE: TABLE 024: MERITOR DRIVE AXLE LUBE INTERVALS

NOTE: BREAK-IN CHANGE HAS BEEN ELIMINATED
SERVICE
4-1. TIE ROD ENDS
4-2. STEERING KNUCKLES, U-JOINTS
AND OUTER DRIVE SHAFT SEALS
4-3. CHECK OIL LEVEL
4-4. CHANGE PETROLEUM OIL:
REGULAR HIGHWAY
4-5. CHANGE PETROLEUM OIL: HEAVY
DUTY ON AND OFF HIGHWAY
4-6. CHANGE SYNTHETIC OIL: HEAVY
DUTY ON HIGHWAY
4-7. CHANGE SYNTHETIC OIL: HEAVY
DUTY ON AND OFF HIGHWAY
LUBE TYPE / LUBE INTERVALS: PERFORM THE SERVICE AT WHICHEVER
NOTES INTERVAL COMES FIRST WHEN GIVEN A CHOICE
BELOW.
A-15 3,000 MILES or 4,800 KILOMETERS
M 18,000 MILES or 29,000 KILOMETERS or 5 MONTHS
C 5,000 MILES or 8,000 KILOMETERS or 200 HOURS
C 100,000 MILES or 160,000 KILOMETERS or ANNUALLY
C 25,000 MILES or 40,000 KILOMETERS or ANNUALLY
C 250,000 MILES or 400,000 KILOMETERS or 3 YEARS
C 50,000 MILES or 80,000 KILOMETERS or 200 HOURS

Form No. 3628504R1

Page 214 Printed in the United States of America
 SECTION 6 LUBRICATION, SEALERS AND MAINTENANCE INTERVALS

Lubrication Interval Tables (cont.)

Front Axle (cont.)

02 FRONT AXLE: TABLE 025: MERITOR NON DRIVE AXLE LUBE INTERVALS
SERVICE
5-1. KINGPINS AND BUSHINGS (12,000
lb & 13,000 lb CAPACITY)
5-2. BALL STUDS ON STEERING ARM,
TIE ROD ENDS AND DRAG LINK (12,000
lb & 13,000 lb CAPACITY)
5-3. KINGPINS AND BUSHINGS (14,000
- 18,000 lb CAPACITY)
5-4. BALL STUDS ON STEERING ARM,
TIE ROD ENDS AND DRAG LINK (14,000
- 18,000 lb CAPACITY)
5-5. WHEEL BEARINGS: ON HIGHWAY:
GREASE TYPE, REPACK
5-6. WHEEL BEARINGS: ON/OFF
HIGHWAY: GREASE TYPE, REPACK
5-7. WHEEL BEARINGS: OIL TYPE,
CHECK OIL LEVEL
5-8. WHEEL BEARINGS: OIL TYPE: ON
HIGHWAY, CHANGE OIL
LUBE TYPE / LUBE INTERVALS: PERFORM THE SERVICE AT WHICHEVER
NOTES INTERVAL COMES FIRST WHEN GIVEN A CHOICE
BELOW.
A-15 100,000 MILES or 160,000 KILOMETERS or 12 MONTHS
A-15 100,000 MILES or 160,000 KILOMETERS or 12 MONTHS
A-15 50,000 MILES or 80,000 KILOMETERS or 12 MONTHS
A-15 50,000 MILES or 80,000 KILOMETERS or 12 MONTHS
A-15 AT SEAL REPLACEMENT or AT BRAKE RELINING or
30,000 MILES or 48,000 KILOMETERS
A-15 AT SEAL REPLACEMENT or AT BRAKE RELINING or 6
MONTHS
C 1,000 MILES or 1,600 KILOMETERS
C AT SEAL REPLACEMENT or AT BRAKE RELINE or
100,000 MILES or 160,000 KILOMETERS or 12 MONTHS

Form No. 3628504R1

Printed in the United States of America Page 215
 SECTION 6 LUBRICATION, SEALERS AND MAINTENANCE INTERVALS

Lubrication Interval Tables (cont.)

Front Axle (cont.)

02 FRONT AXLE: TABLE 025: MERITOR NON DRIVE AXLE LUBE INTERVALS (cont.)
SERVICE LUBE TYPE / LUBE INTERVALS: PERFORM THE SERVICE AT WHICHEVER
NOTES INTERVAL COMES FIRST WHEN GIVEN A CHOICE
BELOW.
5-9. WHEEL BEARINGS: OIL TYPE: C AT SEAL REPLACEMENT or AT BRAKE RELINE or 12
ON/OFF HIGHWAY: OIL CHANGE MONTHS
5-10. UNITIZED WHEEL HUB: INSPECT S 200,000 MILES or 320,000 KILOMETERS or 24 MONTHS
FOR END PLAY

Springs

03 SUSPENSION: TABLE 031: SUSPENSION LUBE INTERVALS

SERVICE LUBE TYPE / LUBE NOTES
SPECIAL INTERVAL NOTE: Make the suspension lubrication intervals for the following maintenance the same as
your vehicles engine oil change intervals.
1-1. Spring Pins A-15
1-2. Walking Beam Bronze Center Bushing A-15

Form No. 3628504R1

Page 216 Printed in the United States of America
 SECTION 6 LUBRICATION, SEALERS AND MAINTENANCE INTERVALS

Lubrication Interval Tables (cont.)

Brakes

04 BRAKES: TABLE 041: BRAKE LUBE INTERVALS

SERVICE LUBE TYPE / LUBE AS REQD AT OVER INTERVALS: PERFORM THE
NOTES HAUL SERVICE AT WHICHEVER
INTERVAL COMES FIRST.
MILES (KILOMETERS) X 1,000 6(9.5) 18 (29) 24 (38)
MONTHS 1 5 5
1-1. Brake Pedal Pivot A-14 X
1-2. Parking Brake Relay Lever A-15 X
1-3. Parking Brake Linkage A-14 X
1-4. Brake Camshafts and O, A-15 X
Manual Slack Adjusters
1-5. Brake Pedal to Brake Valve A-14 X
Pivot
1-6. Brake Automatic Slack O, A-15 X
Adjusters

Form No. 3628504R1

Printed in the United States of America Page 217
 SECTION 6 LUBRICATION, SEALERS AND MAINTENANCE INTERVALS

Lubrication Interval Tables (cont.)

Steering

05 STEERING: TABLE 051: STEERING LUBE INTERVALS

SERVICE LUBE TYPE / INTERVALS: PERFORM THE SERVICE AT WHICHEVER INTERVAL COMES FIRST
LUBE NOTES WHEN GIVEN A CHOICE BELOW.
MILES (KILOMETERS) X 1,000 6 (9.5) 10 (16) 18 (29) 50 (80) 100 (160) 300 (480) 500 (800)
MONTHS 1 5 6 12
1-1. POWER STEERING, CHECK D, E X
PUMP FLUID LEVEL
1-2. POWER STEERING, SHEPPARD D, E X
AND ROSS TAS, CHANGE FLUID
IN RESERVOIR FOR (SEVERE
OFF-HIGHWAY APPLICATIONS)
1-3. POWER STEERING, SHEPPARD D, E X
AND ROSS TAS, CHANGE FLUID IN
RESERVOIR (ON HIGHWAY)
1-4. POWER STEERING, ROSS D, E X
TAS AND SHEPPARD, (SEVERE
OFF-HIGHWAY APPLICATIONS),
CHANGE FILTER IN RESERVOIR
1-5. POWER STEERING, ROSS TAS D, E X
AND SHEPPARD, CHANGE FILTER IN
RESERVOIR (ON HIGHWAY)

Form No. 3628504R1

Page 218 Printed in the United States of America
 SECTION 6 LUBRICATION, SEALERS AND MAINTENANCE INTERVALS

Lubrication Interval Tables (cont.)

Steering (cont.)

05 STEERING: TABLE 051: STEERING LUBE INTERVALS (cont.)

SERVICE LUBE TYPE / INTERVALS: PERFORM THE SERVICE AT WHICHEVER INTERVAL COMES FIRST
LUBE NOTES WHEN GIVEN A CHOICE BELOW.
MILES (KILOMETERS) X 1,000 6 (9.5) 10 (16) 18 (29) 50 (80) 100 (160) 300 (480) 500 (800)
MONTHS 1 5 6 12
1-6. STEERING GEAR INPUT SHAFT A-15 X
BEARING CAP: SHEPPARD
1-8. OUTPUT SHAFT SEAL: ROSS L X
TAS
1-9. U-JOINTS, SLIP JOINT, A-14 X
STEERING COLUMN

Form No. 3628504R1

Printed in the United States of America Page 219
 SECTION 6 LUBRICATION, SEALERS AND MAINTENANCE INTERVALS

Drive Shaft

06 DRIVE SHAFT: TABLE 061: DRIVE SHAFT LUBE INTERVALS

SERVICE
1-1. ON HIGHWAY DRIVE SHAFT SLIP
JOINT
1-2. ON HIGHWAY DRIVE SHAFT
U-JOINT
1-3. OFF HIGHWAY DRIVE SHAFT SLIP
JOINT
1-4. OFF HIGHWAY DRIVE SHAFT
U-JOINT
1-5. SPL XS DRIVE SHAFT (ON
HIGHWAY ONLY) SLIP JOINT
1-6. SPL XS DRIVE SHAFT (ON
HIGHWAY ONLY) U-JOINT
LUBE TYPE / LUBE NOTES INTERVALS: PERFORM THE SERVICE AT
WHICHEVER INTERVAL COMES FIRST.
R 10,000 MILES (16,000 KILOMETERS)
or 3 MONTHS
R 10,000 MILES (16,000 KILOMETERS)
or 3 MONTHS
R 5,000 MILES (8,000 KILOMETERS)
or 1 MONTH
R 5,000 MILES (8,000 KILOMETERS)
or 1 MONTH
PERMANENTLY LUBRICATED FOR UNIT LIFE
R 100,000 MILES (160,000 KILOMETERS)
or 6 MONTHS

Form No. 3628504R1

Page 220 Printed in the United States of America
 SECTION 6 LUBRICATION, SEALERS AND MAINTENANCE INTERVALS

Front End Sheet Metal

09 FRONT END: TABLE 091: FRONT END LUBE INTERVALS

SERVICE LUBE TYPE / LUBE NOTES INTERVALS: PERFORM THE
SERVICE AT WHICHEVER
INTERVAL COMES FIRST.
MILES (KILOMETERS) X 1,000 6(9.5)
MONTHS 1
1-1. HOOD LINKAGE A-15 X
1-2. HOOD TILT LINKAGE A-15 X

Clutch

11 CLUTCH: TABLE 111: CLUTCH LUBE INTERVALS

SERVICE LUBE TYPE / LUBE NOTES INTERVALS: PERFORM THE
SERVICE AT WHICHEVER INTERVAL
COMES FIRST.
1-1. CLUTCH PEDAL LINKAGE A-14 6,000 MILES (9,500 KILOMETERS)
or 1 MONTH
1-2. CLUTCH RELAY AND RELEASE FORK A-15 6,000 MILES (9,500 KILOMETERS)
SHAFT (MERITOR) or 1 MONTH
1-3. CLUTCH RELEASE SLEEVE BEARING, A-15 1 MONTH
FORK (MERITOR)

Form No. 3628504R1

Printed in the United States of America Page 221
 SECTION 6 LUBRICATION, SEALERS AND MAINTENANCE INTERVALS

Clutch (cont.)

11 CLUTCH: TABLE 111: CLUTCH LUBE INTERVALS (cont.)

SERVICE LUBE TYPE / LUBE NOTES INTERVALS: PERFORM THE
SERVICE AT WHICHEVER INTERVAL
COMES FIRST.
1-4. ON HIGHWAY CLUTCH RELAY AND A-15 25,000 MILES (40,000 KILOMETERS)
RELEASE FORK SHAFT (EATON SOLO) or 1 MONTH
1-5. ON HIGHWAY CLUTCH RELEASE SLEEVE A-15 25,000 MILES (40,000 KILOMETERS)
BEARING, FORK (EATON SOLO) or 1 MONTH
1-6. ON HIGHWAY CLUTCH RELAY AND A-15 20,000 MILES (32,000 KILOMETERS)
RELEASE FORK SHAFT (EATON EASY PEDAL) or 1 MONTH
1-7. ON HIGHWAY CLUTCH RELEASE SLEEVE A-15 20,000 MILES (32,000 KILOMETERS)
BEARING, FORK (EATON EASY PEDAL) or 1 MONTH
1-8. ON HIGHWAY CLUTCH RELEASE SLEEVE A-15 50,000 MILES (80,000 KILOMETERS)
BEARING, FORK (EATON SOLO EXTENDED
LUBE)
1-9. OFF HIGHWAY CLUTCH RELAY AND A-15 250 HOURS or 1 MONTH
RELEASE FORK SHAFT (EATON EASY PEDAL
AND SOLO)
1-10. OFF HIGHWAY CLUTCH RELEASE A-15 250 HOURS or 1 MONTH
SLEEVE BEARING, FORK (EATON EASY PEDAL
AND SOLO)

Form No. 3628504R1

Page 222 Printed in the United States of America
 SECTION 6 LUBRICATION, SEALERS AND MAINTENANCE INTERVALS

Engine

12 ENGINE: TABLE 121: ENGINE LUBE INTERVALS

SERVICE
1-1. RADIATOR SHUTTERS: LUBE
SHUTTER VANE BEARINGS ON
AUTOMATIC SHUTTERS
LUBE TYPE / LUBE NOTES INTERVALS: PERFORM THE SERVICE
AT WHICHEVER INTERVAL COMES
FIRST.
A-14, CHECK/ LUBE SHUTTERS ON 24,000 MILES
VEHICLES BEING RETURNED TO
38,000 KILOMETERS
SERVICE FROM STORAGE.
900 HOURS

12 MONTHS
1-2. ENGINE LUBE INTERVALS
REFER TO THE ENGINE MANUAL THAT CAME WITH THE VEHICLE.
1-3. COOLING SYSTEM FILTERS

Transmission

13 TRANSMISSION: TABLE 132: ALLISON AUTOMATIC TRANSMISSION LUBE INTERVALS

SERVICE LUBE TYPE / LUBE NOTES
2-1. TRANSMISSION LUBE K, REFER TO SEPARATE TRANSMISSION OPERATORS MANUAL THAT
INTERVALS CAME WITH THE VEHICLE.

Form No. 3628504R1

Printed in the United States of America Page 223
 SECTION 6 LUBRICATION, SEALERS AND MAINTENANCE INTERVALS

Transmission (cont.)

13 TRANSMISSION: TABLE 133: FABCO TRANSFER CASE LUBE INTERVALS

SERVICE LUBE TYPE / LUBE INTERVALS: PERFORM THE SERVICE AT WHICHEVER
NOTES INTERVAL COMES FIRST WHEN GIVEN A CHOICE BELOW.
4-1. G 1,000 MILES or 1,600 KILOMETERS

CHECK FLUID LEVEL

4-2. G 3,000 MILES or 4,800 KILOMETERS

TRANSFER CASE: BREAK-IN DRAIN,

PETROLEUM OIL
4-3. CHANGE PETROLEUM OIL G 10,000 MILES or 16,000 KILOMETERS

13 TRANSMISSION: TABLE 134: INTERNATIONAL-SPICER MANUAL TRANSMISSION LUBE INTERVALS

SERVICE
5-1. CHECK FLUID LEVEL
5-2. BREAK-IN CHANGE: PETROLEUM
OIL ONLY
5-3. PETROLEUM CHANGE
5-4. SYNTHETIC OIL CHANGE
LUBE TYPE / LUBE NOTES INTERVALS: PERFORM THE SERVICE AT
WHICHEVER INTERVAL COMES FIRST.
J 5,000 MILES or 8,000 KILOMETERS or 1
MONTH
J 5,000 MILES or 8,000 KILOMETERS
J 100,000 MILES or 160,000 KILOMETERS
J 250,000 MILES or 400,000 KILOMETERS or
36 MONTHS

Form No. 3628504R1

Page 224 Printed in the United States of America
 SECTION 6 LUBRICATION, SEALERS AND MAINTENANCE INTERVALS

Transmission (cont.)

13 TRANSMISSION: TABLE 135: MERITOR MANUAL TRANSMISSION LUBE INTERVALS

SERVICE
6-1. CHECK FLUID LEVEL
6-2. BREAK-IN PETROLEUM OIL
CHANGE
6-3. PETROLEUM OIL CHANGE
6-4. SYNTHETIC OIL CHANGE
LUBE TYPE / LUBE NOTES INTERVALS: PERFORM THE SERVICE AT
WHICHEVER INTERVAL COMES FIRST.
I 10,000 MILES or 16,000 KILOMETERS or 1
MONTH
I 5,000 MILES or 8,000 KILOMETERS
I 50,000 MILES or 80,000 KILOMETERS
I 250,000 MILES or 400,000 KILOMETERS or
36 MONTHS

13 TRANSMISSION: TABLE 136: MERITOR FREEDOMLINE

TRANSMISSION LUBE INTERVALS
SERVICE LUBE TYPE / INTERVALS
LUBE NOTES
6-5. I 500,000 MILES
SYNTHETIC
800,000 KILOMETERS
OIL CHANGE

Form No. 3628504R1

Printed in the United States of America Page 225
 SECTION 6 LUBRICATION, SEALERS AND MAINTENANCE INTERVALS

Transmission (cont.)

13 TRANSMISSION: TABLE 137: FULLER AUXILIARY TRANSMISSION LUBE INTERVALS

SERVICE LUBE TYPE / LUBE NOTES INTERVALS
7-1. ON HIGHWAY CHECK FLUID H 1,000 MILES or 1,600 KILOMETERS
LEVEL
7-2. OFF HIGHWAY CHECK FLUID H 40 HOURS
LEVEL
7-3.. ON HIGHWAY BREAK-IN H 3,000 MILES or 4,800 KILOMETERS
CHANGE: PETROLEUM OIL
7-4. OFF HIGHWAY BREAK-IN H 40 HOURS
CHANGE: PETROLEUM OIL
7-5. ON HIGHWAY CHANGE H 25,000 MILES or 40,000 KILOMETERS
PETROLEUM OIL
7-6. OFF HIGHWAY CHANGE H 1,000 HOURS
PETROLEUM OIL

13 TRANSMISSION: TABLE 137: FULLER TRANSMISSION LUBE INTERVALS

SERVICE LUBE TYPE / LUBE NOTES INTERVALS
7-1. ON HIGHWAY CHECK FLUID H 10,000 MILES or 16,000 KILOMETERS
LEVEL, PETROLEUM AND SYNTHETIC
OIL
7-2. OFF HIGHWAY CHECK FLUID H 30 HOURS
LEVEL, PETROLEUM AND SYNTHETIC
OIL

Form No. 3628504R1

Page 226 Printed in the United States of America
 SECTION 6 LUBRICATION, SEALERS AND MAINTENANCE INTERVALS

Transmission (cont.)

13 TRANSMISSION: TABLE 137: FULLER TRANSMISSION LUBE INTERVALS (cont.)

SERVICE LUBE TYPE / LUBE NOTES INTERVALS
7-3. ON HIGHWAY BREAK-IN CHANGE: H 3,000 MILES or 4,800 KILOMETERS
PETROLEUM OIL
7-4. OFF HIGHWAY BREAK-IN H 30 HOURS
CHANGE: PETROLEUM OIL
7-5. OFF HIGHWAY BREAK-IN H 3,000 MILES or 4,800 KILOMETERS
CHANGE: SYNTHETIC OIL
7-6. ON HIGHWAY CHANGE H 50,000 MILES or 80,000 KILOMETERS
PETROLEUM OIL
7-7. ON HIGHWAY CHANGE H 250,000 MILES or 400,000 KILOMETERS
SYNTHETIC OIL
7-8. OFF HIGHWAY CHANGE H 1,000 HOURS
PETROLEUM AND SYNTHETIC OIL
7-9. SEVERE OFF HIGHWAY CHANGE H 500 HOURS
PETROLEUM AND SYNTHETIC OIL

Form No. 3628504R1

Printed in the United States of America Page 227
 SECTION 6 LUBRICATION, SEALERS AND MAINTENANCE INTERVALS

Rear Axle

14 REAR AXLE: TABLE 141: EATONSPICER REAR AXLE LUBE INTERVALS

NOTE: THE FOLLOWING INTERVALS APPLY TO DIFFERENTIALS AND WHEEL ENDS
SERVICE
1-1. TWO SPEED AXLE
(ELECTRONIC): LUBE
1-2. CHECK OIL LEVEL
1-3. BREAK-IN CHANGE FOR
PETROLEUM OIL
1-4. ON HIGHWAY: PETROLEUM OIL
1-5. ON-OFF HIGHWAY SEVERE
SERVICE: PETROLEUM OIL
1-6. ON HIGHWAY: SYNTHETIC OIL
1-7. ON-OFF HIGHWAY SEVERE
SERVICE: SYNTHETIC OIL
LUBE TYPE / LUBE INTERVALS: PERFORM THE SERVICE AT WHICHEVER
NOTES INTERVAL COMES FIRST WHEN GIVEN A CHOICE BELOW.
N AT OVER HAUL
C 3,000 MILES 4,800 KILOMETERS
C 3,000 MILES 4,800 KILOMETERS
C 120,000 MILES (192,000 KILOMETERS) OR 6 MONTHS
C 60,000 MILES (96,000 KILOMETERS) OR 12 MONTHS
C 250,000 MILES (400,000 KILOMETERS) OR 36 MONTHS
C 120,000 MILES (192,000 KILOMETERS) OR 12 MONTHS

Form No. 3628504R1

Page 228 Printed in the United States of America
 SECTION 6 LUBRICATION, SEALERS AND MAINTENANCE INTERVALS

Rear Axle (cont.)

14 REAR AXLE: TABLE 143: MERITOR REAR AXLE LUBE INTERVALS

NOTE: THE FOLLOWING INTERVALS APPLY TO DIFFERENTIALS AND WHEEL ENDS.

NOTE: BREAK-IN CHANGE HAS BEEN ELIMINATED

SERVICE
ON HIGHWAY
2-1. CHECK OIL LEVEL
2-2. CHECK DRAIN PLUG FOR METAL PARTICLES.
2-3. PETROLEUM OIL CHANGE.
2-4. SEMI or FULL SYNTHETIC OIL CHANGE
OFF HIGHWAY
2-5. CHECK OIL LEVEL
2-6. CHECK DRAIN PLUG FOR METAL PARTICLES.
2-7. PETROLEUM OIL CHANGE.
2-8. SEMI or FULL SYNTHETIC OIL CHANGE
LUBE TYPE / LUBE NOTES INTERVALS: PERFORM THE SERVICE AT
WHICHEVER INTERVAL COMES FIRST.
C 25,000 MILES (40,000 KM) or 1 MONTH
100,000 MILES (160,000 KM)
C 100,000 MILES (160,000 KM) or 1 YEAR
C 250,000 MILES (400,000 KM) or 3 YEARS
C 5,000 MILES (8,000 KM) or 1 MONTH
100,000 MILES (160,000 KM)
C 25,000 MILES (40,000 KM) or 1YEAR
C 50,000 MILES (80,000 KM) or 1 YEAR

Form No. 3628504R1

Printed in the United States of America Page 229
 SECTION 6 LUBRICATION, SEALERS AND MAINTENANCE INTERVALS

Rear Axle (cont.)

14 REAR AXLE: TABLE 143: MERITOR REAR AXLE LUBE INTERVALS (cont.)
ADVANCED LUBE AXLES
ON HIGHWAY
2-9. CHECK OIL LEVEL C 25,000 MILES (40,000 KM) or 1 MONTH
2-10. CHECK DRAIN PLUG FOR METAL PARTICLES. 100,000 MILES (160,000 KM)
2-11. PETROLEUM OIL CHANGE. C 100,000 MILES (160,000 KM) or 1 YEAR
2-12. SEMI or FULL SYNTHETIC OIL CHANGE C 250,000 MILES (400,000 KM) or 3 YEARS
OFF HIGHWAY
2-13. CHECK OIL LEVEL C 5,000 MILES (8,000 KM) or 1 MONTH
2-14. CHECK DRAIN PLUG FOR METAL PARTICLES. 100,000 MILES (160,000 KM)
2-15. PETROLEUM OIL CHANGE. C 40,000 MILES (64,000 KM) or 1 YEAR
2-16. SEMI or FULL SYNTHETIC OIL CHANGE C 80,000 MILES (128,000 KM) or 1 YEAR
AXLES WITH PUMP AND FILTER SYSTEM
2-17. ON HIGHWAY SYNTHETIC OIL CHANGE C 500,000 MILES (800,000 KM)
2-17. OFF HIGHWAY SYNTHETIC OIL CHANGE C 100,000 MILES (160,000 KM) or 1 YEAR
2-18. ON or OFF HIGHWAY FILTER CHANGE 100,000 MILES (160,000 KM)

Form No. 3628504R1

Page 230 Printed in the United States of America
 SECTION 6 LUBRICATION, SEALERS AND MAINTENANCE INTERVALS

Cab

16 CAB: TABLE 161: CAB LUBE INTERVALS

SERVICE LUBE TYPE / LUBE NOTES AS REQUIRED INTERVALS: PERFORM
THE SERVICE AT
WHICHEVER INTERVAL
COMES FIRST.
MILES (KILOMETERS) X 1,000 6 (9.5)
MONTHS 1
1-1. Door Check, Hinges, Latches, Strikers A-15 X
1-2. Door Lock Cylinders A-4 X
1-3. Door Window Regulators A-5 X
1-4. Seat Adjuster Slides A-15 X

Form No. 3628504R1

Printed in the United States of America Page 231
 SECTION 6 LUBRICATION, SEALERS AND MAINTENANCE INTERVALS

Special Instructions Lubricant Application Table (cont.)

(Referenced In The Lube Type/Lube Notes Column Of The TABLE -T defines the lubricants referenced in the Lubrication
Lubrication Tables) Table and lists some typical usages of each type of
lubricant.
1. Special Instructions for Lubrication:
LUBRICANT TYPE APPLICATION
a.
8. SAE 85W-150 Grease Lubricant 05-1
or SAE-90 Sp. Type Lubricant
Lubricant Application Table
Meeting MIL-L-2105SC Class
TABLE -T defines the lubricants referenced in the Lubrication
9. Silicone Grease (PN: 991954C1) 04-1
Table and lists some typical usages of each type of
lubricant. 10. Antifreeze Not in Tables
LUBRICANT TYPE APPLICATION 11. Super Heavy Duty "DOT 3" Brake 04-1
Fluid
1. Aeroshell Grade 5 Grease (PN: 04-1
991953C1) 12. Fleetrite CI-4 15W-40 (Engine Oil) Not in Tables
2. Cam and Ball Bearing Lubricant 08-1 13. Mobile SHC 32 Low Temp Lubricant 16-1
(Delco-Remy # 1948791) or Equivalent
3. Dexron III 16-1 14. Light Engine Oil 04-1, 05-1, 11-1,
12-1, 16-1
4. Lock Oil 16-1
15. GC/LB NLGI #2 Multi-Purpose 02-1, 02-2, 02-3,
5. Lubriplate 105 Lubricant or 16-1
Lithium Complex Grease or 04-1, 05-1,
Equivalent
Equivalent Lithium Complex Based 09-1, 11-1,
6. NLGI #1-1/2 (PN: 990647C1) 04-1 Moly Grease. Optional Synthetic 13-1, 16-1
7. Power Steering Fluid 04-1 Grease P/N: 2644067R1.

Form No. 3628504R1

Page 232 Printed in the United States of America
 SECTION 6 LUBRICATION, SEALERS AND MAINTENANCE INTERVALS

Special Instructions (cont.)

b. International / Spicer front and rear axles: NOT

APPLICABLE for 5000i or 9000i.
c. Meritor Axles: front and rear: Axles factory filled
with synthetic Cognis Emgard 75W-90 will have a tag
attached to the fill plug that reads as follows: "Filled
with synthetic lube. Do Not Mix."

Meritor Rear Axle Lubrication Specification Chart

Rear Axle Lubrication Type Ambient Temperature Viscosity
Meritor 0-76-A Hypoid Gear Oil Above 10 deg. F (-12 deg. C) GL-5, SAE 85W/140
Meritor 0-76-B Hypoid Gear Oil Above -15 deg. F (-26 deg. C) GL-5, SAE 85W/140
Meritor 0-76-D Hypoid Gear Oil Above -15 deg. F (-26 deg. C) GL-5, SAE 80W/90
Meritor 0-76-E Hypoid Gear Oil Above -40 deg. F (-40 deg. C) GL-5, SAE 75W (Max. outside temp.
35 deg. F (1.6 deg. C))
Meritor 0-76-L Hypoid Gear Oil Above -40 deg. F (-40 deg. C) GL-5, SAE 75W/140
There is no upper limit on these outside temperatures, but the axle sump must never exceed 250 deg. F (121 deg. C).

Form No. 3628504R1

Printed in the United States of America Page 233
 SECTION 6 LUBRICATION, SEALERS AND MAINTENANCE INTERVALS

Special Instructions (cont.)

Eaton-Spicer Lubricant Viscosity/Ambient Temperature Synthetic lube used at the factory is Cognis Emgard
75W-90. Axles filled with synthetic lube will have a tag
VISCOSITY/AMBIENT TEMPERATURE
attached to the fill plug that reads as follows: "Filled with
RECOMMENDATIONS
synthetic lube. Do Not Mix."
Grade Ambient Temperature Range
d. Sheppard and Ross Power Steering Gears:
75W -40 deg. F to -15 deg. F (-40 deg. C to
-26 deg. C) For all models use 15W40 Engine Oil: Fleetrite Part No.
CAN # 990625c2.
75W-80 -40 deg. F to 80 deg. F (-40 deg. C to
27 deg. C) e. Bleeding Sheppard and Ross Power Steering
75W-90 -40 deg. F to 100 deg. F (-40 deg. C to Refer to GROUP 05 -STEERING in the Master Service
38 deg. C) Manual for bleeding procedures.
75W-140 -40 deg. F and above (-40 deg. C and
above)
80W-90 -15 deg. F to 100 deg. F (-26 deg. C to
38 deg. C)
80W-140 -15 deg. F and above (-26 deg. C and
above)
85W-140 10 deg. F and above (-12 deg. C and
above)

The use of separate oil additives and/or friction modifiers

are not approved for use in Eaton Drive Axles.
Limited slip additive is no longer required. Todays gear
lubes (mineral and synthetic) have additives that will
protect limited slip clutch packs.

Form No. 3628504R1

Page 234 Printed in the United States of America
 SECTION 6 LUBRICATION, SEALERS AND MAINTENANCE INTERVALS

Special Instructions (cont.)

f. Lubrication Procedures - see the Figure below:

All Dana Axles and Meritor Axles with Easy Steer Front
Axles. With chassis load on axle, force grease through
thrust bearings. Then with axle lifted clear of floor, force
grease between king pin and bushing surfaces. Use
Fleetrite EP2 Lithium Complex Based Moly Grease.
Meritor King Pins with Sealed Front Axles (02ARA) -
Lubricate with vehicle on ground.

Form No. 3628504R1

Printed in the United States of America Page 235
 SECTION 6 LUBRICATION, SEALERS AND MAINTENANCE INTERVALS

Special Instructions (cont.)

g. FABCO Transfer Cases

FABCO Transfer Case Lubrication Specification Chart

APPLICATION TYPE OIL GRADE OIL TEMPERATURE
ON-HIGHWAY MIL-L-2104E Heavy-Duty Engine Oil* SAE 50 Above +10 deg. F
SAE 30 Below +10 deg. F
Mineral Gear Oil** SAE 90 Above +10 deg. F
SAE 80 Below +10 deg. F
SAE 90 Above +10 deg. F
SAE 80 Below +10 deg. F
OFF-HIGHWAY AND MINING MIL-L-2104E Heavy-Duty Engine Oil* SAE 50 Above +10 deg. F
EQUIPMENT
SAE 30 Below +10 deg. F
SPECIAL RECOMMENDATIONS For MIL-L-2104B Heavy-Duty Engine Oil* SAE 20W Below +0 deg. F
extreme cold weather where
temperature is consistently below 0
deg. F
* Heavy-Duty Engine Oil - Make sure to specify heavy duty type meeting MIL-L-2104E
** Mineral Oil inhibits against corrosion, oxidation and foam.

Form No. 3628504R1

Page 236 Printed in the United States of America
 SECTION 6 LUBRICATION, SEALERS AND MAINTENANCE INTERVALS

Special Instructions (cont.)

h. Eaton-Fuller Transmission

Eaton-Fuller Transmission Lubrication Specification Chart

Lubricant Type Ambient Temperature Viscosity
Eaton, Roadranger Synthetic All CD SAE 50
CD-50 Transmission Fluid
Engine Oil API-CD, or SF, SG Above 10 deg. F (-12 deg. C) SAE 50
(MIL-L-2104B, C, or D) previous
Above 10 deg. F (-12 deg. C) SAE 40
API designations are acceptable.
Below 10 deg. F (-12 deg. C) SAE 30
Mineral Gear Oil API-GL-1 (Rust and Above 10 deg. F (-12 deg. C) SAE 90
Oxidation Inhibited)
Below 10 deg. F (-12 deg. C) SAE 80

Eaton-Fuller Auxiliary Transmission Lubrication Specification Chart

Lubricant Type Ambient Temperature Viscosity
Heavy Duty Engine Oil MIL-L-2104B Above 10 deg. F (-12 deg. C) SAE 50

Below 10 deg. F (-12 deg. C) SAE 30

Mineral Gear Oil API-GL-1 (Rust and Above 10 deg. F (-12 deg. C) SAE 90
Oxidation Inhibited)
Below 10 deg. F (-12 deg. C) SAE 80

Do not use oil additives or friction modifiers.

Form No. 3628504R1

Printed in the United States of America Page 237
 SECTION 6 LUBRICATION, SEALERS AND MAINTENANCE INTERVALS

Special Instructions (cont.)

Do not use GL-5 gear oils because they may cause transmission failure or damage.

Synthetic CD50 should be used when lubrication operating temperatures frequently exceed 250 deg. F (120 deg. C). Intermittent
transmission oil temperatures to 300 deg. F (149 deg. C) will not harm the transmission.

i. Meritor

Meritor Transmission Lubrication Specification Chart

LUBRICANT TYPE GRADE (SAE) OUTSIDE TEMPERATURE
Heavy-Duty Engine Oil MIL-L2104B, C, D or E, 50 Above 10 deg. F (-12 deg. C)
or API-CD, CE, SF, or SG (Previous API
40 Above 10 deg. F (-12 deg. C)
Designations Acceptable)*
30 Above -15 deg. F (-26 deg. C)
Mineral Gear Oil with Rust and Oxidation 90 Above 10 deg. F (-12 deg. C)
Inhibitor API-GL-1*
80 Above -15 deg. F (-26 deg. C)
Synthetic Oil - 2104E or 46152D MIL-L*; Meritor 50 All
Spec. 081
Freedomline Synthetic oil specifications: 50 Above 60 deg. F (-51 deg. C)

Mobiltrans SHC 50 Full-synthetic Oil 50 Above 60 deg. F (-51 deg. C)

Cognis EMGARD (#2924) Full-synthetic Oil

* Do not use multi-weight and GL-5 EP gear oils because they may cause transmission failure or damage.

Form No. 3628504R1

Page 238 Printed in the United States of America
 SECTION 6 LUBRICATION, SEALERS AND MAINTENANCE INTERVALS

Special Instructions (cont.)

j. International/Spicer Transmission

International/Spicer Transmissions - Non-Synchronized Lubrication Specification Chart

Lubricant Type Ambient Temperature Viscosity
Synthetic Engine Oil Meeting MIL-L-2104D orE, All CD SAE 50
or MIL-L-46152B, API-SF or API-CD
Heavy Duty Engine Oil Meeting MIL-L-2104D, or Above 0 deg. F (-18 deg. C) SAE 50
E, or API-CD, CE, SF, or SG; CAT TO-4
Below 0 deg. F (-18 deg. C) SAE 30
Automotive Mineral Gear Oil API MT-1 Above 0 deg. F (-18 deg. C) SAE 80-90

Below 0 deg. F (-18 deg. C) SAE 75

k. Allison Automatic Transmissions

Refer to separate Allison Transmission Operators
Manual for more lubrication details.

Form No. 3628504R1

Printed in the United States of America Page 239
 SECTION 6 LUBRICATION, SEALERS AND MAINTENANCE INTERVALS

Special Instructions (cont.)

Oil Check Procedure (see the Figure below)

Always clean around the end of the fill tube before
removing the dipstick. Dirt or foreign matter must not be
permitted to enter the oil system. It can cause valves to
stick, cause undue wear of transmission parts, or clog
passages.

NOTE: Check for abnormal oil level, milky appearance
or any trace of coolant in the oil.
COLD CHECK
NOTE: A cold oil check may be made when the sump
temperature is 60-120 deg. F (15-49 deg. C).
Run the engine for at least 1 minute to clear the oil
system of air.
With the engine running at idle and parked on a level
spot, wipe the dipstick clean and check the oil level.
Any level within the COLD RUN (60 - 120 deg. F)
band is satisfactory for operating the vehicle. If the
level is not within the COLD RUN (60 - 120 deg. F)
band, add or drain oil as necessary to bring the level
to the middle of the COLD RUN (60 - 120 deg. F)
band.

Form No. 3628504R1

Page 240 Printed in the United States of America
 SECTION 6 LUBRICATION, SEALERS AND MAINTENANCE INTERVALS

Special Instructions (cont.)

HOT CHECK A grease fitting is provided at the output shaft dirt and
water seal. The grease fitting should be serviced before
NOTE: If the transmission has reached normal and after winter WITH A LOW PRESSURE grease gun.
operating temperature of 160-200 deg. F (71-93 Use Fleetrite GC/LB NLGI #2 Lithium Complex Grease
deg. C), hot check must be made. The oil level rises as or Fleetrite EP2 Lithium Complex Based Moly Grease.
temperature increases.
Park the vehicle on a level spot, shift to (N) neutral
and apply the parking brake. Let the engine run at
idle speed.
Wipe the dipstick clean and check the oil level. The
safe operating level is any level between the top of
the cold run area and the hot full dot on the dipstick.
If fluid is above the hot full dot, the transmission is
over full.
If not within this range, add or drain oil as necessary
to within the HOT RUN area.
l. Sheppard Power Steering Gears (see the Figure
below)
A grease fitting is provided to remove contaminants
from the salt seal in the input shaft bearing cap cover.
Add chassis grease WITH LOW PRESSURE when
the vehicle is serviced. Use Fleetrite GC/LB NLGI #2
Lithium Complex Grease or Fleetrite EP2 Lithium
Complex Based Moly Grease.
Ross TAS Power Steering Gears

Form No. 3628504R1

Printed in the United States of America Page 241
 SECTION 6 LUBRICATION, SEALERS AND MAINTENANCE INTERVALS

Special Instructions (cont.)

m. Front Drive Axles (see the Figure below) n. Use RHEOLUBE 362 or equivalent. RHEOLUBE 362
is available from Eaton Corporation under part number
Spicer Front Driving Axles only - Lubricate with
113741. RHEOLUBE 362 is manufactured by NYE
Fleetrite EP2 Lithium Complex Based Moly Grease.
Specialists Lubricants, New Bedford, Mass.
Lube axle shaft U-joint whenever axle shafts are
removed. Lube trunnion bearings when bearing caps o. Typical Automatic Slack Adjuster and Camshaft
are removed for service. No periodic lubrication is Lube Points (see the Figure below)
required.
Lubricate with Fleetrite GC/LB NLGI #2 Lithium
Meritor: Lubricate with NGLI #2 Multipurpose Complex Complex Grease or Fleetrite EP2 Lithium Complex
Based Moly Grease. Lube wheel bearings, steering Based Moly Grease.Grease automatic slack adjuster
knuckle bearings, steering U-joints and outer drive shaft with low pressure grease gun.
seals. To lubricate U-joints, raise wheel off ground
and rotate wheel so that grease fitting appears in lube
access hole.

Form No. 3628504R1

Page 242 Printed in the United States of America
 SECTION 6 LUBRICATION, SEALERS AND MAINTENANCE INTERVALS

Special Instructions (cont.)

p. Hydraulic Brakes q. Typical Drag Link Installation (see the Figure below)
NOT APPLICABLE FOR 5000i and 9000i models Lubricate with Fleetrite GC/LB NLGI #2 Lithium
Complex Grease or Fleetrite EP2 Lithium Complex
Based Moly Grease.

Form No. 3628504R1

Printed in the United States of America Page 243
 SECTION 6 LUBRICATION, SEALERS AND MAINTENANCE INTERVALS

Special Instructions (cont.)

r. Typical U-Joint, Typical Slip Joint (see the Figure s. Front steer axles with unitized wheel hubs are lubricated
below) (greased) for life. The bearings and seals are not
serviceable. If end play is out of specification, replace
Lubricate with Fleetrite GC/LB NLGI #2 Lithium
unitized wheel hub assembly. For inspection and
Complex Grease or Fleetrite EP2 Lithium Complex
service procedures on this axle, refer to Meritor
Based Moly Grease.
service manual.

Form No. 3628504R1

Page 244 Printed in the United States of America
 SECTION 6 LUBRICATION, SEALERS AND MAINTENANCE INTERVALS

Unit Refill Capacities

Front Drive Axle Capacities

Front Drive Axle Capacities

This table contains capacities for each axle model provided by Fabco, Meritor and Spicer. INTERNATIONAL
Codes are not listed in the table because each axle model may have more than one INTERNATIONAL Code
and the capacities are approximately the same for each front axle model regardless of the code.
Vendor Model Liters Pints
FABCO SDA-1600 11.3 24
SDA-1800 14 30
SDA-2100 14 30
SDA-2300 16 34
RF16145 6.2 13.0
RF21-160 20.7 43.7
MERITOR
MX-17140 7.6 16
MX-23160 20.3 43

Form No. 3628504R1

Printed in the United States of America Page 245
 SECTION 6 LUBRICATION, SEALERS AND MAINTENANCE INTERVALS

Unit Refill Capacities (cont.)

Rear Axle Refill Capacities

Rear Axle Refill Capacities

Code Forward Rear Notes
Liters Pints Liters Pints
14AHG 17.5 37
14ARK 17.6 37.2
14ARX 22.4 47.3
14ASA 22 46.6
14ASB 22 46.6
14ASD 22 46.6
14ASG 18.5 39.1
14ASM 27.9 59.0
14051 16 35
14ERB 28 59
14AHE 17.5 37
14ARB 18.7 39.5
14ASE 18.5 39.1
14ATN 22 47
14GJH 18.5 39.0 17.5 37.0

Form No. 3628504R1

Page 246 Printed in the United States of America
 SECTION 6 LUBRICATION, SEALERS AND MAINTENANCE INTERVALS

Unit Refill Capacities (cont.)

Rear Axle Refill Capacities (cont.)

Rear Axle Refill Capacities (cont.)

Code Forward Rear Notes
Liters Pints Liters Pints
14GJJ 18.5 39.0 17.5 37.0
14GJK 18.5 39.0 17.5 37.0
14GJN 18.5 39.0 17.5 37.0
14GGU 18.9 40.0 17.5 37.0
14GJD 14.6 31 16.9 36
14GJE 14.6 31 16.9 36
14GRB 12 26 15 32
14GRC 12 26 15 32
14GRD 18 37 20 42
14GRJ 26 55 26 55
14GRM 26 55 26 55
14GRN 12 26 15 32
14GRP 18 37 20 42
14GRR 19 39 16 35
14GRS 19 39 16 35

Form No. 3628504R1

Printed in the United States of America Page 247
 SECTION 6 LUBRICATION, SEALERS AND MAINTENANCE INTERVALS

Unit Refill Capacities (cont.)

Rear Axle Refill Capacities (cont.)

Rear Axle Refill Capacities (cont.)

Code Forward Rear Notes
Liters Pints Liters Pints
14GSX 14 30 12 26
14GTJ 14.2 30.2 12.2 25.8
14GTS 26.5 56.1 17 36
14GTT 26.5 56.1 17 36
14GTW 26.5 56.1 17 36
14GUR 14.2 30.2 12.2 25.8
14GUU 14.2 30.2 12.2 25.8
14HRC 18 38.1 15.7 33.2
14HRE 18 38.1 15.7 33.2
14GEP 14.6 31.00 13.3 28.00
14GER 14.6 31.00 13.3 28.00
14GGG 14.6 31.00 13.3 28.00
14GGJ 14.6 31.00 13.3 28.00
14GJP 14.6 31.00 17.0 36.00
14GVB 14.3 30.2 14.9 31.4

Form No. 3628504R1

Page 248 Printed in the United States of America
 SECTION 6 LUBRICATION, SEALERS AND MAINTENANCE INTERVALS

Unit Refill Capacities (cont.)

Rear Axle Refill Capacities (cont.)

Rear Axle Refill Capacities (cont.)

Code Forward Rear Notes
Liters Pints Liters Pints
14GVC 14.3 30.2 14.9 31.4
14GJL 18.5 39 17.5 37
14GJM 18.5 39 17.5 37
14GJR 18.5 39 17.5 37
NOTES

A. Add 2 pints (0.946 liter) of forward rear axle differential capacity total to inter-axle differential.

B. Add an additional 2 pints (0.946 liter) of gear lubricant to inter-axle differential forward rear axle.

C. Add 1 pint (0.47 liter) of this total at pinion cage plug on single or tandem rear axles.

D. Fill forward rear and rear axle through fill hole located on side of carrier housing.

Cooling System Refill Capacities
Cooling system refill capacities vary considerably due to
differences in engine models, variations in engine models, in
addition to the amount of coolant remaining in the system after
draining. Total capacity may range from 6 to 22 gallons.
If system has been drained, fill with fresh 50/50 diluted
concentrate coolant or 50/50 pre-mixed coolant. If the system
has been flushed with water, a significant amount of the
freshwater flush will remain in the system. In this case
refilling with a mixture with a higher percentage (60 to 66%) of
concentrated coolant concentrate is advised in order to achieve
a final mixture close to 50/50.

Form No. 3628504R1

Printed in the United States of America Page 249
 SECTION 6 LUBRICATION, SEALERS AND MAINTENANCE INTERVALS

Unit Refill Capacities (cont.)

Cooling System Refill Capacities (cont.)

Fill the system and run the vehicle until the thermostat opens.
Check the coolant concentration and add additional water or
concentrated undiluted coolant to adjust the concentration. Run
the vehicle and retest

Bypass Filter Capacity: (If So Equipped)

Bypass Filter Capacity

International Engines Liters Quarts
International 11 12
Fleetguard

Power Steering Gear Refill Capacities

Fill power steering pump reservoir to indicator level.

Transmission (Main) Refill Capacities

Transmission (Main) - Refill Capacities

CODE VENDOR MODEL LITERS(1) PINTS(1) NOTES
13DDS SPICER PSO125-10V 12.8 27
13GHJ FULLER FR14210B 11.1 23.5

Form No. 3628504R1

Page 250 Printed in the United States of America
 SECTION 6 LUBRICATION, SEALERS AND MAINTENANCE INTERVALS

Unit Refill Capacities (cont.)

Transmission (Main) Refill Capacities (cont.)

Transmission (Main) - Refill Capacities (cont.)

CODE VENDOR MODEL LITERS(1) PINTS(1) NOTES
13GHN EATON FULLER FRLO16410CT2 Lightning 11.1 23.5
13GGT FULLER FR12210B 11.1 23.5
13GHA FULLER FR13210B 11.1 23.5
13GHB FULLER FRO13210B 11.1 23.5
13GHC FULLER FRO13210C 11.1 23.5
13GHL FULLER FRO14210C 11.1 23.5
13GHN FULLER FRO15210B 11.1 23.5
13GHP FULLER FRO-15210C . . 11.1 23.5
13GHR FULLER FRO16210B 11.1 23.5
13GHS FULLER FRO-16210C 11.1 23.5
13GHW FULLER RTO(F)-14908LL 13.3 28.0
13GHX FULLER RTO(F)-16908LL 13.3 28.0
13GKZ FULLER FRO/FROF-18210C 11.1 23.5
13GML EATON FULLER FRLO14410CT2 Lightning 12.8 27.0
13GMM EATON FULLER FRLO15410CT2 Lightning 12.8 27.0
13GMN EATON FULLER FRLO16410CT2 Lightning 12.8 27.0

Form No. 3628504R1

Printed in the United States of America Page 251
 SECTION 6 LUBRICATION, SEALERS AND MAINTENANCE INTERVALS

Unit Refill Capacities (cont.)

Transmission (Main) Refill Capacities (cont.)

Transmission (Main) - Refill Capacities (cont.)

CODE VENDOR MODEL LITERS(1) PINTS(1) NOTES
13GPL FULLER RTOC16909A 13.3 28.0
13GJS FULLER RTLO18913A 13.3 28.0
13GKL FULLER RTLO(F)-16918B 13.3 28.0
13GKK FULLER RTLO(F)-14918B 13.3 28.0
13GKM FULLER RTLO(F)-18918B 13.3 28.0
13GMV FULLER RTLO18918AS2 AutoShift 13.3 28.0
13GNM FULLER RTLO(F)20918B 13.3 28.0
13GGK FULLER FR11210B 11.1 23.5
13GGM FULLER FRO11210C 11.1 23.5
13GGV FULLER FRO12210C 11.1 23.5
13GHV FULLER RTO (F)-11908LL 13.2 28.0
13GMY FULLER RTO(F) -11909ALL 13.2 28.0
13GMZ FULLER RTO(F) -14909ALL 13.2 28.0
13GNA FULLER RTO(F) -16909ALL 13.2 28.0
13GJS FULLER RTLO18913A 13.2 28.0
13GKH FULLER RTLO(F)-14913A 13.2 28.0

Form No. 3628504R1

Page 252 Printed in the United States of America
 SECTION 6 LUBRICATION, SEALERS AND MAINTENANCE INTERVALS

Unit Refill Capacities (cont.)

Transmission (Main) Refill Capacities (cont.)

Transmission (Main) - Refill Capacities (cont.)

CODE VENDOR MODEL LITERS(1) PINTS(1) NOTES
13GKJ FULLER RTLO(F)-16913A 13.2 28.0
13GHY FULLER RTO(F)-16915 . 13.2 28.0
13MEM ZF MERITOR MO13G9BM13 9.7 20.5
13MEN ZF MERITOR MO14G9BM14 9.7 20.5
13MET ZF MERITOR M13G10AM13 9.7 20.5
13MEU ZF MERITOR M14G10AM14 9.7 20.5
13MEV ZF MERITOR M15G10AM15 9.7 20.5
13MEY ZF MERITOR MO13G10AM13 9.7 20.5
13MEZ ZF MERITOR MO14G10AM14 9.7 20.5
13MGA ZF MERITOR MO15G10AM15 9.7 20.5
13MGB ZF MERITOR MO16G10AM16 9.7 20.5
13MGG ZF MERITOR MO14G10CM14 9.7 20.5
13MGH ZF MERITOR MO15G10CM15 9.7 20.5
13MGJ ZF MERITOR MO16G10CM16 9.7 20.5
13MGM ZF MERITOR MO14G10CM16 Torq2 9.7 20.5
13MGN ZF MERITOR MO16G10CM18 Torq2 9.7 20.5

Form No. 3628504R1

Printed in the United States of America Page 253
 SECTION 6 LUBRICATION, SEALERS AND MAINTENANCE INTERVALS

Unit Refill Capacities (cont.)

Transmission (Main) Refill Capacities (cont.)

Transmission (Main) - Refill Capacities (cont.)

CODE VENDOR MODEL LITERS(1) PINTS(1) NOTES
13MGV ZF MERITOR MO14Z12AA14 FreedomLine 10.9 23.0
13MGW ZF MERITOR MO16Z12AA16 FreedomLine 10.9 23.0
13GRH FULLER RTOC-1609A-T2 13.3 28
13GAH FULLER FR15210B 11.1 23.5
13GHK FULLER FRO-14210B 11.1 23.5
13GPB EATON FULLER FRLO(F)15410C 12.8 27.0
13GPC EATON FULLER FRLO(F)16410C 12.8 27.0
13GPD EATON FULLER FRLO(F)14410C 12.8 27.0
13GPM EATON FULLER RTO16910BDM3, UltraShift 12.3 26.0
13GPN EATON FULLER RTO14910BAS3, AutoShift 12.3 26.0
13GPP EATON FULLER RTO14910CAS3, AutoShift 12.3 26.0
13GPR EATON FULLER RTO16910BAS3, AutoShift 12.3 26.0
13GPS EATON FULLER RTO16910CAS3, AutoShift 12.3 26.0
13GPW EATON FULLER RTO14910BDM3, UltraShift 12.3 26.0
13GRL EATON FULLER RTO12910BDM3, UltraShift 12.3 26.0
13GKJ FULLER RTLO-16913A 13.3 28

Form No. 3628504R1

Page 254 Printed in the United States of America
 SECTION 6 LUBRICATION, SEALERS AND MAINTENANCE INTERVALS

Unit Refill Capacities (cont.)

Transmission (Main) Refill Capacities (cont.)

Transmission (Main) - Refill Capacities (cont.)

CODE VENDOR MODEL LITERS(1) PINTS(1) NOTES
13GRE FULLER RTLO(F)14913A 13.3 28
13GPT EATON FULLER RTLO16918AAS3, AutoShift 13.3 28
13447 SPICER PSO1406A 19.4 41
ALLISON AUTO TRANSMISSIONS
13AKR ALLISON 4000_EVS_P, 5 Spd, Gen 4 47.3 100
13AKT ALLISON 4500_EVS_P, 5 Spd, Gen 4 47.3 100
13AKL ALLISON 4000_RDS_PR, 5 Spd, Gen 4 47.3 100
13AKM ALLISON 4000_RDS_P, 6 Spd, Gen 4 47.3 100
13AKN ALLISON 4500_RDS_P, 5 Spd, Gen 4 47.3 100
13AKP ALLISON 4500_RDS_P, 6 Spd, Gen 4 47.3 100
* All oil level checks must be performed with the engine at idle, transmission in neutral. A hot check must be
performed with operating temperatures stabilized between 160-200 deg. F. Some dipsticks provide a cold range
indicator mark to assure that the oil level is sufficient to operate the vehicle to perform a HOT CHECK. Refer to L. for
additional information. Also refer to separate Allison Transmission Operators Manual for additional information.

Form No. 3628504R1

Printed in the United States of America Page 255
 SECTION 6 LUBRICATION, SEALERS AND MAINTENANCE INTERVALS

Unit Refill Capacities (cont.)

Transmission (Main) Refill Capacities (cont.)

Notes & Description Chart

NOTES DESCRIPTION
(1) Capacity is approximate and can vary depending on engine angle in chassis.
(2) Some dipsticks for Allison Transmissions have a 72 degree Full Mark instead of Cold Run
Range.
(3) After Oil is Circulated, ADD OIL AS NEEDED TO BRING LEVEL TO COLD RUN RANGE.
(4) Capacity is approximate and can vary with different cooling systems.
(5) It is recommended that synthetic lube be used in these units.
(6) Synthetic lube is mandatory regardless of model.
(7) Synthetic lube Code 13WLB Mandatory option with these transmissions in combination
with aero bumpers.
(8) Synthetic lube Code 13WLC.

Transmission (Auxiliary) Refill Capacities

Transmission (Auxiliary) Refill Capacities

CODE VENDOR MODEL LITERS (1) PINTS (1) NOTES
13607 FULLER AT-1202 5.2 11

Form No. 3628504R1

Page 256 Printed in the United States of America
 SECTION 6 LUBRICATION, SEALERS AND MAINTENANCE INTERVALS

Unit Refill Capacities (cont.)

Transfer Case Refill Capacities

Transfer Case Refill Capacities

This table is in order of the International Codes in the left column.
CODE VENDOR MODEL LITERS(1) PINTS(1)
13TJG Fabco TC-142 19 40
13TJJ Fabco TC-170 6 13
13TJK Fabco TC-170 6 13
13TJN Fabco TC-143 6 13
13TJP Fabco TC-270 10.4 22
13TJU Fabco 170 8.5 18
13151 Fabco 170 8.5 18
(1) Capacity is approximate and can vary depending upon inclination.

Form No. 3628504R1

Printed in the United States of America Page 257
 SECTION 6 LUBRICATION, SEALERS AND MAINTENANCE INTERVALS

Unit Refill Capacities (cont.)

Air Conditioning Refill Capacities

Refrigerant Quantity (By Model and Type)

Air Conditioner Refrigerant Refill Capacities

MODEL LBS. OZ. KG
5000i 4 Lbs. 1.8
9000i 4 Lbs. 1.8

Sealers

Sealers
Product (Loctite
Except Where
Application Noted) Color Size Part Number
THREAD LOCKING - Locks/Seals differential and transmission drain, fill and General Purpose Blue 6 ml 577588-C1*
temperature sending plugs, lock nuts, bolts, screws and other fasteners. Seals Lock N Seal
18 ml 577589-C1*
to form a leakproof assembly against air, fuel and hydraulic leaks. Cures rapidly #242
and easily disassembled with hand tools.
Extra strength adhesive for large fasteners and heavy duty parts. Seals against Heavy Duty Lock Red 6 ml 576016C1*
air, oil, air conditioning and hydraulic leaks. Locks/Seals differential capscrews, N Seal #277
18 ml 576017C1*
case bolts and studs, power divider mounting bolts. Locks Rockwell differential
carrier bearing cap bolts. May require extra effort for disassembly.

Form No. 3628504R1

Page 258 Printed in the United States of America
 SECTION 6 LUBRICATION, SEALERS AND MAINTENANCE INTERVALS

Sealers (cont.)
Sealers (cont.)
Product (Loctite
Except Where
Application Noted) Color Size Part Number
SEALING - Seals fuel, water, gas and hydraulic fittings, threaded vacuum line Pipe Sealant White 6 mi 554209C1*
connectors and air brake line connections instantly. Easily removable with hand w/Teflon
36 ml 554211C1*
tools.
Seals, protects electrical connections and wiring from salt, dirt and corrosion. Dielectric Clear 3 oz 2501657C1
Prevents voltage leakage at connections and excellent for the sealing of air Tune-Up Grease
cleaner elements.
Seals oil pan, transmission and timing cover gaskets. Seals hose connections Make-A- Gasket Grayish 3 oz. 554206C1
and threaded assemblies. Non-hardening. #2
Brown
RETAINING OR MOUNTING PARTS - Seals and mounts cup plugs, gears, Sleeve and Green 18 ml 554210C1*
bushings and oil seals. Restores press fits and prevents leakage. Bearing Mount
#609
GASKETING Superflex RTV Clear 3 oz. 554204C1
#595 Silicone
Seals and repairs weather stripping, insulates and oil seals engine oil pan and RTV Silicone by Black 4.7 oz 446839C1
valve cover gaskets. Special applications are rear axle cover, output shaft Dow Corning &
Black 7 oz. 991443C1
retainer, axle shaft ranges, differential carrier to axle housing and power divider General Electric
intermediate case to main carrier housing mounting surface. Stays flexible.
Form-A-Gasket
NOTE: Once RTV silicone sealant has been installed, parts must be assembled
#593
before sealant starts to set-up.

Form No. 3628504R1

Printed in the United States of America Page 259
 SECTION 6 LUBRICATION, SEALERS AND MAINTENANCE INTERVALS

Sealers (cont.)
Sealers (cont.)
Product (Loctite
Except Where
Application Noted) Color Size Part Number
Self-seating gasket. Low volatility. Non-corrosive to electrical contact Ultra Blue No Blue 3 oz. 1653885C1*
components such as speed shift motor cover. Will not harm aluminum, iron, Leak Silicone
plastic or steel. Gasket #587
Use where Gasket Eliminator #515 is specified. Gasket Purple 50 ml 474517C2*
Eliminator #515
Seals differential assemblies to rear axle housing, rear axle shaft range shifter, Gasket Red 6 ml 1693855C1
transmission cover and power dividers. Replaces cut gaskets; easily removed. Eliminator #518
50 ml 1693856C1
To be used on Spicer heavy axles.
250 ml 1693857C1
All-purpose adhesive which sets fast to hold gaskets in place, yet permits High Tack Red 16 oz. 991445C1
moving for alignment. Holds and seats felt, cork, metal, paper, rubber gaskets. Adhesive Sealant Brush Can
Resists gasoline, oil, kerosene, propane and butane. #98D
BONDING - Bonds loose vinyl trim, weather stripping, appointments, name Gelmatic Instant Clear 5 ml 2501622C1
plates and body side molding. Adhesive #21937
Bonds rearview mirror to windshield and window toggles to glass. Rearview Mirror Amber .5 ml (one 554212C1
Adhesive #312 repair)
A professional quality, black super weatherstrip adhesive. Fast drying and Super Black 5 oz. 991444C1
blends with black automotive weatherstrip for less clean-up. High strength. Weatherstrip
Adhesive #82

Form No. 3628504R1

Page 260 Printed in the United States of America
 SECTION 6 LUBRICATION, SEALERS AND MAINTENANCE INTERVALS

Sealers (cont.)
Sealers (cont.)
Product (Loctite
Except Where
Application Noted) Color Size Part Number
Strips form-in-place gaskets, baked gaskets, dried oil, grease and paint. Gasket Remover 10.75 oz. 554259C1
Removes carbon deposits from valves, heads and pistons. #4MA
*It is suggested that Clean N Cure Primer be used. Refer to CLEANERS, in this table.

NOTE: For sealants to bond properly, it is essential that surfaces

are clean, free of oil residue and all instructions are followed
closely.

Special Instructions

Spicer recommends the use of #518 Gasket Eliminator on all

mating surfaces on their heavy axles. The mating surface must
be clean and dry and free of oil film prior to applying the #518.
Refer to the following Figure for bead size.

Form No. 3628504R1

Printed in the United States of America Page 261
 SECTION 6 LUBRICATION, SEALERS AND MAINTENANCE INTERVALS

Sealers (cont.)
Special Instructions (cont.)

Form No. 3628504R1

Page 262 Printed in the United States of America
 SECTION 6 LUBRICATION, SEALERS AND MAINTENANCE INTERVALS

Sealers (cont.)
Special Instructions (cont.)

Form No. 3628504R1

Printed in the United States of America Page 263
 SECTION 6 LUBRICATION, SEALERS AND MAINTENANCE INTERVALS

Form No. 3628504R1

Page 264 Printed in the United States of America
 SECTION 7 CUSTOMER ASSISTANCE
Service Information
The continued premium performance of this International truck
can best be assured through proper vehicle servicing. This can
be accomplished in several ways.
International Truck Dealers ... Your local International
truck dealer provides an excellent resource through his
knowledgeable, experienced, and well equipped service staff
to handle all your maintenance, repair and replacement work;
International Master Service Manual ... Those persons who
are properly trained technicians with the facilities, equipment,
tools, safety instructions and know-how to properly and safely
service a bus, medium duty and/or heavy duty chassis can
purchase the appropriate individual printed Service Manual
sections applicable to specific vehicle component groups for
this International vehicle;
International Engine Diagnostic and Service Manuals ...
Engine diagnostic and engine service manuals for all current
International engines are also available to these trained persons
for purchase.
These service resources are also available in CD-ROM
format with quarterly updates. The Diamond ISIS CD-ROM
set contains all recent available chassis and component
service information, including TSI Letters, Circuit Diagrams,
Troubleshooting Guides and other technical information for
virtually all International models and engines.
Form No. 3628504R1
Printed in the United States of America
Information can also be obtained by calling Moore Wallace
North America, International Order Desk at (630) 3137507
(Toll-Free Fax Order phone number 1-800-882-0484) or by
visiting www.internationaldelivers.com
NOTE: When ordering any service information, be sure to
provide your trucks model designation, build date, engine
series, and the Vehicle Identification Number (VIN).
To obtain Caterpillar or Cummins engine service publications,
contact your local International truck dealer or the nearest
Caterpillar or Cummins authorized service facility.
International Warranty Program
Standard Warranty Optional Service Contracts Custom
Service Contracts Performance PM
The International Warranty Program provides International
customers with a better choice when it comes to Standard
Warranty and Service Contract Coverage. The Standard
Warranty is the first tier of the International Warranty Program.
It provides the foundation for all extended coverages.
Vehicle Coverage, Towing, Engine and Engine Electronics,
Major Component, and Pre-Packaged System Component
protection can be obtained under the International Warranty
Program through Optional Service Contracts.
Custom Service Contracts, the most flexible aspect of
the International Warranty Program, can provide extended
Page 265
 SECTION 7 CUSTOMER ASSISTANCE
International Warranty Program (cont.)
protection that is specifically tailored to meet each customers
specific requirements.
Finally, through Performance PM, customers can obtain a
comprehensive preventative maintenance program designed to
ensure consistency in pricing and the level of service received.
ADVANTAGES of International Warranties
* Extends warranty protection to specified length and
component coverage to suit individual needs
* Honored at over 1,000 International Dealer locations in
North America
* Stabilized and predictable maintenance costs
* Increased owner confidence and peace of mind
* Improved resale value on your vehicle International
Warranties are transferable for a nominal fee
* Most coverage is 100% parts and labor with NO
DEDUCTIBLES
* International offers a customized warranty program to suit
your needs your specification your vocation
* International, North Americas leader in truck manufacturing,
is also North Americas leader in warranty value
Form No. 3628504R1
Page 266 Printed in the United States of America
* International provides Optional Service Contracts, Custom
Service Contracts, and Performance PM designed to assure
the lowest possible cost of ownership
* Optional Service Contracts have been pre-packed by
International to fit most common applications
* Custom Service Contracts are designed to meet your
individual needs
HOW TO OBTAIN International Warranties
* Standard Warranty: Your new International vehicle is
automatically registered in the International Warranty
system at the time of delivery. No further action on your part
is required.
* Optional Service Contracts, Custom Service Contracts,
or Performance PM: These programs are sold exclusively
through your International Dealer. To be eligible, your
vehicle must have been delivered less than six months ago
and still be covered under the Standard Warranty. If you
would like the predictable cost of ownership and peace
of mind provided by the International Warranty Program,
please contact your International Dealer today!
 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.

Battery posts, terminals and related accessories contain

lead and lead compounds, chemicals known to the State of
California to cause cancer and reproductive harm. Wash
hands after handling.