• 2 SAW

Operation and Maintenance of Y

Vehicles International
b
 DIARY

1) Familiarization : International Vehicle, instrument panel.

2) Checks Before the Trip : Oil System, cooling, Air, etc.
3) Basic Operational Concepts : Power, torque and fuel
efficiency.
4) Operating Suggestions : Double clutch, up and down shifts,
Engine Brake, etc. And I finish the trip.
5) Latest Recommendations : Fuses,
Multiplexing, how to tow the vehicle.
KTERNATIOI Our New Products

9000 Series
LONESTAR

T PROSTAR

CITYSTAR

PAYSTAR WORKSTAR
DURASTAR
 Equivalences
• 9200 – 9400 – 9800 – 9900 =
DIARY 3
Equivalences 5
N DuraStar (4300, 4400) and Buses (3000): Motor International 7
WorkStar 7
ENGINE IDENTIFICATION PLATE 11
MEASUREMENT TOOLS 12
2. Checks Before the Trip 19
Engine Oil Selection 21
“S” Gasoline engines 21
“C” Diesel engines 21
Intake Air System 24
Draining Separator Filters 26
3. Basic Operational Concepts 31
OPERATING RANGES 36
Engine start 38
4. Operation suggestion: To drive you must take into account…. 38
Expensive Operational Repairs? 46
End of the Trip 51
End of the Trip 52
• 5. Latest Recommendations…. 53
•
• ProStar
• Translate
• LoneStar 9000
Series
WorkStar
PayStar
DuraStar
CityStar
IMT EH NATIONAL »

N DuraStar (4300, 4400) and Buses (3000): Motor International

DT466, DT530 (195, 215, 250 HP) (Midrange)

WorkStar
7400: International DT466, DT530 Engine (275 to 300 HP) (Range
medium-heavy)

heavy)

7600: Cummins ISM Engine (305, 350, 380, 400 and 425 HP) (Range
9000 Series, PayStar: Cummins ISM (400-450 HP) or ISX engine
(400-450 HP) (Heavy Range )

For other configurations see

special applications.
 ProStar: CUMMINS ISX ENGINE (400-450)
INTERNATIONALb

TranStar: CUMMINS ISM ENGINE (400-425)

LoneStar: CUMMINS ISX ENGINE (400-450)

All models have the model name on the door.
On the door is the No. From VIN (No. Vehicle identification). The last 8
numbers.
 HEAVY RANGE: CUMMINS ISM and ISX
iMTERM
ATIDMAL

Engines MIDDLE TO HEAVY RANGE: INTERNATIONAL

DT530

Cummins ISM Cummins ISX

MID-RANGE:
INTERNATIONAL DT466
International DT466,
DT530
ENGINE IDENTIFICATION PLATE

XX 15 8255

• Certificate ine Ito 79310987

400 ? 1800 — I 2C£XH »mxF

356 “ .686 X 1 M< HO.79FB9A1C
"INTERNATIONALb

MEASUREMENT TOOLS

In the event of failures on the road (red or amber fault codes), first
of all you must check 100% of your vehicle's fluids.
You should also check that all vehicle components must work
under normal operating measurements:

Parameter Unit Value (Maximum

Allowable)

Engine Oil Pressure PSI/Kpa 10 / 69 (idle)

Engine Oil Temperature F/C 250/ 121

Temperature of F/C 206/96 (Cummins)

Engine Coolant 212/100 (Navistar)

Temperature of F/C 250 / 121

Transmission

Differential Temperature F/C 250 / 121

TACHOMETER AND SPEEDOMETER
 Coolant
Temperature: Fan
Activation
Automatic: Cummins
(206°F) International
(212°F)

Engine Oil
Temperature:
Maximum allowable Oil Pressure:
250°F Measured at Operating
Temperature (Hot
Engine)
Minimum: 10 PSI
At 1200 RPM: 30 PSI

Temperature of
Transmission:
Maximum allowable
250°F
Front rear differential temperature clocks (FR AXLE) and rear rear differentials (RR AXLE),
these should work maximum up to 250 °F (121 ° C).
Audible Alarm Programmed at 235ºF
Heater Engine Brake ON/OFF Fog Light Fan
Rear view Three levels of braking Manual
mirrors intensity
On Transtar, ProStar, LoneStar models, the engine brake can be activated
from the helm.
The cruise option is available at the helm in the TranStar, ProStar, LoneStar,
DuraStar and WorkStar series.
On the 9000 and PayStar series, the cruise option is found on switches on
the dashboard.
 PROCEDURES FOR FAILURES IN THE FIELD
ELECTRONIC CHARACTERISTICS
There are two types of fault codes. ENGINE
a) Active.- They are those that are present on the engine and
physically the word “Warning Engine” is observed in amber
(warning) or “Stop Engine” in red (stop).
The red codes will activate the engine protection, which within 30
seconds the engine will turn off.

b) Inactive.- They are those that were active at some point and that
were resolved and remained in history.

If a faultREDcode
ENGINE
is activated, the word “WARN ENG” or “STOP ENG” will
AMBER ENGINE

appear on the display.

3•

— * 2 40
□ jM

RRND4321
BBBBBEB

RESET

—Display
2. Checks Before the Trip
You should perform the following checks on your engine
and truck daily.

1. Oil level .
2. Coolant level.
3. Air Sistem.
4. Condition and tension of belts.
5. Draining fuel and compressed air filters.
6. General visual inspection.
 Engine Oil
Selection

• International recommends the use

of Premium lubricants that meet
the following characteristics:
• Multigrade Oil.
• SAE 15W40 (Viscocity)
• API CI4. (Quality)
• Change frequency (including filter
of oil and fuel: 250 hours,
8,000 km or 3 months (whatever
happen
first) on International engines and
300 hours, 12,000 km, 3 months
for ISM and ISX engines

------"spark"

“S” Gasoline engines

“C” Diesel engines

• compression EG8011
Steering or
Power Steering
Oil: SAE 15W40
API Motor Oil
Specification - CI4
or CJ4

Depending on the
temperature, the
same manner
must be between
MAX and ADD.
Coolant Liquid:
Composed of
antioxidant
compounds,
antifreeze and water.

You do not need to

add additional
additives.

Correct level: Between

MAX and ADD.

ADD = Add.
 Intake Air System
• Be guided by the indicator of
Restriction , to decide he
replacement of the Air Filter.
• Under no circumstances should you try
to:
• Clean.
• Shake.
• Blow out the Air Filter.
• These actions will cause damage to the
Filter and the filter element resulting in wear
engine premature.
 Draining Separator Filters

The fuel filter must be purged daily due to water

accumulation .
 Draining of Tanks and Filters

• Daily duty to
drain air tanks for
avoid
accumulation of water and
oil.
• This will allow a greater
amount of air to exist in
the tanks and the
performance of the service
brakes will be more
optimal .
• The accumulation of water in the air tanks mixes with the oil that
comes from the compressor, this liquid causes the entire air
system to be contaminated (brakes, valves, etc.).
 OTHER DRIVETRAIN LUBRICANTS
General inspection
Description Viscosity Quality Amount Frequency
(SAE)
Clutch pedal free play. (API) Dear (GL) (Km)/(Hr)

Fault codes on the main board.

1) TireTransmission
wear pattern80W 90 PSI).GL – 1
(120 4 50,000/1000
(Box)
General Lights and accessories (horn, etc.).
2)
Lubricant leaks (engine, transmission, differential, steering,
50,000/1000
Differential 85W 140 GL – 5 5
etc.)(Crown) –
3) Front
ENGINE
Wheels.
WATER
50,000/1000
4) IN FUEL
Address 15W 40 IQ – 4 1.5 CHECK
5) ELEC SYS
Each
service
Fat NGLI EP – 2
 3. Basic Operational Concepts
Your Engine Data Plate provides identification of the
model and other important data
about the engine such as the following:
• Engine Serial Number .
• Model.
• Indicated Power and RPM.
• Indicated Torque and RPM.
• Valve Calibration Data.
• Governed Motor Speed.
It is very important that before operating the engine
the driver must read its data plate in order to better
understand the operation required by the engine.
 TORQUE AND POWER
Torque and power are frequently talked about when engine specifications are
mentioned, and the concept of power is usually used more,
leaving aside torque. Let's know the importance of each of them and how they
LATEC TIPS relate to each other.
001 Torque and power are two indicators of engine performance, they tell us how much force it
can produce and how fast it can work.
 It is the force produced by rotating bodies. To understand how torque arises in a
TORQUE
combustion engine, we must understand the mechanism in a Diesel engine. The explosion of fuel in the cylinder
generates force that acts through the pistons and connecting rod on the crankshaft. In this case, the torque is the
product of the piston force and the length of the crankshaft journal. It is very similar to the pedal mechanism of a
bicycle. The more force you apply to the pedal with your feet, the better starting and climbing capacity you will have.
TORQUE TRANSLATES INTO STRENGTH
 It is the speed with which work is done, that is, the work per unit of time.
POWER In a diesel engine, if we multiply the torque by the rpm (revolutions per
minute) of the engine, we obtain the power.

POWER TRANSLATES INTO SPEED

In all internal combustion engines, torque is not constant, it depends on the engine rotation
speed (rpm).
During engine operation, the length of the crankshaft journal is always the same, however,
the piston force varies depending on the engine revolutions. At very low revs, the
combustion force of the explosion is still weak and therefore the torque is low. However,
when the driver accelerates, more fuel is delivered to the engine, causing the combustion
pressure, rotational speed and therefore also the torque to increase.

At a certain engine rpm, the highest combustion pressure is reached and therefore, the
maximum torque. This is the most efficient point of combustion.

However, if the number of revolutions continues to increase - that is, it accelerates more -
the torque decreases again. This is because there is no longer enough time to build up the
combustion pressure in the cylinder; The engine simply turns faster. Therefore, the
combustion of gases becomes less efficient, reducing their torque.
 CONCLUSION

The vehicle's best climbing ability

Torque (Lb-ft) Power (HP)
and strength is achieved at the
point of maximum torque. And the
maximum speed is achieved at the
maximum engine power.
#585/58/858/6

In conclusion, the ideal engine

working range is between the
888/88/8/8/8
§88/

maximum torque range and the maximum power range.

 OPERATING RANGES
Engine Model Power Torque Operating Economic Governed
(RPM) (RPM) Range Range (RPM) Speed
(RPM) (RPM)

Inter. DT466 2300 1400 1400-2300 1400-1800 2400

Inter. DT530 2200 1200 1200-2200 1200-1600 2200

Cummins ISM 1800 1200 1200-1800 1200-1500 2100

Cummins ISX 1800 1200 1200-1800 1200-1500 1800

For other urban and/or vocational configurations, see

actual driving curve and transmission type-model.
NEVER LET THE RPM FALL BELOW THE MAXIMUM TORQUE!

THE SELECTION OF EXCHANGE WILL DEPEND ON THE TYPE OF

LOAD, TERRAIN AND/OR CONDITION IN WHICH IT IS FOUND!
 Engine start
WAIT
TO
START

• At initial engine start you must open the key

switch and wait for the diagnostic lights to
come on.
• The electronic system is carrying out a
diagnostic test, if there are no faults, the lights
turn off and this gives you the certainty that
your engine is in perfect condition and you can
apply gear.
• You must keep driving until the engine runs for
a maximum of 20 seconds. If the engine does
not start, you must wait at least 2 minutes to
try starting again.
"INTERNATIONALb

4. Operation suggestion: To
drive you must take into
account….
1) Always select a gear for initial start, which should
be the strongest gear the transmission has.

2) Always use normal double clutch procedures when shifting with the lever. - Joins and
separates two moving shafts.

3) Never hit or shake the gear lever to complete the gear engagements.

4) Never move forward with the gear lever in the neutral position.

5) Never move the range selector with the gear lever in neutral while the vehicle is moving,
always use the PRE SELECTION shifting procedure.

6) Never downshift when the speed is too high on the road.

7) In most cases, depending on the engine and axle ratios, valuable fuel can be saved by
operating the vehicle at less than the regulated RPM while going straight.

8) Do not drag the motor below peak torque (depending on the motor one is operating).
 Under normal operating conditions, the
LOCK rear axle differential allows one wheel on the axle to rotate faster than the road
DIRECTORY when required (=example, when cornering) and at the same time transmit the
necessary traction to the drive of each wheel. .

In a curve. The wheel outside the curve will rotate at a higher speed than the inside one,
because it covers a greater distance.

The differential works perfectly while the two wheels are in contact with the ground surface. However, if one of them loses contact with
the ground or skids, the traction goes to that wheel causing it to skid while the one with the most grip on the ground will remain
IWIERNATIONA
L

motionless; The truck will not collapse due to this loss of traction. With the Differential Lock activated (that is, putting the Switch to the
"LOCK" position, the axle works like a rigid axle , resulting in the traction being distributed between the two wheels 505 for each one of
them and eliminating the function of the differential. The Differential Lock is a pneumatically activated system . In a truck that has a
differential lock and the axle system is Tandem type (two drive axles ), both the front rear axle (TD) and the rear axle (TT) may have
differential lock.
LOCK
DIRECTORY

To Activate the Differential Lock To disable Differential Lock :

With the vehicle c □ at very low speed or stopped, move the unlock switch to the "LOCE" Stop the vehicle, set the lock switch to the "DIFF" position
and momentarily lift your foot off the accelerator. Never engage the lock with the vehicle position. Then drive normally. while it
is parked. The speed of the 105 wheels is not the same at the time of engagement (e.g., when
cornering or with a wheel slipping).

NAV^TAR.
IWIERNATIONA
L

In a truck with a Tandem type traction system , there is a device called

LOCK POWER DIVIDER also known as power differential or AD (Irte' Axle
POWER DIVIDER Differential) that is installed at the input of the first differential.

Its function is to transmit the traction coming from the gearbox.

changes towards the days axles The traction will be transmitted in greater
torques and turns of rod axle. resistance to rotation.
percentage for the axis that
ra After
DIVIDE
R
However, conditions of yes on the the
BLOCKIN
the way ther G
Rear Axle pending traction in any of the e is BETWEEN
AXLES
axles, the truck will significantly reduce its pulling capacity. The Divider Lock , also called
PDL [Power Divider Lock) forces the traction to be distributed 50% to the front axle and
50% to the rear axle , so that it improves the traction of the truck on bad roads , with little
traction or with irregular surfaces
INTERNATIOwaL

POWER DIVIDER LOCK

To Activate the Divider Lock:

With the vehicle traveling at low speeds or stopped, move the splitter lock switch to Headlight Disable Splitter Lock.
the "LOCK" position and momentarily lift the accelerator pedal to interrupt engine
torque and allow engagement. Drive at low speed on terrain with very low traction. With the vehicle running or stopped, move the splitter lock
switch to the “PDL” position and really lift your foot off the
accelerator.
 TO CONSIDER...
For the most critical road conditions ( unpaved road or skid), lock both the differential (DIFF LOCK} and the PDL
power divider) - Always engage the PDL first and then the DIFFLOCK.

Roads in good condition but with rainy conditions (low traction and slippage J P engage only the FDL.

Never lock the Divider when one of the wheels is slipping.

Failure to follow this recommendation may cause severe damage to the Power Divider.

The Differential Lock [DIFF LOCK] is used at low speeds and for short periods of time. Never exceed 40 km/hour
with the differential lock activated.

Try not to use the differential lock on steep descents since with the DIFF LOCK activated the stability of the truck
is lost. Remember that DIFF LOCK causes understeering .

Splitter Lockup can occur for long periods of time, whenever a low traction condition exists on the road.

It is recommended to use the PDL during hitching and unhitching to the trailer. This prevents slipping and makes
operation easier.

NAVISTAR
Expensive Operational Repairs?
Problem Cost Time Cause

Reparation of $ 1500.00 3 days operation

Transmission

Clutch Change $ 1140.00 1 day Operation

Reparation of $ 2000.00 3 days Operation

Differential

$ 1000.00 1.5 Days Inspection,

Repair maintenance.
Fuse box
We, like you, sell time. Vehicle stopped time, it is a
non-producing vehicle
 Engine Brake Operation

• The engine brake is a

component designed to
provide braking effect when
descending slopes.
• The engine brake turns your
engine into an air compressor.

In engines Navistar
(International) auxiliary brake
type is of
exhaust,
throttled the exhaust gas outlet.
Maximum Time: 6 continuous
seconds.
Operating it for longer periods of
time can cause severe engine
damage.
 Engine Brake Operation

• Then allow your engine

to raise the RPM to
obtain the best braking
effect this is between
1800 (Cummins ISX) and
2100 (Cummins ISM)
RPM (GOVERNED
SPEED).
• A
recommendation
It is important to use a
lower gear going
downhill than you used
going up the hill.
 Engine Brake Operation

• However, remember that the

best downhill gear is the one
that allows you to go down
the hill without using the
service brakes as much, and
maintaining full control of
your truck withbraking
minimum
using a maximum of 10 psi of
air pressure in the service
brakes for speed control .

WARNING: NEVER EXCEED

YOUR MOTOR SPEED
GOVERNED OR YOU WILL
 Engine Brake Operation

CAUSE RISK OF HARM TO YOUR

ENGINE DUE TO OVERSPEED.
 End of the Trip

• At the end of a trip, leaving the

engine at idle speed for cooling
purposes depends on the
operating conditions.
• Allowing the engine to idle for
3 to 5 minutes is enough time
for the engine to reduce any
high temperatures it may have,
both in internal components
and in the turbocharger, thus
avoiding possible damage.
 End of the Trip

• IMPORTANT TIP : Before leaving the vehicle, carry out a final

visual inspection in order to
detect signs of breakdown.
• Check for:
Appearance changes.
Coolant or oil leaks.
Intake or exhaust leaks.
And a final inspection of the
vehicle.
• If you find any changes, report it
immediately to the maintenance
staff.
iMTERM ATIDMAL

• 5. Latest Recommendations….
Something very important and that can definitely be a cause of
starting problems is undoubtedly the protection elements (Fuses).

NOTE: F30 THRU F41 LOCATED IN ENGINE ENOIKE COMPARTMENT . RI TURN/HAZARD

ECM AND AUX ELECTRONICS LOCATED IN POWER FUSES R2 FLASHER ASS WARNING
BATTERY BOX. LT RELAY
FL * ZOA HEADLIGHTS F 15 JOA BACK-UP/AIR SUSP R3 HEADLIGHT DIMMER
IBF IOA R4 BLOWER MOTOR
F2 * 20 A PARK/TAIL LIGHTS FUEL FILTER R.S. CRANK RELAY
F3 20 A TURN SIGNAL F17 IOA DAY-TIME LIGHTS RR IGNITION RELAY
F4 ISA STOP LIGHTS/CRUISE FIS* 10A WIPER, HEATER H7 AIR SUSPENSION
F5 IOA CARGO LIGHTS F19 10A ACC BODY CONN R.S. HORN RELAY COLUMN
FB IOA ECM / DIAGNOSTIC F20 SA ENG SIGNAL MODULE F.S. SHFT
LOCK
F7 IOA DAY-TIME LIGHTS F21 IOA BRAKE RJO COLUMN SHIFT
LOCK
FB 25A BLOWER MOTOR F22 IOA A0S R] 1 AB5 SIGNAL GRD
F9 LOA ENGINE CRANKING F23 2OA BATT BODY CONN HORN R1Z BRAKE/CRUISE
No IOA IDLE VALIDATION F24 20 A RELAY INTERFACE
FL 1 IOA XMSN OIL/EODY BUILDER R13
BRAKE SWITCH TIMING
F12 5A REGULATORY INJECTOR
F13 IOA CLUSTER/CRUISE + 1 YPE I BREAKER ONLY
F14 IOA IGN BODY CONN
 Under no circumstances should you try to “bypass” the fuses
with wire or cable.
Fuses as protection elements protect the electrical system from
overcurrents and short circuits.
The fact that it opens means that there is a problem and it must be

“Bypassing” a fuse puts electronic components at risk and increases the

possibility of a fire.
be
evaluated.
It is recommended that the operator carry
fuses of all capacities (40, 30, 10
amps) to replace them if it is necessary to
change them.
Battery cables must always be free of contaminating agents. Dust creates
high resistance to the flow of current.
Only on WorkStar, DuraStar, TranStar,
 Directions for towing your vehicle
Front axle suspension (Steering)
Remove the axle shafts to prevent the wheels from driving the differential and
transmission. The ends of the wheel hubs should be capped to prevent loss of axle
lubricant and entry of contaminants.
The front rear axle must be suspended and the rear rear axle half shafts removed.
Cover the hubs to avoid oil loss.
Do not force or hit the half shafts when disassembling.
HE recommends for
tow preferably suspend the
axles
later.
In this case, it is necessary to drain ½
Gl of transmission oil to prevent it
from entering the clutch.
Thank you