PROSTAR Intro Study Guide

Study Guide

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A N AV I S TA R C O M PA N Y

Study Guide TMT-100717

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International® ProStar™ Series: Introduction for Technicians

International ProStar Series: Introduction for Technicians ®

TMT-100717

©2006 International Truck and Engine Corporation, 4201 Winfield Road, Warrenville, IL 60555. All rights reserved. No part of this publication may be duplicated or stored in an information retrieval system without the express written permission of International Truck and Engine Corporation.

Table of Contents Introduction........................................................................3 Module 1: Engine & Drivetrain........................................7 Engines.................................................................................................... 7 Exhaust Aftertreatment........................................................................ 8 Cooling System..................................................................................... 8 Clutches................................................................................................ 10 Transmissions....................................................................................... 10

Module 2: Electrical System.........................................13 Module 3: Front Air Suspension..................................15 Module 4: Power Steering System..............................17 Module 5: Brakes & Air System....................................19 International® ProStar ™ Braking System..................................... 19 Bendix® ABS-6 Configurations........................................................ 19 WABCO® ABS Configurations.......................................................20 Air System Diagnostics...................................................................... 22

Module 6: Cab Features.................................................25 Bumper.................................................................................................. 25 Cab Suspension.................................................................................. 26 HVAC..................................................................................................... 26

Conclusion........................................................................31

International® ProStar ™ Series: Introduction for Technicians


Introduction The International® ProStar ™ is the result of five years and $300 million in development. Designed with continuous collaboration from dealer and customer advisory boards, the International® ProStar ™ provides bestin-class fuel economy, unparalleled driver satisfaction, unprecedented uptime, and the lowest cost of ownership. Fuel economy and driver satisfaction for the International® ProStar ™ are features experienced when you see and operate the vehicle. Unprecedented uptime and low cost of ownership are experienced first-hand in the shop. Every maintenance feature of the International® ProStar ™ has been implemented with an ease-ofserviceability design. • Scheduled maintenance is synchronized at 25,000 mile intervals to provide more efficient service and more uptime. • The tilt-out bumper provides direct access to the engine compartment service points.

“The International® ProStar ™ provides best-in-class fuel economy, unparalleled driver satisfaction, unprecedented uptime, and the lowest cost of ownership.”


• Fluid maintenance is streamlined with service-at-a-glance reservoirs and easy access. • The two-piece fan shroud provides easy service access to the fan and fan hub. • A fully refined multiplexed electrical system reduces wiring by 40%. It also provides computer-controlled monitoring features that improve safety and simplify maintenance. • The optional Vehicle Information Display provides a single checkpoint for performance information all across the vehicle. And these are just the highlights.

“The International® ProStar ™ is designed to reduce complexity and streamline service procedures.”

From the choices in engine and drivetrain components, to easeof-serviceability and the latest in computer-monitored diagnostics, the International® ProStar ™ is designed to reduce complexity and streamline service procedures for technicians. To receive credit for completing this program, you are required to take a post-test on ISIS®/Education/Service/ Online Testing.


Shop Safety When performing diagnostics, repairs, or maintenance, keep in mind that proper service techniques, environmental concerns, and safety are the most important parts of this process. Be sure to follow each warning, caution, and note as they are presented throughout this training program. Warnings indicate procedures and safety measures that must be followed precisely to avoid the risk of death or injury to yourself or other shop personnel, and to avoid damage to the vehicle, equipment or components. Cautions indicate a procedure that you must follow exactly to avoid equipment or component damage. Notes indicate operations, procedures or instructions that are important for proper service. When performing service work of any kind, always protect the interior of the vehicle by using a paper floor mat, a steering wheel cover, and a seat cover. When working on the engine, keep the work area and tools as clean as possible. Also, clean all connections

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Warning

Before beginning diagnostic or service procedures, always shift the transmission to park or neutral, set the parking brake, and block the wheels.

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Warning

Always provide ventilation when operating an engine in an enclosed area. Inhalation of exhaust gas can be fatal.

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Warning

Whenever performing procedures that require the batteries to be disconnected, always disconnect the main negative battery cable first. When reconnecting, always connect the main negative battery cable last.


before disconnecting or removing components.

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Warning

When working with the engine, always wear safety glasses with side shields and chemical-blocking nitrile gloves.

As components are removed, cover all openings. Be sure that you know the location of properly rated and charged fire extinguishers. Be sure you know the location of an emergency eyewash station.


Engine & Drivetrain Engines With the launch of the 2007 International® ProStar ™, five different engine configurations fulfill specific owner needs. These advanced engines meet the emission regulations for 2007 while delivering a wide range of power and performance options. The initial engine offered is the Cummins® ISX, with the Cummins® ISM, Caterpillar® C13, and Maxxforce™ 11 and 13 to be offered in the future. Some key features of the new MaxxForce™ engine include: • Performance-driven direct injection high-pressure common rail electronic fuel system capable of multiple injection events. • Durable single overhead cam actuated with four valves per cylinder and roller rocker arms. • Compacted Graphite Iron cylinder block for high strength and low weight. • Rugged gear-driven air compressor and power steering pump.

Module 1 Objectives Upon completion, you will be able to: • Identify engine options. • Identify key features of the new MaxxForce™ engine. • Identify the Diesel Particulate Filter. • Describe the streamlined engine service features. • Identify transmission options.


• Low-noise rear gear train and pad mounted accessories.

Exhaust Aftertreatment The exhaust aftertreatment is now considered an integral part of the engine system. This system has been developed to meet the EPA’s 2007 emissions regulations.

“The new component in the aftertreatment is the Diesel Particulate Filter, also known as the DPF.”

The new component in the aftertreatment is the Diesel Particulate Filter, also known as the DPF. The DPF is one of the main components added to the system to meet the 2007 standards. The International® ProStar ™ provides easy access to the DPF with a simple two-clamp, one-fitting removal.

Cooling System The International® ProStar ™ cooling system module for these engines features a two-piece fan shroud, simplifying fan and fan hub service, and improving belt tensioner access. Cooling system service is faster with a see-through surge tank and standing access to the coolant drain. An optional quick-connect vacuum drain and quickfill fitting is also available. Cooling system service is further streamlined by making it possible to remove the charge air cooler without


removing the entire radiator. And, if you do have to remove the radiator for service, the transmission oil cooler and A/C condenser can be disconnected from the frame mount and set aside without having to disconnect the oil and refrigerant lines. Other engine service features include a locking outboard engine oil level gauge, and a telescoping oil fill tube wide enough for no-funnel filling. The oil drain plug is also positioned for ease of use and quick-change service. An air cleaner filter minder maximizes element life and minimizes cost. It also protects the engine because the filter can be checked without letting dust and dirt in. An optional in-dash indicator adds convenience. Fuel/water separator placement provides driver’s side visual inspection with an indicator showing filter life. Options include heat-by-return-fuel-tothe-filter or a separate electric element. Optional fuel/water separator placement under the hood uses less fuel line, blocking fewer engine components.

“An air cleaner filter minder maximizes element life and minimizes cost.”

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Clutches “The new clutch linkage maximizes uptime by including service-free nylon bushings and sealed bearings on the bell crank to eliminate maintenance.”

All clutches for the International® ProStar ™ are carry-over designs from the current 9000i product offerings. The new clutch linkage maximizes uptime by including service-free nylon bushings and sealed bearings on the bell crank to eliminate maintenance. Remote clutch cross-shaft bushing zerks help reduce service time and promote clean application of the grease. Both features lead to an increased level of service follow through.

Transmissions International® ProStar ™ transmission options include five Fuller® manual models, five Eaton® third generation automated models, and the ZF automated manual transmission. The optional automated manual transmissions for the International® ProStar ™ include the implementation of shift controls on the steering wheel. This proprietary design was developed with Eaton® and Meritor®. The transmission is easier to access and remove with the air tanks mounted under the battery box.


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Electrical System The International® ProStar ™ utilizes the Diamond Logic® Electrical System. Road-ready components are integrated with computer technology and multiplexed wiring. Multiplexing the electrical system allows an overall reduction of wires and connections as well as improved harness routing and clipping. Multiplexing also aids equipment integration with self-diagnostics and other vehicle options. Batteries are equipped with view eyes to provide quick charge checks. The improved alternator is designed to resist heat and last longer when used with hotter running, lower emissions engines. The forward chassis harness includes all wiring for lighting and other hardware from the front bumper to the bottom front corners of the cab. The center chassis harness includes all wiring for lighting and hardware under and immediately behind the cab. And the rear chassis harness includes all wiring for lighting and hardware for rear axles and end-of-frame.

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Module 2 Objectives Upon completion, you will be able to: • Identify the benefits of a multiplexed electrical system. • Identify the major components. • Describe the features of the optional Vehicle Information Display.

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“The body controller, ABS controller, and power distribution center are located inside the cab.”

Design improvements include moving the body controller, ABS controller, and power distribution center inside the cab, reducing exposure to heat, cold, moisture, and corrosion. All fusing is in one location, except for the sleeper, which has its own fuse block and dedicated electrical control panel. In addition, all truck programming and fault management works through one portal for both factory and customized solutions. Diagnostic trouble code reporting is improved with text fault code descriptions on an optional Vehicle Information Display that interfaces with vehicle monitoring systems. The system utilizes filtering to eliminate nuisance codes, and self-healing capabilities to erase codes no longer active. More in-depth information regarding electrical system theory and operation, diagnostics and service will be covered in subsequent programs.


Front Air Suspension

Module 3

The International® ProStar ™ will be offering in the future the option of a multilink, 100% air front suspension system, rated at 12,000 lbs., and featuring a Hendrickson fabricated axle.

Objectives

This system is designed by International® and utilizes four longitudinal torque rods, one transverse torque rod, a non-bushed swaybar, and hydraulic, non-gas-charged shocks. Air ride height is maintained with two Hadley 1500 series valves.

• Describe the maintenance reducing features.

Maintenance-reducing features of the air front suspension system include: • A two-piece steering knuckle that allows the kingpin bearings to be replaced, eliminating the need for kingpin removal. Permanently installed kingpins are cryogenically pressed into place. • Reduced bushing maintenance due to the non-bushed swaybar. Huck-bolted frame brackets never need to be re-torqued, and there are no U-bolts to maintain on the fabricated axle.

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Upon completion, you will be able to: • Identify the components of the optional front air suspension.

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Power Steering System Power steering on the International® ProStar ™ features an optional tilt and telescoping steering column. This is fully adjustable with a maximum extension of over 5 inches. The column also features a stow-away position for easy entry and exit.

Module 4 Objectives Upon completion, you will be able to: • Identify the components of the power steering system. • Describe the maintenance reducing features.

A see-through power steering fluid reservoir provides quick check convenience. The no-tool power steering fluid filter replacement decreases service time. Power steering service is facilitated by an intermediate shaft that can only be assembled one way, ensuring correct phasing of the U-joints. Three grease zerks, one each at the upper and lower U-joints and one at the slip joint, all line up for easy access with the wheels pointed straight ahead. These require Mobil SHC 100 synthetic grease. The lube interval for the draglink is 50,000 miles. The grease zerks here are oriented for easy access. The TRW PCF-60 gear has what is known as positive center feel. Its purpose is to reduce wander by providing the driver with a stiffer oncenter feel. This limits the amount of

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Caution

When lubricating the steering shaft, only use Mobil SHC 100 grease.

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driver input necessary to keep the tractor heading straight down the road. The Sheppard HD94 steering gear is an available option.


Brakes & Air System

Module 5

International® ProStar™ . Braking System

Objectives

Bendix® and WABCO® both offer an antilock brake system for use on the International® ProStar ™.

• Identify the different brake system configurations.

Both systems employ a 4-channel arrangement for the 4 x 2 and 6 x 4 configured vehicles, and are electronically controlled by an ECU located behind the passenger-side trim panel.

• Describe the features of the air dryers.

Bendix® ABS-6 Configurations The Bendix® ABS-6 is the next generation of their antilock braking system. It’s available in three different configurations, depending on the specific model of ABS controller installed on the vehicle. • The Standard model is ABS only. • The Premium model has ABS with an upgrade to automatic traction control, or ATC. • The Advanced model includes both ABS and ATC with the addition of an Electronic Stability Program, or ESP®.

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Upon completion, you will be able to:

• Identify the two air dryer configurations.

• Describe the optional air system diagnostics.

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“This ESP® feature provides both yaw control and roll stability management under varied road and driving conditions.”

ESP® is a registered trademark of DaimlerChrysler and is used by Bendix® Commercial Vehicle Systems under license from DaimlerChrysler. This ESP® feature provides both yaw control and roll stability management under varied road and driving conditions. Both the International® ProStar ™ and International® ProStar ™ Premium vehicles are equipped with the Standard EC-60™ ABS Controller. The International® ProStar ™ Limited vehicle is equipped with the Premium EC-60™ ABS Controller. All Bendix®-equipped vehicles can be ordered with any of the Bendix® controller options.

WABCO® ABS Configurations WABCO® ABS is an option on the International® ProStar ™ and available in the following three configurations: • ABS only • ABS with traction control • ABS with traction control and roll stability The International® ProStar ™ air system features an air compressor discharge tube with a Compu-Check fill port to fill the system with shop air. The air is


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sent through the air dryer first to further protect the system. The standard air dryer is the Bendix® AD-IS, mounted inside the left frame rail just behind the transmission. This integrated solution air dryer features fewer parts and lower weight compared to typical air charging systems. While standard air dryers work well in most applications, they periodically interrupt the drying process to purge accumulated moisture. For high airdemand applications, such as bulk loaders, the International® ProStar ™ can be outfitted with the optional Bendix® AD-IS with EverFlow™ module. This upgrade contains all the features and benefits of the standard AD-IS system, with the addition of a second desiccant cartridge to provide an uninterrupted supply of clean, dry air. Some additional benefits of both the standard AD-IS and the optional AD‑IS with EverFlow™ are that the primary and secondary reservoirs, including the suspension and accessory components, are plumbed directly to these air dryer assemblies. Some examples of these air accessories are the air horn, air slide fifth wheel, and the power divider lock. Both of these units have built-

“This integrated solution air dryer features fewer parts and lower weight compared to typical air charging systems.”

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in pressure protection valves to protect against pressure losses at the reservoirs and air accessories.

“The International® ProStar ™ also features an array of optional diagnostic and monitoring systems for the air brakes and tires.”

The International® ProStar ™ also features an array of optional diagnostic and monitoring systems for the air brakes and tires. These include: • tire pressure monitoring • brake monitoring • air system diagnostics Optional air system diagnostics track the overall performance of the air brake system. The information is then communicated to the Vehicle Sensor Module, or VSM, and the optional Vehicle Information Display. The VSM uses this diagnostic information to determine if warnings need to be displayed to alert the driver and service technician.

Air System Diagnostics The main areas that diagnostics are performed are compressor performance and governor performance. Compressor performance is monitored by comparing the actual time required by the air compressor to build up


operating pressure to a normal recovery time calculated at the factory. When poor compressor performance is detected, it is displayed on the Vehicle Information Display. Governor performance is monitored by tracking the governor’s cut-in and cutout pressures. This helps determine when the governor has degraded to the point that service is required. Poor performance is displayed on the Vehicle Information Display. The optional E-Stroke Brake Chamber monitor uses Hall Effect sensors located inside each chamber to track the position of the slack adjusters. These sensors are monitored by the VSM. The system monitors proper operation, detects problems when they occur, and displays an in-cab warning on the Vehicle Information Display when the brake chamber stroke is out of adjustment. Potential operating problems the system can detect include over-stroke, dragging, or a non-actuating condition at each of the wheel ends. The optional brake lining wear monitor employs a wire loop sensor embedded in each brake lining. When the wire loop is worn through, a signal is sent to the VSM and a warning is displayed

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“When poor compressor performance is detected, it is displayed on the Vehicle Information Display.”

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on the Vehicle Information Display. The screen alerts the driver of the need for brake maintenance and its specific location. This warning provides the driver sufficient time to schedule service since the worn lining has approximately 25% of its material remaining when the warning is first initiated.

“The optional Tire Pressure Monitoring System, or TPMS, warns the driver of both sudden and slow air leaks.”

The optional Tire Pressure Monitoring System, or TPMS, warns the driver of both sudden and slow air leaks. It also monitors the temperature of all tires. This is accomplished with sensor/ transmitters inside each wheel rim, one front and two rear antennas, and a TPMS controller relaying information to the Vehicle Information Display. Each tire is monitored using the display. Warnings occur instantly when a tire shows signs of low pressure or leakage.


Cab Features

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Module 6

Bumper

Objectives

The cab of the International ProStar ™ is constructed of double-sided electrogalvanized steel for long life. Stateof-the-art corrosion testing has been utilized to ensure the International® ProStar ™ is one of the most corrosionresistant cabs available in the industry today. ®

Multi-piece hood construction allows for independent fender repair, minimizing repair costs and downtime. The tilt-away design of the bumper allows it to tilt forward 60 degrees for easier service access to the engine compartment and wheel wells. The fourpiece split design allows replacement of individual portions of the bumper, lowering repair costs and simplifying service. The optional chassis skirt provides a quick release lever allowing easy access to the battery box. An easy-to-fill see-through windshield washer bottle holds over 2 gallons to reduce fluid service frequency. A low fluid level warning is visible in the gauge cluster display.

Upon completion, you will be able to: • Describe the maintenance reducing cab features. • Identify suspension components for both day and sleeper cabs. • Identify HVAC components for both day and sleeper cabs. • Describe HVAC operation for both day and sleeper cabs.

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Cab Suspension “New, outboardmounted shocks are more stable and accessible.”

Cab suspension on day cabs features a single cab air spring. This reduces leak points, and provides easy access for service. The day cab rear air ride suspension features a longer track bar to absorb lateral loads. New, outboardmounted shocks are more stable and accessible, and further improve performance with more shock travel. The two rear mounted sleeper cab struts are also outboard mounted for easy service access. Their modular design streamlines service and repairs.

HVAC The International® ProStar ™ heating, ventilation, and air conditioning, or HVAC, system provides climate control for the driver environment. The expansion valve type air conditioning system uses the Body Controller to engage the air conditioning clutch. Inputs, such as system high side pressure, are used to protect the compressor, and evaporator temperatures are used to prevent evaporator freeze-up.


This system can sustain a 75°F (24°C) cab temperature in 110°F (43°C) heat, or a 90°F (32°C) cab temperature in –10°F (–23°C) conditions. The system is divided between the cab and engine compartment. On the cab side, the module contains the blower motor, mode door, temp door, door actuators, and heater core. The compressor, condenser, evaporator and remaining components are located on the engine side. The cab module blower draws fresh outside air into the cab for ventilation and all A/C settings, except MAX A/C, where cab air is recirculated. Cab heater shut-off valves located on the engine can be operated by hand to block the flow of hot coolant to the heater. This can improve air conditioning efficiency during the warmer months. The sleeper cab uses the primary HVAC system with an auxiliary interior module. This rear HVAC module is an air recirculation system for both heater and A/C functions and can maintain the same cab temperatures. The additional blower motor, temp door actuator motor, heater core, and A/C evaporator are located in the sleeper area under the lower bunk area.

“This system can sustain a 75°F cab temperature in 110°F heat, or a 90°F cab temperature in –10°F conditions.”

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The blower motor runs at 30% of full power when the engine is not running. It is controlled by the driver or the occupant of the lower bunk. Optional controls from the upper bunk are also available. Like the primary HVAC system, the auxiliary system is also an expansion valve system. The auxiliary HVAC unit communicates with the Body Controller via the SAE J1939 Body Builder datalink. All control communication is accomplished using this datalink. The auxiliary unit discharge temperature and auxiliary unit blower speed are controlled independently.

“The instrument panel has two dedicated rocker multiplex switches for the rear HVAC system.”

The instrument panel has two dedicated rocker multiplex switches for the rear HVAC system. One controls the sleeper blower setting, while the other controls the sleeper temperature setting. These control settings are displayed to the operator in the gauge cluster in the form of a bar graph. The gauge cluster communicates with the Body Controller via the SAE J1939 Powertrain datalink. In the sleeper area on Trim Levels LH1 and LH2 there are two potentiometers with rotary knobs; one for blower


speeds, the other for temperature control. Trim Level LH2+ offers an LED sleeper control head. The control settings from the LED sleeper control head are displayed to the operator in both the control head and the gauge cluster display. Either of these options are incorporated into the sleeper control panel located in the sleeper back panel. On a sky-rise vehicle these controls are available in the upper bunk area. The control of the auxiliary HVAC system is accomplished by a last touch system between the instrument panel and the sleeper control panel. The International® ProStar ™ HVAC system monitors itself to ensure proper operating conditions, including refrigerant charge quantity. An air temperature sensor is used to vary the temperature door position to react to changes in evaporator/ heater core temperature, keeping the discharge temperature at a steady state. These blend air doors are electronically actuated. In all modes except MAX A/C, the front HVAC module is operated on a 100% fresh air mode, while the rear auxiliary unit operates in recirculation mode

Note The operation of the auxiliary HVAC system requires the front blower motor to be activated.

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100% of the time. Variables such as high-side pressure and evaporator in and out temperatures are monitored. The system can issue warning or fault messages and, if necessary, disengage the clutch on the compressor to shut the system off. In vehicles with an electronically controlled engine fan, the HVAC system can turn the engine fan on to aid in condenser performance and pressure management.

“An optional, no-idle HVAC system will also be available for the International® ProStar ™ sleeper cab.”

An optional, no-idle HVAC system will also be available for the International® ProStar ™ sleeper cab. More in-depth information regarding this system and the cab and sleeper HVAC system theory and operation, diagnostics, and service is covered in subsequent programs.

International® ProStar ™ Series: Introduction for Technicians 31

Conclusion The International® ProStar ™ provides best-in-class fuel economy, unparalleled driver satisfaction, unprecedented uptime, and the lowest cost of ownership in the industry. Thoroughly tested state-of-the-art technology makes the International® ProStar ™ more reliable, easier to operate, and easier to maintain than any other line haul tractor on the road. Completion of this educational process is a key component towards International® Technician Certification. You are now required to take a post-test via ISIS®/Education/Service/Online Testing.

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PROSTAR Intro Study Guide

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