Contents

Introduction

• General information
• Rules for the operation of diesel engines in the cold season
• Vehicle inspection
• Security controls and precautions
• Braking system
• Cab
• Electrical devices

Datasheet

• Operations
• Security system for persons in the cab
• Seat adjustment
• Seat belts
• Luggage compartment access models 9600, 9700, 9800
• Dashboard and controls
• Dashboard for 2000, 8000 series cars
• Dashboard of car models 9600, 9700, 9800
• 5000 Series controls
• Controls of models 9100, 9200, 9300, 9400
• Top panel for 5000, 9100, 9200, 9300, 9400 series
• General view of the dashboard models 5000, 9100, 9200, 9300, 9400
• The central unit of the dashboard of the 5000, 9100, 9200, 9300, 9400 series models
• Right and left instrument clusters on the dashboard of 5000, 9100, 9200, 9300, 9400 series cars
• Side dashboard for 5000, 9100, 9200, 9300, 9400 series models
• Controls in cab sleeper (9000 series) and cab sleeper in standard and 9800 series
• Vehicle operation (NAVISTAR electronic international engines)
• Bridges
• Front axle (4x4, 6x6)
• Two-speed rear axle
• Traction compensator
• Differential with adjustable traction
• Controlled differential lock
• Brakes
• ABS anti-lock system (if equipped)
• Automatic control system of adhesion of wheels with road surface (ATC)
• Air suspension (trailer coupling and uncoupling)
• Cab
• Cab air suspension
• Raising the cab
• Clutch and transmission
• Clutch
• Transmission
• Controls (transmission)
• Transfer case
• Driving control system
• Driving control systems (engines not "INTERNATIONAL")
• Driving control systems (INTERNATIONAL engines)
• Electronic engine controls
• Control systems for engines "CATERPILLAR" 3406E and 3176В
• JACOBS brake operation
• Engine brake switches
• Progressive shift mode
• Safe engine shutdown function
• Definition of trouble codes
• Electronic engine control system "CUMMINS" CELECT
• Electronic injection control, 60 series (DDEC II) DETROIT DIESEL engines
• Doors and door locks
• Electrical equipment (wiring diagrams)
• Connecting auxiliary electrical equipment
• Fuses, circuit breakers
• Lighting switches
• Alarms
• Ignition lock
• Engine
• Air filter, restrictor valve
• Troubleshooting
• Engines "INTERNATIONAL"

Operating instructions

• Movement
• Car operation during the cold season
• Car operation during the hot season
• Cooling system
• Charge air cooling
• Antifreeze
• Radiator blinds
• Engine oil
• Fuel
• Cab heating
• Models 9600, 9700, 9800
• 5000, 9100, 9200, 9300, 9400 series models (for vehicles manufactured before February 1997)
• Climate control panel in the sleeping compartment of the standard 9000 series cab
• Hood
• Steering
• 2000, 8000 series adjustable steering column
• Models 9600, 9700, 9800
• Models 9100, 9200, 9300, 9400
• Windscreen wiper control
• Towing
• Operation of the coupling (fifth wheel) device

Maintenance

• General information
• Recommendations
• Front axle
• Wheel alignment
• Rear axle
• Brakes
• Pneumatic brakes
• Air dryer (brakes)
• Cab
• Car care
• Clutch
• Electrical circuits
• Engine
• Air intake system (engine)
• Charge air cooler (engine)
• Engine cooling system
• Frame and tow hooks
• Fuel system
• Noise level
• Cardan shaft
• Springs
• Steering
• Tires
• Wheels
• Lubrication work
• General provisions
• Engine oil specification
• Special instructions
• Checking the oil level (transmission)
• Refueling volumes
• Engine cooling system
• Oil pan and oil filters
• Transfer case
• Fuse and Lamp Values ??Tables

Cabins series 5000 and 9000 INTERNATIONAL

• Description
• Location of the plate with the identification number of the vehicle (VIN)
• Cab air suspension system
• Windshield washers
• Windshield and rain protection seals
• Rear window glass and seal (excluding SLEEPER models)
• Bonnet seals
• Front sun visor on 5000 series (up to 7 September 1995)
• Front sun visor on 9200/9300/9400, 5000 (after September 7, 1995) and 9100 (after March 1997)
• Side sun visor
• Ignition switch cylinder
• Instrument panel (released before June 1994)
• Salon floor mat
• Headliner in saloon
• Driver and passenger seats
• Rear panel
• Engine cover
• Engine cover access door (5000 series)
• Cab door and hinge
• Cab door glass
• Window regulator unit
• Window drive motor
• Channel glass door
• Door ventilation window
• Lighting when opening the door
• Latch block
• Door lock block
• Exterior door handle
• Inner door handle
• Cab door opening seals
• Impact Tongue
• Cabin. Removal / Installation
• General information for installation
• Day cab air suspension (models 9200/9300/9400 without DETROIT DIESEL engines)
• Pneumatic cab suspension (models 9200/9300/9400 for daytime operation with DETROIT DIESEL engines)
• Pneumatic cab suspension (9200/9300/9400 with pro sleeper cab, manufactured before May 1997)
• Pneumatic Cab Suspension (Daytime 9100 Models)
• Pneumatic Cab Suspension (9200/9300/9400 with pro sleeper cab, manufactured after May 1997)

9800 series cabins

• Description
• General information
• Location of the plate with the identification number of the vehicle (VIN)
• Windshield wipers
• Dashboard
• Operation
• Windshield wipers
• Windshield washer
• Maintenance
• Service availability
• Windshield washer
• Check and fill hydraulic tilt cab
• Pumping the hydraulic cab tilt system
• Windshield
• Sun visor and clip
• Ignition lock cylinder
• Cab doors and hinges
• Fasteners and upholstery
• Inner door handle
• Lighting when opening the door
• Exterior door handle
• Door mechanism tongue
• Latch block
• Door lock block
• Cab door glass
• Window regulator - manual or electric
• Channels and seals
• Door ventilation window
• Cabin trim
• Sun visor
• Cab
• Lattice block
• Wiper motor
• Removing the wiper arm
• Wiper mechanism
• Pump motor and reservoir (up to July 1996)
• Pump motor and reservoir (after July 1996)
• Driver and passenger seats
• Passenger Seat Belts
• Interior upholstery components
• Passenger side mat and floor panel
• Cab air suspension system
• Cab tilt
• Special instructions for latching
• Components
• Cab tilt hydraulic system
• Lifting the cab mechanically (using a winch)
• Troubleshooting and how to fix them
• Cab tilt hydraulic system
• Windshield wiper system - electrical
• Cab air suspension system
• Lubrication
• Adjustment
• Combination of the cab and chassis
• Adjusting the front and rear cab mounts
• Cab door
• Door hinge
• Impact tongue
• Windshield wipers
• Cab air suspension system
• Specifications
• Tightening torques

HENDRICKSON pneumatic suspension

• Description
• Suspension height control valve
• Pressure safety valve
• Main spring talk
• Boom service
• Cross bar
• Crossbar
• Pneumatic cushion
• Air bag frame bracket
• Shock absorber bracket to frame
• Shock absorber
• Air bag support bracket
• Height control valve
• Rapid pressure relief valve

HENDRICKSQN suspension systems

• Description
• Service procedure
• U / UE, RT / RTE, RT2 / RTE2 Series
• RS Series
• Replacing the centering sleeves - rubber or bronze (on a car)
• Three-piece beam end adapter, U / UE, RT / RTE, RT2 / RTE2, RS
• Beam end in pin-with-bar
• Beam block
• Jet rods with double attachment
• Torque rods with tie bolt
• Tapered rods
• Transverse jet thrust
• Removing the axle block and beams (complete disassembly of the suspension for overhaul)
• Disassembly
• Spring hangers series U / UE, RT / RTE, RT2 / RTE2
• Rubber shock suspensions - RS series
• U / UE, RT / RTE, RT2 / RTE2 series
• RS Series
• Possible malfunctions and methods of their elimination
• Lubrication
• Tightening torques table

Pneumatic suspension IROS INTERNASHIONAL

• Description
• Height adjustment valve
• Description
• Operation
• Service checks (valve on vehicle)
• Suspension height adjustment
• Draft shortening instructions
• Air supply lines
• Suspension air release function
• Description
• Operation
• Main leaf spring
• Removing the main spring beam
• Installing the main spring beam
• Shock absorbers
• Jet rods
• Removal and installation
• Pneumatic suspension cushions
• Shock absorbers
• Main spring 6alki
• Jet rods
• Installing the main spring beam bushings
• Installation of ladders and ladder nuts
• Checking the tightness of ladders and ladder nuts
• Suspension heights
• Procedure for checking / setting frame height For driving on trucks

Spring suspension INTERNATIONAL 4x2 and 6x4 with jet rods

• Description
• Maintenance
• Retightening the ladder nuts
• Checking and cleaning
• Service
• Replacing the bearings (bushings) of the balancer - suspension assembly
• Suspension spring blocks
• Leaf spring - disassembly / assembly
• Installation of the suspension (springs)

Double drive axles EATON INTERNEJTIONAL

• Identification
• Bridge and cup
• Carter bridge
• Ring gear and main gear drive
• Description
• Inspection
• Cleaning
• Inspection by car
• Inspection outside the vehicle
• Axle case inspection
• Fork reuse instructions
• Wheel bearing adjustment
• Dismantling
• Center differential lock
• Installation
• First differential cup
• First axle crankcase cover
• Second differential cup
• Center differential lock
• Lubrication
• Lubricant change intervals
• Change grease
• Wheel journal lubrication

ROCKWELL rear axles

• Description
• Standard differentials without locking
• Differentials with driver controlled locking
• Towing instructions
• Axle axle installation
• Removing the differential cup from the axle housing
• Air pressure method
• Manual engagement method
• Dismantling the differential lock assembly
• Removing the differential from the cup
• Dismantling the ring gear main differential assembly
• Separating pinion and bearing cage
• Cleaning
• General procedures
• Build
• Pinion bearing preload adjustment
• Fork or flange method
• Adjusting the pinion shim pack thickness (pinion depth)
• Installing the pinion gear, bearing cage and shim packs in the cup
• Main differential and ring gear assembly
• Differential gear rotation resistance test
• Differential installation
• Dial indicator method
• Micrometer method
• Checking ring gear runout
• Ring gear backlash adjustment
• Checking the imprints of the teeth of the gear pair
• Hand rolling position of the contact mark
• Installing the differential switch assembly
• Manual engagement method
• Adjustments
• Ring gear backlash adjustment
• Pinion Bearings - preload
• .Driving gear-depth in cup
• Hypoid gear pair - tooth contact imprints (Hand Rolled)
• Differential bearing preload adjustment
• Main differential gears - rolling resistance
• Ring gear runout
• Sensor switch - installation
• Bearing for guiding - riveting on pinion
• Stop screw or stop block - clearance
• General information
• American standard fasteners
• Metric fasteners

Clutch

• 14 (356 mm) and 15-1 / 2 (394 mm) retractable spicer twin disc clutch
• Description
• Slave disk options
• Clutch brake with torque limiting
• Tension springs
• Automatic adjustment mechanism
• Spacers made of fixed cylindrical pins
• Adjusting ring
• Release bearing and bushing
• Installing a 15.5-inch SOLO HEAVY-DUTY clutch
• Measurement
• Installing the clutch on the flywheel
• Installing transmission
• Assembly and Lubrication

Front axle

• Hubs, bearings and seals (non-drive axles)
• Description
• Wheel bearings
• Bearing outer ring (cage)
• Front wheel hub cap
• Operation
• Maintenance
• Grease lubricated wheel bearings
• Oil lubricated wheel bearings
• Removing the hub seals
• Cleaning and checking
• Checking and preparing the hole in the hub
• Checking and preparing the journal
• Installation
• Cleaning and checking the hub
• Anti-lock brake system (ABS) hubs - air brakes
• Wheel studs
• Alloy spoked wheel studs
• Troubleshooting and how to fix them
• Front axles "INTERNATIONAL" with I-beam "SPICER"
• Description
• Troubleshooting and how to fix them
• Precautions
• Maximum limits for front axle kingpin
• Replacing the king pin bushing
• Installing the PRE-SIZED bushing
• Installing king pin seals (all axles)
• Installing the steering knuckle
• Lubrication
• Specifications
• Tightening torques

Steering

• Power steering SHEPPARD M-SERIES
• Description
• Identification
• How it works
• Oil flow through the mechanism
• General diagnostics
• Hydraulic diagnostics
• Recommendations for oil flow and pressure
• Most common problems
• Glossary of terms and definitions
• Preventive maintenance
• Liquid types
• Change fluid and filter
• Cleaning the relief valve seats
• Replacing the input shaft seal
• Replacing the Sector Shaft Seal
• Single Gear Hydraulic Bleed
• Dual steering systems
• Installing discharge plungers
• Withdrawal
• Installation
• Dismantling the steering gear
• Repair of parts of the assembly
• M-SERIES - optional built-in unloader valve
• Cleaning
• Inspection
• Build
• Dual steering system
• Description
• How it works
• Slave transmission
• Troubleshooting
• Steering column positioning
• Adjustments
• Steering axle stop
• Specifications
• Steering gear TRW / ROSS-TAS 40, 55, 65 and 85
• Service tips
• Identification
• Glossary
• Input shaft seal
• Description
• How it works
• Withdrawal
• Disassembly
• Build
• Worm preload adjustment
• Poppet valve
• Valve body / worm screw
• Roller bearing or circlip
• Body fittings. Plugs, screws, fittings
• Adjustment
• Sector shaft
• Poppet valve adjustment
• Reinstalling the poppet valve
• Filling and bleeding the system
• System filling
• Air bleeding
• Lubrication
• Tightening torques table
• Steering column
• Description
• Operation
• Maintenance
• Steering wheel
• Steering column
• Tilt mechanism
• Cardan joints
• Align
• Vehicles with power steering
• Vehicles with mechanical steering
• Tightening torques
• Special tools
• Standard Steering Column 5000 Series, 9000 CONV
• Description
• Maintenance
• Steering wheel
• Steering column

Air Compressors BENDIXTU-FLO 550 TU-FLO

• Description
• Maintenance
• Possible malfunctions and methods of their elimination
• Repair
• Specifications

Model ABS

• Schemes