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NAVISTAR DuraStar, TranStar, WorkStar, RXT – 3200, 4100, 4300, 4400, 7300, SERVICE MANUAL

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NAVISTAR RXT 3200-4100-4300-4400-7300 SERVICE MANUAL contains high quality images, diagrams, instructions to help you to operate, maintenance, diagnostic, and repair your machine. This document is printable, without restrictions, contains searchable text and bookmarks for easy navigation.

NAVISTAR RXT 3200-4100-4300-4400-7300 SERVICE MANUAL includes:

Numbered table of contents easy to use so that you can find the information you need fast.
Detailed sub-steps expand on repair procedure information.
Numbered instructions guide you through every repair procedure step by step.
Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
Notes, cautions and warnings throughout each chapter pinpoint critical information.
Bold figure number help you quickly match illustrations with instructions.
Detailed illustrations, drawings and photos guide you through every procedure.
Enlarged inset helps you identify and examine parts in detail.

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TABLE OF CONTENT OF THE NAVISTAR RXT 3200-4100-4300-4400-7300 SERVICE MANUAL

1. Table of Contents (Chapter 1)
INSTRUCTIONS AND CHARTS (Chapter 2)
12 VOLT POWER DİSTRİBUTİON, Grounds, Data Bus and Electrical System Controller (Chapter 3)
CAB ACCESSORİES (Chapter 4)
12V CHARGING + CRANKING SYSTEM (Chapter 5)
FANS AND ENGİNE ACCESSORİES (Chapter 6)
ELECTRONİC ENGİNES (Chapter 7)
GAUGES WITH AND WITHOUT Internaı WARNING LIGHT (Chapter 8)
LIGHTS (Chapter 9)
CHASSIS ACCESSORİES (Chapter 10)
TRANSMISSIONS (Chapter 1 1)
AİR CONDITIONING (Chapter 12)
CONNECTOR COMPOSITES (Chapter 1 3)

TABLE OF CONTENTS (CHAPTER 1)…………………………………………………………………..
2. INSTRUCTIONS AND CHARTS (CHAPTER 2)………………………………………………………. 1
2.1. ABBREVIATIONS, P. 1…………………………………………………………………………. 1
2.2. ACRONYMS, P. 2……………………………………………………………………………… 2
2.3. CIRCUIT DIAGRAM INSTRUCTIONS, P. 3……………………………………………………. 3
2.4. CIRCUIT NUMBER IDENTIFICATION AND COLOR, P. 4……………………………………… 4
2.5. CIRCUIT NUMBER IDENTIFICATION AND COLOR, P. 5……………………………………… 5
2.6. CIRCUIT NUMBER IDENTIFICATION AND COLOR, P. 6……………………………………… 6
2.7. LAMP BULB CHART, P. 7……………………………………………………………………… 7
2.8. RELAY FUNCTION AND WIRING GUIDE, P. 8………………………………………………… 8
2.9. SCHEMATIC SYMBOL CHART, P. 9…………………………………………………………… 9
2.10. SCHEMATIC SYMBOL CHART, P. 10………………………………………………………… 10
2.11. SCHEMATIC SYMBOL CHART, P. 11………………………………………………………… 11
2.12. SCHEMATIC SYMBOL CHART, P.12…………………………………………………………. 12
3. 12 VOLT POWER DISTRIBUTION, GROUNDS, DATA BUS AND ELECTRICAL SYSTEM
CONTROLLER (CHAPTER 3)………………………………………………………………………. 13
3.1. BATTERY FEED, DUAL, P. 1…………………………………………………………………. 13
3.2. BATTERY FEED, DUAL, P. 2…………………………………………………………………. 14
3.3. BATTERY FEED, DUAL, P. 3…………………………………………………………………. 15
3.4. ACCESSORY FEED, P. 4…………………………………………………………………….. 16
3.5. IGNITION FEED — STANDARD, THEFT DETERRENT, REMOTE START/STOP, P. 5. . . . . . . . . . 17
3.6. IGNITION FEED RELAY 1, P. 6………………………………………………………………. 18
3.7. IGNITION FEED RELAY 2, P. 7………………………………………………………………. 19
3.8. IGNITION FEED RELAY 3, P. 8………………………………………………………………. 20
3.9. J1708 DATA LINK — PUBLIC EFFECTS, P. 9……………………………………………….. 21
3.10. J1708 DATA LINK — PUBLIC EFFECTS, P. 10………………………………………………. 22
3.11. J1708 DATA LINK — PRIVATE WITH POWER WINDOW AND LOCK, P. 11…………………. 23
3.12. J1939 DATA LINK, P. 12……………………………………………………………………… 24
3.13. J1939 DATA LINK WITH OPTIONS, P. 13……………………………………………………. 25
3.14. J1939 DATA LINK WITH OPTIONS, P. 14……………………………………………………. 26
3.15. J1939 DATA LINK — I6 ENGINE, P. 15………………………………………………………. 27
3.16. J1939 DATA LINK — IBB ENGINE, P. 16…………………………………………………….. 28
3.17. GROUND — IP, P. 17…………………………………………………………………………. 29
3.18. GROUND — IP, P. 18…………………………………………………………………………. 30
3.19. GROUND — IP, P. 19…………………………………………………………………………. 31
3.20. GROUND — IP, P. 20…………………………………………………………………………. 32
3.21. GROUND — CHASSIS, P. 21………………………………………………………………… 33
3.22. GROUND — CHASSIS, P. 22………………………………………………………………… 34
3.23. GROUND — CHASSIS, P. 23………………………………………………………………… 35
3.24. GROUND — CHASSIS, P. 24………………………………………………………………… 36
3.25. GROUND — CHASSIS WITH HEAVY DUTY DIESEL, P. 25…………………………………. 37
3.26. ENGINE GROUND — V8 ENGINE, P. 26…………………………………………………….. 38
3.27. ENGINE GROUND — IBB ENGINE, P. 27……………………………………………………. 39
3.28. ZERO VOLT REFERENCE, P. 28…………………………………………………………….. 40
3.29. BATTERY FEED, SINGLE, P. 29……………………………………………………………… 41
3.30. BATTERY FEED, SINGLE, P. 30……………………………………………………………… 42
3.31. J1939 DATA LINK — V8 ENGINE, P. 31……………………………………………………… 43
3.32. GROUND — SEAT AND SEATBELT SENSOR, P. 32………………………………………… 44
3.33. LATCHING RELAY, P. 33……………………………………………………………………… 45

CAB ACCESSORIES (CHAPTER 4)………………………………………………………………… 46
4.1. CIGAR LIGHTER AND POWER FEED, P. 1………………………………………………….. 46
4.2. CIGAR LIGHTER AND POWER FEED, P. 2………………………………………………….. 47
4.3. CB POWER RADIO, P. 3……………………………………………………………………… 48
4.4. COMPASS DISPLAY, P. 4…………………………………………………………………….. 49
4.5. FRONT DOOR WINDOWS AND LOCKS (POWER), P. 5…………………………………….. 50
4.6. FRONT DOOR WINDOWS AND LOCKS (POWER) FOR CREW, P. 6……………………….. 51
4.7. HORN, ELECTRIC AND AIR, P. 7……………………………………………………………. 52
4.8. HORN, ELECTRIC AND AIR, P. 8……………………………………………………………. 53
4.9. MIRRORS (HEATED, LIGHTED AND POWER), P. 9…………………………………………. 54
4.10. MIRRORS (HEATED, LIGHTED AND POWER), P. 10……………………………………….. 55
4.11. MIRRORS (HEATED, LIGHTED AND POWER), P. 11……………………………………….. 56
4.12. POWER MIRRORS — HEATED AND MOTORIZED WITH WINDSHIELD WITH FPB, P. 11A… 57
4.13. 2–WAY RADIO, P. 12…………………………………………………………………………. 58
4.14. WINDSHIELD WIPER, P. 13………………………………………………………………….. 59
4.15. WASHER PUMP, P. 14……………………………………………………………………….. 60
4.16. SWITCH PACK OPTIONAL GAUGE PACK, P. 15……………………………………………. 61
4.17. ROOF AUX LOAD, P. 16……………………………………………………………………… 62
4.18. SATELLITE COMMUNICATION — QUALCOMM IMCT, P. 17………………………………… 63
4.19. SATELLITE COMMUNICATION — TRIPMASTER, P. 18…………………………………….. 64
4.20. COMPUTER PREWIRED — XATA SYSTEM, P. 19………………………………………….. 65
4.21. CADEC GPS SYSTEM, P. 20………………………………………………………………… 66
4.22. SATELLITE COMMUNICATION — MOBILEMAX, P. 21………………………………………. 67
4.23. SELF CONTAINED AIR SEAT, P. 22………………………………………………………….. 68
4.24. HEATED SEATS, P. 23……………………………………………………………………….. 69
4.25. AWARE SYSTEM, P. 24………………………………………………………………………. 70
4.26. EATON VORAD COLLISION AVOIDANCE SYSTEM, P. 25………………………………….. 71
4.27. EATON VORAD COLLISION AVOIDANCE SYSTEM, P. 26………………………………….. 72
4.28. EATON VORAD COLLISION AVOIDANCE SYSTEM VS400, P. 27………………………….. 73
4.29. BACK-UP CAMERA, P. 28……………………………………………………………………. 74
4.30. SATELLITE COMMUNICATION — QUALCOMM IMCT W/ MVPC KEYBOARD, P. 29……….. 75
4.31. AIR SHIELD LIGHT, P. 30…………………………………………………………………….. 76
4.32. SATELLITE COMMUNICATION — QUALCOMM OMNIVISION, P. 31……………………….. 77
4.33. RADIO (ENTERTAINMENT), SPEAKERS — W/ 12 WAY CONNECTOR, P. 32………………. 78
4.34. RADIO (ENTERTAINMENT), SPEAKERS — W/ 16 WAY CONNECTOR, P. 33………………. 79
4.35. SEATBELT AND SEAT SENSOR, P. 34………………………………………………………. 80
4.36. SEATBELT AND SEAT SENSOR, P. 35………………………………………………………. 81
4.37. SEATBELT AND SEAT SENSOR, P. 36………………………………………………………. 82
4.38. SEATBELT AND SEAT SENSOR, P. 36A…………………………………………………….. 83
5. 12V CHARGING + CRANKING SYSTEM (CHAPTER 5)……………………………………………. 84
5.1. I6 / V8 ENGINES WITH MANUAL TRANSMISSION, P. 1…………………………………….. 84
5.2. IBB ENGINES WITH MANUAL TRANSMISSION, P. 2……………………………………….. 85
5.3. I6 AND V8 ENGINES WITH ALLISON TRANSMISSION, P. 3………………………………… 86
5.4. IBB ENGINES WITH ALLISON TRANSMISSION, P. 4……………………………………….. 87
5.5. I6 ENGINE WITH AUTOSHIFT, ULTRASHIFT AND EATON HYBRID TRANSMISSION, P. 5. . . 88
5.6. IBB ENGINES WITH AUTOSHIFT AND ULTRASHIFT TRANSMISSION, P. 6……………….. 89
5.7. I6 POWER PACK, P. 7……………………………………………………………………….. 90
5.8. ROCKER START, P. 8………………………………………………………………………… 91

FANS AND ENGINE ACCESSORIES (CHAPTER 6)……………………………………………….. 92
6.1. FAN WIRING, I6 / V8 ENGINES, P. 1…………………………………………………………. 92
6.2. SNOWVALVE, P. 2……………………………………………………………………………. 93
6.3. STARTING AID — COLD START ASSIST (IBB ENGINE), P. 3………………………………. 94
6.4. FAN WIRING — IBB ENGINE, P. 4…………………………………………………………… 95
6.5. ELECTRIC AIR COMPRESSOR WITH MD, P. 5……………………………………………… 96
7. ELECTRONIC ENGINES (CHAPTER 7)…………………………………………………………….. 97
7.1. ELECTRONIC ENGINE CONTROLS, I6 ENGINES, P. 1…………………………………….. 97
7.2. ELECTRONIC ENGINE CONTROLS, I6 ENGINES, P. 2…………………………………….. 98
7.3. ELECTRONIC ENGINE CONTROLS, I6 ENGINES, P. 3…………………………………….. 99
7.4. ELECTRONIC ENGINE CONTROLS, I6 ENGINES, P. 4……………………………………. 100
7.5. ELECTRONIC ENGINE CONTROLS, I6 ENGINES, P. 5……………………………………. 101
7.6. CRUISE CONTROL, P. 6……………………………………………………………………. 102
7.7. ELECTRONIC ENGINE CONTROLS, IBB ENGINES, P. 7………………………………….. 103
7.8. ELECTRONIC ENGINE CONTROLS, IBB ENGINES, P. 8………………………………….. 104
7.9. ELECTRONIC ENGINE CONTROLS, IBB ENGINES, P. 9………………………………….. 105
7.10. ELECTRONIC ENGINE CONTROLS, IBB ENGINES, P. 10………………………………… 106
7.11. ELECTRONIC ENGINE CONTROLS, IBB ENGINES, P. 11…………………………………. 107
7.12. ELECTRONIC ENGINE CONTROLS, V8 ENGINES, P. 12………………………………….. 108
7.13. ELECTRONIC ENGINE CONTROLS, V8 ENGINES, P. 13………………………………….. 109
7.14. ELECTRONIC ENGINE CONTROLS, V8 ENGINES, P. 14………………………………….. 110
7.15. ELECTRONIC ENGINE CONTROLS, V8 ENGINES, P. 15………………………………….. 111
7.16. ENGINE ECM POWER — V8 ENGINE, P. 16……………………………………………….. 112
7.17. ELECTRONIC ENGINE CONTROLS — I6 ENGINE, P. 17………………………………….. 113
8. GAUGES WITH AND WITHOUT INTERNAL WARNING LIGHT (CHAPTER 8)…………………… 114
8.1. IP/GAUGES, P. 1……………………………………………………………………………. 114
8.2. WARNING LIGHT LIST, P. 2…………………………………………………………………. 115
8.3. WARNING LIGHTS CONTROLLED BY ENGINE, TRANSMISSION, ABS
CONTROLLER, P. 3…………………………………………………………………………. 116
8.4. ENGINE OIL PRESSURE AND TEMP, SPEEDOMETER, TACHOMETER, VOLTMETER
AND WATER TEMP GAUGE CIRCUITS, P. 4……………………………………………….. 117
8.5. IP/GAUGES AND WARNING LIGHTS — GAUGE CLUSTER, P. 5………………………….. 118
8.6. AIR PRESSURE INPUT CIRCUIT, P. 6……………………………………………………… 119
8.7. AXLE TEMPERATURE, GAUGE INPUT CIRCUIT, P. 7……………………………………… 120
8.8. FUEL GAUGE CIRCUITRY (SINGLE TANK), P. 8…………………………………………… 121
8.9. DIFFERENTIAL LOCK WARNING LAMPS, P. 9…………………………………………….. 122
8.10. PARK BRAKE SWITCH HYDRAULIC, P. 10………………………………………………… 123
8.11. GAUGES AND WARNING LIGHTS — AMMETER, P. 11……………………………………. 124
8.12. FRONT AXLE ENGAGEMENT WARNING LAMP, P. 12…………………………………….. 125
8.13. WARNING LIGHTS — RIGHT BANK — OPTIONAL, P. 13…………………………………. 126
8.14. WARNING LIGHTS – LEFT BANK — OPTIONAL, P. 14……………………………………. 127
8.15. LOAD MONITORING, P. 15…………………………………………………………………. 128
8.16. AIR PARK BRAKE AND MANUAL TRANSMISSION OIL TEMP GAUGE, P. 16. . . . . . . . . . . . . . . . . 129
9. LIGHTS (CHAPTER 9)…………………………………………………………………………….. 130
9.1. BACK-UP LIGHTS N/ ALLISON TRANSMISSION, P. 1…………………………………….. 130
9.2. BACK-UP LIGHTS W/ ALLISON TRANSMISSION, P. 2…………………………………….. 131
9.3. LIGHT SYSTEMS — CLEARANCE, MARKER, PARK, TAIL, TURN AND STOP LIGHTS,
P. 3………………………………………………………………………………………….. 132

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