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PRINTED IN THE UNITED STATES OF AMERICA 2005 International Truck
and Engine Corporation
NOTICE 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.
Be advised that this motor vehicle may be equipped with computer
/ recording devices. Their function is to allow an authorized
individual to download data or information relating to the
operation or performance of this vehicle. The stored data or
information may be neither downloaded nor retrieved except by the
vehicles registered owner, or, in the alternative, by another
individual or entity authorized by the registered owner, such as an
International Dealer, who may need this data or information to
properly service or diagnose this vehicle for repair or following
an accident. Any access to this information without the owners
consent may be in violation of law and may subject that person or
entity to criminal penalties.
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.
Important
The information, specifications, and illustrations contained in
this manual are based on data that was current at the time of
publication. International Truck and Engine Corporation reserves
the right to make changes and/or improvements at any time without
notification or liability, or without applying those changes or
improvements to vehicles previously manufactured.
Make sure your use of this completed vehicle conforms to all
federal, state and local requirements and regulations imposed on
owners and operators.
4400 USPS
(United States Postal Service) Supplem
ent 2645023R1
MED
IUM
DU
TY MO
DEL
A
pril 2004
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Please inform us of any errors you might find in this Operators
Manual. Include the Operators Manual form number / date and a
detailed description of the error, along with the page number(s)
and/or figure(s) that contain the error.
We also welcome suggestions for improving our International
Operators Manuals.
International and the International Diamond logo are registered
trademarks of International Truck and Engine Corporation, or its
subsidiaries, in the United States and other countries.
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IMPORTANT IT IS IMPORTANT THAT THE VEHICLE IDENTIFICATION NUMBER
(VIN), AND COMPONENT FEATURE CODE AND SERIAL NUMBERS BE RECORDED.
THESE NUMBERS ARE REQUIRED TO OBTAIN INFORMATION PERTINENT TO THIS
VEHICLE. VEHICLE IDENTIFICATION NUMBER (VIN) 1000 Series: Located
next to the Hydro-Max brake booster
3000 Series: Located engine side of cowl panel, upper right
CF, 4000, 5000i, 7000, 8000, 9000i Series: Located left door
opening, rear post
COMPONENT IDENTIFICATION NUMBERS Component feature codes appear
on the vehicle line set ticket (see page 2).
Component serial numbers appear on the components.
Feature Code Number: Serial Number:
FRONT AXLE REAR AXLE TRANSFER CASE TRANSMISSION ENGINE
ENGINE SERIAL NUMBER LOCATION CATERPILLAR: Stamped on plate left
rear side of crankcase
CUMMINS: Stamped on plate left side of gear case, front of
engine
INTERNATIONAL: Stamped on pad located on crankcase, left
side
WORLD HEADQUARTERS International Truck and Engine Corporation
4201 Winfield Road Warrenville, Illinois 60555 USA
INTERNATIONAL INTERNET SITE internationaldelivers.com
SALES REGIONS MIDWEST International Truck and Engine Corporation
4201 Winfield Road PO Box 1488 Warrenville, Illinois 60555
630-753-5900 NORTHEAST International Truck and Engine Corporation
7192 North Park Drive Pennsauken, New Jersey 08109 856-665-9333
SOUTHEAST International Truck and Engine Corporation 2400 Commerce
Avenue Building 1100, Suite 100 Duluth, Georgia 30096
678-584-2700
SOUTHWEST International Truck and Engine Corporation 2595 North
Dallas Parkway, Suite 203 Frisco, Texas 75034 972-377-1200 WEST
International Truck and Engine Corporation 3017 Douglas Boulevard,
Suite 300 Roseville, California 95661 916-774-7526 CANADA
International Truck and Engine Corporation Canada [Corporation des
Camions et Moteurs International Canada] 5500 North Service Road
4th Floor Box 5337 Burlington, Ontario L7L 5H7 905-332-3323 MEXICO
Camiones y Motores International de Mexico, S. A. de C. V. Ejrcito
Nacional 904 8 Piso Col, Palmas Polanco 11510 Mexico D.F.
525-262-6666 BRAZIL International Caminhes do Brasil Ltda. Av.
Carlos Gomes, 466 6 andar CEP 90480-000-Porto Alegre RS-BRASIL
011-55-51-316-2000
CUSTOMER ASSISTANCE CENTER 800-448-7825
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USPS 4400 Model Supplement to Section C Vehicle Controls
CS - 1
TABLE OF CONTENTS SECTION C VEHICLE CONTROLS Table of Contents
Section C Vehicle
Controls.........................................................................................................................................................................
1
introduction.....................................................................................................................................................................................................................................
3 cab header and overhead console
................................................................................................................................................................................................
3
INTERIOR CAB
CONTROLS.....................................................................................................................................................................................................
4 USPS INSTRUMENT CLUSTER
...........................................................................................................................................................................................
5 WARNING INDICATORS
.......................................................................................................................................................................................................
6 WARNING INDICATOR TABLE
.............................................................................................................................................................................................
6 LOWER (IP) LEFT SWITCH
BANK........................................................................................................................................................................................
7 CENTER CONTROL SWITCH PANEL COMPONENTS
.......................................................................................................................................................
8 CENTER CONTROL SWITCH PANEL COMPONENTS -
CONT.........................................................................................................................................
9 CENTER CONTROL SWITCH PANEL COMPONENTS -
CONT.......................................................................................................................................
10 SWITCH PANEL SWITCH FUNCTIONS
.............................................................................................................................................................................
11
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Supplement to Section C Vehicle Controls USPS 4400 Model
CS - 2
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USPS 4400 Model Supplement to Section C Vehicle Controls
CS - 3
SUPPLEMENT TO SECTION C VEHICLE CONTROLS INTRODUCTION
The vehicle controls enable the driver to manage the operation
of the majority of the vehicles functions. This section describes
the switches, controls, and adjustments that are located in the cab
header, overhead console, instrument panel, and elsewhere within
the vehicles cab.
CAB HEADER AND OVERHEAD CONSOLE OVERHEAD CONSOLE CAB HEADER
The overhead console provides storage, interior lighting, and
optional compass and temperature monitoring functions.
The monitor for the Rear Vision camera is mounted in the cab
header.
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Supplement to Section C Vehicle Controls USPS 4400 Model
CS - 4
LOWER (IP) SWITCHES (LEFT OF STEERING COLUMN) (See table on page
CS-7 for explanation)
INTERIOR CAB CONTROLS The Interior Cab Controls include the USPS
center panel switches, and lower panel controls.
USPS CENTER CONTROL PANEL
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USPS 4400 Model Supplement to Section C Vehicle Controls
CS - 5
USPS INSTRUMENT CLUSTER
The following is a description of the gauges, warning
indicators, and LED display options.
USPS Lift Axle Indicators NOTE: See Section D, Vehicle
Operation, for MODE & SET/RESET switch-selected display
functions.
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Supplement to Section C Vehicle Controls USPS 4400 Model
CS - 6
WARNING INDICATORS
The following table lists the unique gauge cluster Warning
indicators that apply to the USPS vehicle operation.
WARNING INDICATOR TABLE WARNING LIGHT NAME COLOR
LOWER AXLE RED RAISE AXLE RED PTO RED
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USPS 4400 Model Supplement to Section C Vehicle Controls
CS - 7
LOWER (IP) LEFT SWITCH BANK SWITCH NAME SWITCH FUNCTION SWITCH
INDICATOR
STATUS
PARK LIGHT OFF/PARK/HEADLAMP SWITCH
A three-position switch that selects, in turn, the cluster
backlights and Park/Running/Marker lights in the P (Park) position,
then the headlamps along with all the above lights in the
(Headlamp) position.
PANEL DIMMER SWITCH A momentary switch in both up and down
position; holding the switch in either position adjusts cluster and
panel backlighting a maximum of eight brightness or dimming
steps.
LIFT GATE/ON A momentary switch that raises or lowers the cargo
area door.
Indicator lit when in ON position.
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Supplement to Section C Vehicle Controls USPS 4400 Model
CS - 8
CENTER CONTROL SWITCH PANEL COMPONENTS
PANEL COMPONENTS 1. Filter Minder 2. Cigar Lighter 3. Air Park
Brake
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USPS 4400 Model Supplement to Section C Vehicle Controls
CS - 9
CENTER CONTROL SWITCH PANEL COMPONENTS - CONT.
KEYED IGNITION (START) SWITCH
KEYLESS START PANEL WITH START/STOP SWIITCHES AND KEYLESS START
FOB
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Supplement to Section C Vehicle Controls USPS 4400 Model
CS - 10
CENTER CONTROL SWITCH PANEL COMPONENTS - CONT.
SWITCH PANEL SWITCHES
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USPS 4400 Model Supplement to Section C Vehicle Controls
CS - 11
SWITCH PANEL SWITCH FUNCTIONS SWITCH NAME SWITCH FUNCTION SWITCH
INDICATOR
STATUS
HEATED MIRROR ON/OFF A momentary switch that, when pushed and
released, turns on the mirror heating element - On/Off.
The indicator is lit when the switch is turned to the ON
position.
TRACTION DISABLE ON/OFF This switch disables the ABS traction
feature. The indicator is lit when the switch is turned to the
DISAB position.
AIR SUSPENSION DUMP- DUMP/SUSP This switch allows the operator
to release the air from the air bags in an air suspension system
when the vehicles speed is less than a predetermined speed.
The indicator is lit when the switch is turned to the DUMP
position.
ENGINE START A momentary switch that, when pushed and held, will
crank the engine as long as its held
The indicator is lit when the switch is in the ENGINE START
position.
ENGINE STOP A momentary switch that, when pushed turns off the
engine. The indicator is lit when the switch is in the ENGINE STOP
position.
LIFTAXLE/UP A momentary switch that is pushed when the RAISE
AXLE warning light is lit.
The indicator is lit when the switch is in the UP position.
LIFT AXLE/DOWN A momentary switch that is pushed when the LOWER
AXLE warning light is lit.
The indicator is lit when the switch is in the DOWN
position.
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USPS 4400 Model Supplement to Section D Vehicle Operation
DS- 1
TABLE OF CONTENTS SECTION D VEHICLE OPERATION Table Of Contents
Section D Vehicle
Operation.................................................................................................................................................................
1 Engine
Starting..........................................................................................................................................................................................................................
3
Keyless Starting
System........................................................................................................................................................................................................
4 lift Axle system
..........................................................................................................................................................................................................................
5
Lift Axle System Operation
....................................................................................................................................................................................................
5 Lift Axle
Controls....................................................................................................................................................................................................................
5 Driver Controlled Lift Axle Operation
.....................................................................................................................................................................................
5 Driver Controlled Lift Axle Operation
.....................................................................................................................................................................................
6 ESC-Controlled Lift Axle Operation
.......................................................................................................................................................................................
6
air suspensions
.........................................................................................................................................................................................................................
7 International Ride Optimized Suspension (IROS) (OPTIONAL)
...............................................................................................................................................
7
Air Suspension Dump Switch
................................................................................................................................................................................................
8 ESC-Controlled Air Suspension
Operation............................................................................................................................................................................
8 Air Suspension Dump System Faults
....................................................................................................................................................................................
8
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Supplement to Section D Vehicle Operation USPS 4400 Model
DS- 2
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USPS 4400 Model Supplement to Section D Vehicle Operation
DS- 3
SUPPLEMENT TO SECTION D - VEHICLE OPERATION ENGINE STARTING
WARNING To avoid accidental movement, which could possibly
result in property damage and personal injury, never start the
engine unless you're sure the transmission selector is in neutral
and the park brake is applied. NOTE: When starting the vehicle,
automatic transmissions must be in neutral before the starter will
engage, and manual transmissions require the clutch pedal to be
depressed before the starter will engage.
CAUTION Do not attempt to use the conventional keyed ignition
switch when the keyless starting system has been used to start the
vehicle. To do so will cause damage to vehicle equipment. The
vehicle may be started using either the conventional keyed ignition
switch or the keyless starting system. See the existing 4200, 4300,
and 4400 Operator manual for the standard keyed ignition switch
starting procedure. The following paragraphs describe the keyless
starting system.
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Supplement to Section D Vehicle Operation USPS 4400 Model
DS- 4
Keyless Starting System The keyless starting system consists of
the blue keyless start FOB, ENGINE START switch, ENGINE STOP
switch, and the Start Control Panel.
a. Place the FOB in front of the Antenna target on the start
control panel to turn on the vehicle electrical system. The vehicle
will then perform its ESC controlled cluster warning indicator and
gauge power up sequences, and at the same time turns on all of the
Start Control Panel lights.
NOTE: If the FOB code is not recognized, the Start Control Panel
red Valid ID will be lit and therefore, will not turn the vehicles
systems on.
b. To engage the air starter, press and hold the ENGINE START
switch until the engine turns over. The green ENGINE START switch
indicator and the yellow Start indicator will be turned on until
the engine starts.
c. Release the ENGINE START switch when the engine starts. The
yellow Start indicator will turn off, and the green Run indicator
will turn on and remain on as long as the engine is running.
d. To turn the engine and all vehicle systems off, press and
hold the ENGINE STOP switch until the engine stops. The ENGINE STOP
switch red indicator will be lit until complete system shut
down.
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USPS 4400 Model Supplement to Section D Vehicle Operation
DS- 5
LIFT AXLE SYSTEM
WARNING The lift axle automatically raises to the Up position
whenever the ignition is turned Off. Ensure that all bystanders are
clear of lift axle(s) until all axle movement has stopped. Failure
to observe these precautions could result in personal injury or
death. This vehicle may be equipped with a lift axle that provides
increased load carrying capacity. The lift axle is designated as a
Tag axle, due to its location, behind the drive axle. The use of
the lift axle allows the vehicle to safely carry up to XXX pounds
of cargo.
Lift Axle System Operation
The lift axle system consists of the ESC commanded cluster
indicators, the load monitoring sensor, two lift axle control
switches, and the lift axle itself. The lift axle system is used
along with the IROS air suspension, when loading or unloading cargo
(See IROS section for further details).
The lift axle system will be utilized after the vehicle has been
loaded or unloaded. After the cargo has been loaded, the vehicle
should be driven away from the loading dock to a flat surface. The
load monitoring sensor then determines whether or not the lift axle
should be raised or lowered and alerts the driver using the cluster
warning lights.
Lift Axle Controls The raising or lowering of the lift axle is
done by the driver, or, depending on vehicle operational
situations, can be ESC-controlled. The controls used by the driver
to control the lift axle are two, 2 position, multiplexed switches
(LIFT AXLE/UP, and LIFT AXLE/DOWN).
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Supplement to Section D Vehicle Operation USPS 4400 Model
DS- 6
Driver Controlled Lift Axle Operation The driver can use the
LIFT AXLE/UP or LIFT AXLE/DOWN switch to the raise or lower the
lift axle as long as the vehicle speed is below 5 mph. After the
vehicle has been loaded or unloaded and moved away from the dock
(to a flat surface) the ESC will indicate, via the RAISE AXLE or
LOWER AXLE cluster indicator, whether or not to raise or lower the
lift axle.
Perform the following lift axle operations, when loading or
unloading cargo:
a. Maneuver the vehicle in position against loading dock, place
the transmission in Neutral, and set the Park brake. This will
cause the lift axle to automatically raise, and, if the vehicle
weight is above a predetermined weight value, the air suspension
will Dump. The LIFT AXLE/UP switch indicator will be on while the
lift axle is being raised, and the SUSPENSION/DUMP switch indicator
will be off. The LIFT AXLE/UP switch indicator will remain on while
the lift axle is being raised and will go off after the lift axle
is in raised position.
b. If the lift axle is not currently raised, momentarily push
the LIFT AXLE/UP switch to the UP position. If the vehicle weight
is above a predetermined weight value, the air suspension will
Dump. The switch indicator will be on, and will remain on while the
lift axle is being raised.
c. After cargo is loaded, release Park brake and pull vehicle
away from loading dock and drive to a flat surface. Place the
transmission in Neutral and ensure that the air suspension has been
set to ride height (SUSP/DUMP switch to the SUSP position) and wait
for 30 seconds (this allows the load sensor to determine cargo
load).
d. If the Instrument cluster LOWER AXLE light comes on,
momentarily push the LIFT AXLE/DOWN switch to the DOWN position.
The switch indicator will be on steadily as the lift axle is being
lowered, and will remain on while the lift axle is being lowered.
After the lift axle is in lowered position the LOWER AXLE light
will go off.
Notes: (1) The load sensor only works accurately if the lift
axle is raised, which places the load completely on rear axle) (2)
Either switch indicator will flash slowly, if the ESC inhibits the
drivers request to raise or lower the lift axle. (3) Either switch
indicator will flash rapidly If there is a system malfunction. (4)
The lift axle automatically raises to the up or resting position
whenever the ignition is turned Off.
ESC-Controlled Lift Axle Operation The ESC, under certain
conditions, will determine and control the operation of the lift
axle. The following will describe the ESC-controlled lift axle
operations:
a. Same as a. above.
b. After loading/unloading, move the vehicle to a flat surface
and wait for 30 seconds for the ESC to determine cargo weight.
c. If the load monitoring sensor determines the cargo weight is
equal to or greater than a predetermined weight value, the ESC will
turn on the Lower Axle cluster indicator. If the driver doesnt push
the LIFT AXLE/DOWN switch, the ESC will automatically lower the
lift axle whenever the speed of the vehicle reaches 5 mph. The
Lower Axle cluster light and the LIFT AXLE/DOWN switch indicator
will be on steadily while the lift axle is being lowered, and then
will go off when the lift axle is in the lowered position.
d. If, at a vehicle speed less than 5 mph, the driver places the
SUSP/DUMP switch in the DUMP position, the lift axle will
automatically be raised. The SUSP/DUMP switch and the LIFT AXLE/UP
switch indicators will be on while the lift axle is being raised
and will turn off when the lift axle is in its raised position.
(See the Air Suspension section for details of the Air
Suspension/Dump switch).
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USPS 4400 Model Supplement to Section D Vehicle Operation
DS- 7
AIR SUSPENSIONS The United States Postal Service (USPS) vehicle
is equipped with either the International Ride Optimized Suspension
(IROS) suspension or the Hendrickson Air Suspension (HAS-230). The
Hendrickson Air Suspension is only used when the vehicle is
equipped with a lift axle. All other vehicles with air suspensions
will use the IROS.
Both suspensions utilize the same switch to release air from or
filling the air suspensions. The following description of the IROS
system also applies to the Hendrickson Air Suspension, and any
references to lift axle operation will be assumed as applying to
the Hendrickson Air Suspension.
INTERNATIONAL RIDE OPTIMIZED SUSPENSION (IROS) (OPTIONAL)
CAUTION
The vehicle must not be operated on the road before the
suspension air springs are inflated. This will prevent suspension
damage and ride degradation. Failure to observe this may result in
property damage. The International Ride Optimized Suspension (IROS)
is a variable rate suspension system that automatically adjusts to
different loads to maintain constant frame height. The system
provides improved vehicle ride and increased driver comfort. This
feature also allows the rear of the vehicle to lower several inches
for cargo loading and unloading.
The system is controlled by the two position DUMP/SUSP switch
with an indicator light in the DUMP position. This switch controls
solenoids, which directs air to the suspension dump and height
valve.
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Supplement to Section D Vehicle Operation USPS 4400 Model
DS- 8
When the DUMP/SUSP switch is in the DUMP position and the
vehicle speed is below 5 mph, air supplied to the air suspension is
released, lowering the frame for loading. Placing the switch is the
SUSP position causes air to fill or remain in the air suspension
for proper operating ride height.
The DUMP/SUSP switch will operate the IROS system only if the
ignition switch is in either ACC(essory) or ON positions and the
air tanks have sufficient pressure to fill the suspension. When the
ignition switch is turned off, power to the solenoid will be
removed, therefore, the suspension will remain in the state last
set by the DUMP/SUSP switch.
NOTE: The suspension will dump when the ignition switch is in
the either ACC(essory) or ON position, but will only fill when the
ignition switch is in the ON position.
Air Suspension Dump Switch Notes: (1) To lower the suspension
(SUSP/DUMP switch to DUMP), the vehicle speed must be less than 5
mph.
(2) The SUSP/DUMP switch functions will be inhibited by either a
Traction Control or ABS event. When either of these events occur,
the SUSP/DUMP switch will have to be manually recycled after the
event has passed in order to complete the operation.
The following is the operation of the Air Suspension Dump
(SUSP/DUMP) switch in controlling the vehicle ride height:
a. When the SUSP/DUMP switch is pushed to the DUMP position, the
ESC releases air from the air suspension bag. The switch indicator
comes on and remains while the suspension is being lowered.
b. When the SUSP/DUMP switch is pushed to the SUSP position, the
driver is requesting the ESC to fill the air suspension bag, and
the switch indicator will be off.
ESC-Controlled Air Suspension Operation The following lists the
circumstances that require ESC control of ride height.
a. The ESC will automatically switch from DUMP to SUSP if, while
the ESC is commanding a DUMP operation, the vehicle speed exceeds 5
mph. Once this occurs, the only means to deflate the suspension
will be to recycle the SUSP/DUMP switch to the DUMP position.
b. On vehicles equipped with a lift axle, the suspension will
automatically dump if the vehicles lift axle is raised by the
driver, and the vehicle weight is greater than a predetermined
weight value.
c. When the Park brake is set, and the cargo weight is above a
predetermined value, the suspension will automatically Dump.
Air Suspension Dump System Faults a. The cluster will issue an
audible 10 beep alarm whenever the driver pushes the DUMP position
of the SUSP/DUMP switch, and the
vehicle exceeds 5 mph.
b. The SUSP/DUMP switch indicator will blink rapidly in the
event of a system component failure or a bad system signal status,
when the SUSP/DUMP switch is in the DUMP position.
c. The SUSP/DUMP switch indicator will blink slowly in the event
of an ESC command fault, regardless of the position of the
SUSP/DUMP switch.