This is the Eaton hybrid system manual, publication S10024, for International 3200, DuraStar and WorkStar trucks with Unit Code 10HEV. It covers high-voltage safety, hybrid system description and remove-and-install procedures for the hybrid cooling components.
Official document details
| Brand | International Trucks (Navistar) |
| Model coverage | 3200, DuraStar and WorkStar (Unit Code 10HEV) |
| System / Group | 3000 Series / Eaton Hybrid |
| Publication no. | S10024 |
| Year / Revision | 10/15/2009 |
| Pages | 71 |
| File size | 8.8 MB |
| Format | |
| Language | English |
Inside the Eaton hybrid system manual
- Safety precautions and high-voltage warnings
- Hybrid system overview and International components
- Power Electronics Carrier (PEC) and Hybrid Drive Unit
- Hybrid Control Module and Electric Clutch Actuator
- 12-volt hybrid electrical components
- Heat exchanger removal and torque chart
Copyrighted by Navistar in October 2009, the manual leads with safety because the drive system uses potentially dangerous high voltage. Repeated warnings state that only trained technicians may work inside high-voltage components, that orange cables and conduit identify high-voltage circuits, and that the system must be de-energised using the voltage-disabling procedures before service. The description section maps the International-supplied cooling parts (heat exchanger, fan, pump, reservoir and cables) and the Eaton components including the Power Electronics Carrier, Hybrid Drive Unit, inverter motor controller, Hybrid Control Module and Electric Clutch Actuator, plus optional DC/DC converter, auxiliary power generator and electric PTO. A hood switch and a redundant hardwired engine-speed sensor provide interlocks. Remove-and-install steps focus on draining the cooling system and pulling the heat exchanger, with a torque chart closing the book.
Applicable truck models
The manual applies to 3200, DuraStar and WorkStar hybrids and stresses that orange cables and conduit carry hazardous voltage. Torque values include 19 to 24 lb-ft on the heat exchanger bolts and 8 to 10 lb-ft on cooling panel bolts. Verify coverage against your VIN and build sheet on the International Trucks website.
Who needs the Eaton hybrid system manual
Only trained high-voltage technicians should use this reference. It supports safe hybrid cooling-system drain and fill, heat exchanger and radiator guard removal, and inspection of orange high-voltage harnesses on medium-duty International hybrids.
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