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Western Star 4700 Maintenance Manual

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WESTERN STAR
Maintenance Manual
STI-445-6
A24-01243-000

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Summary of Contents for Western Star 4700

  • Page 1 ® WESTERN STAR Maintenance Manual STI-445-6 A24-01243-000...

  • Page 2: Models

    WESTERN STAR MAINTENANCE MANUAL Models: 4700 Models 4800 Models 4900 Models 5700 Models 5900 Models 6900 Models STI-445-6 (12/15) Published by Daimler Trucks North America LLC 4747 N. Channel Ave. Portland, OR 97217 Printed in U.S.A.
  • Page 3 Western Star Driver’s Manual. IMPORTANT: Descriptions and specifications in this manual were in effect at the time of printing. Western Star Trucks reserves the right to discontinue models and to change specifications or design at any time without notice and without incurring obligation.
  • Page 4 ™ EZWiring EZWiring makes Western Star, Freightliner, Freightliner Custom Chassis Cor- poration, Sterling, and Thomas Built Buses products’ wiring drawings and float- ing pin lists available online for viewing and printing. EZWiring can also be ac- cessed from within PartsPro.
  • Page 5 Field Service Campaigns Field service campaigns are concerned with non-safety-related service work or replacement of parts. All field service campaigns are distributed to dealers; cus- tomers receive notices that apply to their vehicles. I–2 Western Star Maintenance Manual, March 2011...
  • Page 6 Introduction Page Description For an example of a Western Star Maintenance Manual page, see Fig. Rear Axle 35−01 Drive Axle Lubricant Level Check NOTICE Failure to keep the rear axle filled to the proper level with the recommended lubricant can result in rear axle damage.
  • Page 7 83 ....Heater and Air Conditioner 88 ....Hood, Grille, and Cab Fenders I–4 Western Star Maintenance Manual, March 2011...

  • Page 8: Table Of Contents

    Verification of Inspections Log............00–12 Western Star Maintenance Manual, September 2015...

  • Page 9: Determining Scheduled Maintenance Intervals

    • regional delivery that is mostly freeway miles • interstate transport Performing regular maintenance will help ensure that your Western Star vehicle delivers safe, reliable ser- • any highway operation with high annual mileage vice and optimum performance for years to come.
  • Page 10 Use Service Schedule I (severe service) maintenance intervals for vehicles that operate under severe conditions, such as extremely poor roads, heavy dust accumulation, extreme climate, frequent short distance travel, construction-site operation, logging, city operation, or farm operation. Table 1, Maintenance Service Schedule Table 00/2 Western Star Maintenance Manual, September 2015...
  • Page 11 48 000 3000 31st 31,000 49 600 3100 32nd 32,000 51 200 3200 33rd 33,000 52 800 3300 34th 34,000 54 400 3400 Table 2, 1st through 34th Maintenance for Service Schedule I Vehicles 00/3 Western Star Maintenance Manual, September 2015...
  • Page 12 M1 and M2 65,000 104 600 6500 66th 66,000 106 200 6600 67th 67,000 107 800 6700 68th 68,000 109 400 6800 Table 3, 35th through 68th Maintenance for Service Schedule I Vehicles 00/4 Western Star Maintenance Manual, September 2015...
  • Page 13 156 100 9700 98th 98,000 157 700 9800 99th 99,000 159 300 9900 100th M1, M2, M3, and M4 100,000 160 900 10,000 Table 4, 69th through 100th Maintenance for Service Schedule I Vehicles 00/5 Western Star Maintenance Manual, September 2015...
  • Page 14 400 000 21st 262,000 420 000 22nd 275,000 440 000 23rd 287,000 460 000 24th M1, M2, M3, and M4 300,000 480 000 Table 5, 1st through 24th Maintenance for Service Schedule II Vehicles 00/6 Western Star Maintenance Manual, September 2015...

  • Page 15: Engine Belt Inspection

    Numbers in this table are reference numbers match- operations listed in the "Pretrip and Post-Trip Inspec- ing those in the text of this manual. tion and Maintenance" chapter of the Western Star Driver’s Manual. Maintenance Operation Sets for Groups 00 through 88 Maintenance Interval Maint.
  • Page 16 • • • 46–06 Steering Shaft Lubrication • • • • • 47–01 Fuel Filter Replacement • • • • • 47–02 Fuel Separator Sight Bowl Cleaning and Element Replacement • • • 00/8 Western Star Maintenance Manual, September 2015...
  • Page 17 If equipped with an oil-coalescing desiccant cartridge, replace the cartridge once a year, regardless of mileage. Otherwise use the M4 maintenance interval. Complete this procedure every 25,000 miles (40 225 km), 3 months, or 500 operating hours, whichever comes first. Table 6, Maintenance Operation Sets for Groups 00 through 88 00/9 Western Star Maintenance Manual, September 2015...

  • Page 18: Initial Maintenance (Im) Operations

    NOTE: Numbers in this table are reference numbers this table, perform all daily and weekly maintenance matching those in the text of this manual. operations listed in the "Pretrip Inspection and Daily Maintenance" chapter of the Western Star Driver’s Manual. Initial Maintenance (IM) Operations Maintenance...

  • Page 19: Lubrication And Fluid Level Check

    For Detroit axles, complete this procedure once a year or at the following applicable interval, whichever comes first: every 5000 miles (8000 km) for Schedule I vehicles; or every 100,000 miles (161 000 km) for Schedule II vehicles. Table 8, Maintenance Operation 00-06, Lubrication and Fluid Level Check for Service Schedules I and II 00/11 Western Star Maintenance Manual, September 2015...

  • Page 20: M1 Maintenance Interval Operations Table

    If equipped with an oil-coalescing desiccant cartridge, replace the cartridge once a year, regardless of mileage. Otherwise use the M4 maintenance interval. † Complete this procedure every 25,000 miles (40 225 km), 3 months, or 500 operating hours, whichever comes first. Table 9, MI Maintenance Interval Operations for Service Schedules I and II 00/12 Western Star Maintenance Manual, September 2015...

  • Page 21: M2 Maintenance Interval Operations Table

    Intervals vary by transmission model, application, lubricant, and use. Contact Allison to determine the precise interval(s) for the transmission model and lubri- cant used on the vehicle. Table 10, M2 Maintenance Interval Operations for Service Schedules I and II 00/13 Western Star Maintenance Manual, September 2015...

  • Page 22: M3 Maintenance Interval Operations Table

    Alcohol Evaporator Cleaning and Inspection 60–02 Mirror Folding Check For 5700 models, complete this procedure every 300,000 miles (485 000 km). Table 11, M3 Maintenance Interval Operations for Service Schedules I and II 00/14 Western Star Maintenance Manual, September 2015...

  • Page 23: M4 Maintenance Interval Operations Table

    Fluid Change, Hydraulic Clutch Control 26–04 ESS Transmission Filter and Boot Inspection 26–05 Transmission Inspection 42–03 Air Dryer Desiccant Replacement 49–02 CAT CGI Bellows Replacement Table 12, M4 Maintenance Interval Operations for Service Schedules I and II 00/15 Western Star Maintenance Manual, September 2015...

  • Page 24: Noise Emission Controls Maintenance

    5. The removal of the fan shroud. pair of noise emission controls, should be genuine 6. The removal of, or rendering inoperative, en- Western Star parts. If other than genuine Western gine exhaust components, including the ex- Star parts are used, for replacement or repair of haust pipe clamping.
  • Page 25 Table 13, Verification of Inspections Log (Group 01) Engine Rear Supports and Engine Noise Panels Verification of Inspections Log (Group 20) Fan Drive Date Mileage Item Cost Maintenance Facility Table 14, Verification of Inspections Log (Group 20) Fan Drive 00/17 Western Star Maintenance Manual, September 2015...
  • Page 26 General Information Verification of Inspections Log: 00–12 Verification of Inspections Log (Group 49) Exhaust System Components Date Mileage Item Cost Maintenance Facility Table 15, Verification of Inspections Log (Group 49) Exhaust System Components 00/18 Western Star Maintenance Manual, September 2015...
  • Page 27 Safety Precautions ..............01–00 Western Star Maintenance Manual, September 2015...

  • Page 28: Engine Noise Panel Inspection (Noise Emission Control)

    Fig. 1 for Caterpillar noise panel locations. If the Fig. panels are torn, contact your Western Star dealer to have them replaced. Cummins M11, N14, ISC, and 3. Inspect the pulleys for excessive play or wobble. ISL engines, and Detroit Diesel Series 60 and DD13 Excessive play or wobble indicates a failure of engines do not have engine noise panels.

  • Page 29: Engine-Support Fasteners Check (Noise Emission Control)

    Check the front engine-support fasteners for tight- Fig. 15 for DD Series 60 model. ness. Tighten the 3/4-inch fasteners 260 to 310 lbf·ft (350 to 420 N·m). Fig. 16 for DD 13/15/16 models. 01/2 Western Star Maintenance Manual, September 2015...
  • Page 30 6. Uneven Rib Wear Fig. 2, Damaged Belts NOTE: At engine overhaul, and whenever the engine has been removed, inspect the lower and upper isolators (Refs. 6 and 7), and replace them if they are worn. 01/3 Western Star Maintenance Manual, September 2015...
  • Page 31 Fig. 3, EPDM Belt Wear 04/05/2001 f011983 1. Stop Bar 2. Idler Arm Stops 04/11/2001 f011982 A. Shoulder Fig. 5, Cummins Self-Tensioner 1. Spring-Loaded Tensioner 2. Label Green Zone Fig. 4, Caterpillar Self-Tensioner 01/4 Western Star Maintenance Manual, September 2015...
  • Page 32 1. Fan Clutch 2. Air Conditioning Compressor 3. Alternator 4. Spring-Loaded Tensioner 04/30/2001 f011977 1. Fan Clutch Fig. 7, Caterpillar 3126B 2. Air Conditioning Compressor 3. Alternator Fig. 9, Caterpillar C15 and C16 01/5 Western Star Maintenance Manual, September 2015...
  • Page 33 1. Fan Clutch 2. Air Conditioning Compressor 3. Alternator 4. Spring-Loaded Tensioner Fig. 10, Cummins ISX Signature 600 (pre-2007) 04/30/2001 f011980 1. Fan Clutch 2. Air Conditioning Compressor 3. Alternator Fig. 12, Cummins N14 01/6 Western Star Maintenance Manual, September 2015...
  • Page 34 3. AC Compressor 6. Crank Shaft Pulley Fig. 14, Cummins ISC/ISL 01/19/2012 f012182a 1. Fan Belt 4. AC Drive Belt 2. Alternator 5. Fan Clutch 3. AC Compressor Fig. 13, Cummins ISX (2007 or later) 01/7 Western Star Maintenance Manual, September 2015...
  • Page 35 6. Water Pump Fig. 16, DD 13/15/16 01/07/2011 f012191 1. Alternator 2. AC Belt 3. Air Conditioning Compressor 4. Fan Clutch 5. Fan Belt 6. Spring-Loaded Tensioner Fig. 15, Detroit Diesel Series 60 01/8 Western Star Maintenance Manual, September 2015...
  • Page 36 Engine 08/22/2001 f011992 1. Transmission Housing 2. Transmission Nodal Mount Bracket 3. Bolt, 5/8–18 x 4 4. Frame Bracket 5. Nut, 5/8–18 6. Lower Isolator 7. Upper Isolator Fig. 17, Rear Engine-Support 01/9 Western Star Maintenance Manual, September 2015...
  • Page 37 Intake Piping Inspection ............. 09–01 Western Star Maintenance Manual, January 2015...

  • Page 38: Table Of Contents

    6. Check the condition of the gear clamp. If wear is clamps were loose, disassemble for further in- evident, replace the gear clamp with a constant- spection. torque clamp. Constant-torque clamps should be 09/1 Western Star Maintenance Manual, January 2015...

  • Page 39: Check The Tightness And Condition Of The Clamp

    firewall. The air intake is through ducting built 5. Clamp, Elbow Duct to Turbo into the hood and routed into the top of the air Fig. 2, Frontwall-Mounted Air Cleaner, 4700 Models cleaner canister. See Fig. 1. Check that the bolts on the canister mounting brackets are tight.

  • Page 40: Air Cleaner Outlet Hose Clamp

    4. Spring Clamp 5. Charge Air Cooler Hose 07/30/2009 f090470 1. Air Cleaner Housing Fig. 4, Frontwall-Mounted Air Cleaner, Non–4700 2. Front Isolator Top Nut (2) Models 3. Air Restriction Indicator 09–02 Air Cleaner Element 4. Air Cleaner Outlet Hose Clamp 5.
  • Page 41 See Section mounted restriction gauge. 09.05 of the Western Star Workshop Manual for replacement instructions. Vehicles may be equipped with either a manual-reset restriction indicator with graduations (Fig.
  • Page 42 C. Damaged Insert, Countersunk 1. Insert The standard cowl-mounted air cleaner system used 2. Screw on Western Star trucks is a reverse air flow design. Fig. 9, Air-Cleaner-Housing Fasteners, 5700 Models The air flow in this system flows from the inside of 09/5...
  • Page 43 4. Clean the inside of the canister thoroughly. Use a clean damp cloth to wipe every surface clean. 09/6 Western Star Maintenance Manual, January 2015...

  • Page 44: Elbow

    4. Inspect the air restriction indicator mounted at the outlet end pipe of the canister, and reset it. 09/7 Western Star Maintenance Manual, January 2015...
  • Page 45 Air Intake 07/18/2011 f090492 1. Charge Air Cooler Core 2. Constant-Torque Clamps 3. Turbo Out Elbow 4. Clamp, Turbo Out Elbow Fig. 14, Charge Air Cooler and Piping 09/8 Western Star Maintenance Manual, January 2015...

  • Page 46: Safety Precautions

    Safety Precautions ..............13–00 Western Star Maintenance Manual, September 2015...
  • Page 47 Tighten the connections and replace the lines and fasteners if needed. 3. For the air governor, inspect the piping and con- nections for leaks. Replace gaskets and faulty components as needed. 13/1 Western Star Maintenance Manual, September 2015...
  • Page 48 Safety Precautions ..............15–00 Western Star Maintenance Manual, September 2015...
  • Page 49 15–01 Alternator and Starter 2. Inspect the battery cables for wear and replace as needed. Clean cable connector terminals with Check a wire brush. Consult your Western Star Dealer for troubleshooting, adjustment, and battery re- 1. Disconnect the batteries. placement.
  • Page 50 Safety Precautions ..............20–00 Western Star Maintenance Manual, September 2015...
  • Page 51 The coolant supplied with a Western Star vehicle is a 50/50 mix of antifreeze and water giving protection 09/07/2011 f200745 down to –35°F (–37°C).
  • Page 52 (i.e., diesel fuel). A strong diesel smell indicates that fuel is contami- nating the coolant, and the vehicle must be taken to a Western Star dealer to have the source found and the cooling system chemically flushed. 02/05/2013 f500390 5.
  • Page 53 Torque hose clamps will hold enough torque to operating properly, or the thermostat may be stuck automatically keep consistent sealing pressure. closed. Take your vehicle to a Western Star dealer to Due to temperature changes, the screw tip ex- have the problem repaired.
  • Page 54 Replace the cap if the vacuum-relief valve is stuck. 7. Shut off the air at the pressure gun nozzle and allow the radiator to refill with water, then repeat 20/4 Western Star Maintenance Manual, September 2015...
  • Page 55 Allow the engine to warm to normal operating temperature. Check the radiator and hoses for leaks. Repair as required. 14. Shut off the engine and check the coolant level. See "Coolant Inspection" 20–01. 20/5 Western Star Maintenance Manual, September 2015...
  • Page 56 Sleeve Assembly Bronze Bushing Lubrication ..........25–03 Western Star Maintenance Manual, September 2015...
  • Page 57 fittings in the transmission clutch housing. yoke finger and sleeve bushing contact points. Fig. 3 Fig. 4. Wipe the dirt from the grease Fig. fittings and lubricate with multipurpose chassis 5. Install the clutch inspection plate. grease. 25/1 Western Star Maintenance Manual, September 2015...
  • Page 58 Using a pressure-type grease gun equipped with high-temperature grease only, lubricate until grease flows from the release bearing housing. 25/2 Western Star Maintenance Manual, September 2015...
  • Page 59 fit the bleed valve tight enough available through SPX Kent-Moore Tools and so it does not fall off when fluid is may be used to complete the following proce- pumped out. 25/3 Western Star Maintenance Manual, September 2015...
  • Page 60 5) with new DOT 4 brake fluid from a tightly sealed container. 3. Remove the cap from the bleed valve of the slave cylinder. See Fig. 7. On the valve, install a transparent drain hose connected to a catch 25/4 Western Star Maintenance Manual, September 2015...
  • Page 61 Transmission Inspection ............. 26–05 Western Star Maintenance Manual, September 2015...
  • Page 62 3. Operate the engine at idle (500 to 800 rpm) until 4. Shift from DRIVE to NEUTRAL, and then shift to normal operating temperature is reached. Check REVERSE to fill the hydraulic system. that the sump temperature is 160 to 200°F (71 to 26/1 Western Star Maintenance Manual, September 2015...
  • Page 63 fluid level is at or above 3/4 of the sight glass, level with the lower edge of the fill opening. See then it is at or above the minimum fill level. See Table 1 for approved transmission lubricants. Fig. 26/2 Western Star Maintenance Manual, September 2015...
  • Page 64 26–02 Manual Transmission then tighten it 50 lbf·ft (68 N·m). Fluid Change NOTICE Operating a transmission with the fluid level higher or lower than recommended can result in transmission damage. Do not overfill the transmis- 26/3 Western Star Maintenance Manual, September 2015...
  • Page 65 The filter is mounted in a vertical position, N·m). and should be filled with fluid before installation 8. Operate the vehicle to check for correct opera- to ensure the proper fluid level in the transmis- tion. 26/4 Western Star Maintenance Manual, September 2015...
  • Page 66 26 (12.3) Meritor 10-Speed RTLO–14610B 28 (13.2) RM10–115A 20 (9.5) RTO/RTX–14708LL 29 (13.7) RMX10–115A 20 (9.5) RT–14710B 26 (12.3) RM10–125A 20 (9.5) RTX–14710B/C 26 (12.3) RMX10–125A 20 (9.5) RTLO–15610B 28 (13.2) RM10–135A 20.5 (9.7) 26/5 Western Star Maintenance Manual, September 2015...
  • Page 67 filter element Wear safety goggles when using compressed air will last the life of the vehicle. to clean parts, as permanent harm to eyes could result from flying debris. 26/6 Western Star Maintenance Manual, September 2015...
  • Page 68 1. Remove the filter from its location on the top wrench can crush or damage the breather stem and right-hand side of the transmission. produce metal particles that could enter the transmis- sion). 2. Clean the filter with solvent. 26/7 Western Star Maintenance Manual, September 2015...
  • Page 69 160 to 200°F (71 to 93°C). 8. Install the fluid filters on the cover assemblies. 9. Install the filter and cover assemblies into the filter compartment. Align each cover assembly 26/8 Western Star Maintenance Manual, September 2015...
  • Page 70 7. Drain Plug 4. O-Ring Fig. 8, Allison Transmission Filter Locations and Components with the holes in the channel plate sump, and push the cover assemblies in by hand to seat the seals. 26/9 Western Star Maintenance Manual, September 2015...
  • Page 71 The oil 7. Operate the engine for five minutes after filling part number can be found in module 348 in the transmission, then check the fluid level again. PartsPro. 26/10 Western Star Maintenance Manual, September 2015...
  • Page 72 Do not overfill the transmis- the main air system and the transmission reserve sion. Overfilling will force fluid out of the case air tank. See Fig. through the main shaft openings. 26/11 Western Star Maintenance Manual, September 2015...
  • Page 73 Fig. 13, Detroit Transmission Air Filter (typical installation) 4. Remove and discard the air filter. 5. Install a new air filter. 6. Install the air filter canister. 7. Start the engine and charge the air system. 26/12 Western Star Maintenance Manual, September 2015...
  • Page 74 Trailer Electrical Connector Lubrication ..........31–05 Western Star Maintenance Manual, December 2015...

  • Page 75: Mounting Bolt

    1. Disconnect the tractor from the trailer. For in- new parts. Replace all loose mounting bolts with structions, see the Western Star Driver’s Manual. 5/8–11 SAE grade 8 bolts, grade C locknuts, and 2. Thoroughly steam clean the fifth wheel.
  • Page 76 16. Pull Handle 25. Hair Pin Cotter 8. Cotter Pin, 3/16" x 1" 17. Bolt, Bumper 26. Wedge 9. Bumper Spring 18. Bushing 27. Step Jaw 10. Handle Spring Fig. 1, Fontaine Fifth Wheel 31/2 Western Star Maintenance Manual, December 2015...
  • Page 77 MOP 31–02 for lubrication instructions. Castloc II and Simplex Series 1. Disconnect the tractor from the trailer. For in- structions, see Chapter 10 of the Western Star 03/28/2013 f311140 Driver’s Manual. 1. Release Handle 2.
  • Page 78 8. Check all mounting bolts for signs of fatigue, and 5. The lever bar and operating handle must be in tighten them to the proper torque. For torque proper alignment. See Fig. 6. Compare the lever 31/4 Western Star Maintenance Manual, December 2015...
  • Page 79 1. Disconnect the tractor from the trailer. For in- the adjustment bolt clockwise one full turn, then structions, see the Western Star Driver’s Manual. reset the jam nut. Lock and unlock the mecha- 2. Thoroughly steam clean the fifth wheel.
  • Page 80 Inspect the locking plungers for full en- 10. Replace cracked, worn, or damaged parts with gagement. new parts. Replace all loose mounting bolts with 5/8–11 SAE grade 8 bolts, grade C locknuts, and 31/6 Western Star Maintenance Manual, December 2015...
  • Page 81 fittings. A “low temp” grade grease rated for -30°F (-34°C) or lower such as Cato Oil and 31/7 Western Star Maintenance Manual, December 2015...
  • Page 82 2. Disengage and engage the locking plungers. parts. For sliding fifth wheels spray diesel fuel on the Check that the plungers are securely seated slide path of the base plate. without binding. If the locking plungers do no op- 31/8 Western Star Maintenance Manual, December 2015...
  • Page 83 4. Plunger Adjusting Bolt • Front Frame Brackets Fig. 13, Holland Fifth Wheel Sliding Mechanism • Front Suspension Spring Brackets erate properly see Group 31 of the Western Star • Fuel Tank Brackets Workshop Manual for adjustment procedures. • Radius Rods 3.
  • Page 84 • If the 294 bolt is fractured, DO NOT USE. Con- tact Premier Mfg. Co. 1 year after installation date: • Regardless of service duty, replace the 294 bolt with a new one. 31/10 Western Star Maintenance Manual, December 2015...
  • Page 85 Suspension U-Bolt Torque Check ............32–03 Western Star Maintenance Manual, September 2015...
  • Page 86 These suspensions quickly self 32/1 Western Star Maintenance Manual, September 2015...
  • Page 87 Many technicians find it difficult to differentiate be- it condenses and forms a film on the outside of the tween a misting shock and a true leaker, which shock body. When mixed with road debris and dust, 32/2 Western Star Maintenance Manual, September 2015...
  • Page 88 2. Inspect the brackets for cracks in the castings. Fig. 5, Misting Shock Inspect the V-rod tower welds for cracking or other signs of damage. Also check for contact between the frame rail and the upper axle clamp 32/3 Western Star Maintenance Manual, September 2015...
  • Page 89 4. Visually check the air spring piston for cracks, height-control valve housing. The bolts should chips, and broken areas. Check the air bag for not be loose, and should not require tightening. Only if necessary, tighten the valve housing 32/4 Western Star Maintenance Manual, September 2015...
  • Page 90 Be sure that the fasteners are torqued correctly. 8. If the axle stop measurement is not correct, con- Fasteners that are not tight can cause separation tact your Western Star dealer to adjust the level- of components or premature failure of compo- ing valves.
  • Page 91 32/6 Western Star Maintenance Manual, September 2015...
  • Page 92 If any problem is found, take the vehicle to your movement to prevent serious injury. Western Star dealer to have the problem corrected. 1. Inspect the fasteners that attach the suspension Neway Suspension brackets to the frame for proper torque.

  • Page 93: Front Suspension

    For some applications, like twin steer, the grease wheels are chocked to prevent accidental vehicle fitting is toward the inside, for clearance. When movement to prevent serious injury. 32/8 Western Star Maintenance Manual, September 2015...
  • Page 94 For Hendrickson RT2 and RTE2 Series, lubricate the bronze, ball-indented bushings in the spring eye, as follows. 1. Park the vehicle on a level surface, apply the parking brakes, and chock the front tires. 32/9 Western Star Maintenance Manual, September 2015...
  • Page 95 Group for torque specifications. Turn the wrench in a clockwise motion (looking up) until the torque wrench clicks. See Fig. 3. Remove the chocks. 07/13/2001 f320910 Fig. 11, Tightening Pattern for U-Bolt Nuts 32/10 Western Star Maintenance Manual, September 2015...

  • Page 96: Front Axle

    Wheel Alignment Check ............. 33–07 Western Star Maintenance Manual, September 2015...
  • Page 97 When lubricating knuckle Fig. 3. Knuckle pins without grease fittings are pin bushings, do not raise the front axle. Wipe the permanently lubricated. lube fittings clean, and apply multipurpose chassis 33/1 Western Star Maintenance Manual, September 2015...
  • Page 98 Do not the vehicle and then slightly toward the rear. replace the boot only. Then center the cross tube between the stop po- 33/2 Western Star Maintenance Manual, September 2015...
  • Page 99 Replace the entire cross tube assembly if either clamp is welded to the cross tube. 7. Check for proper installation of the tie rod end clamp to the cross tube. Make sure that the tie 33/3 Western Star Maintenance Manual, September 2015...
  • Page 100 filler plug. seen or touched is not sufficient. It must be level Install and tighten the fill plug 40 to 60 lbf·ft (54 with the bottom of the fill hole. to 81 N·m). 33/4 Western Star Maintenance Manual, September 2015...
  • Page 101 10. Remove the chocks. Then drive the vehicle, un- oughly. The drained oil should be stored appro- loaded, for 1 to 2 miles (2 to 3 km) at speeds not priately for recycling. 33/5 Western Star Maintenance Manual, September 2015...
  • Page 102 General Information If any of these listed conditions occur, the vehicle The axles and wheels are aligned at Western Star could need a front end alignment. using Hunter laser alignment equipment. Correct front axle alignment is needed to ensure long tire life, ease of handling, and steering stability.
  • Page 103 -1/32 to +3/32 inch. If corrections are needed, take the vehicle to your Western Star Dealer to adjust the toe-in. The Toe-in should be set as close as possible to +1/32 inch. 33/7 Western Star Maintenance Manual, September 2015...
  • Page 104 Two-Speed-Axle Shift Unit Lubricant Level Check ......... . 35–02 Western Star Maintenance Manual, September 2015...
  • Page 105 Fig. 4). If low, check for oil leaks (and make lubricants, and Table 4 Table 5 for axle ca- corrections as needed), and add oil to the level pacities. of the fill plug. 35/1 Western Star Maintenance Manual, September 2015...
  • Page 106 • For Meritor axles: 35 lbf·ft (47 N·m). Actual oil capacity might vary slightly depending on gear ratio. Table 2, Detroit Rear Axle Lubricant Capacity • For Dana Spicer axles: 50 lbf·ft (68 N·m). 35/2 Western Star Maintenance Manual, September 2015...
  • Page 107 3 degrees.: Forward 30 (14.2) Table 5, Meritor Drive Axle Lubricant Capacities for MT–40–14X Tandem Axles Rear 32 (15.14) Forward 30.2 (14.3) RT–40–145 Rear 25.8 (12.2) Forward 30.2 (14.3) RT–40–145P Rear 25.8 (12.2) 35/3 Western Star Maintenance Manual, September 2015...
  • Page 108 If operating under adverse conditions, check the breathers more often. If the breather is damaged or plugged, have it cleaned or replaced. For the location of the breather on Detroit 35/4 Western Star Maintenance Manual, September 2015...
  • Page 109 flushed. be used as a fill or level hole. 4. Clean the fill and drain plugs. Change them if 2. Clean the area around the fill plug, then remove necessary. the fill plug. 35/5 Western Star Maintenance Manual, September 2015...
  • Page 110 100,000 miles (160 000 km). Clean 2. Clean the oil fill plug and the area around it (see away the collected material deposited on Fig. 3), then remove it from the oil fill hole. 35/6 Western Star Maintenance Manual, September 2015...
  • Page 111 Do not point the air stream in the direction of other persons. Wash the strainer in solvent, and blow it dry with compressed air to remove oil and metal particles. 35/7 Western Star Maintenance Manual, September 2015...
  • Page 112 Wheel Nut and Rim Nut Torque Check ..........40–01 Western Star Maintenance Manual, December 2015...
  • Page 113 Fig. 1 for each of the three stages of tightening as follows: 1. Tighten each nut 50 lbf·ft (68 N·m). 2. Tighten each nut 100 lbf·ft (136 N·m). 3. Tighten each nut 150 lbf·ft (203 N·m). 40/1 Western Star Maintenance Manual, December 2015...
  • Page 114 12-Stud Wheel Rim Clamp and Nuts Adaptor Wheel Nut on Inside Bolt M22 x 1.5 450–500 (610–680) Circle † 50 (68) Adaptor Wheel Nut on Outside Bolt 3/4–10 100 (136) Circle 150 (203) 40/2 Western Star Maintenance Manual, December 2015...
  • Page 115 On front axles with over 12,000 lb (5448 kg) capacity, tighten the wheel nuts 240 to 265 lbf·ft (325 to 359 N·m). Gunite part number W–854 nut with a phosphate-and-oil coating must be used. Table 1, Wheel Fastener Torque For additional information on 12-stud wheel rims, see Section 40.00, Subject 220 of the Western Star Workshop Manual. 40–02 Tire Check Tires should be inspected closely during the first 3000 to 10,000 miles (5000 to 16 000 km) for abnor- mal wear.
  • Page 116 Safety Precautions ..............41–00 Western Star Maintenance Manual, September 2015...
  • Page 117 If the bearing mount is shaft, or can be rocked on its shaft, take it to an loose on the frame, have your Western Star authorized Western Star dealer for service. dealer tighten the mounting fasteners to the 4.
  • Page 118 See Fig. 7. Visually examine the driveshaft tubes for dents, item 2. Have your Western Star dealer repair or bends, twists, or other damage. If any tube ap- replace the yoke plug as needed. If the yoke...
  • Page 119 fitting. complete U-joint. 5. If grease does not appear at one seal, use a pry- ing tool to pry the U-joint trunnion away from the non-purging seal, or tap the driveshaft or yoke 41/3 Western Star Maintenance Manual, September 2015...
  • Page 120 See Fig. 5. This ensures complete lubrication of the splines. 3. Wipe the purged grease from the pressure-relief hole and slip joint seal, and any excess grease from the grease fitting. 41/4 Western Star Maintenance Manual, September 2015...
  • Page 121 Versajust Slack Adjuster Inspection and Lubrication......... 42–08 Western Star Maintenance Manual, September 2015...
  • Page 122 If air pressure build-up is ex- connection before re-installing it. Repeat the pro- tremely slow after two to three minutes, raise cess until all connections are properly sealed. the engine speed to 1000 to 2000 rpm. 42/1 Western Star Maintenance Manual, September 2015...
  • Page 123 Rotate the end 19. Start the engine, build air pressure, and check cover until it completely separates from the des- the air brake system for leaks. iccant cartridge. 42/2 Western Star Maintenance Manual, September 2015...
  • Page 124 Then separate the desiccant car- sembly could release the spring, resulting in per- tridge from the end cover. sonal injury. 3. Pull the cartridge bolt out of the cover and re- move the cartridge. 42/3 Western Star Maintenance Manual, September 2015...
  • Page 125 Rotate the cartridge clockwise about one full NOTE: It may be necessary to rotate the car- turn. Tighten the cartridge firmly. tridge slightly until the anti-rotation lugs are 42/4 Western Star Maintenance Manual, September 2015...
  • Page 126 4. Clean the top surface of the dryer base with a During the off season, drain the unit of alcohol. At commercial cleaning solvent. regular engine service intervals, open the drain cock to remove moisture from the alcohol evaporator. Be- 42/5 Western Star Maintenance Manual, September 2015...
  • Page 127 Slack adjusters that have a grease fitting must be 000 km), whichever comes first. The extended lubricated periodically to ensure proper brake opera- maintenance camshaft bushings are lubricated tion. during the brake reline service interval. 42/6 Western Star Maintenance Manual, September 2015...
  • Page 128 For operating temperatures of –20°F (–29°C) and NOTE: If equipped with an extended- higher, use Texaco Multifak EP-2 or Mobil Grease maintenance Q Plus ™ brake system, the slack No. 77. adjuster will not have a grease fitting. These 42/7 Western Star Maintenance Manual, September 2015...
  • Page 129 If the vehicle moves, the parking brakes are not operating correctly and must be repaired before the vehicle is returned to service. See Group 42 of the Western Star Workshop Manual for repair procedures. Brake Component Inspection 1. Park the vehicle on a level surface, set the park- ing brake, and chock the tires.
  • Page 130 Check Star Workshop Manual for repair procedures. for improper operation or adjustment of the slack adjuster. See Group 42 of the Western Star Workshop Manual for inspection and trouble- shooting procedures.
  • Page 131 Operating Stroke (Inches) 2. Inspect the slack adjuster for physical damage, 30 Long Stroke 2-1/2 paying attention to the link, boot, and clevis. If 24 Long 42/10 Western Star Maintenance Manual, September 2015...
  • Page 132 Brakes Actuator Stroke–Long Stroke Recommended Maximum Brake Actuator Size Operating Stroke (Inches) 24 Long Stroke 2-1/2 20 Long 16 Long Table 3, Actuator Stroke–Long Stroke 42/11 Western Star Maintenance Manual, September 2015...
  • Page 133 Steering Shaft Lubrication............46–04 Western Star Maintenance Manual, September 2015...
  • Page 134 3) from the steering gear and allow the oil to 2. Using a pressure gun, apply clean grease at the drain. grease fittings until old grease is forced out of the socket. Use multipurpose chassis grease 46/1 Western Star Maintenance Manual, September 2015...
  • Page 135 Do not use pliers to aid in removal of the filter; Flat Reservoir, Top Return Port pliers could cause metal chips to enter the steering system. 1. Set the parking brake and chock the rear tires. 46/2 Western Star Maintenance Manual, September 2015...
  • Page 136 fitting until old grease is forced out of the seals. Use multipurpose chassis grease NLGI 11. Fill the reservoir with an approved power steer- Grade 2 (8% 12-hydroxy lithium stearate grease) ing fluid to the line between the MIN COLD and 46/3 Western Star Maintenance Manual, September 2015...
  • Page 137 Fig. 7, TRW TAS Series Sector Shaft Lubrication type grease gun. See Fig. 7. Use of a high- pressure power grease gun will supply grease too quickly and could affect the high pressure seal, contaminating the hydraulic fluid. 46/4 Western Star Maintenance Manual, September 2015...
  • Page 138 Safety Precautions ..............47–00 Western Star Maintenance Manual, September 2015...
  • Page 139 filter can be used; 3. Turn the drain plug counterclockwise to open it. see Chapter 21 of the Western Star Driver’s Manual for instructions. 4. When the fuel/water separator is completely drained, turn the drain plug clockwise to close it.
  • Page 140 fluids have 8. On Fuel Pro 382 units, install the grommet on cooled. Draining it when the engine is hot could the bottom of the new filter. cause severe personal injury due to scalding. 47/2 Western Star Maintenance Manual, September 2015...
  • Page 141 11.3 Install and hand-tighten the vent cap tom of the fuel separator. O-ring and vent cap. 11.4 Start the engine. When the lubricating oil reaches its normal operating pressure, 47/3 Western Star Maintenance Manual, September 2015...
  • Page 142 4. Lower Housing 12. Grommet 7. Clear Cover 5. Cover O-Ring 13. Inlet Port/Check Valve 6. Filter Element 14. Heat Exchanger Fig. 5, DAVCO Fuel Pro 482 7. Spring Fig. 4, DAVCO Fuel Pro 382 47/4 Western Star Maintenance Manual, September 2015...
  • Page 143 10. Check Valve Assembly 4. Vent Cap O-Ring 11. Fuel Inlet Port 5. Vent Cap 12. Pre-Heater 6. Collar 13. Fuel Outlet Port 7. Clear Cover 14. Water-In-Fuel Sensor Fig. 6, DAVCO Diesel Pro 243 47/5 Western Star Maintenance Manual, September 2015...
  • Page 144 4. O-ring (when equipped with heater) 5. Stainless Steel V-Clamp (when equipped with heater) 6. Heater Assembly 7. Gasket 8. Sight Bowl Heater Rod 9. Sight Bowl Assembly 10. Vacuum Breaker/Drain Valve Fig. 7, ConMet Fuel Separator 47/6 Western Star Maintenance Manual, September 2015...
  • Page 145 Safety Precautions ..............49–00 Western Star Maintenance Manual, December 2015...
  • Page 146 NOx emissions. nents and alignment. Align or replace as necessary; see Group 49 of the Western Star Workshop Inspection Manual, or take the vehicle to an authorized Freight- To meet EPA10 emissions regulations for vehicles liner dealer.
  • Page 147 See Section 49.02 of the West- IMPORTANT: The aftertreatment device (ATD), ern Star Workshop Manual for repair procedures. which is part of the aftertreatment system (ATS), requires special attention during regularly scheduled maintenance inspections; see Fig. 49/2 Western Star Maintenance Manual, December 2015...
  • Page 148 Once a seal clamp is loosened or 4. If present, check the condition of the insulation removed, it must be replaced. material around the exhaust pipe between the turbocharger and the ATD. 49/3 Western Star Maintenance Manual, December 2015...
  • Page 149 Check the inlet/outlet mm) deep could cause internal damage to the tubes for leakage, dents, and corrosion, and DPF, causing it to malfunction. check for holes in the muffler. Replace parts as 49/4 Western Star Maintenance Manual, December 2015...
  • Page 150 On vehicles with CAT EPA07 compliant engines, re- 6. Check the U-bolt clamps for tightness, and place the CGI bellows at the M4 maintenance inter- tighten as needed. val to prevent a later failure. 49/5 Western Star Maintenance Manual, December 2015...
  • Page 151 8. Center Pipe 2. Inlet Pipe 6. CGI Bellows 9. Clamp 3. U-Clamp 7. Center Pipe-Support Brace 10. Outlet Pipe 4. Forward Pipe-Support Brace Fig. 5, CAT EPA07 Exhaust Installation with CGI Bellows 49/6 Western Star Maintenance Manual, December 2015...
  • Page 152 Use a straightedge to align the pipes so 1. Park the vehicle, set the parking brake, chock that the pipe ends that attach to the bel- the wheels. lows are parallel and concentric. 2. Open the hood. 49/7 Western Star Maintenance Manual, December 2015...
  • Page 153 13. Install the slip clamp with the retaining ring and 10. Remove the forward CGI pipe from the truck. graphite gasket ring onto the forward CGI pipe. Fig. 13 for proper installation. 49/8 Western Star Maintenance Manual, December 2015...
  • Page 154 12, Ref. A. 17. Install the slip clamps on the bellows. Tighten the slip clamps 11 lbf·ft (15 N·m). 18. Start the engine and check for exhaust leaks. Tighten any clamps as needed. 49/9 Western Star Maintenance Manual, December 2015...
  • Page 155 Safety Precautions ..............60–00 Western Star Maintenance Manual, December 2015...
  • Page 156 For vehicles with folding cab-mounted main mirrors, • Cab side extenders make sure that the mirrors fold freely on the pivot • Roof fairing/deflector points. Pivot each mirror fully forward and backward • Bumper 60/1 Western Star Maintenance Manual, December 2015...
  • Page 157 02/13/2015 f602539 Ride height is not adjustable. 1. Combined Air Spring/Shock Absorber Fig. 3, Air Spring/Shock Absorber Suspension • Hood • Side fairings Replace or repair damaged or missing components as needed. 60/2 Western Star Maintenance Manual, December 2015...
  • Page 158 Door Seal, Door Latch, Door Hinge, and Door Check Lubrication....... 72–01 Western Star Maintenance Manual, June 2010...
  • Page 159 Table 1. Use an appropriate applicator that will not leave material behind. Approved Grease NLGI Application Lubricant Grade Door Latches ConocoPhillips Triton® 460 Door Checks ConocoPhillips Megaplex® XD3 Table 1, Approved Grease 72/1 Western Star Maintenance Manual, June 2010...

  • Page 160: Heater And Air Conditioner

    Safety Precautions ..............83–00 Western Star Maintenance Manual, September 2015...
  • Page 161 0.024 inch (0.6 mm), replace the clutch. For instructions, see Section 83.04, Sub- and Replacement ject 140 of the Western Star Workshop Manual. For a Sanden compressor, if the drive plate The cab HVAC assembly has either two pleated, clutch needs adjustment, see Section 83.01,...
  • Page 162 2. From inside the cab, remove the fasteners that 4. Remove the two air filters from the air intake ple- attach the HVAC cover, if equipped, to the HVAC num. See Fig. assembly. Remove the HVAC cover. See Fig. 83/2 Western Star Maintenance Manual, September 2015...
  • Page 163 Make sure the arrow on the air filter is point- Allow the pre-filter to air dry. ing toward the sleeper HVAC assembly; see 5. Install the pre-filter, as removed. Fig. 5. Install the drawer in the cabinet. 83/3 Western Star Maintenance Manual, September 2015...
  • Page 164 5. Install the air filters in the sleeper HVAC assem- bly. Make sure the arrow on the air filter is point- ing toward the sleeper HVAC assembly; see Fig. 6. Install the drawer in the cabinet. 83/4 Western Star Maintenance Manual, September 2015...
  • Page 165 Hood Rear Support Lubrication............88–01 Western Star Maintenance Manual, June 2010...
  • Page 166 Approved Suppliers of Multi-Purpose Lithium Grease Supplier Grease Chevron Delo Heavy Duty EP Exxon Unirex EP2 Mobil Mobil Grease XHP 222 Shell Retinax LC Grease Texaco Starplex 2 Table 1, Approved Suppliers of Multi-Purpose Lithium Grease 88/1 Western Star Maintenance Manual, June 2010...

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