Table of Contents
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Table of Contents
Related Manuals for Western Star 6900
Summarization of Contents
Introduction
Descriptions of Service Publications
Details the various types of service publications distributed.
Maintenance Manual Contents
General Information
Covers general information and index for maintenance procedures.
Engine
Details maintenance procedures for the vehicle's engine.
Air Intake
Procedures related to the air intake system.
Air Compressor
Maintenance and inspection of the air compressor.
Alternators and Starters
Procedures for checking alternators and starters.
Engine Cooling/Radiator
Maintenance related to the engine cooling system and radiator.
Clutch
Maintenance procedures for the vehicle's clutch system.
Transmission
Maintenance and service for the transmission.
Frame and Frame Components
Maintenance of the vehicle's frame and associated components.
Suspension
Procedures for inspecting and maintaining the suspension system.
Front Axle
Maintenance and inspection of the front axle components.
Rear Axle
Procedures for maintenance and inspection of the rear axle.
Wheels and Tires
Maintenance related to wheels and tires.
Driveline
Inspection and maintenance of the driveline components.
Brakes
Maintenance and inspection procedures for the brake system.
Steering
Maintenance and inspection of the steering system.
Fuel
Maintenance and service for the fuel system.
Exhaust
Inspection and maintenance of the exhaust system.
Cab
Maintenance and inspection of cab components.
Doors
Lubrication and maintenance of doors.
Heater and Air Conditioner
Maintenance for the heater and air conditioning system.
Hood, Grille, and Cab Fenders
Maintenance related to hood, grille, and cab fenders.
General Information
Determining Scheduled Maintenance Intervals
Guide to determining the correct maintenance intervals based on service type.
Initial Maintenance (IM) Operations
List of operations for initial maintenance (IM).
Lubrication and Fluid Level Check
Procedures for checking lubrication and fluid levels.
M1 Maintenance Interval Operations Table
Table outlining M1 maintenance interval operations.
M2 Maintenance Interval Operations Table
Table outlining M2 maintenance interval operations.
M3 Maintenance Interval Operations Table
Table outlining M3 maintenance interval operations.
M4 Maintenance Interval Operations Table
Table outlining M4 maintenance interval operations.
Maintenance Operation Sets Table
Table detailing maintenance operation sets for various groups.
Maintenance Service Table
Table outlining maintenance service schedules.
Noise Emission Controls Maintenance
Maintenance procedures for noise emission controls.
Vehicle Maintenance Schedule Tables
Tables detailing vehicle maintenance schedules.
Verification of Inspections Log
Log for verifying inspections.
Determining Scheduled Maintenance Intervals: 00–01
Types of Service
Explanation of different service schedules (I and II) and their usage.
Maintenance Operation Sets Table: 00–04
Maintenance Operation Sets for Groups 00 through 88
Lists maintenance operations grouped by section for the entire manual.
Initial Maintenance (IM) Operations: 00–05
Initial Maintenance (IM) Operations
Details the operations required for initial maintenance (IM).
Lubrication and Fluid Level Check: 00–06
Maintenance Operation 00–06, Lubrication and Fluid Level Check for Service Schedules I and II
Lists operations for lubrication and fluid level checks for service schedules.
M1 Maintenance Interval Operations Table: 00–07
M1 Maintenance Interval Operations for Service Schedules I and II
Details the maintenance operations required at the M1 interval.
M2 Maintenance Interval Operations Table: 00–08
M2 Maintenance Interval Operations for Service Schedules I and II
Details the maintenance operations required at the M2 interval.
M3 Maintenance Interval Operations Table: 00–09
M3 Maintenance Interval Operations for Service Schedules I and II
Details the maintenance operations required at the M3 interval.
M4 Maintenance Interval Operations Table: 00–10
M4 Maintenance Interval Operations for Service Schedules I and II
Details the maintenance operations required at the M4 interval.
Noise Emission Controls Maintenance: 00–11
Federal Law, Part 205: Transportation Equipment Noise Emission Controls
Information on federal law regarding noise emission controls.
Recommendations for Replacement Parts
Guidance on selecting replacement parts for noise emission controls.
Western Star Noise Emission Controls Warranty
Information regarding the warranty for noise emission controls.
Tampering With Noise Controls is Prohibited
Details on federal law prohibiting tampering with noise controls.
Maintenance Instructions
Instructions for maintaining noise emission controls.
Verification of Inspections Log: 00–12
Verification of Inspections Log (Group 01) Engine Rear Supports and Engine Noise Panels
Inspection log for engine rear supports and noise panels.
Verification of Inspections Log (Group 20) Fan Drive
Inspection log for fan drive components.
Engine
Engine Belt Inspection
Procedure for inspecting the engine drive belt.
Engine Noise Panel Inspection (Noise Emission Control)
Inspection of engine noise panels for emission control.
Engine-Support Fasteners Check (Noise Emission Control)
Checking engine support fasteners for noise control.
Pacbrake® Inspection and Maintenance
Inspection and maintenance of the Pacbrake system.
Safety Precautions
Safety precautions specific to engine operations.
01–02 Engine Belt Inspection
Belt and Pulley Inspection
Inspect drive belts and pulleys for wear and damage.
Belt Tension Inspection
Procedure for checking engine belt tension.
Air Intake
Air Cleaner Element Inspection and Replacement
Procedure for inspecting and replacing the air cleaner element.
Charge Air Cooler Inspection
Inspection of the charge air cooler system.
Intake Piping Inspection
Inspect the intake piping for condition and leaks.
09–01 Intake Piping Inspection
Engine-Mounted Air Cleaner, 5700 Models
Intake piping inspection for engine-mounted air cleaners.
Frontwall-Mounted Air Cleaner, 4700 Models
Intake piping inspection for frontwall-mounted air cleaners.
Cowl-Mounted Air Cleaner
Intake piping inspection for cowl-mounted air cleaners.
09–02 Air Cleaner Element Inspection and Replacement
Engine-Mounted Air Cleaner, 5700 Models
Inspection and replacement for engine-mounted air cleaners.
09–03 Charge Air Cooler Inspection
Frontwall-Mounted Air Cleaner, Non–4700 Models
Charge air cooler inspection for frontwall-mounted air cleaners.
Air Compressor
Air Compressor Inspection
Procedure for inspecting the air compressor.
Safety Precautions
Safety precautions for air compressor service.
Alternators and Starters
Alternator and Starter Check
Procedure for checking the alternator and starter.
Battery Check
Steps for inspecting and checking the vehicle's batteries.
Safety Precautions
Safety precautions for alternator and starter service.
Engine Cooling/Radiator
Coolant Inspection
Procedure for inspecting the engine coolant level and condition.
Cooling System Inspection (Noise Emission Control)
Inspect cooling system for noise emission control.
Cooling System Pressure-Flush
Procedure for flushing the cooling system under pressure.
Pressure/Filler Cap Test
Test for the pressure/filler cap.
Safety Precautions
Safety precautions for engine cooling system service.
20–01 Coolant Inspection
General Information
General information about engine heat and cooling system operation.
Inspection
Instructions for inspecting the coolant level and system.
Clutch
Clutch Release Bearing Lubrication
Procedure for lubricating the clutch release bearing.
Clutch Release Cross-Shaft Lubrication
Lubrication of the clutch release cross-shaft.
Clutch Replacement, Detroit™ Automated Transmissions
Information on clutch replacement for Detroit automated transmissions.
Fluid Change, Hydraulic Clutch Control
Procedure for changing fluid in the hydraulic clutch control.
Fluid Level Check, Hydraulic Clutch Control
Procedure for checking fluid level in the hydraulic clutch control.
Safety Precautions
Safety precautions for clutch system service.
Sleeve Assembly Bronze Bushing Lubrication
Lubrication of the sleeve assembly bronze bushing.
Transmission
Allison Transmission Fluid and Filter Change
Procedure for changing Allison transmission fluid and filter.
Allison and Eaton Fuller Transmission Breather Check
Check breathers on Allison and Eaton Fuller transmissions.
Detroit™ Automated Transmission Air Filter Replacement
Procedure for replacing the air filter on Detroit automated transmissions.
Detroit™ Automated Transmission Fluid Change and Magnetic Plug Cleaning
Change fluid and clean magnetic plug on Detroit automated transmissions.
Detroit™ Automated Transmission Fluid Level Inspection
Inspect fluid level for Detroit automated transmissions.
ESS Transmission Filter and Boot Inspection
Inspect ESS transmission filter and boot.
Manual Transmission Air Filter/Regulator Check, and Clean or Replace
Check, clean, or replace manual transmission air filter/regulator.
Manual Transmission Fluid Change
Procedure for changing manual transmission fluid.
Safety Precautions
Safety precautions for transmission service.
Transmission Fluid Level Inspection
Procedure for inspecting transmission fluid level.
Transmission Inspection
General inspection of the transmission.
26–01 Transmission Fluid Level Inspection
Allison Transmission
Fluid level inspection for Allison transmissions.
Cold Check
Procedure for checking transmission fluid level when cold.
Hot Check
Procedure for checking transmission fluid level when hot.
26–03 Manual Transmission Air Filter/Regulator Check, and Clean or Replace
Eaton/Fuller
Air filter/regulator check for Eaton/Fuller transmissions.
Meritor
Air filter/regulator check for Meritor transmissions.
26–07 Allison Transmission Fluid and Filter Change
Allison 3000 Family and 4000 Family Transmissions
Fluid and filter change for Allison 3000/4000 family transmissions.
Frame and Frame Components
Fifth Wheel Inspection
Inspection procedures for the fifth wheel.
Fifth Wheel Lubrication
Lubrication procedures for the fifth wheel.
Frame Fastener Torque Check
Check torque of frame fasteners.
Holland Fifth Wheel Sliding Mechanism Inspection
Inspect Holland fifth wheel sliding mechanism.
Premier 690 Coupling Inspection
Inspection of the Premier 690 coupling.
Safety Precautions
Safety precautions for frame and component service.
Trailer Electrical Connector Lubrication
Lubrication of trailer electrical connectors.
31–01 Fifth Wheel Inspection
Fontaine
Fifth wheel inspection procedures for Fontaine models.
Holland FWS1
Inspection procedures for Holland FWS1 fifth wheels.
31–02 Fifth Wheel Lubrication
Fontaine
Lubrication procedures for Fontaine fifth wheels.
Holland FWS1
Lubrication procedures for Holland FWS1 fifth wheels.
Holland FW35
Lubrication procedures for Holland FW35 fifth wheels.
Suspension
Safety Precautions
Safety precautions for suspension system service.
Suspension Inspection
General procedures for inspecting the suspension system.
Suspension Lubrication
Lubrication procedures for suspension components.
Suspension U-Bolt Torque Check
Check the torque of suspension U-bolts.
32–01 Suspension Inspection
Front Suspension Check
Inspect front suspension assemblies for damage.
Front and Rear Suspension Shock Absorber Check
Check front and rear suspension shock absorbers.
Quick Test
Quick test to check shock absorber function.
Rear Suspension Check
TufTrac Suspension
Inspection procedures for TufTrac suspension.
AirLiner Suspension
IMPORTANT: To prevent voiding the warranty on Barksdale height-control valves, note the following:
Important notes regarding Barksdale height-control valve warranty.
Hendrickson HAS
WARNING
Warning regarding fastener torque for Hendrickson HAS suspension.
Neway Suspension
WARNING
Warning regarding inspections for Neway suspension.
32–02 Suspension Lubrication
Front Suspension
Lubrication procedures for front suspension components.
Rear Suspension
Freightliner
Lubrication for Freightliner rear suspensions.
Chalmers
Lubrication requirements for Chalmers rear suspension.
Hendrickson
Lubrication for Hendrickson rear suspensions.
Neway
Lubrication requirements for Neway rear suspension.
Reyco
Lubrication requirements for Reyco rear suspension.
32–03 Suspension U-Bolt Torque Check
CAUTION
Caution regarding retorquing U-bolt nuts.
Front Axle
Front Axle Wheel Bearing Lubrication
Procedure for lubricating front axle wheel bearings.
Front Drive Axle Lubricant Change
Procedure for changing front drive axle lubricant.
Front Drive Axle Lubricant Level Check
Procedure for checking front drive axle lubricant level.
Knuckle Pin Lubrication
Lubrication of knuckle pins.
Safety Precautions
Safety precautions for front axle service.
Tie Rod Inspection
Inspection of tie rod ends and boots.
Tie Rod Lubrication
Lubrication of tie rod ends.
Wheel Alignment Check
Procedure for checking wheel alignment.
33–01 Knuckle Pin Lubrication
Detroit™ Axles
Knuckle pin lubrication for Detroit axles.
Dana Spicer Axles
Knuckle pin lubrication for Dana Spicer axles.
Meritor Axles
Knuckle pin lubrication for Meritor axles.
33–07 Wheel Alignment Check
General Information
General information on wheel alignment and its importance.
Toe-In Inspection
Procedure for inspecting toe-in for accurate alignment.
Rear Axle
Axle Lubricant and Filter Change, and Magnetic Strainer Cleaning and Check
Change axle lubricant, filter, clean magnetic strainer.
Drive Axle Breather Check
Check drive axle breathers for clogging.
Drive Axle Lubricant Level Check
Procedure for checking drive axle lubricant level.
Safety Precautions
Safety precautions for rear axle service.
Two-Speed-Axle Shift Unit Lubricant Level Check
Check lubricant level in the two-speed-axle shift unit.
35–01 Drive Axle Lubricant Level Check
NOTICE
Notice regarding proper lubricant levels for axle damage prevention.
35–02 Two-Speed-Axle Shift Unit Lubricant Level Check
CAUTION
Caution regarding maintaining proper lubricant level in shift unit.
35–04 Axle Lubricant and Filter Change, and Magnetic Strainer Cleaning and Check
Detroit™
Axle lubricant change procedures for Detroit axles.
CAUTION
Caution regarding draining hot axle oil.
Meritor Axles
Axle lubricant change procedures for Meritor axles.
Wheels and Tires
Tire Check
Procedure for inspecting tires for wear and damage.
Wheel Nut and Rim Nut Torque Check
Check torque of wheel and rim nuts.
40–01 Wheel Nut and Rim Nut Torque Check
CAUTION
Caution regarding wheel nut torque.
Driveline
Driveline Inspection
Procedure for inspecting the driveline.
Driveline Lubrication
Lubrication procedures for the driveline.
Safety Precautions
Safety precautions for driveline service.
41–01 Driveline Inspection
CAUTION
Caution regarding driveline capscrew tightness.
41–02 Driveline Lubrication
Universal Joint Lubrication
Lubrication procedures for universal joints.
Brakes
Air Brake System Valve Inspection
Inspect air brake system valves.
Air Dryer Desiccant Replacement
Procedure for replacing air dryer desiccant.
Air Dryer Inspection
Inspect the air dryer for proper function.
Alcohol Evaporator Cleaning and Inspection
Clean and inspect the alcohol evaporator.
Brake Inspection
Procedure for inspecting the foundation brake system.
Camshaft Bracket Lubrication
Lubrication of camshaft brackets.
Safety Precautions
Safety precautions for brake system service.
Slack Adjuster Lubrication
Lubrication of slack adjusters.
Versajust Slack Adjuster Inspection and Lubrication
Inspect and lubricate Versajust slack adjusters.
42–03 Air Dryer Desiccant Replacement
IMPORTANT: ...
Important note on replacing desiccant cartridges annually.
Bendix AD-9 Air Dryers
Procedure for replacing desiccant in Bendix AD-9 air dryers.
WARNING
Warning regarding disassembly of desiccant cartridge assembly.
NOTICE
Notice about dirt or obstructions in O-ring grooves.
IMPORTANT: ...
Important note on replacing Nylok nuts on air dryer cover.
Bendix AD–IP Air Dryers
WARNING
Warning about disassembling desiccant cartridge assembly.
Bendix AD-9si, AD-IS and CR Turbo 2000 Air Dryers
IMPORTANT: ...
Important note on using silicone grease with Bendix kits.
WABCO System Saver 1200, 1200 Plus, and Twin Air Dryers
NOTICE
Notice regarding desiccant cartridge type and service intervals.
42–04 Alcohol Evaporator Cleaning and Inspection
Midland
Maintenance for Midland alcohol evaporators.
Off Season
Off-season service for alcohol evaporators.
42–05 Camshaft Bracket Lubrication
IMPORTANT: ...
Important note to perform Brake Inspection before lubrication.
NOTE: ...
Note regarding Q Plus™ brake system camshaft lubrication.
42–06 Slack Adjuster Lubrication
IMPORTANT: ...
Important note to perform Brake Inspection before lubrication.
Dana Spicer and Haldex
CAUTION
Caution against using moly-disulfide grease on slack adjusters.
42–07 Brake Inspection
IMPORTANT: ...
Important note on performing brake inspection before lubrication.
Parking Brake Operational Check
Operational check of the parking brake system.
CAUTION
Caution regarding parking brake operational check.
Brake Component Inspection
Inspection of foundation brake components.
WARNING
Warning regarding automatic slack adjuster adjustment.
42–08 Versajust Slack Adjuster Inspection and Lubrication
IMPORTANT: ...
Important note to perform Brake Inspection before lubrication.
In Service Inspection
Inspection of slack adjuster during service.
Steering
Drag Link Inspection
Inspection of the drag link.
Drag Link Lubrication
Lubrication of the drag link.
Power Steering Fluid and Filter Changing
Procedure for changing power steering fluid and filter.
Power Steering Gear Lubrication
Lubrication of the power steering gear.
Safety Precautions
Safety precautions for steering system service.
Steering Shaft Lubrication
Lubrication of the steering shaft.
46–01 Drag Link Inspection
WARNING
Warning regarding steering system component criticality.
46–03 Power Steering Fluid and Filter Changing
WARNING
Warning regarding proper fluid use in power steering system.
Cylindrical Reservoir, Bottom Return Port (Fig. 2)
Procedure for changing fluid in cylindrical reservoir system.
46–04 Steering Shaft Lubrication
IMPORTANT: ...
Important note on lubricating steering shafts with zerk fittings.
IMPORTANT: ...
Important note on additional U-joints on steering column.
46–05 Power Steering Gear Lubrication
TRW TAS Series
Lubrication of TRW TAS Series power steering gear.
CAUTION
Caution regarding grease application to sector shaft.
Fuel
Fuel Filter Replacement
Procedure for replacing the fuel filter.
Fuel Separator Sight Bowl Cleaning and Element Replacement
Clean sight bowl and replace element in fuel separator.
Fuel Tank Band Nut Tightening
Procedure for tightening fuel tank band nuts.
Safety Precautions
Safety precautions for fuel system service.
47–02 Fuel Separator Sight Bowl Cleaning and Element Replacement
Alliance/Racor
Maintenance for Alliance/Racor fuel/water separators.
WARNING
Warning regarding diesel fuel flammability.
DAVCO Fuel Pro® 382 and 482, and Diesel Pro® 243
Maintenance for DAVCO Fuel Pro and Diesel Pro separators.
NOTE: ...
Note regarding temporary filters for emergencies.
WARNING
Warning regarding draining hot fuel/water separators.
ConMet Fuel Separator Sight Bowl Cleaning
WARNING
Warning regarding diesel fuel flammability.
47–03 Fuel Tank Band Nut Tightening
Rectangular Fuel Tank
Tightening fuel tank band nuts for rectangular tanks.
Cylindrical Fuel Tank
Tightening fuel tank band nuts for cylindrical tanks.
Exhaust
CAT CGI Bellows Replacement
Procedure for replacing CAT CGI bellows.
Exhaust System Inspection (Noise Emission Control)
Inspect exhaust system for noise emission control.
Safety Precautions
Safety precautions for exhaust system service.
49–01 Exhaust System Inspection (Noise Emission Control)
EPA10 and Newer Exhaust System
Information on EPA10 and newer exhaust systems.
Inspection
Inspection of EPA10 exhaust systems.
IMPORTANT: ...
Important note on ATD inspection for EPA10 emissions.
EPA07 Exhaust System
Definitions of ATS Components
Definitions of Aftertreatment System (ATS) components.
Inspection
Inspection of EPA07 exhaust systems.
IMPORTANT: ...
Important note on ATD inspection for EPA07 emissions.
Cab
Aerodynamic Component Inspection
Inspect aerodynamic components for damage.
Cab Suspension Inspection
Inspect the cab suspension system.
Mirror Folding Check
Check the folding mechanism of cab-mounted mirrors.
Safety Precautions
Safety precautions for cab service.
60–01 Cab Suspension Inspection
Fig. 1, Single Air Spring Cab Suspension (typical)
Diagram of single air spring cab suspension.
Fig. 2, Dual Air Spring Cab Suspension (typical)
Diagram of dual air spring cab suspension.
Fig. 3, ...
Diagram of combined air spring/shock absorber suspension.
60–03 Aerodynamic Component Inspection
Include:
List of aerodynamic components to inspect.
Doors
Door Seal, Door Latch, Door Hinge, and Door Check Lubrication
Lubrication procedures for door seals, latches, hinges, and checks.
72–01 Door Seal, Door Latch, Door Hinge, and Door Check Lubrication
NOTE: ...
Note regarding use of penetrating oils on door seals.
Door Seals
Lubrication of door seals.
Door Latches
Lubrication of door latches.
Door Hinges
Lubrication of external door hinges.
Door Checks
Lubrication of door checks.
Heater and Air Conditioner
Air Conditioner Inspection
Inspection procedures for the air conditioning system.
HVAC Air Filter Cleaning and Replacement
Cleaning and replacing HVAC air filters.
Safety Precautions
Safety precautions for HVAC system service.
83–01 Air Conditioner Inspection
WARNING
Warning regarding eye protection when working on AC system.
HVAC Pre-Filter Cleaning
NOTE: ...
Note regarding HVAC pre-filter installation and fasteners.
Hood, Grille, and Cab Fenders
Hood Rear Support Lubrication
Lubrication procedure for hood rear support.
88–01 Hood Rear Support Lubrication
Table 1, Approved Suppliers of Multi-Purpose Lithium Grease
List of approved suppliers and grades for multi-purpose lithium grease.
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