Table of Contents
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Table of Contents
Related Manuals for Western Star 4900
Summarization of Contents
Foreword
Environmental Concerns and Recommendations
Guidance on proper disposal of materials and recycling efforts to preserve the environment.
Parts Replacement Considerations
Notice regarding the use of new parts for suspension, axle, and steering components.
Introduction
Descriptions of Service Publications
Details on major service publications like Workshop/Service, Maintenance, and Driver's Manuals.
Recall Campaigns
Information on service work related to recall notices, primarily concerning vehicle safety.
Field Service Campaigns
Details on non-safety-related service work or parts replacement campaigns.
Page Description
Explanation of the components and structure of a typical maintenance manual page.
General Information
Index, Alphabetical
Alphabetical listing of topics covered in the manual for quick reference.
Determining Scheduled Maintenance Intervals
Guidance on identifying correct maintenance intervals based on vehicle service type and conditions.
Types of Service
Description of Service Schedule I (severe) and Service Schedule II (long-haul) for maintenance planning.
Maintenance Service Schedule Table
Table outlining maintenance intervals for Service Schedule I and II vehicles based on miles and hours.
Vehicle Maintenance Schedule Tables
Detailed tables showing maintenance operations for Service Schedule I vehicles at specific mileage intervals.
Maintenance Operation Sets Table
Table listing maintenance operation sets for various groups, indicating intervals for IM, M1, M2, M3, M4.
Initial Maintenance (IM) Operations
List of operations to be performed during the initial maintenance interval across all service schedules.
Lubrication and Fluid Level Check
Operations required for lubrication and fluid level checks at the M1 maintenance interval.
M1 Maintenance Interval Operations Table
Table detailing all maintenance operations to be performed at the M1 maintenance interval.
M2 Maintenance Interval Operations Table
Table listing all maintenance operations to be performed at the M2 maintenance interval, including M1 operations.
M3 Maintenance Interval Operations Table
Table detailing all maintenance operations for the M3 interval, including M1 and M2 operations.
M4 Maintenance Interval Operations Table
Table listing all maintenance operations for the M4 interval, including M1, M2, and M3 operations.
Noise Emission Controls Maintenance
Information on maintaining vehicle noise emission controls and related federal laws.
Recommendations for Replacement Parts
Guidance on using genuine Western Star parts for noise emission control components.
Western Star Noise Emission Controls Warranty
Reference to the vehicle owner's warranty information book for noise emission controls.
Tampering With Noise Controls is Prohibited
Federal law regarding the alteration or removal of noise control devices.
Verification of Inspections Log
Description of logs for verifying maintenance on engine rear supports and engine noise panels.
Engine
Index, Alphabetical
Alphabetical index for Engine-related maintenance operations.
Safety Precautions
Essential safety measures to be followed before performing any engine-related procedures.
Engine Noise Panel Inspection (Noise Emission Control)
Procedure for inspecting engine noise panels for damage or wear.
Engine Belt Inspection
Instructions for inspecting engine drive belts and pulleys for wear and damage.
Pacbrake® Inspection and Maintenance
Guidance on inspecting and maintaining the Pacbrake exhaust brake system.
Engine-Support Fasteners Check (Noise Emission Control)
Procedure for checking and tightening engine support fasteners for noise emission control.
Air Intake
Index, Alphabetical
Alphabetical index for Air Intake system maintenance operations.
Intake Piping Inspection
Instructions for inspecting air intake piping and ducting for damage and proper clamp tightness.
Air Cleaner Element Inspection and Replacement
Procedure for inspecting and replacing air cleaner elements, emphasizing proper sealing.
Charge Air Cooler Inspection
Steps for inspecting the charge air cooler piping, clamps, and core for damage or leaks.
Air Compressor
Index, Alphabetical
Alphabetical index for Air Compressor maintenance operations.
Safety Precautions
Essential safety measures to be followed before performing any air compressor related procedures.
Air Compressor Inspection
Procedure for inspecting air compressor intake hoses, connections, and coolant lines.
Alternators and Starters
Index, Alphabetical
Alphabetical index for Alternators and Starters maintenance operations.
Safety Precautions
Essential safety measures to be followed before working on alternators and starters.
Alternator and Starter Check
Procedure for checking alternator bracket fasteners, belt tension, and electrical connections.
Battery Check
Instructions for inspecting battery cables, hold-down assembly, and terminals for wear and corrosion.
Engine Cooling/Radiator
Index, Alphabetical
Alphabetical index for Engine Cooling/Radiator maintenance operations.
Safety Precautions
Critical safety warnings for working on the engine and cooling system, especially regarding hot components.
Coolant Inspection
General information and procedure for inspecting engine coolant levels and condition.
Cooling System Inspection (Noise Emission Control)
Procedure for inspecting cooling system hoses, clamps, and related components for wear or leaks.
Pressure/Filler Cap Test
Steps for testing the radiator pressure/filler cap to ensure it maintains proper system pressure.
Cooling System Pressure-Flush
Procedure for flushing the cooling system, including draining, filling, and checking for leaks.
Clutch
Index, Alphabetical
Alphabetical index for Clutch system maintenance operations.
Safety Precautions
Essential safety measures before performing clutch system maintenance.
Clutch Release Bearing Lubrication
Procedure for lubricating the clutch release bearing and associated contact points.
Clutch Release Cross-Shaft Lubrication
Instructions for lubricating the clutch release cross-shaft grease fittings.
Sleeve Assembly Bronze Bushing Lubrication
Procedure for lubricating the bronze bushing located between the clutch bearing housing and transmission.
Fluid Level Check, Hydraulic Clutch Control
Steps for checking the fluid level in the hydraulic clutch control system reservoir.
Fluid Change, Hydraulic Clutch Control
Procedure for changing the hydraulic clutch control fluid for reliable operation.
Pressure Bleeding
Detailed steps for performing pressure bleeding of the hydraulic clutch system.
Manual Bleeding
Procedure for manually bleeding the hydraulic clutch system with two people.
Clutch Replacement, Detroit™ Automated Transmissions
Information on replacing the clutch assembly for Detroit Automated transmissions.
Transmission
Index, Alphabetical
Alphabetical index for Transmission system maintenance operations.
Safety Precautions
Essential safety measures before performing any transmission-related procedures.
Transmission Fluid Level Inspection
Procedure for checking transmission fluid levels for Allison transmissions, including cold and hot checks.
Meritor Transmission
Specific instructions for checking fluid levels in Meritor transmissions, including fill plug and sight glass methods.
Manual Transmission Fluid Change
Procedure for changing manual transmission fluid and filters, including lubricant recommendations.
Manual Transmission Air Filter/Regulator Check, and Clean or Replace
Procedure for checking, cleaning, or replacing the manual transmission air filter/regulator.
ESS Transmission Filter and Boot Inspection
Instructions for inspecting ESS transmission filters and protective boots for damage.
Transmission Inspection
Procedure for inspecting the transmission for oil leaks at various points.
Allison and Eaton Fuller Transmission Breather Check
Guidance on checking the transmission breather for blockages to prevent pressure build-up.
Allison Transmission Fluid and Filter Change
Procedure for changing fluid and filters in Allison 3000 and 4000 Family transmissions.
Detroit™ Automated Transmission Fluid Change and Magnetic Plug Cleaning
Procedure for changing fluid and cleaning magnetic plugs in Detroit Automated transmissions.
Detroit™ Automated Transmission Fluid Level Inspection
Steps for checking the fluid level in Detroit Automated transmissions.
Detroit™ Automated Transmission Air Filter Replacement
Procedure for replacing the air filter on Detroit Automated transmissions, if equipped.
Frame and Frame Components
Index, Alphabetical
Alphabetical index for Frame and Frame Components maintenance operations.
Safety Precautions
Essential safety measures before performing maintenance on fifth wheels and frame components.
Fifth Wheel Inspection
Detailed procedure for inspecting Fontaine, Holland, Castloc, Simplex, and Jost fifth wheels.
Holland FW35
Specific inspection steps for the Holland FW35 fifth wheel assembly.
Castloc II and Simplex Series
Inspection procedures for Castloc II and Simplex Series fifth wheels.
Holland Fifth Wheel Properly Closed
Description of the correct state for a Holland fifth wheel when properly closed and locked.
Jost
Inspection steps for Jost fifth wheels, including bracket pins and locking mechanisms.
Fifth Wheel Lubrication
Guidelines for lubricating fifth wheels after inspection, including specific instructions for Fontaine and Holland models.
Holland FW35
Lubrication instructions for the Holland FW35 fifth wheel, including oil and grease application points.
Holland Fifth Wheel Sliding Mechanism Inspection
Procedure for inspecting and adjusting the sliding mechanism of Holland fifth wheels.
Frame Fastener Torque Check
Procedure for checking the torque of frame fasteners on various chassis components.
Trailer Electrical Connector Lubrication
Instructions for lubricating trailer electrical connectors to prevent corrosion.
Suspension
Index, Alphabetical
Alphabetical index for Suspension system maintenance operations.
Safety Precautions
Essential safety measures before performing any suspension system maintenance.
Suspension Inspection
General guidance and inspection procedures for front and rear suspension components.
Front Suspension Check
Procedure for inspecting front spring assemblies for damage and wear.
Front and Rear Suspension Shock Absorber Check
Method for inspecting shock absorbers for wear, damage, or internal failure.
Quick Test
A quick test to identify potentially failed shock absorbers by comparing their temperature.
Shock Absorber Inspection
Detailed checks for conditions indicating shock absorber replacement, including misting vs. leaking.
Rear Suspension Check
Inspection procedures for rear suspension systems, including TufTrac.
TufTrac Suspension
Specific inspection steps for TufTrac suspension spring assemblies and brackets.
AirLiner Suspension
Inspection procedures for AirLiner suspension components, including air springs and fasteners.
Chalmers Suspension
Inspection steps for Chalmers suspension, focusing on fasteners, bushings, and walking beams.
Hendrickson RS Series
Inspection procedures for Hendrickson RS Series suspension components like brackets and U-bolts.
Hendrickson RT Series
Inspection steps for Hendrickson RT Series suspension fasteners and spring brackets.
Hendrickson HAS
Inspection procedures for Hendrickson HAS suspension components, including fasteners and air bags.
Neway Suspension
Inspection procedures for Neway suspension components, including fasteners and shock absorbers.
Reyco Suspension
Inspection procedures for Reyco suspension components, including U-bolts and shock absorbers.
Suspension Lubrication
General lubrication instructions for front and rear suspension components.
Front Suspension
Lubrication steps for front suspension spring pins and rear shackle pins.
Rear Suspension
Lubrication procedures for rear suspension systems, including Freightliner, Hendrickson, Neway, and Reyco.
Freightliner
Specific lubrication requirements for Freightliner single-axle and tandem-axle rear suspensions.
Tandem Axle
Lubrication of the equalizer cap-and-tube assembly on tandem axles.
Hendrickson
Lubrication for Hendrickson RT2 and RTE2 Series suspension bushings.
Suspension U-Bolt Torque Check
Procedure for checking and retorquing suspension U-bolt nuts to prevent breakage and tire wear.
Front Axle
Index, Alphabetical
Alphabetical index for Front Axle maintenance operations.
Safety Precautions
Essential safety measures before performing any front axle maintenance.
Knuckle Pin Lubrication
Procedure for lubricating knuckle pin assemblies on Detroit, Dana Spicer, and Meritor axles.
Tie Rod Lubrication
Instructions for lubricating tie rod ends on some axles.
Tie Rod Inspection
Procedure for inspecting tie rod end boots for damage and checking the cross tube for movement.
Front Axle Wheel Bearing Lubrication
Procedure for checking lubricant levels in front axle hub caps.
Front Drive Axle Lubricant Level Check
Steps for checking the lubricant level in front drive axles, ensuring proper lubrication.
Front Drive Axle Lubricant Change
Procedure for changing front drive axle lubricant, including flushing and recommended lubricants.
Wheel Alignment Check
General information on wheel alignment and procedure for inspecting tire wear related to alignment.
Toe-In Inspection
Detailed steps for performing a toe-in inspection using alignment equipment.
Rear Axle
Index, Alphabetical
Alphabetical index for Rear Axle maintenance operations.
Safety Precautions
Essential safety measures before performing any rear axle maintenance.
Drive Axle Lubricant Level Check
Procedure for checking the lubricant level in drive axles for Detroit, Meritor, and Dana Spicer axles.
Two-Speed-Axle Shift Unit Lubricant Level Check
Steps for checking the lubricant level in the two-speed-axle shift unit.
Drive Axle Breather Check
Procedure for checking axle breathers to ensure they are not clogged.
Axle Lubricant and Filter Change, and Magnetic Strainer Cleaning and Check
Procedure for changing axle lubricant and filters, and cleaning magnetic strainers.
Wheels and Tires
Index, Alphabetical
Alphabetical index for Wheels and Tires maintenance operations.
Wheel Nut and Rim Nut Torque Check
Procedure for checking and retorquing wheel and rim nuts to prevent damage and ensure safety.
Tire Check
Guidelines for inspecting tires for abnormal wear, damage, and proper inflation pressure.
Driveline
Index, Alphabetical
Alphabetical index for Driveline maintenance operations.
Safety Precautions
Essential safety measures before performing any driveline maintenance.
Driveline Inspection
Procedure for inspecting universal joints, yokes, slip joints, and midship bearings for wear and damage.
Driveline Lubrication
Instructions for lubricating universal joints and slip joints on Meritor RPL Series drivelines.
Brakes
Index, Alphabetical
Alphabetical index for Brakes system maintenance operations.
Safety Precautions
Essential safety measures before performing any brake system maintenance.
Air Brake System Valve Inspection
Guidance on air valve maintenance, especially if the air dryer desiccant is not replaced per schedule.
Air Dryer Inspection
Procedure for inspecting the air dryer system, including checking for proper purging and air leaks.
Air Dryer Desiccant Replacement
Procedure for replacing the desiccant cartridge in Bendix AD-9 Air Dryers.
Alcohol Evaporator Cleaning and Inspection
Maintenance instructions for the alcohol evaporator, including off-season draining and freeze season reactivation.
Camshaft Bracket Lubrication
Procedure for lubricating camshaft brackets and bushings, ensuring proper brake operation.
Slack Adjuster Lubrication
Instructions for lubricating slack adjusters, ensuring proper brake operation.
Brake Inspection
Procedure for inspecting brake components, including parking brake operation and brake chamber pushrod stroke.
Versajust Slack Adjuster Inspection and Lubrication
Detailed inspection and lubrication procedure for Versajust slack adjusters, including stroke measurement.
Steering
Index, Alphabetical
Alphabetical index for Steering system maintenance operations.
Safety Precautions
Essential safety measures before performing any steering system maintenance.
Drag Link Inspection
Procedure for inspecting the drag link for ball stud looseness, boot damage, and axial movement.
Drag Link Lubrication
Instructions for lubricating drag link grease fittings.
Power Steering Fluid and Filter Changing
Procedure for changing power steering fluid and filter, using approved fluids and proper techniques.
Steering Shaft Lubrication
Procedure for lubricating steering shaft U-joints and slip joints.
Power Steering Gear Lubrication
Instructions for lubricating the power steering gear sector shaft.
Fuel
Index, Alphabetical
Alphabetical index for Fuel system maintenance operations.
Safety Precautions
Essential safety measures before performing any fuel system maintenance, emphasizing flammability.
Fuel Filter Replacement
Reference to engine manufacturer's manual for fuel filter removal and installation procedures.
Fuel Separator Sight Bowl Cleaning and Element Replacement
Procedure for cleaning and replacing elements in Alliance/Racor fuel/water separators.
ConMet Fuel Separator Sight Bowl Cleaning
Maintenance procedure for cleaning the sight bowl on ConMet fuel separators.
Fuel Tank Band Nut Tightening
Procedure for tightening fuel tank band nuts on rectangular and cylindrical fuel tanks.
Exhaust
Index, Alphabetical
Alphabetical index for Exhaust system maintenance operations.
Safety Precautions
Essential safety measures before performing any exhaust system maintenance.
Exhaust System Inspection (Noise Emission Control)
Procedure for inspecting the exhaust system for leaks, binding, grounding, and vibrations.
EPA10 and Newer Exhaust System
Overview of EPA10 emissions regulations and aftertreatment system components.
Definitions of Aftertreatment (ATS) Terms
List of definitions for terms related to exhaust aftertreatment systems.
Inspection
Inspection requirements for EPA07 emissions regulations and aftertreatment systems.
Pre-EPA07 Exhaust System Inspection
Inspection steps for exhaust systems on vehicles manufactured before EPA07 regulations.
Cab
Index, Alphabetical
Alphabetical index for Cab maintenance operations.
Safety Precautions
Essential safety measures before performing any cab system maintenance.
Cab Suspension Inspection
Procedure for inspecting air spring systems, shock absorbers, and mounting brackets.
Mirror Folding Check
Procedure for checking the folding function of cab-mounted main mirrors.
Aerodynamic Component Inspection
Inspection of aerodynamic components like side extenders, roof fairings, and bumpers for damage.
Doors
Index, Alphabetical
Alphabetical index for Doors maintenance operations.
Door Seal, Door Latch, Door Hinge, and Door Check Lubrication
Procedure for lubricating door seals, latches, hinges, and checks with approved greases.
Heater and Air Conditioner
Index, Alphabetical
Alphabetical index for Heater and Air Conditioner maintenance operations.
Safety Precautions
Essential safety measures before working on the air conditioning system.
Air Conditioner Inspection
Procedure for inspecting the A/C compressor hub, clutch clearance, and hoses.
HVAC Air Filter Cleaning and Replacement
Procedure for cleaning or replacing cab HVAC filters, distinguishing between pleated and foam types.
HVAC Pre-Filter Cleaning
Instructions for cleaning and replacing the HVAC pre-filter.
Sleeper Fresh-Air Filter Replacement
Procedure for replacing air filters in the sleeper HVAC assembly.
Hood, Grille, and Cab Fenders
Index, Alphabetical
Alphabetical index for Hood, Grille, and Cab Fenders maintenance operations.
Hood Rear Support Lubrication
Procedure for lubricating hood rear support brackets and isolators with approved grease.
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