Western Star 4900 Manuals

Manuals and User Guides for Western Star 4900. We have 1 Western Star 4900 manual available for free PDF download: Maintenance Manual

Western Star 4900 Maintenance Manual

Western Star 4900 Maintenance Manual (167 pages)

Brand: Western Star | Category: Trucks | Size: 4 MB

Table of Contents

Models
2
- Page Description
  6
- Maintenance Manual Contents
  7
- Table of Contents
  8
- Index, Alphabetical
  8
Determining Scheduled Maintenance Intervals
9
Initial Maintenance (IM) Operations
18
Lubrication and Fluid Level Check
19
M1 Maintenance Interval Operations Table
20
M2 Maintenance Interval Operations Table
21
M3 Maintenance Interval Operations Table
22
M4 Maintenance Interval Operations Table
23
Noise Emission Controls Maintenance
24
Veriﬁcation of Inspections Log
25
- Title of Maintenance Operation (MOP)
  27
- Engine Belt Inspection
  28
- Engine Noise Panel Inspection (Noise Emission Control)
  28
  - Caterpillar
    29
  - Cummins
    29
- Engine-Support Fasteners Check (Noise Emission Control)
  29
  - Pacbrake Inspection and Maintenance
    29
  - Caterpillar Self-Tensioner
    31
  - Cummins Self-Tensioner
    31
  - EPDM Belt Wear
    31
  - Cowl-Mounted Air Cleaner
    38
  - Engine-Mounted Air Cleaner
    38
  - Frontwall-Mounted Air Cleaner
    38
  - Intake Piping Inspection
    38
- Check the Tightness and Condition of the Clamp
  39
- Air Cleaner Element Inspection and Replacement
  40
- Air Cleaner Outlet Hose Clamp
  40
- Elbow
  44
- Air Compressor Inspection
  47
- Safety Precautions
  47
  - Alternator and Starter Check
    49
  - Battery Check
    49
- Coolant Inspection
  51
- Cooling System Inspection (Noise Emission Control)
  53
- Cooling System Pressure-Flush
  54
- Pressure/Filler Cap Test
  54
- Clutch Release Bearing Lubrication
  57
- Clutch Release Cross-Shaft Lubrication
  57
- Safety Precautions
  57
- Fluid Level Check, Hydraulic Clutch Control
  58
  - Sleeve Assembly Bronze Bushing Lubrication
    58
  - Pressure Bleeding
    59
  - Clutch Replacement, Detroit Automated Transmissions
    60
  - Manual Bleeding
    60
  - Allison Transmission
    62
  - Cold Check
    62
  - Hot Check
    62
- Safety Precautions
  62
- Allison Transmission Fluid and Filter Change
  69
- Detroit Automated Transmission Air Filter Replacement
  72
- Detroit Automated Transmission Fluid Level Inspection
  72
  - Detroit Transmission Air Filter
    73
  - Isolated Transmission Reserve Air Tank
    73
- Fifth Wheel Inspection
  75
  - Fontaine
    75
  - Holland FWS1
    75
- Mounting Bolt
  75
  - Fontaine Fifth Wheel
    76
  - Castloc II and Simplex Series
    77
  - Holland FW35
    77
  - Holland FWS1 Fifth Wheel
    77
  - Lever Bar and Release Handle Alignment
    77
  - Holland Fifth Wheel Properly Closed
    78
  - Lever Bar and Operating Handle Alignment
    78
  - Simplex Series Fifth Wheel
    78
  - Bracket Pin Bolt Locking Tabs
    79
  - Jost
    79
  - Measuring Fifth Wheel Top Plate Lift
    79
  - Jost Fifth Wheel
    80
  - Jost Fifth Wheel Adjustment
    80
- Fifth Wheel Lubrication
  81
- Frame Fastener Torque Check
  83
  - Holland Fifth Wheel Sliding Mechanism
    83
  - Trailer Electrical Connector Lubrication
    83
- Premier 690 Coupling Inspection
  84
- Safety Precautions
  86
  - Suspension Inspection
    86
  - Shock Absorber Inspection
    87
  - Shock with Broken Eye and Tube
    87
  - Shock with Cracked Bushing
    87
  - Temperature Touch Test
    87
  - Bent and Dented Shock
    88
  - Misting Shock
    88
  - Rear Suspension Check
    88
  - Tuftrac Suspension
    88
  - Airliner Suspension
    89
  - Airliner Axle Stop Measurement
    90
  - Chalmers Suspension
    90
  - Hendrickson RS Series
    91
  - Hendrickson RT Series
    91
  - Hendrickson HAS
    92
  - Neway Suspension
    92
  - Front Suspension
    93
  - Reyco Suspension
    93
  - Suspension Lubrication
    93
  - Rear Suspension
    94
  - Tandem Axle
    94
  - Suspension U-Bolt Torque Check
    95
  - Tightening Pattern for U-Bolt Nuts
    95
  - Front Axle
    96
  - Dana Spicer Axles
    97
  - Detroit Axles
    97
  - Knuckle Pin Lubrication
    97
  - Meritor Axles
    97
  - Dana Spicer Knuckle Pin Lubrication
    98
  - Knuckle Pin Lubrication, Meritor Axles
    98
  - Tie Rod Inspection
    98
  - Tie Rod Lubrication
    98
  - Check Movement of Tie Rod End
    99
  - Front Axle Wheel Bearing Lubrication
    99
  - Drive Axle Housing
    100
  - Drive Axle Lubrication Level
    100
  - Front Drive Axle Lubricant Level Check
    100
  - Front Hubcap Inspection Window
    100
  - Eaton Drive Axle Recommended Lubricants
    101
  - Front Drive Axle Lubricant Change
    101
  - Meritor Drive Axle Recommended Lubricants
    101
  - Tire Wear Due to Excessive Camber
    102
  - Tire Wear Due to Excessive Toe-In
    102
  - Toe-In Inspection
    102
  - Wheel Alignment Check
    102
  - Setting Trammel Bar Pointers
    103
  - Trammel Bar Positioning
    103
  - Wheel Toe-In
    103
  - Detroit Tandem Axle
    105
  - Drive Axle Lubricant Level Check
    105
  - Axle Lubricant Level Check
    106
  - Detroit Drive Axle Lubricants
    106
  - Plug and Breather Locations, Dana Spicer Axles
    106
  - Plug and Breather Locations, Meritor Axles
    106
  - Meritor Drive Axle Lubricant Capacities for Single Axles
    107
  - Meritor Drive Axle Lubricant Capacities for Tandem Axles
    107
  - Meritor Drive Axle Recommended Lubricant
    107
  - Drive Axle Breather Check
    108
  - Two-Speed-Axle Shift Unit Lubricant Level Check
    108
  - Axle Lubricant and Filter Change, and Magnetic Strainer Cleaning/Check
    109
  - Meritor Axle Oil Filter Removal
    110
  - Dana Spicer Tandem-Drive Axle Magnetic Strainer
    111
  - Wheel Nut and Rim Nut Torque Check
    113
  - Wheel Nut and Rim Nut Tightening Sequence
    114
  - Tire Check
    115
  - Wheel Fastener Torque
    115
  - Driveline Inspection
    117
  - Meritor RPL Series U-Joint
    117
  - Meritor U-Joint Fasteners for Bearing Caps
    117
  - Components of a Basic Driveline
    118
  - Driveline Lubrication
    119
  - Slip Joint and U-Joint Lubrication
    119
  - Slip Joint Spline Wear Checking
    119
  - Universal Joint Lubrication
    119
  - Slip Joint Spline Lubrication
    120
- Air Brake System Valve Inspection
  122
- Air Dryer Inspection
  122
- Air Dryer Desiccant Replacement
  123
  - AD-9 Air Dryer (Exploded View)
    124
  - Bendix AD–IP Air Dryers
    124
  - End Cover to Housing Torque Pattern
    125
- Alcohol Evaporator Cleaning and Inspection
  126
  - Desiccant Cartridge Replacement
    126
  - Desiccant Cartridge Replacement, WABCO Air Dryers
    126
- Camshaft Bracket Lubrication
  127
- Freeze Season Reactivation
  127
- Slack Adjuster Lubrication
  127
  - Dana Spicer Slack Adjuster
    128
  - Gunite Slack Adjuster
    128
  - Brake Component Inspection
    129
  - Brake Inspection
    129
  - Meritor Slack Adjuster
    129
  - Parking Brake Operational Check
    129
  - Brake Chamber Stroke Speciﬁcations
    130
  - Actuator Stroke–Long Stroke
    131
  - Actuator Stroke–Standard Stroke
    131
- Versajust Slack Adjuster Inspection and Lubrication
  131
- Drag Link Inspection
  134
- Drag Link Lubrication
  134
- Power Steering Fluid and Filter Changing
  134
- Safety Precautions
  134
  - Approved Power Steering Fluids
    135
  - Flat Reservoir, Top Return Port
    135
  - Power Steering Reservoir, Side View
    135
  - Power Steering Reservoir, Top View
    135
  - Power Steering Reservoir
    136
- Steering Shaft Lubrication
  136
- Fuel Filter Replacement
  139
- Fuel Separator Sight Bowl Cleaning and Element Replacement
  139
  - Fuel/Water Separator Assembly, Alliance/Racor
    140
  - Conmet Fuel Separator Sight Bowl Cleaning
    141
  - DAVCO Collar Wrench
    141
  - DAVCO Fuel/Water Separator
    141
  - DAVCO Fuel Pro 382
    142
  - DAVCO Fuel Pro 482
    142
  - Cylindrical Fuel Tank
    143
  - DAVCO Diesel Pro 243
    143
- Fuel Tank Band Nut Tightening
  143
- Safety Precautions
  146
  - Deﬁnitions of ATS Components
    147
  - Diesel Exhaust Fluid (DEF) Filter Replacement
    147
  - EPA07 Exhaust System
    147
  - One-Box ATS Sensor Locations
    148
  - Pre-EPA07 Exhaust System Inspection
    149
  - Two-Box ATS Sensor Locations
    149
  - 2HV Two-Box ATS Sensor Locations
    150
  - CAT CGI Bellows Replacement
    150
  - CAT EPA07 Exhaust Installation with CGI Bellows
    151
  - Typical EPA07 Aftertreatment Device
    151
  - Donaldson Sealclamp Wide-Band Exhaust Clamp
    152
  - Exhaust Isolator
    152
  - V-Band Coupling and Flex Hose
    152
  - Measuring the Pipe Gap (Typical)
    153
  - Aft Facing Slip Clamp Installation
    154
  - CGI Bellows Installation
    154
  - Forward Facing Slip Clamp Installation
    154
- Aerodynamic Component Inspection
  156
- Cab Suspension Inspection
  156
- Mirror Folding Check
  156
  - Single Air Spring Cab Suspension (Typical)
    156
  - Air Spring/Shock Absorber Suspension
    157
  - Door Checks
    159
  - Door Hinges
    159
  - Door Latches
    159
  - Door Seals
    159
  - Heater and Air Conditioner
    160
  - Acceptable Compressor Clutch Clearances
    161
- Safety Precautions
  161
- HVAC Air Filter Cleaning and Replacement
  161
- Hub/Rotor Clearance
  161
- Air Conditioner Inspection
  161
- Cab Fresh-Air Filter Replacement
  162
- Cab Fresh-Air Filter Cleaning, Foam Filters
  162
- HVAC Cover
  162
- Cab Fresh-Air Filters
  162
- HVAC Pre-Filter Cleaning
  163
- Sleeper Fresh-Air Filter Replacement
  163
- HVAC Pre-Filter
  163
- Sleeper Fresh-Air Filter Cleaning, Foam Filters
  164
- Orientation of Sleeper Fresh-Air Filters
  164
- Hood Rear Support Lubrication
  166
- Approved Suppliers of Multi-Purpose Lithium Grease
  166

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