WESTERN STAR MAINTENANCE MANUAL. Models: EX 4900 FA 4900 SA XD

Transcription

1 WESTERN STAR MAINTENANCE MANUAL Models: EX 4900 FA 4900 SA XD STI-445- (0/07P) Published by Freightliner LLC 4747 N. Channel Ave. Portland, OR 9727 Printed in U.S.A.

2 Foreword When performed on a regular basis, lubricating the parts of your vehicle is the least costly way of obtaining safe and reliable vehicle operation. Added benefits and savings occur when you check that the engine, undercarriage, and noise emission control parts are in good working order during lubrication. Perform the operations in this maintenance manual at scheduled intervals based upon distance traveled or hours of operation. Perform daily, pretrip inspection and maintenance as outlined in the Western Star Driver s Manual. IMPORTANT: Descriptions and specifications in this manual were in effect at the time of printing. Freightliner LLC reserves the right to discontinue models and to change specifications or design at any time without notice and without incurring obligation. Descriptions and specifications contained in this publication provide no warranty, expressed or implied, and are subject to revision and editions without notice. For additional information, please contact Freightliner LLC, Service Systems and Documentation, P.O. Box 3849, Portland, OR , U.S.A. or refer to and Environmental Concerns and Recommendations Whenever you see instructions in this manual to discard materials, you should attempt to reclaim and recycle them. To preserve our environment, follow appropriate environmental rules and regulations when disposing of materials. NOTICE: Parts Replacement Considerations Do not replace suspension, axle, or steering parts (such as springs, wheels, hubs, and steering gears) with used parts. Used parts may have been subjected to collisions or improper use and have undetected structural damage Freightliner LLC All rights reserved. No part of this publication, in whole or in part, may be translated, reproduced, stored in a retrieval system, or transmitted in any form by any means, electronic, mechanical, photocopying, recording, or otherwise, without the prior written permission of Freightliner LLC. Freightliner LLC Service Systems and Documentation (POC-SSD) P.O. Box 3849 Portland, OR

3 Descriptions of Service Publications Introduction Freightliner LLC distributes the following major service publications. Workshop/Service Manual Maintenance Manual Driver s/operator s Manual Parts Technical Manual Service Bulletins Recall Bulletins Field Service Modifications Workshop/service manuals contain service and repair information for all vehicle systems and components, except for major components such as engines, transmissions, and rear axles. Each workshop/service manual section is divided into subjects that can include general information, principles of operation, removal, disassembly, assembly, installation, specifications, and troubleshooting. Maintenance manuals contain routine maintenance procedures and intervals for vehicle components and systems. They have information such as lubrication procedures and tables, fluid replacement procedures, fluid capacities, specifications, procedures for adjustments and for checking the tightness of fasteners. Maintenance manuals do not contain detailed repair or service information. Driver s/operator s manuals contain information needed to enhance the driver s understanding of how to operate and care for the vehicle and its components. Each manual contains a chapter that covers pretrip inspection and daily maintenance of vehicle components. Driver s/operator s manuals do not contain detailed repair or service information. Freightliner LLC publishes this manual to aid in the identification of serviceable replacement vehicle parts. This manual is used in conjunction with the parts book and the service parts catalog microfiche. Service bulletins provide the latest service tips, field repairs, product improvements, and related information. Some service bulletins are updates to information in the workshop/service manual. These bulletins take precedence over workshop/service manual information, until the latter is updated; at that time, the bulletin is usually canceled. The service bulletins manual is available only to dealers. When doing service work on a vehicle system or part, check for a valid service bulletin for the latest information on the subject. IMPORTANT: Before using a particular service bulletin, check the current service bulletin validity list to be sure the bulletin is valid. These bulletins pertain to special situations that involve service work or replacement of parts in connection with a recall notice. Recall bulletins pertain to matters of vehicle safety. All bulletins are distributed to dealers; customers receive notices that apply to their vehicles. This publication is concerned with non-safety-related service work or replacement of parts. All field service modifications are distributed to dealers; customers receive notices that apply to their vehicles. Western Star Maintenance Manual, January 2003 I

4 Introduction Page Description For a page example of the printed manual, see Fig.. A B C 09/2/200 D A. Maintenance Operation Number consists of the Group Number followed by the Sequence Number B. Group Title C. Group Number D. Release Date E. Group Number/Page Number E f02023 Fig., Page Example of the Printed Manual I 2 Western Star Maintenance Manual, January 2003

5 Maintenance Manual Contents Introduction Group No. Group Title General Information 0... Engine AirIntake 3... AirCompressor 5... Alternators and Starters Engine Cooling/Radiator Clutch Transmission 3... Frame and Frame Components Suspension Front Axle Rear Axle Wheels and Tires 4... Driveline Brakes Steering Fuel Exhaust Cab Doors Heater and Air Conditioner Western Star Maintenance Manual, January 2003 I 3

6 General Information 00 Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Determining Scheduled Maintenance Intervals Initial Maintenance (IM) Operations Lubrication and Fluid Level Check M Maintenance Interval Operations Table M2 Maintenance Interval Operations Table M3 Maintenance Interval Operations Table M4 Maintenance Interval Operations Table Maintenance Operation Sets Tables Maintenance Service Table Metric/U.S. Customary Conversion Tables Noise Emission Controls Maintenance Torque Specifications Tables Vehicle Maintenance Schedule Tables Verification of Inspections Log Western Star Maintenance Manual, October 2007

7 General Information 00 Determining Scheduled Maintenance Intervals: 00 0 Determining Scheduled Maintenance Intervals Performing regular maintenance will help ensure that your Western Star vehicle delivers safe, reliable service and optimum performance for years to come. Failure to follow a regular maintenance program can result in inefficient operation and unscheduled downtime. To determine the correct maintenance intervals for your vehicle, you must first determine the type of service or conditions in which the vehicle will be operating. Generally, most vehicles operate under conditions that fall within one of the two types of service described. Before placing your new vehicle in service, determine the type of service (Service Schedule I or II) that applies to the intended use of the vehicle. After determining the vehicle s type of service, refer to the Maintenance Service Table (00 02) or the Vehicle Maintenance Schedule Tables (00 03) to determine how often maintenance should be performed. When the vehicle reaches the distance given for a maintenance interval, see the applicable Maintenance Interval Operations Table for a list of the maintenance operations to be performed at that maintenance interval. Use the maintenance operation numbers to find detailed instructions in the manual on each operation. Types of Service Service Schedule I (severe service) applies to vehicles that travel less than 60,000 miles ( km) annually or that operate under severe conditions. Examples of Service Schedule I usage are: operation on extremely poor roads or where there is heavy dust accumulation constant exposure to extreme hot, cold, salt air, or other extreme climates frequent short-distance travel construction-site operation city operation such as fire truck or garbage truck logging farm operation Service Schedule II (long-haul transport) applies to vehicles that travel more than 60,000 miles ( km) annually with minimal city or stop-and-go operation. Examples of Service Schedule II usage are: regional delivery that is mostly freeway miles interstate transport any highway operation with high annual mileage NOTE: Maintenance instructions in this manual are based on average vehicle use and normal operating conditions. Unusual vehicle operating conditions may require service at more frequent intervals. Western Star Maintenance Manual, October /

8 00 Maintenance Service Table: General Information Service Schedule Service Schedule I* (severe service) vehicles that travel up to 60,000 miles ( km) annually Service Schedule II (long-haul transport) vehicles that travel over 60,000 miles ( km) annually Maintenance Service Schedule Table Maintenance Interval Operation Maintenance Intervals Frequency Miles km Hours Initial Maintenance (IM) first Maintenance (M) every Maintenance 2 (M2) every Maintenance 3 (M3) every 0, Maintenance 4 (M4) every 20, Initial Maintenance (IM) first 2, Maintenance (M) every 2, Maintenance 2 (M2) every 50, Maintenance 3 (M3) every 00, Maintenance 4 (M4) every 300, * For Service Schedule I (severe service) vehicles equipped with an hourmeter, use maintenance intervals based on hours of operation rather than distance traveled. 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, Maintenance Service Schedule Table 00/2 Western Star Maintenance Manual, October 2007

9 General Information 00 Vehicle Maintenance Schedule Tables: st through 34th Maintenance for Service Schedule I Vehicles Maint. Required Maintenance Operation Service I Service Date No. Interval Miles km Hours st Initial Maintenance (IM)/M nd M rd M th M th M and M th M th M th M th M th M, M2, and M3 0, th M, th M 2, th M 3, th M 4, th M and M2 5, th M 6, th M 7, th M 8, th M 9, th M, M2, M3, and M4 20, st M 2, nd M 22, rd M 23, th M 24, th M and M2 25, th M 26, th M 27, th M 28, th M 29, th M, M2, and M3 30, st M 3, nd M 32, rd M 33, th M 34, Table 2, st through 34th Maintenance for Service Schedule I Vehicles Western Star Maintenance Manual, October /3

10 00 Vehicle Maintenance Schedule Tables: General Information 35th through 68th Maintenance for Service Schedule I Vehicles Maint. Required Maintenance Operation Service I Service Date No. Interval Miles km Hours 35th M and M2 35, th M 36, th M 37, th M 38, th M 39, th M, M2, M3, and M4 40, st M 4, nd M 42, rd M 43, th M 44, th M and M2 45, th M 46, th M 47, th M 48, th M 49, th M, M2, and M3 50, st M 5, nd M 52, rd M 53, th M 54, th M and M2 55, th M 56, th M 57, th M 58, th M 59, th M, M2, M3, and M4 60, st M 6, nd M 62, rd M 63, th M 64, th M and M2 65, th M 66, th M 67, th M 68, Table 3, 35th through 68th Maintenance for Service Schedule I Vehicles 00/4 Western Star Maintenance Manual, October 2007

11 General Information 00 Vehicle Maintenance Schedule Tables: th through 00th Maintenance for Service Schedule I Vehicles Maint. Required Maintenance Operation Service I Service Date No. Interval Miles km Hours 69th M 69, th M, M2, and M3 70, st M 7, nd M 72, rd M 73, th M 74, th M and M2 75, th M 76, th M 77, th M 78, th M 79, th M, M2, M3, and M4 80, st M 8, nd M 82, rd M 83, th M 84, th M and M2 85, th M 86, th M 87, th M 88, th M 89, th M, M2, and M3 90, st M 9, nd M 92, rd M 93, th M 94, th M and M2 95, th M 96, th M 97, th M 98, th M 99, th M, M2, M3, and M4 00, ,000 Table 4, 69th through 00th Maintenance for Service Schedule I Vehicles Western Star Maintenance Manual, October /5

12 00 Vehicle Maintenance Schedule Tables: General Information st through 24th Maintenance for Service Schedule II Vehicles Maint. No. Required Maintenance Operation Interval Service Date Miles km st Initial Maintenance (IM)/M 2, nd M 25, rd M 37, th M and M2 50, th M 62, th M 75, th M 87, th M, M2, and M3 00, th M 2, th M 25, th M 37, th M and M2 50, th M 62, th M 75, th M 87, th M, M2, and M3 200, th M 22, th M 225, th M 237, th M and M2 250, st M 262, nd M 275, rd M 287, th M, M2, M3, and M4 300, Table 5, st through 24th Maintenance for Service Schedule II Vehicles 00/6 Western Star Maintenance Manual, October 2007

13 General Information 00 Maintenance Operation Sets Tables: IMPORTANT: At each Maintenance Operation Set, in addition to the maintenance operations listed here, perform all daily and weekly maintenance operations listed in the "Pretrip Inspection and Daily Maintenance" chapter of the Western Star Driver s Manual. NOTE: Maintenance operations appearing in italics in these tables are for noise emission control components. Numbers in these tables are reference numbers matching those in the text of this manual. Maintenance Operation Sets for Groups 00 through 32 Maint. Oper. Maintenance Interval Operation Description No. IM M M2 M3 M Lubrication and Fluid Level Check 0 0 Engine Noise Panel Inspection 0 02 Engine Belt Inspection 0 03 Packbrake Inspection and Maintenance 0 04 Engine-Support Fasteners Check 09 0 Intake Piping Inspection Air Cleaner Element Inspection and Replacement Charge Air Cooler Inspection 3 0 Air Compressor Inspection, Bendix 5 0 Alternator and Starter Check 5 02 Battery Check 20 0 Coolant Inspection Cooling System Inspection Pressure/Filler Cap Test Cooling System Pressure-Flush 25 0 Clutch Release Bearing Lubrication Clutch Release Cross-Shaft Lubrication Sleeve Assembly Bronze Bushing Lubrication 26 0 Transmission Fluid Level Inspection Manual Transmission Fluid Change Manual Transmission Air Filter/Regulator Check, and Cleaning or Replacement ESS Transmission Filter and Boot Inspection Transmission Inspection 3 0 Fifth Wheel Inspection 3 02 Fifth Wheel Lubrication 3 03 Holland Fifth Wheel Sliding Mechanism Inspection 3 04 Frame Fastener Torque Check 32 0 Suspension Inspection Suspension Lubrication Suspension U-Bolt Torque Check Table 6, Maintenance Operation Sets for Groups 00 through 32 Western Star Maintenance Manual, October /7

14 00 Maintenance Operation Sets Tables: General Information Maintenance Operation Sets for Groups 33 through 83 Maint. Oper. Maintenance Interval Operation Description No. IM M M2 M3 M Knuckle Pin Lubrication Tie Rod Lubrication Tie Rod Inspection Front Axle Wheel Bearing Lubrication Front Drive Axle Lubricant Level Check Front Drive Axle Lubricant Change Wheel Alignment Check 35 0 Drive Axle Lubricant Level Check Two-Speed-Axle Shift Unit Lubricant Level Check Drive Axle Breather Check Drive Axle Lubricant Change 40 0 Wheel Nut and Rim Nut Torque Check Tire Check 4 0 Driveline Inspection 4 02 Driveline Lubrication Air Dryer Inspection Air Dryer Desiccant Replacement Alcohol Evaporator Cleaning and Inspection Camshaft Bracket Lubrication Slack Adjuster Lubrication Brake Inspection 46 0 Drag Link Inspection Drag Link Lubrication Power Steering Fluid and Filter Change Power Steering Fluid Level Inspection Power Steering Gear Lubrication Steering Shaft Lubrication 47 0 Fuel Filter Replacement Fuel Separator Sight Bowl Cleaning and Element Replacement Fuel Tank Band Nut Tightening 49 0 Exhaust System Inspection 60 0 Cab Suspension Inspection 72 0 Door Seal, Door Latch, and Door Hinge Lubrication 83 0 Air Conditioner Inspection 00/8 Western Star Maintenance Manual, October 2007

15 General Information 00 Maintenance Operation Sets Tables: Maintenance Operation Sets for Groups 33 through 83 Maint. Oper. Maintenance Interval Operation Description No. IM M M2 M3 M HVAC Air Filter Replacement Table 7, Maintenance Operation Sets for Groups 33 through 83 Western Star Maintenance Manual, October /9

16 00 Initial Maintenance (IM) Operations: General Information IMPORTANT: After performing all operations listed in this table, perform all daily and weekly maintenance operations listed in the "Pretrip Inspection and Daily Maintenance" chapter of the Western Star Driver s Manual. NOTE: Numbers in this table are reference numbers matching those in the text of this manual. Initial Maintenance (IM) Operations Maintenance Operation Number Operation Description MI Maintenance Interval Operations Table 5 0 Alternator and Starter Check 5 02 Battery Check Manual Transmission Fluid Change Manual Transmission Air Filter/Regulator Check, and Cleaning or Replacement 3 04 Frame Fastener Torque Check Suspension U-Bolt Torque Check Front Drive Axle Lubricant Change Wheel Alignment Check Drive Axle Lubricant Change Table 8, Initial Maintenance (IM) Operations for all Service Schedules Check 00/0 Western Star Maintenance Manual, October 2007

17 General Information 00 Lubrication and Fluid Level Check: Table 9 summarizes all operations that must be performed to complete Lubrication and Fluid Level Check Operation called for as an M maintenance interval for Service Schedule I and II vehicles. Maintenance operation numbers given in the table are reference numbers used to help you find detailed instructions in the manual on the lubrication or fluid checking. Maintenance Operation 00 06, Lubrication and Fluid Level Check for Service Maintenance Operation No. Operation Description Check 25 0 Clutch Release Bearing Lubrication Clutch Release Cross-Shaft Lubrication Sleeve Assembly Bronze Bushing Lubrication 26 0 Transmission Fluid Level Inspection 3 02 Fifth Wheel Lubrication Suspension Lubrication 33 0 Knuckle Pin Lubrication Tie Rod Lubrication Front Axle Wheel Bearing Lubrication Front Drive Axle Lubricant Level Check 35 0 Drive Axle Lubricant Level Check 4 02 Driveline Lubrication Camshaft Bracket Lubrication Slack Adjuster Lubrication Drag Link Lubrication Power Steering Fluid Level Inspection Power Steering Gear Lubrication Steering Shaft Lubrication 72 0 Door Seal, Door Latch, and Door Hinge Lubrication Table 9, Maintenance Operation 00-06, Lubrication and Fluid Level Check for Service Schedules I and II Western Star Maintenance Manual, October /

18 00 M Maintenance Interval Operations Table: General Information The M Maintenance Interval Operations table lists all maintenance operations that are to be performed at the M maintenance interval. Maintenance operation numbers are reference numbers used to help you find detailed instructions in this manual on the maintenance operations to be performed. M Maintenance Interval Operations for Service Schedules I and II Maintenance Operation Number Operation Description Lubrication and Fluid Level Check 3 0 Air Compressor Inspection, Bendix 20 0 Coolant Inspection 3 0 Fifth Wheel Inspection 32 0 Suspension Inspection Tie Rod Inspection Drive Axle Breather Check 40 0 Wheel Nut and Rim Nut Torque Check Tire Check 4 0 Driveline Inspection Air Dryer Inspection Brake Inspection 46 0 Drag Link Inspection 47 0 Fuel Filter Replacement Fuel Tank Band Nut Tightening 49 0 Exhaust System Inspection HVAC Air Filter Replacement Table 0, MI Maintenance Interval Operations for Service Schedules I and II Check 00/2 Western Star Maintenance Manual, October 2007

19 General Information 00 M2 Maintenance Interval Operations Table: The M2 Maintenance Interval Operations table lists all maintenance operations that are to be performed at the M2 maintenance interval. Maintenance operation numbers are reference numbers used to help you find detailed instructions in this manual on the maintenance operations to be performed. Perform all M maintenance interval operations at the M2 maintenance interval. NOTE: Maintenance operations appearing in italics in this table are for noise emission control components. M2 Maintenance Interval Operations for Service Schedules I and II Maintenance Operation Number Operation Description M Maintenance Interval Operations Table 0 03 Pacbrake Inspection and Maintenance Cooling System Inspection Pressure/Filler Cap Test Manual Transmission Fluid Change Manual Transmission Air Filter/Regulator Check, and Cleaning or Replacement 3 03 Holland Fifth Wheel Sliding Mechanism Inspection Power Steering Fluid and Filter Change Fuel Separator Sight Bowl Cleaning and Element Replacement 60 0 Cab Suspension Inspection 83 0 Air Conditioner Inspection Table, M2 Maintenance Interval Operations for Service Schedules I and II Check Western Star Maintenance Manual, October /3

20 00 M3 Maintenance Interval Operations Table: General Information The M3 Maintenance Interval Operations table lists all maintenance operations that are to be performed at the M3 maintenance interval. Maintenance operation numbers are reference numbers used to help you find detailed instructions in this manual on the maintenance operations to be performed. Perform all maintenance interval operations in M and M2 when performing M3 maintenance interval operations. NOTE: Maintenance operations appearing in italics in this table are for noise emission control components. M3 Maintenance Interval Operations for Service Schedules I and II Maintenance Operation Number Operation Description M Maintenance Interval Operations Table M2 Maintenance Interval Operations Table 0 0 Engine Noise Panel Inspection 0 02 Engine Belt Inspection 0 04 Engine Support Fasteners Check 09 0 Intake Piping Inspection Air Cleaner Element Inspection and Replacement Charge Air Cooler Inspection 5 0 Alternator and Starter Check 5 02 Battery Check 3 04 Frame Fastener Torque Check Suspension U-Bolt Torque Check Front Drive Axle Lubricant Change Two-Speed-Axle Shift Unit Lubricant Level Check Drive Axle Lubricant Change Alcohol Evaporator Cleaning and Inspection Table 2, M3 Maintenance Interval Operations for Service Schedules I and II Check 00/4 Western Star Maintenance Manual, October 2007

21 General Information 00 M4 Maintenance Interval Operations Table: 00 0 The M4 Maintenance Interval Operations table lists all maintenance operations that are to be performed at the M4 maintenance interval. Maintenance operation numbers are reference numbers used to help you find detailed instructions in this manual on the maintenance operations to be performed. Perform all maintenance interval operations in M, M2, and M3 when performing M4 maintenance interval operations. M4 Maintenance Interval Operations for Service Schedules I and II Maintenance Operation Number Operation Description M Maintenance Interval Operations Table M2 Maintenance Interval Operations Table M3 Maintenance Interval Operations Table Cooling System Pressure Flush ESS Transmission Filter and Boot Inspection Transmission Inspection Air Dryer Desiccant Replacement Table 3, M4 Maintenance Interval Operations for Service Schedules I and II Check Western Star Maintenance Manual, October /5

22 00 Noise Emission Controls Maintenance: 00 General Information General Information Federal Law, Part 205: Transportation Equipment Noise Emission Controls Part 205, Transportation Equipment Noise Emission Controls, requires the vehicle manufacturer to furnish with each new vehicle, such written instructions for the proper maintenance, use, and repair of the vehicle by the ultimate purchaser to provide reasonable assurance of the elimination or minimization of noise emission control degradation throughout the life of the vehicle. In compliance with the law, the noise emission controls maintenance information in each applicable group of this manual, in conjunction with the vehicle service manual, provides these instructions to owners. Recommendations for Replacement Parts Replacement parts, used for the maintenance or repair of noise emission controls, should be genuine Western Star parts. If other than genuine Western Star parts are used, for replacement or repair of components affecting noise emission control, the owner should be sure that such parts are warranted by their manufacturer or to be equivalent to the genuine Western Star parts in performance and durability. Western Star Noise Emission Controls Warranty Refer to the vehicle owner s warranty information book for warranty information concerning noise emission controls. Tampering With Noise Controls is Prohibited Federal law prohibits the following acts or the causing thereof:. The removal or rendering inoperative, by any person (other than for the purposes of maintenance, repair, or replacement) of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while the vehicle is in use. 2. The use of the vehicle after such a device or element of design for the purpose of noise control has been removed or rendered inoperative by any person. Among those acts presumed to constitute tampering are the acts listed below:. The removal of engine sound-suppression panels. 2. The removal of cab tunnel or hood soundsuppression panels. 3. The removal of, or rendering inoperative, the engine speed governor so as to allow the engine speed to exceed the manufacturer s specifications. 4. The removal of, or rendering inoperative, the engine fan clutch, including bypassing the control on any thermostatic fan drive to cause it to operate continuously. 5. The removal of the fan shroud. 6. The removal of, or rendering inoperative, engine exhaust components, including the exhaust pipe clamping. 7. The removal of air intake components. Maintenance Instructions Scheduled intervals are in the maintenance tables in this group. A "Verification of Inspections Log (Groups 0, 20, and 49)" follows. These logs should be filled in each time the noise emission controls on the vehicle are maintained, repaired, or replaced. 00/6 Western Star Maintenance Manual, October 2007

23 General Information 00 Verification of Inspections Log: 00 2 Verification of Inspections Log Verification of Inspections Log (Group 0) Engine Rear Supports and Engine Noise Panels Date Mileage Item Cost Maintenance Facility Table 4, Verification of Inspections Log (Group 0) Engine Rear Supports and Engine Noise Panels Verification of Inspections Log (Group 20) Fan Drive Date Mileage Item Cost Maintenance Facility Table 5, Verification of Inspections Log (Group 20) Fan Drive Western Star Maintenance Manual, October /7

24 00 Verification of Inspections Log: 00 2 General Information Verification of Inspections Log (Group 49) Exhaust System Components Date Mileage Item Cost Maintenance Facility Table 6, Verification of Inspections Log (Group 49) Exhaust System Components 00/8 Western Star Maintenance Manual, October 2007

25 General Information 00 Metric/U.S. Customary Conversion Tables: 00 3 When You Know U.S. Customary Length Multiply By To Get Metric When You Know Metric Multiply By To Get U.S. Customary inches (in) 25.4 millimeters (mm) inches (in) inches (in) 2.54 centimeters (cm) inches (in) feet (ft) meters (m) 3.28 feet (ft) yards (yd) meters (m).094 yards (yd) miles (mi).609 kilometers (km) miles (mi) Area square inches (in 2 ) square millimeters (mm 2 ) square inches (in 2 ) square inches (in 2 ) square centimeters (cm 2 ) 0.55 square inches (in 2 ) square feet (ft 2 ) square meters (m 2 ) square feet (ft 2 ) Volume cubic inches (in 3 ) cubic millimeter (mm 3 ) cubic inches (in 3 ) cubic inches (in 3 ) cubic centimeters (cm 3 ) cubic inches (in 3 ) cubic inches (in 3 ) liters (L) cubic inches (in 3 ) fluid ounces (fl oz) milliliters (ml) fluid ounces (fl oz) pints (pt) liters (L) 2.34 pints (pt) quarts (qt) liters (L).0567 quarts (qt) gallons (gal) liters (L) gallons (gal) cubic feet (ft 3 ) liters (L) cubic feet (ft 3 ) cubic feet (ft 3 ) cubic meters (m 3 ) cubic feet (ft 3 ) Weight/Force ounces (av) (oz) grams (g) ounces (av) (oz) pounds (av) (lb) kilograms (kg) pounds (av) (lb) U.S. tons (t) kilograms (kg) U.S. tons (t) U.S. tons (t) metric tons (t).023 U.S. tons (t) Torque/Work Force inch-pounds (lbf in).298 Newton centimeters (N cm) inch pounds (lbf in) foot-pounds (lbf ft).3558 Newton meters (N m) foot pounds (lbf ft) Pressure/Vacuum inches of mercury (inhg) kilo Pascals (kpa) inches of mercury (inhg) pounds per square inch (psi) kilo Pascals (kpa) pounds per square inch (psi) Table 7, Metric/U.S. Customary Conversions When You Know Subtract Then Divide By To Get When You Know Multiply By Then Add To Get degrees Fahrenheit ( F) 32.8 degrees Celsius ( C).8 32 degrees Fahrenheit ( F) Table 8, Temperature Conversions Western Star Maintenance Manual, October /9

26 00 Torque Specifications Tables: 00 4 General Information Torque Values for U.S. Customary Thread Fasteners With Lubricated* or Plated Threads Thread Diameter Pitch Grade 5 Bolt Grade 5 or BNut Regular Hex Grade 8 or 8.2 Bolt Grade 8 or CNut Grade 5 Bolt Grade B Nut Flanged Grade 8 or 8.2 Bolt Grade G Nut Torque: lbf ft (N m) Torque: lbf ft (N m) Torque: lbf ft (N m) Torque: lbf ft (N m) f f f f f f f f / (9) 8 () 6 (8) 0 (4) / () 9 (2) 7 (9) 2 (6) 5/6 8 5 (20) 6 (22) 3 (8) 2 (28) 5/ (22) 7 (23) 4 (9) 23 (3) 3/ (35) 28 (38) 23 (3) 37 (50) 3/ (4) 32 (43) 25 (34) 42 (57) 7/ (57) 45 (6) 35 (47) 60 (8) 7/ (64) 50 (68) 40 (54) 66 (89) / (87) 68 (92) 55 (75) 9 (23) / (98) 77 (04) 65 (88) 02 (38) 9/ (25) 98 (33) 80 (08) 30 (76) 9/ (40) 0 (49) 90 (22) 46 (98) 5/8 28 (73) 36 (84) 0 (49) 80 (244) 5/ (97) 54 (209) 30 (76) 204 (277) 3/ (306) 24 (327) 200 (27) 320 (434) 3/ (343) 269 (365) 220 (298) 357 (484) 7/ (495) 388 (526) 320 (434) 55 (698) 7/ (545) 427 (579) 350 (475) 568 (770) (789) (863) (884) * Western Star recommends that all plated and unplated fasteners be coated with oil before installation. Use these torque values if either the bolt or nut is lubricated or plated (zinc-phosphate conversion-coated, cadmium-plated, or waxed). Table 9, Torque Values for U.S. Customary Thread Fasteners With Lubricated or Plated Threads 00/20 Western Star Maintenance Manual, October 2007

27 General Information 00 Torque Specifications Tables: 00 4 Torque Values for U.S. Customary Thread Fasteners With Dry (Unlubricated)* Plain (Unplated) Threads Thread Diameter Pitch Grade 5 Bolt Grade5orB Nut Regular Hex Grade 8 or 8.2 Bolt Grade8orC Nut Grade 8 or 8.2 Bolt Flanged Grade G Nut Torque: lbf ft (N m) Torque: lbf ft (N m) Torque: lbf ft (N m) f f f f f f / () 0 (4) / (2) 2 (6) 5/6 8 5 (20) 22 (30) 22 (30) 5/ (23) 25 (34) 3/ (38) 40 (54) 40 (54) 3/ (42) 45 (6) 7/ (6) 65 (88) 65 (88) 7/ (68) 70 (95) / (95) 95 (29) 95 (29) / (02) 0 (49) 9/ (36) 40 (90) 40 (90) 9/6 8 0 (49) 55 (20) 5/8 35 (83) 90 (258) 90 (258) 5/ (20) 25 (292) 3/ (325) 340 (46) 340 (46) 3/ (366) 380 (55) 7/ (522) 540 (732) 7/ (576) 600 (83) (786) 820 (2) (86) 900 (220) (88) 95 (24) * Threads may have residual oil, but will be dry to the touch. Male and female threads (bolt and nut) must both be unlubricated and unplated; if either is plated or lubricated, use Table 9. Western Star recommends that all plated and unplated fasteners be coated with oil before installation. Table 20, Torque Values for U.S. Customary Thread Fasteners With Dry (Unlubricated) Plain (Unplated) Threads Western Star Maintenance Manual, October /2

28 00 Torque Specifications Tables: 00 4 General Information Torque Values for Metric Thread Fasteners With Lubricated* or Plated Threads Thread Diameter Pitch Class 8.8 Bolt Class 8 Nut Class 0.9 Bolt Class 0 Nut Torque: lbf ft (N m) Torque: lbf ft (N m) f23000 f2300 f23002 f23003 M6 5 (7) 7 (9) M8 2 (6) 7 (23) M8 x 3 (8) 8 (24) M0 24 (33) 34 (46) M0 x (37) 38 (52) M2 42 (57) 60 (8) M2 x.5 43 (58) 62 (84) M4 66 (89) 95 (29) M4 x.5 72 (98) 03 (40) M6 03 (40) 48 (20) M6 x.5 0 (49) 57 (23) M8 47 (99) 203 (275) M8 x.5 65 (224) 229 (30) M (282) 288 (390) M20 x.5 23 (33) 320 (434) M (384) 392 (53) M22 x.5 35 (427) 43 (584) M (488) 498 (675) M24 x (53) 542 (735) M (75) 729 (988) M27 x (77) 788 (068) M30 75 (969) 990 (342) M30 x (074) 096 (486) * Western Star recommends that all plated and unplated fasteners be coated with oil before installation. Use these torque values if either the bolt or nut is lubricated or plated (zinc-phosphate conversion-coated, cadmium-plated, or waxed). Table 2, Torque Values for Metric Thread Fasteners With Lubricated or Plated Threads 00/22 Western Star Maintenance Manual, October 2007

29 General Information 00 Torque Specifications Tables: 00 4 Spring Assembly U-Bolt High Nuts U-Bolt Torque Values Description Size Torque*: lbf ft (N m) 5/8 8 3/4 6 7/8 4 4 Stage : Hand-tighten Stage 2: 60 (8) Stage 3: 200 (27) Stage 4: 80 to 230 (245 to 33) Stage : Hand-tighten Stage 2: 60 (8) Stage 3: 200 (27) Stage 4: 270 to 330 (367 to 449) Stage : Hand-tighten Stage 2: 60 (8) Stage 3: 200 (27) Stage 4: 420 to 500 (57 to 680) Stage : Hand-tighten Stage 2: 60 (8) Stage 3: 200 (27) Stage 4: 520 to 600 (707 to 86) * Tighten in a diagonal pattern as shown in Fig.. Table 22, U-Bolt Torque Values /3/200 f32090 Fig., Tightening Pattern for U-Bolt High Nuts Western Star Maintenance Manual, October /23

30 Engine 0 Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Engine Belt Inspection Engine Noise Panel Inspection (Noise Emission Control) Engine-Support Fasteners Check (Noise Emission Control) Pacbrake Inspection and Maintenance Western Star Maintenance Manual, January 2007

31 Engine Engine Noise Panel Inspection (Noise Emission Control) If equipped, inspect for torn engine panels. See Fig. for Caterpillar noise panel locations. If the panels are torn, contact your Western Star dealer to have them replaced. Cummins M and N4 engines, and Detroit Diesel Series 60 engines do not have engine noise panels. /29/95. Oil Pan Noise Panel (C0 engine only) 2. Left-Side Noise Panel (3406 engines only) Fig., Caterpillar Engine Noise Panels 0 02 Engine Belt Inspection Visual Inspection f0040 Inspect the belts by gently twisting the belt to view the belt sidewalls and bottom. Visually inspect all belts for the following conditions.. Inspect the belt for glazing. See Fig. 2, Ref. A. Glazing is represented by shiny sidewalls, and is caused by heat generated by a loose belt slipping in the pulleys. 2. Check for ply separation. See Fig. 2, Ref. B. Oil, grease, or belt dressing can cause the belt to fall apart in layers. Repair any oil or coolant leaks that are contaminating the belts, before replacing 2 the belts. DO NOT USE BELT DRESSING ON ANY BELT. 3. Check the belt for a jagged or streaked sidewall. See Fig. 2, Ref. C. Jagged or streaked sidewalls are the result of foreign objects, such as sand or gravel in the pulley, or a rough pulley surface. Remove foreign objects or have the damaged pulley replaced as required, when replacing the belts. 4. Check for cuts or breaks in the cord body. See Fig. 2, Ref. D. Cord breaks or cuts are caused by over-stretching the belt, foreign objects in the pulley, or prying or forcing the belt during removal or installation. 5. Check for uneven ribs on serpentine (Poly-V) belts. See Fig. 2, Ref. E. Foreign objects in the pulley will erode the undercord ribs, causing the belt to loose its gripping power. 6. Visually inspect the pulleys for excessive play or wobble. Excessive play or wobble indicates a failure of the pulley bearing. Check for belt squealing or squeaking. Have the pulley bearings replaced as required. NOTE: If it is difficult to distinguish the location of a supposed bearing noise, place a stethoscope on the component being checked, not the pulley, to isolate the area from outside interference. 7. Inspect all pulleys for foreign objects, oil, or grease in the groves. Clean the pulley and repair any oil or coolant leaks that are contaminating the pulley, and remove foreign objects or have damaged pulleys replaced as required, before replacing the drive belts. Replace engine drive belt(s) if any conditions described are found. V-belts are installed either as individuals or matched sets. If one belt of a matched set requires replacement always replace all belts of the set at the same time. Matched belts must be from the same manufacturer. Belt Tension Inspection Worn or loose drive belts may cause engine overheating and discharged batteries. Excessive tension may cause premature bearing failure. Over- or under-tensioned drive belts will result in premature belt wear. Poly-V belts, or serpentine belts are tensioned by a spring-loaded idler pulley that requires Western Star Maintenance Manual, January /

32 0 Engine A D B E /2/94 C F f5000a A. Glazing B. Separating Layers C. Streaked Sidewalls D. Tensile Break E. Uneven Ribs F. Cracks Fig. 2, Belt Damage Conditions no tension adjustment. The following diagrams show belt arrangements on the various engines. Caterpillar: See Fig. 3 for 326B model. See Fig. 4 for C0 and C2 models. See Fig. 5 for C5 and C6 models. Cummins: See Fig. 6 for ISX (Signature 600) model. See Fig. 7 for ISM model. See Fig. 8 for N4 model. Detroit Diesel: See Fig. 9 for Series 60 model. Threaded Adjustment Type The ONLY accurate way to check belt tension is to use a belt tension gauge. If belts require adjustment see your Western Star dealer /30/200 f0975. Fan Clutch 2. Air Conditioning Compressor 3. Alternator 4. Spring-Loaded Tensioner Fig. 3, Caterpillar 326B 0/2 Western Star Maintenance Manual, January 2007

33 Engine /30/200 f0976. Fan Clutch 2. Air Conditioning Compressor 3. Alternator 4. Spring-Loaded Tensioner Fig. 4, Caterpillar C0 and C2 2 04/30/200 f0978. Fan Clutch 2. Air Conditioning Compressor 3. Alternator 4. Spring-Loaded Tensioner Fig. 6, Cummins ISX (Signature 600) 3 04/30/200 f0977. Fan Clutch 2. Air Conditioning Compressor 3. Alternator Fig. 5, Caterpillar C5 and C6 Spring-Loaded Idler Type On belts with a spring-loaded idler pulley, belt tension is automatically adjusted. To check that the spring-loaded idler pulley is holding tension on the belts, apply the parking brakes, and chock the tires to prevent the vehicle from moving. Remove the key from the ignition and place it in your pocket. Caterpillar On Caterpillar engines, there is a red and green decal on the side of the idler arm mount. See Fig. 0. A properly tensioned belt is indicated by the shoulder of the idler arm aligned with the green zone of the decal. As the belt stretches, the shoulder will drift into the red zone. If the idler arm shoulder moves into the red zone, the belt needs to be replaced. Cummins On Cummins engines, a properly tensioned belt is indicated by the stop bar being in the center between the idler arm stops. See Fig.. As the belt stretches, the idler arm stop will rotate to the stop Western Star Maintenance Manual, January /3

34 0 Engine /30/200 f0979. Fan Clutch 2. Air Conditioning Compressor 3. Alternator 4. Spring-Loaded Tensioner Fig. 7, Cummins ISM 3 04/30/200 f098. Fan Clutch 2. Air Conditioning Compressor 3. Alternator 4. Spring-Loaded Tensioner Fig. 9, Detroit Diesel Series /30/200 f0980. Fan Clutch 2. Air Conditioning Compressor 3. Alternator Fig. 8, Cummins N4 bar. If the idler arm stop has rotated to contact the stop bar, the belt needs to be replaced. 04//200 f0982 A. Shoulder. Spring-Loaded Tensioner 2. Label Green Zone 2 A Fig. 0, Caterpillar Self-Tensioner 0/4 Western Star Maintenance Manual, January 2007

35 Engine /05/200 f0984. V-Groove 2. Pointer 04/05/200 f0983. Stop Bar 2. Idler Arm Stops Detroit Diesel Fig., Cummins Self-Tensioner The idler arm pivot on Detroit Diesel Series 60 engines has a pointer cast into the arm. See Fig. 2. This pointer should align with the V-groove mark at the rear of the mount, when belt tension is correct. As the belt stretches, the pointer will drift to the left of the V-groove. If the pointer is moved past the end of the V-groove, the belt needs to be replaced Pacbrake Inspection and Maintenance With frequent use, the Pacbrake exhaust brake will operate maintenance-free. If the vehicle is used inconsistently or seasonally, it will be necessary to perform preventative maintenance. If the vehicle is exposed to excess moisture, or is used only for periodical or seasonal use, perform the following steps.. With the engine off, using any oil-free or nonpetroleum-based high-heat lubricant, spray or coat a sufficient amount on the restricter valve shaft and the attaching locations at each end of the actuation cylinder. Fig. 2, Detroit Diesel Self-Tensioner 2. With your hands or a pair of pliers, motion the valve several times to distribute the lubricant down the shaft and the attaching locations. NOTE: Operation of the Pacbrake could be affected by starting the engine and idling for short periods of time. During a cold engine start-up, moisture occurs in the engine and exhaust system that creates a corrosion hazard. The brake housing may trap water in the valve shaft bore, causing a corrosion hazard. The brake housing may trap water in the valve shaft bore, causing corrosion resulting in an improper or nonfunctioning brake. If it is necessary to periodically start the engine, attain normal operating temperatures before shutting the engine down Engine-Support Fasteners Check (Noise Emission Control) Front and rear engine supports for vehicles built from January 2007 require no periodic maintenance. Mounts should be inspected when the engine is removed for service. For vehicles manufactured prior to January 2007, perform the following check. Check the rear engine-support fasteners (see Fig. 3, Ref. 3) for tightness. Tighten the 5/8-inch fasteners 50 to 80 lbf ft (203 to 244 N m). Western Star Maintenance Manual, January /5

36 0 Engine /22/200. Transmission Housing 2. Transmission Nodal Mount Bracket 3. Bolt, 5/8 8 x 4 4. Frame Bracket 5. Nut, 5/ Lower Isolator 7. Upper Isolator f0992 Fig. 3, Rear Engine-Support Check the front engine-support fasteners for tightness. Tighten the 3/4-inch fasteners 260 to 30 lbf ft (350 to 420 N m). 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. 0/6 Western Star Maintenance Manual, January 2007

37 Air Intake 09 Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Air Cleaner Element Inspection and Replacement Charge Air Cooler Inspection Intake Piping Inspection Western Star Maintenance Manual, January 2004

38 Air Intake Intake Piping Inspection Cowl-Mounted Air Cleaner. Check the connections between the plastic or aluminum piping and the rubber elbows. See Fig /22/200. Rubber Elbow 2. Gear Clamp 3. Constant-Torque Clamp 4. Turbocharger 5. Plastic Pipe 6. Flex Hose 7. Air Cleaner 6 5 Fig., Air Intake, Cowl-Mounted Air Cleaner 2. Check the tightness and condition of the clamping hardware. Clamps should be tightened to 25 lbf in (280 N cm). 3. Inspect the mating surfaces of the plastic or aluminum pipes. If it appears that the rubber elbow has moved on the plastic pipe, or if the hose clamps were loose, disassemble for further inspection. 4. After disassembly of the plastic pipe from the rubber connection elbow, inspect the ends of the pipe for evidence of the rubber elbow rubbing on it. If chaffing marks are visible replace the worn pipe. Wipe any dust from the inside of the pipe. 5. Check the inside of the rubber elbow for wear and contamination. If the rubber elbow is reusable, clean it internally with a shop towel, or f09048 soap and water. Blow-dry the elbow as needed, and install it. 6. Check the condition of the gear clamp. If wear is evident, replace the gear clamp with a constanttorque clamp. Constant-torque clamps should be used if a vehicle is routinely exposed to rough road conditions or off-road applications. 7. Check the two band clamps that hold the air cleaner in place on the cowl. Ensure the canister has not slipped downwards and allowed the top band to come in contact with the lower flange of the canister cover. If this condition is present, loosen the two band clamp bolts and slide the canister upward until the band clamp is well below the canister cover flange. 8. Inspect the alignment and fit of the rubber elbow that passes through the cowl and attaches the intake duct to the canister outlet pipe. Adjust as necessary to ensure a proper connection. Be certain the clamps are torqued 25 lbf in (280 N cm). Do not over-torque. Under-Hood Air Cleaner This style of air intake system has the air cleaner element mounted horizontally across the left side of the firewall. The air intake is through ducting built into the hood and routed into the top of the air cleaner canister. See Fig. 2.. Check that the bolts on the canister mounting brackets are tight. 2. Check the mounting angle of the air cleaner canister inlet boot. It must be rotated forward slightly to ensure a correct seal to the hood intake duct. Inspect the hood and boot contact points for proper contact as evident by the polished area on the hood where the boot contacts it. 3. Check the connection points of the entire intake system to ensure the alignment of the rubber hoses to the charge air cooler pipe connections are correct. Check the piping for evidence of movement at the joint connections. Retorque all clamps to 25 lbf in (280 N cm). Replace any clamps that are corroded or fail to operate smoothly when retorquing. Western Star Maintenance Manual, January /

39 09 Air Intake 08/24/200. Restriction Indicator 2. Air Intake Boot 3. Canister Mounting Clamp 4. Spring Clamp 5. Charge Air Cooler Hose Air Cleaner Element Inspection and Replacement Method Replace the air cleaner element at the recommended interval or when the air restriction indicator reaches 20 to 25 inh 2 O, if equipped with an air restriction indicator. Reset the air restriction indicator. If the maximum restriction is not reached, record the air restriction value. If the value is higher than the previous recording, reset the air restriction indicator. If the value is lower than the previous recording, inspect the air cleaner and air cleaner element for cracks, leaks, or any other damage. If the air cleaner or air cleaner element is damaged, replace it and reset the air restriction indicator. Method Fig. 2, Under-Hood Air Cleaner Replace the air cleaner element at the recommended interval or when the air restriction indicator reaches 4 f to 25 inh 2 O, if equipped with an air restriction indicator. Reset the air restriction indicator. If the maximum restriction is not reached, inspect the air cleaner and air cleaner element for cracks, leaks, or any other damage. If the air cleaner or air cleaner element is damaged, replace it and reset the air restriction indicator. Cowl-Mounted Air Cleaner The standard cowl-mounted air cleaner system used on Western Star trucks is manufactured by Fleetguard Nelson Inc. The air flow in this system flows from the inside of the element, outward through the filter element into the canister, then into the air intake piping on route to the turbocharger. It is highly recommended that only Nelson original equipment filter elements are used to service the air cleaner assemblies. Aftermarket replacement elements may vary in size to the original equipment, or may use a different type of seal at the top and bottom of the element. A variance in the size of the element, or the thickness and type of seal material, can affect the crush of the gasket seal and could result in a poor seal on one of the mating surfaces. Elements that do not fit properly may allow the element to bounce in the canister and allow dirt to pass over the upper seal and into the canister and intake piping. If the vehicle is equipped with dual air cleaners, replace both elements at the same interval.. Remove the eight nylon cap nuts that secure the cap to the canister. See Fig. 3. Take note of the position of the blank portion of the air intake screen so the cover can be reinstalled in the correct position. 2. After removing the canister cap, carefully pull the element straight up out of the canister, ensuring no dust or debris is dropped into the canister. 3. Inspect the clean side of the element and canister for evidence of contamination. The clean side of the element is the area outside the gaskets on either end of the element, including the top cover. If debris is present, find the leak, determine the cause, and correct the problem area immediately. 4. Clean the inside of the canister thoroughly. Use a clean damp cloth to wipe every surface clean. If unable to remove all debris, use a vacuum cleaner to remove all remaining dirt, dust, and contamination. 09/2 Western Star Maintenance Manual, January 2004