Western Star 4700/4800/4900/5900/6900 Series Trucks OEM Service & Repair Manual

WESTERN STAR WORKSHOP MANUAL Models: 4700 Series 4800 Series 4900 Series 5900 Series 6900 Series STI-458, S16 (9/11) Published by Daimler Trucks North America LLC 4747 N. Channel Ave. Portland, OR 97217 Printed in U.S.A.

Foreword The purpose of this manual is to assist the service technician when the vehicle is serviced. Major drivetrain component service information is not included in this manual, but is located in each manufacturer’s service manual. Instructions and procedures are those recommended by Western Star Trucks or the component manufacturer. Maintenance schedules and additional service information are included in the Western Star Maintenance Manual. IMPORTANT: Descriptions and specifications in this manual were in effect at the time of printing. Western Star Trucks reserves the right to discontinue models, and to change specifications or design at any time without notice and without incurring obligation. Descriptions and specifications contained in this publication provide no warranty, expressed or implied, and are subject to revision and editions without notice. Refer to www.Daimler-TrucksNorthAmerica.com and www.WesternStarTrucks.com for more information, or contact Daimler Trucks North America LLC at the address below. 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. © 2002–2010 Daimler Trucks North America 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 Daimler Trucks North America LLC. Daimler Trucks North America LLC is a Daimler company. Daimler Trucks North America LLC Service Systems and Documentation (CVI-SSD) P.O. Box 3849 Portland, OR 97208-3849

Daimler Trucks North America LLC distributes the following major service publications in paper and electronic (via ServicePro ® ) formats. Workshop/Service Manual Workshop/service manuals contain service and repair information for all vehicle systems and components, except for major components such as engines, trans- missions, 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 Manual 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 Manual 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 and post-trip inspections, and daily, weekly, and monthly maintenance of vehicle components. Driver’s/ operator’s manuals do not contain detailed repair or service information. Service Bulletins Service bulletins provide the latest service tips, field repairs, product improve- ments, 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. Parts Technical Bulletins Parts technical bulletins provide information on parts. These bulletins contain lists of parts and BOMs needed to do replacement and upgrade procedures. Web-based repair, service, and parts documentation can be accessed using the following applications on the AccessWesternStar.com website. ServicePro ServicePro ® provides Web-based access to the most up-to-date versions of the publications listed above. In addition, the Service Solutions feature provides diagnostic assistance with Symptoms Search, by connecting to a large knowledge base gathered from technicians and service personnel. Results for both docu- ments and service solutions can be narrowed by initially entering vehicle identification data. PartsPro PartsPro ® is an electronic parts catalog system, showing the specified vehicle’s build record. EZWiring EZWiring ™ makes Freightliner, Sterling, Western Star, Thomas Built Buses, and Freightliner Custom Chassis Corporation products’ wiring drawings and floating pin lists available online for viewing and printing. EZWiring can also be accessed from within PartsPro. Introduction Descriptions of Service Publications Western Star Workshop Manual, Supplement 14, May 2010 I–1

Warranty-related service information available on the AccessWesternStar.com website includes the following documentation. Recall Campaigns Recall campaigns cover situations that involve service work or replacement of parts in connection with a recall notice. These campaigns pertain to matters of vehicle safety. All recall campaigns are distributed to dealers; customers receive notices that apply to their vehicles. Field Service Campaigns Field service campaigns are concerned with non-safety-related service work or replacement of parts. All field service campaigns are distributed to dealers; customers receive notices that apply to their vehicles. Introduction Descriptions of Service Publications I–2 Western Star Workshop Manual, Supplement 14, May 2010

For an example of a Western Star Workshop Manual page, see Fig. 1. f020124 A B E G 33.02 Front Axle Oil Seals General Information Western Star Workshop Manual, Supplement 0, February 2002 050/1 General Information 1 2 3 F D C 10/28/2005 A. Section Title B. Section Number (made up of the Group Number— first two digits, followed by a sequence number—last two digits) C. Subject Title D. Manual Title E. Release (Supplement) Date F. Subject Number G. Subject Page Number Fig. 1, Example of a Western Star Workshop Manual Page Introduction Page Description Western Star Workshop Manual, Supplement 14, May 2010 I–3

Group No. Group Title 00 ...................... General Information 01 ................................ Engine 09 .............................. Air Intake 13 ......................... Air Compressor 15 ................... Alternators and Starters 20 ................... Engine Cooling/Radiator 25 ................................ Clutch 26 ........................... Transmission 30 ......................... Throttle Control 31 ............. Frame and Frame Components 32 ............................ Suspension 33 ............................. Front Axle 35 ............................. Rear Axle 40 ........................ Wheels and Tires 41 .............................. Driveline 42 ................................ Brakes 46 ............................... Steering 47 ................................. Fuel 49 ............................... Exhaust 54 .......... Electrical, Instruments, and Controls 60 .................................. Cab 72 ................................ Doors 82 ............. Windshield Wipers and Washer 83 ................. Heater and Air Conditioner 88 .............. Hood, Grille, and Cab Fenders 91 ............... Seats and Restraint Systems 98 ................................. Paint Introduction Workshop Manual Contents I–4 Western Star Workshop Manual, Supplement 14, May 2010

The following is a list of definitions for abbreviations and symbols used in Freightliner publications. A .......... amperes AAVA ...... auxiliary air valve assembly ABS ....... antilock braking system ABS ....... acrylonitrile-butadiene-styrene A/C ........ air conditioner AC ......... alternating current acc ........ accessories ACM ....... aftertreatment control module ACPU ..... air conditioning protection unit ADLO ..... auto-disengagement lockout AGM ....... absorbed glass mat AGS ....... automated gear shift AG2 ....... Aluminum Generation 2 a.m. ....... ante meridiem (midnight to noon) AM ........ amplitude modulation amp(s) .... ampere(s) AMT ....... automated mechanical transmission AMU ....... air management unit ANSI ...... American National Standards Institute API ........ American Petroleum Institute API ........ application programming interface ARI ........ Air Conditioning and Refrigeration Institute ASA ....... American Standards Association ASF ....... American Steel Foundries ASR ....... automatic spin regulator assy . ...... assembly ASTM ..... American Society for Testing and Materials ATC ....... automatic temperature control ATC ....... automatic traction control ATC ....... automatic transmission control ATD ....... aftertreatment device ATF ........ automatic transmission fluid ATS ....... aftertreatment system attn ........ attention aux. ....... auxiliary av ......... avoirdupois (British weight system) AWD ....... all-wheel drive AWG ...... American wire gauge AWS ....... American Welding Society BAT ....... battery BBC ....... bumper-to-back-of-cab BHM ....... bulkhead module BOC ....... back-of-cab BOM ....... bill of material BTDC ...... before top dead center Btu(s) ..... British thermal unit(s) C .......... common (terminal) CAC ....... charge air cooler CAN ....... controller area network CARB ..... California Air Resources Board CAT ....... Caterpillar CB ......... circuit breaker CB ......... citizens’ band CBE ....... cab behind engine CCA ....... cold cranking amperes CCR ....... California Code of Regulations CD-ROM . . compact-disc/read-only memory CDTC ...... constant discharge temperature control CEL ....... check-engine light CFC ....... chlorofluorocarbons (refrigerant-12) cfm ........ cubic feet per minute CFR ....... Code of Federal Regulations CGI ........ clean gas induction CGW ...... central gateway CHM ....... chassis module CIP ........ cold inflation pressure CLDS ...... cab load disconnect switch CLS ....... coolant level sensor cm ......... centimeters cm 3 ........ cubic centimeters CMVSS .... Canadian Motor Vehicle Safety Standard Co. ........ company COE ....... cab over engine Corp. ...... corporation CPC ....... common powertrain controller CPU ....... central processing unit CRT ....... cathode ray tube cSt ........ centistokes (unit of measurement for describing the viscosity of general liquids) cu ft ....... cubic feet cu in ...... cubic inches CUM ....... Cummins CVSA ...... Commercial Vehicle Safety Alliance CWS ....... collision warning system DC ......... direct current DCA ....... diesel coolant additive DCDL ...... driver-controlled differential lock DDA ....... Detroit Diesel Allison (obs) DDC ....... Detroit Diesel Corporation DDDL ...... Detroit Diesel Diagnostic Link DDE ....... Detroit Diesel Engines DDEC ..... Detroit Diesel Electronic (engine) Control DDR ....... diagnostic data reader DDU ....... driver display unit def ........ defrost DEF ....... diesel exhaust fluid DFI ........ direct fuel injection DGPS ..... differential global positioning system DHD ....... dealer help desk dia. ........ diameter DIAG ...... diagnosis DIP ........ dual inline package (switch) DIU ........ driver interface unit DLA ....... datalink adaptor DLM ....... datalink monitor DLU ....... data logging unit DMM ...... digital multimeter DOC ....... diesel oxidation catalyst DOT ....... Department of Transportation DPF ....... diesel particulate filter DRL ....... daytime running lights DRM ....... dryer reservoir module DSM ....... district service manager DTC ....... diagnostic trouble code DTC ....... discharge temperature control DTNA ...... Daimler Trucks North America DVOM ..... digital volt/ohm meter ea. ......... each EBS ....... electronic braking system ECA ....... electric clutch actuator ECAP ...... electronic control analyzer programmer ECAS ...... electronically controlled air suspension List of Abbreviations 00.01 List of Abbreviations Western Star Workshop Manual, Supplement 22, May 2014 050/1

ECI ........ electronically controlled injection ECL ....... engine coolant level ECM ....... electronic control module ECT ....... engine coolant temperature ECU ....... electronic control unit EDM ....... electronic data monitor EEPROM . . electrically erasable programmable read-only memory EFG ....... electric fuel gauge EFPA ...... electronic foot pedal assembly EGR ....... exhaust gas recirculation ELC ....... extended-life coolant EMC ....... electromagnetic compatibility EMI ........ electromagnetic interference EOA ....... electric over air EP ......... extreme pressure (describes an antiwear agent added to some lubricants) EPA ....... Environmental Protection Agency EPS ....... engine position sensor ESC ....... electronic stability control ESC ....... enhanced stability control ESD ....... electrostatic discharge ESS ....... engine syncro shift (transmission) etc. ........ et cetera (and so forth) ETEC ...... electronic truck engine control EUI ........ electronic unit (fuel) injectors EVA ....... electronic vibration analyzer EXM ....... (chassis) expansion module E85 ........ 85% ethanol fuel FAS ....... Freightliner air suspension FCCC ...... Freightliner Custom Chassis Corporation FCU ....... forward control unit FET ........ field effect transistor Fig. ........ figure fl oz ....... fluid ounces FLA ....... post-1984 advancements Freightliner COE FLB ....... enhanced Freightliner FLA COE FLC ....... steel-cab Freightliner 112 Conventional FLD ....... post-1984 advancements Freightliner 112/120 aluminum-cab Conventional FLR ....... forward-looking radar FM ......... frequency modulation FMCSA .... Federal Motor Carrier Safety Administration FMEA ..... failure mode effects analysis FMI ........ failure mode indicator FMSI ...... Friction Materials Standards Institute FMVSS .... Federal Motor Vehicle Safety Standard FRP ....... fiberglass reinforced plastic FSA ....... field service authorization FSM ....... fleet service manager ft .......... feet ft 3 ......... cubic feet ft 3 /min ..... cubic feet per minute FTL ........ Freightliner F.U.E.L..... fuel usage efficiency level g .......... grams gal ......... gallons GAWR ..... gross axle weight rating GHG ....... greenhouse gas GHG14 .... greenhouse gas and fuel efficiency regulations GL ......... gear lubricant GND ....... ground gpm ....... gallons per minute GPS ....... global positioning system GVWR ..... gross vehicle weight rating HBED ..... hard-braking event data HCM ....... hybrid control module HCOE ..... high cab over engine HCU ....... hydraulic control unit HD ......... heavy-duty HDU ....... hybrid drive unit HEPA ...... high-efficiency particulate air (filter) HEST ...... high exhaust system temperature HEV ....... hybrid electric vehicle HFC ....... hydrogenated fluorocarbons (refrigerant-134a) hp ......... horsepower hp ......... high pressure HRC ....... Rockwell "C" hardness hr(s) ....... hour(s) HSA ....... hill start aid HSD ....... high-side driver htr . ........ heater HVAC ...... heating, ventilating, and air conditioning HVLP ...... high velocity, low pressure H/W ....... hardware Hz ......... hertz IAD ........ interaxle differential ICS ........ integrated child seat ICU ........ instrumentation control unit i.d.......... inside diameter ID .......... identification IFI ......... Industrial Fasteners Institute IFS ........ independent front suspension IGN ........ ignition ILB ........ intelligent lightbar ILO ........ in lieu of (in the place of) in .......... inches in 3 ......... cubic inches Inc. ........ incorporated inH 2 O ..... inches of water inHg ....... inches of mercury I/O ......... input/output IP .......... instrument panel ISO ........ International Organization for Standardization IVS ........ idle validation switch k ........... kilo (1000) kg ......... kilograms km ......... kilometers km/h ....... kilometers per hour kPa ........ kilopascals kW ........ kilowatts L .......... liters lb .......... pounds LBCU ...... lightbar control unit lbf·ft ....... pounds force feet lbf·in ...... pounds force inches LCD ....... liquid crystal display LCOE ...... low cab over engine LED ....... light-emitting diode LFL ........ lower flammability limit LH ......... left-hand LHD ....... left-hand drive LH DR ..... left-hand-drive LHK ....... liters per hundred kilometers LHS ....... low-hydrogen steel LIN ........ Local Interconnect Network LLC ....... limited liability company L/min ...... liters per minute LNG ....... liquefied natural gas LPG ....... liquefied petroleum gas List of Abbreviations 00.01 List of Abbreviations Western Star Workshop Manual, Supplement 22, May 2014 050/2

LPG ....... liquid propane gas LPI ........ liquid propane injection LPR ....... low pressure reservoir LRR ....... low-rolling resistance LSD ....... low-side driver LVD ....... low-voltage disconnect m .......... meters max. ....... maximum M-B ........ Mercedes-Benz MCM ...... motor control module MESA ..... Mining Enforcement Safety Act mfr . ........ manufacturer mi ......... miles MID ........ message identifier MIL ........ malfunction indicator lamp (light) MIL ........ military specification min. ....... minutes min. ....... minimum misc. ...... miscellaneous mL ........ milliliters mm ........ millimeters mod. ...... module mpg ....... miles per gallon mph ....... miles per hour MSF ....... modular switch field MMT ....... methylcyclopentadienyl manganese tricarbonyl MSHA ..... Mining Safety and Health Administration MVDA ..... Motor Vehicle Dealers Association n .......... negative (front axle wheel alignment specification) N .......... nitrogen N/A ........ not applicable N·cm ...... Newton-centimeters NC ......... normally closed (terminal or switch) NCG ....... noncondensable gases NHTSA .... National Highway Traffic Safety Administration NIOSH ..... National Institute for Occupational Safety and Health NITE ....... no idle thermal environment NLA ....... no longer available NLGI ...... National Lubricating Grease Institute N·m ........ Newton-meters NO ........ normally open (terminal or switch) NOAT ...... Nitrited Organic Acid Technology NOx ....... nitrogen oxides no. ........ number NPT ....... national pipe thread NPTF ...... national pipe thread fitting NT ......... nylon tube or nylon tubing NTSB ...... National Transportation Safety Board OAT ....... Organic Acid Technology OBD(s) .... on-board diagnostic(s) obs ........ obsolete OC ........ open circuit OCV ....... open circuit voltage o.d. ........ outside diameter O.D. ....... overdrive OEM ....... original equipment manufacturer OPD ....... overfill protection device OSHA ..... Occupational Safety and Health Administration oz ......... ounces ozf·in ...... ounces force inches p .......... positive (front axle wheel alignment specification) PACE ...... programmable electronically controlled engine PAG ....... polyalkylene glycol (oil) parm ...... parameter PAS ....... passenger advisory system PC ......... personal computer PCB ....... printed circuit board PDC(s) .... parts distribution center(s) PDI ........ pre-delivery inspection PDM ....... power distribution module PEC ....... power electronics carrier PEEC ...... programmable electronic engine control PID ........ parameter identifier PKP ....... Purple-K powder PLC ....... power line carrier PLD ....... Pumpe-Linie-Düse (pump- line-nozzle) PNDB ..... power-net distribution box PM ........ particulate matter p.m. ....... post meridiem (noon to midnight) p/n ........ part number PO ......... purchase order POE ....... polyol ester PRD ....... pressure relief device PRD ....... product requirements document PSA ....... pressure-sensitive adhesive PSG ....... pressure sensor governor psi ......... pounds per square inch psia ....... pounds per square inch, atmosphere psig ....... pounds per square inch, gauge pt .......... pints PTCM ..... pressure time control module PTO ....... power takeoff PTP ....... powertrain protection PTPDM .... powertrain power distribution module pvc ........ polyvinyl chloride PWM ...... pulse width modulation pwr ........ power qt .......... quarts qty . ........ quantity R&O ..... rust inhibitors and oxidants R–12 ...... refrigerant-12 (CFC) R–134a .... refrigerant-134a (HFC) RAM ....... random access memory RC ......... reserve capacity recirc. ..... recirculation Ref(s). ..... reference(s) regen ...... regeneration RELS ...... reduced engine load at stop RFI ........ radio frequency interference RH ......... right-hand RHD ....... right-hand drive RH DR ..... right-hand-drive R/I ......... removal and installation RMA ....... return material authorization ROM ....... read-only memory rpm ........ revolutions per minute R/R ........ removal and replacement RSA ....... roll-stability advisor RSG ....... road speed governor RSM ....... regional service manager RTS ....... ready-to-spray RTV ....... room temperature vulcanizing RV ......... recreational vehicle SA ......... source address S-ABA ..... self-setting automatic brake adjusters List of Abbreviations 00.01 List of Abbreviations Western Star Workshop Manual, Supplement 22, May 2014 050/3

SAE ....... Society of Automotive Engineers SB ......... service bulletin SBT ....... seat back thickness SBW ....... shift-by-wire SCA(s) .... Supplemental Coolant Additive(s) SCR ....... selective catalytic reduction SCU ....... system control unit (speedometer) SD ......... severe-duty SDU ....... step deployment unit SEL ....... shutdown engine light SEM ....... switch expansion module SEO ....... stop engine override SHM ....... switch hub module SI .......... service information SI .......... Système International SID ........ subsystem identifier SM ........ system malfunction SMC ....... sheet molded compound S/N ........ serial number SOC ....... state-of-charge SPACE .... seat pretensioner activation for crash survival enhancement SPG ....... special purpose grease SPN ....... suspect parameter number sq in ...... square inches SRP ....... seating reference point SRS ....... supplemental restraint system SRS ....... synchronous reference sensor SRT ....... standard repair time SSD ....... side sensor display SSID ....... smart switch identification SST ....... stainless steel std. ........ standard S/W ........ software SW ........ switch TAM ....... thermocouple amplifier module TBB ....... Thomas Built Buses TBS ....... turbo boost sensor TCM ....... transmission control module TCU ....... transmission control unit TDC ....... top dead center TDR ....... technician diagnostic routine TEM ....... truck equipment manufacturer temp ...... temperature TIG ........ tungsten inert gas TIR ........ total indicator reading TMC ....... Technology and Maintenance Council TPMS ...... tire pressure monitoring system TPS ....... thermal protection switch TPS ....... throttle position sensor TRS ....... timing reference sensor TSO ....... truck specification order TSU ....... transmission shift unit TXV ....... thermal expansion valve U.D. ....... underdrive ULSD ...... ultralow-sulfur diesel UNC ....... unified national coarse UNF ....... unified national fine U.S. ....... United States U.S.A. ..... United States of America USC ....... United States customary (measures) V .......... volts VCU ....... vehicle control unit VDC ....... vehicle data computer Vdc ........ volts, direct current VIMS ...... vehicle information management system VIN ........ vehicle identification number VIP ........ vehicle instrumentation and protection (Kysor) VIW ........ vehicle interface wiring (connector) VOC ....... volatile organic compounds VOM ....... volt-ohmmeter VRS ....... variable resistance sensor VSG ....... variable speed governor VSS ....... vehicle speed sensor VSU ....... vehicle security unit WB ........ wire braid WI ......... work instructions WIF ........ water-in-fuel WOT ....... wide open throttle – ........... minus or negative + ........... plus or positive ± ........... plus-or-minus > ........... greater than < ........... less than x ........... by (used in fastener size descriptions) " ........... inches ° ........... degrees (of an angle) °C ......... degrees Celsius (centigrade) °F .......... degrees Fahrenheit # ........... number % .......... percent & .......... and © .......... copyright ™ .......... trademark ® .......... registered trademark List of Abbreviations 00.01 List of Abbreviations Western Star Workshop Manual, Supplement 22, May 2014 050/4

Western Star 4700/4800/4900/5900/6900 Series Trucks OEM Service & Repair Manual

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