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Western Star 47X 2020, Maintenance Manual

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Title of Maintenance Operation (MOP)

MOP Number

Determining Scheduled Maintenance Intervals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00–01

Initial Maintenance (IM) Operations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00–04

M1 Maintenance Interval Operations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00–05

M2 Maintenance Interval Operations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00–06

M3 Maintenance Interval Operations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00–07

Maintenance Operation Sets Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00–08

Noise Emission Controls Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00–09

Service Schedule Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00–02

Vehicle Maintenance Schedule Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00–03

Verification of Inspections Log. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00–10

General Information

00

Index, Alphabetical

47X and 49X Maintenance Manual, October 2020

Summary of Contents for 47X 2020

Page 1: ...47X AND 49X MAINTENANCE MANUAL Models 47X 49X STI 507 3 09 10 2021 Published by Daimler Trucks North America LLC 4747 N Channel Ave Portland OR 97217 Printed in U S A...

Page 2: ......

Page 3: ...ision 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 Enviro...

Page 4: ...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 Truc...

Page 5: ...s to informa tion 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...

Page 6: ...aigns 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 co...

Page 7: ...4 Check the level of the lubricant The lubricant must be level with the bottom of the oil fill hole see For Freightliner axles see Table 1 for approved Fig 4 If low add lubricant axle lubricants and l...

Page 8: ...tor 25 Clutch 26 Transmission 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...

Page 9: ...ons 00 05 M2 Maintenance Interval Operations 00 06 M3 Maintenance Interval Operations 00 07 Maintenance Operation Sets Table 00 08 Noise Emission Controls Maintenance 00 09 Service Schedule Table 00 0...

Page 10: ......

Page 11: ...nance Interval Operation Table for a list of the maintenance opera tions to be performed at that maintenance interval Use the maintenance operation reference numbers to find detailed instructions in t...

Page 12: ...16 000 Maintenance 2 M2 every 50 000 80 000 Maintenance 3 M3 every 150 000 240 000 Schedule II Long Haul Transport vehicles that annually travel over 60 000 miles 100 000 km Initial Maintenance IM fir...

Page 13: ...2 and M3 150 000 240 000 16th M1 160 000 256 000 17th M1 170 000 272 000 18th M1 180 000 288 000 19th M1 190 000 304 000 20th M1 and M2 200 000 320 000 21st M1 210 000 336 000 22nd M1 220 000 352 000...

Page 14: ...1 and M2 500 000 800 000 51st M1 510 000 820 000 52nd M1 520 000 837 000 53rd M1 530 000 853 000 54th M1 540 000 869 000 55th M1 and M2 550 000 885 000 56th M1 560 000 901 000 57th M1 570 000 917 000...

Page 15: ...000 1 340 000 84th M1 840 000 1 352 000 85th M1 and M2 850 000 1 370 000 86th M1 860 000 1 384 000 87th M1 870 000 1 400 000 88th M1 880 000 1 416 000 89th M1 890 000 1 432 000 90th M1 M2 and M3 900...

Page 16: ...15 M1 375 000 604 000 16 M1 and M2 400 000 644 000 17 M1 425 000 684 000 18 M1 450 000 724 000 19 M1 475 000 764 000 20 M1 and M2 500 000 805 000 21 M1 525 000 845 000 22 M1 550 000 885 000 23 M1 575...

Page 17: ...les km 36 M1 M2 and M3 900 000 1 448 000 37 M1 925 000 1 490 000 38 M1 950 000 1 529 000 39 M1 975 000 1 569 000 40 M1 and M2 1 000 000 1 609 000 Table 3 Maintenance for Service Schedule II General In...

Page 18: ...l maintenance IM Maintenance Operation Number Initial Maintenance IM Operations for Service Schedules I and II Check 00 05 Perform all M1 Operations 31 03 Frame Fastener Torque Check 32 02 Suspension...

Page 19: ...Camshaft Bracket Lubrication 42 10 WABCO System Saver Air Dryer Desiccant Cartridge Replacement 42 11 Versajust Slack Adjuster Inspection and Lubrication 42 12 Bendix Automatic Drain Valve Operating...

Page 20: ...Fuller Manual Transmission Air Filter Regulator Check Cleaning or Replacement 32 01 Suspension Inspection 32 02 Suspension U Bolt Torque Check 33 01 Knuckle Pin Lubrication 33 02 Tie Rod Inspection 33...

Page 21: ...tor Pressure Flushing and Coolant Change 25 03 Fluid Change Hydraulic Clutch Control 26 03 Eaton Fuller Transmission Fluid Change and Magnetic Plug Cleaning 35 01 Axle Lubricant and Filter Change and...

Page 22: ...uid Level Inspection 26 05 Eaton Fuller Manual Transmission Air Filter Regulator Check Cleaning or Replacement 31 01 Fifth Wheel Inspection 31 02 Fifth Wheel Lubrication 31 03 Frame Fastener Torque Ch...

Page 23: ...leeper Access Door Release Cable and Latch Lubrication 83 01 Air Conditioner Inspection 83 02 Air Filter Replacement 83 03 Battery Powered HVAC System BPHS Inspection On vehicles equipped with Detroit...

Page 24: ...Noise Controls is Prohibited Federal law prohibits the following acts or the caus ing thereof 1 The removal or rendering inoperative by any per son other than for purposes of maintenance repair or re...

Page 25: ...n Clutch Date Mileage Item Cost Maintenance Facility Verification of Inspections Log Group 49 Verification of Inspections Log Group 49 Exhaust System Components Date Mileage Item Cost Maintenance Faci...

Page 26: ......

Page 27: ...Title of Maintenance Operation MOP MOP Number Air Cleaner Inspection 09 01 Air Intake 09 Index Alphabetical 47X and 49X Maintenance Manual August 2020...

Page 28: ......

Page 29: ...e Fig 3 Ensure the bonds be tween the rubber and the steel plates are com pletely intact See Fig 4 If a mounting isolator is damaged replace it For isolator replacement instructions see Section 09 01...

Page 30: ...ir intake grate may be required if the debris is not expelled from the cavity See Fig 6 for Pre Cleaner location in the truck f090528a 12 05 2019 4 5 6 7 8 2 1 3 1 1 Air Cleaner Housing 2 Nut 3 Forwar...

Page 31: ...f090544 04 15 2020 1 2 1 Pre Cleaner 2 Filter Housing Fig 6 Pre Cleaner Location Air Intake 09 47X and 49X Maintenance Manual August 2020 09 3...

Page 32: ......

Page 33: ...Title of Maintenance Operation MOP MOP Number Air Compressor Inspection 13 01 Safety Precautions 13 00 Air Compressor 13 Index Alphabetical 47X and 49X Maintenance Manual August 2020...

Page 34: ......

Page 35: ...ath 13 01 Air Compressor Inspection 1 Inspect the air compressor intake hoses and connections at the air intake at the air cleaner the resonator and the air compressor for physi cal damage or loose co...

Page 36: ......

Page 37: ...Maintenance Operation MOP MOP Number Alternator Battery and Starter Connections Check 15 01 Safety Precautions 15 00 Alternators and Starters 15 Index Alphabetical 47X and 49X Maintenance Manual Augu...

Page 38: ......

Page 39: ...be free of corrosion dirt and moisture Connections should not have signs of thermal distortion warp ing discoloration high amperage heating or dis coloring If needed disconnect cables scrub and clean...

Page 40: ...r as needed 7 Check the terminals on the battery shut off switch and the magnetic switch Make sure the terminal connections are clean and tight Coat the terminal connections with dielectric red enamel...

Page 41: ...Fan Clutch Check Noise Emission Control 20 03 Pressure Relief Cap Check 20 01 Radiator Pressure Flushing and Coolant Change 20 02 Safety Precautions 20 00 Engine Cooling Radiator 20 Index Alphabetica...

Page 42: ......

Page 43: ...the pressure relief cap that opens under vacuum This prevents the collapse of hoses and other parts that are not internally supported when the system cools In spect the vacuum relief valve to be sure...

Page 44: ...clamps must be tightened to the cor rect torque The screw tip of the clamp must ex tend about 1 4 inch 6 mm from the clamp hous ing and the Belleville washer stacks must be collapsed almost flat Use...

Page 45: ...low the retainer plate the fan clutch liner has remaining life If the tool is sitting above the retainer plate re place the fan clutch liner 3 Connect the battery cables 4 Start the engine and check f...

Page 46: ...ittings Using a wet finger or a soapy water solution check for a leak in the same areas See Fig 6 and Fig 7 8 If a leak is detected remove the fan blade In stall a new seal kit 9 Check the fan drive f...

Page 47: ...Number Clutch Release Bearing Lubrication 25 01 Fluid Change Hydraulic Clutch Control 25 03 Fluid Level Check Hydraulic Clutch Control 25 02 Safety Precautions 25 00 Clutch 25 Index Alphabetical 47X...

Page 48: ......

Page 49: ...le lubricating it See Fig 1 3 Clean the grease fitting On some vehicles a lube tube will be used and the fitting may be at the 9 o clock position on the left side of the bell housing see Fig 2 NOTICE...

Page 50: ...fluid is hazardous It may be a skin irritant and can cause blindness if it gets in your eyes Always wear safety glasses when handling it or bleeding hydraulic lines If you get it on your skin wash it...

Page 51: ...ay need to be refilled during the bleeding process to pre vent air from re entering the system 2 Remove the reservoir lid and fill the reservoir see Fig 3 with new DOT 4 brake fluid from a tightly sea...

Page 52: ......

Page 53: ...ion Fluid Level Inspection 26 02 Eaton Fuller Manual Transmission Air Filter Regulator Check Cleaning or Replacement 26 05 Eaton Fuller Transmission Fluid Change and Magnetic Plug Cleaning 26 03 Eaton...

Page 54: ......

Page 55: ...aches operat ing temperature Shift the transmission to neu tral N and shut down the engine 1 Apply the parking brakes and chock the rear tires Place a large drain pan under the transmis sion 2 Clean t...

Page 56: ...ill plug and install a new seal on it Install the plug in the side of the gear case then tighten it 45 lbf ft 60 N m 26 03 Eaton Fuller Transmission Fluid Change and Magnetic Plug Cleaning NOTE Inform...

Page 57: ...ate the canister an additional 180 to 270 degrees to firmly tighten the filter Wipe the filter clean of any fluid after it is tightened 6 Add fluid until it is level with the lower edge of the fill op...

Page 58: ...luid level in the transmission Some transmissions are equipped with a sight glass for checking the fluid level For transmissions not so equipped check the fluid level at the fill plug Checking at the...

Page 59: ...end cap NOTE Do not remove disassemble or adjust the air regulator If the air regulator is not keep ing air pressure between 58 and 63 psi 400 and 435 kPa replace the air filter regulator It cannot b...

Page 60: ...stall the small O ring in the end cap then in stall the end cap and tighten it until firm CAUTION A leaking air filter or air lines can cause slow or hard shifting of the transmission and eventual tra...

Page 61: ...on MOP MOP Number Fifth Wheel Inspection 31 01 Fifth Wheel Lubrication 31 02 Frame Fastener Torque Check 31 03 Safety Precautions 31 00 Frame and Frame Components 31 Index Alphabetical 47X and 49X Mai...

Page 62: ......

Page 63: ...ing Tighten bolts and nuts as needed Replace missing or dam aged bolts 5 Inspect the fifth wheel for bent worn damaged and missing parts replace them as needed with genuine Holland parts 6 Using a Hol...

Page 64: ...acket Pin 7 Bracket Retainer Pin 8 Cotter Pin 3 16 x 1 9 Bumper Spring 10 Handle Spring 11 Bolt Secondary Safety Lock 12 Flat Washer 13 Secondary Safety Lock 14 Bushing Secondary Safety Lock 15 Hex Lo...

Page 65: ...h 5 8 11 SAE grade 8 bolts grade C locknuts and hardened washers Do not re use bolts nuts and washers on fifth wheel mountings 12 After inspecting the fifth wheel lubricate all mov ing parts with a ch...

Page 66: ...ate all mov ing parts with a chassis or multipurpose grease Apply a generous coating of grease to the top plate to fill the grooves or depressions on the top plate See MOP 31 02 in this manual for lu...

Page 67: ...closing it Separate the jaw and wedge with a screwdriver and grease the full length of their mating surfaces Lubricate the top and bottom contact surfaces of the jaw and wedge See Fig 6 Open and clos...

Page 68: ...grease rated for 30 F 34 C or lower such as Cato Oil and Grease 5213 Craftsman Chemical Co LTF 2 Mystic LP 200 or equivalent is recommended Jost Lubricate the kingpin lock using a hand pump grease gu...

Page 69: ...torque the nut not the bolt head whenever possible This will give a true torque read ing by eliminating bolt body friction When checking the torque of frame fasteners inspect the frame for cracks and...

Page 70: ......

Page 71: ...f Maintenance Operation MOP MOP Number Safety Precautions 32 00 Suspension Inspection 32 01 Suspension U Bolt Torque Check 32 02 Suspension 32 Index Alphabetical 47X and 49X Maintenance Manual Februar...

Page 72: ......

Page 73: ...be replaced For threaded and bronze bushings ensure the center pin is free to rotate within the outer bushing If the pin is seized replace the complete spring assembly For maintenance free rubber bush...

Page 74: ...n Allen wrench while loosening or tightening the nuts that attach the valve to the bracket Because the mounting studs are threaded into the valve body loosening the nuts without holding the studs can...

Page 75: ...ns If the dis tance is within the acceptable range apply the parking brakes f320838b 02 21 2017 A Measure Point Suspension Height Measurement Min Target Max A Measure Here 2 3 8 inch 60 mm 2 5 8 inch...

Page 76: ...Suspension Ride Height Measurement Single Leaf Spring 40k Low and Mid Ride f321046a 02 21 2017 A Measure Point Suspension Height Measurement Min Target Max A Measure Here 2 3 4 inch 70 mm 3 inch 76 mm...

Page 77: ...until the torque wrench clicks then release pressure on the torque wrench and turn the wrench again until it clicks If the nut turns on the second application the bolt is stretching and must be replac...

Page 78: ......

Page 79: ...le Alignment Check 33 04 Knuckle Pin Lubrication 33 01 Safety Precautions 33 00 Steer Axle Hub Cap Vent Plug Inspection 33 05 Tie Rod Inspection 33 02 Tie Rod Lubrication 33 03 Front Axle 33 Index Alp...

Page 80: ......

Page 81: ...ing knuckle pin bushings do not raise the front axle Wipe the lube fittings clean and apply multipurpose chassis grease NLGI Grade 1 6 12 hydroxy lithium stearate grease or NLGI Grade 2 8 12 hydroxy l...

Page 82: ...checked for correct alignment at the same time Alignment of the rear axle s has a direct impact on how the vehicle tracks All axles front and rear should be aligned whenever alignment is done Three fa...

Page 83: ...nches that the front of the wheels are closer together than the rear of the wheels as viewed from the top Wheel toe in is adjustable If it is not adjusted correctly the vehicle could pull to one side...

Page 84: ...wheel if any of these condi tions exist 5 On each side of the vehicle check the height of the chassis above the ground Sagging fatigued or broken suspension springs create a lopsided vehicle appearan...

Page 85: ...r correcting wheel alignment make sure the vehicle is at curb weight Curb weight is the weight of the unloaded vehicle complete with acces sories and full fuel tanks If a road test is necessary the ro...

Page 86: ...aused by damage in one or more of the following front axle compo nents the knuckle pin the knuckle pin bushings the axle spindle or the axle beam Replace twisted or otherwise damaged components Don t...

Page 87: ...the U bolt nuts to the value in the appropriate table in Group 32 of the Western Star 47X and 49X Workshop Manual for com plete procedure U bolt nuts need periodic retightening Refer to Group 32 of t...

Page 88: ...s for the left and right sides should be a minimum of 1 0 de gree and no more than 5 0 degrees apart from each other while not exceeding the upper and lower limits f320083a 10 21 2016 1 2 3 4 5 6 1 Ax...

Page 89: ...nd RH caster angle settings should be a minimum of 1 0 degree and no more than 5 0 degrees apart from each other LH degrees 4 5 1 5 RH degrees 4 5 1 5 f330303 02 08 2017 Total Toe Degrees 0 09 0 09 Pu...

Page 90: ...erance f330306 02 08 2017 Tracking Lateral Offset Inches 0 0 25 Rear Suspension f330307 02 08 2017 RDA Thrust Angle Degrees 0 0 18 f330308 02 08 2017 FDA RDA Scrub Angle Degrees 0 0 08 f330309 02 08 2...

Page 91: ...n Torque lbf ft N m M22 339 459 U Bolt Nuts 7 8 14 400 542 U Bolt Nuts 7 8 16 460 624 U Bolt Nuts 3 4 16 300 406 Meritor Stopscrew Locknut 50 65 68 88 Table 5 Miscellaneous Torque Values Tie Rod Clamp...

Page 92: ...ater to enter the hub and contaminate the oil For examples of a leaking vent plug see Fig 15 and Fig 16 Evidence of a leaking vent plug may appear as Oil splatter around the wheel Gooey gummy oil arou...

Page 93: ...vent plug clean with a rag 4 Remove the vent plug and check the oil for evi dence of water contamination If there is evidence of water contaminated oil in the hub disassemble the effected axle end cle...

Page 94: ......

Page 95: ...OP Number Axle Breather and Axle Lubricant Level Inspection 35 02 Axle Lubricant and Filter Change and Magnetic Strainer Cleaning 35 01 Safety Precautions 35 00 Rear Axle 35 Index Alphabetical 47X and...

Page 96: ......

Page 97: ...ls For a two speed axle with a shift unit also change the shift unit lubricant see under the heading Two Speed Axles With Shift Unit All Axle Models Detroit Model 4 and Model 6 1 Park the vehicle on a...

Page 98: ...S 93K219 01 Mobil Delvac 1 Gear Oil 75W 90 meets this specification For more product information see http bevo mercedes benz com or https ddcsn ddc freightliner com cps rde xchg ddcsn hs 5931 htm Detr...

Page 99: ...ough the oil fill hole Lubri cant should be level with the bottom of the oil fill hole 5 2 Install and tighten the fill plug 30 lbf ft 41 N m Detroit Drive Axle Lubricant New Final Drive Lubricant Typ...

Page 100: ...n equalizer additive and recommended drive axle lubricant must be changed at the Maintenance 2 M2 interval instead of the Maintenance 3 M3 interval rec ommended in the Maintenance Operation Chart for...

Page 101: ...d not be used as a fill or level hole 6 1 With the vehicle on a level surface fill the axle through the oil fill hole Lubricant should be level with the bottom of the oil fill hole To check fluid leve...

Page 102: ...eyes Do not point the air stream in the direction of other persons 4 2 Wash the strainer in solvent and blow it dry with compressed air to remove oil and metal particles 4 3 Install and tighten the ma...

Page 103: ...rough the oil fill hole or standpipe opening Lubricant should be level with the bottom of the oil fill hole or the top of the standpipe opening To check fluid level see Fig 2 6 2 Install and tighten t...

Page 104: ...the breather is plugged or damaged clean or re place it as needed Meritor NOTICE Failure to keep the rear axle filled to the proper level with the recommended lubricant can result in rear axle damage...

Page 105: ...l with the bottom of the fill hole or the top of the standpipe opening 4 Check that the lubricant is level with the bottom of the fill hole or with the top of the standpipe opening See Fig 2 If low ch...

Page 106: ......

Page 107: ...Title of Maintenance Operation MOP MOP Number Tire Check 40 02 Wheel Nut Check 40 01 Wheels and Tires 40 Index Alphabetical 47X and 49X Maintenance Manual August 2020...

Page 108: ......

Page 109: ...500 610 678 NOTE If using specialty fasteners consult the manufacturer for recommended torque levels Table 1 Disc Wheel Fastener Torque 40 02 Tire Check Tires should be inspected closely during the f...

Page 110: ......

Page 111: ...Title of Maintenance Operation MOP MOP Number Driveline Inspection 41 01 Driveline Lubrication 41 02 Safety Precautions 41 00 Driveline 41 Index Alphabetical 47X and 49X Maintenance Manual August 2020...

Page 112: ......

Page 113: ...N m Fig 2 Meritor RPL35 U joints 150 lbf ft 200 N m Fig 4 U joints with yoke straps 125 lbf ft 169 N m Fig 3 Table 1 U Joint Torque Specifications 3 Check the driveline yokes or flanges for cracks and...

Page 114: ...n 0 007 inch 0 18 mm replace both the sleeve yoke and the splined shaft 7 Visually examine the driveshaft tubes for dents bends twists or other damage If any tube ap pears to be damaged replace it 8 E...

Page 115: ...ply the parking brakes and chock the tires 2 Wipe all old grease and dirt from each U joint grease fitting See Fig 6 3 Use a hand type grease gun or a high pressure gun with a low pressure adapter to...

Page 116: ...tension Lubricate the U joint until new grease is seen at the seal then tighten the cap screws to the correct torque specifications If the bearing will not take grease replace the U joint Refer to Gr...

Page 117: ...c Drain Valve Operating and Leakage Tests 42 12 Bendix E 6 Foot Control Valve Inspection and Lubrication 42 09 Brake Inspection 42 05 Haldex Slack Adjuster Lubrication 42 06 Meritor Camshaft Bracket L...

Page 118: ......

Page 119: ...dual air pressure open the line slowly 3 Identify tag and disconnect the three air lines from the end cover 4 Disconnect the harness connector from the heater and thermostat assembly 5 Loosen the bolt...

Page 120: ...e 6 bolts 12 washers and 6 new Nylok nuts Torque the Nylok nuts in a star pattern 17 to 24 lbf ft 23 to 33 N m See Fig 2 08 09 95 f421383 1 2 3 4 5 9 10 11 12 13 14 15 17 18 19 21 22 23 24 25 10 10 10...

Page 121: ...car tridge bolt 5 Using a clean rag wipe clean the inside of the end cover Clean the cartridge bolt bore in the end cover and the sealing surfaces for the large and small diameter desiccant cartridge...

Page 122: ...in the air brake system by opening the reservoir drain cocks Examine the discharge Some trace of water in the discharge is normal A discharge of a milky gray liquid indi cates excessive moisture is pr...

Page 123: ...ng will increase When the temperature goes above 45 F 7 C mea sured resistance should be infinite ohms If the heater thermostat does not operate as outlined replace it If it does operate as outlined i...

Page 124: ...ke Chock the tires Once the tires are chocked release the parking brake 2 Grip the caliper carrier assembly by the chamber and verify that it slides in and out freely Free play movement is 0 024 to 0...

Page 125: ...42 f422616 11 28 2016 135 135 444 602 Table 2 Torque Compensation with Meritor Extension Tool 3256B1354 Drum Brakes 1 Park the vehicle on a level surface shut down the engine and set the parking brake...

Page 126: ...chamber stroke See Table 3 for the proper stroke for the type of chamber being used If the stroke is too short the brakes may drag or will not fully apply Check for improper operation or adjustment o...

Page 127: ...e to lubricate slack adjusters could lead to dragging brakes or a brake failure resulting in property damage personal injury or death CAUTION Do not use moly disulfide loaded grease or oil Both the li...

Page 128: ...drive tire 4 Cage the drive tire park brake chamber opposite of the tire that is chocked 5 Grease the S cam tube on the caged park brake chamber side only 6 Uncage the park brake chamber 7 Move the dr...

Page 129: ...d brake side only 6 Uncage the park brake 7 Move the drive tire chock to the other side of the axle and chock the other set of tires 8 Cage the drive tire park brake chamber opposite of the tire that...

Page 130: ...ei ther a standard or oil coalescing desiccant car tridge When replacing the desiccant cartridge it is very important to use the same type of car tridge that was originally installed on the dryer Oil...

Page 131: ...ng properly With the system charged apply the brakes several times Each time the brakes are applied an exhaust of air should occur from the exhaust port of the drain valve If no air comes out push the...

Page 132: ......

Page 133: ...peration MOP MOP Number Drag Link Inspection 46 01 Drag Link Lubrication 46 03 Power Steering Fluid and Filter Change 46 02 Safety Precautions 46 00 Steering 46 Index Alphabetical 47X and 49X Maintena...

Page 134: ......

Page 135: ...loose re place the drag link See Group 46 of the West ern Star 47X and 49X Workshop Manual for re placement instructions If there is 1 8 inch 3 mm movement or more do not drive the vehicle until the...

Page 136: ...n the steering wheel from full left to full right several times Add fluid to the reservoir as needed to maintain the fluid level between the MIN COLD and MAX HOT lines 16 Shut down the engine 17 Raise...

Page 137: ...P MOP Number Fuel Filter Replacement 47 01 Fuel Tank Band Nut Tightening 47 03 Fuel Water Separator Element Checking and Replacement 47 02 Safety Precautions 47 00 Fuel 47 Index Alphabetical 47X and 4...

Page 138: ......

Page 139: ...he fuel water separator to collect the draining fuel The drain valve has a 3 8 inch 9 5 mm slip on hose con nection 3 Open the drain valve See Fig 1 4 When the fuel water separator is completely drain...

Page 140: ...t f470759 04 22 2020 1 2 3 5 6 7 8 9 10 4 1 O Ring Filter Element 2 O Ring Clear Bowl 3 Drain Valve 4 WIF Sensor 5 Heater 6 Clear Bowl 7 Filter Element 8 Port Plug M22 9 Vent Plug 10 Return Fuel Heati...

Page 141: ...result 8 Install the new filter and grommet assembly and cover O ring on the housing Position the filter element so the key is lined up with the keyway on the separator plate of the housing Use the ar...

Page 142: ...released into the atmosphere the vapors can ignite in the presence of any igni tion source Do not expose the fuel to or work with the fuel system near open flame or intense heat To do so could cause...

Page 143: ...and water sensor wiring har nesses if equipped 11 If equipped with a priming pump use it to fill the filter bowl assembly Prime the fuel water separa tor 12 Start the engine and check for leaks 13 Shu...

Page 144: ......

Page 145: ...Title of Maintenance Operation MOP MOP Number Exhaust System Maintenance 49 01 Safety Precautions 49 00 Exhaust 49 Index Alphabetical 47X and 49X Maintenance Manual August 2020...

Page 146: ......

Page 147: ...e ATS If any problems are discov ered refer to the engine manufacturer s service literature for repair instructions NOTE Diesel exhaust fluid creeps causing white crystals to form around the line fitt...

Page 148: ......

Page 149: ...enance Operation MOP MOP Number Electrical Component Inspection 54 02 Trailer Cable Inspection and Cleaning 54 01 Electrical Instruments and Controls 54 Index Alphabetical 47X and 49X Maintenance Manu...

Page 150: ......

Page 151: ...onents protected area Missing leaking or damaged covers will result in moisture and de bris entering the component and will result in component failure When it is determined that a cover has not prope...

Page 152: ...ing the connection and the com ponent and will result in component failure When it is determined that connector seals have not properly prevented moisture and debris from entering the component the en...

Page 153: ...amic Component Inspection 60 03 Baggage Door and Sleeper Access Door Release Cable and Latch Lubrication 60 04 Cab Shock Absorber Bracket Torque Check 60 02 Mirror Folding Check 60 01 Cab 60 Index Alp...

Page 154: ......

Page 155: ...pection Inspect aerodynamic components if equipped for structural damage cracks or wear These may in clude Chassis fairings Battery access kickplate Side skirts Cab side extenders Roof fairing deflect...

Page 156: ...G A G E E A C C S S 1 2 1 Sleeper Access Door Handle 2 Baggage Door Handle Fig 2 Sleeper Door Release Handles 05 07 2012 f602471 A NOTE Baggage door latch shown Sleeper access door latch is similar A...

Page 157: ...n MOP MOP Number Air Conditioner Inspection 83 01 Air Filter Replacement 83 02 Dual HVAC System Inspection 83 03 Safety Precautions 83 00 Heater and Air Conditioner 83 Index Alphabetical 47X and 49X M...

Page 158: ......

Page 159: ...op Manual 3 Inspect the drive plate If the drive plate shows visible signs of damage due to excessive heat replace the drive plate and pulley assembly For removal and installation procedures see Group...

Page 160: ...r flow arrow is correctly oriented and install the access panel Make sure the access panel locks into position Cab Recirculation Air Filter Replacement The recirculation air filter is located on the e...

Page 161: ...AC System air filter is located on the forward side of the blower fan housing In vehicles with 60 inch and 72 inch sleepers the Dual HVAC System air filter is located on the forward side of the blower...

Page 162: ...e and clear old fuel from the lines 2 Verify that the unit completes the start up cycle and continues to produce warm exhaust External A C Condenser Inspection and Cleaning The Dual HVAC System A C co...

Page 163: ...e stream of water can be used to clean it 3 Clean out any debris in the module 4 Install the cover f832189 06 02 2020 2 1 1 HVAC Cover Panel 2 Air Filter Fig 7 Sleeper HVAC Access Panel 36 inch Sleepe...

Page 164: ...tem Filter 48 inch Sleeper f832200 06 01 2020 1 2 4 3 1 Lower Bunk 2 Lower Bunk Strut 3 Front Center Bunk Partition 4 Storage Compartment Divider Fig 10 Lower Bunk Assembly 48 Inch Sleeper Heater and...

Page 165: ...ilter Fig 11 Removing the Dual HVAC System Filter 36 inch Sleeper Remove the condenser cover Fig 12 Condenser Cover Fasteners compact style condenser Heater and Air Conditioner 83 47X and 49X Maintena...

Page 166: ......

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