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Western Star 4700 User Manual

Western Star 4700
166 pages
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®
WESTERN STAR
Maintenance Manual
STI-445-6
A24-01243-000

Table of Contents

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Western Star 4700 Specifications

General IconGeneral
BrandWestern Star
Model4700
CategoryTrucks
LanguageEnglish

Summary

General Information (Group 00)

Determining Scheduled Maintenance Intervals (00-01)

How to determine maintenance intervals based on service schedule I or II.

Maintenance Service Table (00-02)

Outlines maintenance intervals for severe and long-haul transport service.

Initial Maintenance (IM) Operations (00-05)

Lists initial maintenance tasks to be performed on new vehicles.

Lubrication and Fluid Level Check (00-06)

Procedures for checking and topping up lubrication and fluid levels.

Noise Emission Controls Maintenance (00-11)

Information on maintaining noise emission controls and prohibited tampering.

Engine (Group 01)

Safety Precautions (01-00)

Critical safety measures before performing engine maintenance.

Engine Belt Inspection (01-02)

Inspect drive belts and pulleys for wear, damage, or misalignment.

Air Intake (Group 09)

Intake Piping Inspection (09-01)

Inspect air intake piping, ducts, and clamps for damage and leaks.

Air Cleaner Element Inspection and Replacement (09-02)

Inspect and replace air cleaner elements and housing for damage.

Air Compressor (Group 13)

Safety Precautions (13-00)

Safety guidelines for working on air compressor systems.

Air Compressor Inspection (13-01)

Inspect air compressor hoses, connections, and coolant lines for damage.

Alternators and Starters (Group 15)

Safety Precautions (15-00)

Safety measures when working with batteries, alternators, and starters.

Battery Check (15-02)

Inspect battery cables, hold-down assembly, and terminals.

Engine Cooling/Radiator (Group 20)

Safety Precautions (20-00)

Safety measures for handling hot cooling systems.

Coolant Inspection (20-01)

Check coolant level and condition to prevent overheating.

Cooling System Pressure-Flush (20-04)

Procedure for flushing and refilling the engine cooling system.

Clutch (Group 25)

Safety Precautions (25-00)

Safety measures for clutch system maintenance.

Clutch Release Bearing Lubrication (25-01)

Lubricating the clutch release bearing and contact points.

Fluid Level Check, Hydraulic Clutch Control (25-04)

Checking and maintaining the hydraulic clutch fluid level.

Transmission (Group 26)

Safety Precautions (26-00)

Safety measures when working on transmission systems.

Transmission Fluid Level Inspection (26-01)

Checking transmission fluid level for Allison and Eaton/Fuller transmissions.

Allison Transmission Fluid and Filter Change (26-07)

Steps for changing fluid and filters in Allison transmissions.

Frame and Frame Components (Group 31)

Safety Precautions (31-00)

Safety measures when servicing fifth wheels and frame components.

Fifth Wheel Inspection (31-01)

Inspect fifth wheel assembly, mounting, and related parts for wear and damage.

Fifth Wheel Lubrication (31-02)

Lubricating fifth wheel moving parts for proper operation.

Suspension (Group 32)

Safety Precautions (32-00)

Safety measures when inspecting suspension components.

Suspension Inspection (32-01)

Inspect suspension spring assemblies and shock absorbers.

Suspension U-Bolt Torque Check (32-03)

Checking torque on suspension U-bolt nuts to prevent breakage.

Front Axle (Group 33)

Safety Precautions (33-00)

Safety measures when working on front axle components.

Knuckle Pin Lubrication (33-01)

Lubricating knuckle pin assemblies using regulated pressure.

Front Drive Axle Lubricant Level Check (33-05)

Checking front drive axle lubricant level to prevent damage.

Rear Axle (Group 35)

Safety Precautions (35-00)

Safety measures when working on rear axle components.

Drive Axle Lubricant Level Check (35-01)

Checking rear axle lubricant level to prevent damage.

Axle Lubricant and Filter Change, and Magnetic Strainer Cleaning and Check (35-04)

Changing axle lubricant, filters, and cleaning magnetic strainers.

Wheels and Tires (Group 40)

Wheel Nut and Rim Nut Torque Check (40-01)

Checking wheel nut torque to prevent shimmy and tire damage.

Tire Check (40-02)

Inspect tires for abnormal wear, damage, and proper pressure.

Driveline (Group 41)

Safety Precautions (41-00)

Safety measures when working on the driveline.

Driveline Inspection (41-01)

Inspect universal joints, yokes, and slip joints for wear and damage.

Driveline Lubrication (41-02)

Lubricating universal joints and slip joints for proper operation.

Brakes (Group 42)

Safety Precautions (42-00)

Safety measures when working on the air brake system.

Air Dryer Inspection (42-02)

Inspect the air dryer for proper operation and leaks.

Air Dryer Desiccant Replacement (42-03)

Replacing the desiccant cartridge in the air dryer.

Brake Inspection (42-07)

Perform operational checks and inspect foundation brake components.

Steering (Group 46)

Safety Precautions (46-00)

Safety measures when working on the steering system.

Drag Link Inspection (46-01)

Inspect the drag link for wear, damage, and looseness.

Power Steering Fluid and Filter Changing (46-03)

Procedures for changing power steering fluid and filter.

Fuel (Group 47)

Safety Precautions (47-00)

Safety measures when working with the fuel system, especially regarding flammability.

Fuel Separator Sight Bowl Cleaning and Element Replacement (47-02)

Cleaning and replacing the filter element in fuel/water separators.

Exhaust (Group 49)

Safety Precautions (49-00)

Safety measures when working on the exhaust system.

Exhaust System Inspection (Noise Emission Control) (49-01)

Inspect the exhaust system for leaks, binding, and vibrations.

Cab (Group 60)

Safety Precautions (60-00)

Safety measures when working on cab components.

Cab Suspension Inspection (60-01)

Inspect air springs, shock absorbers, and mounting brackets.

Doors (Group 72)

Door Seal, Door Latch, Door Hinge, and Door Check Lubrication (72-01)

Lubricating door seals, latches, hinges, and checks.

Heater and Air Conditioner (Group 83)

Safety Precautions (83-00)

Safety measures when working on the air conditioning system.

Air Conditioner Inspection (83-01)

Inspect the A/C compressor hub, clearance, and hoses.

HVAC Air Filter Cleaning and Replacement (83-02)

Cleaning and replacing cab fresh-air and pre-filters.

Hood, Grille, and Cab Fenders (Group 88)

Hood Rear Support Lubrication (88-01)

Lubricating hood rear support brackets and isolators.