Western Star: Driver's Manual

®
WESTERN STAR
Driver’s Manual
STI-444-6
A24-01242-000
Foreword
Introduction performed. The EDR is designed to record data re-

lated to vehicle dynamics and safety systems for ap-
This manual provides information needed to operate proximately 60 seconds. This data can help provide
and understand the vehicle and its components. a better understanding of the circumstances in which
More detailed information is contained in the Owner’s crashes and injuries occur. Data recorded includes
Warranty Information for North America booklet and the following items:
in the vehicle’s workshop and maintenance manuals. • how various systems in the vehicle were oper-
Custom-built Western Star vehicles are equipped ating
with various chassis and cab components. Not all of • engine system information
the information contained in this manual applies to
every vehicle. For details about components in your • how far (if at all) the driver was depressing the
vehicle, refer to the chassis specification pages in- accelerator
cluded in all new vehicles and to the vehicle specifi-
• if the driver was depressing the brake pedal
cation decal located inside the vehicle.
• how fast the vehicle was traveling
For your reference, keep this manual in the vehicle
at all times. NOTE: Data is not recorded by the EDR under
IMPORTANT: Descriptions and specifications in normal driving conditions. Personal data such
this manual were in effect at the time of printing. as name, gender, age, and crash location are
Western Star Trucks reserves the right to dis- not recorded. However, other parties such as
continue models and to change specifications or law enforcement could combine the EDR data
design at any time without notice and without with the type of personally identifying data rou-
incurring obligation. Descriptions and specifica- tinely acquired during a crash investigation.
tions contained in this publication provide no To read data recorded by an EDR, special equipment
warranty, expressed or implied, and are subject is required, and access to the vehicle or the EDR is
to revisions and editions without notice. needed. In addition to the vehicle manufacturer, other
parties that have the special equipment, such as law
Environmental Concerns and enforcement, can read the information if they have
access to the vehicle or the EDR.
Recommendations
Whenever you see instructions in this manual to dis- Emissions and Fuel Efficiency
card materials, you should first attempt to reclaim Compliance
and recycle them. To preserve our environment, fol-
low appropriate environmental rules and regulations This vehicle must be regularly inspected and main-
when disposing of materials. tained as indicated in the Western Star Maintenance
Manual, and in the Pre- and Post-Trip Inspections
Event Data Recorder and Maintenance chapter in this manual, in order to
continue satisfactory performance and ensure cover-
This vehicle is equipped with one or more devices age of the vehicle under the manufacturer’s warranty.
that record specific vehicle data. The type and Many maintenance procedures ensure that the ve-
amount of data recorded varies depending on how hicle and engine continue to comply with applicable
the vehicle is equipped (such as the brand of engine, emissions standards. Maintenance procedures, using
if an air bag is installed, or if the vehicle features a components engineered to comply with greenhouse
collision avoidance system, etc.). gas emissions and fuel efficiency regulations, may be
performed by an authorized Daimler Trucks North
This vehicle is equipped with an event data recorder America dealer, an independent outlet, or the vehicle
(EDR). The main purpose of an EDR is to record owner or operator.
data in certain crash or near-crash situations, such
as air bag deployment or hitting a road obstacle, that The vehicle owner is responsible for determining the
will assist in understanding how a vehicle’s systems suitability of replacement components to maintain
STI-444-6 (6/15)
A24-01242-000
Printed in U.S.A.
Foreword
compliance with federal and local jurisdictional regu- Place de Ville Tower C, 330 Sparks Street, Ot-
lations. Components including, but not limited to, tawa, Ontario, Canada K1A 0N5.
tires, cab/sleeper side extenders, chassis fairings,
bumper, hood, vehicle speed limiters, and idle reduc- For additional road safety information, please visit
tion timers are specifically designed and manufac- the Road Safety website at: www.tc.gc.ca/
tured to exacting standards for regulatory fuel effi- roadsafety.
ciency and greenhouse gas emissions compliance. It
is important that these components are always re-
placed with components that meet or exceed the per-
formance of the originally installed components.
Customer Assistance Center

Having trouble finding service? For over-the-road
breakdown assistance, customer concerns, literature
requests, and the location of the nearest dealer, call
1-866-850-STAR (7827). Call night or day, weekdays
or weekends. Our people are knowledgeable, profes-
sional, and committed to following through to help
you keep your truck moving.
Reporting Safety Defects

If you believe that your vehicle has a defect which
could cause a crash or could cause injury or
death, you should immediately inform the National
Highway Traffic Safety Administration (NHTSA) in
addition to notifying Western Star Trucks.
If the NHTSA receives similar complaints, it may
open an investigation, and if it finds that a safety
defect exists in a group of vehicles, it may order a
recall and remedy campaign. However, NHTSA
cannot become involved in individual problems
between you, your dealer, or Western Star Trucks.
To contact NHTSA, you may call the Vehicle
Safety Hotline toll-free at 1-888-327-4236 (TTY:
1-800-424-9153); go to www.safercar.gov; or
write to: Administrator, NHTSA, 1200 New Jersey
Avenue, SE, Washington, DC 20590. You can also
obtain other information about motor vehicle safety
from www.safercar.gov.
Canadian customers who wish to report a safety-
related defect to Transport Canada, Defect Investi-
gations and Recalls, may telephone the toll-free
hotline 1-800-333-0510, or contact Transport
Canada by mail at: Transport Canada, ASFAD,
© 2001–2015 Daimler Trucks North America LLC. All rights reserved. Daimler Trucks North America LLC is a Daimler
company.
No part of this publication, in whole or 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 per-
mission of Daimler Trucks North America LLC. For additional information, please contact Daimler Trucks North
America LLC, Service Systems and Documentation, P.O. Box 3849, Portland OR 97208–3849 U.S.A. or refer to
www.Daimler-TrucksNorthAmerica.comand www.WesternStarTrucks.com.
Contents
Chapter Page
Introduction, Environmental Concerns and Recommendations,
Event Data Recorder, Emissions and Fuel Efficiency Compliance,
Customer Assistance Center, Reporting Safety Defects . . . . . . . . . . . . . . . . . . . . Foreword
1 Vehicle Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1
2 Vehicle Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1
3 Instruments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.1
4 Driver Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1
5 Climate Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1
6 Seats and Restraints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.1
7 Cab and Sleeper Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.1
8 Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.1
9 Engine Starting, Operation, and Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.1
10 Optional Engine Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.1
11 Emissions and Fuel Efficiency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.1
12 Brake Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.1
13 Steering System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.1
14 Manual Transmissions and Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.1
15 Automated and Automatic Transmissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.1
16 Drive Axles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.1
17 Fifth Wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.1
18 Trailer Couplings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.1
19 Headlight Aiming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.1
20 Vehicle Appearance and Care . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20.1
21 In An Emergency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.1
22 Pre- and Post-Trip Checklists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22.1
23 Pre- and Post-Trip Inspections and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23.1
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I.1
1
Vehicle Identification
Component Information Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1
Federal Motor Vehicle Safety Standard Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1
Canadian Motor Vehicle Safety Standard Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1
Component GWR Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1
Emissions Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
Component Information Label

NOTE: Labels shown in this chapter are ex-
amples only. Actual specifications may vary from
1
vehicle to vehicle.
The component information label lists the vehicle
model, identification number, and major component
models. It also lists the major assemblies and instal-
lations shown on the chassis specification sheet.
One copy of the component information label is at-
2
tached to the inside of the glove box; another copy is
inside the rear cover of the Owner’s Warranty Infor-
mation for North America booklet. An illustration of
the label is shown in Fig. 1.1.
06/28/2011 f602081
1. Certification Label
2. Noise Emission Label
Fig. 1.2, Label Locations
Canadian Motor Vehicle Safety

Standard Labels
In Canada, tractors with fifth wheels are certified by
06/28/2011 f080173
means of a statement of compliance label with the
Canadian National Safety Mark attached to the
Fig. 1.1, Component Information Label driver-side door frame B-pillar. See Fig. 1.5.
Trucks built without a cargo body and tractors built
Federal Motor Vehicle Safety without a fifth wheel that are intended for service in
Standard Labels Canada have an incomplete vehicle certification label
(similar to Fig. 1.4) attached to the driver-side
NOTE: Due to the variety of Federal Motor Ve- B-pillar. After completion of the vehicle, a complete
hicle Safety Standard (FMVSS) certification re- certification label must be attached by the final-stage
quirements, not all of the labels shown will apply manufacturer to certify that the vehicle conforms to
to your vehicle. all applicable Canada Motor Vehicle Safety Standard
(CMVSS) regulations in effect on the date of
The FMVSS labels are attached to the driver-side completion.
door frame B-pillar, as shown in Fig. 1.2. Tractors
with or without fifth wheels purchased in the U.S. are
certified by means of a certification label. See Component GWR Label
Fig. 1.3. The component GWR label is located on the A-pillar
Trucks built without a cargo body that are intended of the driver-side door frame. The label provides
for service in the U.S. have an incomplete vehicle maximum GWR ratings for each component.
certification label attached by the final-stage manu- See Fig. 1.6 for a typical component GWR label.
facturer. See Fig. 1.4. This label will be attached to
the incomplete vehicle document included with the
vehicle, and certifies that the vehicle conforms to all
applicable FMVSS regulations in effect on the date of
completion.
1.1
06/28/2011 f080175
Fig. 1.3, Vehicle Certification Label
06/28/2011 f080174
Fig. 1.4, Incomplete Vehicle Certification Label
(3)]. It is the owner’s responsibility to maintain the

vehicle so that it conforms to EPA regulations.
EPA Noise Emission Control Label

A vehicle noise emission control label (Fig. 1.9) is
located on the driver-side B-pillar as shown in
Fig. 1.2. It is the owner’s responsibility to maintain
the vehicle so that it conforms to EPA regulations.
10/10/2006 f080024
IMPORTANT: Certain Western Star incomplete
Fig. 1.5, Canadian National Safety Mark vehicles may be produced with incomplete noise
control hardware. Such vehicles will not have a
Emissions Labels vehicle noise emission control information label.
For such vehicles, it is the final-stage manufac-
Aftertreatment System Indicators turer’s responsibility to complete the vehicle in
Label conformity to U.S. EPA regulations (40 CFR Part
205) and label it for compliance.
Engines and vehicles manufactured after December
31, 2006 and domiciled in the U.S. or Canada are
required to meet all EPA regulations effective as of Vehicle Emission Control Information
the vehicle build date, and are equipped with an Label
emission aftertreatment system (ATS). Vehicles do-
miciled outside of the U.S. and Canada may not Model year 2013 and later vehicles meet additional
have aftertreatment equipment, depending upon local requirements as specified by federal greenhouse gas
statutory emissions guidelines. See Table 1.1. and fuel efficiency regulations (GHG14). These ve-
hicles are equipped with components that increase
A warning label on the driver-side visor contains im- fuel efficiency and reduce GHG emissions. Compo-
portant warning indicators in the instrument cluster nents may include, but are not limited to, low rolling
that pertain to the ATS. See Fig. 1.7 or Fig. 1.8. resistance tires; aerodynamic devices such as hood,
It is a violation of U.S. federal law to alter exhaust cab side extenders, and fuel tank fairings; vehicle
plumbing, ATS, or other components in any way that speed limiters; and idle shutdown timers.
would bring the engine/vehicle out of compliance with
certification requirements [Ref: 42 U.S.C. S7522(a)
1.2
06/28/2011 f080172
Fig. 1.6, Component GWR Label
EXHAUST AFTERTREATMENT SYSTEM INFORMATION

INDICATOR WARNING
CHECK STOP
LAMP(S)
(Solid) (Flashing) (Flashing)
Level 1 Level 2 Level 3 Level 4
Indicator Lamp Filter Regeneration Filter Parked Regeneration Service Regeneration Required. HEST (High Exhaust
Message(s) Recommended. Regeneration Required − Engine Engine Derate To Idle Only. System Temperature)
Necessary Derate
Diesel Particulate Filter is reaching Filter is now Filter has reached Filter has exceeded maximum Flashing
Filter Condition capacity. reaching maximum maximum capacity. capacity. A regeneration is in
Switch.
capacity. progress.
Required Action Bring vehicle to To avoid engine Vehicle must be Vehicle must be parked, and a
highway speeds to derate, bring vehicle parked, and a Parked Service Regeneration must be Solid
allow for an to highway speeds Regeneration must performed. Check engine Exhaust components
Automatic to allow for an be performed. operator’s manual for details. and exhaust gas are at
Regeneration or Automatic Engine will begin Engine will shut down. high temperature. When
perform a Parked Regeneration, or derate. stationary, keep away
Regeneration. perform a Parked from people and
Regeneration as flammable materials or
soon as possible. vapors.
For a driver performed Parked Regeneration, vehicle must be equipped with a dash mounted Regeneration Switch.
02/20/2009 f080156
Fig. 1.7, ATS Indicators, EPA07
Applicable Emissions System Based on Build Date and EPA Regulations

Build Date Regulation: Emissions Components
EPA07 (reduce nitrogen oxides (NOx) emissions to 1.1 g/bhp-hr, and reduce
January 1, 2007–December 31,
particulate matter emissions to 0.01 g/bhp-hr): Aftertreatment device (ATD) containing
2009
a diesel particulate filter that traps soot and ash.*
EPA10 (reduce NOx emissions to 0.2 g/bhp-hr): EPA07-type ATD, with additional
January 1, 2010–December 31,
selective catalyst reduction (SCR) technology that utilizes diesel exhaust fluid (DEF)
2012
to convert NOx to nitrogen and water vapor.
GHG14: Aerodynamic and fuel efficiency components including, but not limited to,
tires, cab/sleeper side extenders, chassis fairings, bumper, hood, vehicle speed
From March 5, 2012
limiters, and idle reduction timers specifically designed to meet regulatory fuel
efficiency and greenhouse gas emissions standards.
* Cummins, Detroit, and Mercedes-Benz ATD’s are also equipped with a diesel oxidation catalyst to break down pollutants.
Table 1.1, Applicable Emissions System Based on Build Date and EPA Regulations
1.3
IMPORTANT
DPF Regen Needed Diesel Particulate Filter (DPF)
regeneration is needed.
If flashing, regenerate as soon as
possible. Engine derate possible.
Hot Exhaust Hot exhaust can cause fire.
Keep flammables and people away
from exhaust.
DEF Refill Needed Diesel Exhaust Fluid (DEF) level is

low. Engine derate likely.
DEF
Refill tank with certified DEF.
See operator’s manual for complete instructions. 24−01656−000
11/30/2010 f080162
Fig. 1.8, ATS Indicators, EPA10 and Newer
A Vehicle Emission Control Information Label is lo-

cated on the driver-side door. See Fig. 1.10. It is the
owner’s responsibility to maintain the vehicle so that
it conforms to EPA and NHTSA regulations.
06/28/2011 f080171 Certified Clean Idle Label

Fig. 1.9, Vehicle Noise Emission Control Label The California Air Resources Board (CARB) requires
model year 2008 and newer heavy-duty diesel en-
MANUFACTURED BY:
VEHICLE EMISSION CONTROL INFORMATION
DATE OF MANUFACTURE:
gines to be equipped with a non-programmable en-
VIN:
VEH FAMILY CD:
GVWR−KG
REGULATORY CLASS:
gine shutdown system that automatically shuts down
GVWR−LBS EMISSION CONTROL IDENTIFIERS:
the engine after five minutes of idling in order to limit
THIS VEHICLE COMPLIES WITH U. S. EPA REGULATIONS FOR XXXX HEAVY DUTY VEHICLES.
SEE OWNER’S MANUAL FOR PROPER MAINTENANCE OF THIS VEHICLE. U PART NO. 24−01177−060 REV A emissions of particulate matter and NOx.
03/06/2012 f080184
Certified vehicles are equipped with a label placed
Fig. 1.10, Vehicle Emission Control Information Label near the bottom edge of the driver-side door. See
Fig. 1.11.
1.4
CERTIFIED
CLEAN IDLE
02/20/2012 f080179
Fig. 1.11, CARB Clean Idle Label
1.5
2
Vehicle Access
Door Locks and Handles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1
Grab Handles and Access Steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2
Back-of-Cab Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5
Hood Opening and Closing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7
Vehicle Access
Door Locks and Handles

To unlock either door from outside the cab, insert the 2
key in the lock and turn it one-quarter turn towards
the front of the vehicle. See Fig. 2.1. Turn the key
back to the original position to remove it. Pull out on
the paddle latch to open the door.
1
03/21/2001 f720394 11/02/2011 f545852

1. Lock 2. Paddle Latch 1. Unlock Button 2. Lock Button
Fig. 2.1, Exterior Door Handle Fig. 2.2, Key Fob
To lock either door from outside the cab, insert the Key Fob Programming
key in the lock and turn it one-quarter turn towards
the rear of the vehicle. Turn the key back to the origi- A maximum of four fobs can be programmed to work
nal position to remove it. If the door is closed, it will on one vehicle. Whenever a new fob will be used, all
now be locked. If the door is open, close the door existing fobs must be reprogrammed at the same
firmly. time. Any existing fobs that were previously pro-
grammed will no longer work on the vehicle unless
To lock either door from inside the cab, push the lock they are all reprogrammed at the same time.
button down. Pull the lock button up to unlock the
door from the inside. 1. Remove the passenger-side electrical access
panel, located next to the glove box. See
To open either door from inside the cab, pull the lock Fig. 2.3.
button up, then pull the interior door latch out and
push the door outwards. 2. Locate the 2-wire connector in the area between
the auxiliary and main power distribution mod-
Remote Keyless Entry ules (PDMs) with circuit 443* and ground.
Remote keyless entry is optional on Western Star NOTE: If the 2-wire connector cannot be lo-
vehicles. The remote entry key fob can be used to cated, the connector may be hanging below the
unlock the doors from outside the cab. PDM. In this case, remove the heater cover
panel, which is located below the fuse panel.
To unlock both doors, press the unlock button. To
lock both doors, press the lock button. See Fig. 2.2. 3. Use a short length of wire or a paperclip to short
the two terminals together three times within five
seconds.
4. Wait three seconds.
2.1
Vehicle Access
be especially careful when entering or exiting the

vehicle.
Always maintain three-point contact with the ve-
hicle when entering or exiting the cab. Three-
point contact means both feet and one hand, or
both hands and one foot.
When steps are mounted on battery box covers,
make sure that the cover is latched and secure
before using the steps.
Do not step on the fuel tank, battery box, frame,
etc. unless adequate slip resistant surfaces and
A 2 1 handholds are provided.
3 Do not jump from the vehicle.
11/04/2011 f543948a
For ease of entry and exit, there are multiple grab
A. The two-wire connector is located next to the handles: a handle on the A-pillar (optional on the
auxiliary power distribution module. driver’s side), handles on the inside of the door, and
1. Glove Box sidewall grab handles. In addition, the steering wheel
2. Main Power Distribution Module may be used to provide a secure handhold. There
3. Auxiliary Power Distribution Module are at least two access steps to provide secure
Fig. 2.3, Passenger-Side Electrical Access Panel footholds.
(removed) IMPORTANT: Vehicles built before November 7,
5. Press and hold the first fob’s lock button for two 2011 have lower door grab handles on the in-
seconds. The LED in the fob will flash while the side of each door. Vehicles built on or after No-
button is held. vember 7, 2011 have lower pockets on the in-
side of each door, which may be used as a
6. Press the lock button on the second fob for one secure handhold.
second. The LED in the fob will flash while the
button is held.
Entering the Driver’s Side
7. Repeat step 6 for any additional fobs.
1. Open the driver-side door and place anything
NOTE: The system will exit program mode after that you are carrying in the cab.
one minute of no activity. 2. Grasp the sidewall grab handle with your right
hand. See Fig. 2.4 or Fig. 2.5.
Grab Handles and Access 3. Grasp the lower door pocket or grab handle with
Steps your left hand.
The grab handles, access steps, and steering wheel 4. Place your right foot on the bottom step, and pull
are all part of the cab access system. Use these yourself up.
"helping hands" when getting into or out of the cab. 5. Place your left foot on the top step.
They will increase your security and comfort.
6. Grasp the steering wheel or A-pillar grab handle,
CAUTION if equipped, with your left hand.
7. Step into the cab with your right foot first, and
Slipping or falling from the vehicle can result in grasp the steering wheel with your right hand.
personal injury or property damage.
Wet or dirty shoes greatly increase the chance of
slipping or falling. If your shoes are wet or dirty,
2.2
Vehicle Access
2 3 4 5
2 4 5
3
6
08/17/2011 f720392
1. Lower Door Handle 4. Door Latch
2. Door Lock Button 5. Sidewall Grab Handle
3. Upper Door Grab
Handle
Fig. 2.4, Driver-Side Cab Access (vehicles built before
November 7, 2011)
Exiting the Driver’s Side

1
IMPORTANT: Do not attempt to exit the cab
08/17/2011 f720729
while carrying any items in your hands. Place
1. Lower Door Pocket 4. A-Pillar Grab Handle
them in an accessible location on the seat or 2. Upper Door Pocket 5. Sidewall Grab Handle
cab floor and make sure they will not get in your 3. Door Latch
way as you exit, then retrieve them after you
have exited the cab. Fig. 2.5, Driver-Side Cab Access (vehicles built
November 7, 2011 and later)
CAUTION 4. Move your left hand to the lower door pocket or

grab handle.
Always face in when exiting the cab. Do not at-
5. Step to the ground with your left foot first.
tempt to exit with your back to the cab, as you
would going down a flight of stairs. It is easier to
slip or lose your balance. If you slip when exiting Entering the Passenger’s Side
in this way, there is a greater likelihood of per- 1. Open the passenger-side door and place any-
sonal injury. thing that you are carrying in the cab.
1. Grasp the steering wheel with both hands, place 2. Grasp the sidewall grab handle with your left
your left foot on the top step, and stand on the hand. See Fig. 2.6 or Fig. 2.7.
threshold, facing into the cab.
3. Grasp the lower door pocket or grab handle with
2. Grasp the sidewall grab handle with your right your right hand.
hand. See Fig. 2.4 or Fig. 2.5.
4. Place your left foot on the bottom step.
3. Move your right foot to the bottom step.
5. Place your right foot on the top step and move
your right hand to the A-pillar grab handle.
2.3
Vehicle Access
2 3 4
4
3
2
6
08/17/2011 f720393
1. A-Pillar Grab Handle 4. Door Lock Button
2. Door Latch 5. Lower Door Grab
3. Upper Door Grab Handle 1
Handle 6. Sidewall Grab Handle
Fig. 2.6, Passenger-Side Cab Access (vehicles built
before November 7, 2011)
5
6. Place your left foot on the top step, then move 08/17/2011 f720728
your left hand to the A-pillar grab handle. 1. Sidewall Grab Handle 4. Upper Door Pocket
2. Door Latch 5. Lower Door Pocket
7. Step into the cab with your left foot first. 3. A-Pillar Grab Handle
Exiting the Passenger’s Side Fig. 2.7, Passenger-Side Cab Access (vehicles built
November 7, 2011 and later)
IMPORTANT: Do not attempt to exit the cab
while carrying any items in your hands. Place 2. Place your left foot on the top step.
them in an accessible location on the seat or 3. Move your left hand to the sidewall grab handle.
cab floor and make sure they will not get in your
way as you exit, then retrieve them after you 4. Move your right foot to the bottom step.
have exited the cab. 5. Move your right hand to the lower door pocket or
grab handle.
CAUTION 6. Step to the ground with your left foot first.
Always face in when exiting the cab. Do not at- Entering the Driver’s Side, Right-
tempt to exit with your back to the cab, as you
would going down a flight of stairs. It is easier to Hand-Drive Vehicles
slip or lose your balance. If you slip when exiting 1. Open the driver-side door, and place anything
in this way, there is a greater likelihood of per- that you are carrying in the cab.
sonal injury.
2. Grasp the sidewall grab handle with your left
1. Grasp the A-pillar grab handle with both hands, hand.
then place your right foot on the top step while
facing inward. See Fig. 2.6 or Fig. 2.7.
2.4
Vehicle Access
3. Grasp the lower door pocket or grab handle with 3. Grasp the lower door pocket or grab handle with
your right hand. your left hand.
4. Place your left foot on the bottom step. 4. Place your right foot on the bottom step.
5. Place your right foot on the top step. 5. Place your left foot on the top step and move
your left hand to the A-pillar grab handle.
6. Move your right hand to the steering wheel or
A-pillar grab handle, if equipped. 6. Place your right foot on the top step, then move
your right hand to the A-pillar grab handle.
7. Step into the cab with your left foot first, and
grasp the steering wheel with your left hand. 7. Step into the cab with your right foot first.
Exiting the Driver’s Side, Right-Hand- Exiting the Passenger’s Side, Right-
Drive Vehicles Hand-Drive Vehicles
IMPORTANT: Do not attempt to exit the cab IMPORTANT: Do not attempt to exit the cab
while carrying any items in your hands. Place while carrying any items in your hands. Place
them in an accessible location on the seat or them in an accessible location on the seat or
cab floor and make sure they will not get in your cab floor and make sure they will not get in your
way as you exit, then retrieve them after you way as you exit, then retrieve them after you
have exited the cab. have exited the cab.
CAUTION CAUTION
Always face in when exiting the cab. Do not at- Always face in when exiting the cab. Do not at-
tempt to exit with your back to the cab, as you tempt to exit with your back to the cab, as you
would going down a flight of stairs. It is easier to would going down a flight of stairs. It is easier to
slip or lose your balance. If you slip when exiting slip or lose your balance. If you slip when exiting
in this way, there is a greater likelihood of per- in this way, there is a greater likelihood of per-
sonal injury. sonal injury.
1. Grasp the steering wheel with both hands, place 1. Grasp the A-pillar grab handle with both hands,
your right foot on the top step, and stand on the then place your left foot on the top step while
threshold, facing into the cab. standing up from the seat facing inward.
2. Grasp the sidewall grab handle with your left 2. Place your right foot on the top step.
hand.
3. Move your right hand to the sidewall grab
3. Move your left foot to the bottom step. handle.
4. Move your right hand to the lower door pocket or 4. Move your right foot to the bottom step.
grab handle.
5. Move your left hand to the lower door pocket or
5. Step to the ground with your right foot first. grab handle.
6. Step to the ground with your left foot first.
Entering the Passenger’s Side, Right-
Hand-Drive Vehicles Back-of-Cab Access
1. Open the passenger-side door and place any-
thing that you are carrying in the cab. When trailer air and electrical connections cannot be
reached conveniently from the ground, Federal Motor
2. Grasp the sidewall grab handle with your right Carrier Safety Regulations require that tractors have
hand. adequate back-of-cab access. Grab handles are typi-
cally located on the backwall of the cab or sleeper, or
on the inside of the cab extender, if equipped. See
2.5
Vehicle Access
Fig. 2.8. A grab handle may also be provided on the

exhaust stack. Steps may be mounted on the fuel
tank(s), battery or tool box(es), or on metal brackets
secured to the frame rail. A deck plate is mounted
across the top of the frame rails. All other areas are
not meant to support back-of-cab access 2
CAUTION
Follow these rules for back-of-cab access. Failing
to follow these rules could lead to a fall, and pos-
sible personal injury.
Never step on any exterior part unless it has a
slip-resistant surface meant for safe stepping. If
the surface is movable, such as a battery box
cover with a slip-resistant surface, be certain it is 3
firmly secured.
Be careful not to trip on items such as chains or
air lines in the back-of-cab area.
Always follow safety procedures for back-of-cab
access, maintaining three-point contact—both
1
hands and one foot, or both feet and one hand—
whenever moving around, and always face in to-
ward the deck plate when climbing up or down.
Wet or dirty shoes, steps, or grab rails greatly 1
increase the chance of slipping or falling. If your
shoes or the contact areas are wet or dirty, clean
and dry them as much as possible before ac- 09/24/2007 f602335
cessing the back of cab area, and be especially 1. Steps 3. Deck Plate
careful when climbing or standing on the vehicle. 2. Grab Handle
Never jump onto, or off of, a vehicle; doing so Fig. 2.8, Back-of-Cab Access
creates a very high likelihood of a fall and per-
sonal injury. 1. Facing the deck plate, grasp the grab handle
IMPORTANT: Climb onto, and down from, be- with both hands. Reach up as far as is comfort-
able.
hind the cab while facing in toward the vehicle,
as you would on a ladder. Do not climb up or 2. Place one foot on the bottom step and pull your-
down facing out away from the vehicle. self up.
3. Place your other foot on the top step.
Accessing Back-of-Cab Area
4. Move your lower hand to a higher position on the
grab handle.
WARNING
5. Step onto the deck plate.
External surfaces of the exhaust system remain
hot after the engine has been shut down. When Exiting Back-of-Cab Area
accessing the back of the cab or sleeper, do not
touch any part of the exhaust system other than 1. Face the center of the vehicle and grasp the
the exhaust-mounted grab handle, if equipped, or sidewall grab handle with both hands.
severe burns could occur. 2. Place one foot at a time on the top step.
2.6
Vehicle Access
3. Move your upper hand to a lower position on the Closing the Hood
grab handle.
1. Grasp and lift the grab handle to tilt the hood
4. Move one foot to the bottom step. toward the closed position.
5. Step to the ground with your upper foot first. 2. As the hood goes over center, put one foot on
the bumper step and slowly lower the hood with
Hood Opening and Closing both hands on the grab handle. See Fig. 2.9.
The hood can be raised to a full-open position. A IMPORTANT: Make sure that both latches are
spring helps you to raise the hood, and to lower it to fully engaged before operating the vehicle.
the operating position. In the operating position, the
3. Make sure the hood is flush with the cowl, then
hood is secured to the cab-mounted cowl by a hold-
secure the hood by engaging both hood hold-
down latch on each side.
down latches.
Opening the Hood
1. Release both hood hold-down latches by pulling
the ends outward.
NOTICE
Do not let the hood free-fall to the full-open posi-
tion. To do so could cause damage to the hood
or hood springs.
2. Using the bumper step for leverage, slowly tilt
the hood with both hands on the grab handle.
See Fig. 2.9.
03/22/2001 f880526
Fig. 2.9, Hood Opening and Closing
3. As the hood starts to open, put your foot on the

ground, and walk backwards as you pull. The
hood will stop in the full-open position.
2.7
3
Instruments
Warning and Indicator Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.1
Standard Instruments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3
Optional Instruments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.6
Overhead Instrument Panel, Optional . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.8
Instruments
Warning and Indicator Lights • STOP engine

• trailer antilock braking system (ABS)
Vehicles built since January 1, 2007 are equipped
with a located behind the steering wheel, and con- • tractor ABS
tains all standard and optional warning and indicator
• parking brake engaged
lamps, or telltales.
The following lamps are optional:
See Table 3.1 for a listing of standard and commonly
used optional telltales. • rear suspension air pressure
The following fixed-position lamps are standard: • check transmission
• left-turn signal • transmission temperature
• high-beam headlights • service transmission
• daytime running lights • wheel spin
• right-turn signal • unfastened seat belt
• low air pressure • intake heater
• wait to start (EPA10 and newer vehicles) • water in fuel
• high exhaust system temperature (HEST) • fuel filter restriction
• diesel particulate filter (DPF) status • optimized idle
• malfunction indicator lamp (MIL) • power takeoff (PTO) engaged
• CHECK engine
Common Lightbar Lamps

Indicates a critical engine condition (low oil pressure, low coolant
level, high coolant temperature, high DPF soot level, or
CHECK Engine uncontrolled DPF regeneration). Correct the condition as soon as
possible. If the condition worsens, the STOP engine lamp will
illuminate.
Indicates a serious fault which requires engine shutdown
immediately. The engine protection system will reduce the
maximum engine torque and speed, and, if the condition does not
improve, will shut down the engine within 30 to 60 seconds.
STOP Engine The driver must safely bring the vehicle to a stop on the side of the
road and shut down the engine as soon as the red light is seen. If
the engine shuts down while the vehicle is in a hazardous location,
restart the engine after turning the key to the OFF position for a
few seconds. Move the vehicle to a safer location.
Slow (10-second) flashing indicates a regeneration (regen) is in
progress.
High Exhaust System Temperature Solid illumination indicates high exhaust temperatures at the outlet
(HEST) of the tail pipe, when speed is below 5 mph (8 km/h). It does not
signify the need for service; it only alerts the vehicle operator to
high exhaust temperatures when a regen is in progress.
3.1
Instruments

Solid illumination indicates a regen is required. Change to a more
challenging duty cycle (such as highway driving ) to raise exhaust
Diesel Particulate Filter (DPF) temperatures for at least twenty minutes, or perform a parked
Status regen.
Blinking indicates that a parked regen is required immediately. An
engine derate and shutdown will occur.
Indicates an engine emissions-related fault. See the engine

Malfunction Indicator Lamp (MIL)
operation manual for details.
Flashes on and off whenever the outside left-turn signal lights are
Left-Turn Arrow
activated.
Flashes on and off whenever the outside right-turn signal lights are
Right-Turn Arrow
activated.
High-Beam Headlights Indicates the high-beam headlights are on.
Daytime Running Lights Indicates the daytime running lights are on.
Indicates a problem with the truck/tractor ABS is detected. Repair

Tractor ABS
the vehicle ABS immediately to ensure full braking capability.
Indicates a problem with the trailer ABS is detected. Repair the

Trailer ABS
trailer ABS immediately to ensure full braking capability.
Activates with an audible warning when air pressure in the primary

Low Air Pressure
or secondary reservoir falls below 70 psi (483 kPa).
Parking Brake Indicates the parking brake is engaged.
Power Takeoff (PTO) Indicates that the PTO function is engaged.
Unfastened Seat Belt Illuminates with the ignition ON and the driver seat belt unfastened.
WATER Indicates that the fuel may contain water. The driver must drain
IN FUEL Water In Fuel
any water collected in the fuel/water separator.
3.2
Instruments
Fuel Filter Restriction Indicates the fuel filter has been clogged and requires service.
WAIT Illuminates when starting the engine during cold conditions. Wait
TO START Wait To Start
until the lamp goes out before turning the ignition key to START.
Transmission Overheat Indicates high transmission temperature.
CHECK
TRANS Check Transmission Indicates an undesirable transmission condition.
Service Transmission Indicates a transmission service is due.
Indicates that the rear suspension air pressure is below operating

Rear Suspension Low Air Pressure
range.
WHEEL
SPIN Wheel Spin Indicates that the ATC function is engaged.
Table 3.1, Common Lightbar Lamps
Engine Protection System fault type) if the condition does not improve. Bring
the vehicle to a stop on the side of the road before
the engine shuts down.
WARNING
Some vehicles may have a shutdown-override
When the red STOP engine lamp illuminates, switch, which may be used to momentarily override
most engines are programmed to shut down au- the shutdown sequence. See Chapter 10 for detailed
tomatically within 30 seconds. The driver must information regarding the shutdown process.
immediately move the vehicle to a safe location IMPORTANT: Do not attempt to restart the en-
at the side of the road to prevent causing a haz-
gine while the vehicle is moving. Bring the ve-
ardous situation that could cause bodily injury,
property damage, or severe damage to the en- hicle to a safe stop, then restart the engine.
gine. To restart the engine, turn the ignition switch to OFF,
The STOP engine lamp illuminates when the engine leave it there a few seconds, then turn the switch to
protection system is activated. On some engines, the START. The engine will run for a short period and
engine protection system will derate the engine, al- shut down again if the condition does not improve.
lowing it to run at lower rpm and slower vehicle
speed. Drive the vehicle to a safe location or to a Standard Instruments
service facility.
Standard instruments are present on every vehicle.
On other engines, the engine protection system will They are listed here in alphabetical order, to make
shut down the engine. It will first derate the engine, the information easier to find.
then shut it down completely 30 to 60 seconds after
the indicator illuminates (depending on the critical
3.3
Instruments
Coolant Temperature Gauge Engine Oil Pressure Gauge

NOTICE NOTICE
A sudden increase in coolant temperature may A sudden decrease or absence of oil pressure
indicate engine or cooling system failure. Bring may indicate mechanical failure. Bring the vehicle
the vehicle to a safe stop and investigate the to a safe stop and investigate the cause to pre-
cause to prevent further damage. Do not operate vent further damage. Do not operate the engine
the engine until the cause has been determined until the cause has been determined and cor-
and corrected. rected.
During normal engine operation, the coolant tem- The engine oil pressure gauge (Fig. 3.2) displays the
perature gauge (Fig. 3.1) should read between 175 current engine oil pressure. If engine oil pressure
and 195°F (79 and 91°C). If the temperature remains falls below the minimum levels shown in Table 3.3,
below 160°F (71°C) or exceeds the maximum tem- the CHECK engine lamp will illuminate. If the condi-
perature shown in Table 3.2, inspect the cooling sys- tion does not improve, the STOP engine lamp will
tem to determine the cause. illuminate and an audible warning will sound. The
engine will then derate or shut down, depending on
If coolant temperature rises above the maximum
the type of engine protection system installed.
temperature listed in Table 3.2, the CHECK engine
lamp will illuminate. If the condition does not im-
prove, the STOP engine lamp will illuminate and an
audible warning will sound. The engine will then der-
ate or shut down, depending on the type of engine
protection system installed.
05/14/2001 f610537
Fig. 3.2, Engine Oil Pressure Gauge
Minimum Oil Pressure *

At Idle Speed: At Rated RPM:
Engine Model
psi (kPa) psi (kPa)
05/11/2001 f610535 Caterpillar 10–20 (69–138) 30–45 (207–310)
Cummins 15 (103) 35 (241)
Fig. 3.1, Coolant Temperature Gauge Detroit Diesel 14 (97) 55 (350)
Mercedes-Benz 7 (50) 36 (250)
Maximum Coolant Temperature * Pressures apply with the engine at operating temperature. Oil pressure
Engine Make Temperature: °F (°C) may be higher on a cold engine. Observe and record pressures when the
engine is new to create a guide for checking engine condition.
Caterpillar 215 (101)
Cummins 225 (107) Table 3.3, Minimum Oil Pressure
Detroit Diesel 215 (101)
Mercedes-Benz 203 (95)
Table 3.2, Maximum Coolant Temperature
3.4
Instruments
Fuel/Diesel Exhaust Fluid (DEF) Air pressure gauges (Fig. 3.4) register the pressure
in the primary and secondary air systems. Normal
Gauge, EPA10 and Newer pressure with the engine running is 100 to 120 psi
The fuel and DEF levels are measured in a dual pur- (689 to 827 kPa) in both systems.
pose fuel/DEF gauge. See Fig. 3.3.
2
4
05/14/2001 f610556
3
11/09/2009 f611046
Fig. 3.4, Air Pressure Gauge (reservoir A shown)
1. Diesel Fuel Level Indicator
2. DEF Symbol A low air pressure warning lamp and audible warn-
3. DEF Level Indicator ing, connected to both the primary and secondary
4. Low DEF Warning Lamp (activates below 10% systems, activate when air pressure in either system
DEF)
drops below a minimum pressure of 65 to 75 psi
5. Low Fuel Warning Lamp (activates at 1/8 tank of
fuel) (448 to 517 kPa).
When the engine is started, the warning lamp and
Fig. 3.3, Fuel/DEF Gauge, EPA10 and Newer Vehicles
audible warning remain on until air pressure in both
The diesel fuel level is indicated at the top of the systems exceeds minimum pressure.
gauge, with a low-fuel warning lamp that illuminates
when the diesel fuel level registers 1/8th of capacity. Speedometer
The DEF level is indicated in the lightbar on the Three speedometer face options are available. The
lower portion of the gauge. There is a low DEF level U.S. version of the speedometer (Fig. 3.5) registers
warning lamp that illuminates amber when the DEF speed in both miles per hour (mph) and kilometers
level reaches 10% of capacity. See Chapter 11 for per hour (km/h), with mph in larger numbers.
details of the DEF gauge functions. The metric version of the speedometer face reverses
this arrangement, with km/h in larger numbers. The
Primary and Secondary Air Pressure metric-only version, installed on vehicles bound for
Gauges Australia, shows km/h exclusively.
WARNING Tachometer
The tachometer (see Fig. 3.6) indicates engine
If air pressure falls below minimum pressure, the speed in revolutions per minute (rpm) and serves as
braking ability of the vehicle will be limited. Slow a guide for shifting the transmission and keeping the
the vehicle down and bring it to a gradual stop. engine in the appropriate rpm range. For low idle and
Do not attempt to move the vehicle until air pres- rated rpm, see the engine identification plate.
sure has risen above the minimum level. Moving
a vehicle without adequate braking power could Voltmeter
cause an accident resulting in property damage,
personal injury, or death. The voltmeter (see Fig. 3.7) indicates the vehicle
charging system voltage when the engine is running
3.5
Instruments
12 14
10 16
VOLTS
07/01/2003 f610666
Fig. 3.7, Voltmeter

Miles
started or when electrical devices in the vehicle are
09/09/2004 f610530a
being used.
Fig. 3.5, Speedometer (U.S. version) If the voltmeter shows an undercharged or over-
charged condition for an extended period, have the
charging system and batteries checked at a repair
facility.
On a vehicle equipped with a battery isolator system,
the voltmeter measures the average voltage of all the
batteries when the engine is running. When the en-
gine is stopped, the voltmeter shows only the iso-
lated battery voltage and does not indicate the volt-
age of the engine-starting batteries.
Optional Instruments
Optional instruments are not found on every vehicle.
They are listed here in alphabetical order, to make
the information easier to find.
05/11/2001 f610532 Air Restriction Gauge

Fig. 3.6, Tachometer The air intake restriction gauge measures the
vacuum on the engine side of the air cleaner. On
and the battery voltage when the engine is stopped. standard installations, it is mounted on the air intake
By monitoring the voltmeter, the driver can stay duct in the engine compartment. See Fig. 3.8.
aware of potential battery charging problems and As an option for easier viewing, an air intake restric-
have them fixed before the batteries discharge tion gauge may be located under the lightbar. See
enough to create starting difficulties. Fig. 3.9.
The voltmeter will normally show approximately 13.7
NOTE: Rain or snow can wet the air filter, caus-
to 14.1 volts when the engine is running. The voltage
of a fully charged battery is 12.7 to 12.8 volts when ing a temporarily higher than normal reading.
the engine is stopped. A completely discharged bat- Air intake restriction vacuum is measured in inches
tery will produce only about 12.0 volts. The voltmeter of water (inH2O). For vehicles equipped with a
will indicate lower voltage as the vehicle is being graduated indicator or a restriction gauge on the
dash, check the gauge with the engine off. If the air
3.6
Instruments
Air Intake Maximum Restriction Values (inH2O)

EPA07 and
Pre-EPA07 GHG14
Engine Make EPA10
Engines Engines
Engines
Cummins 25 25 25
Mercedes-Benz 22 22 –
Caterpillar 25 – –
Table 3.4, Air Intake Maximum Restriction Values
02/12/2015 f090514
Fig. 3.8, Air Intake Restriction Indicator, Graduated
05/14/2001 f610551
Fig. 3.10, Ammeter
05/14/2001 f610552
Fig. 3.9, Air Intake Restriction Gauge
restriction value equals or exceeds the value shown

in Table 3.4, the air cleaner element needs to be TRACTOR
APPL. PSI
replaced.
Ammeter
05/14/2001 f610549
The ammeter (Fig. 3.10) gauge displays current flow-
ing to and from the battery. When the batteries are Fig. 3.11, Tractor Application Air Gauge
charging, the meter needle moves to the positive
side of the gauge. When the batteries are being dis- Application Air Pressure Gauge
charged, the needle moves to the negative side. A
consistent negative reading when the engine is run- The application air pressure gauge (Fig. 3.11) regis-
ning indicates a possible problem with the charging ters the air pressure being used to apply the brakes,
system. and should be used for reference only. The gauge
will not register until the foot pedal is depressed or
Air Intake Maximum Restriction Values (inH2O) the hand brake lever is applied.
EPA07 and
Pre-EPA07 GHG14
Engine Make EPA10
Engines Engines
Engines
Detroit 20 22 18
3.7
Instruments
Drive Axle Oil Temperature Gauges • Detroit Diesel engines: 200 to 230°F (93 to
110°C)
NOTICE Under heavy loads, such as when climbing steep
grades, temperatures that exceed the normal oil tem-
A sudden increase in oil temperature that is not perature range for a short period are not unusual. If
caused by a load increase may indicate mechani- the temperature returns to normal when the load de-
cal failure. Bring the vehicle to a safe stop and creases, there is no problem.
investigate the cause to prevent further damage.
Do not operate the vehicle until the cause has
been determined and corrected.
During normal operation, drive axle oil temperature
gauges (Fig. 3.12) should read between 160 and
220°F (71 and 104°C).
05/11/2001 f610533
REAR
REAR Fig. 3.13, Engine Oil Temperature Gauge
F
Turbocharger Boost Pressure Gauge
04/16/2013 f610547 The turbocharger boost pressure gauge (Fig. 3.14)
measures the pressure in the intake manifold, in ex-
Fig. 3.12, Rear Drive Axle Oil Temperature Gauge cess of atmospheric pressure, being created by the
turbocharger.
Under heavy loads, such as when climbing steep
grades, temperatures that exceed the normal oil tem-
perature range for a short period are not unusual. If
the temperature returns to normal when the load de-
creases, there is no problem.
Engine Oil Temperature Gauge

NOTICE
A sudden increase in oil temperature that is not
caused by a load increase may indicate mechani-
cal failure. Bring the vehicle to a safe stop and 05/14/2001 f610540
investigate the cause to prevent further damage.
Fig. 3.14, Turbocharger Boost Pressure Gauge
Do not operate the engine until the cause has
been determined and corrected.
During normal operation, the engine oil temperature
Overhead Instrument Panel,
gauge (Fig. 3.13) should read as follows: Optional
• Cummins engines: 180 to 225°F (82 to 107°C) The optional overhead instrument panel may hold a
citizen’s band (C/B) radio, AM/FM radio, and storage
area with netting. The underside of the overhead
3.8
Instruments
console also holds the sun visors and the optional

dome/reading light assembly. For more information
on the dome/reading light assembly, see Chapter 7.
3.9
4
Driver Controls
Control Panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1
Ignition Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1
Lighting Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3
Horn Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.5
Powertrain Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.6
Windshield Wiper Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.11
Brake Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.11
Adjustable Steering Column Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.12
Suspension/Trailer Connection Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.13
Climate Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.13
Seat Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.14
Driver Controls
Control Panels DataStar Display Module

NOTE: Western Star vehicles are offered with The DataStar display module, shown in Fig. 4.3, dis-
various chassis and body components. Because plays operator-selected vehicle and engine param-
of the various options, the information contained eters for the time and distance of up to six different
in this chapter may not apply to every vehicle. trips. Four keys allow the operator to scroll through
the vehicle parameters, set the time and alarm, and
The right-hand dash control panel contains a face reset trip logs.
vent, the majority of the driver switch controls, auto-
mated and automatic transmission controls, and the Battery input powers the DataStar display and must
DataStar display module, if equipped. If there is a be continuously connected for the clock to maintain
dash-mounted air intake restriction indicator, it is the time. When the ignition is on, the DataStar is fully
often mounted on the right-hand panel as well. functional. Turning the ignition off puts the DataStar
display into sleep mode, and the display turns off to
The ignition switch control panel (below the right- reduce current drain. When the ignition is turned on
hand dash panel) contains the ignition switch, ciga- again, the DataStar display will come up in the same
rette lighter, and climate controls. mode it was in when the ignition was turned off.
The lightbar and instrument gauges are located be-
hind the steering wheel. Ignition Switch
NOTE: Control locations may vary from those The ignition switch has four positions: OFF, ACCES-
shown depending on vehicle options. SORY, ON, and START. See Fig. 4.4.
Figure 4.1 shows typical lower dash panel controls;
figure 4.2 shows typical upper dash panel controls
1 2 3 4 5 6 7 8 9 10
20
16 17 18 19
21
06/06/2001
11 12 13 14 15 f610499
1. Headlights 8. Wipers On/Intermittent 15. Suspension Height
2. Dash Lights 9. Wipers High/Low 16. Engine Brake
3. Clearance Lights 10. Windshield Washer 17. Engine Brake Speed
4. Trailer Clearance Lights 11. Interaxle Lock 18. Engine Brake Speed
5. Driving Lights 12. Differential Lock 19. Blank
6. Backup Lights (sometimes labeled 13. Lift Axle 20. Parking Brake Control Valve
Hook Up Lights) 14. Fifth Wheel Slide Control 21. Trailer Air Supply Valve
7. Fog Lights
Fig. 4.1, Lower Dash Control Panel
4.1
Driver Controls
1 2 3 4 5 6
8 9 10 11
10/30/2006 f610560a
1. Cruise Control On/Off 4. Engine Fan 8. Mirror Defog
2. Cruise Control Set/Decelerate 5. Engine Diagnosis (EPA07 only) 9. Driver-Side Mirror Adjust
Resume/Accelerate 6. Idle Speed 10. Passenger-Side Mirror Adjust
3. Request/Inhibit Regen 7. DataStar 11. Power Window
Fig. 4.2, Upper Dash Control Panel
In the OFF position, the key slot is vertical. The key

can be inserted and removed only in the OFF posi-
tion.
The following functions are operable when the igni-
SET CONTRAST: 52% tion switch is in the OFF position (regardless of
MORE LESS whether the key is inserted):
• high-beam headlights
• taillights
05/26/2009 f545540 • brake lights

• road lights
Fig. 4.3, DataStar LCD Display Module
• dome lights
• clearance lights
• turn signals
• hazard warning lights
2
• utility and baggage lights
• spotlights
• electric horn
• clock
• refrigerator
1
05/07/2001 f610492 • television
1. Ignition Switch 2. Cigarette Lighter
Fig. 4.4, Ignition Switch and Cigarette Lighter
4.2
Driver Controls
Turn the key counterclockwise to the ACCESSORY

position. In addition to all the functions that are oper-
able with the ignition switch in the OFF position, the
following functions are operable when the switch is in 6 5
the ACCESSORY position:
5
• radio/stereo system
• heater and A/C fan
• mirror defog
• windshield wipers
• beacons 4 7 7
3
• power windows
• windshield washer
• outside air temperature display
Turn the key clockwise past the OFF position to the
ON position. With the switch in the ON position, the
warning and indicator lamps illuminate. Wait for three
1
seconds before starting the engine. 2
02/08/2005 f544575
Turn the key clockwise past the ON position to the 1. Fog Light 5. Clearance Light
START position and start the engine. Do not operate 2. Road Light 6. Identification Lights
the starter longer than thirty seconds, and wait at 3. Dual Headlights 7. Clearance Light
least two minutes between starting attempts to allow 4. Turn Signal/Side-
the starter to cool. Release the key the moment the Marker Lights
engine starts.
Fig. 4.5, Exterior Lights
Switching on the ignition and releasing the parking
brake automatically activates the daytime running Backup Lights
lights, if equipped. The daytime running lights will
operate until the parking brake is applied or the NOTE: Depending on the mounting, backup
headlights are turned on. lights are sometimes referred to as hook-up
lights.
Lighting Controls Backup lights activate only when the vehicle is in re-
verse, and are designed to be used while backing up
IMPORTANT: Unless otherwise noted below,
at night.
press the upper half of the switch to activate the
desired light(s). Press the lower half of the Clearance Lights
switch to turn the light(s) off.
Press the upper half of the clearance lights switch to
Exterior Light Controls activate all clearance lamps including back-of-sleeper
and mirrors.
Exterior light controls are listed here in alphabetical
order. See Fig. 4.5 for exterior light locations. At the Driving Lights
rear of the vehicle there are taillights, brake lights
Driving lights are designed to extend the range of the
with turn signals, backup lights, and optional utility
high-beam headlights, and can only be activated
lights.
when the headlight high-beams are on. When head-
See Fig. 4.6 for exterior and interior light switches. lights are dimmed, the driving lights automatically
turn off.
4.3
Driver Controls
1 2 3 4 5
HEAD CL / ID DRIVING FOG BACKUP

LIGHTS LIGHTS LIGHTS LIGHTS LIGHTS
TRAILER
DASH SLEEPER
CL / ID
HEAD LT.
LIGHTS LIGHTS INTERRUPT
LIGHTS
9 8 7 6
08/22/2011 f545815
1. Headlights Switch 5. Backup Lights Switch (sometimes 7. Trailer Clearance Lights Switch
2. Tractor Clearance Lights Switch labeled Hook Up Lights) 8. Sleeper Lights Switch
3. Driving Lights Switch 6. Headlight Interrupt Switch 9. Dash Lights Switch
4. Fog Lights Switch
Fig. 4.6, Exterior and Interior Light Switches
Fog Lights Headlight Interrupt

Fog lights are designed to reduce glare in foggy con- When the headlight interrupt switch is activated, the
ditions. The headlights must be on and set on low daytime running lights blink. The headlight interrupt
beam for the fog lights to activate. switch only operates when the headlights are on.
Hazard Warning Lights Headlights

The hazard flasher switch is located underneath the The headlight switch is operated by pushing the
turn signal lever, as shown in Fig. 4.7. Pull the haz- upper half of the switch once for the parking lights,
ard light switch tab out to activate all of the turn sig- illuminating the taillights and side marker lamps on
nal lights and both of the telltales on the lightbar will both the tractor and trailer. Pressing the upper half of
flash. To cancel the hazard lights, move the turn sig- the switch a second time activates the headlights. An
nal lever up or down. audible warning will sound if the lights are left on
when the ignition is turned off.
Western Star vehicles may be equipped with an op-
tional hazard light switch located on the right-hand High-Beam Headlights
dash panel. To operate the hazard lights, press the
upper half of the switch. To cancel the hazard lights, With the low-beam headlights on, push the button on
press the lower half of the switch. the end of the turn-signal lever to turn on the high-
beam headlights. See Fig. 4.7. Push the button
again to turn the high-beams off.
4.4
Driver Controls
Interior Light Controls

5 The cab is equipped with a dome light and optional
high-intensity reading lights. The sleeper section is
equipped with accessory lights and high-intensity
reading lights. Baggage compartments may be
6 equipped with accessory lights.
When the panel lights are on, most switch icons are
backlit with a colored light to allow the driver to find
switches more easily in the dark. When a switch is
activated, the lightbar on the switch is backlit with a
colored light.
Dash Lights
4 The dash lights switch is operated by pushing the
3 upper half of the switch and holding to obtain the
2
brightness desired. Pushing and holding the lower
half of the switch will dim the dash lights.
05/07/2001 1 f610493
1. Tilt/Telescopic Steering Column Lever Overhead Console Lights
2. Hazard Warning Light Tab
3. Turn Signal Lever In cabs with an overhead console, there is an op-
4. High-Beam Headlight Switch tional overhead light assembly containing a diffuse
5. Electric Horn dome light and clear reading lights.
6. Trailer Brake Hand Control Valve Lever
Fig. 4.7, Steering Column-Mounted Controls
Rear Dome Light
The standard rear dome light is installed on the back
When the high-beam headlights are on, a blue light of the cab above the rear window.
illuminates on the lightbar.
Trailer Clearance Lights Horn Controls

The trailer clearance lights switch activates the trailer Air Horn
clearance lamps independent of the tractor lamps.
The air horn is controlled by a wire lanyard hanging
Turn Signals from the center of the overhead console. Pull down-
ward on the lanyard to sound the air horn.
The turn-signal switch is typically a non-canceling
combination turn-signal, hazard, and headlight- Electric Horn
dimmer unit that mounts to a bracket on the left side
of the steering column. See Fig. 4.7. The electric horn button is located in the center of
the steering wheel. See Fig. 4.7. To sound the horn,
Moving the turn signal switch down turns on the left- press down on the button. The horn will sound as
turn signal; moving it up turns on the right-turn sig- long as the button is pressed, up to 60 seconds.
nal. To manually cancel the signal, move the lever to
the neutral position.
When a turn signal is activated, a green telltale light
flashes on the lightbar.
On a self-canceling turn signal switch, the switch au-
tomatically returns to the neutral position when the
steering wheel returns to the straight ahead position
after a turn.
4.5
Driver Controls
Powertrain Controls Axle Switches

Aftertreatment System Regen Axle switch controls are listed here in alphabetical
order.
Switches
NOTE: See Chapter 16 for detailed information
about axle switch functions.
about the operation of the regeneration (regen)
switches and the aftertreatment system (ATS). Differential Lock Switch
The regen request switch is used to initiate a parked
regen. See Fig. 4.8.
Some vehicles may be equipped with an optional
regen request/inhibit switch; see Fig. 4.9. To request
a parked regen, press the upper half of the switch.
To stop a regen in progress or prevent the start of a
regen, press the lower half of the switch. Regen will
not occur until the switch is no longer active.
07/22/2011 f545803
Fig. 4.10, Forward Drive Axle Differential Lock Switch
08/02/2011 f610852a
Fig. 4.8, Regen Request Switch
07/22/2011 f545804
Fig. 4.11, Rear Drive Axle Differential Lock Switch
The differential lock switch, as shown in Fig. 4.10 or

Fig. 4.11, provides maximum traction for slippery
conditions by forcing the wheels on each drive axle
governed by the switch to rotate together. Engage-
11/01/2006 f610852
ment can be at any speed, provided the wheels are
Fig. 4.9, Regen Request/Inhibit Switch not slipping or spinning.
4.6
Driver Controls
Interaxle Lock Switch

The interaxle lock switch allows the driver to lock the
drive axles together, causing the drive axle shafts to
rotate together. See Fig. 4.12. Use this feature only
under adverse road conditions where greater traction
is needed.
LIFT
AXLE
08/22/2011 f545817
Fig. 4.13, Lift Axle Switch
Cruise Control Switches

about cruise control operation.
07/22/2011 f545802
On/Off Switch
Press the upper half of the cruise control on/off
Fig. 4.12, Interaxle Lock Switch switch to activate it. See Fig. 4.14.
Leave the control in the UNLOCK position for normal
highway operation. When a spinning or slipping ac-
tion occurs at any of the drive wheels, press the
upper half of the switch to LOCK the differential and
prevent the wheels from spinning.
NOTICE SET/DECEL
CRUISE
Do not shift into LOCK while the rear wheels are CONTROL
spinning. Come to a halt before engaging to pre- RES/ACCEL
vent damage to the interaxle and main differen-
tials.
Do not permit rear wheels to spin freely for more
than ten seconds when traction is lost. Shift into 07/15/2011 f545790
LOCK to prevent damage to the interaxle and
main differentials. 1. Cruise Control On/Off Switch
2. Cruise Control Set/Resume Switch
Lift Axle Switch Fig. 4.14, Cruise Control Switches
The lift axle switch controls the lift axle operation.
NOTE: Cruise control is canceled if the brake or
See Fig. 4.13. Pushing the upper half of the switch
will lower the lift axle. clutch pedal is depressed, or engine speed
drops below 1200 rpm.
4.7
Driver Controls
Set/Decelerate/Resume/Accelerate Switch
The set/decelerate/resume/accelerate switch can
only be used when cruise control has been activated.
See Fig. 4.14.
M
Press the upper half of the switch momentarily to set
the cruise speed (with the engine running at the de- HIGH
sired speed). Press and hold the upper half of the ENGINE
BRAKE MED
switch to decelerate slowly. Release the switch when
LOW
the desired speed is reached.
Press the lower half of the switch momentarily to re-
sume the previously set cruise speed. Press the
lower half of the switch and hold to accelerate slowly.
Release the switch when the desired speed is 07/15/2011 f545791
achieved. 1. Engine Brake On/Off
2. Engine Brake Intensity Switch
NOTICE Fig. 4.15, Engine Brake Switches
When the cruise control is engaged, do not at-
tempt to shift gears without using the clutch Engine Diagnostic Switch (EPA07
pedal. Failure to follow this precaution will result vehicles)
in a temporarily uncontrolled increase in engine
speed. Transmission damage and gear stripping The engine diagnostic switch is used to signal the
could result. engine ECM to flash codes on the indicator light.
Press the upper half of the switch once to activate it.
Engine Brake Switches See Fig. 4.16.

about engine brake operation.
Whenever vehicle braking is required on good road
conditions, the engine brake may be used in con-
junction with the service brakes. There is no time
limit for operation of the engine brake. However, an
engine brake does not provide the precise control of, ENGINE
and is not a substitute for, service brakes. DIAGN
Two dash-mounted switches control the engine
brake:
• The ENGINE BRAKE switch is used to turn the
engine brake on and off. See Fig. 4.15. 08/22/2011 f545819
• The HIGH/MED/LOW engine brake intensity
Fig. 4.16, Engine Diagnostic Switch
switch (HIGH/LOW in some cases) controls the
amount of engine braking. When the engine
brake is on, the status bar illuminates, indicat- Engine Fan Switch
ing the current intensity setting. Press the upper half of the engine fan switch to over-
ride the automatic fan control and cause the engine
fan to run continuously. See Fig. 4.17. This switch is
intended for temporary use, or if the automatic fan
control fails. Press the lower half of the switch to re-
turn to automatic fan control.
4.8
Driver Controls
ENGINE ENGINE
FAN BRAKE
08/22/2011 f545818
07/18/2011 f545792
Fig. 4.17, Engine Fan Switch
Fig. 4.18, Exhaust Brake Switch
Exhaust Brake Switch
about exhaust brake operation.
An exhaust brake is an optional auxiliary braking sys-
tem that assists but does not replace the service
brake system on vehicles with Cummins engines.
The exhaust brake may be used in conjunction with IDLE
the service brakes in off-highway and mountain driv- SPEED
ing as well as in traffic or high-speed highway driv-
ing. Exhaust brakes are not intended for use as the
primary braking system during vehicle operation.
To turn the exhaust brake on, press the upper half of
the rocker switch. See Fig. 4.18. 08/22/2011 f545820
The exhaust brake turns itself off automatically. In Fig. 4.19, Idle Speed Switch (Cummins engines)
addition, depressing the accelerator or clutch pedal
deactivates the exhaust brake. The ABS, when ac- 2. Press the PTO switch. See Fig. 4.20. When the
tive, also deactivates the exhaust brake. light is steadily illuminated, the PTO is engaged
and ready to operate. In stationary mode, the
Idle Speed Switch vehicle must remain in neutral with the parking
brake set.
The idle speed switch may be installed on vehicles
with Cummins engines to change the idle speed of 3. To activate the mobile mode, shift from neutral to
the engine. See Fig. 4.19. reverse, 1st, or 2nd gear. The clutch will open
and the PTO will disengage for a moment.
Power Takeoff Controls 4. Touch the accelerator pedal to close the clutch
Engine power takeoffs (PTO) are devices used to tap and engage the PTO in mobile mode. The PTO
into engine power to run auxiliary devices, such as may be operated with the transmission in re-
hydraulic pumps that power additional equipment. verse, neutral, 1st, or 2nd gear only.
The following instructions are general guidelines for NOTE: Do not attempt to change gears while
operating a PTO. the vehicle is moving. The transmission will ig-
1. Set the parking brake and put the transmission in nore the request.
neutral.
4.9
Driver Controls
Eaton Fuller automated transmissions use a shift se-

lection module. See Fig. 4.21. Shifts can be made
automatically, or manually using the shift selection
ON module.
PTO 3 PTO
R 4
OFF N 5
08/22/2011 f545816 SERVICE

2
D 6
Fig. 4.20, PTO Switch
5. MANUAL 7
To end the mobile mode, bring the vehicle to a
stop. The clutch will open and shut down power 1 SHIFT
to the PTO. LOW 8
6. To resume stationary mode, shift to neutral. The EATON FULLER
TRANSMISSIONS
PTO will engage.
7. To end stationary mode, press the dash switch. 07/20/2011 f611129
When the light in the switch goes out, power to 1. Upshift/Downshift Buttons
the PTO is shut off. 2. Service Needed Indicator
3. PTO Activation Button
Transmission Controls 4. Reverse Mode Button
5. Neutral Button
Manual Transmissions 6. Drive Mode Button
7. Manual Mode Selector
NOTE: See Chapter 14 for complete manual 8. Low Mode Button
transmission operating instructions.
Fig. 4.21, Shift Selection Module, UltraShift and
if equipped, the transmission range control and split- AutoShift Transmissions
ter valves are attached to the gear shift knob.
The current gear is displayed on the gear indicator.
To operate a range-shift transmission, move the shift
At the start of a shift, the current gear continues to
knob through all the low-range gear positions and
display until the transmission has been pulled into
then pull the range-preselection lever up to move into
neutral. As the transmission is synchronizing for the
the high-range ratios. Use the same shift knob posi-
new (target) gear, the gear indicator flashes the num-
tions in both the low and high ranges.
ber of the target gear. When the shift is complete,
Dependent on the transmission model, some ratios the gear indicator displays the new gear, without
can be split using the splitter-control button (located flashing.
on the side of the shift knob).
Allison Automatic Transmissions
Eaton Automated Transmissions
NOTE: See Chapter 15 for complete automatic
NOTE: See Chapter 15 for complete automated transmission operating instructions.
transmission operating instructions.
HD-series automatic transmissions have six forward
speeds and one reverse speed. These transmissions
4.10
Driver Controls
have electronic shift controls that can be pro- To turn the windshield wipers on at a constant speed,
grammed to allow the use of different numbers of press the upper half of the ON–WIPER–INT DELAY
geared speeds. See Fig. 4.22. switch. Press the upper half of the HIGH/LOW switch
to select high speed; press the lower of the HIGH/
LOW switch to select low speed.
To turn the windshield wipers off, move the ON–
WIPER–INT DELAY switch to the middle (WIPER)
position.
1 To turn the windshield wipers on intermittently, press
the lower half of the ON–WIPER–INT DELAY switch.
2
The default intermittent interval is six seconds.
The interval can be changed by turning the wipers off
for a specific period of time, then pressing the lower
half of the ON-WIPER-INT DELAY switch again to
activate the desired interval. See Table 4.1 for
settings.
Setting Intermittent Wiper Operation

Switch Off Interval Wiper Interval
Less than 1 second 1 second
10/31/94 f600369a Interval set to the period switch
1 to 25 seconds is in the Off position (1 to 25
1. Indicator Panel 2. MODE ID Lamp seconds)
Fig. 4.22, Allison Shift Selector 25 to 50 seconds 25 seconds
More than 50 seconds 6 seconds
Windshield Wiper Controls Table 4.1, Setting Intermittent Wiper Operation
The windshield wipers are operated by two rocker
switches located on the lower right-hand dash control The windshield washers are operated by a rocker
panel. See Fig. 4.23. The 3-position ON–WIPER– switch labeled WASHER, located on the lower right-
INT DELAY switch turns the wipers on and off, and hand dash control panel. See Fig. 4.23. Press and
controls intermittent wiper operation. The HIGH/LOW hold the upper half of the washer switch to spray the
switch controls constant speed wiper operation. windshield. Release the switch when enough washer
fluid has been sprayed on the windshield.
Brake Controls
about brake systems.
ON HIGH Parking Brake Control Valve

WASHER
−WIPER− The parking brake control valve applies both the trac-
LOW
INT DELAY tor and trailer spring parking brakes. See Fig. 4.24,
Item 2. Pushing the knob in releases the spring park-
ing brakes.
If the trailer is not equipped with spring parking
08/23/2011 f545824
brakes, pulling out the parking brake valve applies
the tractor parking brakes and the trailer service
Fig. 4.23, Windshield Wiper Switches brakes.
4.11
Driver Controls
on the right-hand control panel. See Fig. 4.25.

Pressing the switch will temporarily allow more drive
1 wheel spin. Pressing the switch again will cause the
2
system to go back to normal operation.
03/10/99 f610291
1. Trailer Air Supply Valve (red knob)
2. Parking Brake Control Valve (yellow knob)
Fig. 4.24, Brake Valve Knobs
Trailer Air Supply Valve

The trailer air supply valve charges the trailer air
supply system and releases the trailer spring parking
brakes. See Fig. 4.24, Item 1.
Pull the trailer air supply valve out before disconnect- 05/15/2001 f610494
ing a trailer or when operating a vehicle without a
trailer. Fig. 4.25, ATC Switch
Trailer Brake Lever NOTICE

The trailer brake lever, located on the right-hand side
of the steering column is used for applying the trailer The ATC option is intended to be used under
service brakes without applying the truck or tractor specific slippery conditions that require momen-
service brakes. See Fig. 4.7, Item 6. The valve can tary increased wheel spin. Using this option for
be partially or fully applied, but in any partially-on an extended period of time may damage the ve-
position it will be overridden by a full application of hicle brake system.
the service brake pedal. Moving the lever down ap-
plies the trailer brakes, while moving it up releases Adjustable Steering Column
the trailer brakes. The lever will automatically return
to the up position when it is released. Controls
Adjust the seat to the desired ride position, then tilt
Antilock Braking System or telescope the steering column as needed using
The Meritor WABCO® Antilock Braking System the steering column lever in Fig. 4.7.
(ABS) controls wheel speed during emergency stops To tilt the steering column, pull the lever up toward
or wheel lock situations. the driver. Tilt the wheel to the desired position and
During emergency or reduced-traction stops, fully release the lever.
depress the brake pedal until the vehicle comes to a To telescope the steering column, push the lever
safe stop. Do not pump the brake pedal. With the down (away from the driver) and pull or push the
brake pedal fully depressed, the ABS will control all steering wheel to the desired position. Release the
wheels to provide steering control and a reduced lever to lock the steering column in place.
braking distance.
Vehicles with ABS may have Automatic Traction Con-
trol (ATC). The ATC system automatically limits
wheel spin during reduced-traction situations. If the
vehicle has ATC, there will be an ATC switch located
4.12
Driver Controls
sion will not absorb road shocks and compo-

WARNING nents may be damaged.
Make sure that the control lever is back in the To lower the rear of the vehicle, press the upper half
neutral position and the steering column is of the rocker momentarily. To raise the suspension to
locked before driving the vehicle. Never tilt the its normal height, press the lower half of the switch.
column while driving the vehicle. Doing so could
cause loss of vehicle control, personal injury, Fifth Wheel Slide Control Switch
and property damage.
NOTICE
Suspension/Trailer Connection
Do not activate the fifth wheel slide control valve
Controls while the vehicle is in motion. To do so could
cause damage to the fifth wheel member, the
Air-Suspension Dump Control Switch kingpin, the cab or trailer, and ultimately to the
drivetrain.
NOTICE The fifth wheel air slide switch permits repositioning
of the sliding fifth wheel from inside the cab. See
Do not operate the vehicle over uneven ground
Fig. 4.27. Moving the air slide control valve switch to
such as ramps, speed bumps, curbs, etc., with
the lock position deactivates the control valve and
the air springs deflated. Doing this may lead to
locks the fifth wheel to the baseplate. Moving the
air bag separation from the piston, preventing the
switch to the unlock position activates the control
suspension air springs from inflating.
valve and unlocks the fifth wheel slide mechanism,
The suspension dump switch allows the air in the air allowing changes to the total length of the tractor-
suspension to be quickly exhausted, lowering the trailer and changes to axle loads to comply with vary-
rear of the vehicle. Fig. 4.26. This makes it easier to ing jurisdictional laws. For detailed operating instruc-
connect to, or disconnect from, a trailer. tions for fifth wheel slide, coupling, and uncoupling
procedures, refer to Chapter 17.
07/22/2011 f545805
07/22/2011 f545806
Fig. 4.26, Air-Suspension Dump Switch
Fig. 4.27, Fifth Wheel Slide Control Switch
NOTICE Climate Controls
Never exhaust air from the suspension while NOTE: See Chapter 5 for detailed climate con-
driving. When the air is exhausted, the suspen- trol panel operating instructions.
4.13
Driver Controls
The climate control panel allows you to control the • Isolator: This feature reduces the amount of
heating, ventilating, defrosting, and air conditioning road shock by isolating the occupant from the
functions. Western Star vehicles have several heater motion of the vehicle, and allowing the upper
and air conditioner options. seat to move in a simple pendulum motion. A
lockout feature is used whenever the isolator is
Options for the cab include:
not desired.
• heater only
• Height Adjustment: This adjustment moves
• heater and air conditioner the entire seat up or down. The adjustment is
either manually- or air-controlled, depending on
• heater and air conditioner with automatic tem- the make of the seat.
perature control (ATC)
• Bottom Cushion Angle (fore-and-aft bottom
Options for a sleeper unit include: cushion height): This adjustment enables the
• no heater or air conditioner occupant to raise or lower the front or back of
the bottom cushion. This adjustment is easier
• heater only to perform when all weight is removed from the
• heater and air conditioner seat.
• heater and air conditioner with ATC • Fore-and-Aft Seat Slide (seat track adjust-
ment): This adjustment moves the entire seat
The ATC feature automatically controls the heating forward or backward on its track.
and cooling system to maintain the cab and sleeper
air temperature close to the temperature set by the • Seat Tilt: This adjustment allows the seat as-
user. The ATC adjusts the air temperature blown sembly (back and bottom cushions) to tilt for-
through the air outlets to maintain the selected tem- ward or backward.
perature. • Headrest Adjustment: This adjustment
changes the angle of the upper part of the
Seat Controls backrest to provide head and upper back
support.
about seat controls and adjustments.
WARNING
Keep hands, tools, and other objects away from
the scissor points under the seats. Failure to do
so could cause personal injury.
The following is a description of adjustments that can
be made to various Western Star seats. Not all seats
have all of the adjustments listed below. See
Fig. 4.28.
• Backrest Tilt: This adjustment enables the
backrest to pivot forward or backward.
• Lumbar Support: Lumbar support changes
the shape of the backrest to give more or less
support to the occupant’s lumbar (lower back)
area. This adjustment is either mechanical or
air controlled, depending on make and model
of the seat.
4.14
Driver Controls
1
3 4
2
8
6 7
5
10/26/2000 f910149a
1. Backrest Tilt 5. Bottom Cushion Angle (fore-and- 7. Seat Tilt
2. Lumbar Support aft cushion height) 8. Headrest Adjustment
3. Isolator 6. Fore-and-Aft Seat Slide (seat
4. Height Adjustment track adjustment)
Fig. 4.28, General Seat Adjustments
4.15
5
Climate Controls
Climate Control Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1
Cab Climate Control Panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1
Sleeper Climate Control Panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.4
Climate Controls
Climate Control Options On vehicles equipped with ATC, the AUTO setting on
the fan switch places the heater and air conditioner
The climate control panel allows you to control the system in the automatic fan speed control mode.
heating, ventilating, defrosting, and air conditioning When the fan switch is set to AUTO, the fan speed
functions. Western Star vehicles have several heater will vary as necessary to maintain the temperature
and air conditioner options. set by the user.
Options for the cab include: Temperature Control Switch
• heater only To select the desired temperature:
• heater and air conditioner • Vehicles Without ATC: Turn the switch to the
• heater and air conditioner with automatic tem- left (counterclockwise) for cool air, or to the
perature control (ATC) right (clockwise) for hot air.
Options for a sleeper unit include: • Vehicles With ATC: Press and release the right
side of the temperature up/down switch to in-
• no heater or air conditioner crease the temperature to the desired setting.
• heater only Press and release the left side of the tempera-
ture up/down switch to decrease the tempera-
• heater and air conditioner ture to the desired setting. Press and hold the
• heater and air conditioner with ATC temperature up/down switch to change the de-
sired temperature in large increments.
The ATC feature automatically controls the heating
and cooling system to maintain the cab and sleeper Mode Control Switch
air temperature close to the temperature set by the
user. The ATC adjusts the air temperature blown The mode control switch allows the driver to control
through the air outlets to maintain the selected tem- the flow of air through the face outlets, the floor out-
perature. lets, the defrost (windshield) outlets, or a combination
of these outlets to provide six air selection modes.
See Fig. 5.3.
Cab Climate Control Panels
• Face Mode (using recirculating air): Directs all
The standard cab climate control panel has a fan airflow through the face or instrument panel
switch, a temperature control switch, and a mode outlets, using recirculated air.
control switch that allows the driver to control heat-
ing, cooling, defrosting, and ventilating. The control • Face Mode (using fresh air): Directs all airflow
panel may also be equipped with an optional A/C through the face or instrument panel outlets,
switch and/or an optional BUNK switch. See Fig. 5.1. using fresh air.
Vehicles equipped with ATC have an LED display. • Bi-Level Mode: Directs the airflow equally to
See Fig. 5.2. the face outlets and the floor outlets.
• Floor Mode: Directs all airflow through the floor
Controls outlets.
Fan Switch • Floor/Defrost Mode: Directs the airflow equally
to the floor outlets and the defrost outlets.
The fan switch activates the fan, which forces fresh
air or recirculated air through the air outlets. The fan • Defrost Mode: Directs all airflow through the
switch has four fan speed settings and an off posi- defrost outlets.
tion. See Fig. 5.1.
NOTE: The face mode using recirculating air is
To operate the fan switch, turn the fan switch clock- the only mode that recirculates the air in the
wise to increase airflow; turn the fan switch counter- cab. All other modes draw in fresh air from out-
clockwise to decrease airflow. side the vehicle.
5.1
Climate Controls
2 3 4
BUNK A/C
02/10/2003 7 6 5 f610640
1. Fan Off Position 4. Mode Control Switch 6. Bunk Switch
2. Fan Switch 5. Air Conditioner Switch 7. Indicator
3. Temperature Control Switch
Fig. 5.1, Cab Climate Control Panel, No ATC
Automatic Temperature Control
6 5 4
12/13/2002 f610628
1. Fan Off Position 3. Mode Control Switch 5. Temperature Up/Down Switch
2. LED Display 4. Bunk Switch (optional) 6. Fan Switch
Fig. 5.2, Cab Climate Control Panel With ATC
Bunk Switch conditioner can still be controlled from the sleeper

when the BUNK switch is on.
The optional BUNK switch allows the driver to control
the sleeper heater and air conditioner from the cab. Air Conditioner (A/C) Switch
Press the BUNK switch to turn the sleeper heater
and air conditioner on. When the bunk switch is on, The air conditioner cools and dehumidifies the air
the indicator light is on. The sleeper heater and air inside the cab. Press the optional A/C switch to turn
5.2
Climate Controls
ing the right side of the temperature up/down switch

3 4 for five seconds. The current error status will be
5
shown on the LED display. Press the right side of the
2
temperature up/down switch again repeatedly to
6
scroll the display through any existing error codes. If
an error code is displayed, contact your Western Star
1 dealer for service.
Modes
Recirculation Mode
02/06/2003 f610641 WARNING

1. Face Mode (recirculating air)
2. Face Mode (fresh air) Do not use the recirculation mode when the
3. Bi-Level Mode heater is on and the vehicle is in motion. Driving
4. Floor Mode with the recirculation mode on while the heater is
5. Floor and Defrost Mode on may cause the windows to be obscured by
6. Defrost Mode moisture or ice, which could result in an accident
possibly causing personal injury or property
Fig. 5.3, Mode Control Switch Settings
damage.
the air conditioner on or off. When the air conditioner Do not use the recirculation mode for more than
is on, the A/C switch illuminates. 20 minutes at a time because the air inside the
IMPORTANT: Operate the air conditioner at cab may become stuffy and the windows may
become obscured by moisture, which could re-
least five minutes each month, even during cool
sult in an accident possibly causing personal in-
weather. This helps prevent drying and cracking jury or property damage.
of the refrigerant compressor seals and reduces
the chance of refrigerant leaks in the system. When the mode control switch (see Fig. 5.3) is
turned to the face mode using recirculating air, the
LED Display, Vehicles With ATC Only air in the cab is recirculated through the heater and
air conditioner system. This is the only mode that
The LED display shows the temperature to which the uses recirculated air. Fresh air, or outside air, is cir-
heater or air conditioner has been set in degrees culated through the heating and air conditioning sys-
Fahrenheit or degrees Celsius. tem when any other mode is selected.
Changing Temperature Units The recirculation mode can be used to prevent dusty
or smoky air from entering the cab, or to decrease
The temperature units can be changed from Fahren- the time required to cool or heat the cab interior dur-
heit (°F) to Celsius (°C) or from Celsius to Fahrenheit ing extreme outside temperature conditions. When
by turning the ignition on, turning the fan switch off, the outside air is clear or the desired cab tempera-
and pressing and holding the left side of the tem- ture is reached, change the mode control switch to a
perature up/down switch for five seconds. The cur- fresh-air mode. The recirculation mode can be used
rent temperature unit will then be shown on the LED when the air conditioner is on whether the vehicle is
display. Press the left side of the temperature up/ moving or not.
down switch again to toggle between °F and °C.
Changing the temperature units on the cab climate Defrost Mode
control panel will also effect the sleeper climate con-
trol panel. The defrost mode is used to deice, defrost, or defog
the windows.
Error Codes
NOTE: When the defrost mode is on, the air
Error codes can be displayed by turning the ignition conditioner is on. The air conditioner is used to
on, turning the fan switch off, and pressing and hold-
5.3
Climate Controls
dehumidify the air entering the cab and to re- Temperature Control Switch
move the moisture from the windshield.
To select the desired temperature, turn the switch to
the left (counterclockwise) for cool air, or to the right
Sleeper Climate Control Panels (clockwise) for hot air.
The standard sleeper climate control panel has a fan Air Conditioner (A/C) Switch
switch, a temperature control switch, and a power
switch that allow you to control the heating and air The air conditioner cools and dehumidifies the air
conditioning functions in the sleeper. A vehicle with inside the sleeper. Press the optional A/C switch to
an air conditioner has an air conditioner switch on turn the air conditioner on or off.
the control panel. See Fig. 5.4.
Vehicles with ATC have button controls instead of
Controls, Vehicles With ATC
switch controls. See Fig. 5.5. The controls for the sleeper heater and air condi-
tioner are located on the right side of the ATC
Controls, Vehicles Without ATC sleeper control panel. See Fig. 5.5.
Power Switch and Indicator Power Switch and Indicator
The power switch is used to turn the sleeper heater
Turn the sleeper heater and air conditioner on by
and air conditioner on and off. When the heater or air
pressing the ON button. The current set temperature
conditioner is on, the indicator illuminates.
is displayed for five seconds, after which it returns to
the time display. When the heater or air conditioner
Fan Switch is on, the indicator illuminates. To turn the sleeper
The fan switch controls the fan speed and forces air heater and air conditioner off, press the OFF button.
through the air outlets. The fan switch has three
speed settings and an off position. See Fig. 5.4. Fan Switch
To operate the fan switch, turn the switch clockwise To operate the fan switch, press the fan up or fan
to increase airflow; turn the fan switch counterclock- down button repeatedly to incrementally increase or
wise to decrease airflow. decrease the fan speed. Press either button for at
1 2 3
02/11/2003
5 4 f610642
1. Fan Switch 3. Indicator 5. Air Conditioner Switch
2. Power Switch 4. Temperature Control Switch
Fig. 5.4, Sleeper Climate Control Panel, No ATC
5.4
Climate Controls
2 3 4 5
6
ON
PM
ALARM TIME OFF

1
7
SET − DISP SET + AUTO
Automatic Temperature Control
10 9 8
01/14/2003 f610629
1. Alarm Button 6. Temperature Up Button
2. Time Button 7. Temperature Down Button
3. Fan Up Button 8. Automatic Fan Button
4. Heater and Air Conditioner On Button 9. Fan Down Button
5. Heater and Air Conditioner Off Button 10. Display Button
Fig. 5.5, Sleeper Climate Control Panel With ATC
least two seconds to continuously increase or de- perature. The temperature setting is displayed on the
crease the fan speed. The fan speed setting is dis- sleeper control panel. The display returns to the time
played on the sleeper control panel in 10 percent display five seconds after a temperature up/down
increments. When the highest or lowest fan speed is button is pressed and released.
selected, HI or LO is displayed. The display returns
The temperature units can be changed from °F to °C
to the time display five seconds after a fan up/down
or from °C to °F by pressing the temperature up and
button is pressed and released.
temperature down buttons simultaneously. Changing
In the ATC mode, fan speed is determined by the the temperature units on the ATC sleeper control
system as required. The fan speed is based on the panel will also change the temperature units on the
difference between the set point temperature and the ATC cab control panel.
actual sleeper cab temperature. The greater the dif-
ference, the greater the fan speed. The AUTO fan Auto Button
function is disabled when either the fan up or fan
Press the AUTO button to enable automatic control
down button is pressed.
of the fan speed. The display will show the current
Temperature Control Switch set temperature for five seconds, then return to the
time display. When in the automatic mode, the fan
Temperature is displayed with a three-digit annotation speed can vary to maintain the temperature set by
and can be displayed either in degrees Celsius or the user. When automatic control is turned on, the
degrees Fahrenheit. A capital "C" or "F" is displayed indicator above the AUTO button illuminates.
for the appropriate temperature scale.
Alarm Button
To select the desired temperature, press the tem-
perature up or temperature down button repeatedly Momentarily press the ALARM button to turn the
to incrementally increase or decrease the set tem- alarm on and to illuminate the alarm indicator above
perature. Press either button for at least two seconds the ALARM button. Momentarily press the button
to continuously increase or decrease the set tem- again to deactivate the alarm.
5.5
Climate Controls
When pressing the ALARM button, the display shows be off. All clock functions, including the alarm, will
the alarm time setting for five seconds before return- continue to work internally.
ing to the current time display. If the ALARM button
is pressed and held down continuously for more than Temperature Slave Mode Feature
one second, the alarm time setting can be viewed
The temperature slave mode allows the set tempera-
without changing the state of the alarm indicator. If
ture of the cab heater and air conditioner to be auto-
either the SET+ or SET– buttons are pressed simul-
matically tied to the sleeper heater and air condi-
taneously with the ALARM button held down, the
tioner. In this mode, the set temperature in the
alarm time setting will increase or decrease. When
vehicle will be the same whether the set temperature
the ALARM button is released after changing the
is changed on the cab climate control panel or the
alarm time, the alarm will be turned on and the indi-
sleeper climate control panel. To enable the tempera-
cator will be illuminated. When the ALARM is sound-
ture slave mode, press the SET+ and SET– buttons
ing, press the ALARM button to turn the alarm off
simultaneously. The display will read S–ON when the
and to reset the alarm for the next 24-hour cycle.
temperature slave mode is enabled.
To set the snooze function, press any button on the
To disable the temperature slave mode, press the
control panel, except the ALARM button, when the
SET+ and SET– buttons simultaneously. The display
alarm is sounding. The alarm will sound again after
will read S–OFF indicating that the temperature slave
seven minutes. The alarm indicator flashes when the
mode is disabled. When disabled, the temperatures
snooze function is set.
for the cab and sleeper can be changed indepen-
To cancel the snooze function, press the ALARM but- dently for separate temperature control. If you wish
ton. This will also reset the alarm for the next 24- to maintain a temperature in the sleeper that is differ-
hour cycle. ent than the temperature in the front of the cab, it is
recommended that a curtain be used between the
Time Button sleeper and the front of the cab.
The clock controls are located on the left side of the Turning on the Sleeper Air Conditioner
ATC sleeper control panel under the display. The dis-
play will show the clock time as the default mode. When the Cab Air Conditioner is Off
Press the TIME button to display the current time. If The sleeper ATC control panel can turn on the air
the TIME button is held down and either the SET+ or conditioner even if the cab HVAC unit is turned off
SET– buttons are pressed simultaneously with the but the engine is running. By pressing the ON button,
TIME button, the clock setting will increase or de- the ATC sleeper control panel will turn on the cab
crease. unit and the bunk indicator light on the cab control
panel will be illuminated. If cooling is needed in the
Display Button sleeper, the cab HVAC unit will switch on to a low
blower fan setting and the A/C compressor clutch will
Press the DISP button to allow the display and illumi- engage. If cooling is no longer required in the
nation of the control panel to scroll through three illu- sleeper or if heat is needed, the cab unit fan and the
mination levels: bright, dim, and off. If you want the compressor clutch will be turned off after a five-
alarm, time, or temperature setting to be displayed minute delay.
when the display is in the off mode, press the
ALARM, TIME, or temperature up/down buttons to Accessory Heaters
display the corresponding display for five seconds.
After five seconds, the display will turn off. If the Optional accessary heaters are available from the
alarm sounds while in the display off mode, the cur- factory in several configurations. Familiarize yourself
rent time will be displayed simultaneously. The dis- with the equipment on your specific vehicle, and fol-
play will remain on for five minutes, then turn off. low the manufacturer’s operating and maintenance
instructions.
When the vehicle ignition is not powered, the sleeper
climate control panel is in a power-saving mode and
the display and illumination of the control panel will
5.6
Climate Controls
WARNING
Do not operate fuel-operated heaters in an area
where flammable vapors, including gasoline or
diesel fumes, are present, such as at filling sta-
tions and tank farms. Turn off a fuel-operated
heater and allow it shut down completely before
entering an area where flammable gases or liq-
uids are present. Heaters continue to operate for
up to three minutes after being turned off.
Failure to observe these precautions could cause
an explosion or fire, resulting in serious property
damage, and personal injury or death.
5.7
6
Seats and Restraints
Seats, General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.1
Western Star High-Back Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2
Bostrom Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3
National Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.4
ABTS Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.4
Seat Belts and Tether Belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.5
Sleeper Compartment Restraints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.9
Seats, General Information • Lumbar Support changes the shape of the

backrest to give more or less support to the
Unless otherwise noted, all seat adjustments should occupant’s lumbar (lower back) area. This ad-
be made while seated and before the engine is justment is either mechanical or air controlled,
started. depending on the seat model.
Due to the high degree of adjustability of mid- and • Isolator feature reduces the amount of road
high-back air suspension seats, it is possible to com- shock by isolating the occupant from the mo-
bine the seat back recline adjustment and the seat tion of the vehicle, and allowing the upper seat
slide adjustment so that the seat back contacts the to move in a simple pendulum motion. A lock-
back wall. Use care when adjusting the seat to pre- out feature is used whenever the isolator is not
vent damage to the seat and the cab interior. desired.
• Height Adjustment moves the entire seat up or
WARNING down. The adjustment is either manually- or
air-controlled, depending on the seat model.
Keep hands, tools, and other objects away from
the scissor points under the seats. Failure to do • Bottom Cushion Angle (fore-and-aft bottom
so could cause personal injury. cushion height) enables the occupant to raise
or lower the front or back of the bottom cush-
The following is a description of adjustments that can ion. This adjustment is easier to perform when
be made to various Western Star seats. Not all seats all weight is removed from the seat.
have all of the adjustments listed below. See
Fig. 6.1. • Fore-and-Aft Seat Slide (seat track adjustment)
moves the entire seat forward or backward on
• Backrest Tilt enables the backrest to pivot for- its track.
ward or backward.
1
3 4
2
8
6 7
5
10/26/2000 f910149a
1. Backrest Tilt 5. Bottom Cushion Angle (fore-and- 7. Seat Tilt
2. Lumbar Support aft cushion height) 8. Headrest Adjustment
3. Isolator 6. Fore-and-Aft Seat Slide (seat
4. Height Adjustment track adjustment)
Fig. 6.1, General Seat Adjustments
6.1
• Seat Tilt allows the seat assembly (back and Backrest Tilt
bottom cushions) to tilt forward or backward.
To tilt the backrest, lean forward slightly to remove
• Headrest Adjustment changes the angle of the pressure from the cushion, then turn the knob for-
upper part of the backrest to provide head and ward or rearward to achieve the desired position.
upper back support.
Lumbar Support
Western Star High-Back Seat To adjust the lumbar support, use the lumbar support
See Fig. 6.2 for seat adjustment controls. Not all switches on the side of the seat.
models of the seat have all the adjustments listed
below.
1
6
2 4 10
3 9
5 8
7
07/18/2007 f910576
NOTE: Not all models of the seat have all the adjustment controls shown.
1. Rear Cushion Height Adjustment 4. Bottom Cushion Extension Handle 8. Shock Absorber Lever
Knob 5. Fore/Aft Seat Slide Lever 9. Height Adjustment Switch
2. Fore/Aft Isolator 6. Backrest Tilt Knob 10 Lumbar Support Switches
3. Front Cushion Height Adjustment 7. Heater Button
Knob
Fig. 6.2, Western Star High-Back Seat
6.2
Height Adjustment ate with the key in accessory mode. Optimized Idle
may also turn seat heating off to reduce stress on
To raise or lower the height of the seat, use the the batteries.
height adjustment switch on the side of the seat.
Bottom Cushion Extension Bostrom Seat

See Fig. 6.3 for Bostrom seat adjustment controls.
To adjust the fore-and-aft position of the seat cush-
ion, remove your weight from the seat, then lift up
and pull forward on the cushion adjustment handle.
To return the cushion to the aft position, lift up and
push rearward.
Fore/Aft Seat Slide

To adjust the fore-and-aft position of the entire seat,
move the fore-and-aft seat adjustment lever to the
left and slide the seat forward or backward to the 1
desired position. Move the lever back to its original 6
position to lock the seat in place.
Fore/Aft Isolator
To engage the isolator, turn the isolator knob rear-
ward to the unlocked position. Turn the isolator knob
5 2
forward to the locked position when the isolator fea-
ture is not desired. 3
4
12/03/2010 f910131a
Shock Absorber 1. Backrest Tilt Lever
To adjust the amount of damping the shock absorber 2. Lumbar Support Switches (LSO models)
3. Height Adjustment Switch
provides, move the lever up to increase damping; 4. Bottom Cushion Tilt Knob
move the lever down to decrease damping. 5. Isolator and Fore/Aft Seat Slide Lever
6. Lumbar Support Knob (non-LSO models)
Front Cushion Height
Fig. 6.3, Bostrom Seat Adjustment Controls
To adjust the height of the front of the cushion, re-
move your weight from the seat, then turn the adjust- Backrest Tilt
ment knob toward the front of the seat (clockwise) to
increase cushion height. To lower the cushion height, To tilt the backrest, lean forward slightly to remove
turn the adjustment knob toward the rear of the seat pressure from the cushion and hold the backrest tilt
(counterclockwise). lever rearward. Lean forward or backward slowly to
the desired position and release the lever to lock the
Rear Cushion Height backrest in place.
To adjust the height of the rear of the seat cushion, Lumbar Support
remove your weight from the seat and turn the rear
cushion adjustment knob to one of three positions. To increase lumbar support on luxury seat option
(LSO) models, press the plus sign on the lumbar
Heater support switch. To decrease lumbar support, press
the minus sign on the switch.
To turn on the heat option, press the button. To turn
off the heat option, press the button again. If the ve- To increase lumbar support on non-LSO models, ro-
hicle has Optimized Idle, seat heating will not oper- tate the lumbar support knob forward. To decrease
lumbar support, rotate the knob rearward.
6.3
Height Adjustment
To raise the seat, press the upper portion of the
height adjustment switch. To lower the seat, press
the lower portion of the switch.
Bottom Cushion Tilt 7

To adjust the bottom cushion tilt, rotate the bottom
cushion tilt knob to increase or decrease tilt.
6
Fore-and-Aft Seat Slide
1
hold the fore-and-aft adjustment lever to the left and 5
slide the seat forward or backward to the desired
position.
4 2
Isolator 3
To engage the isolator, put the isolator lever in the

11/14/2000 f910445
center position. Lock out the isolator by moving the
lever to the right. 1. Backrest Tilt Knob
2. Lumbar Support Switch
3. Height Adjustment Switch
National Seat 4. Fore-and-Aft Seat Slide Lever
5. Bottom Cushion Fore-and-Aft Slide Handle
See Fig. 6.4 for National seat adjustment controls. 6. Isolator Handle
7. Rear Cushion Adjustment Knob
Backrest Tilt
Fig. 6.4, National 2000 Series Seat Adjustment Controls
To tilt the backrest, turn the backrest tilt knob until
the desired position is reached. desired position. Move the lever back to its original
position to lock the seat in place.
Lumbar Support
Isolator
To adjust the lumbar support, use the lumbar support
switch on the side of the seat. To engage the isolator, turn the isolator lever to the
horizontal position. Lock out the isolator by turning
Height Adjustment the isolator lever down.
To raise or lower the height of the seat, use the Rear Cushion Adjustment
height adjustment switch on the side of the seat.
To adjust the height of the rear of the seat cushion,
Bottom Cushion Fore-and-Aft Slide remove your weight from the seat and turn the rear
cushion adjustment knob to one of three positions.
To adjust the bottom cushion, lift the bottom cushion
adjustment handle and pull forward or push back to
the desired setting. ABTS Seat
See Fig. 6.5 for ABTS (all-belts-to-seat) seat adjust-
Fore-and-Aft Seat Slide ment controls.
move the fore-and-aft seat adjustment lever to the
left and slide the seat forward or backward to the
6.4
Track Adjustment
lift the track adjustment handle and slide the seat to
the desired position.
Isolator
10 Pull up the isolator control handle to lock out the iso-
lation movement.
Lumbar Adjustment
Push the middle rocker switch to adjust the lower
lumbar bag. Push the forward switch to adjust the
upper lumbar bag.
9
8
Seat Height Adjustment
Push the seat height adjustment switch to raise or
lower the seat suspension.
Seat Tilt Control

7
Set the seat tilt control to one of the five positions to
set cushion rake adjustment.
1
Backrest Adjustment
6 2 To tilt the backrest backward, pull up on the recliner
5
4 handle while leaning backward. To tilt the backrest
3
11/30/2011 f910676 forward, pull up on the recliner handle while leaning
1. Cushion Extension Adjustment Lever forward.
2. Track Adjustment Handle
3. Isolator Control Handle Armrest Adjustment
4. Upper Lumbar Adjustment Switch
5. Lower Lumbar Adjustment Switch Rotate the control knob, located on the underside of
6. Seat Height Adjustment Switch the armrest, to set the desired angle of the armrest.
7. Seat Tilt Control
8.
9.
Recliner Handle
Armrest Control Knob
Shoulder Belt Height Control
10. Shoulder Belt Height Control Adjust the shoulder belt height. The height can be
adjusted vertically by 3 inches (75 mm).
Fig. 6.5, ABTS Seat Adjustment Controls
Cushion Extension Adjustment Seat Belts and Tether Belts

Move the cushion extension adjustment lever to the Seat belt assemblies are designed to secure persons
left and move the seat cushion to the desired posi- in the vehicle to help reduce the chance of injury or
tion. the amount of injury resulting from accidents or sud-
den stops. For this reason, Daimler Trucks North
America LLC (DTNA) urges that the driver and all
passengers, regardless of age or physical condition,
use seat belts when riding in the vehicle.
6.5
Inspect the seat belts and tether belts (if so

WARNING equipped).
Always use the vehicle’s seat belt system when 1. Check the web for fraying, cuts, extreme dirt and
operating the vehicle. Failure to do so can result dust, or for severe fading from exposure to sun-
in severe personal injury or death. light, especially near the buckle latch plate and in
the D-loop guide area.
Seat belt assemblies in DTNA vehicles meet Federal
Motor Vehicle Safety Standard 209, "Type 1" and 2. Check operation of the buckle, latch, Komfort
"Type 2" requirements. Latch or Sliding Komfort Latch (if equipped), web
retractor, and upper seat belt mount on the door
When transporting a child, always use a child re- pillar. Check all visible components for wear or
straint system or the vehicle seat belts as appropri- damage.
ate. To determine whether a child restraint system is
required, review and comply with applicable state 3. Check the seat belt and tether belt connection
and local laws. Any child restraint used must comply points and tighten any that are loose.
with Federal Motor Vehicle Safety Standard 213,
"Child Restraint Systems." When providing a child Seat Belt Operation
restraint system, always carefully read and follow all Seat Belt With Komfort Latch or Sliding
instructions pertaining to installation and usage for
the child. Make certain the child remains in the re- Komfort Latch
straint system at all times when the vehicle is in NOTE: For vehicles not equipped with the Kom-
motion. fort Latch or the Sliding Komfort Latch, see the
In addition to seat belt assemblies, tether belts are seat belt operation under the heading Three-
installed on suspension-type seats. Tether belts help Point Seat Belt.
secure the seat to the floor and are intended to re-
strain the seat and seat belt in case of an accident or WARNING
sudden stop.
IMPORTANT: Seat belts have a finite life which Wear three-point seat belts only as described
may be much shorter than the life of the vehicle. below. Three-point seat belts are designed to be
Regular inspections and replacement as needed worn by one person at a time. In case of an acci-
dent or sudden stop, personal injury or death
are the only assurance of adequate seat belt
could result from misuse.
security over the life of the vehicle.
Fasten the seat belts before driving. Fastening a
Seat Belt Inspection three-point seat belt while driving creates a haz-
ard.
WARNING When engaged and used properly, the Komfort Latch
(Fig. 6.6) and the Sliding Komfort Latch (Fig. 6.7)
Inspect and maintain seat belts. When any part of introduce a small amount of slack into the seat belt,
a seat belt system needs replacement, the entire resulting in a more comfortable ride.
seat belt must be replaced, both retractor and
1. Slowly pull the link end of the seat belt out of the
buckle side. Any time a vehicle is involved in an
retractor and pull it across your lap (from out-
accident, and the seat belt system was in use,
board to inboard) far enough to engage the
the entire vehicle seat belt system must be re-
buckle. If the retractor locks too soon, allow the
placed before operating the vehicle. Do not at-
belt to retract slightly, then slowly pull it out
tempt to modify the seat belt system; doing so
again.
could change the effectiveness of the system.
Failure to replace worn or damaged seat belts, or 2. Fasten the seat belt by pushing the latch into the
making any modifications to the system, may re- buckle. Listen for an audible click. See Fig. 6.8.
sult in personal injury or death.
3. Tug on the seat belt to make sure it is securely
fastened. If the buckle unlatches, repeat this
6.6
A B
01/18/95 f910004a
Fig. 6.8, Fastening the Three-Point Belt
03/11/2010 f910620
WARNING
A. Disengaged B. Engaged
Before activating the Komfort Latch or the Slid-
Fig. 6.6, Komfort Latch
ing Komfort Latch, make sure the amount of
slack in the shoulder strap is set as described
below. Excess slack in the shoulder strap re-
duces the effectiveness of the seat belt, and in-
creases the risk of injury or death in an accident.
5. Position the shoulder strap diagonally across
your chest with the adjustable D-loop bracket (if
equipped). The shoulder strap must be centered
on your shoulder and chest, away from your face
and neck. See Fig. 6.9. If desired, engage the
Komfort Latch or Sliding Komfort Latch as fol-
lows.
If equipped with a Sliding Komfort Latch, make
sure that the shoulder strap is snug against your
chest. Without loosening the shoulder strap,
push the Sliding Komfort Latch switch to the
"ON" position. See Fig. 6.7. To activate the latch
lean forward until you hear a click. This will allow
for approximately 1 inch (2.5 cm) of slack be-
11/18/2010 f910621a tween your chest and the shoulder harness.
Once engaged, the latch will allow you to lean
Fig. 6.7, Sliding Komfort Latch
forward about 5 inches (13 cm) without having to
step. If the problem continues, replace the seat reset the latch. Leaning forward more than 5
belt. inches (13 cm) will disengage the Sliding Kom-
fort Latch, requiring it to be reset.
4. Snug the seat belt to your waist.
If equipped with a Komfort Latch, pull on the
shoulder strap to lessen the pressure of the strap
6.7
on your shoulder and chest. Allow no more than

1 inch (2.5 cm) of slack between your chest and
the shoulder harness. More slack can signifi-
cantly reduce the seat belt effectiveness in an
accident or a sudden stop. While holding the belt
slack, press the Komfort Latch lever up, clamp-
ing the seat belt webbing (Fig. 6.10 and
Fig. 6.11).
01/06/95 f910006a
Fig. 6.11, Locking the Komfort Latch

A B C If equipped with a Komfort Latch, unbuckle the
08/09/2010 f910634 seat belt (Fig. 6.12), then release the Komfort
A. Correct—Belt is centered on your shoulder and Latch by giving the shoulder belt a quick tug. If
chest, away from your face and neck. you lean forward against the shoulder belt, the
B. Wrong—Belt must not rub against face or neck. Komfort Latch will automatically release, and will
C. Wrong—Belt must not hang off shoulder. need to be reset.
Fig. 6.9, Proper Shoulder Strap Fit
01/06/95 f910048a
A. 1 Inch (2.5 cm) Maximum 01/18/95 f910049a
Fig. 6.10, Adjusting Shoulder Harness Clearance, Fig. 6.12, Releasing the Three-Point Seat Belt
Komfort Latch
NOTE: Neither the Komfort Latch nor the Sliding
6. Unbuckle the seat belt and release the Komfort Komfort Latch need to be manually released in
Latch or the Sliding Komfort Latch as follows. an emergency situation. Each will release by
If equipped with a Sliding Komfort Latch, un- itself under rough road or other abnormal condi-
buckle the seat belt (Fig. 6.12), then tug on the tions. Make sure the seat belt is completely re-
shoulder belt to release the Sliding Komfort tracted when it is not in use.
Latch, or press the Sliding Komfort latch to the
"OFF" position, then unbuckle the seat belt.
6.8
Three-Point Seat Belt Sleeper Compartment

NOTE: For vehicles equipped with the Komfort Restraints
Latch or the Sliding Komfort Latch, see the seat
belt operation under the heading Seat Belt With WARNING
Komfort Latch or Sliding Komfort Latch.
Do not use the sleeper compartment while the
WARNING vehicle is in motion unless a bunk restraint is
installed and used. Not using the bunk restraint
Wear three-point seat belts only as described increases the chance of injury, or the degree of
below. Three-point seat belts are designed to be injury, from accidents or sudden stops to all oc-
worn by one person at a time. In case of an acci- cupants of the vehicle.
dent or sudden stop, personal injury or death
could result from misuse. On vehicles equipped with a sleeper compartment,
bunk restraints should be used whenever the sleeper
Fasten the seat belts before driving. Fastening a compartment is occupied and the vehicle is moving.
three-point seat belt while driving creates a haz- Restraints are designed to lessen the chance of in-
ard. jury or the amount of injury resulting from accidents
or sudden stops.
1. Slowly pull the link end of the three-point seat
belt out of the retractor and pull it across your
lap (from outboard to inboard) far enough to en-
Bunk Restraint Adjustment
gage the buckle. If the retractor locks too soon, 1. Make sure the belt is attached to the bunk sup-
allow the belt to retract slightly, then slowly pull it port and sleeper wall.
out again.
2. To lengthen the belt, tip the link end downward
2. Fasten the seat belt by pushing the latch into the and pull the link until it connects with the buckle.
buckle. Listen for an audible click. See Fig. 6.8.
3. After the belt is connected, shorten it by pulling
3. Tug on the seat belt to make sure it is securely on the loose end until the belt is snug, but com-
fastened. If the buckle unlatches, repeat this fortable. Be sure the belts are not twisted. See
step. If the problem continues, replace the seat Fig. 6.13.
belt.
4. Snug the seat belt to your waist.
5. Position the shoulder strap diagonally across
your chest with the adjustable D-loop bracket (if
equipped). The shoulder strap must be centered
on your shoulder and chest, away from your face
and neck. See Fig. 6.9.
6. To unbuckle the seat belt, press the release but-
ton on the buckle. See Fig. 6.12.
NOTE: Make sure the seat belt is completely
retracted when it is not in use.
6.9
A
1
2
3
08/18/2011 f910472
A. Pull on the loose end to shorten the belt.
1. Belt 3. Release Buckle
2. Connector
Fig. 6.13, Bunk Restraint Adjustment
6.10
7
Cab and Sleeper Features
Windows and Mirrors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.1
Cab Amenities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.2
Sleeper Amenities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.3
Windows and Mirrors

Power Mirrors
The standard outside mirrors are mounted on the
door frame. There is a primary rear view mirror and a
convex mirror.
Power mirrors are controlled by two switches MIRROR
DEFOG
mounted on the dash control panel. See Fig. 7.1.
The switches allow the driver to rotate the mirrors on
a horizontal plane.
08/18/2011 f545813
To defog the mirror(s), press the upper half of the switch.

To turn off heat to the mirror(s), press the lower half of
the switch.
Fig. 7.2, Mirror Defog Switch
MIRROR
08/18/2011 f545814
Fig. 7.1, Mirror Control Switch
Optional mirrors may be mounted on the outside of

the cab. Cab-mounted mirrors are controlled by
switches located in the overhead console. 1
One or both outside mirrors may be heated to clear
fog, frost, or ice.
To defog the mirrors, press the upper half of the mir-
ror defog switch (MIRROR DEFOG). See Fig. 7.2.
When the mirror defog switch is on, the status bar
illuminates.
Down-View Mirror
An optional down-view mirror may be installed on the
door frame to allow the driver a view of the area ad-
jacent to the side of the cab. See Fig. 7.3.
Windows
The windows in both doors are normally operated by 08/18/2011 f602461
window cranks.
1. Down-View Mirror (passenger side shown)
Power windows are optional, and may be installed on
one or both sides. Power window switches (POWER Fig. 7.3, Down-View Mirror
7.1
WINDOW) may be located on the door, or on the To activate the cigar lighter, push in the element
dash control panel. knob. It will pop out when heated. Grasp the element
knob and pull it out of the socket.
To raise the window, press the upper half of the
switch. To lower the window, press the lower half of To remove the ash tray, push down on the center
the switch. See Fig. 7.4. bar, and swing outwards. To install the ash tray, in-
sert in the opening then swing upwards until the bar
snaps into place.
Cup Holders
Single and dual cup holders are optional, and are
located below the right-hand dash control panel.
POWER Glove Box

WINDOW
The glove box (Fig. 7.6) is located on the right side
of the dash face, and is equipped with a lock. To lock
the latch, insert the key in the lock, and turn it ½-turn
clockwise. Remove the key. To unlock the latch, in-
08/18/2011 f545812
sert the key in the lock, and turn it ½-turn counter-
clockwise.
Fig. 7.4, Power Window Switch The glove box door is hinged at the bottom. To open
the unlocked door, push the button in with your
Cab Amenities thumb and pull gently on the tang-style latch. The
door will swing downwards, then stop in the open
Western Star vehicles are available with many op- position. To close the door, swing it upwards, and put
tional features. The following are some of those gentle pressure on the latch. The door will be se-
options. cured, but not locked.
Cigar Lighter/Accessory Plug
The cigar lighter/accessory plug (Fig. 7.5) is located
on the lower right-hand dash panel, above the igni-
tion switch. The ash tray is located to the left of the
cigar lighter.
1 1 2
2
3
03/21/2001 f610481
1. Fuse/Relay Panel 3. Glove Box
2. Fuse/Relay Panel
Fig. 7.6, Passenger-Side Dash Panels

03/21/2001 f610479
1. Ash Tray 2. Cigar Lighter
Fig. 7.5, Ash Tray and Lighter
7.2
Electronic Device Mount NOTE: See Chapter 5 for detailed information

regarding sleeper climate controls and the digi-
Some vehicles may be equipped with an optional tal clock.
electronic device mounting station and 12 volt outlet
on the dash. The standard bolt pattern allows the Baggage Compartment Doors
mounting of a variety of devices including navigation
systems, cell phone holders, portable music players, To unlock, insert the baggage door key in the lock
and other electronic devices. Mounting systems can and turn counterclockwise 1/4-turn. Push the button,
be found at www.ram-mount.com. and the latch will spring open. To lock, press the
latch in, turn the key clockwise 1/4-turn, then remove
Lighting the key. If the baggage compartment door is un-
locked, it can be opened simply by pushing the
See Chapter 4 for detailed information regarding button.
lighting controls.
Lighting
Storage Areas
Reading lamps are operated manually with a rocker
There is a storage bin located on the right-hand side switch. The light beam direction is adjustable by
of the overhead console (Fig. 7.7). This storage bin moving the lens assembly in the desired direction.
has an elastic mesh cover to keep objects in place. There are other courtesy lamps provided in the
Some vehicles have an elastic-topped pouch, located sleeper. These will operate when a cab door is
on the rear cab panel between the seats. If the ve- opened. Some sleepers have light switches located
hicle has a passenger bench seat, there are storage on the cab or sleeper instrument panels.
areas on the front of and inside the seat base.
Remote Engine Start
The remote engine start option (Fig. 7.8) includes a
key switch, ignition light, CHECK engine warning
light, and a STOP engine warning light. To activate
the sleeper start controls, turn on the sleeper start
switch on the dash, then turn the sleeper key switch
to ON. Return the engine control to the cab by first
1 turning the cab key switch ON and set the sleeper
start switch to OFF.
2
Sleeper Door
The sleeper door is not intended for entry or exit.
The door is intended only as a convenient means to
3 stow or remove personal belongings in the sleeper
03/21/2001 f610480 area. To open the sleeper door, reach behind the
1. Double Reading Lamp (optional) latch cover at the rear upper corner, locate the flat
2. Storage Bin handle, and push down.
3. Single Reading Lamp (optional) IMPORTANT: The sleeper doors are two-stage
Fig. 7.7, Overhead Console Area latching. When closing the doors, ensure that
they are completely latched to prevent wind
Sleeper Amenities noise and water intrusion.
Western Star sleepers are available with many op-
tional features. The following are some of those
options.
7.3
4 2
1 3
05/14/2001 f610564
1. Sleeper Start 3. Climate Control Panel

2. Digital Clock 4. Warning Lights
Fig. 7.8, Sleeper Control Panel
Sliding Side Window

The sliding side window is locked with an over-center
toggle lever. When unlocked, the window may be
adjusted to suit.
Vent
The air vent is operated using a simple, over-center
latch. The vent will open in two directions. Push the
knob firmly forward or back to open. The center posi-
tion is closed.
7.4
8
Electrical System
Vehicle Power Distribution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.1
Battery Disconnect Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.2
Battery Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.3
Electrical System
Vehicle Power Distribution IMPORTANT: The covers on the underhood

PDM units must be in place to protect against
Power Distribution, EPA10 and Newer water splash and dust intrusion.
There are three standard power distribution modules The powertrain PDM houses many of the fuses and
(PDMs) on vehicles that are compliant with EPA10 relays for the engine, transmission, and aftertreat-
and newer regulations: the dash electrical panel, the ment system (ATS). There is a label on the cover of
powertrain PDM, and the powernet distribution box the powertrain PDM identifying the fuses and relays.
(PNDB). See Fig. 8.1 for the typical locations of the The PNDB houses up to three MIDI fuses and four
power distribution modules located in the engine ATO fuses. A label on the cover of the PNDB identi-
compartment. fies the fuses.
08/17/2011 f545811
1. MEGA Fuse Location (EPA07 and earlier vehicles)
2. Powertrain PDM (EPA10 and newer vehicles)
3. PNDB (EPA10 and newer vehicles)
Fig. 8.1, PDM Locations
8.1
Electrical System
Vehicles may also be equipped with a secondary

PNDB. The secondary PNDB sources power to any
of the following:
• fleet management communications
• trailer end-of-frame connection
• shore power inverter
• bodybuilder PDM (housing any fuses and re-
lays necessary for customer-installed truck
body equipment)
The dash electrical panel is located inboard of the
passenger-side glove box. Access to the panel is
achieved by removing the four screws located in
each corner of the panel cover. See Fig. 8.2. A decal 11/13/2001 1 2 f543949
showing the layout of the fuses, breakers, and relays 1. Decal Option Panel
is on the back of the panel cover. See Fig. 8.3. 2. Decal Main Panel
1 Fig. 8.3, Electrical Panel Decals
Battery Disconnect Switches

Your Western Star vehicle may be equipped with a
cab load disconnect switch (CLDS) or a battery isola-
tion switch.
2 Cab Load Disconnect Switch, EPA10

and Newer
The optional CLDS (Fig. 8.4) is used to minimize
draw on the battery, and should be turned off when
the vehicle is parked for an extended period of time.
11/13/2001 f543947 When the CLDS is set to OFF, it signals the PNDB to
1. Electrical Panel Cover disconnect battery power to the circuits powered by
2. Mounting Screws the MIDI fuses.
Fig. 8.2, Dash Panel

The CLDS is mounted on the cab floor outboard of
the driver’s seat, on the lower driver-side dash panel,
or near the battery box.
Pre-EPA10 Power Distribution
IMPORTANT: The ignition should be turned OFF
Vehicles that are not compliant with EPA10 or newer
regulations have one PDM in the engine compart-
before using the CLDS.
ment (see Fig. 8.1) and two MEGA fuses in the dash
electrical panel. Pre-EPA10 Battery Isolation Switch
The dash electrical panel is located inboard of the The optional battery isolation switch (see Fig. 8.5) is
passenger-side glove box. Access to the panel is located on the cab floor outboard of the driver’s seat,
achieved by removing the four screws located in on a bracket near the driver-side kick panel below
each corner of the panel. See Fig. 8.2. A decal, the dash, or near the battery box. The battery isola-
showing the layout of the fuses, breakers and relays, tion switch disconnects the power to most cab cir-
is on the back of the panel cover. See Fig. 8.3. cuits and engine power wiring. Use it whenever the
8.2
Electrical System
Battery Access
The batteries on a Western Star vehicle may be lo-
cated in a variety of locations, including under the
passenger seat, under the cab, behind the cab, or
under the sleeper bunk, if equipped. Some vehicles
may have two batteries in the step compartments on
both sides of the vehicle.
05/13/2009 f545527
Fig. 8.4, Cab Load Disconnect Switch
vehicle is to be put out of service for extended peri-

ods.
IMPORTANT: The battery isolation switch does
not completely isolate the batteries from the
electrical system. For service operations that
require that the batteries be disconnected, al-
ways shut down the engine and remove the
negative battery cables.
NOTE: Whenever battery power is discon-
nected, clocks, radios, and the Datastar contrast
must be reset.
06/01/2001 f610529
Fig. 8.5, Battery Isolation Switch
8.3
9
Engine Starting, Operation,
and Shutdown
Engine Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.1
Engine Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.1
Engine Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.3
Engine Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.3
Engine Starting, Operation, and Shutdown
Engine Starting NOTICE

This engine chapter is to serve as a guide for best
practices only. Each engine model may have operat- If the oil pressure gauge indicates no oil pres-
ing characteristics that are unique to that particular sure, shut down the engine within approximately
engine, and will be documented in the engine manu- ten seconds to avoid engine damage.
facturer’s literature. Always refer to specific instruc- 7. Check the oil pressure gauge for any drop in lu-
tions and recommendations from the engine manu- bricating oil pressure or mechanical malfunction
facturer. in the lubricating oil system.
NOTE: Before starting the engine, read Chap-
ter 3 for detailed information on how to read the Cold-Weather Starting
instruments and see Chapter 4 for detailed in- See the engine manufacturer’s operation manual for
formation on how to operate the controls. Read starting aids that are approved for specific engines.
the engine manufacturer’s operating instructions
before starting the engine. Starting After Extended Shutdown
Before engine start-up, complete the engine pretrip
WARNING inspections in Chapter 23.
Never pour fuel or other flammable liquid into the
air inlet opening in the air intake in an attempt to NOTICE
start the vehicle. This could result in a flash fire
causing serious personal injury or property Failure to eliminate water-diluted lubricating oil
damage. may lead to serious engine damage at startup.
An engine in storage for an extended period of time
1. Before engine start-up, complete the engine pre-
(over winter, for example) may accumulate water in
trip inspections in Chapter 23.
the oil pan through normal condensation of moisture
2. Set the parking brake. on the internal surfaces of the engine. Oil diluted by
water cannot provide adequate bearing protection at
3. Place the transmission in neutral. On vehicles start-up. For this reason, change the engine oil and
with manual transmissions, fully depress the filters after extended storage.
clutch pedal.
4. Turn the ignition switch to the ON position. The Engine Operation
buzzer will sound for three seconds.
During cold conditions, the WAIT TO START Safety and Environmental
lamp may illuminate. Wait until the lamp goes out Considerations
before turning the ignition key to START.
All engines on Western Star vehicles comply with the
NOTE: The length of time the WAIT TO START requirements of the Federal (U.S.) Clean Air Act.
lamp remains illuminated depends on the ambi- Once an engine is placed in service, the responsibil-
ent temperature. The lower the ambient tem- ity for meeting both state and local regulations is with
perature, the longer the lamp will be illuminated. the owner/operator.
NOTE: The engine electronics supply the cor- IMPORTANT: Depending upon local jurisdic-
rect amount of fuel for starting the engine. Ac- tional emissions guidelines, vehicles that are
celerator pedal pressure is unnecessary and domiciled outside of the U.S. and Canada may
could interfere with engine starting. not have engines and/or emissions aftertreat-
ment systems that are compliant with EPA07,
5. Turn the ignition key to the START position. Re- EPA10, or GHG14 regulations.
lease the key the moment the engine starts.
6. Apply load gradually during the warm-up period.
9.1
from maximum torque rpm at the low end, to engine

NOTICE rated speed at the high end. Most engines deliver
best fuel economy when operated in the low- and
It is extremely important that the following guide- mid-speed segments of the efficiency range and pro-
lines be followed for engines that comply with duce maximum horsepower at rated speed, which is
EPA07 or newer regulations, or damage may also the recommended maximum speed of the en-
occur to the aftertreatment device, and the war- gine. For further engine-specific information, refer to
ranty may be compromised. the engine manufacturer’s operation manual.
• Use ultralow-sulfur diesel with 15 ppm sul- Prolonged idling of engines is not recommended, and
fur content or less. is illegal in some states. Idling produces sulfuric acid,
• Do not use fuel blended with used engine that is absorbed by the lubricating oil, and eats into
lube oil or kerosene. bearings, rings, valve stems, and engine surfaces. If
you must idle the engine for cab heat or cooling, use
• Use only engine lube oil with a sulfated ash the high idle function of the cruise control switches.
level less than 1.0 wt%; currently referred An idle speed of 900 rpm should be enough to pro-
to as CJ-4 oil. vide cab heat in ambient temperatures that are
Adequate maintenance of the engine and the diesel above freezing.
particulate filter (DPF) are the responsibility of the If the engine is programmed with the idle shutdown
owner/operator, and are essential to keep the emis- timer, ninety seconds before the preset shutdown
sion levels low. Good operating practices, regular time, the CHECK engine light will begin to flash at a
maintenance, and correct adjustments are factors rapid rate. If the position of the clutch pedal or ser-
that will help keep emissions within the regulations. vice brake changes during this final ninety seconds
The driver should be familiar with the vehicle warning the idle shutdown timer will be disabled until reset.
system in order to bring the vehicle to a safe stop if
the engine malfunctions. If the driver doesn’t under- Cold-Weather Operation
stand how the warning system works, an engine Satisfactory performance of a diesel engine operating
shutdown could occur, causing a safety hazard. See in low ambient temperatures requires modification of
Chapter 10 for more information. the engine, surrounding equipment, operating prac-
tices, and maintenance procedures. The lower the
Engine Break-In temperature, the greater the amount of modification
Each engine must pass a full-load operating test on required. For service products approved for use in
a dynamometer before shipment, thereby eliminating cold weather for your engine, see the engine manu-
the need for a break-in. Before running the engine facturer’s engine operation manual.
for the first time, follow the instructions in the engine If satisfactory engine temperature is not maintained,
manufacturer’s operation manual specific to your maintenance costs will increase due to greater en-
engine. gine wear. If the engine coolant gets too cold, raw
fuel will wash the lubricating oil off the cylinder walls
Normal Operation and dilute the crankcase oil, causing all moving parts
of the engine to suffer from poor lubrication.
WARNING If the engine is in good mechanical condition and the
precautions necessary for cold-weather operation are
Do not operate the engine in an area where flam- taken, ordinary cold weather will not cause difficulty
mable vapors such as gasoline or diesel fumes in starting or loss of efficiency.
are present. Shut off the engine when in an area
The following points are important to observe when
where flammable liquids or gases are being
operating in cold weather:
handled. Failure to observe these precautions
could result in serious injury or death. • Check for cracks in the batteries, for corrosion
Every engine has an operating range in which it per- of the terminals, and for tightness of the cable
forms most efficiently. The operating range extends clamps at the terminals.
9.2
• Charge the batteries to full capacity. Replace Engine Shutdown

damaged batteries.
1. With the vehicle stopped, set the parking brake
• If equipped, turn off the load disconnect switch
and place the transmission in neutral.
after the engine is shut down, to prevent bat-
tery discharge.
• Have the alternator output checked at an au-
NOTICE
thorized service provider. Idle the engine one to two minutes before shut-
• Check the condition and tension of the drive ting it down. After hard operation, shutting down
belts. the engine without idling may cause damage to
the turbocharger.
• Refer to the engine manufacturer’s operation
manual for recommended heaters, low- 2. Allow the engine to idle one to two minutes be-
viscosity lubricating oils, winter-grade fuels, fore shutting it down.
and approved coolants.
NOTICE
NOTICE
Except in an emergency, do not shut down the
For Detroit engines (EPA07 and newer), use of a engine when the coolant temperature is above
winterfront is not recommended, as it can cause 194°F (90°C). To do so could damage the engine.
false fault codes with the engine and aftertreat- 3. Turn off the ignition switch and shut down the
ment system, and possible emission component engine.
failures.
If using a winterfront, leave at least 25% of the grille Engine Cooling
opening exposed in sectioned stripes that run per-
pendicular to the charge-air-cooler tube-flow direc- The cooling system used on all Western Star ve-
tion. This assures even cooling across each tube, hicles is a pressure type system. This raises the
and reduces header-to-tube stress, and possible coolant boiling point, permitting higher operating tem-
chance of component failure. For engine-specific peratures. The coolant supplied in your vehicle will
guidelines, see below: be a 50/50 mix of antifreeze and water, giving protec-
tion down to –35°F (–37°C). It is recommended that
Cummins and Mercedes-Benz engines: A winterfront
an antifreeze mixture be used at all times, as, in ad-
may be used to improve cab heating while idling, and
dition to providing frost protection, it is a more effec-
only when the ambient temperature remains below
tive coolant, and has a higher boiling point than tap
10°F (-12°C).
water.
Detroit engines (EPA07 and newer): Use of a winter-
front is not recommended. Using a winterfront can Over-concentration of antifreeze or coolant condi-
cause excessive fan run time, increased fuel con- tioner can cause silicate to precipitate out of the
sumption, and failure of the DEF system heaters to coolant, forming silica gel on cooling system heat
operate correctly, resulting in fault codes, poor per- transfer surfaces (fuel coolers, oil coolers, radiators,
formance, and power reduction. A winterfront should and heater cores), resulting in reduced coolant flow
only be used temporarily in the following situations: and overheating.
• to improve cab heating while idling in an ex- Hard water (with high levels of calcium and magne-
tremely cold ambient temperature; sium ions) encourages formation of silica gel. Do not
use softened water as the salt used to artificially
• when the ambient temperature remains below soften it is corrosive. Most engine manufacturers pre-
-22°F (-30°C) and the engine is unable to fer the use of distilled or de-ionized water to reduce
maintain a running coolant temperature of the potential and severity of silicate dropouts.
175°F (80°C) during normal over-the-road op-
eration. Never exceed a 60/40 antifreeze-to-water ratio. If the
level is low, add a 50/50 antifreeze solution to main-
tain solution concentrations. Note that checking the
9.3
engine coolant level is part of the pretrip inspection.

See Chapter 23 for more information.
9.4
10
Optional Engine Systems
Engine Protection—Warning and Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.1
Engine Idle Limiting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.1
Cruise Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.2
Auxiliary Braking Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.3
Power Takeoff (PTO) Governor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.5
Engine Protection—Warning Do not operate the vehicle further until the problem
causing the shutdown has been corrected.
and Shutdown
The driver should be familiar with the vehicle warning
system in order to bring the vehicle to a safe stop if
the engine malfunctions. If the driver doesn’t under- CHECK STOP
stand how the warning system works, an engine
shutdown could occur.
The engine will begin a warning and shutdown pro- 1 2 3
cess if the engine coolant temperature, coolant level, 07/09/2009 f611036
engine oil pressure, or exhaust aftertreatment system 1. Malfunction Indicator 2. CHECK Engine Lamp
(ATS) reach preset levels. On some engines, the en- Lamp (MIL) 3. STOP Engine Lamp
gine will also begin the warning and shutdown pro-
Fig. 10.1, Engine Warning Lights
cess when the engine oil temperature or the intake
air temperature reach preset levels. Detroit Diesel Some vehicles may have a shutdown-override
engines will begin the warning and shutdown process switch, which can be used to momentarily override
if water is detected in the fuel. the shutdown sequence. This switch resets the shut-
See the engine manufacturer’s operation manual for down timer, restoring power to the level before the
specific details for your vehicle. derate for another 30 or 60 seconds (depending on
the critical fault type). The switch must be pressed
See Chapter 11 for the warning and shutdown again after five seconds to obtain a subsequent
modes associated with the ATS. override.
Electronic engine protection is programmable as an In WARNING mode, the amber CHECK engine lamp
option, and can be specified as one of the following will flash and a buzzer will sound. The engine elec-
modes: DERATE and SHUTDOWN (factory default), tronics log the event for diagnostic purposes. The
WARNING, or OFF. CHECK engine lamp will go out if the problem stops.
In OFF mode, the individual sensor indicator lamps
WARNING will illuminate if a problem exists, but no shutdown
action will be started and the event will not be re-
When the red STOP engine or engine protection
corded.
light illuminates, most engines are programmed
to shut down automatically within 30 seconds.
The driver must immediately move the vehicle to Engine Idle Limiting
a safe location at the side of the road to prevent
causing a hazardous situation that could cause Idle Shutdown Timer
bodily injury, property damage, or severe damage This feature is an optional 1- to 100-minute idle shut-
to the engine. down system. Its purpose is to conserve fuel by
In DERATE and SHUTDOWN mode, the red STOP eliminating excessive idling and allowing a turbo-
engine lamp will illuminate when the problem is seri- charger cool-down period. Idle shutdown timing and
ous enough to reduce power or speed. See parameters are programmable. See the engine
Fig. 10.1. Engine power will ramp down, then the manufacturer’s operation manual for specific details
engine will shut down if the problem continues. The for your vehicle.
driver has 30 or 60 seconds (depending on the criti-
cal fault type) after the STOP engine lamp illumi- California Engine Idle Limit
nates to move the vehicle safely off the road. If the
In order to meet the California Air Resources Board
vehicle cannot be moved to a safe location within
(CARB) engine idle limiting standard, vehicles are
that time, the engine can be restarted by turning the
equipped with an engine idle shutdown feature. The
ignition switch OFF for at least five seconds, then
automatic shutdown feature is required on all
back ON. Repeat this action until the vehicle is safely
off the road.
10.1
California-certified engines (with the exception of en-

gines used in specific vehicle types that are exempt
from the requirement). Owners that wish to have the
shutdown feature disabled on vehicles operating in
California should consult with California authorities to
determine if their vehicle qualifies for the exemption.
When the CARB engine idle limiting feature is en- SET/DECEL
CRUISE
abled, the engine will typically shut down after five
minutes of continuous idling when the transmission is
CONTROL
RES/ACCEL
in neutral and the parking brake is set. It will also
shut down after 15 minutes when the transmission is
in neutral, with the parking brake off. See the engine
manufacturer’s operation manual for specific details
for your vehicle.
07/15/2011 f545790
After an automatic shutdown, the engine may be re-
started and operated normally. Fig. 10.2, Cruise Control Switches
Activating or momentarily changing the position of Cruise at a particular speed
the brake pedal, clutch pedal, accelerator pedal,
shutdown override switch, or parking brake during 1. Press the upper part of the cruise control on/off
the final 30 seconds will cause the shutdown timer to switch to turn cruise control on.
reset.
2. Hold the accelerator pedal down until the speed-
ometer reaches the desired speed.
Cruise Control
NOTE: Cruise control is cancelled if the brake
or clutch pedal is depressed, or engine speed
WARNING drops below 1200 rpm.
Do not use the cruise control system when driv- 3. Press the upper half of the Set/Resume/
ing conditions do not permit maintaining a con- Accelerate/Decelerate switch momentarily to set
stant speed, such as in heavy traffic or on roads the cruise speed (with the vehicle moving at the
that are winding, icy, snow-covered, slippery, or desired speed).
roads with a loose driving surface. Failure to fol-
low this precaution could cause a collision or To decrease cruise speed, press and hold the
loss of vehicle control, possibly resulting in per- upper half of the Set/Resume/Accelerate/
sonal injury or property damage. Decelerate switch to decelerate slowly. Release
the switch when the desired speed is achieved.
NOTICE To increase cruise speed, press and hold the
lower half of the Set/Resume/Accelerate/
When the cruise control is engaged, do not at- Decelerate switch to accelerate slowly. Release
tempt to shift gears without using the clutch the switch when the desired speed is achieved.
pedal. Failure to follow this precaution will result
in a temporarily uncontrolled increase in engine Disengage cruise control
speed. Transmission damage and gear stripping
could result.
NOTE: The speed memory is lost whenever the
ignition is turned off or the cruise control system
Cruise control is activated by two dash-mounted is turned off.
switches: an on/off switch (CRUISE CONTROL) and
a Set/Decelerate/Resume/Accelerate switch. See 1. Depress the brake pedal (automatic or manual
Fig. 10.2. transmissions)
or
10.2
Depress the clutch pedal (manual transmissions property damage. Service brakes are the primary
only). vehicle braking system.
NOTE: To resume the preselected cruise speed, Two dash-mounted switches (Fig. 10.3) control the
increase vehicle speed to above minimum engine brake:
cruise control speed and momentarily press the • The on/off switch (ENGINE BRAKE), is used to
lower half of the Set/Resume/Accelerate/ turn the engine brake on and off.
Decelerate switch. Cruise will return to the last
• The engine brake intensity switch (HIGH/MED/
speed selected.
LOW or, in some cases, HIGH/LOW) controls
2. Press the lower half of the on/off switch. the amount of engine braking. When the en-
gine brake is on, a status bar illuminates on
Auxiliary Braking Applications the intensity switch, indicating the current set-
ting.
Engine Brake Since the engine brake is most effective at rated en-
Each engine manufacturer uses a specific engine gine speed, gear selection is very important. Gearing
brake for their engine. Regardless of the manufac- down the vehicle within the limits of the rated engine
turer, the engine brake is operated with the principles speed makes the engine brake more effective. Rec-
outlined in this chapter. Refer to the engine manufac- ommended engine braking speed is above 1800 rpm
turer’s operation manual for details of their particular and below the rated speed.
engine brake product.
WARNING
To avoid injury from loss of vehicle control, do M
not activate the engine brake system under the
following conditions:
ENGINE HIGH
• on wet or slippery pavement, unless the MED
vehicle is equipped with antilock braking
BRAKE
LOW
system (ABS) and you have had prior expe-
rience driving under these conditions;
• when driving without a trailer or pulling an
empty trailer;
07/15/2011 f545791
• if the tractor drive wheels begin to lock, or
there is fishtail motion after the engine Fig. 10.3, Engine Brake Switches
brake is activated.
Whenever vehicle braking is required on good road WARNING
conditions, the engine brake may be used in con-
junction with the service brakes. There is no time The engine brake must be disengaged when
limit for operation of the engine brake. However, an shifting gears using the clutch pedal. If the en-
engine brake does not provide the precise control of, gine brake is engaged when the transmission is
and is not a substitute for, service brakes. in neutral, the braking power of the engine brake
can stall the engine, which could result in loss of
WARNING vehicle control, possibly causing personal injury
Usage of the engine brake as the primary braking "Control speed" is the speed at which the engine
system can cause unpredictable stopping dis- brake performs 100 percent of the required downhill
tances, that could result in personal injury or braking, resulting in a constant speed of descent.
10.3
The control speed varies, depending on vehicle dash switch to maintain constant speed of de-
weight and the downhill grade. scent. Grade descent speed should be such that
the service brakes are used infrequently and re-
For faster descent, select a higher gear than that
main cool, thus retaining their effectiveness.
used for control speed. Service brakes must then be
used intermittently to prevent engine overspeed and 4. For maximum retarding, maintain the top gov-
to maintain desired vehicle speed. erned speed of the engine through the appropri-
For slower descent, select a lower gear, being care- ate selection of gears. When shifting gears, the
ful not to overspeed the engine. Occasional deactiva- engine brake will disengage when the clutch
tion of the engine brake may be necessary to main- pedal is depressed, then engage when the clutch
tain the designated road speed under these pedal is released.
conditions. 5. To cancel the engine brake application, press the
If the engine is equipped with both cruise control and lower half of the on/off switch.
an engine brake, the engine brake can operate auto-
matically while cruise control is activated. The maxi- Exhaust Brake
mum amount of braking is selected with the dash An exhaust brake is an optional auxiliary braking sys-
switches. When the vehicle returns to the set cruise tem that assists but does not replace the service
speed, the engine brake will turn off. brake system on vehicles with Cummins engines.
The engine brake will only operate when the accel- Exhaust brakes are not intended for use as the pri-
erator and clutch pedals are fully released. mary braking system during vehicle operation.
Vehicles equipped with ABS have the ability to turn The exhaust brake is controlled by a dash-mounted
the engine brake off if wheel slip is detected. The rocker switch. See Fig. 10.4.
engine brake will automatically turn back on once
wheel slip is no longer detected.
Engine Brake Operation

Depending on the brake type, the engine brake may
be disabled when engine temperature falls below a
set level.
ENGINE
NOTICE BRAKE
Do not allow the engine to exceed its governed
speed, or serious engine damage could result.
To operate the engine brake after the engine is
warmed up and the vehicle is in motion: 07/18/2011 f545792
1. Remove your feet from both the clutch and ac-
Fig. 10.4, Exhaust Brake Switch
celerator pedals.
2. Press the upper half of the on/off switch to turn To turn the exhaust brake on, press the upper half of
the engine brake on. The engine brake will en- the switch.
gage at the rate last set on the engine brake in- The exhaust brake turns itself off automatically. In
tensity switch. addition, depressing the accelerator or clutch pedal
3. Press the upper or lower half of the intensity deactivates the exhaust brake. The ABS, when ac-
switch to select the desired braking intensity. tive, also deactivates the exhaust brake.
Use the intensity switch set at the LOW position
when driving on flat, open stretches of road. If
the service brakes are still required to slow down
on a grade, switch to a higher setting on the
10.4
Exhaust Brake Operation • The exhaust brake retards the vehicle with
a smooth braking effect.
WARNING • During a descent, the tachometer usually
shows a drop in rpm, depending on the
Do not use the exhaust brake when driving on grade and the vehicle load.
slippery or low-traction road surfaces. Failure to
• Depending on the grade and vehicle load,
follow this precaution could result in a loss of
vehicle control and possible personal injury or the retarding force of the exhaust brake
property damage. may be noticeable.
1. 5. Apply the service brakes to reduce engine rpm

Before starting the engine, make sure that the
exhaust brake is off. Wait until the engine has or make a slower descent by using a lower gear.
reached normal operating temperature before 6. Make sure the exhaust brake is turned off before
activating the exhaust brake. shutting down the engine.
2. When approaching a downhill grade, press the
upper half of the exhaust brake switch to turn the Power Takeoff (PTO) Governor
exhaust brake on. When the exhaust brake is on,
the status bar is illuminated. Engine power takeoffs (PTO) are devices used to tap
into engine power to run auxiliary devices, such as
3. Remove your feet from the accelerator and hydraulic pumps that power additional equipment.
clutch pedals. The following are general guidelines for operating a
PTO.
NOTICE • Set the parking brake and put the transmission
in neutral.
Do not allow the engine to exceed its governed
speed, or serious engine damage could result. • Press the upper half of the PTO switch. When
the status bar light is steadily illuminated, the
NOTE: The exhaust brake is only active when PTO is engaged and ready to operate. In sta-
engine speed is between 1100 and 2700 rpm. tionary mode, the vehicle must remain in neu-
4. While going down a grade, use a low enough tral with the parking brake set.
gear to safely descend with a minimum applica- • To activate the mobile mode, shift from neutral
tion of the service brakes. As a general guide- to reverse, 1st, or 2nd gear. The clutch will
line, use the same gear as you would to ascend open and the PTO will disengage for a mo-
the hill. ment.
The following conditions should exist if the brake • Touch the accelerator pedal to close the clutch
is operating properly: and engage the PTO in mobile mode. The
• A slight change in the sound of the engine PTO may be operated with the transmission in
may be noticeable. neutral or reverse, 1st, or 2nd gears only. Do
not attempt to change gears while the vehicle
• Exhaust smoke should appear normal. is moving. The transmission will ignore the re-
• Engine temperature should remain in the quest.
normal operating range. • To deactivate mobile mode, bring the vehicle to
• Road speed will usually decrease when the a stop. The clutch will open and shut down
exhaust brake is applied during a descent. power to the PTO.
When the vehicle is carrying a heavy load • To resume stationary mode, shift to neutral.
or the grade is extremely steep, you may The PTO will engage.
need to apply the service brakes occasion-
ally. • To deactivate stationary mode, press the lower
half of the PTO switch. When the light in the
switch goes out, power to the PTO is shut off.
10.5
11
Emissions and Fuel
Efficiency
Greenhouse Gas Emissions and Fuel Consumption Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.1
EPA-Regulated Emissions Aftertreatment Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.1
Diesel Exhaust Fluid and Tank, EPA10 and Newer Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.3
Emissions and Fuel Efficiency
Greenhouse Gas Emissions • Engine lube oil must have a sulfated ash
level less than 1.0 wt %; currently referred
and Fuel Consumption to as CJ-4 oil.
Standards IMPORTANT: Using non-specification fuels or
oils can lead to shortened diesel particulate filter
Vehicles and/or engines manufactured after Decem-
ber 31, 2006 and domiciled in the U.S. or Canada (DPF) cleaning or replacement intervals. For
are required to meet all EPA and NHTSA regulations example, using CJ-4+ oil with 1.3% sulfated ash
effective as of the vehicle build date. Engines manu- (30% more ash content) may result in the need
factured between January 1, 2007 and December 31, for DPF cleaning or replacement 20 to 30%
2009 meet EPA07 requirements. Engines manufac- sooner than would normally be required.
tured between January 1, 2010 and December 31,
2012 meet EPA10 requirements. IMPORTANT: See the engine manufacturer’s
operation manual for complete details and op-
Model year 2013 and later vehicles meet additional eration of the ATS.
requirements as specified by NHTSA and EPA 2014
fuel efficiency and greenhouse gas emission stan- EPA07 Engines
dards (GHG14). These vehicles are equipped with
components that increase fuel efficiency and reduce Engines built between January 1, 2007 and Decem-
GHG emissions. Components may include, but are ber 31, 2009 are required to meet EPA07 guidelines
not limited to, low-rolling resistance tires; aerody- for reduced exhaust emissions of particulate matter
namic devices such as hood, cab/sleeper extenders, and nitrogen oxides (NOx). NOx is limited to just
and fuel tank fairings; vehicle speed limiter; and idle over 1 gram per brake horsepower hour (g/bhp-hr),
shutdown timer. If replacement of any drag-reducing and particulate matter cannot exceed 0.01 g/bhp-hr.
component is required, the replacement component The EPA07 ATS varies according to engine manufac-
must meet or exceed the drag reduction performance turer and vehicle configuration, but the exhaust muf-
of the originally installed component in order to main- fler is replaced by an aftertreatment device (ATD).
tain compliance with GHG14. Inside the ATD, the exhaust first passes over the die-
sel oxidation catalyst (DOC), then passes through
EPA-Regulated Emissions the diesel particulate filter (DPF), which traps soot
Aftertreatment Systems particles. The soot is burned to ash during a process
called regeneration (regen).
IMPORTANT: Depending on local jurisdictional
guidelines, vehicles that are domiciled outside of EPA10 and Newer Engines
the U.S. and Canada may not have emissions
The EPA mandates that all engines built after De-
aftertreatment systems (ATS) that are compliant cember 31, 2009 must reduce the level of emissions
with EPA regulations. exhausted by the engine to the following levels:
• Nitrogen Oxides (NOx) – 0.2 g/bhp-hr
NOTICE
• Particulate Matter (PM) – .01 g/bhp-hr
Follow these guidelines for engines that comply
To meet EPA guidelines, engines that are compliant
with EPA07 or newer regulations, or damage may
with EPA10 and newer regulations use an ATS that
occur to the aftertreatment device (ATD) and the
has, in addition to a DOC/DPF device like that used
warranty may be compromised.
in an EPA07 ATD, a Selective Catalytic Reduction
• Use ultralow-sulfur diesel with 15 ppm sul- (SCR) devide to reduce NOx downstream of the en-
fur content or less. gine. After exhaust gases leave the DPF, a controlled
quantity of diesel exhaust fluid (DEF) is injected into
• Do not use fuel blended with used engine
the exhaust stream. In the presence of heat, DEF is
lube oil or kerosene. converted to ammonia gas, which reacts with NOx in
the selective catalyst chamber to yield nitrogen and
water vapor, which exit through the tailpipe.
11.1
Regeneration
The harder an engine works, the better it disposes of
soot. If the exhaust temperature is high enough, a
process called passive regeneration (regen) occurs
as the vehicle is driven normally. However, if the en-
gine isn’t running hot enough, the electronic controls
may initiate an active regen, whereby extra fuel is
injected into the exhaust stream to superheat and
reduce the soot trapped in the DPF to ash. Active
regen happens only when the vehicle is moving
above a certain speed, determined by the engine
manufacturer. See your engine operation manual for
complete details. Both active and passive regen hap-
pen automatically, without driver input. 08/02/2011 f610852a
WARNING Fig. 11.1, Regen Switch
in progress or prevent the start of a regen, press the

Active regeneration can occur automatically any-
lower half of the switch. Regen is then delayed until
time the vehicle is moving. The exhaust gas tem-
the switch is no longer active.
perature could reach 1500°F (800°C), which is hot
enough to cause a fire, heat damage to objects NOTE: The regen switch can initiate a parked
or materials, or personal injury to persons near regen only when the DPF lamp is illuminated.
the exhaust outlet. The exhaust temperature can
remain high even after the vehicle has stopped.
When stopping the vehicle shortly after an auto-
matic regen, ensure the exhaust outlets are di-
rected away from structures, trees, vegetation,
flammable materials, and anything else that may
be damaged or injured by exposure to high heat.
See Regen Switches, below, for instructions on
preventing automatic regen if necessary.
When operating conditions do not allow for ATD filter
cleaning by active or passive regen, the vehicle may
require a driver-activated parked regen. When this
occurs, the DPF lamp illuminates, indicating that a
regen is required. The driver must either bring the
vehicle up to highway speed to increase the load 11/01/2006 f610852
(thus starting an active regen), or park the vehicle
and initiate a parked regen. See Regen Switches, Fig. 11.2, Regen Request/Inhibit Switch
below, for instructions on initiating a parked regen.
Regen Switches WARNING

The regen request switch, located on the dash, is During parked regen, exhaust temperatures are
used to initiate a parked regen. See Fig. 11.1. The very high and could cause a fire, heat damage to
function of the switch varies by the engine make and objects or materials, or personal injury to per-
model in the vehicle. See the engine operation sons near the exhaust outlet.
manual for switch operation details. Before initiating a parked regen, make certain the
Some vehicles may be equipped with a regen exhaust outlets are directed away from struc-
request/inhibit switch. See Fig. 11.2. To stop a regen tures, trees, vegetation, flammable materials, and
11.2
anything else that may be damaged or injured by Malfunction Indicator Lamp (MIL)
prolonged exposure to high heat.
A steadily illuminated yellow malfunction indicator
To initiate a parked regen, perform the following lamp (MIL) indicates an engine fault that affects the
steps. emissions. See Fig. 11.5.
1. Park the vehicle away from all flammable materi-
als, put the transmission in neutral, and set the DPF Lamp
parking brake. When soot accumulates in the DPF and the DPF sta-
2. Start and warm the engine until the coolant tem- tus lamp illuminates, see Fig. 11.6, perform a parked
perature is at least 150°F (66°C). regen or bring the vehicle up to highway speed to
increase the load (thus starting an active regen).
3. Press and hold the regen switch for five sec-
onds. The engine will increase rpm and initiate If the DPF status lamp blinks while the CHECK en-
the regen process. As the regen process is initi- gine lamp is illuminated, initiate a parked regen im-
ated, engine rpm increases and the HEST lamp mediately in order to prevent an engine derate.
illuminates to indicate extremely high exhaust If the red STOP engine lamp illuminates with the
temperatures. blinking DPF lamp and the CHECK engine lamp,
IMPORTANT: The driver must remain with the begin a parked regen in order to prevent an engine
shutdown. Park the vehicle and perform a parked
vehicle during the entire regen cycle.
regen.
4. The regen cycle will finish after 20 to 60 minutes,
at which time engine idle speed drops to normal High Exhaust System Temperature
and the vehicle can be driven normally. The (HEST) Lamp
HEST lamp is extinguished when vehicle speed
exceeds 5 mph (8 km/h) or the system has Slow (10-second) flashing of the high exhaust sys-
cooled to normal operating temperature. tem temperature (HEST) lamp indicates that a
parked regen is in progress, and the engine’s high
5. To stop a parked regen at any time during the idle speed is being controlled by the engine software,
process: not the vehicle driver.
• depress the clutch pedal, brake pedal, or Steady illumination of the HEST lamp alerts the
accelerator pedal; driver of high exhaust temperature during the regen
• press and hold the regen inhibit switch until process if the vehicle speed is below 5 mph (8 km/
idle returns to normal; h), or during a parked regen. See Fig. 11.7.
• shut down the engine. Maintenance

ATS Warning Lamps Authorized service facilities must perform any DPF
service. For warranty purposes, maintain a record
There are three warning lamps that alert the driver of that includes:
high exhaust temperature, the need to perform a
• date of cleaning or replacement;
parked regen or service the DPF, or of an engine
fault that affects emissions. A decal attached to the • vehicle mileage;
driver’s sun visor explains the ATS warning lamps.
See Fig. 11.3. • particulate filter part number and serial number.
See Fig. 11.4 for an explanation of the ATS warn-

ings, and actions required to avoid engine protection
Diesel Exhaust Fluid and Tank,
sequences. EPA10 and Newer Engines
Diesel Exhaust Fluid
Diesel exhaust fluid (DEF) is used in the ATS to
lower NOx in the exhaust stream. DEF is colorless
11.3
IMPORTANT
DPF Regen Needed Diesel Particulate Filter (DPF)
1
regeneration is needed.
If flashing, regenerate as soon as
possible. Engine derate possible.
2
Hot Exhaust Hot exhaust can cause fire.
Keep flammables and people away
from exhaust.
3
DEF Refill Needed Diesel Exhaust Fluid (DEF) level is
low. Engine derate likely.
DEF
Refill tank with certified DEF.
See operator’s manual for complete instructions. 24−01656−000
11/30/2010 f080161
Fig. 11.3, Warning Lamp Decal, Sun Visor
and close to odorless (it may have a slightly pungent Pre-2013 DEF supply lines are electrically-heated
odor similar to ammonia). It is nontoxic, nonflam- and are purged when the engine is shut down; com-
mable, and biodegradable. It is mildly corrosive to plete purging of the DEF lines requires approximately
aluminum, but does not affect the strength or struc- five minutes after the engine is shut down.
ture of the aluminum.
DEF supply lines with engine model year 2013 and
White crystals may be noticeable around compo- newer are designed to survive freezing conditions
nents that come into contact with DEF. The crystals while containing DEF, so purging is not required.
are easily removed with water.
DEF consumption varies depending on ambient con- DEF Tank
ditions and vehicle application. Engines that are compliant with EPA10 and newer
regulations are equipped with a DEF tank located on
Freezing Conditions the driver’s side of the vehicle behind the battery box
DEF freezes to slush at around 12°F (-11°C). It is not or forward of the fuel tank. See Fig. 11.8. The DEF
damaged or destroyed if frozen, and is fully usable tank has a 19 mm filler neck inlet that prevents the
when thawed. The DEF in the tank is allowed to hose from a diesel outlet from being inserted, and
freeze while a vehicle is non-operational. At start-up, has a blue cap for easy identification.
normal operation of the vehicle is not inhibited if the
DEF is frozen; an immersion heater with engine cool-
ant flowing through it warms the DEF once the en-
gine is running, allowing the SCR system to operate.
11.4
EXHAUST AFTERTREATMENT SYSTEM INFORMATION

INDICATOR WARNING
CHECK CHECK STOP
LAMP(S)
(Solid) (Flashing) (Flashing) (Flashing)
Level 1 Level 2 Level 3 Level 4
Indicator Lamp Filter Regeneration Filter Regeneration Parked Regeneration Parked Regeneration Required − HEST (High Exhaust
Message(s) Recommended Necessary Required − Engine Engine Shut Down System Temperature)
Derate
Diesel Particulate Filter is reaching Filter is now Filter has reached Filter has exceeded Flashing
Filter Condition capacity. reaching maximum maximum capacity. maximum capacity. A regeneration is in
Switch.
capacity. progress.
Required Action Bring vehicle to To avoid engine Vehicle must be Vehicle must be parked and a
highway speeds to derate bring vehicle parked and a Parked Parked Regeneration or Service Solid
allow for an Automatic to highway speeds Regeneration must Regeneration must be performed. Exhaust Components
Regeneration or to allow for an be performed − Check engine operator’s manual and exhaust gas are
perform a Parked Automatic engine will begin for details −engine will shut down. at high temperature.
Regeneration. Regeneration or derate. When stationary, keep
perform a Parked away from people and
Regeneration as flammable materials
soon as possible. or vapors.
For a driver performed Parked Regeneration, vehicle must be equipped with a dash mounted Regeneration Switch.
See Engine Operator’s Manual for complete Regeneration Instructions.

24−01583−000B
06/29/2009 f080147
Fig. 11.4, ATS Warning Lamps
09/25/2006 f610814a 09/25/2006 f610815a
Fig. 11.5, Malfunction Indicator Lamp (MIL) Fig. 11.6, Diesel Particulate Filter (DPF) Status Lamp
Fuel/DEF Gauge DEF in the tank. The DEF light bar illuminates as fol-
lows.
The diesel fuel and DEF levels are measured in a
dual-purpose gauge. See Fig. 11.9. • Four bars illuminated green—Between 75%
and 100% full
Fuel level is indicated at the top of the gauge. Below
the fuel level, a low fuel warning lamp illuminates • Three bars illuminated green—Between 50%
amber when the fuel level drops below 1/8th of the and 75% full
capacity. • Two bars illuminated green—Between 25%
The lower portion of the gauge has a DEF warning and 50% full
lamp that illuminates amber when the DEF tank is • One bar illuminated green—Between approxi-
near empty, and a lightbar that indicates the level of mately 10% and 25% full
11.5
• One bar of the DEF level indicator illuminates

amber—DEF very low, refill DEF.
• The DEF warning lamp illuminates solid amber.
DEF Empty
When the DEF level reads empty, the following
lamps notify the drive. See Fig. 11.11.
• One bar of the DEF level indicator flashes
red—DEF empty, refill DEF.
09/25/2006 f610816a • The DEF warning lamp flashes amber.
Fig. 11.7, High Exhaust System Temperature (HEST) • The MIL lamp illuminates.
Lamp
Pre-2013 Detroit engines: Power is limited, with a 55
mph (90 km/h) speed limit.
Cummins and 2013 Detroit engines: Power is limited
with progressively harsher engine power limits
applied.
DEF Tank Empty and Ignored

If the empty warning is ignored and the DEF tank is
not refilled, the red STOP engine lamp illuminates in
addition to the MIL lamp and CHECK engine lamp
(on vehicles with a Cummins ISB or ISC/L engine.)
See Fig. 11.12.
If the DEF is not refilled, a 5 mph (8 km/h) speed
1 limit is applied after the next engine shutdown, while
2 parked and idling, or if a fuel refill is detected.
07/24/2009 f470541
1. DEF Tank 2. Fuel Tank
DEF Contamination or SCR Tampering
Fig. 11.8, DEF Tank Located Forward of the Fuel Tank NOTICE
• One bar illuminated amber—DEF very low, re-
Once contaminated DEF or tampering has been
fill DEF
detected, the vehicle must be taken to an autho-
• One bar flashing red—DEF empty, refill DEF rized service facility to check the SCR system for
damage and to deactivate the warning lights and
DEF Warnings and Engine Limits engine limits.
IMPORTANT: Ignoring the DEF warning lights If contaminated DEF or tampering with the ATS is
results in limited engine power, with the applica- detected, the DEF warning light flashes and the MIL
tion of a 5 mph (8 km/h) speed limit. lamp illuminates to warn the driver. The CHECK en-
gine lamp also illuminates on vehicles with a Cum-
DEF Level Low—Initial Warning mins ISB or ISC/L engine. See Fig. 11.12.
When the DEF level is low, the following lamps notify • Detroit engines: Engine power is limited with
the driver. See Fig. 11.10. Refill the DEF tank in progressively harsher limits applied. If the fault
order to cancel the warning sequence.
11.6
1/2 1/2 1/2

ULTRA LOW SULFUR ULTRA LOW SULFUR ULTRA LOW SULFUR
DIESEL FUEL ONLY DIESEL FUEL ONLY DIESEL FUEL ONLY
E F E F E F
DEF DEF DEF
1 E F E F E F
2
A B C
11/08/2010 f611037
A. Green bars—DEF level indicators C. One bar flashing red—DEF empty, refill DEF
B. One bar illuminated amber—DEF very low, refill DEF
1. Low Fuel Warning Lamp 2. DEF Warning Lamp
Fig. 11.9, Fuel/DEF Gauge
A A
B B
07/09/2009 f470537 11/08/2010 f470539a

A. DEF Warning Lamp (illuminated) NOTE: MIL illuminates. CHECK engine lamp illuminates
B. DEF Lightbar (one bar amber) if Cummins ISB or ISC/L engine. Engine power is lim-
ited.
Fig. 11.10, DEF Level Low Initial Warning A. DEF Warning Lamp (flashing)
B. DEF Lightbar (one bar flashing red)
is not corrected, the STOP engine light illumi-
nates and a 5 mph (8 km/h) speed limit is ap- Fig. 11.11, DEF Empty Warning
plied after the next engine shutdown, while
parked and idling, or if a fuel refill is detected.
• Cummins engines: Engine power is limited with
progressively harsher limits applied. If the fault
is not corrected, the STOP engine light illumi-
nates and a 5 mph (8 km/h) speed limit is ap-
plied after the next engine shutdown, or while
parked and idling.
11.7
11/08/2010 f470540a
NOTE: STOP engine light and MIL illuminate, engine
power is limited, speed limit of 5 mph (8 km/h)
A. DEF Warning Lamp (flashing)
B. DEF Lightbar (one bar flashing red)
Fig. 11.12, DEF Empty and Ignored Warning
11.8
12
Brake Systems
Air Brake System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.1
Meritor WABCO® Antilock Braking System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.3
Roll-Stability Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.5
Brake Systems
Air Brake System the rear brake chambers (on which the axle
load has been greatly reduced) receive reduced
General Information, Brake System (proportional) air pressure, while the front axle
A dual air brake system consists of two independent
brake chambers receive full (normal) air pres-
air systems that use a single set of brake controls. sure. This results in a different brake pedal
Each system has its own reservoirs, plumbing, and "feel," as the pedal seems to require more travel
brake chambers. The primary system operates the and/or effort to slow or stop the vehicle. How-
service brakes on the rear axle; the secondary sys- ever, the air brake proportioning system actually
tem operates the service brakes on the front axle. improves vehicle control when the tractor is in
Service brake signals from both systems are sent to bobtail mode. When the tractor is towing a
the trailer. trailer, the rear brake chambers will receive full
(normal) application air pressure.
Brake System Operation
NOTE: If equipped with main and auxiliary
transmissions, do not shift both transmissions
WARNING into neutral while the vehicle is rolling. Shifting
Do not operate the vehicle with the front brakes both transmissions back into gear would be diffi-
backed off or disconnected. Backing off or dis- cult while the vehicle is rolling.
connecting the front brakes will not improve ve- On tractor-trailer vehicles, if both the primary and
hicle handling and may lead to loss of vehicle secondary systems become inoperative, the trailer
control, resulting in property damage or personal service brakes or spring parking brakes will automati-
injury. cally apply when air pressure drops below 35 to 45
Before driving your vehicle, allow time for the air psi (241 to 310 kPa). The tractor spring parking
compressor to build up a minimum of 100 psi (690 brakes will automatically apply when air pressure
kPa) pressure in both the primary and secondary drops below 20 to 30 psi (138 to 207 kPa). On
systems. Monitor the air pressure system by observ- straight trucks, spring parking brakes will apply when
ing the dual system air pressure gauge and the low- air pressure drops below 20 to 30 psi (138 to 207
air-pressure warning light and buzzer. The warning kPa). Do not wait for the brakes to apply automati-
light and buzzer shut off when air pressure in both cally. When the warning light and buzzer first come
systems reaches 64 to 76 psi (441 to 524 kPa). on, immediately bring the vehicle to a safe stop. Be-
fore continuing operation of the vehicle, correct the
IMPORTANT: Before driving the vehicle, secure cause of the air loss.
all loose items in the cab so that they will not fly
forward during a full brake application. Make WARNING
sure all passengers are wearing seat belts.
During normal brake stops, depress the foot brake If a trailer or combination vehicle is not equipped
control pedal until braking action slows down the ve- with spring parking brakes, do not park it by pull-
hicle. Increase or decrease the pressure on the ing out only the trailer air supply valve knob.
pedal so that the vehicle comes to a smooth, safe This would apply only the trailer service brakes.
stop. Apply the spring parking brakes if the vehicle is If air were to bleed from the trailer brake system,
to be parked. the trailer brakes would release, possibly causing
an unattended runaway vehicle.
When parking a vehicle attached to a trailer that
does not have spring parking brakes, apply the trac-
tor parking brakes. Chock the trailer tires before dis- WARNING
connecting the vehicle from the trailer.
Do not use the trailer service brakes for parking;
IMPORTANT: An air brake proportioning system they are not designed for this purpose. If air
may be used in tractor air brake systems when bleeds out of the trailer air tank during parking,
the vehicle is not equipped with antilock braking the vehicle could roll, causing serious personal
system (ABS). When operating in bobtail mode, injury or property damage.
12.1
Brake Systems
NOTICE
5
Never apply the service and spring parking
brakes simultaneously. To do so transmits exces-
sive input force to the brake components, which
could damage or cause eventual failure of brake 6
actuating components.
Do not use the spring parking brakes if the ser-
vice brakes are hot, such as after descending a
steep grade. To do so could damage the brakes.
Allow hot brakes to cool before using the spring
parking brakes.
Do not use the spring parking brakes during
freezing temperatures if the service brakes are 4
wet. To do so could cause them to freeze. If the 3
brakes are wet, drive the vehicle in low gear and
2
lightly apply the brakes to heat and dry them.
05/07/2001 1 f610493
Brake Controls 1. Tilt/Telescopic Steering Column Lever
2. Four-Way Hazard Flasher
The trailer brake lever is used for applying the trailer 3. Turn Signal Lever
brakes without applying the truck or tractor service 4. Headlight Dimmer Switch
brakes. It is usually mounted on the steering column. 5. Electric Horn
See Fig. 12.1. The valve can be partially or fully ap- 6. Trailer Brake Control Lever
plied, but in any partially on position it will be overrid-
Fig. 12.1, Trailer Brake Control Lever
den by a full application of the service brake pedal.
Moving the lever clockwise (down) applies the trailer
brakes, while moving it counterclockwise (up) re-
leases the trailer brakes. The lever will remain in the 1
2
selected position until it is manually moved.
The red octagonal-shaped knob actuates the trailer
air supply valve. See Fig. 12.2. After the vehicle’s air
hoses are connected to a trailer and the pressure in
both air systems is at least 65 psi (448 kPa), the
trailer air supply valve must be pushed in. It should
stay in to charge the trailer air supply system and to 03/10/99 f610291
release the trailer spring parking brakes. 1. Trailer Air-Supply-Valve Knob
Pull the trailer air supply valve out before disconnect- 2. Parking-Brake-Valve Knob
ing a trailer or when operating a vehicle without a Fig. 12.2, Brake Valve Knobs
trailer. If pressure in both air systems drops to 35 to
45 psi (241 to 310 kPa), the trailer air supply valve If the trailer is not equipped with spring parking
automatically pops out, exhausting the trailer air sup- brakes, pulling out the parking brake valve applies
ply, and applying the trailer service or spring parking the tractor spring parking brakes and the trailer ser-
brakes. vice brakes. When the tractor and trailer parking
The yellow diamond-shaped knob actuates the park- brakes (or trailer service brakes) are both applied,
ing brake valve. See Fig. 12.2. Pulling out the park- the trailer brakes are released by pushing in the
ing brake valve applies both the tractor and trailer trailer air supply valve, leaving the tractor parking
spring parking brakes and automatically causes the brakes applied. Air pressure in the primary or sec-
trailer air supply valve to pop out. ondary reservoir must be at least 65 psi (448 kPa)
12.2
Brake Systems
before the tractor spring parking brakes, or the trailer secondary air system will continue to operate the
service or spring parking brakes, can be released. front brakes and the trailer brakes (if equipped).
On trailers not equipped with spring parking brakes, Secondary Air System
chock the trailer tires before disconnecting the truck
or tractor. Loss of air pressure in the secondary air system
causes the front axle brakes to become inoperative.
When parking a truck or tractor with a trailer (combi- The primary air system will continue to operate the
nation vehicle), and the trailer is not equipped with rear service brakes and the trailer brakes (if
spring parking brakes, apply the truck or tractor equipped).
spring parking brakes.
Brake System Conditions Automatic Slack Adjusters

Automatic slack adjusters should never be manually
The warning light and buzzer come on if air pressure adjusted except during routine maintenance of the
drops below 64 to 76 psi (441 to 524 kPa) in either foundation brakes (e.g., replacing shoes), during
system. If this happens, check the dual system air slack adjuster installation, or in an emergency situa-
pressure gauge to determine which system has low tion.
air pressure. Although the vehicle’s speed can be
reduced using the foot brake control pedal, either the When the brake pushrod stroke exceeds the legal
front or rear service brakes will not be operating at brake adjustment limit on a vehicle, there is likely a
full capacity, causing a longer stopping distance. mechanical problem with the foundation brake com-
Bring the vehicle to a safe stop and have the air sys- ponents or the adjuster is improperly installed.
tem repaired before continuing. Visit a repair facility as soon as possible when
IMPORTANT: In the event of a total loss of ser- brakes equipped with automatic slack adjusters are
vice brakes with full system air pressure, use determined to be out of adjustment.
the parking brake control valve (yellow knob) to
bring the vehicle to a complete stop in the saf- NOTICE
est location possible.
Manually adjusting an automatic slack adjuster to
Before a vehicle with insufficient system air pressure bring the pushrod stroke within legal limits is not
can be moved, the spring parking brakes must be repairing. In fact, continual adjustment of auto-
released by applying an external air source at the matic slack adjusters may result in premature
gladhands, or by manually caging the parking brake wear of the adjuster itself. Further, the improper
springs. adjustment of some automatic slack adjusters
may cause internal damage to the adjuster,
WARNING thereby preventing it from properly functioning.
Do not release the spring parking brakes and Meritor WABCO® Antilock
then drive the vehicle. There would be no means
of stopping the vehicle, which could result in se- Braking System
rious personal injury or vehicle damage. Before
The Meritor WABCO Antilock Braking System (ABS)
releasing the spring parking brakes, make the
is an electronic wheel speed monitoring and control
connection to a towing vehicle or chock the tires.
system that works with the standard air brake sys-
After correcting the brake system problem, uncage tem. ABS passively monitors vehicle wheel speed at
the spring parking brakes before resuming normal all times, and controls wheel speed during emer-
vehicle operation. gency stops or wheel lock situations.
Primary Air Brake System IMPORTANT: For proper ABS system operation,
do not change tire sizes. The sizes of the tires
Loss of air pressure in the primary air system causes installed during production are programmed into
the rear service brakes to become inoperative. The the electronic control unit. Installing different
12.3
Brake Systems
sized tires could result in a reduced braking patibility will result in the illumination of the trailer
force, leading to longer stopping distances. ABS lamp during vehicle start-up and fault detection.
See Fig. 12.3.
ABS includes signal-generating tone wheels and sen-
sors located in the wheel hubs of each sensed
wheel. The sensors transmit vehicle wheel speed
1
WHEEL
information to an electronic control unit (located be- SPIN
hind the center dash). The control unit’s main circuit
interprets the speed sensor signals and calculates
wheel speed, wheel retardation, and a vehicle refer-
ence speed. If the calculations indicate wheel lockup,
the main circuit signals the appropriate modulator
valve to reduce braking pressure. During emergency
2 3
braking, the modulator valve alternately reduces, in-
creases, or maintains air pressure supply in the 07/15/2011 f610752
brake chamber to prevent front and rear wheel
1. ATC Warning Light 3. Trailer ABS Warning
lockup. 2. Tractor ABS Warning Light
The Meritor WABCO ABS combines one front-axle Light
control channel with one rear-axle control channel to Fig. 12.3, ABS Dash Lights
form one control circuit. For example, the sensor and
modulator valve on the left-front axle form a control The trailer ABS lamp will not illuminate unless a com-
circuit with the sensor and modulator valve on the patible trailer is connected to the tractor. The dash-
right-rear axle. If, during vehicle operation, the safety mounted lamp will operate as follows when a com-
circuit senses a failure in any part of the ABS, the patible trailer is properly connected to the tractor:
tractor ABS warning lamp illuminates and the control
circuit where the failure occurred is switched to nor- • When the ignition key is turned to the ON posi-
mal braking action. The remaining control circuit will tion, the trailer ABS lamp will illuminate mo-
retain the ABS effect. Even if the ABS is completely mentarily, then turn off.
inoperative, normal braking ability is maintained. An • If the lamp illuminates momentarily during ve-
exception would be if a modulator valve (or combina- hicle operation, then shuts off, a fault was de-
tion modulator valve) is damaged and inoperative. As tected and corrected.
these components are an integral part of the air
brake system, normal braking may be impaired or • If the lamp illuminates and stays on during ve-
inoperative. hicle operation, there is a fault with the trailer
ABS. Repair the trailer ABS system immedi-
Although the ABS improves vehicle control during ately to ensure full antilock braking capability.
emergency braking situations, the driver still has the
responsibility to change driving styles depending on IMPORTANT: If a compatible trailer is con-
existing traffic and road conditions. For example, the nected, and the lamp is not illuminating momen-
ABS cannot prevent an accident if the driver is tarily when the ignition key is turned to the ON
speeding or following too closely. position, it is possible that the lamp is burnt out.
During emergency or reduced-traction stops, fully
depress the brake pedal until the vehicle comes to a Automatic Traction Control
safe stop. Do not pump the brake pedal. With the Vehicles with electronic engines and ABS may have
brake pedal fully depressed, the ABS will control all Automatic Traction Control (ATC). On these vehicles,
wheels to provide steering control and a reduced the ATC system automatically limits wheel spin dur-
braking distance. ing reduced-traction situations. In normal braking ap-
plications, the standard air brake system is in effect.
ABS, Trailer Compatibility
If the vehicle has ATC, there will be a momentary-
The Meritor WABCO ABS is designed to communi- contact rocker switch on the dash labeled Deep Mud
cate with a trailer ABS, if they are compatible. Com- and Snow with an ATC icon. See Fig. 12.4. Pressing
12.4
Brake Systems
the switch will temporarily allow more drive wheel warning lights go out if all of the tractor’s ABS com-
spin. Pressing the switch again will cycle the system ponents are working.
back to normal operation.
IMPORTANT: If any of the ABS warning lights
do not work as described above, or come on
while driving, repair the ABS immediately to en-
sure full antilock braking capability.
Roll-Stability Control
The roll-stability control system automatically reduces
engine power, applies the engine brake, and/or ap-
plies the tractor and trailer brakes when the accelera-
tion sensor detects that the vehicle is at risk of rolling
over. The control can intervene even before an advi-
sory message is displayed.
A decal (Fig. 12.5) on the auxiliary dash panel, and
an amber-colored dash indicator light (Fig. 12.6), in-
dicate that the vehicle is equipped with the roll-
05/15/2001 f610494 stability system components.
Fig. 12.4, Deep Mud and Snow Switch The dash indicator light illuminates whenever the roll-
stability control system intervenes. See Fig. 12.6.
An additional solenoid valve is installed. During
reduced-traction situations, the ATC solenoid valve NOTE: The roll-stability control indicator is lo-
controls air pressure to the modulator valves and cated on the lightbar in place of the standard
they in turn increase, hold, or reduce pressure to the WHEEL SPIN indicator.
appropriate brake chambers to provide better traction
whenever wheel spin occurs.
When the ATC system is in the NORMAL mode, it SAFETY INSTRUCTIONS
will apply gentle braking to the spinning wheel, to
feed power to the wheel(s) with better traction. If lamp indicates traction
both wheels are spinning, the system will signal the OR roll control event.
engine to reduce power. Follow instructions in
driver’s manual.
NOTICE 24−01204−000
07/11/2003 f080125
The deep snow and mud option is intended to be
used under specific slippery conditions that re- Fig. 12.5, Roll-Stability Decal
quire momentary increased wheel spin. Using
this option for an extended period of time may
damage the vehicle brake system. WARNING
ATC includes a deep snow and mud option to in- The Roll Stability Control system is intended only
crease available traction on extra soft surfaces like as an aid for a conscientious and alert driver.
snow, mud, or gravel. The activation of the deep Carefully read the information in this manual to
snow and mud option is indicated by a flashing understand this system and its limitations. The
WHEEL SPIN lamp. Roll Stability Control system is not a substitute
After the ignition switch is turned on, the tractor ABS for safe driving procedures. Failure to drive
lamp and the WHEEL SPIN indicator lamp come on safely, and use the system properly, could result
for about three seconds. After three seconds, the in personal injury and/or death and property
damage.
12.5
Brake Systems
06/26/2003 f602128
Fig. 12.6, Roll-Stability Indicator Lamp
12.6
13
Steering System
Power Steering System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.1
Steering System
Power Steering System ing wheel spokes should be at the 3 o’clock and 9
o’clock positions or within 10 degrees of these posi-
The power steering system includes the integral tions. See Fig. 13.1.
power steering gear, hydraulic hoses, power steering
pump, reservoir, steering wheel and column, and
other components. Some models are also equipped
with a separate hydraulic power cylinder on the right
side of the front axle, or a right-hand slave gear.
The power steering pump, driven by the engine, pro- 10 10
vides the power assist for the steering system. If the
engine is not running, there is no power assist. If the
power-assist feature does not work due to hydraulic
1 2
fluid loss, steering pump damage, or some other
cause, bring the vehicle to a safe stop. Do not drive
the vehicle until the cause of the problem has been
corrected. 10 10
WARNING
06/06/2003 f461970
Driving the vehicle without the power-assist fea-
ture of the steering system requires much greater 1. 9 o’Clock 2. 3 o’Clock
effort, especially in sharp turns or at low speeds, Fig. 13.1, Steering Wheel Centered
which could result in an accident and possible
injury.
NOTICE
Never steam clean or high-pressure wash the
steering gear. Internal damage to gear seals, and
ultimately the steering gear, can result.
Drivers should carefully use the power available with
a power steering system. If the front tires become
lodged in a deep chuckhole or rut, drive the vehicle
out instead of using the steering system to lift the
tires out of the hole.
NOTICE
Avoid turning the tires when they are against a
curb, as this places a heavy load on steering
components and could damage them.
An optional power steering fluid cooler mounted in
front of the radiator or behind the cab is available.
Certain applications may limit or require the use of a
power steering fluid cooler.
Steering Wheel Adjustment

When there is no load on the vehicle and the front
tires are pointed straight ahead, the standard steer-
13.1
14
Manual Transmissions and
Clutch
Eaton® Fuller® Transmission Operation Tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.1
Eaton Fuller Splitter and Range-Shift Transmissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.1
Eaton Fuller Deep Reduction Transmissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.4
Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.7
Manual Transmissions and Clutch
Eaton® Fuller® Transmission Eaton Fuller Splitter and

Operation Tips Range-Shift Transmissions
Refer to the Eaton website (www.roadranger.com) Combination splitter and range-shift transmissions
for additional information. allow the choice of two splitter ratios in each gear, as
well as the additional ratios provided by a low range
Follow these important operation principles:
and a high range.
• For all conditions, use the highest gear that is
still low enough to start the vehicle moving with General Information, Range-Shift
the engine at or near idle speed, and without Transmissions
slipping the clutch excessively.
When operating on-highway with no load or IMPORTANT: Not all ratios are used in each
under ideal conditions, use 1st gear to start the range, and the shift patterns vary between
vehicle moving forward. transmissions. Read the shift pattern decal on
the dash for the operating instructions for the
When operating off-road or under adverse con-
transmission installed in your vehicle.
ditions, use LOW gear to start the vehicle mov-
ing forward. The range-preselection lever selects the low or high
range for each transmission ratio. It is used once
• Use the clutch brake to stop gear rotation
during an upshift sequence and once during a down-
when shifting into LOW or reverse while the
shift sequence.
vehicle is stationary. The clutch brake is actu-
ated by depressing the clutch pedal all the way To operate a range-shift transmission, move the gear
to the floor. shift lever through all the low-range gear positions
and then pull the range-preselection lever up to
• Partially disengage the clutch to break engine move into the high-range ratios.
torque during normal gear shifts.
IMPORTANT: Always preselect range shifts
• Double-clutch between all upshifts and down-
when upshifting or downshifting. Preselection
shifts that require movement of the shift knob.
Splitting of gears does not require movement requires that the range lever be moved to the
of the shift knob. necessary position before starting to shift. Pre-
selecting range shifts prevents damage to the
• Never push the range-preselection lever down transmission and provides for smoother shifts.
into low range while operating in high range,
except when downshifting from 5th gear to 4th General Information, Splitter Control
gear.
• Do not shift from high range to low range at Dependent on the transmission model, some ratios
can be split using the splitter-control button (located
high vehicle speeds.
on the side of the gear shift lever).
• Never make a range shift or a splitter shift
while the vehicle is in reverse. IMPORTANT: Always preselect splitter shifts.
Preselection requires that the splitter-control
• Never move the range-preselection lever with button be moved to the necessary position be-
the transmission in neutral while the vehicle is fore starting to shift. Preselecting splitter shifts
moving. allows for smoother and faster shifting. Com-
• Skip ratios while shifting only when operating plete the shift immediately after preselecting the
conditions permit, depending on the load, split to avoid unnecessary wear on transmission
grade, and road speed. components.
• Never coast with the transmission in neutral.
14.1
Eaton Fuller 13-Speed Splitter and 5. Upshift from LOW (or 1st gear) through 4th gear,
double-clutching when moving the gear shift
Range-Shift Transmissions lever, and accelerating to 80 percent of engine
Eaton Fuller 13-speed transmissions have thirteen governed speed.
forward speeds and two reverse speeds. Each trans- 6. While in 4th gear, pull the range-preselection
mission consists of a 5-speed front section and a lever up into high range and move the splitter-
3-speed auxiliary section. The auxiliary section con- control button to the low (rearward) position.
tains low- and high-range ratios, plus a splitter gear. Double-clutch into 5th gear, engage the clutch,
See Fig. 14.1 for the shift pattern. and accelerate.
7. Upshift progressively through the high range
Hi 5 5 7 7 1
R Dir OD Dir OD gears.
Lo 1 3
To shift from 5th direct to 5th overdrive (or 5th
underdrive to 5th direct on RT model transmis-
A sions), move the splitter-control button to the
N high position, then immediately release the ac-
celerator. Press and release the clutch pedal,
B
6 6 8 8 then, accelerate again.
LOW Dir OD Dir OD
2 4 C D
Continue upshifting through the shift pattern.
03/13/96 f260044a Double-clutch when moving the gear shift lever
A. High Range C. High (forward) (6th to 7th, etc.); single-clutch during split shifts
B. Low Range D. Low (rearward) (6th direct to 6th overdrive, etc.).
1. Splitter Control Button
Downshifting
Fig. 14.1, Eaton Fuller 13-Speed Transmission Shift
Pattern IMPORTANT: Never use the clutch brake when
downshifting, or as a brake to slow the vehicle.
LOW gear is used only as a starting gear; it is never
used with the transmission in high range. The other 1. To downshift from 8th overdrive to 8th direct (or
four ratios are used once in the low range and once 8th direct to 8th underdrive on RT model trans-
again in the high range. missions), move the splitter-control button to the
low position, then immediately release the accel-
High range gear ratios can be split by using the erator. Press and release the clutch pedal, then
splitter-control button with the underdrive ratio (RT accelerate once the transmission has shifted.
models), or overdrive ratio (RTO models). Low range
gear ratios cannot be split. 2. Start the downshift from 8th direct to 7th over-
drive by moving the splitter-control button to the
Upshifting high position, then double-clutch into 7th gear.
1. Put the transmission in neutral. Start the engine 3. Downshift progressively through each of the high
and bring the air system pressure up to 100 to range gears, alternating the procedures in steps
120 psi (689 to 827 kPa). 1 and 2 above until reaching 5th direct.
2. Position the range-preselection lever down, in 4. When in 5th direct and ready for the downshift to
low range. 4th, push the range-preselection lever down and
move the splitter-control button to the high posi-
3. Make sure the splitter-control button is in the low tion. Double-clutch into 4th gear, engage the
(rearward) position. See Fig. 14.1. clutch, and accelerate.
4. To start the vehicle moving, press the clutch 5. Continue downshifting from 4th gear to 1st gear,
pedal to the floor, shift into LOW or 1st gear, as conditions require.
then engage the clutch with the engine at or near
idle speed. Accelerate to 80 percent of engine
governed speed.
14.2
Eaton Fuller 18-Speed Splitter and drive (rearward) position (Fig. 14.2). Double-
clutch into 1st gear.
Range-Shift Transmissions
Eaton Fuller 18-speed transmissions have eighteen Double-clutch when moving the gear shift lever
forward speeds and four reverse speeds. Each trans- (1st to 2nd to 3rd to 4th); single-clutch during
mission consists of a 5-speed front section and a split shifts (1st direct to 1st overdrive, etc.).
4-speed auxiliary section. The auxiliary section con-
tains low- and high-range ratios, plus a splitter gear. 5. When in 4th overdrive, use the range-
See Fig. 14.2. preselection lever and the splitter-control button
to upshift to 5th gear.
1 While in 4th gear, pull the range-preselection
5 5 7 7 lever up into high range and move the splitter-
Dir OD Dir OD
R 1 1 3 3 control button to the low position. Double-clutch
Dir OD Dir OD
into 5th gear, engage the clutch, and accelerate.
A
N 6. Upshift progressively through the high range
gears.
6 6 8 8
Dir OD Dir OD B
LOW LOW
2 2 4 4 To shift from 5th direct to 5th overdrive (or 5th
Dir OD
Dir OD Dir OD underdrive to 5th direct on RT model transmis-
C D sions), move the splitter-control button to the
03/13/96 f260157a
high position, then immediately release the ac-
A. High Range C. Overdrive (forward) celerator. Press and release the clutch pedal,
B. Low Range D. Direct Drive (rearward) and accelerate.
1. Splitter Control Button
Fig. 14.2, Eaton Fuller 18-Speed Transmission Shift Double-clutch when moving the gear shift lever
Pattern (6th to 7th, etc.); single-clutch during split shifts
(6th direct to 6th overdrive, etc.).
LOW gear in the front section is used only as a start-
ing gear; it is never used when the transmission is in Downshifting
high range. LOW gear can be split, to provide both a
direct and an overdrive ratio. IMPORTANT: Never use the clutch brake when
downshifting, or as a brake to slow the vehicle.
Upshifting
1. To downshift from 8th overdrive to 8th direct (or
1. Put the transmission in neutral. Start the engine 8th direct to 8th underdrive on RT model trans-
and bring the air system pressure up to 100 to missions), move the splitter-control button to the
120 psi (689 to 827 kPa). low position, then immediately release the accel-
2. Position the range-preselection lever down, in erator. Press and release the clutch pedal, then
low range and make sure the splitter-control but- accelerate once the transmission has shifted.
ton is in the low position. See Fig. 14.2. 2. Start the downshift from 8th direct to 7th over-
3. To start the vehicle moving, press the clutch drive by moving the splitter-control button to the
pedal to the floor, shift into LOW, then engage high position, then immediately double-clutch into
the clutch with the engine at or near idle speed. 7th gear.
To shift from LOW direct to LOW overdrive, 3. Downshift progressively through each of the high
move the splitter-control button into the overdrive range gears, alternating the procedures in steps
(forward) position, then immediately release the 1 and 2 above until reaching 5th direct.
accelerator. Press and release the clutch pedal,
and accelerate. 4. When in 4th overdrive, push the range-
preselection lever down and move the splitter-
4. Upshift from LOW overdrive to 1st direct by first control button to the high position. Double-clutch
moving the splitter-control button into the direct
14.3
through into 4th gear, engage the clutch, and 4. Upshift progressively from 1st gear through 5th
accelerate. gear, double-clutching when moving the gear
shift lever.
5. Continue downshifting from 4th overdrive to 4th
direct, then 4th direct to 3rd overdrive, etc. 5. When in 5th gear and ready to move to 6th gear,
Double-clutch when moving the gear shift lever pull the range-preselection lever up into the high
(4th to 3th, etc.); single-clutch during split shifts range. Double-clutch into 6th gear, engage the
(4th direct to 3rd overdrive, etc.). clutch, and accelerate.
Eaton Fuller 10-Speed Range-Shift NOTE: If after attempting to shift into the high
range the transmission remains in neutral, the
Transmissions range synchronizer protection device may be
Eaton Fuller 10-speed transmissions have ten selec- activated. Move the gear shift lever to neutral to
tive, evenly-spaced forward ratios. Each transmission allow the range shift to complete, then shift back
consists of a 5-speed front section, and a 2-speed into gear.
auxiliary section. The ten forward speeds are ob-
6. Upshift progressively through the high range
tained by twice using a 5-speed shift pattern: the first
gears, double-clutching when moving the gear
time in low range, the second time in high range.
shift lever and accelerating to 80 percent of en-
See Fig. 14.3 for the shift patterns, noting that the
4th/9th and the 5th/10th shift positions in the RT (di- gine governed speed.
rect ratio) transmissions are directly opposite in the
RTO (overdrive ratio) transmissions.
Downshifting
IMPORTANT: Never use the clutch brake when
A B downshifting, or as a brake to slow the vehicle.
Hi 7 9 Hi 7 10
R R
Lo 2 4 Lo 2 5 1. Downshift progressively through each of the high
range gears, double-clutching between shifts.
C
N N 2. When in 5th gear and ready to move to 4th gear,
push the range-preselection lever down into the
6 8 10 D 6 8 9 low range. Double-clutch into 4th gear, engage
1 3 5 1 3 4 the clutch, and accelerate.
03/13/96 f260043a
3. Downshift progressively through the low range
A. RT Transmissions C. High Range gears, double-clutching when moving the gear
B. RTO Transmissions D. Low Range shift lever, as conditions require.
Fig. 14.3, Eaton Fuller 10-Speed RT and RTO
Transmissions Shift Patterns Eaton Fuller Deep Reduction
Upshifting Transmissions
1. Put the transmission in neutral. Start the engine General Information
and bring the air system pressure up to 100 to
120 psi (689 to 827 kPa). Eaton Fuller 10-speed deep reduction transmissions
have a 5-speed front section, and a 2-speed auxiliary
2. Position the range-preselection lever down, in section, with a deep reduction gear. The low-low,
low range. deep reduction gear is used only when operating
3. To start the vehicle moving, press the clutch under adverse conditions. Low gear in the front sec-
pedal to the floor; shift into 1st gear, then engage tion is used only for rough, off-highway conditions, as
the clutch with the engine at or near idle speed. a starting ratio. The remaining four forward positions
Accelerate to 80 percent of engine governed are used once in the low range and once in the high
speed. range. See Fig. 14.4 for the shift pattern, noting that
the 3rd/7th and 4th/8th shift positions in RT-LL trans-
missions are opposite of the RTO-LL transmissions.
14.4
• Never move the deep reduction button from a

A 1 B
rearward position to a forward position when
5 8 5 7
1 4 1 3 the transmission is in high range.
• Deep reduction gears are best suited for heavy
C loads and steep inclines.
N N
D
Upshifting Deep Reduction
6 7 6 8
2 3 2 4 Transmissions
E F
03/13/96 f260026a There are several patterns of upshifting, depending
on the vehicle load and the road conditions. See
A. All RTO Transmissions
Table 14.1 for suggested shifting sequences.
B. All RT Transmissions
C. High Range The following instructions are recommended for start-
D. Low Range ing a loaded vehicle moving under adverse condi-
E. Deep Reduction IN (forward) tions.
F. Deep Reduction OUT (rearward)
1. Deep Reduction Button 1. Put the transmission in neutral. Start the engine,
and bring the vehicle air system pressure up to
Fig. 14.4, Eaton Fuller 10-Speed Deep Reduction Shift 100 to 120 psi (689 to 827 kPa).
Patterns
2. Position the range preselection lever down, into
Eaton Fuller 15-speed deep reduction transmissions low range.
have a 5-speed front section, and a 2-speed auxiliary
3. Move the deep reduction button to the forward
section. They also have five additional deep reduc-
position, to engage the deep reduction gears.
tion ratios. The 5-speed front section and the low
and high range sections provide ten evenly and pro- 4. Depress the clutch pedal to the floor; shift into
gressively spaced forward speeds. The five deep re- low-low gear (10-speed transmissions) or 1st
duction ratios are also evenly and progressively gear of deep reduction (15-speed transmissions);
spaced; however, they do overlap the low range ra- then engage the clutch, with the engine at or
tios, and should be used only when operating under near idle speed, to start the vehicle moving. Ac-
adverse conditions. See Fig. 14.5 for the shift pat- celerate to 80 percent of engine governed speed.
terns, noting that the 4th/9th, and the 5th/10th shift
positions in RT (direct ratio) transmissions are di- 5. For 10-speed transmissions:
rectly opposite to the RTO (overdrive ratio) positions. When ready for the next upshift, move the deep
Use the following tips when shifting: reduction button rearward, then momentarily de-
press the clutch pedal. Do not move the shift
• Use the clutch brake to stop gear rotation lever.
when shifting into low-low, low-1st (whichever
is used as a starting ratio) or reverse, when For 15-speed transmissions:
the vehicle is stationary. Shift upward from 1st gear of deep reduction to
5th gear of deep reduction, double-clutching be-
• For normal upshifts and downshifts, only a par-
tween shifts and accelerating to 80 percent of
tial disengagement of the clutch is necessary
engine governed speed. See Table 14.1.
to break engine torque.
When ready for the next upshift, move the deep
• When making the shift from a deep reduction reduction button rearward, then double-clutch
ratio to a low range ratio, move the deep re- into 4th gear.
duction button from a forward position to a
rearward position, then complete the shift im-
mediately.
14.5
10
A B
9
Lo Hi 7 9 8 1 Lo Hi 7 10
R 2 2 4 4 R 2 2 5 5
7 DR Lo DR Lo
DR DR Lo DR Lo DR
6
5
4 4
N 3 2 N
5 2
4 1
3
5
6 8 10 6 8 9
1 1 3 3 5 5 2 1 1 3 3 4 4
DR Lo DR Lo DR Lo 1 6 7 DR Lo DR Lo DR Lo
3
03/13/96 f260045a
A. Eaton Fuller RT transmissions shift pattern B. Eaton Fuller RTO transmissions shift pattern
1. High Range 4. High Range 6. Forward for IN
2. Low Range 5. Low Range 7. Rearward for OUT
3. Deep Reduction
Fig. 14.5, Eaton Fuller 15-Speed Model Shift Patterns
Eaton Fuller Shift Progressions

Deep Reduction Low Range High Range
Transmission Model Adverse Conditions Off-Highway and On-Highway and Ideal
All Conditions
Only Adverse Conditions Conditions
R R R R 5 8
1 4 1 4
10-Speed RTO
LOW 6 7
LOW−
LOW 2 3 2 3
f260335 f260333 f260336 f260337
R R R R 5 7
1 3 1 3
10-Speed RT LOW 6 8
LOW−
LOW 2 4 2 4
f260335 f260338 f260339 f260340
R R R 7 10
2
DR
5
DR Lo
2
Lo
5
Lo
2
Lo
5 R
15-Speed RTO
1 3 4 1 3 4 1 3 4 6 8 9
DR DR DR Lo Lo Lo Lo Lo Lo
f260341 f260342 f260343 f260344
6
R 2 4 R 2 4 R 2 4 R 7
DR DR Lo Lo Lo Lo
15-Speed RT 6
1 3 5 1 3 5 1 3 5 8 10
DR DR DR Lo Lo Lo Lo Lo Lo
f260345 f260346 f260347 f260348
Table 14.1, Eaton Fuller Shift Progressions
6. Shift upward from low gear (10-speed transmis- double-clutching between shifts, and accelerating
sions) or 4th gear (15-speed transmissions), to to 80 percent of engine governed speed.
the top gear in low range (see Table 14.1),
14.6
7. While in the top gear of the low-range shift pat-

tern, flip the range preselection lever up. Double- NOTICE
clutch into the bottom gear in high range (see
Table 14.1). Do not allow the clutch to slip longer than two
seconds. Clutch slippage for longer than two
8. With the transmission in high range, shift pro- seconds may severely damage the clutch disc,
gressively upward through each of the high pressure plate, or flywheel. Damage caused by
range gears (see Table 14.1), double-clutching clutch slippage due to improper break-in is not
between shifts. warrantable.
Downshifting Deep Reduction During initial operation of a new vehicle or a vehicle

with a new clutch, check for clutch slippage during
Transmissions acceleration. If the clutch slips, decelerate until the
1. With the transmission in high range, shift pro- clutch does not slip. Allow the clutch to cool 15 to 30
gressively downward to the bottom gear in high seconds, then gradually accelerate again. If the
range, double-clutching between shifts. clutch continues to slip, repeat the procedure as
many as five times. If the clutch slips after five at-
2. When in the bottom gear of the high-range shift tempts, stop the vehicle and allow the clutch to cool
pattern, push the range preselection lever down. for at least one hour. Notify your Western Star dealer
Double-clutch into the top gear of the low-range of the problem.
shift pattern.
IMPORTANT: Never move the deep reduction
Moving the Vehicle in the Proper Gear
button to a forward position when the transmis- An empty vehicle can be started in a higher gear
sion is in high range. than can a partially- or fully-loaded vehicle. Select
the gear combination that allows the vehicle to start
3. With the transmission in low range, downshift moving with an idling engine or, if necessary, just
through the low range gears, as conditions re- enough throttle to prevent stalling the engine.
quire.
Gear Shifting Techniques
Clutch Upshift into a higher gear only when the vehicle
Clutch General Information speed allows the transmission input shaft speed to
match the flywheel speed when engaging the clutch.
To ensure long service life of the clutch, start in the This technique results in the smallest speed differ-
right gear, be alert to clutch malfunctions, and know ence between the clutch disc and the flywheel, and
when to adjust the clutch. causes the least heat and wear on the clutch assem-
Typical operation will not break down the clutch fric- bly. When downshifting, increase the input shaft
tion surfaces. Heat and wear are almost nonexistent speed to match the flywheel by slightly revving the
when a clutch is fully engaged. However, during the engine.
moment of engagement, when the clutch is picking
up the load, considerable heat is generated. If a
Vehicle Loading
clutch slips excessively, high temperatures develop Clutches are designed for specific vehicle applica-
quickly between the flywheel, driven discs, and pres- tions and loads.
sure plates. An improperly adjusted or slipping clutch
can generate temperatures high enough to destroy
the clutch.
NOTICE
Exceeding vehicle load limits can result in dam-
Clutch Operation age to the clutch and the entire powertrain.
Clutch Break-In
The clutch may slip for a short time while the friction
surfaces break-in on a new or newly-installed clutch.
14.7
Clutch Brake the clutch pedal will also put a constant thrust
load on the release bearing, thinning the bearing
Apply the clutch brake by depressing the clutch lubricant and increasing the wear on the bearing.
pedal all the way to the floor plate. The last part of
pedal travel will compress the clutch brake plates Holding the Vehicle On an Incline
together, stopping the transmission input shaft. The
clutch brake stops the transmission gears from rotat- Always use the vehicle service brakes to prevent the
ing in order to quickly engage a transmission gear vehicle from rolling backwards while stopped on a
after idling in neutral. hill. Slipping the clutch on a hill to maintain vehicle
position will quickly damage the clutch assembly.
NOTICE Coasting
Never apply the clutch brake when making down- Coasting with the clutch pedal depressed and the
shifts or upshifts. If the clutch brake is applied transmission in a low gear can cause high driven
when the vehicle is moving, the clutch brake will disc speed. The clutch speed can be much higher
try to stop or decelerate the vehicle, causing under these conditions than when the engine is driv-
rapid wear of the clutch brake friction discs. Con- ing the clutch. This condition creates a hazardous
siderable heat will be generated, causing damage situation due to the lack of vehicle control and due to
to the release bearings and the transmission the high clutch disc speed. Engaging the clutch
front bearings. under these conditions can cause component dam-
age because of the shock loads to the clutch and
Using the Clutch drivetrain.
Use the clutch pedal only when starting the engine,
launching the vehicle from a stop, or shifting. To WARNING
launch a stationary vehicle, depress the clutch pedal
all the way to the floor plate (see Clutch Brake Always shift into the gear that is correct for the
above) and shift from neutral to a low gear. Slowly traveling speed of the vehicle and engage the
raise your foot until the clutch starts to engage. In clutch. Coasting with the clutch disengaged can
this position the clutch is starting to connect the prevent engagement of the correct transmission
transmission input shaft to the flywheel and is caus- gear which can cause loss of vehicle control,
ing the most heat and wear. Slightly increase the en- possibly resulting in personal injury or property
gine speed and smoothly allow the clutch pedal to damage.
return to the rest position. Do not allow the clutch to High clutch disc speeds while coasting can also
remain in the partially-engaged position any longer cause the clutch facing to be thrown off the disc.
than necessary to obtain a smooth start. Flying debris from the clutch can cause injury to
Double-clutch to shift gears while the vehicle is mov- persons in the cab.
ing. Depress the clutch pedal most of the way in, but
not all the way to the floor plate. Depressing the Clutch Maintenance
clutch pedal to the floor plate will engage the clutch
brake. Shift the transmission into neutral and fully
Checking the Clutch Adjustment
release the clutch pedal. When upshifting, wait for Report erratic clutch operation as soon as possible to
the engine speed to decrease to the road speed. give maintenance personnel a chance to inspect, lu-
When downshifting, increase the engine speed to bricate, and adjust the clutch components. Notice
match the road speed. Fully release the clutch pedal any gradual decrease in the distance the clutch
after completing the shift. pedal moves before resistance is felt.
NOTICE NOTICE
Riding the clutch while driving is damaging to Operating the vehicle with incorrect free pedal
the clutch because partial clutch engagement could result in clutch damage.
causes slippage and heat. Resting your foot on
14.8
A correctly adjusted clutch must have about 3/4 inch first or reverse gear from neutral with the clutch
(19 mm) of travel at the top of its stroke before a pedal fully depressed, the clutch pedal is out of ad-
stronger resistance can be felt. See Fig. 14.6. If the justment or the clutch brake is worn and needs to be
free pedal travel is less than this distance, have the replaced.
clutch adjusted.
Lubricating the Clutch Release Bearing
Check the clutch free pedal travel daily and note it in
the driver’s report.
NOTICE
Failure to lubricate the release bearing and link-
age as recommended could result in release
bearing and clutch damage.
On vehicles equipped with a greaseable release
bearing, the release bearing should be lubricated at
regular intervals. See the Western Star Maintenance
Manual for intervals and procedures.
02/09/96 f250306
A. Free Pedal
Fig. 14.6, Clutch Free Pedal Travel
Adjusting the Clutch

Clutches have an internal adjustment and external
linkage adjustment. See Group 25 of the Western
Star Workshop Manual for clutch adjustment proce-
dures and specifications.
NOTICE
Operating the vehicle with the clutch improperly
adjusted could result in clutch or clutch brake
failure.
Checking the Clutch Brake Operation

Clutch brake operation can be felt as an increased
resistance as the clutch pedal approaches the bot-
tom of its stroke. If the gears grind when shifting into
14.9
15
Automated and Automatic
Transmissions
Eaton® Fuller® Automated Transmissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.1
Allison Automatic Transmissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.5
Automated and Automatic Transmissions
Eaton® Fuller® Automated

Transmissions
Refer to the Eaton website (www.roadranger.com)
for additional information.
3 PTO
General Information, Automated R 4
Transmissions
The Eaton Fuller UltraShift is a heavy-duty fully auto-
N 5
mated transmission. The UltraShift uses a dry clutch SERVICE

2
system, so no clutch pedal is required to shift gears. D 6
The Eaton Fuller AutoShift transmission requires the
driver to use the clutch to start and stop the vehicle. MANUAL 7
However, the driver does not need to use the clutch 1 SHIFT
to shift gears.
LOW 8
The Eaton Fuller automated transmissions use a shift EATON FULLER
selection module located on the dash control panel. TRANSMISSIONS
See Fig. 15.1. Shifts can be made automatically, or

manually using the shift selection module. 07/20/2011 f611129
The current gear is displayed on the indicator shown 1. Upshift/Downshift Buttons

in Fig. 15.2. At the start of a shift, the current gear 2. Service Needed Indicator
continues to display until the transmission has been 3. PTO Activation Button
4. Reverse Mode Button
pulled into neutral. As the transmission is synchroniz-
5. Neutral Button
ing for the new (target) gear, the gear indicator 6. Drive Mode Button
flashes the number of the target gear. When the shift 7. Manual Mode Selector
is complete, the gear indicator displays the new gear, 8. Low Mode Button
without flashing.
Fig. 15.1, Shift Selection Module, UltraShift and
Automated Transmission Operation AutoShift Transmissions
Modes
The shift selection module controls the driving mode,
which includes drive, manual, reverse, or low.
IMPORTANT: In all modes but low, it is possible
to shift manually by pressing the upshift or
downshift selectors as needed. When the en-
gine speed is within 75 rpm of the load-based
shift point for an automatic shift, the transmis-
sion will advance the shift.
Drive Mode
Press the drive mode button (D) on the shift selec-
10/13/2003 f610680
tion module to put the transmission in drive mode.
NOTE: The gear indicator displays the current gear. In
In drive mode, upshifts and downshifts are made by this example, it displays first gear.
the transmission without driver intervention. The
Fig. 15.2, Gear Indicator
transmission will shift automatically when the driver
15.1
presses the drive mode button (D) and depresses Reverse Mode
the accelerator pedal.
To put the transmission in reverse, press the reverse
If driving conditions require, it is still possible to re- mode button on the shift selection module.
quest a manual shift. The transmission will make the
The UltraShift transmission has two reverse gears:
shift if the engine speed is within 75 rpm of the load-
reverse low and reverse high. The AutoShift trans-
based shift point for that gear.
mission may have multiple reverse gears. To shift
If the vehicle is stopped while in drive mode, the manually between the reverse gears, press the up-
upshift/downshift buttons can be used to change the shift or downshift arrow button until the desired re-
starting gear. This selection becomes the default verse gear is displayed.
starting gear until it is changed by the driver again,
Reverse low is the default reverse gear. When re-
or the vehicle is shut down.
verse low is selected, the letter R displays on the
The transmission controller adapts to the working gear indicator. See Fig. 15.3. When reverse high is
conditions of each vehicle and its driver. After selected, the letter H is displayed.
power-up or a load change, it needs to learn the new
conditions. While learning, it may hold a gear too
long before upshifting. If this occurs, start the upshift
manually. It may take three or four shifts before the
transmission succeeds in learning the new load-
based shift points, but after that it will handle the
shifting automatically.
Automatic skip shifts may occur in drive mode if con-
ditions are appropriate.
Manual Mode
In manual mode, upshifts and downshifts are made
by the driver. This allows the driver to respond to a
wide range of driving conditions, such as blind cor-
10/14/2003 f610681
ners, tight curves, and steep hills.
To change to manual mode, press the manual mode Fig. 15.3, Gear Indicator: Reverse Low Gear
button (MANUAL) on the shift selection module. If
manual mode is selected while the vehicle is moving, IMPORTANT: Under normal conditions, do not
the current gear will be maintained until the driver select reverse with the vehicle moving forward.
requests a shift using the proper upshift/downshift The vehicle must be moving at less than two miles
arrow button. If the manual mode is selected while per hour (3 km/h) before selecting reverse. If reverse
the vehicle is not moving, the starting gear will be is selected when the vehicle is moving faster, an au-
maintained until the driver requests a shift. In down- dible alert will sound and continue sounding at three-
hill situations in particular, the driver must be alert to second intervals until the vehicle slows to the proper
vehicle speed by downshifting and/or using the ser- speed or the driver selects the drive mode.
vice brakes as needed. A shift request will be refused
if the selected gear would cause engine overspeed Low Mode
or excessive lugging.
Low mode should be used to maximize engine brak-
To upshift, press the upshift arrow button on the shift ing and minimize the use of the brake pedal. It is
selection module; to downshift, press the downshift most useful when descending steep hills or when
arrow button. See Fig. 15.1. A shift request will be coming to a stop. Engine speed will be increased by
refused if the selected gear would cause engine 200 rpm and shift points will be offset by 200 rpm.
overspeed or excessive lugging.
To select low mode, press the low mode button
(LOW) on the shift selection module. When in low,
15.2
the current gear is maintained. Requests to upshift

are not enabled.
IMPORTANT: If the engine is approaching over-
speed, the transmission controller will override
the current gear setting and upshift to prevent
engine damage.
If low mode is selected from neutral while the vehicle
is stopped, the vehicle will start up in first gear and
stay there until the engine approaches overspeed.
Neutral
IMPORTANT: Always start the engine with the
10/13/2003 f610678
transmission in neutral (N) and the parking
brake set. Fig. 15.4, Gear Indicator: Power Up Dot Display
WARNING
Do not coast in neutral. Coasting in neutral can
cause an accident, possibly resulting in severe
personal injury or death.
Neutral is always available during operation, what-
ever the vehicle speed. When in neutral, requests to
upshift or downshift are ignored. If the driver selects
drive mode while the vehicle is moving in neutral, the
transmission will shift into the appropriate gear given
the engine speed.
When shifting from neutral, always depress the brake
pedal. If the brake pedal is not depressed, the trans- 10/13/2003 f610679
mission will not shift and an audible alert will sound.
To reset the transmission, select neutral again and Fig. 15.5, Gear Indicator: Neutral
attempt the shift again, this time with the brake pedal
depressed. 3. On vehicles with an AutoShift transmission, de-
press the clutch pedal all the way to the floor.
Before shutting down the engine, return the transmis-
sion to neutral. 4. Apply the service brake and start the engine.
5. On vehicles with an AutoShift transmission, re-
Powering Up
lease the clutch to allow the speed sensor on the
1. With the parking brake set, turn the ignition input shaft to get a reading, then depress the
switch on and allow the shift selection module to clutch pedal again.
power up. The gear indicator will show the dot
display, arranged in a square pattern. All dots in NOTE: When in drive mode, the transmission
the pattern should light up, without gaps or defaults to second gear when starting off. If de-
spaces. See Fig. 15.4. sired, the driver can select to start off in first
gear. No other start gear is available.
2. Wait for the gear indicator to show a solid N. See
Fig. 15.5. When the N is solid (not flashing), the 6. Select the desired mode (drive, manual, low, or
transmission controller is powered up. reverse), then select the desired starting gear.
15.3
Downshifting
WARNING
To request a downshift, push the downshift arrow
When starting or stopping on hills and grades, button on the shift selection module. If the gear is
use extra care to prevent the vehicle from rolling available, the transmission will downshift and the
back. A rollback accident could cause death, seri- new gear will display on the gear indicator. If the
ous personal injury, or property damage. gear requested is unavailable, a tone will sound.
7. On a level grade, release the parking and ser- Before starting down a hill, downshift to a speed that
vice brakes. you can control without hard pressure on the service
brakes. Before entering a curve, downshift if neces-
8. Move the vehicle forward by doing one of the sary. This lets you use some power through the
following: curve to help the vehicle be more stable in the turn.
• Vehicles with an UltraShift transmission: It also allows you to regain speed faster as you
depress the accelerator pedal. come out of the curve.
• Vehicles with an AutoShift transmission: NOTE: The AutoShift transmission is able to
release the clutch and depress the accel- perform triple downshifts when the next three
erator pedal. lower gears are available and conditions are
appropriate.
Powering Down
Skip shifts can be performed only in manual mode.
1. On vehicles equipped with an Autoshift transmis- To skip shift, press the downshift button twice or
sion, depress the clutch pedal to the floor. three times. The number of the gear engaged will
2. Bring the vehicle to a halt appear on the gear indicator.
3. Apply the service brakes. For best engine braking, select low mode while mov-
ing. In low, downshifts are performed at higher rpm
4. Select neutral (N) on the shift selection module. than in drive.
When the N on the gear indicator is solid (not
flashing), the transmission controller is ready to IMPORTANT: If the engine is approaching over-
power down. speed, the transmission controller will override
the current gear setting and upshift to prevent
5. Set the parking brake and shut down the engine.
engine damage.
Upshifting
Transmission Diagnostics
To request an upshift, push the upshift arrow button
on the shift selection module. If the gear is available, Clutch Protection Fault, UltraShift
the transmission will upshift and the new gear will Transmissions
display on the gear indicator. If the gear requested is Even though a vehicle with an UltraShift transmission
unavailable, a tone will sound. does not have a clutch pedal, it does have a me-
Upshifts are not available in low mode, except to pre- chanical clutch. As you slowly increase and decrease
vent engine overspeed. engine rpm from a stop, the mechanical clutch is en-
gaging and disengaging, just like slipping the clutch
NOTE: The AutoShift transmission is able to with a manual transmission. Excessive clutch slip-
perform triple upshifts when the next three page creates heat and reduces the life of the clutch.
higher gears are available and conditions are Conditions that can cause clutch damage include:
appropriate.
• Using the accelerator pedal to hold the vehicle
Skip shifts can be performed only in manual mode. on a hill
To skip shift, press the upshift button twice or three
• Starting the vehicle from a stop in a gear that’s
times. The number of the gear engaged will appear
too high
on the gear indicator.
• Overloading the vehicle
15.4
• Using high idle with the vehicle in gear appear on the gear indicator when the vehicle is re-
started.
The transmission controller is programmed to prevent
clutch damage. When the clutch overheats, the fol- Complete the following steps.
lowing alerts take place:
1. Set the parking brake.
• The TRANS TEMP light comes on
2. Turn off the ignition and wait at least two min-
• The gear indicator displays "C," then "A" utes.
• A warning tone sounds at one-second intervals 3. Depress the brake pedal and release the parking
brake.
The alerts continue until the clutch cools, the accel-
erator pedal is released, or the clutch is fully en- 4. On vehicles with an AutoShift transmission, de-
gaged. press the clutch partway to the floor.
5. Select neutral by pressing the neutral button (N)
System Problem
on the shift selection module, then turn on the
In the event of a problem, complete the following ignition key. Do not attempt to start the engine
steps. yet.
1. Note the driving conditions at the time the prob- 6. Release the pressure on the brake pedal slightly.
lem occurred.
7. Once the transmission is in neutral, a solid N will
2. Record the status of the transmission at the time appear on the gear indicator and the vehicle will
of the problem (current mode, current gear, en- start. Apply the service brakes and start the en-
gine speed, etc.). gine.
3. Complete the transmission reset procedure. 8. If the gear indicator continues to display a dash,
contact an authorized Western Star or Eaton ser-
Transmission Reset Procedure vice facility.
In some cases, proper transmission operation can be
restored by resetting the transmission controller. Allison Automatic
1. When it is safe to do so, stop the vehicle. Transmissions
2. Select neutral by pressing the neutral button (N) Refer to the Allison website for additional information
on the shift selection module. (www.allisontransmission.com).
3. Set the parking brake.
General Information, Allison
4. Shut down the engine.
Transmissions
5. Wait at least two minutes.
HD-series automatic transmissions have six forward
6. Restart the engine. speeds and one reverse speed. These transmissions
7. If the problem continues or the transmission have electronic shift controls that can be pro-
doesn’t achieve neutral after power-up, contact grammed to allow the use of different numbers of
an authorized Western Star or Eaton service fa- geared speeds. For instance, the transmission can
cility. be programmed to operate as a 4-speed, 5-speed, or
6-speed unit in the "primary" shift mode. If needed, a
Locked In Gear "secondary" shift mode can be programmed to pro-
vide another shift configuration to optimize vehicle
If the vehicle is shut down while in gear, the trans- use under different operating conditions.
mission may become locked in gear. The transmis-
sion will attempt to get to neutral during the next To activate a secondary shift mode, or other special
power-up if neutral is selected on the shift selection functions programmed into the electronic control unit
module. If neutral can’t be achieved, a dash (–) will (ECU), press the Mode button. See Fig. 15.6.
"MODE ON" is displayed in the indicator panel just
15.5
above the push buttons. A label just above the Mode sion fluid and will result in severe damage to the
button identifies the special function. transmission.
NOTICE
Do not allow the vehicle to coast in neutral. This
can result in severe transmission damage.
The following tips highlight important operation prin-
1
ciples.
2 • Start the engine, then check the digital display
on the shift selector. Under "Select" at the top
of the unit, the display should always show the
"primary" shift mode. Under "Monitor," the cur-
rent gear should be displayed.
• Use reverse to back the vehicle. Completely
stop the vehicle before shifting from a forward
gear to reverse, or from reverse to forward.
There is only one reverse gear.
• Select drive (D) for all normal driving condi-
10/31/94 f600369a tions. The vehicle will start out in 1st gear, and
1. Indicator Panel 2. Mode ID as speed increases, the transmission will up-
shift through each gear automatically. As the
Fig. 15.6, Allison Push Button Shift Selector vehicle slows down, the transmission will
downshift automatically.
NOTE: Each time a button is pressed on the
shift selector, a short beep will be heard. This • The pressure of your foot on the accelerator
indicates that the ECU has received input to pedal influences the automatic shifting. When
change operation. the pedal is fully depressed, the transmission
will automatically upshift near the governed
The HD-series transmission is designed to warn the speed of the engine. A partially depressed
driver of transmission malfunctions. The driver should pedal will cause the upshifts to occur at a
know the extent of the warning system in order to lower engine speed.
safely operate the vehicle.
• Occasionally the road, load, or traffic conditions
Allison Transmission Operation make it desirable to restrict the automatic shift-
ing to a lower range. The lower the gear range,
the greater the engine braking power.
WARNING
Use the up or down buttons on the shift selec-
Never shift from neutral (N) to drive (D) or re- tor to reach the desired gear. The "SELECT"
verse (R) at engine speeds above idle. The ve- indicator will display your choice, and the
hicle will lurch forward or backward, which could "MONITOR" indicator will show the selected
cause property damage and personal injury. gear once it is reached. In the lower gear
ranges, the transmission will not upshift above
the highest gear selected unless the engine
NOTICE governed speed is exceeded.
The engine should never be operated for more • Use neutral and apply the parking brake when
than thirty seconds at full throttle with the trans- the vehicle is parked with the engine running.
mission in gear and the output stalled. Prolonged
operation of this type will overheat the transmis-
15.6
16
Drive Axles
Drive Axles with Differential Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.1
Interaxle Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.2
Drive Axles
Drive Axles with Differential

Lock
The driver-controlled differential lock feature (side-to-
side wheel lock, traction control, or traction equalizer)
provides maximum traction for slippery conditions by
forcing the wheels on each drive axle governed by
the switch to rotate together. When the differential
lock is engaged, the clutch collar completely locks
the differential case, gearing, and axle shafts to-
gether, maximizing the traction of both wheels.
Differential Lock Switch

There are several differential lock options available:
07/22/2011 f545804
• a switch to control the differential lock on the
forward drive axle (see Fig. 16.1). Fig. 16.2, Rear Drive Axle Differential Lock Switch
WARNING
Locking the wheels when the vehicle is traveling
down steep grades or when the wheels are slip-
ping could damage the differential and/or lead to
loss of vehicle control, causing personal injury
NOTICE
Engage the differential lock only when the ve-
hicle is stopped or moving at less than 5 mph (8
km/h). Engaging the differential lock at high
speeds can cause internal axle damage.
07/22/2011 f545803
1. With the engine running, press the upper half of
Fig. 16.1, Forward Drive Axle Differential Lock Switch the differential lock switch to engage the differen-
tial lock.
• a switch to control the differential lock on the
2. If the vehicle is moving, briefly let up on the ac-
middle drive axle.
celerator to relieve torque on the gearing, allow-
• a switch to control the differential lock on the ing the differential to fully lock.
rear drive axle (see Fig. 16.2).
WARNING
Differential Lock Operation
Be especially careful when driving under slippery
NOTE: On some vehicles, the differential lock
conditions with the differential locked. Though
system is connected through the low speed forward traction is improved, the vehicle can still
range of the transmission. If this system is used, slip sideways, causing possible loss of vehicle
the transmission must be in the low speed control, personal injury, and property damage.
range for the wheels to fully lock. In addition,
3. Drive cautiously and do not exceed 25 mph (40
shifting out of low speed range will also disen-
km/h). When the differential is fully locked, the
gage the differential lock.
16.1
Drive Axles
turning radius will increase because the vehicle Interaxle Lock Switch
understeers. See Fig. 16.3.
The interaxle lock switch allows the driver to lock the
drive axles together. See Fig. 16.4.
A
02/09/96 f350079a
A. Turning Radius When the Differential Lock is

Engaged (understeer condition)
B. Turning Radius When the Differential Lock is
Disengaged
Fig. 16.3, Turning Radii 07/22/2011 f545802
4. Press the lower half of the differential lock switch Fig. 16.4, Interaxle Lock Switch
to disengage the differential lock after leaving
poor road conditions. Interaxle Lock Operation
NOTE: If the differential lock is engaged when
the engine is shut down, the differential lock will NOTICE
disengage.
The interaxle lock should not be engaged on a
5. If the vehicle is moving, briefly let up on the ac- vehicle with obviously spinning wheels. Engage-
celerator to allow the wheels to fully unlock, then ment at high speed or power can damage the
resume driving at normal speed. axle(s).
1. With the engine running, press the upper half of
Interaxle Lock the interaxle lock switch to engage the interaxle
The interaxle lock (axle lock, interaxle differential lock. Do not wait until traction is lost and the tires
lockout) feature is available on vehicles wth tandem- are spinning before engaging the interaxle lock.
or tridem-drive axles. The interaxle lock causes the 2. If the vehicle is moving, briefly let up on the ac-
drive axle shafts to rotate together, and is recom- celerator until the interaxle lock engages.
mended for use under adverse road conditions
where greater traction is needed.
NOTICE
See the axle manufacturer’s website for more infor-
mation. Do not operate the vehicle continuously with the
When engaged, the interaxle lock essentially makes interaxle locked during extended good road con-
the driveshaft a solid connection between the drive ditions. To do so could result in damage to the
axles. Power entering the forward drive axle is trans- axle gearing and excessive driveline and tire
mitted straight through to the rearmost axle(s). Drive- wear.
line torque is now delivered equally and the drive 3. Proceed over poor road conditions with caution.
axles, and wheels, turn together at the same speed.
The interaxle lock increases drivetrain and tire wear 4. Press the lower half of the interaxle lock switch
and should be used only when improved traction is to disengage the interaxle lock after leaving poor
required. road conditions.
16.2
Drive Axles
NOTE: If the interaxle lock is engaged when the

engine is turned off, the interaxle lock will disen-
gage.
5. If the vehicle is moving, briefly let up on the ac-
celerator to allow the interaxle lock to disengage,
then resume driving at normal speed. Once the
interaxle lock disengages, the indicator light will
go off.
16.3
17
Fifth Wheels
Fifth Wheels, General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.1
Fifth Wheel Coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.1
Fifth Wheel Uncoupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.5
Fifth Wheel Slide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.7
Fifth Wheels
Fifth Wheels, General NOTICE

Information
Do not operate the vehicle over uneven ground
such as ramps, speed bumps, curbs, etc. with
WARNING the air springs deflated. Doing this may lead to
Do not use any fifth wheel that fails to operate suspension air springs from inflating.
properly. Doing so may cause loss of vehicle
control, possibly resulting in severe personal in- Fifth Wheel Lubrication
jury or death.
Air-Suspension Dump Valve WARNING

Keep the fifth wheel plate lubricated to prevent
WARNING binding between the tractor and trailer. A binding
fifth wheel could cause erratic steering and loss
Never exhaust air from the suspension while of vehicle control, possibly resulting in personal
driving. The suspension will not absorb road injury or death.
shocks, possibly damaging components, and ve-
hicle handling may be compromised. This could The standard fifth wheel plate must be kept well lu-
result in loss of vehicle control, possibly result- bricated with chassis grease to prevent friction and
ing in severe personal injury or death. binding between the vehicle fifth wheel plate and the
trailer.
The air-suspension dump valve may be used to ad-
just the vehicle height in order to aid with coupling to For a low-lube fifth wheel plate, inspect the condition
or uncoupling from a trailer. See Fig. 17.1. When the of the low-lube pads. There should be no damaged
switch is set to DOWN, the air-suspension dump or missing pieces. Slight puckering at the outside
valve deflates the air springs to lower the rear of the edges is normal.
vehicle. In the UP position, the automatic ride-control For lubrication instructions, see Group 31 of the
valves operate for normal driving. Western Star Maintenance Manual.
Fifth Wheel Coupling

Fifth wheel coupling is activated with the lock control
handle located on either the right or left side of the
fifth wheel. Coupling is complete when the kingpin
has been forced into the jaws and the lock control
handle has moved to the locked position.
NOTICE
Some fifth wheels may be mounted on sliding
rails. Before attempting to couple a trailer to a
sliding fifth wheel, the slide feature must be
locked to prevent the top plate from sliding rap-
07/22/2011 f545805 idly forward or rearward, causing damage to the
fifth wheel or kingpin.
Fig. 17.1, Air-Suspension Dump Valve
17.1
Fifth Wheels
Coupling, Fontaine and Holland Fifth

Wheels
1
NOTE: For a tractor equipped with a Jost fifth
wheel, see the heading Coupling, Jost Fifth 2
Wheel below.
1. Chock the front and rear trailer tires.
2. Ensure the fifth wheel jaw is fully open and the
operating rod is in the unlocked position. See
Fig. 17.2 or Fig. 17.3.
1
3
1
A
11/02/2010 f310447
2 1. Safety Latch 3. Operating Rod
2. Operating Rod (unlocked)
(locked)
1 Fig. 17.3, Holland Simplex SE Locking Mechanism
D
C A
B
2
10/26/2010 f310110a
NOTE: Make sure the safety latch is down when the

control handle is locked.
B
A. Unlocked B. Locked
1. Safety Latch 2. Lock Control Handle
10/28/2010 f311124
Fig. 17.2, Fontaine Locking Mechanism
A. Fifth wheel must lift C. Ramps tilted down
3. Make sure the fifth wheel top plate is tilted so the trailer D. 4 to 8 inches
B. Adjust trailer height
ramps are as low as possible.
4. Position the tractor so that the center of the fifth Fig. 17.4, Trailer Connection Point, Standard Fifth
Wheel Plate
wheel is in line with the trailer kingpin. The king-
pin should be in a position to enter the throat of
the locking mechanism. NOTICE
Attempting to couple at the wrong height may
cause improper coupling, which could result in
damage to the fifth wheel or kingpin.
5. Adjust the trailer height if required.
17.2
Fifth Wheels
For a standard fifth wheel plate, the trailer When lockup has occurred, the fifth wheel con-
should contact the fifth wheel approximately 4 to trol handle moves to the locked position. Make
8 inches (10 to 20 cm) behind the fifth wheel sure that the safety latch is down over the lock
pivot. See Fig. 17.4. control handle to hold the control handle in the
locked position (the safety latch will only rotate
For a low-lube fifth wheel plate, the fifth wheel
down if the operating rod is fully retracted in the
must slide freely under the trailer, and the trailer
locked position). See Fig. 17.2 or Fig. 17.3.
should contact the fifth wheel at the pivot. See
Fig. 17.5.
B
A B
09/10/2010 f311126
A. No gap between trailer B. Kingpin inside lock
and fifth wheel
Fig. 17.6, Coupling Inspection
A
9. Release the tractor parking brake. Test for king-
pin lockup by slowly inching the tractor forward,
09/10/2010 f311125
pulling on the trailer against the chocks.
A. Adjust trailer height B. Ramps tilted down
10. After lockup is completed, connect the tractor-to-
Fig. 17.5, Trailer Connection Point, Low-Lube Fifth trailer air system lines and the electrical cable to
Wheel Plate the trailer. Take care to prevent dirt or foreign
material from entering the air system lines.
6. With the fifth wheel lock opening aligned with the
trailer kingpin, back the tractor slowly toward the
trailer. After sliding under the trailer, stop to avoid NOTICE
hitting the kingpin too hard, then resume backing
slowly until the fifth wheel locks. Always make sure the connection hanger keeps
the trailer air hoses and electrical cables posi-
For a standard fifth wheel plate, the fifth wheel tioned so that they do not rub on anything. Rub-
must lift the trailer. bing may wear through hoses or cables, resulting
For a low-lube fifth wheel plate, do not lift the in air leaks, or exposed or broken wires, poten-
trailer as this may damage the fifth wheel plate. tially affecting trailer brake or electrical systems.
7. Set the tractor parking brake. 11. Charge the air brake system and check that the
air connections do not leak.
WARNING
WARNING
A visual inspection is required by law. Some im-
proper couplings can pass a pull test. Sound is Incorrect fifth wheel lock adjustment could cause
not reliable. Get out of the cab and look. Incor- the trailer to disconnect, possibly resulting in se-
rect coupling could cause the trailer to discon- rious personal injury or death.
nect, possibly resulting in serious personal injury 12. With the trailer tires chocked and the brakes set,
or death. check for clearance between the kingpin and the
8. Perform a coupling inspection, checking that fifth wheel jaws by moving the tractor forward
there is no gap between the bottom of the trailer and backward against the locked kingpin. If slack
and the fifth wheel, and that the kingpin is se- is present, uncouple the trailer and have the fifth
curely locked. See Fig. 17.6.
17.3
Fifth Wheels
wheel inspected and adjusted by a certified For a low-lube fifth wheel plate, the fifth wheel
technician. must slide freely under the trailer, and the trailer
should contact the fifth wheel at the pivot. See
Coupling, Jost Fifth Wheel Fig. 17.5.
NOTE: For a tractor equipped with a Fontaine
or Holland fifth wheel, see the heading Cou- 1
pling, Fontaine and Holland Fifth Wheels 2
above.
1. Tilt the ramp down.
2. Open the kingpin locks. See Fig. 17.7.
03/10/99 f610291
A 1. Trailer Air Supply Valve Knob

2. Parking Brake Valve Knob
Fig. 17.8, Brake Valve Knobs
8. Back the tractor under the trailer.

For a standard fifth wheel plate, the fifth wheel
must lift the trailer.
For a low-lube fifth wheel plate, do not lift the
09/10/2010 f311128 trailer as this may damage the fifth wheel plate.
A. Lock held open by catch mechanism 9. After sliding under the trailer, stop to avoid hitting
the kingpin too hard, then resume backing slowly
Fig. 17.7, Jost Release Handle Unlocked
until the fifth wheel locks.
3. Back the tractor close to the trailer, centering the 10. Set the tractor parking brake.
kingpin on the fifth wheel.
4. Chock the trailer tires. WARNING
5. Connect the air lines and electrical cable. A visual inspection is required by law. Some im-
6. Ensure that the trailer air supply valve (trailer proper couplings can pass a pull test. Sound is
brake) is pulled out, and that the trailer parking not reliable. Get out of the cab and look. Incor-
brakes are set. See Fig. 17.8. rect coupling could cause the trailer to discon-
nect, possibly resulting in serious personal injury
or death.
NOTICE
11. Perform a physical check for positive kingpin
Attempting to couple at the wrong height may lockup, ensuring that there is no gap between
cause improper coupling, which could result in the trailer and the fifth wheel. See Fig. 17.6.
damage to the fifth wheel or kingpin.
12. Ensure that the release handle is in the locked
7. Adjust the trailer height (if required). position adjacent to the casting. See Fig. 17.9.
For a standard fifth wheel plate, the trailer 13. Release the tractor parking brake and test for
should contact the fifth wheel approximately 4 to kingpin lockup by slowly moving the tractor for-
8 inches (10 to 20 cm) behind the pivot. See ward, pulling on the trailer against the chocks.
Fig. 17.4.
17.4
Fifth Wheels
OK OK
09/10/2010 f311127
Fig. 17.9, Jost Release Handle Locked
Fifth Wheel Uncoupling To unlock the mechanism, manually rotate

the safety indicator toward the rear of the
Manual Uncoupling fifth wheel. See Fig. 17.10, View B.
1. Set the tractor and trailer parking brakes. Pull the operating rod out. When the
upper operating rod shoulder is outside
2. Chock the trailer rear wheels. the slot, raise the handle and place the
3. Lower the trailer landing gear until the weight is shoulder of the upper rod against the plate
removed from the fifth wheel. casting, above the slot. See Fig. 17.10,
View C.
4. Disconnect the tractor-to-trailer air system lines
The fifth wheel is now in the lock position
and electrical cable. Plug the air lines to prevent
and is ready for uncoupling. As the tractor
dirt or foreign material from entering the lines.
pulls away from the trailer the kingpin
5. Verify that both the parking brake and trailer air forces the jaw to rotate, contacting the
supply knobs are out (see Fig. 17.8), the tractor lock. Continued rotation of the jaw forces
and trailer parking brakes are set, and that the the lock to move outward, and drops the
trailer is prepared for uncoupling. upper rod back into the slot. See
Fig. 17.10, View D. The wheel is now
6. Release the kingpin locking mechanism following ready for coupling.
the instructions for each manufacturer listed
below. 6.3 Jost: Pull the retractable handle out, then
secure it in the open position with the
6.1 Fontaine: Lift the safety latch and pull the catch. See Fig. 17.7.
lock control handle to the unlocked posi-
tion. See Fig. 17.2. 7. Release the tractor parking brake, then drive for-
ward slowly, allowing the trailer to slide down the
6.2 Holland: In the locked position the safety fifth wheel and pick-up ramps.
indicator swings freely over the operating
rod. See Fig. 17.10, View A. Air-Actuated Uncoupling
An air-actuated kingpin release valve is optional with
all fifth wheels. See Fig. 17.11.
17.5
Fifth Wheels
1
4
A 2 C
B D
11/02/2010 f311133
A. Locked Position
B. Unlatched Position (safety indicator rotated towards the rear of the fifth wheel)
C. Lock Position (upper rod resting against casting above slot)
D. Open Position (ready for coupling)
1. Safety Indicator 3. Upper Rod
2. Operating Rod 4. Plate Casting
Fig. 17.10, Holland Kingpin Locking Mechanism
NOTE: In the event of an air system failure, air-

actuated kingpins can be manually released fol- WARNING
lowing the instructions for manual unlocking.
Once the kingpin release valve has been pulled
the kingpin lock is released. The vehicle MUST
NOT be driven with the trailer until the trailer has
been uncoupled and coupled again. Failure to do
so may result in separation of the trailer from the
17.6
Fifth Wheels
tractor, possibly causing serious personal injury 5. Drive out from under the trailer.
or death.
Air-Activated Kingpin Unlock, Jost Fifth
Preparing the Trailer for Uncoupling Wheels
Before using the air valve to unlock a fifth wheel 1. Verify that both the parking brake and trailer air
kingpin, prepare the trailer as follows. supply knobs are out (see Fig. 17.8), the tractor
1. Set the tractor and trailer parking brakes. and trailer parking brakes are set, and that the
trailer is prepared for uncoupling.
2. Chock the rear trailer tires.
NOTE: If the trailer parking brake is not set, the
3. Lower the trailer landing gear until the weight is air-actuated valve will not activate.
removed from the fifth wheel.
2. Release the tractor parking brake.
4. Disconnect the tractor-to-trailer air lines and elec-
trical cable. Plug the air lines to prevent dirt or 3. Pull and hold the kingpin release valve, then
foreign material from entering the lines. drive forward slowly.
4. After the trailer has slid down the fifth wheel and
Air-Activated Kingpin Unlock, Fontaine pick-up ramps, let go of the kingpin release
and Holland Fifth Wheels valve.
1. Verify that both the parking brake and trailer-air
supply knobs are out (see Fig. 17.8), the tractor Fifth Wheel Slide
and trailer parking brakes are set, and that the
trailer is prepared for uncoupling.
WARNING
NOTE: If the tractor parking brake is not set, the
air-actuated kingpin-release valve will not acti- Adjust the fifth wheel slide correctly, and do not
vate. overload any tractor axle by incorrectly loading
the trailer. Incorrect slide adjustment or improper
2. Pull and hold the kingpin release valve axle loading could cause erratic steering and
(Fig. 17.11) until the kingpin lock mechanism loss of vehicle control, possibly resulting in seri-
opens and locks in place. ous personal injury or death.
On sliding fifth wheel assemblies, the fifth wheel
plate is attached to rails that allow forward and rear-
ward movement of the fifth wheel in order to opti-
mally distribute the load across the axles. Slots are
evenly spaced along the slide rails, and retractable
wedges are positioned through the slots to hold the
fifth wheel in the desiposition.
The amount of load distribution on the front steering
axle and rear drive axle(s) will have a direct effect on
the steering control of the tractor. Determine the front
and rear axle weights by weighing the tractor on
scales designed for this purpose.
The maximum axle weight ratings are shown on the
10/26/2010 f611102
Federal Motor Vehicle Safety Standard (FMVSS)
Fig. 17.11, Air-Actuated Kingpin Release Valve label or Canadian Motor Vehicle Safety Standard
(CMVSS) label attached to the driver-side door
3. Let go of the kingpin release valve. frame. The desired load on the axle is no less than
80 percent of the maximum axle weight rating, but in
4. Release the tractor parking brake.
17.7
Fifth Wheels
no instances should the axle load exceed the maxi-

mum axle weight rating given on the FMVSS or
CMVSS label.
Manual Slide Operation

Use the following procedure to manually slide the
fifth wheel. See Fig. 17.12.
10/26/2010 f310050
Fig. 17.13, Sliding Fifth Wheel Manual Release,

Fontaine
5
4
6
3
2
07/25/95 f310190 8
1. Locking Wedge 3
2. Slide Release Pull Handle 2
Fig. 17.12, Manual Release Sliding Fifth Wheel, 1 7

Fontaine
1. Stop the tractor and trailer in a straight line on

10/26/2010 f310445
level ground. Pull the trailer air supply knob to
set the trailer parking brakes. 1. Baseplate 5. Slider Saddle Plate
2. Bolted Stop 6. Safety Latch
2. Set the tractor parking brake, then release the 3. Baseplate Rail 7. Operating Rod
sliding mechanism using the appropriate method 4. Fifth Wheel Mount 8. Operating Lever
for the fifth wheel manufacturer.
Fig. 17.14, Sliding Fifth Wheel Manual Release, Holland
2.1 Fontaine: Lift the slide release pull handle Simplex
to disengage it from the guide plate. Then,
pull out the handle until it is in the un- 3. Lower the trailer landing gear just enough to re-
locked position and can be positioned move the weight from the tractor.
against the guide plate to hold it out. The 4. Chock the front and rear trailer tires to prevent
handle will stay in the unlocked position the trailer from moving.
until it is manually disengaged from the
guide plate. See Fig. 17.13.
NOTICE
2.2 Holland: Pull the operating rod out. Make
sure both side plungers have released. When moving the fifth wheel to the desiposition,
See Fig. 17.14. be sure the trailer landing gear will not at any
time come in contact with the tractor frame or
17.8
Fifth Wheels
other components. Make sure that the front of For Jost fifth wheels, the mechanism activates as
the trailer will not come in contact with the rear shown in Fig. 17.17.
of the cab or with other components if they ex-
2. Lower the trailer landing gear just enough to re-
tend beyond the rear of the cab.
move the weight from the tractor.
5. Release the tractor parking brake, then slowly
3. Pull the trailer air supply knob to set the trailer
move the tractor forward or backward until the
parking brakes.
fifth wheel is in the desilocation.
4. Slowly move the tractor forward or backward
WARNING until the fifth wheel is in the desilocation.
Check that the locking wedges have seated in the

slots. Failure to achieve complete lockup may
allow disengagement of the tractor from the
trailer, possibly resulting in serious personal in-
jury or death.
6. Set the tractor parking brake, then lock the slid-
ing member in position using one of the following
methods:
6.1 Fontaine: Disengage the slide release
pull handle from the guide plate. The slide
release pull handle is spring-loaded in the
locked position and will seek the locked
position when disengaged from the guide
plate. After the slide release pull handle 07/22/2011 f545806
returns to the fully locked position, visually
and physically check the locking wedges Fig. 17.15, Fifth Wheel Slide Switch
to make sure they are fully inserted into
the slots in the slide rails. Make sure the 1
handle is locked in position against the
guide plate.
6.2 Holland: Raise the operating rod so that it
is free to move inward. Make sure that the
lock pins have seated in the base plate
rail holes and the operating rod moves
into the locked position.
NOTE: The fifth wheel may need to be moved
slightly to enable the locking wedges to enter
the fully locked position.
Air Slide Operation

The slide feature may be operated with a dash-
mounted switch that operates an air cylinder that 2
locks and unlocks the slide. 07/25/95 f310189
1. Press the top half of the air-slide switch to en- 1. Locking Wedge 2. Air Cylinder
able the air-slide feature. See Fig. 17.15 Fig. 17.16, Air-Operated Sliding Fifth Wheel, Fontaine
Ensure the locking plungers have released. See
Fig. 17.16.
17.9
Fifth Wheels
that the plungers have engaged by tugging the

tractor forward while the trailer brakes are locked
and the tires are chocked.
NOTE: The fifth wheel may need to be moved
slightly to enable the locking wedges to fully
lock.
09/10/2010 f311131
A. Unlocked B. Locked
Fig. 17.17, Jost Sliding Fifth Wheel
NOTICE
Ensure the trailer landing gear does not come in
contact with the tractor frame or other compo-
nents, and that the front of the trailer will not
come in contact with the rear of the cab or other
components if they extend beyond the rear of the
cab.
5. Set the tractor parking brake.
WARNING
Check that the locking wedges have seated in the
slots. Failure to achieve complete lockup may
allow disengagement of the tractor from the
trailer, possibly resulting in serious personal in-
jury or death.
6. Press the lower half of the air-slide switch to dis-
able the air-slide feature. Visually inspect the
locking wedges or plungers to make sure that
they are fully inserted in the slide rail slots. Verify
17.10
18
Trailer Couplings
Air-Suspension Dump Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.1
Premier Trailer Couplings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.1
Trailer Couplings
Air-Suspension Dump Valve (www.premier-mfg.com) for complete safety,

operation, and maintenance instructions.
WARNING Trailer couplings are attached to the rear closing
crossmember. The Premier trailer couplings
Never exhaust air from the suspension while (Fig. 18.2) are designed for use with trailers having a
driving. The suspension will not absorb road maximum gross weight of 100,000 lbs (45 455 kg).
shocks, possibly damaging components, and ve- The Premier 2200 and 2400 trailer couplings are air-
hicle handling may be compromised. This could adjusted couplings with a rigid pintle hook. An air
result in loss of vehicle control, possibly result- chamber mounted forward of the coupling operates a
ing in severe personal injury or death. push rod, which pushes against a shoe inside the
The air-suspension dump valve may be used to ad- coupling. The shoe maintains constant pressure on
just the vehicle height in order to aid with coupling to the eye of the trailer drawbar when it’s over the pintle
or uncoupling from a trailer. See Fig. 18.1. When the hook. This takes up any slack in the trailer connec-
switch is set to DOWN, the air-suspension dump tion, providing smoother towing and less wear on the
valve deflates the air springs to lower the rear of the pintle hook. The air pressure is activated when the
vehicle. In the UP position, the automatic ride-control trailer brakes are released.
valves operate for normal driving.
Trailer Hookup
1. Chock the front and rear tires of the trailer.
2. Push the latch lock towards the mounting plate
as far as possible. Then, while holding the latch
lock in place against the mounting plate, pull the
top of the latch as far as possible toward the
pintle hook.
3. While holding the latch in place, release the latch
lock.
4. Back the vehicle up until the drawbar eye is over
the pintle hook, then lower the trailer.
5. Pull the top of the latch as far as possible toward
the pintle hook. Then, while holding the latch in
07/22/2011 f545805 position, push the latch lock towards the mount-
ing plate.
Fig. 18.1, Air-Suspension Dump Valve
6. While holding the latch lock in place against the
mounting plate, release the latch.
NOTICE
7. Release the latch lock and make sure it is fully
Do not operate the vehicle over uneven ground seated in the slot on top of the latch.
such as ramps, speed bumps, curbs, etc. with
the air springs deflated. Doing this may lead to NOTICE
suspension air springs from inflating. Always make sure the connection hanger keeps
the trailer air hoses and electrical cables posi-
Premier Trailer Couplings tioned so that they do not rub on anything. Rub-
bing may wear through hoses or cables, resulting
General Information in air leaks, or exposed or broken wires, poten-
tially affecting trailer brake or electrical systems.
IMPORTANT: Before operating the Premier cou-
pling, refer to the Premier website 8. Connect the trailer’s electrical and air lines.
18.1
Trailer Couplings
1 1
3 3
A B
12/08/2010 f311138
A. Premiere 2400 Trailer Coupling B. Premiere 2200 Trailer Coupling
1. Latch Lock 3. Pintle Hook
2. Latch
Fig. 18.2, Premiere 2200 and 2400 Trailer Couplings
Trailer Release 6. While holding the latch in place, release the latch
lock.
1. Set the vehicle and trailer parking brakes.
7. Slowly drive the vehicle away from the trailer.
WARNING
If a trailer or combination vehicle is not equipped
with spring parking brakes, do not park it by pull-
ing out only the trailer air supply valve knob.
This would apply only the trailer service brakes.
If air were to bleed from the trailer brake system,
the trailer brakes would release, possibly causing
an unattended runaway vehicle.
2. Chock the front and rear tires of the trailer.
3. Disconnect the trailer air and electrical lines.
Plug the air lines to keep them free of dirt.
4. Take the weight of the trailer drawbar eye off the
pintle hook.
5. Push the latch lock towards the mounting plate
as far as possible. Then, while holding the latch
lock in this position, pull the top of the latch as
far as possible toward the pintle hook.
18.2
19
Headlight Aiming
Preliminary Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.1
Checking Headlight Aim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.1
Adjusting Headlight Aim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.1
Headlight Aiming
Preliminary Checks If the center of any projection is more than 3.9 in

(100 mm) to the side of the marks made in step
Before checking or adjusting the headlight aim, com- 4, adjust the horizontal aim of that headlight.
plete the following inspection: 7. Check the vertical adjustment of the low beams.
• Check that the hood is closed and latched. The center of each beam projection should fall
on or near the marks made during step 4. See
• Remove any large amounts of mud or ice from Fig. 19.2.
the underside of the fenders.
8. Use Table 19.1 to determine the maximum verti-
• Check the springs for sagging or broken cal distance allowable between the marks on the
leaves. wall and the center of each low-beam projection.
• Check the suspension for proper functioning of If the distance between either projection center
the leveling mechanism. On cabs with air sus- and the mark made on the wall or screen is
pensions, make sure that the height is properly greater than the maximum distance given in
adjusted. Table 19.1, adjust the vertical positioning of that
• Check for damage to the hood and hinge as- headlight.
sembly. Repair as necessary. 9. Turn on the high-beam headlights. Ensure the
• With the vehicle unloaded, check that the tires beam projections are parallel to the ground. If
are inflated to the recommended air pressure. the beam projections are not parallel to the
ground, adjust the positioning of the high-beam
• Clean the headlight lenses. Use a soft cloth bulbs.
with mild, non-caustic soap or detergent, and
water.
Adjusting Headlight Aim
Checking Headlight Aim NOTE: Western Star vehicles are offered with
various headlight assembly options. Because of
1. Park the vehicle on a level surface, 25 ft (7.6 m) the various options, the location of adjustment
away from, and perpendicular to, a vertical screws on your vehicle’s headlight assembly
screen or wall. Shut down the engine and set the may vary from what is shown here.
parking brake. Chock the tires.
For adjustment screw locations on a vehicle with
2. On each headlight, find the bulb center behind
dual rectangular headlight assemblies, see Fig. 19.3.
the headlight lens. For adjustment screw locations on a vehicle with
3. Measure the distance from the ground to the dual round headlight assemblies, see Fig. 19.4. For
center of each headlight bulb (Fig. 19.1, Item A). adjustment screw locations on a 4700 model, see
Note those distances. Fig. 19.5.
4. On the screen or wall, mark the locations of each Turn the adjustment screw in either direction until the
headlight bulb center using the distances found beam pattern meets the acceptable standard.
in step 3. See Fig. 19.1, Items 2 and 3.
5. Turn on the low-beam headlights.
NOTE: See the following heading, Adjusting
Headlight Aim, for adjustment instructions.
6. Check the horizontal aim of the low beams. The
center of each beam projection should fall on or
near the marks made during step 4 (Fig. 19.1,
Items 2 and 3).
19.1
Headlight Aiming
2
3
A A
B
B
m)
(7.6
ft
1 25
09/02/2011 f545809
A. Measure the distance from the ground to the center of each headlight bulb.
B. Mark where the center of each headlight projection should appear.
1. Screen or Wall 3. Center of Left-Hand Headlight Projection
2. Center of Right-Hand Headlight Projection
Fig. 19.1, Headlight Aiming Screen/Wall
1
2
09/12/2011 f545833
1. Low-Beam Angle Upper Limit 3. Low-Beam Angle Lower Limit
2. Ideal Low-Beam Projection
Fig. 19.2, Vertical Low-Beam Headlight Variation Limits
19.2
Headlight Aiming
Vertical Low-Beam Headlight Variation Limits

Distance Between Ground Desired Variation (Fig. 19.2, Upper Limit (Fig. 19.2, Item Lower Limit (Fig. 19.2, Item
and Headlight: in (mm) Item 2) : in (mm) 1): in (mm) up 3): in (mm) down
22–36 (560–900) 0 3.9 (100) 3.9 (100)
36–48 (900–1200) 2 (50) down 2 (50) 6 (150)
48–54 (1200–1400) 2.5 (64) down 1.6 (40) 6.5 (165)
Table 19.1, Vertical Low-Beam Headlight Variation Limits
1
2
3
09/14/2011 f545834
02/17/2005 f544577a 1. Horizontal Adjustment Screw
NOTE: The vertical adjustment screws are on top of 2. Vertical Adjustment Screw
each bulb; the horizontal adjustment screws are on the 3. Bezel Mounting Screw
side of each bulb.
Fig. 19.4, Adjustment Screw Locations, Dual Round
Fig. 19.3, Adjustment Screw Locations, Dual Headlights
Rectangular Headlights
19.3
Headlight Aiming
3
2
08/18/2011 f545810
NOTE: Adjustment screw locations may vary.

1. Headlight Lens
2. Horizontal Adjusting Screw
3. Turn Signal
4. Vertical Adjusting Screw
Fig. 19.5, Single Headlight Assembly (4700 model
shown)
19.4
20
Vehicle Appearance and
Care
Cab Washing and Polishing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20.1
Care of Chrome Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20.1
Dashboard Care . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20.1
Vinyl Upholstery Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20.2
Velour Upholstery Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20.2
Star Gauge Face Care . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20.3
Care of Exterior Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20.3
Vehicle Appearance and Care
Cab Washing and Polishing To prevent delamination and deterioration of labels

and stickers on the cab, follow these guidlines care-
IMPORTANT: Carefully read all instructions be- fully:
fore using or applying any cleaner or product to • Do not pressure wash the label or sticker or
the vehicle or components. Failure to follow surfaces near it.
manufacturers’ recommendations can result in
damage to the finish. • Do not use strong alkaline soaps on or near
the label or sticker.
To protect the finish of a new vehicle, follow these
guidelines carefully: Care of Fiberglass Parts
• During the first 30 days, rinse the vehicle fre- Wash unpainted fiberglass air fairings and shields
quently with water. If the vehicle is dirty, use a monthly with a mild detergent, such as dishwashing
mild liquid soap. Do not use detergent. liquid. Avoid strong alkaline cleansers.
• During the first 30 days, do not use anything Apply a wax specifically designed for fiberglass.
abrasive on the vehicle. Brushes, chemicals,
and cleaners may scratch the finish.
Care of Chrome Parts
• During the first 120 days, do not wax the
vehicle. To prevent rust, keep chrome parts clean and pro-
tected at all times. This is especially important during
To extend the life of the vehicle’s finish, follow these winter driving and in coastal areas where there is
guidelines: exposure to salt air.
• Avoid washing the vehicle in the hot sun. When cleaning chrome, use clean water and a soft
• Always wash the vehicle with water. After the cloth or sponge. A mild detergent may also be used.
cab is completely washed, dry it with a towel or Sponge gently, then rinse. If necessary, use a non-
chamois. abrasive chrome cleaner to remove stubborn rust or
• Do not dust painted surfaces with a dry cloth, other material. Do not use steel wool.
as this will scratch the paint. To help protect chrome after cleaning, apply a coat of
• Do not remove ice or snow from a painted sur- polishing wax to the surface. Never use wax on com-
face with a scraper of any sort. ponents that are exposed to high heat, such as ex-
haust pipes.
• To prevent damage to the finish, wax it regu-
larly. Before waxing, if the finish has become
dull, remove oxidized paint using a cleaner
Dashboard Care
specifically designed for this purpose. Remove
all road tar and tree sap before waxing. West- NOTICE
ern Star Trucks recommends using a high
quality brand of cleaner or cleaner-polish and When cleaning the dashboard, instrument panel,
polishing wax. or gauge lens covers, do not use Armor-All Pro-
tectant®, STP Son-of-a-Gun®, window cleaner, or
• Do not let diesel fuel or antifreeze stand on a
other equivalent treatments. These cleaners con-
painted surface. If either should occur, rinse
tain vinyl plasticizers which can cause stress
the surface off with water.
crazing in the interior plastic panels and can re-
• To prevent rust, have any nicks or other dam- sult in cracking of the panels. Some cleaners can
age on the finish touched up as soon as pos- also have an adverse effect on the clear plastic
sible. of instrument panels and gauge lens covers, re-
sulting in a foggy or cloudy appearance. This
• Park the vehicle in a sheltered area whenever
type of damage is not covered by vehicle war-
possible. ranty.
20.1
To clean the dashboard, instrument panel, and gauge sinks and tiles, are abrasive and must be used with
lens covers, use a cloth dampened with warm soapy caution as they can scratch the vinyl or give it a per-
water. Make certain to wring the cloth out well before manent dull appearance.
cleaning, as excess water will damage the electrical
components. Nail Polish and Nail Polish Remover
Prolonged contact with these substances causes per-
Vinyl Upholstery Cleaning manent damage to vinyl. Careful blotting immediately
To prevent soiling, frequent vacuuming or light brush- after contact minimizes damage. Do not spread the
ing to remove dust and dirt is recommended. Harsh liquid during removal.
cleaning agents can cause permanent damage to
vinyl upholstery. Paint, Shoe Heel Marks
To preserve the upholstery and prevent damage, Paint should be removed immediately. Do not use
carefully review the following sections for recom- paint remover or liquid-type brush cleaner on vinyl.
mended cleaning procedures. Waxing or refinishing An unprinted cloth, dampened with naphtha or tur-
improves soil resistance for all vinyls. Any hard wax, pentine may be used. Use care to prevent contact
such as that used on automobiles, may be used. with parts of the upholstery that are not vinyl.
If stains do not respond to any of the treatments de- Shoe Polish
scribed above, it is sometimes helpful to expose the
vinyl to direct sunlight for up to 30 hours. Mustard, Most shoe polishes contain dyes which penetrate
ball point ink, certain shoe polishes, and dyes often vinyl and stain it permanently. Shoe polish should be
bleach out in direct sunlight, leaving the vinyl undam- wiped off as quickly as possible using naphtha or
aged. lighter fluid. If staining occurs, try the procedure used
for sulfide stains.
Ball Point Ink
Sulfide Stains
Ball point ink can sometimes be removed if rubbed
immediately with a damp cloth, using water or rub- Sulfide compounds, such as those found in eggs and
bing alcohol. If this does not work, try the procedure some canned goods, can stain after prolonged con-
used for sulfide stains. tact with vinyl. Remove these stains by placing a
clean, unprinted piece of cloth over the spotted area
Chewing Gum and pouring a liberal amount of 6 percent hydrogen
peroxide onto the cloth. Allow the saturated cloth to
Harden the gum with an ice cube wrapped in a plas- remain on the spot for 30 to 60 minutes. For stub-
tic bag, then scrape it off with a dull knife. Remove born spots, allow the saturated cloth to remain on the
any remaining traces of gum with an all-purpose light area overnight. Use caution to prevent the solution
oil (peanut butter will also work). Wipe off the gum from seeping into the seams, where it can weaken
and oil substance. the cotton thread.
Dirt Tars, Asphalts, and Creosote
Wash the upholstery with warm water and mild soap, Each of these items stains vinyl after prolonged con-
such as saddle or oil soap. Apply soapy water to a tact. They should be wiped off immediately and the
large area and allow to soak for a few minutes, then area carefully cleaned, using a cloth dampened with
rub briskly with a cloth to remove the dirt. This can naphtha.
be repeated several times, as necessary.
If dirt is deeply imbedded, use a soft bristle brush Velour Upholstery Cleaning
after applying the soap.
To prevent soiling, frequent vacuuming or light brush-
If dirt is extremely difficult to remove, wall-washing ing to remove dust and dirt is recommended. Spot
preparations normally found around the home can be clean with a mild solvent or an upholstery shampoo,
used. Powdered cleaners, such as those used for
20.2
or the foam from a mild detergent. When using a sol-

vent or a dry-cleaning product, follow the instructions NOTICE
carefully, and clean only in a well-ventilated area.
Avoid any product that contains carbon tetrachloride Do not use a power buffer, paper towels, chemi-
or other toxic materials. With either method, pretest a cal solvents, or abrasive cleaners on the head-
small area before proceeding. Use a professional light lens, all of which can remove the UV coating
upholstery cleaning service when extensive cleaning from the surface, and result in yellowing of the
is needed. lens.
Chewing Gum or Wax

Harden the gum or wax with an ice cube wrapped in
a plastic bag, then scrape it off with a dull knife. Ex-
cess wax can be absorbed by placing a thick white
blotter over the wax and heating with a warm (not
hot) iron. Remove the remainder by using the proce-
dure for grease and oil-based stains.
Grease and Oil-Based Stains

Dampen a small absorbent cloth with dry-cleaning
solvent or spot remover. Apply the cloth carefully to
the spot from the outer edge to the center. Pat and
blot the spot with a clean, dry cloth. Repeat as nec-
essary, turning the cloth so that the stain does not
redeposit on the fabric.
Mildew
Brush the dry fabric with a soft brush. Sponge with
detergent, and blot. If the fabric is colorfast, dilute a
teaspoon of bleach in one quart (one liter) of cool
water. Apply with a swab, directly on the mildew
stain. Dab repeatedly with clear, cool water, and blot
dry.
Sugar and Water-Based Stains

Apply water-based detergent or cleaner, working in
circular motions. Pat and blot as dry as possible. Re-
peat, if necessary, before drying thoroughly.
Star Gauge Face Care

Use only a damp cloth to clean gauge faces. A mild
detergent solution may be used. Wipe dry with a
clean dry cloth.
Care of Exterior Lights

Clean the headlight lenses by hand only. Use a flan-
nel cloth with mild, non-caustic soap or detergent,
and water.
20.3
21
In An Emergency
Hazard Warning Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.1
Fire Extinguisher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.1
Emergency Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.1
Emergency Filter Replacement, DAVCO Fuel/Water Separator . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.1
Starting with Jumper Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.2
Towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.4
Fire in the Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.6
In An Emergency
Hazard Warning Lights separator) a spin-on fuel filter element may be sup-
plied in the cab.
The hazard warning light flasher (Fig. 21.1) is typi-
cally part of the multifunction turn signal switch. To WARNING
operate the hazard lights, pull the tab out. All of the
turn signal lights and both of the indicator lights on Use extreme care when placing flares in emer-
the control panel will flash. To cancel the hazard gency situations that involve exposure to flam-
warning lights, push the turn signal control lever ei- mable substances such as fuel. An explosion or
ther up or down, then return the lever to its neutral fire could occur causing serious personal injury.
position.
If there is an emergency while driving, cautiously pull
Western Star vehicles may be equipped with an op- off the road, paying attention to other traffic. Turn on
tional hazard warning light switch located on the the hazard warning lights. Place the flares and reflec-
right-hand dash panel. To operate the hazard lights, tor along the side of the road to alert other drivers
press the upper half of the switch. To cancel the haz- that an emergency situation exists.
ard warning lights, press the lower half of the switch.
Emergency Filter
Replacement, DAVCO Fuel/
Water Separator
If the filter cover on the DAVCO fuel/water separator
is broken, it will not be possible to operate the ve-
hicle. A standard spin-on filter will correct this prob-
lem.
Refer to the DAVCO website (www.davcotec.com)
for additional information, .
WARNING
LE
FO UL TE
H
FO US
LT
P R
P
TI
R L
Fluid circulated through the fuel/water separator

to heat the fuel may be diesel fuel returned from
the engine, or engine coolant. Drain the fuel/
water separator only when the engine and fluids
have cooled. Draining it when the engine is hot
06/14/2001 f610501 could cause severe personal injury due to scald-
ing.
Fig. 21.1, Hazard Warning Light Switch Tab (left-hand
drive shown) If returning fuel is released into the atmosphere,
its vapors can ignite in the presence of any igni-
Fire Extinguisher tion source. Do not expose the fuel to, or work
with the fuel system near, open flame or intense
An optional factory-installed fire extinguisher may be heat. To do so could cause fire, possibly result-
located in the cab by the driver’s door, between the ing in serious personal injury or property dam-
seats, or in the sleeper baggage compartment, if age.
equipped. 1. Shut down the engine and set the parking brake.
Chock the tires.
Emergency Kit IMPORTANT: When draining fluid from a fuel/
An optional emergency triangle reflector package, water separator, drain the fluid into an appropri-
flare kit, and (on vehicles with a DAVCO fuel/water ate container, and dispose of it properly. Many
21.1
In An Emergency
jurisdictions now issue fines for draining fuel/

water separators onto the ground.
VENT CAP
FOR REMOVAL OF TOP COLLAR ONLY
2. Put a clean receptacle under the fuel/water sepa-

rator and attach a piece of hose to the drain
valve, to direct fuel into the receptacle.
NOTE: Use a hose with a ½-inch pipe thread to
fit the drain valve on a Fuel Pro 382.
3. Remove the vent cap (Fig. 21.2, Item 4) and
open the drain valve (Fig. 21.2, Item 1). Drain
02/16/2009 f470277
the fuel to just below the collar level, then close
the drain valve.
Fig. 21.3, DAVCO Collar Wrench
4
the fuel/water separator from sealing, and an air
leak will result.
7. Ensure that the drain valve is closed.
3 8. Remove the filter grommet from the filter stud, if
equipped.
5 9. Fill the housing to the top with clean diesel fuel.
10. Install a standard engine spin-on filter (part num-
2 ber FF105 or equivalent) on the filter stud.
11. Install the cover O-ring, clear cover, and the col-
6 lar. Hand-tighten the collar.
12. Install the O-ring in the vent cap, then install and
hand-tighten the vent cap on the fuel/water sepa-
1 rator.
05/05/2009 f470506b
1. Drain Valve 4. Vent Cap 13. Start the engine. When the lubricating oil
2. Lower Housing 5. Collar reaches its normal operating pressure, increase
3. Clear Cover 6. Inlet Port/Check Valve engine speed to high idle for one to two minutes
to purge air from the system.
Fig. 21.2, DAVCO Fuel/Water Separator (Fuel Pro 382
shown)
Starting with Jumper Cables
4. Using a DAVCO collar wrench (Fig. 21.3), re-
move the clear cover and collar. WARNING
NOTE: Broken vent cap and collar warranty
claims will not be accepted if any tool other than Batteries release explosive gas. Do not smoke
a DAVCO collar wrench, p/n 380134, 382002, or when working around batteries. Put out all flames
and remove all sources of sparks or intense heat
232007, is used for removal. During installation, in the vicinity of the battery. Do not allow the ve-
the vent cap and collar are to be hand- hicles to touch each other. Do not lean over the
tightened only, not tightened with a wrench. batteries when making connections, and keep all
5. Remove the filter and dispose of it in an environ- other persons away from the batteries. Failure to
mentally acceptable manner. follow these precautions could lead to severe
personal injury as a result of an explosion or
6. Clean all threads and sealing surfaces very thor- acid burns.
oughly. Even a small amount of dirt will prevent
21.2
In An Emergency
NOTICE
Make sure both electrical systems are the same POS JUMP
voltage. Electronic devices on both vehicles can 3

START STUD
be damaged when connected to a vehicle with a

different operating voltage. 2
NEG JUMP
IMPORTANT: Do not attempt to jump start a START STUD
damaged or frozen battery.

1. Set the parking brake and turn off all lights and
other electrical devices. Ensure that the vehicles
are not touching and both ignition switches are
turned to the OFF position.
2. Access the batteries by removing the battery box 1
cover, if equipped.
01/07/2011 f545726
NOTICE 1. Frame Rail

2. Negative Jump Start Post
Always connect the batteries and jumper cables 3. Positive Jump Start Post
correctly (positive-to-positive and negative-to- Fig. 21.4, Possible Jump Start Post Location
negative). Connecting a charging device back- (passenger-side engine compartment)
wards (positive-to-negative) can severely damage
the vehicle electrical content and cause non- 6. Connect the other end of the negative jumper
warrantable failures. cable to the negative ground stud on the vehicle
requiring the jump start.
IMPORTANT: On vehicles equipped with op-
tional jump start posts, connect to these posts 7. Start the engine of the vehicle providing the jump
instead of the battery terminals. Jump start start and let the engine run a few minutes to
posts may be installed in various locations on charge the batteries of the other vehicle.
the vehicle. See Fig. 21.4. 8. Attempt to start the engine of the vehicle receiv-
3. Connect the positive (+) jumper cable to the ing the jump. Do not operate the starter longer
positive terminal or jump start post on the dis- than 30 seconds, and wait at least two minutes
charged battery. See Fig. 21.5. between starting attempts to allow the starter to
cool.
4. Connect the other end of the positive jumper
9. When the engine starts, let it idle a few minutes.
cable to the positive terminal or jump start post
on the booster battery providing the charge.
WARNING
WARNING Do the next step exactly as instructed and do not
Do the next step exactly as instructed and do not allow the clamps of one cable to touch the
allow the clamps of one cable to touch the clamps of the other cable. Otherwise, a spark
clamps of the other cable. Otherwise, a spark could occur near a battery, possibly resulting in
could occur near a battery, possibly resulting in severe personal injury from explosion or acid
severe personal injury from explosion or acid burns.
burns. 10. Disconnect the negative jumper cable from the
5. Connect the negative (-) jumper cable to the jump started vehicle.
negative terminal or jump start post on the 11. Disconnect the negative jumper cable from the
booster battery. vehicle that provided the jump start.
21.3
In An Emergency
4
D
B
3 E
2
+
+ − −
+ +
− −
C
+ −
+
1 −
01/07/2011 f545725
Disconnect jumper cables in the REVERSE order that they were connected.
A. Discharged Battery C. Positive Jumper Cable E. Booster Battery
B. Negative Ground Stud D. Negative Jumper Cable
1. 1st Connection: Positive Jumper Cable to Discharged Battery
2. 2nd Connection: Positive Jumper Cable to Booster Battery
3. 3rd Connection: Negative Jumper Cable to Booster Battery
4. 4th Connection: Negative Jumper Cable to Negative Ground Stud (discharged battery)
Fig. 21.5, Jumper Connections
12. Disconnect the positive cable from the vehicle

that provided the jump start.
Towing
13. Disconnect the other end of the positive cable When it is necessary to tow the vehicle, make sure
the instructions below are closely followed to prevent
from the jump started vehicle.
damage to the vehicle.
14. Install the battery box cover, if equipped.
WARNING
Do not tow an unbraked vehicle if the combined
weight of both vehicles is more than the sum of
21.4
In An Emergency
the gross axle weight ratings (GAWR) of the tow-

ing vehicle. Otherwise brake capacity will be in- NOTICE
adequate, which could result in personal injury or
death. Do not pass a sling (for example, a rope or chain)
from one tow hook to another to fasten for tow-
Front Towing Hookup ing. Known as reeving, this practice is not per-
missible in most industrial applications of towing
1. Disconnect the batteries at the negative termi- and hoisting. Reeving can overload the hooks
nals. and result in damage to the vehicle.
6. Attach the towing device. Due to the many vari-
NOTICE ables that exist in towing, positioning the lifting
and towing device is the sole responsibility of the
Failure to remove the axle shafts or the driveline towing-vehicle operator.
when towing the vehicle with the rear wheels on
the ground could result in damage to the trans- 7. On vehicles equipped with an air fairing, mea-
mission and other parts. sure the distance from the ground to the bumper,
or from the ground to a frame bracket.
2. Remove the driveline from any drive axle that will
have its wheels touching the ground while the 8. Lift the vehicle, and secure the safety chains. If
vehicle is towed, extra towing clearance is needed, remove the
front wheels.
or
remove the drive axle shafts on both sides of the WARNING
vehicle from any drive axle that will have its
wheels touching the ground while the vehicle is Failure to lower the vehicle could result in the air
towed. fairing striking an overhead obstruction, such as
3. If the axle shafts were removed, cover the ends a bridge or overpass, and causing vehicle dam-
of the hubs with metal plates or plywood cut to fit age or personal injury.
the axle opening, and drilled to fit the axle shaft 9. On vehicles equipped with an air fairing, repeat
studs. This prevents lubricant from leaking out the measurement taken in step 8. The difference
and will keep contaminants from getting into and between the two measurements must not exceed
damaging the wheel bearings and axle lubricant. 14 inches (36 cm). If necessary, lower the ve-
If the driveline(s) were removed, ensure the hicle.
U-joint caps are secure so they will not come off. 10. Connect the clearance lights, taillights, and sig-
nal lights. Connect any special towing lights re-
NOTICE quired by local regulations.
Failure to protect the frame rails from the chains WARNING

could cause damage, leading to eventual frame
failure. Failure to chock the tires or connect the tow
4. If a vehicle with tandem rear axles is to be lifted truck’s air brake system before releasing the
and towed, chain the forward rear-axle assembly spring parking brakes could allow the disabled
to the vehicle frame. This will prevent the forward vehicle to suddenly roll. This could cause prop-
rear-axle assembly from dropping and keep its erty damage or personal injury.
wheels off the ground while being towed. 11. Chock the tires on the disabled vehicle and con-
Use protection to keep the chains from damaging nect the towing vehicle’s air brake system to the
the frame. vehicle being towed. Then, release the spring
parking brakes and remove the chocks.
5. Remove the bumper extension and chrome bum-
per, if so equipped. Remove the bumper fairing,
if so equipped.
21.5
In An Emergency
Rear Towing Hookup

NOTICE
Using a rear towing hookup on a vehicle
equipped with a roof fairing could cause damage
to the cab structure.
If reverse towing at speeds above 45 mph (70
kph) is necessary, hold down the cab with ten-
sion straps looped over the cab shocks and
under the frame rails. Failure to do so could
allow the wind load to lift the cab unexpectedly,
resulting in damage to the air springs and other
components.
1. If the vehicle is equipped with cab air suspen-
sion, and reverse towing at speeds above 45
mph (70 kph) is necessary, hold down the cab as
follows:
1.1 Drain the air from the cab air springs.
1.2 Loop a 2-inch (5-cm) ratchet-style tension
06/24/2014 f602530
strap (rated 2000 lb [900 kg] minimum
work load) over the top of the cab shock NOTE: Typical cab air suspension shown.
and under the frame rail. See Fig. 21.6. Fig. 21.6, Tension Strap Installed to Hold Down the Cab
Tighten the strap for a snug fit. If the cab
is equipped with two or more shocks, re- 6. Lift the vehicle and secure the safety chains. If
strain the aftmost shock on each side of extra clearance is needed, remove the bumper
the vehicle. extension if equipped.
2. Place the front tires straight forward and secure 7. Connect the clearance lights, taillights, and sig-
the steering wheel in this position. nal lights. Also connect any special towing lights
3. Disconnect the battery ground cables. required by local regulations.
NOTICE Fire in the Cab

According to data from the National Highway Traffic
Failure to protect the frame rails from the chains Safety Administration, the incidence of fire in heavy-
could cause damage, leading to eventual frame and medium-duty trucks is rare. Federal Motor Ve-
failure. hicle Safety Standard #302 limits the flammability of
4. On dual drive axles, using protection to keep the specified materials used inside the cab, but despite
chains from damaging the vehicle frame, chain this, most materials will burn. The cab of this vehicle
the forward-rear drive axle to the frame. contains urethane foam, which is flammable.
5. Attach the towing device.
WARNING
NOTE: Due to the many variables that exist in
towing, positioning the lifting and towing device Urethane foam is flammable! Do not allow any
is the sole responsibility of the towing-vehicle flames, sparks, or other heat sources such as
operator. cigarettes or light bulbs to contact urethane
foam. Urethane foam in contact with such heat
sources could cause a serious, rapid fire, which
21.6
In An Emergency
could result in death, severe burns, or gas poi-

soning, as well as damage to the vehicle.
In Case of a Cab Fire

As quickly as possible, bring the vehicle to a safe
stop, apply the parking brake, turn off the ignition,
and get out of the vehicle.
21.7
22
Pre- and Post-Trip
Checklists
Periodic Inspections and Maintenance, General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22.1
Checklists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22.1
Fluids Added . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22.2
Pre- and Post-Trip Checklists
Periodic Inspections and Wheels and Tires Comp.

5 Wheel bearing oil seals and lubrication levels
Maintenance, General 6 Mud Flaps
Information
Saddle Tank Areas Comp.
Regulations in Canada and the U.S. clearly indicate Drain air reservoirs (without automatic drain
that it is the driver’s responsibility to perform an in- 1
valves)
spection, and ensure the complete road-worthiness 2 Fuel tank(s) secure
of a vehicle, before placing it into service. Commer-
3 Frame rails and crossmembers
cial vehicles may be subject to inspection by autho-
4 Visible exhaust components
rized inspectors, and an unsafe vehicle can be taken
"out of service" until the driver or owner repairs it.
Engine Compartment Comp.
Use the following checklists to ensure that vehicle 1 Leakage under engine
components are in good working condition before 2 Air intake system
each trip. Careful inspections eliminate stops later to 3 Engine oil level
fix overlooked or forgotten items. 4 Power steering reservoir level
The checklists in this chapter can be copied and kept 5 Engine coolant level
as a record that the procedures have been com- 6 Visible engine wiring
pleted. For details on how to inspect each item on 7 Frame rails
the checklists, see the corresponding procedure
(step number) in Chapter 23. Cab Comp.
Reset dash-mounted air intake restriction
1
Checklists indicator
2 Air-pressure warning systems
NOTE: Checklists in this chapter correspond 3 Air governor cut-in and cut-out pressures
with the procedures and steps in Chapter 23, 4 Air pressure build-up time
Pre- and Post-Trip Inspections and Mainte- 5 Air system leakage
nance. Your vehicle may not be equipped with 6 Air pressure reserve
all components listed below. 7 Mirrors, windows, windshield
8 Horn, windshield wipers, windshield washers
Daily Pretrip Inspection Checklists 9 Heater and defroster
See the following tables for a list of procedures that 10 Interior lights
should be performed daily, before the first trip. Place 11 Exterior lights
a check mark in the complete (Comp.) column to 12 Seat belts and tether belts
indicate a procedure has been performed. 13 Fuel level
14 Mirror adjustment
Inspector Date 15 Service brakes
16 Backup alarm
Suspension and Slack Adjusters Comp.

1 Suspension components
2 Slack adjusters
Wheels and Tires Comp.

1 Wheel Covers
2 Tire condition
3 Tire inflation
4 Rims and wheel components
22.1
Pre- and Post-Trip Checklists
Weekly Post-trip Inspection Checklist Fluids Added

See the following table for procedures that should be Use the following table to note any fluids that were
performed weekly, post-trip. Place a check mark in added during the inspection and maintenance proce-
the complete (Comp.) column to indicate a procedures.
dure has been performed.
Fluids Added During Inspection
Inspector Date Fluid Amount Added
Wheel Bearing Oil Seal
Lubricant
Engine Compartment Comp. Engine Oil
1 Windshield washer reservoir level Power Steering Fluid
2 Air intake restriction indicator Engine Coolant
3 Allison transmission fluid level Windshield Washer Fluid
4 Water in fuel/water separator Automatic Transmission
Fluid
5 Steering components
Hydraulic Clutch Fluid (DOT
6 Serpentine drive belts
4 brake fluid)
Monthly Post-trip Inspection
Checklists
See the following tables for procedures that should
be performed monthly, post-trip. Place a check mark
in the complete (Comp.) column to indicate a proce-
dure has been performed.
Inspector Date
Brake Components Comp.

1 Brake system components
2 Brake chambers
3 Air brake lines
4 Flex air hoses
5 Brake linings and brake drums
6 Brake lining thickness
Saddle Tank Areas Comp.

Drain air reservoirs (with automatic drain
1
valves)
2 Batteries (location may vary)
3 Aerodynamic components
Engine Compartment Comp.

1 Hood and bumper
2 Hydraulic clutch reservoir
3 Radiator and heater hoses
4 Steering wheel play
22.2
23
Pre- and Post-Trip
Inspections and
Maintenance
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23.1
Daily Pretrip Inspections and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23.1
Weekly Post-Trip Inspections and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23.9
Monthly Post-Trip Inspections and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23.12
Pre- and Post-Trip Inspections and Maintenance
Safety Precautions • spring hangers

• shocks
DANGER • suspension arms
When working on the vehicle, shut down the en- • suspension brackets
gine, set the parking brake, and chock the tires. • axle seats
Before working under the vehicle, always place
jack stands under the frame rails to ensure the • bushings
vehicle can not drop. Failure to follow these 2. Inspect slack adjusters for signs of damage. See
steps could result in serious personal injury or Fig. 23.1, Fig. 23.2, or Fig. 23.3.
death.
Daily Pretrip Inspections and
Maintenance 4
5
Complete the following inspection and maintenance 6
procedures to ensure that vehicle components are in
good working condition before each trip. A driver that 7
3 8
is familiar with the vehicle and drives it regularly can
perform the daily inspections, then add the weekly
and monthly post-trip inspections as scheduled. 2 9
If the driver does not operate the vehicle on a con-
sistent basis, all daily, weekly, and monthly inspec- 1
tion and maintenance procedures should be per-
formed before the trip. 10
IMPORTANT: The pre- and post-trip checklists,

inspections, and maintenance procedures de- 06/17/2003 f421398
tailed in this chapter are not all-inclusive. 1. 7/16-inch Adjusting Nut
Refer to other component and body manufactur- 2. Grease Fitting
ers’ instructions for specific inspection and 3. Boot
maintenance instructions, as well as local, state, 4. Link
and federal guidelines. 5. Brake Chamber Piston Rod
6. Clevis
NOTE: If any system or component does not 7. ½-inch Clevis Pin
pass this inspection, it must be corrected before 8. 1/4-inch Clevis Pin
9. Grease Relief Opening
operating the vehicle. Whenever equipment re- 10. Slack Adjuster Spline
quires adjustment, replacement, and/or repair,
see the Western Star Workshop Manual for pro- Fig. 23.1, Gunite Automatic Slack Adjuster
cedures and specifications.
• Inspect slack adjuster boots, if equipped,
for cuts or tears.
Suspension and Slack Adjuster
Inspection • Inspect anchor straps, if equipped, for
damage.
Walk around the vehicle and visually inspect suspen- • Look for worn clevis pins on brake cham-
sion and slack adjuster components.
ber pushrods.
1. Inspect the following suspension components for
• Look for missing or damaged cotter pins
signs of structural damage, cracks, or wear.
on the clevis pins.
• springs
23.1
1
2
3
4
3
5
6
7
4 8 9
8
7
6
2
5
10/11/2005 A f421397
A. Rotate the control arm toward the brake chamber
until you can feel it contacting the internal stop.
1. Clevis
2. Slack Adjuster
3. Clevis Pin
4. Manual Adjusting Nut
9
5. Control Arm
1 10
6. Control-Arm Washers and Nut 01/31/2011 f422530
7. Anchor Strap Slot 1. Grease Fitting (if equipped)
8. Anchor Strap 2. Slack Adjuster Housing
9. Brake Chamber 3. Brake Chamber Pushrod
Fig. 23.2, Haldex Automatic Slack Adjuster 4. Clevis
5. Clevis Pin (large)
• Ensure chamber piston rods are in line 6. Clevis Pin (small)
7. Actuator Rod
with the slack adjusters.
8. Boot
9. Manual Adjusting Nut
Wheel and Tire Inspection 10. Camshaft Splines
Walk around the vehicle and visually inspect each Fig. 23.3, Meritor Automatic Slack Adjuster
wheel and tire assembly.
prior to inspecting the tires and wheel compo-
IMPORTANT: Wheel covers decrease drag force nents.
as a vehicle moves, thereby improving fuel effi-
ciency. If replacement of a wheel cover is nec- NOTE: During wheel cover installation, ensure
essary, the replacement cover must meet or ex- the V-notch in the liner inner retaining ring is
ceed the drag reduction performance of the centered on the valve stem. The inner and outer
originally installed cover in order to maintain retaining rings should be uniformly aligned to
compliance with greenhouse gas and full effi- each other and to the wheel rim. The outer re-
ciency regulations (GHG14). taining ring of the liner is equipped with two
canvas flaps. When installing the face cover,
1. If the vehicle was originally equipped with wheel make sure the cover retaining ring is inserted
covers, ensure all wheel covers are present. In-
between the two canvas flaps on the liner outer
spect wheel covers for damage or wear. Remove
wheel covers from rear drive wheels, if equipped, retaining ring so that the Velcro strips line up
23.2
between the face cover and the liner. Make cer- Keep compressed air reservoirs and lines dry
tain the detachable view cover is centered on during tire inflation. Use well-maintained inline
the face cover, and the Velcro strips are moisture traps and service them regularly.
pressed firmly in place.
2. Inspect each tire for the following:
NOTICE
• valve stem caps on every tire, screwed on A weekly pressure loss of 4 psi (28 kPa) or more
finger-tight in a tire may indicate damage. The tire should be
inspected and, if necessary, repaired or replaced
• bulges, cracks, cuts, and penetrations by a qualified tire service facility.
• oil contamination (petroleum derivatives will IMPORTANT: The load and cold inflation pres-
soften the rubber and destroy the tire) sure must not exceed the rim or wheel manu-
• tread depth—if tread is less than 4/32 inch facturer’s recommendations, even though the
(3 mm) on any front tire, or less than 2/32 tire may be approved for a higher load inflation.
inch (1.5 mm) on any rear tire, replace the Consult the rim or wheel manufacturer for the
tire correct tire inflation pressure for the vehicle
• debris lodged between duel tire sets load.
IMPORTANT: Low-rolling resistance (LRR) tires 4. Examine each rim and wheel component. Check
minimize wasted energy as a tire rolls, thereby the wheel nuts or rim nuts for indications of
decreasing rolling effort and improving fuel effi- looseness.
ciency. If tire replacement is necessary, replace- 4.1 Remove all dirt and debris from the as-
ment tires must meet or exceed the rolling resis- sembly. Rust streaks or metal build-up
tance of the originally installed tires in order to around stud holes, or out-of-round or worn
maintain compliance with greenhouse gas and stud holes, may be caused by loose wheel
full efficiency regulations (GHG14). nuts.
Contact your tire manufacturer/supplier to deter- WARNING

mine the rolling resistance of the originally in-
stalled tires. Visit www.epa.gov/smartway for Have any worn or damaged wheel components
additional information and resources. replaced by a qualified person using the wheel
manufacturer’s instructions and the wheel indus-
WARNING try’s standard safety precautions and equipment.
Otherwise a vehicle or workshop accident could
Do not operate the vehicle with underinflated or occur, possibly resulting in serious personal in-
overinflated tires. Incorrect inflation can stress jury or death.
the tires and make the tires and rims more sus- 4.2 Inspect for broken, cracked, badly worn,
ceptible to damage, possibly leading to rim or bent, rusty, or sprung rings and rims. See
tire failure and loss of vehicle control, resulting Fig. 23.4.
in serious personal injury or death.
3. Check tire inflation.
For inflation pressures and maximum loads, see NOTICE
the tire manufacturer’s guidelines. Inflate the tires
to the applicable pressures if needed. Use the recommended torque values and follow
If a tire has been run flat or under-inflated, check the proper tightening sequence. Insufficient
the wheel and tire for damage before adding air. wheel nut torque can cause wheel shimmy, re-
sulting in wheel damage, stud breakage, and ex-
treme tire tread wear. Excessive wheel nut torque
23.3
02/09/95 f400001
Fig. 23.4, Worn Stud Holes
can break studs, damage threads, and crack

discs in the stud hole area. 1
4.3 Make sure all wheel nuts are tightened. If 10 8
tightening is necessary, use the tightening
pattern in Fig. 23.5 or Fig. 23.6.
3 6
When tightening a 12-stud wheel rim, use
the tightening sequence in Fig. 23.7 for
each of the three stages of tightening as
5 4
follows:
• Stage 1—Tighten each nut 50 lbf·ft
(68 N·m) 7 9
2
• Stage 2—Tighten each nut 100 lbf·ft 08/23/93 f400081a
(136 N·m)
Fig. 23.5, Tightening Sequence, 10-Stud Disc Wheels
• Stage 3—Tighten each nut 150 lbf·ft
(203 N·m)
5. Inspect the outboard side of all wheel hubs and 1 2
the hub oil seal area on the inboard side of each
wheel for signs of oil leakage. If any oil is found
on wheel and tire or brake components, remove 7 4
the vehicle from service until the leak has been
fixed.
If needed, fill the hubs to the level indicated on
the hub cap. See Group 35 of the Western Star
Maintenance Manual for recommended lubri- 5 6
cants.
6. Check that mud flaps are undamaged and hang
10 inches (25.4 cm) or less from the ground. 3 8
03/08/2012 f400052a
Fig. 23.6, Tightening Sequence, 8-Stud Disc Wheels
23.4
1 3. Inspect visible frame rails for missing bolts, shiny

8 5 areas, or rust streaks. Check all visible cross-
members for damage or signs of looseness.
10 11 4. Inspect visible components of the exhaust sys-
tem to ensure connections are tight.
Inspect upstream of the aftertreatment device
4 3 (ATD), if equipped, for cracking or signs of leaks,
such as soot trails. Inspect downstream of the
ATD for signs of exhaust leaks, such as blister-
6 9
ing or warping of nearby components.
Engine Compartment Inspection

12 7
2 1. Check the ground underneath the engine for fuel,
02/02/2012 f400364
oil, or coolant leaks.
Fig. 23.7, Tightening Sequence, 12-Stud Wheel Rims 2. Inspect the air intake system for leaks or dam-
age.
Saddle Tank Areas Inspection
NOTICE
WARNING
Failure to maintain a sealed air intake system
When draining the air reservoir, do not look into could allow the entry of dirt and contaminants
the air jets or direct them toward anyone. Dirt or into the engine. This could adversely affect en-
sludge particles may be in the airstream and gine performance and result in engine damage.
could cause injury.
2.1 Push the reset button on the air intake
restriction indicator located on the air
NOTICE cleaner, if equipped.
If the water drained from the air reservoirs is 2.2 Check the air intake duct from the air
cloudy or oily, it may indicate a problem with the cleaner to the engine intake. Make sure
compressor. If oil is allowed to contaminate the the duct components are secure and air-
air dryer, it will not remove the water from the air tight.
brake system, which could adversely affect brak- 2.3 Check the vacuator (spitter) valve(s) for
ing. damage, and make sure the lips of the
1. Drain the brake system air reservoirs (reservoirs valve(s) are pliable and free of debris.
without automatic drain valves only). 3. Check the engine oil level.
WARNING NOTICE
Never operate the engine with the fuel tank shut- Operating the engine with the oil level below the
off valves partially closed. This could damage the minimum fill (or "add") mark or above the maxi-
fuel pump, causing sudden loss of engine power, mum fill (or "full") mark could result in engine
possibly resulting in serious personal injury due damage.
to reduced vehicle control.
3.1 Check the oil level with the vehicle parked
2. Ensure fuel tanks are secured to their mounting on a level surface. See the engine manu-
brackets and that the mounting brackets are se- facturer’s guidelines for engine shutdown
cured to the frame. time requirements prior to checking the oil
If equipped with fuel tank shutoff valves, be sure level.
the valves are fully open.
23.5
IMPORTANT: On engines that comply with engine after refilling and check the sight
EPA07 or newer regulations, use CJ-4 en- glass again when the engine is at operat-
gine oil with less than 1% sulfated ash. Fail- ing temperature.
ure to use CJ-4 oil may void the warranty on
emission aftertreatment components.
3.2 If the oil level is at or below the minimum 1
fill (or "add") mark on the dipstick, add
enough oil to maintain the level between
the minimum and maximum fill marks. See
the engine operation manual for recom-
mended lubricants.
4. Check the power steering reservoir fluid level.
The power steering fluid level should be between
the MIN COLD mark and the middle mark just
above it. See Fig. 23.8. If needed, fill the reser-
voir with automatic transmission fluid that meets 2
Dexron III or TES-389 specifications. 3
06/06/2001 f500354
1. Surge Tank 2. Filler Cap
1
Fig. 23.9, Steel Surge Tank
• Translucent Surge Tank: If the coolant is

low, fill the surge tank to the FULL line with
a 50/50 mixture of water and antifreeze.
See Fig. 23.10. Start the engine after refill-
05/21/2007 f462079 ing and check the level again when the
1. Filler Cap engine is at operating temperature.
Fig. 23.8, Power Steering Fluid Reservoir (configuration 6. Inspect visible engine wiring for damage or
may vary) looseness. See Fig. 23.11. Check for loose wir-
ing, chafed insulation, and damaged or loose
hold-down clamps.
NOTICE
7. Inspect visible frame rails for missing bolts, shiny
Low coolant could result in engine overheating, areas, or rust streaks.
which could cause engine damage.
Cab Inspection
IMPORTANT: The surge tank must be cool to
check the coolant level. 1. Push the reset button on the dash-mounted air
intake restriction indicator, if equipped.
5. Check the engine coolant level in the radiator
surge tank. 2. With the ignition switch in the OFF position,
check the air-pressure warning system.
• Steel Surge Tank: Ensure coolant is visible
in the sight glass. See Fig. 23.9. If coolant 2.1 If not previously drained, drain the air res-
is not visible, add a 50/50 mixture of water ervoirs using moderate brake applications
and antifreeze to the surge tank until cool- until pressure in both reservoirs is less
ant is visible in the sight glass. Start the than 70 psi (483 kPa).
23.6
09/07/2011 f200745
1. Filler Cap 3. Low Coolant Sensor 2
2. Sight Glass
1
Fig. 23.10, Plastic Surge Tank
04/12/2010 f545646
2.2 Turn the ignition to the ON position. The
1. Powertrain PDM (PTPDM)
ICU will complete a full gauge sweep and
2. Powernet Distribution Box (PNDB)
bulb check, and the warning buzzer will
sound. Ensure the BRAKE AIR lamp re- Fig. 23.11, Visible Engine Wiring
mains illuminated and the warning buzzer
continues to sound after the gauge sweep 4.1 With the air system fully charged, make
is complete. one full brake application and note the air
pressure reading on the primary air
3. Check air governor cut-in and cut-out pressures. gauge.
3.1 Start the engine and ensure the BRAKE 4.2 Further reduce air pressure using moder-
AIR lamp goes out and the buzzer si- ate brake applications, then run the en-
lences when pressure reaches approxi- gine at governed rpm.
mately 70 psi (483 kPa) in both air reser-
voirs. 4.3 Note the time that the pressure reaches
the previously noted reading on the pri-
The air governor should cut out at ap- mary air gauge, then note the time that
proximately 120 psi (827 kPa). For ve- the air pressure reaches cut-out pressure.
hicles with an optional dryer reservoir
module (DRM), the cut-out pressure is 4.4 If it takes longer than 30 seconds to reach
approximately 130 psi (896 kPa). cut-out pressure after the primary air
gauge passes the previously noted pres-
3.2 With the engine idling, apply the brake
sure (noted after one full brake applica-
pedal several times. The air governor
tion), eliminate any leaks or replace the air
should cut in when pressure in the primary
compressor before operating the vehicle.
air reservoir (top air gauge) reaches ap-
proximately 100 psi (689 kPa). 5. Check air leakage in the system.
4. Check air pressure build-up time.
23.7
5.1 With the parking brake applied, the trans- 10.1 Turn on the headlights and leave them on.
mission out of gear, and the air system Ensure all equipped gauge bulbs illumi-
fully charged, release the service brakes nate in the dash message center.
and shut down the engine.
10.2 Ensure all equipped driver control
5.2 Wait one minute and note the air pressure switches illuminate.
drop in psi (kPa) per minute from the pri-
10.3 Ensure both turn signal indicator bulbs
mary air reservoir.
illuminate in the dash message center
If the pressure drop exceeds the limits when the turn signal switch is activated.
shown in Table 23.1, eliminate any leaks
before operating the vehicle. 11. Check the operation of all exterior lights. See
Fig. 23.12.
6. Check the air pressure reserve.
With the engine still off, make one full brake ap- 1
plication and observe the pressure drop on the
primary air gauge. If pressure drops more than
25 psi (172 kPa), eliminate any leaks before op-
erating the vehicle.
Maximum Allowable Air Leakage

Pressure Drop: 5 2
Description psi (kPa) Per Minute 3
Released Applied
Truck or Tractor Only 2 (14) 3 (21)
Truck or Tractor w/Single Trailer 3 (21) 4 (28)
Table 23.1, Maximum Allowable Air Leakage
4
WARNING
06/06/2001 f602091
When cleaning windshields and windows, always
stand on the ground or on a secure ladder or 1. Clearance Lights 4. Driving/Fog Lights
2. Turn Signal Light 5. Marker Lights
platform. Use a long-handled window cleaner. Do 3. Headlight
not use the cab steps, tires, fenders, fuel tanks,
engine, or under-hood components to access the Fig. 23.12, Exterior Lights
windshield or windows. Doing so could cause a
fall and result in an injury. 11.1 Activate the high-beam headlights and
hazard warning lights.
7. Inspect the mirrors, window glass, and wind-
shield for cracks or other damage. 11.2 Exit the cab and check that all exterior
lights and reflectors are clean and intact.
8. Ensure that the horn, windshield wipers, and
windshield washers are operating properly. 11.3 Check that the brake lights, taillights,
These devices must be in good working order for headlights, turn signals, marker lights,
safe vehicle operation. identification lights, and clearance lights
are working properly.
9. Ensure the heater and defroster are operating
properly. 12. Inspect the seat belts and tether belts.
10. Check the operation of all interior lights.
23.8
13. Check the fuel level in the fuel tank(s). To keep

WARNING condensation to a minimum, fuel tanks should be
filled at the end of each day.
Inspect and maintain seat belts. When any part of
a seat belt system needs replacement, the entire 14. Adjust the rearview and down view mirrors as
seat belt must be replaced, both retractor and necessary.
buckle side. Any time a vehicle is involved in an 15. Test the service brakes.
accident, and the seat belt system was in use,
the entire vehicle seat belt system must be re- 15.1 With the engine running and air system
placed before operating the vehicle. Do not at- fully charged, set the parking brake.
tempt to modify the seat belt system; doing so 15.2 Put the vehicle in the lowest gear and
could change the effectiveness of the system. gently attempt to move it forward. The ve-
Failure to replace worn or damaged seat belts, or hicle should not move.
making any modifications to the system, may re-
sult in personal injury or death. If the vehicle moves, the parking brakes
are not operating correctly and must be
12.1 Check the web for fraying, cuts, extreme repaired before the vehicle is operated.
dirt and dust, or for severe fading from
exposure to sunlight, especially near the 16. Test the backup alarm
buckle latch plate and in the D-loop guide 16.1 Release the parking brake and put the
area. transmission in reverse.
12.2 Check operation of the buckle, latch, Kom- 16.2 Move the vehicle slightly backward to en-
fort Latch or Sliding Komfort Latch (if sure that the backup alarm is operating
equipped), web retractor, and upper seat correctly.
belt mount on the door pillar. Check all
visible components for wear or damage.
12.3
Weekly Post-Trip Inspections
Check the seat belt and tether belt con-
nection points and tighten any that are and Maintenance
loose.
Engine Compartment Inspection
WARNING
WARNING
Never fill fuel tanks to more than 95 percent of
their liquid capacity. This could make them more Washer fluids may be flammable and poisonous.
likely to rupture from impact, possibly causing Do not expose washer fluid to an open flame or
fire and resulting in serious personal injury or any burning material, such as a cigarette. Always
death by burning. comply with the washer fluid manufacturer’s rec-
ommended safety precautions.
Do not mix gasoline or alcohol with diesel fuel.
This mixture could cause an explosion, possibly 1. Check the windshield washer reservoir fluid level.
resulting in serious personal injury or death. Do The reservoir is usually located near the right-
not fill the fuel tanks in the presence of sparks, hand frame rail.
open flames, or intense heat. These could ignite 2. After resetting the air intake restriction indicator
the fuel, possibly causing severe burns. during the daily pretrip inspection, check the indi-
IMPORTANT: On engines that comply with cator again with the engine off.
EPA07 or newer regulations, use ultralow-sulfur 2.1 Check an indicator with graduations to see
diesel (ULSD) with 15 ppm sulfur content or if air restriction exceeds the value shown
less. Failure to use ULSD fuel may void the in Table 23.2.
warranty on emission components. Check a go/no-go indicator without gradu-
ations to see if the colored bar shows
through the clear window.
23.9
Air Intake Maximum Restriction Values (inH2O) DAVCO Models: Remove the vent cap
EPA07 and
and open the drain. See Fig. 23.14.
Pre-EPA07 GHG14
Engine Make EPA10 ConMet Models: Check the water level in
Engines Engines
Engines the sight bowl, if so equipped. To drain the
Detroit 20 22 18 water, loosen the valve at the bottom and
Cummins 25 25 25 allow the water to run out. See Fig. 23.15.
Mercedes-Benz 22 22 –
Caterpillar 25 – –
Table 23.2, Air Intake Maximum Restriction Values 6
5
2.2 4
If air restriction exceeds the maximum al-
lowable value, operate the vehicle for one 3
7
more day, making sure not to run the en-
gine over rated rpm. Refer to the engine 2
operation manual for more information on
rated rpm for your engine.
2.3 If air restriction exceeds the maximum
value again, replace the air cleaner. For 8
instructions, refer to Group 09 of the 1
Western Star Workshop Manual.
9
3. If the vehicle is equipped with an Allison auto-
matic transmission, check the automatic trans-
mission fluid level. 10
4. Check for water in the fuel/water separator, if

equipped. 11
IMPORTANT: When draining fluid from a 02/03/2010 f470552

fuel/water separator, drain the fluid into an 1. Washers (qty 2) 7. Mounting Head
appropriate container and dispose of it prop- 2. Nuts (qty 2) 8. Mounting Bolts (qty 2)
erly. Many jurisdictions now issue fines for 3. Frame Rail 9. Filter Element
draining fuel/water separators onto the 4. Fuel Outlet Port 10. Sight Bowl
ground. 5. Fuel Inlet Port 11. Drain Plug
6. Priming Pump
4.1 Place a suitable container under the fuel/
Fig. 23.13, Alliance Fuel/Water Separator Assembly and
water separator.
Installation
NOTE: A hose may be used to direct water
into the container. Use a hose with a ½-inch 4.4 Stop draining fluid when fuel begins to
drain out.
pipe thread on DAVCO models.
Alliance/Racor Models: turn the drain plug
4.2 If the engine is equipped with a built-in clockwise to close it.
water separator, loosen the drain valve,
and allow the water to run out. Close the DAVCO Models: close the drain valve.
drain valve, taking care not to overtighten Install and hand-tighten the vent cap.
it. ConMet Models: close and tighten the
4.3 Alliance/Racor Models: Turn the drain plug valve finger-tight.
counterclockwise to open it. See 5. Inspect the steering components.
Fig. 23.13.
23.10
10
6
11/30/95 f470167
5 Fig. 23.15, ConMet Fuel/Water Separator
5.1 Inspect tie rods, steering arms, and the

drag link for signs of looseness (i.e., shiny
spots or rust tracks).
4 5.2 Check the steering gear mounting bolts
and pitman arm nut for signs of loose-
ness.
11 5.3 Check the drag link nuts for missing cotter
3 pins.
12
5.4 Inspect the steering intermediate shaft and
2 end yokes for excessive looseness or
other damage.
NOTICE
Do not drive with a drive belt that is visibly worn
or damaged. If it fails, the lack of coolant flow
could rapidly cause damage to engine compo-
1 13
nents.
05/05/2009 f470530
6. Inspect the serpentine drive belts for signs of
1. Inlet Port/Check Valve 8. Vent Cap O-Ring glazing, frayed edges, breaks, cracks, or oil con-
2. Lower Housing 9. Vent Cap
3. Bypass Valve 10. Collar
tamination.
4. Filter Element 11. 120VAC Pre-Heater
5. Spring 12. 12VDC Pre-Heater
6. Cover O-Ring 13. Drain Valve
7. Clear Cover
Fig. 23.14, DAVCO Fuel/Water Separator (Fuel Pro 482
shown)
23.11
Monthly Post-Trip Inspections NOTICE

and Maintenance
If the water drained from the air reservoirs is
Brake Component Inspection cloudy or oily, it may indicate a problem with the
compressor. If oil is allowed to contaminate the
Walk around the vehicle and visually the brake sys- air dryer, it will not remove the water from the air
tem components for visible damage. brake system, which could adversely affect brak-
1. Inspect all visible brake system components for ing.
missing fasteners or signs of looseness, such as 1. Drain the brake system air reservoirs (reservoirs
rust tracks. with automatic drain valves only).
NOTICE NOTE: Battery locations vary between vehicles.

2. Inspect the batteries.
If the external breather tube or breather cap is
missing or incorrectly installed, road dirt and de-
bris can adversely affect the operation of the WARNING
brake chamber. Once inside of the chamber, dirt
and debris can cause the internal parts of the Battery posts, terminals, and related accessories
chamber to deteriorate faster. contain lead and lead compounds, chemicals
known to the State of California to cause cancer
2. Inspect the exterior surfaces of brake chambers and reproductive harm. To prevent possible per-
for damage. Make sure that breather holes are sonal injury, always wash your hands after han-
open and free of debris. dling battery parts and related accessories.
NOTE: Do not route air brake lines on top of 2.1 Remove the battery box cover and inspect
anything likely to be stepped on. all visible battery cables for loose wiring or
damage.
3. Inspect air brake lines for dents, swelling, kinks,
twisting, abrasion, and damage, especially near 2.2 Check that the battery hold-down is se-
moving parts. cure.
4. Inspect flex air hoses for deterioration or signs of IMPORTANT: Aerodynamic components de-
abrasion. crease drag force as a vehicle moves, thereby
5. Inspect for cracked, worn, or oil-contaminated
improving fuel efficiency. If replacement of an
brake linings and brake drums (or rotors). aerodynamic component is necessary, replace-
ment components must meet or exceed the
6. Check the thickness of the brake linings. Re- drag reduction performance of the originally in-
place brake linings on all brake assemblies on stalled component in order to maintain compli-
the axle if any brake linings are worn to less than ance with greenhouse gas and full efficiency
approximately 1/4 inch (6.4 mm) at the thinnest
point.
regulations (GHG14).
3. Inspect the following aerodynamic components, if
Saddle Tank Areas Inspection equipped, for structural damage, cracks, or wear.
• Chassis fairings
WARNING • Roof fairing/deflector
When draining the air reservoir, do not look into • Side skirts
the air jets or direct them toward anyone. Dirt or
sludge particles may be in the airstream and • Cab/sleeper extenders
could cause injury. • Battery access cover
23.12
Engine Compartment Inspection and 4.1 Start the engine. With the front tires
straight ahead, turn the steering wheel
Adjustments until motion is observed at the front
IMPORTANT: If replacement of the hood or wheels.
bumper is necessary, the replacement compo- 4.2 Align a reference mark on the steering
nent must meet or exceed the drag reduction wheel to a rule, then slowly turn the steer-
performance of the originally installed item in ing wheel in the opposite direction until
order to maintain compliance with greenhouse motion is again detected at the wheels.
gas and full efficiency regulations (GHG14). 4.3 Measure the lash (free play) at the rim of
1. Inspect the bumper and hood for structural dam- the steering wheel. Excessive lash exists
age, cracks, or wear. if steering wheel movement exceeds 2-1/2
inches (64 mm) with a 20-inch (508-mm)
2. Check the hydraulic clutch reservoir, if equipped. steering wheel, or 2-1/4 inches (57 mm)
If necessary, add DOT 4 brake fluid. with an 18-inch (450-mm) steering wheel.
3. Inspect the radiator and heater hoses, including 4.4 If there is excessive lash, check the steer-
the clamps and support brackets. ing system for wear or incorrect adjust-
3.1 Inspect the radiator and charge air cooler ment before operating the vehicle.
for damage and accumulated debris.
Straighten bent or damaged fins to permit
airflow across all areas of the cores.
NOTE: When traveling through areas of high
insect concentration, it may be necessary to
clean the exterior of the radiator or the
charge air cooler core as often as every 200
miles (320 km).
3.2 Make sure the radiator inlet and outlet
hoses are pliable and are not cracking or
ballooning.
3.3 Make sure the heater hoses are pliable
and are not cracking or ballooning.
3.4 Tighten hose clamps as necessary.
IMPORTANT: Do not overtighten hose
clamps, as hose life can be adversely af-
fected.
3.5 Ensure hose support brackets are se-
curely fastened. Make sure hoses are not
located near sources of wear, abrasion, or
high heat.
IMPORTANT: When replacing hoses, install
service-type knitted or braided yarn-reinforced
neoprene hose. Extended-service-life silicone
hoses may also be used. See the Alliance Parts
Catalog at www.alliancebrandparts.com or
contact your Freightliner Dealer.
4. Check the steering wheel for excessive play.
23.13
Index
Subject Page Subject Page

A Trailer Air Supply Valve . . . . . . . . . . . . . . . . . . 4.12
Trailer Brake Lever . . . . . . . . . . . . . . . . . . . . . 4.12
ABTS Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.4
Armrest Adjustment . . . . . . . . . . . . . . . . . . . . . 6.5
Backrest Adjustment . . . . . . . . . . . . . . . . . . . . . 6.5
C
Cushion Extension Cab Amenities . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.2
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . 6.5 Cigar Lighter/Accessory Plug . . . . . . . . . . . . . . . 7.2
Isolator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.5 Cup Holders . . . . . . . . . . . . . . . . . . . . . . . . . . 7.2
Lumbar Adjustment . . . . . . . . . . . . . . . . . . . . . 6.5 Electronic Device Mount . . . . . . . . . . . . . . . . . . 7.3
Seat Height Adjustment . . . . . . . . . . . . . . . . . . 6.5 Glove Box . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.2
Seat Tilt Control . . . . . . . . . . . . . . . . . . . . . . . 6.5 Lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.3
Shoulder Belt Height Control . . . . . . . . . . . . . . . 6.5 Storage Areas . . . . . . . . . . . . . . . . . . . . . . . . . 7.3
Track Adjustment . . . . . . . . . . . . . . . . . . . . . . . 6.5 Cab Climate Control Panels . . . . . . . . . . . . . . . . . . 5.1
Adjustable Steering Column Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1
Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.12 Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3
Adjusting Headlight Aim . . . . . . . . . . . . . . . . . . . 19.1 Cab Washing and Polishing . . . . . . . . . . . . . . . . . 20.1
Air Brake System . . . . . . . . . . . . . . . . . . . . . . . . 12.1
Care of Fiberglass Parts . . . . . . . . . . . . . . . . . 20.1
Automatic Slack Adjusters . . . . . . . . . . . . . . . . 12.3 Canadian Motor Vehicle Safety
Brake System Conditions . . . . . . . . . . . . . . . . 12.3 Standard Labels . . . . . . . . . . . . . . . . . . . . . . . . 1.1
Brake System Operation . . . . . . . . . . . . . . . . . 12.1 Care of Chrome Parts . . . . . . . . . . . . . . . . . . . . . 20.1
General Information, Brake Care of Exterior Lights . . . . . . . . . . . . . . . . . . . . 20.3
System . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.1
Checking Headlight Aim . . . . . . . . . . . . . . . . . . . 19.1
Air-Suspension Dump Valve . . . . . . . . . . . . . . . . . 18.1 Checklists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22.1
Allison Automatic Transmissions . . . . . . . . . . . . . . 15.5 Daily Pretrip Inspection
Allison Transmission Checklists . . . . . . . . . . . . . . . . . . . . . . . . . 22.1
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . 15.6 Monthly Post-trip Inspection
General Information, Allison Checklists . . . . . . . . . . . . . . . . . . . . . . . . . 22.2
Transmissions . . . . . . . . . . . . . . . . . . . . . . . 15.5 Weekly Post-trip Inspection
Auxiliary Braking Applications . . . . . . . . . . . . . . . . 10.3 Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . 22.2
Engine Brake . . . . . . . . . . . . . . . . . . . . . . . . 10.3 Climate Control Options . . . . . . . . . . . . . . . . . . . . 5.1
Exhaust Brake . . . . . . . . . . . . . . . . . . . . . . . . 10.4 Climate Controls . . . . . . . . . . . . . . . . . . . . . . . . 4.13
Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.7
B Clutch General Information . . . . . . . . . . . . . . . 14.7
Clutch Maintenance . . . . . . . . . . . . . . . . . . . . 14.8
Back-of-Cab Access . . . . . . . . . . . . . . . . . . . . . . . 2.5 Clutch Operation . . . . . . . . . . . . . . . . . . . . . . 14.7
Accessing Back-of-Cab Area . . . . . . . . . . . . . . . 2.6 Component GWR Label . . . . . . . . . . . . . . . . . . . . 1.1
Exiting Back-of-Cab Area . . . . . . . . . . . . . . . . . 2.6 Component Information Label . . . . . . . . . . . . . . . . 1.1
Battery Access . . . . . . . . . . . . . . . . . . . . . . . . . . 8.3 Control Panels . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1
Battery Disconnect Switches . . . . . . . . . . . . . . . . . 8.2 DataStar Display Module . . . . . . . . . . . . . . . . . . 4.1
Cab Load Disconnect Cruise Control . . . . . . . . . . . . . . . . . . . . . . . . . . 10.2
Switch, EPA10 and Newer . . . . . . . . . . . . . . . 8.2
Pre-EPA10 Battery Isolation Cruise at a particular speed . . . . . . . . . . . . . . . 10.2
Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.2 Disengage cruise control . . . . . . . . . . . . . . . . . 10.2
Bostrom Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3
Backrest Tilt . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3 D
Bottom Cushion Tilt . . . . . . . . . . . . . . . . . . . . . 6.4
Fore-and-Aft Seat Slide . . . . . . . . . . . . . . . . . . 6.4 Daily Pretrip Inspections and
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . 23.1
Height Adjustment . . . . . . . . . . . . . . . . . . . . . . 6.4 Cab Inspection . . . . . . . . . . . . . . . . . . . . . . . 23.6
Isolator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.4 Engine Compartment
Lumbar Support . . . . . . . . . . . . . . . . . . . . . . . 6.3 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . 23.5
Brake Controls . . . . . . . . . . . . . . . . . . . . . . . . . . 4.11 Saddle Tank Areas
Antilock Braking System . . . . . . . . . . . . . . . . . 4.12 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . 23.5
Parking Brake Control Valve . . . . . . . . . . . . . . . 4.11
I-1
Index

Suspension and Slack Aftertreatment System
Adjuster Inspection . . . . . . . . . . . . . . . . . . . 23.1 Indicators Label . . . . . . . . . . . . . . . . . . . . . . 1.2
Wheel and Tire Inspection . . . . . . . . . . . . . . . . 23.2 Certified Clean Idle Label . . . . . . . . . . . . . . . . . 1.4
Dashboard Care . . . . . . . . . . . . . . . . . . . . . . . . 20.1 EPA Noise Emission Control
Diesel Exhaust Fluid and Tank, Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
EPA10 and Newer Engines . . . . . . . . . . . . . . . . 11.3 Vehicle Emission Control
DEF Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.4 Information Label . . . . . . . . . . . . . . . . . . . . . 1.2
DEF Warnings and Engine Engine Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . 9.3
Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.6 Engine Idle Limiting . . . . . . . . . . . . . . . . . . . . . . 10.1
Diesel Exhaust Fluid . . . . . . . . . . . . . . . . . . . . 11.3 California Engine Idle Limit . . . . . . . . . . . . . . . 10.1
Fuel/DEF Gauge . . . . . . . . . . . . . . . . . . . . . . 11.5 Idle Shutdown Timer . . . . . . . . . . . . . . . . . . . . 10.1
Door Locks and Handles . . . . . . . . . . . . . . . . . . . . 2.1 Engine Operation . . . . . . . . . . . . . . . . . . . . . . . . . 9.1
Remote Keyless Entry . . . . . . . . . . . . . . . . . . . 2.1 Cold-Weather Operation . . . . . . . . . . . . . . . . . . 9.2
Drive Axles with Differential Engine Break-In . . . . . . . . . . . . . . . . . . . . . . . 9.2
Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.1 Normal Operation . . . . . . . . . . . . . . . . . . . . . . 9.2
Differential Lock Operation . . . . . . . . . . . . . . . . 16.1 Safety and Environmental
Differential Lock Switch . . . . . . . . . . . . . . . . . . 16.1 Considerations . . . . . . . . . . . . . . . . . . . . . . . 9.1
Engine Protection—Warning
E and Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . 10.1
Engine Shutdown . . . . . . . . . . . . . . . . . . . . . . . . 9.3
Eaton Fuller Deep Reduction Engine Starting . . . . . . . . . . . . . . . . . . . . . . . . . . 9.1
Transmissions . . . . . . . . . . . . . . . . . . . . . . . . . 14.4 Cold-Weather Starting . . . . . . . . . . . . . . . . . . . 9.1
Downshifting Deep Starting After Extended
Reduction Transmissions . . . . . . . . . . . . . . . 14.7 Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . 9.1
General Information . . . . . . . . . . . . . . . . . . . . 14.4 EPA-Regulated Emissions
Upshifting Deep Reduction Aftertreatment Systems . . . . . . . . . . . . . . . . . . . 11.1
Transmissions . . . . . . . . . . . . . . . . . . . . . . . 14.5 ATS Warning Lamps . . . . . . . . . . . . . . . . . . . . 11.3
Eaton Fuller Splitter and EPA07 Engines . . . . . . . . . . . . . . . . . . . . . . . 11.1
Range-Shift Transmissions . . . . . . . . . . . . . . . . 14.1 EPA10 and Newer Engines . . . . . . . . . . . . . . . 11.1
Eaton Fuller 10-Speed Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . 11.3
Range-Shift Transmissions . . . . . . . . . . . . . . 14.4
Regeneration . . . . . . . . . . . . . . . . . . . . . . . . . 11.2
Eaton Fuller 13-Speed
Splitter and Range-Shift
Transmissions . . . . . . . . . . . . . . . . . . . . . . .
Eaton Fuller 18-Speed
14.2 F
Splitter and Range-Shift Federal Motor Vehicle Safety
Transmissions . . . . . . . . . . . . . . . . . . . . . . . 14.3 Standard Labels . . . . . . . . . . . . . . . . . . . . . . . . 1.1
General Information, Range- Fifth Wheel Coupling . . . . . . . . . . . . . . . . . . . . . 17.1
Shift Transmissions . . . . . . . . . . . . . . . . . . . 14.1 Coupling, Fontaine and
General Information, Splitter Holland Fifth Wheels . . . . . . . . . . . . . . . . . . 17.2
Control . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.1 Coupling, Jost Fifth Wheel . . . . . . . . . . . . . . . . 17.4
Eaton® Fuller® Automated Fifth Wheel Slide . . . . . . . . . . . . . . . . . . . . . . . . 17.7
Transmissions . . . . . . . . . . . . . . . . . . . . . . . . . 15.1 Air Slide Operation . . . . . . . . . . . . . . . . . . . . . 17.9
Automated Transmission Manual Slide Operation . . . . . . . . . . . . . . . . . . 17.8
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . 15.1
Fifth Wheel Uncoupling . . . . . . . . . . . . . . . . . . . . 17.5
General Information,
Automated Transmissions . . . . . . . . . . . . . . . 15.1 Air-Actuated Uncoupling . . . . . . . . . . . . . . . . . 17.5
Transmission Diagnostics . . . . . . . . . . . . . . . . 15.4 Manual Uncoupling . . . . . . . . . . . . . . . . . . . . . 17.5
Eaton® Fuller® Transmission Fifth Wheels, General
Operation Tips . . . . . . . . . . . . . . . . . . . . . . . . 14.1 Information . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.1
Emergency Filter Replacement, Air-Suspension Dump Valve . . . . . . . . . . . . . . . 17.1
DAVCO Fuel/Water Separator . . . . . . . . . . . . . . 21.1 Fifth Wheel Lubrication . . . . . . . . . . . . . . . . . . 17.1
Emergency Kit . . . . . . . . . . . . . . . . . . . . . . . . . . 21.1 Fire Extinguisher . . . . . . . . . . . . . . . . . . . . . . . . 21.1
Emissions Labels . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 Fire in the Cab . . . . . . . . . . . . . . . . . . . . . . . . . 21.6
In Case of a Cab Fire . . . . . . . . . . . . . . . . . . . 21.7
I-2
Index

Fluids Added . . . . . . . . . . . . . . . . . . . . . . . . . . . 22.2 Monthly Post-Trip Inspections
and Maintenance . . . . . . . . . . . . . . . . . . . . . . 23.12
G Brake Component Inspection . . . . . . . . . . . . .
Engine Compartment
23.12
Grab Handles and Access Inspection and

Steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2 Adjustments . . . . . . . . . . . . . . . . . . . . . . . 23.13
Entering the Driver’s Side, Saddle Tank Areas
Right-Hand-Drive Vehicles . . . . . . . . . . . . . . . 2.4 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . 23.12
Entering the Driver’s Side . . . . . . . . . . . . . . . . . 2.2
Entering the Passenger’s
Side, Right-Hand-Drive
N
Vehicles . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5 National Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.4
Entering the Passenger’s Backrest Tilt . . . . . . . . . . . . . . . . . . . . . . . . . . 6.4
Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3 Bottom Cushion Fore-and-Aft
Exiting the Driver’s Side, Slide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.4
Right-Hand-Drive Vehicles . . . . . . . . . . . . . . . 2.5 Fore-and-Aft Seat Slide . . . . . . . . . . . . . . . . . . 6.4
Exiting the Driver’s Side . . . . . . . . . . . . . . . . . . 2.3 Height Adjustment . . . . . . . . . . . . . . . . . . . . . . 6.4
Exiting the Passenger’s Isolator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.4
Side, Right-Hand-Drive Lumbar Support . . . . . . . . . . . . . . . . . . . . . . . 6.4
Vehicles . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5
Rear Cushion Adjustment . . . . . . . . . . . . . . . . . 6.4
Exiting the Passenger’s Side . . . . . . . . . . . . . . . 2.4
Greenhouse Gas Emissions
and Fuel Consumption
Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.1
O
Optional Instruments . . . . . . . . . . . . . . . . . . . . . . 3.6
Air Restriction Gauge . . . . . . . . . . . . . . . . . . . . 3.6
H Ammeter . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.7
Hazard Warning Lights . . . . . . . . . . . . . . . . . . . . 21.1 Application Air Pressure
Hood Opening and Closing . . . . . . . . . . . . . . . . . . 2.7 Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.7
Closing the Hood . . . . . . . . . . . . . . . . . . . . . . . 2.7 Drive Axle Oil Temperature
Gauges . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.8
Opening the Hood . . . . . . . . . . . . . . . . . . . . . . 2.7
Engine Oil Temperature
Horn Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.5 Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.8
Air Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.5 Turbocharger Boost
Electric Horn . . . . . . . . . . . . . . . . . . . . . . . . . . 4.5 Pressure Gauge . . . . . . . . . . . . . . . . . . . . . . 3.8
Overhead Instrument Panel,
I Optional . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.8
Ignition Switch . . . . . . . . .
Interaxle Lock . . . . . . . . .
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
. 4.1
16.2
P
Interaxle Lock Operation . . . . . . . . . . . . . . . . . 16.2 Periodic Inspections and
Interaxle Lock Switch . . . . . . . . . . . . . . . . . . . 16.2 Maintenance, General
Information . . . . . . . . . . . . . . . . . . . . . . . . . . . 22.1
Power Steering System . . . . . . . . . . . . . . . . . . . . 13.1
L Steering Wheel Adjustment . . . . . . . . . . . . . . . 13.1
Lighting Controls . . . . . . . . . . . . . . . . . . . . . . . . . 4.3 Power Takeoff (PTO) Governor . . . . . . . . . . . . . . . 10.5
Exterior Light Controls . . . . . . . . . . . . . . . . . . . 4.3 Powertrain Controls . . . . . . . . . . . . . . . . . . . . . . . 4.6
Interior Light Controls . . . . . . . . . . . . . . . . . . . . 4.5 Aftertreatment System
Regen Switches . . . . . . . . . . . . . . . . . . . . . . 4.6
Axle Switches . . . . . . . . . . . . . . . . . . . . . . . . . 4.6
M Cruise Control Switches . . . . . . . . . . . . . . . . . . 4.7
Meritor WABCO® Antilock Engine Brake Switches . . . . . . . . . . . . . . . . . . . 4.8
Braking System . . . . . . . . . . . . . . . . . . . . . . . . 12.3 Engine Diagnostic Switch
ABS, Trailer Compatibility . . . . . . . . . . . . . . . . 12.4 (EPA07 vehicles) . . . . . . . . . . . . . . . . . . . . . . 4.8
Automatic Traction Control . . . . . . . . . . . . . . . . 12.4 Engine Fan Switch . . . . . . . . . . . . . . . . . . . . . . 4.8
I-3
Index

Exhaust Brake Switch . . . . . . . . . . . . . . . . . . . . 4.9 Air-Suspension Dump
Idle Speed Switch . . . . . . . . . . . . . . . . . . . . . . 4.9 Control Switch . . . . . . . . . . . . . . . . . . . . . . . 4.13
Power Takeoff Controls . . . . . . . . . . . . . . . . . . . 4.9 Fifth Wheel Slide Control
Transmission Controls . . . . . . . . . . . . . . . . . . . 4.10 Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.13
Preliminary Checks . . . . . . . . . . . . . . . . . . . . . . . 19.1
Premier Trailer Couplings . . . . . . . . . . . . . . . . . . 18.1 T
General Information . . . . . . . . . . . . . . . . . . . . 18.1
Towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.4
Trailer Hookup . . . . . . . . . . . . . . . . . . . . . . . . 18.1
Front Towing Hookup . . . . . . . . . . . . . . . . . . . 21.5
Trailer Release . . . . . . . . . . . . . . . . . . . . . . . 18.2
Rear Towing Hookup . . . . . . . . . . . . . . . . . . . 21.6
R V
Roll-Stability Control . . . . . . . . . . . . . . . . . . . . . . 12.5
Vehicle Power Distribution . . . . . . . . . . . . . . . . . . . 8.1
Power Distribution, EPA10
S and Newer . . . . . . . . . . . . . . . . . . . . . . . . . . 8.1
Pre-EPA10 Power
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . 23.1 Distribution . . . . . . . . . . . . . . . . . . . . . . . . . . 8.2
Seat Belts and Tether Belts . . . . . . . . . . . . . . . . . . 6.5 Velour Upholstery Cleaning . . . . . . . . . . . . . . . . . 20.2
Seat Belt Inspection . . . . . . . . . . . . . . . . . . . . . 6.6 Chewing Gum or Wax . . . . . . . . . . . . . . . . . . . 20.3
Seat Belt Operation . . . . . . . . . . . . . . . . . . . . . 6.6 Grease and Oil-Based Stains . . . . . . . . . . . . . . 20.3
Seat Controls . . . . . . . . . . . . . . . . . . . . . . . . . . 4.14 Mildew . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20.3
Seats, General Information . . . . . . . . . . . . . . . . . . 6.1 Sugar and Water-Based
Sleeper Amenities . . . . . . . . . . . . . . . . . . . . . . . . 7.3 Stains . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20.3
Baggage Compartment Vinyl Upholstery Cleaning . . . . . . . . . . . . . . . . . . 20.2
Doors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.3 Ball Point Ink . . . . . . . . . . . . . . . . . . . . . . . . . 20.2
Lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.3 Chewing Gum . . . . . . . . . . . . . . . . . . . . . . . . 20.2
Remote Engine Start . . . . . . . . . . . . . . . . . . . . 7.3 Dirt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20.2
Sleeper Door . . . . . . . . . . . . . . . . . . . . . . . . . 7.3 Nail Polish and Nail Polish
Sliding Side Window . . . . . . . . . . . . . . . . . . . . 7.4 Remover . . . . . . . . . . . . . . . . . . . . . . . . . . 20.2
Vent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.4 Paint, Shoe Heel Marks . . . . . . . . . . . . . . . . . 20.2
Sleeper Climate Control Panels . . . . . . . . . . . . . . . 5.4 Shoe Polish . . . . . . . . . . . . . . . . . . . . . . . . . 20.2
Accessory Heaters . . . . . . . . . . . . . . . . . . . . . . 5.6 Sulfide Stains . . . . . . . . . . . . . . . . . . . . . . . . 20.2
Controls, Vehicles With ATC . . . . . . . . . . . . . . . 5.4 Tars, Asphalts, and Creosote . . . . . . . . . . . . . . 20.2
Controls, Vehicles Without
ATC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.4
Sleeper Compartment W
Restraints . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.9 Warning and Indicator Lights . . . . . . . . . . . . . . . . . 3.1
Bunk Restraint Adjustment . . . . . . . . . . . . . . . . 6.9 Engine Protection System . . . . . . . . . . . . . . . . . 3.3
Standard Instruments . . . . . . . . . . . . . . . . . . . . . . 3.3 Weekly Post-Trip Inspections
Coolant Temperature Gauge . . . . . . . . . . . . . . . 3.4 and Maintenance . . . . . . . . . . . . . . . . . . . . . . . 23.9
Engine Oil Pressure Gauge . . . . . . . . . . . . . . . . 3.4 Engine Compartment
Fuel/Diesel Exhaust Fluid Inspection . . . . . . . . . . . . . . . . . . . . . . . . . 23.9
(DEF) Gauge, EPA10 and Western Star High-Back Seat . . . . . . . . . . . . . . . . . 6.2
Newer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5 Backrest Tilt . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2
Primary and Secondary Air Bottom Cushion Extension . . . . . . . . . . . . . . . . 6.3
Pressure Gauges . . . . . . . . . . . . . . . . . . . . . 3.5
Fore/Aft Isolator . . . . . . . . . . . . . . . . . . . . . . . . 6.3
Speedometer . . . . . . . . . . . . . . . . . . . . . . . . . 3.5
Fore/Aft Seat Slide . . . . . . . . . . . . . . . . . . . . . . 6.3
Tachometer . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5
Front Cushion Height . . . . . . . . . . . . . . . . . . . . 6.3
Voltmeter . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5
Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3
Star Gauge Face Care . . . . . . . . . . . . . . . . . . . . 20.3
Height Adjustment . . . . . . . . . . . . . . . . . . . . . . 6.3
Starting with Jumper Cables . . . . . . . . . . . . . . . . . 21.2
Lumbar Support . . . . . . . . . . . . . . . . . . . . . . . 6.2
Suspension/Trailer Connection
Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.13 Rear Cushion Height . . . . . . . . . . . . . . . . . . . . 6.3
I-4
Index
Subject Page
Shock Absorber . . . . . . . . . . . . . . . . . . . . . . . . 6.3
Windows and Mirrors . . . . . . . . . . . . . . . . . . . . . . 7.1
Down-View Mirror . . . . . . . . . . . . . . . . . . . . . . 7.1
Power Mirrors . . . . . . . . . . . . . . . . . . . . . . . . . 7.1
Windows . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.1
Windshield Wiper Controls . . . . . . . . . . . . . . . . . . 4.11
I-5

Western Star: Driver's Manual

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®

Introduction performed. The EDR is designed to record data re-

Customer Assistance Center

Reporting Safety Defects

Component Information Label

Canadian Motor Vehicle Safety

Fig. 1.3, Vehicle Certification Label

Fig. 1.4, Incomplete Vehicle Certification Label

(3)]. It is the owner’s responsibility to maintain the

EPA Noise Emission Control Label

Fig. 1.6, Component GWR Label

EXHAUST AFTERTREATMENT SYSTEM INFORMATION

Fig. 1.7, ATS Indicators, EPA07

Applicable Emissions System Based on Build Date and EPA Regulations

DEF Refill Needed Diesel Exhaust Fluid (DEF) level is

See operator’s manual for complete instructions. 24−01656−000

Fig. 1.8, ATS Indicators, EPA10 and Newer

A Vehicle Emission Control Information Label is lo-

06/28/2011 f080171 Certified Clean Idle Label

Fig. 1.11, CARB Clean Idle Label

Door Locks and Handles

03/21/2001 f720394 11/02/2011 f545852

be especially careful when entering or exiting the

Exiting the Driver’s Side

CAUTION 4. Move your left hand to the lower door pocket or

Fig. 2.8. A grab handle may also be provided on the

Fig. 2.9, Hood Opening and Closing

3. As the hood starts to open, put your foot on the

Warning and Indicator Lights • STOP engine

Common Lightbar Lamps

Common Lightbar Lamps

Indicates an engine emissions-related fault. See the engine

High-Beam Headlights Indicates the high-beam headlights are on.

Indicates a problem with the truck/tractor ABS is detected. Repair

Indicates a problem with the trailer ABS is detected. Repair the

Activates with an audible warning when air pressure in the primary

Parking Brake Indicates the parking brake is engaged.

Power Takeoff (PTO) Indicates that the PTO function is engaged.

Common Lightbar Lamps

Transmission Overheat Indicates high transmission temperature.

Service Transmission Indicates a transmission service is due.

Indicates that the rear suspension air pressure is below operating

Table 3.1, Common Lightbar Lamps

Coolant Temperature Gauge Engine Oil Pressure Gauge

Fig. 3.2, Engine Oil Pressure Gauge

Minimum Oil Pressure *

Fig. 3.7, Voltmeter

05/11/2001 f610532 Air Restriction Gauge

Air Intake Maximum Restriction Values (inH2O)

Fig. 3.8, Air Intake Restriction Indicator, Graduated

Fig. 3.10, Ammeter

Fig. 3.9, Air Intake Restriction Gauge

restriction value equals or exceeds the value shown

Engine Oil Temperature Gauge

console also holds the sun visors and the optional

Control Panels DataStar Display Module

In the OFF position, the key slot is vertical. The key

05/26/2009 f545540 • brake lights

Fig. 4.4, Ignition Switch and Cigarette Lighter