western star 5700 - freightliner trucks

®WESTERN STAR 5700

Driver’s Manual

Part Number A24-01858-000Publication Number STI-499-6

IntroductionThis manual provides information needed to operateand understand the vehicle and its components.More detailed information is contained in the Owner’sWarranty Information for North America booklet andin the vehicle’s workshop and maintenance manuals.

Custom-built Western Star vehicles are equippedwith various chassis and cab components. Not all ofthe information contained in this manual applies toevery vehicle. For details about components in yourvehicle, refer to the chassis specification pages in-cluded in all new vehicles and to the vehicle specifi-cation decal located inside the vehicle.

For your reference, keep this manual in the vehicleat all times.

IMPORTANT: Descriptions and specifications inthis manual were in effect at the time of printing.Western Star Trucks reserves the right to dis-continue models and to change specifications ordesign at any time without notice and withoutincurring obligation. Descriptions and specifica-tions contained in this publication provide nowarranty, expressed or implied, and are subjectto revisions and editions without notice.

Environmental Concerns andRecommendationsWhenever you see instructions in this manual to dis-card materials, you should first attempt to reclaimand recycle them. To preserve our environment, fol-low appropriate environmental rules and regulationswhen disposing of materials.

Event Data RecorderThis vehicle is equipped with one or more devicesthat record specific vehicle data. The type andamount of data recorded varies depending on howthe vehicle is equipped (such as the brand of engine,if an air bag is installed, or if the vehicle features acollision avoidance system, etc.).

This vehicle is equipped with an event data recorder(EDR). The main purpose of an EDR is to recorddata in certain crash or near-crash situations, suchas air bag deployment or hitting a road obstacle, thatwill assist in understanding how a vehicle’s systems

performed. The EDR is designed to record data re-lated to vehicle dynamics and safety systems for ap-proximately 60 seconds. This data can help providea better understanding of the circumstances in whichcrashes and injuries occur. Data recorded includesthe following items:

• how various systems in the vehicle were oper-ating

• engine system information

• how far (if at all) the driver was depressing theaccelerator

• if the driver was depressing the brake pedal

• how fast the vehicle was traveling

NOTE: Data is not recorded by the EDR undernormal driving conditions. Personal data suchas name, gender, age, and crash location arenot recorded. However, other parties such aslaw enforcement could combine the EDR datawith the type of personally identifying data rou-tinely acquired during a crash investigation.

To read data recorded by an EDR, special equipmentis required, and access to the vehicle or the EDR isneeded. In addition to the vehicle manufacturer, otherparties that have the special equipment, such as lawenforcement, can read the information if they haveaccess to the vehicle or the EDR.

Emissions and Fuel EfficiencyComplianceThis vehicle must be regularly inspected and main-tained as indicated in the Western Star MaintenanceManual, and in the Pre- and Post-Trip Inspectionsand Maintenance chapter in this manual, in order tocontinue satisfactory performance and ensure cover-age of the vehicle under the manufacturer’s warranty.Many maintenance procedures ensure that the ve-hicle and engine continue to comply with applicableemissions standards. Maintenance procedures, usingcomponents engineered to comply with greenhousegas emissions and fuel efficiency regulations, may beperformed by an authorized Daimler Trucks NorthAmerica dealer, an independent outlet, or the vehicleowner or operator.

The vehicle owner is responsible for determining thesuitability of replacement components to maintain

Foreword

STI-499-6 (7/17)A24-01858-000

Printed in U.S.A.

compliance with federal and local jurisdictional regu-lations. Components including, but not limited to,tires, cab/sleeper side extenders, chassis fairings,bumper, hood, vehicle speed limiters, and idle reduc-tion timers are specifically designed and manufac-tured to exacting standards for regulatory fuel effi-ciency and greenhouse gas emissions compliance. Itis important that these components are always re-placed with components that meet or exceed the per-formance of the originally installed components.

Customer Assistance CenterHaving trouble finding service? For over-the-roadbreakdown assistance, customer concerns, literaturerequests, and the location of the nearest dealer, call1-866-850-STAR (7827). Call night or day, weekdaysor weekends. Our people are knowledgeable, profes-sional, and committed to following through to helpyou keep your truck moving.

Reporting Safety DefectsIf you believe that your vehicle has a defect whichcould cause a crash or could cause injury ordeath, you should immediately inform the NationalHighway Traffic Safety Administration (NHTSA) inaddition to notifying Western Star Trucks.

If the NHTSA receives similar complaints, it mayopen an investigation, and if it finds that a safetydefect exists in a group of vehicles, it may order arecall and remedy campaign. However, NHTSAcannot become involved in individual problemsbetween you, your dealer, or Western Star Trucks.

To contact NHTSA, you may call the VehicleSafety Hotline toll-free at 1-888-327-4236 (TTY:1-800-424-9153); go to www.safercar.gov; orwrite to: Administrator, NHTSA, 1200 New JerseyAvenue, SE, Washington, DC 20590. You can alsoobtain other information about motor vehicle safetyfrom 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-freehotline 1-800-333-0510, or contact TransportCanada by mail at: Transport Canada, ASFAD,

Place de Ville Tower C, 330 Sparks Street, Ot-tawa, Ontario, Canada K1A 0N5.

For additional road safety information, please visitthe Road Safety website at: www.tc.gc.ca/roadsafety.

© 2017 Daimler Trucks North America LLC. All rights reserved. Daimler Trucks North America LLC is a Daimler com-

pany.

No part of this publication, in whole or part, may be translated, reproduced, stored in a retrieval system, or transmittedin 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 NorthAmerica LLC, Service Systems and Documentation, P.O. Box 3849, Portland OR 97208–3849 U.S.A. or refer towww.Daimler-TrucksNorthAmerica.com and www.WesternStarTrucks.com.

Foreword

www.safercar.gov

www.safercar.gov

www.tc.gc.ca/roadsafety


http://www.Daimler-TrucksNorthAmerica.com

www.WesternStarTrucks.com

ContentsChapter Page

Introduction, Environmental Concerns and Recommendations,Event Data Recorder, Emissions and Fuel Efficiency Compliance,Customer Assistance Center, Reporting Safety Defects . . . . . . . . . . . . . . . . . . . . Foreword

1 Vehicle Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.12 Vehicle Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.13 Instruments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.14 Driver Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.15 Driver Assistance Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.16 Climate Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.17 Seats and Restraints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.18 Cab and Sleeper Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.19 Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.1

10 Engine Starting, Operation, and Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.111 Optional Engine Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.112 Emissions and Fuel Efficiency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.113 Brake Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.114 Steering System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.115 Automated Transmissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.116 Manual Transmissions and Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.117 Drive Axles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.118 Fifth Wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.119 Trailer Couplings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.120 Headlight Aiming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20.121 Vehicle Appearance and Care . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.122 Pre- and Post-Trip Checklists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22.123 Pre- and Post-Trip Inspections and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23.124 In An Emergency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24.125 Telematics Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.1

Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I.1

1

Vehicle IdentificationComponent Information Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1Federal Motor Vehicle Safety Standard Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1Canadian Motor Vehicle Safety Standard Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2Component GWR Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2Emissions Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2

Component Information LabelNOTE: Labels shown in this chapter are ex-amples only. Actual specifications may vary fromvehicle to vehicle.

The component information label lists the vehiclemodel, identification number, and major componentmodels. It also lists the major assemblies and instal-lations shown on the chassis specification sheet.One copy of the component information label is at-tached to the inside of the glove box; another copy isinside the rear cover of the Owner’s Warranty Infor-mation for North America booklet. An illustration ofthe label is shown in Fig. 1.1.

Federal Motor Vehicle SafetyStandard LabelsNOTE: Due to the variety of Federal Motor Ve-hicle Safety Standard (FMVSS) certification re-quirements, not all of the labels shown will applyto your vehicle.

Tractors with or without fifth wheels purchased in theU.S. are marked as certified by means of an FMVSScertification label. See Fig. 1.2. This label is attachedto the driver-side B-pillar, as shown in Fig. 1.3.

The tire and rim portion of the FMVSS certificationlabel certifies suitable tire and rim combinations that

can be installed on the vehicle, for the given grossaxle weight rating. Tires and rims installed on thevehicle at the time of manufacture may have a higherload capacity than that certified by the tire and rimlabel. If the tires and rims currently on the vehiclehave a lower load capacity than that shown on thetire and rim label, then the tires and rims determinethe load limitations on each of the axles.

Trucks built without a cargo body that are intendedfor service in the U.S. have an incomplete vehiclecertification label attached by the final-stage manu-facturer. See Fig. 1.4. This label will be attached tothe incomplete vehicle document included with thevehicle, and certifies that the vehicle conforms to all

applicable FMVSS regulations in effect on the date ofcompletion.

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Fig. 1.1, Component Information Label

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Fig. 1.2, Vehicle Certification Label

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1

2

1. Certification Label2. Noise Emission Label

Fig. 1.3, Label Locations

Vehicle Identification

1.1

Canadian Motor Vehicle SafetyStandard LabelsIn Canada, tractors with fifth wheels are marked ascertified by means of a statement of compliance labelwith the Canadian National Safety Mark attached tothe driver-side door frame B-pillar. See Fig. 1.5.

Trucks built without a cargo body and tractors builtwithout a fifth wheel that are intended for service inCanada have an incomplete vehicle certification label(similar to Fig. 1.4) attached to the driver-sideB-pillar. After completion of the vehicle, a completecertification label must be attached by the final-stagemanufacturer to certify that the vehicle conforms toall applicable Canada Motor Vehicle Safety Standard(CMVSS) regulations in effect on the date ofcompletion.

Component GWR LabelThe component GWR label is located on the A-pillarof the driver-side door frame. The label providesmaximum GWR ratings for each component.

See Fig. 1.6 for a typical component GWR label.

Emissions LabelsAftertreatment System IndicatorsLabelEngines and vehicles manufactured after December31, 2006 and domiciled in the U.S. or Canada arerequired to meet all EPA regulations effective as ofthe vehicle build date, and are equipped with anemission aftertreatment system (ATS). Vehicles do-miciled outside of the U.S. and Canada may nothave aftertreatment equipment, depending upon localstatutory emissions guidelines. See Table 1.1.

A warning label on the driver-side visor contains im-portant warning indicators in the instrument clusterthat pertain to the ATS. See Fig. 1.7.

It is a violation of U.S. federal law to alter exhaustplumbing, ATS, or other components in any way thatwould bring the engine/vehicle out of compliance withcertification requirements [Ref: 42 U.S.C. S7522(a)(3)]. It is the owner’s responsibility to maintain thevehicle so that it conforms to EPA regulations.

EPA Noise Emission Control LabelA vehicle noise emission control label (Fig. 1.8) islocated on the driver-side B-pillar as shown inFig. 1.3. It is the owner’s responsibility to maintainthe vehicle so that it conforms to EPA regulations.

IMPORTANT: Certain Western Star incompletevehicles may be produced with incomplete noisecontrol hardware. Such vehicles will not have avehicle noise emission control information label.For such vehicles, it is the final-stage manufac-turer’s responsibility to complete the vehicle inconformity to U.S. EPA regulations (40 CFR Part205) and label it for compliance.

06/28/2011 f080174

Fig. 1.4, Incomplete Vehicle Certification Label

f08002410/10/2006

Fig. 1.5, Canadian National Safety Mark


1.2

Applicable Emissions System Based on Build Date and EPA RegulationsBuild Date Regulation: Emissions Components

January 1, 2010–December 31,2012

EPA10 (reduce NOx emissions to 0.2 g/bhp-hr): Aftertreatment device (ATD)containing a diesel particulate filter that traps soot and ash, with selective catalystreduction (SCR) technology that utilizes diesel exhaust fluid (DEF) to convert NOx tonitrogen and water vapor.

From March 5, 2012–December31, 2015

GHG14: Aerodynamic and fuel efficiency components including, but not limited to,tires, cab/sleeper side extenders, chassis fairings, bumper, hood, vehicle speedlimiters, and idle reduction timers specifically designed to meet regulatory fuelefficiency and greenhouse gas emissions standards.

From January 1, 2016GHG17: GHG14 components plus OBD16 instrumentation and sensor upgrades, andcomponent technology that meets NHTSA and EPA 2017 fuel efficiency andgreenhouse gas emission standards (GHG17) requirements.

Table 1.1, Applicable Emissions System Based on Build Date and EPA Regulations

Vehicle Emission Control InformationLabelModel year 2013 and later vehicles meet additionalrequirements as specified by federal greenhouse gasand fuel efficiency regulations (GHG14). Model year2017 and later vehicles meet similar requirements asspecified by GHG17 requirements. These vehiclesare equipped with components that increase fuel effi-ciency and reduce GHG emissions. Componentsmay include, but are not limited to, low rolling resis-tance tires; aerodynamic devices such as hood, cabside extenders, and fuel tank fairings; vehicle speedlimiters; and idle shutdown timers.

A Vehicle Emission Control Information Label is lo-cated on the driver-side door. See Fig. 1.9. It is theowner’s responsibility to maintain the vehicle so thatit conforms to EPA and NHTSA regulations.

Certified Clean Idle LabelThe California Air Resources Board (CARB) requiresmodel year 2008 and newer heavy-duty diesel en-gines to be equipped with a non-programmable en-gine shutdown system that automatically shuts down

the engine after five minutes of idling in order to limitemissions of particulate matter and NOx.

Certified vehicles are equipped with a label placednear the bottom edge of the driver-side door. SeeFig. 1.10.

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Fig. 1.6, Component GWR Label


1.3

DPF Regen Needed

Hot Exhaust

DEF Refill Needed

Diesel Particulate Filter (DPF)regeneration is needed.

If flashing, regenerate as soon aspossible. Engine derate possible.

Hot exhaust can cause fire.

Keep flammables and people awayfrom exhaust.

Diesel Exhaust Fluid (DEF) level islow. Engine derate likely.

Refill tank with certified DEF.

24−01656−000

IMPORTANT

DEF

11/30/2010 f080162

See operator’s manual for complete instructions.

Fig. 1.7, ATS Indicators

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Fig. 1.8, Vehicle Noise Emission Control Label

f08018403/06/2012

MANUFACTURED BY:VIN:VEH FAMILY CD:GVWR−KGGVWR−LBS

REGULATORY CLASS:

EMISSION CONTROL IDENTIFIERS:

DATE OF MANUFACTURE:VEHICLE EMISSION CONTROL INFORMATION

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

Fig. 1.9, Vehicle Emission Control Information Label

CERTIFIEDCLEAN IDLE

02/20/2012 f080179

Fig. 1.10, CARB Clean Idle Label


1.4

2

Vehicle AccessDoor Locks and Handles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1Grab Handles and Access Steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1Back-of-Cab Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3Hood Opening and Closing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4

Door Locks and HandlesTo unlock either door from outside the cab, insert thekey in the lock and turn it one-quarter turn towardsthe front of the vehicle. See Fig. 2.1. Turn the keyback to the original position to remove it. Pull out onthe paddle latch to open the door.

To lock either door from outside the cab, insert thekey in the lock and turn it one-quarter turn towardsthe rear of the vehicle. Turn the key back to the origi-nal position to remove it. If the door is closed, it willnow be locked. If the door is open, close the doorfirmly.

To lock either door from inside the cab, push the lockbutton down. Pull the lock button up to unlock thedoor from the inside.

To open either door from inside the cab, pull the lockbutton up, then pull the interior door latch out andpush the door outwards.

Remote Keyless EntryRemote keyless entry is optional on Western Starvehicles. The remote entry key fob can be used tounlock the doors from outside the cab.

To unlock both doors, press the unlock button. Tolock both doors, press the lock button. See Fig. 2.2.

Key Fob ProgrammingA maximum of four fobs can be programmed to workon one vehicle. Whenever a new fob will be used, allexisting fobs must be reprogrammed at the same

time. Any existing fobs that were previously pro-grammed will no longer work on the vehicle unlessthey are all reprogrammed at the same time.

To have the key fobs programmed, take the vehicleto an authorized Western Star dealer or service facil-ity.

Grab Handles and AccessStepsThe grab handles, access steps, and steering wheelare all part of the cab access system. Use these"helping hands" when getting into or out of the cab.They will increase your security and comfort.

CAUTIONSlipping or falling from the vehicle can result inpersonal injury or propert damage.

Wet or dirty shoes greatly increase the chance ofslipping or falling. If your shoes are wet or dirty,be especially careful when entering or exiting thevehicle.

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1

2

1. Lock 2. Paddle Latch

Fig. 2.1, Exterior Door Handle

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1

2

1. Unlock Button 2. Lock Button

Fig. 2.2, Key Fob

Vehicle Access

2.1

Always maintain three-point contact with the ve-hicle when entering or exiting the cab. Three-point contact means both feet and one hand, orboth hands and one foot.

When steps are mounted on battery box covers,make sure that the cover is latched and securebefore using the steps.

Do not step on the fuel tank, battery box, frame,etc. unless adequate slip resistant surfaces andhandholds are provided.

Do not jump from the vehicle.

For ease of entry and exit, there are multiple grabhandles: a handle on the A-pillar (optional on thedriver’s side), handles on the inside of the door, andhandles on the B-pillar. In addition, the steeringwheel may be used to provide a secure handhold.There are at least two access steps to provide se-cure footholds.

Entering the Driver’s Side1. Open the driver-side door and place anything

that you are carrying in the cab.

2. Grasp the B-pillar grab handle with your righthand. See Fig. 2.3.

3. Grasp the lower door pocket with your left hand.

4. Place your right foot on the bottom step, and pullyourself up.

5. Place your left foot on the top step.

6. Grasp the steering wheel or A-pillar grab handle,if equipped, with your left hand.

7. Step into the cab with your right foot first, andgrasp the steering wheel with your right hand.

Exiting the Driver’s SideIMPORTANT: Do not attempt to exit the cabwhile carrying any items in your hands. Placethem in an accessible location on the seat orcab floor and make sure they will not get in yourway as you exit, then retrieve them after youhave exited the cab.

CAUTIONAlways face in when exiting the cab. Do not at-tempt to exit with your back to the cab, as youwould going down a flight of stairs. It is easier toslip or lose your balance. If you slip when exiting

in this way, there is a greater likelihood of per-sonal injury.

1. Grasp the steering wheel with both hands, placeyour left foot on the top step, and stand on thethreshold, facing into the cab.

2. Grasp the B-pillar grab handle with your righthand. See Fig. 2.3, item 5.

3. Move your right foot to the bottom step.

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

5. Step to the ground with your left foot first.

Entering the Passenger’s Side1. Open the passenger-side door and place any-

thing that you are carrying in the cab.

2. Grasp the B-pillar grab handle with your lefthand. See Fig. 2.4.

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2

3 4

5

1. Lower Door Pocket2. Upper Door Pocket3. Door Latch

4. Steering Wheel5. B-Pillar Grab Handle

Fig. 2.3, Driver-Side Cab Access

Vehicle Access

2.2

3. Grasp the lower door pocket with your righthand.

4. Place your left foot on the bottom step.

5. Place your right foot on the top step and moveyour right hand to the A-pillar grab handle.

6. Place your left foot on the top step, then moveyour left hand to the A-pillar grab handle.

7. Step into the cab with your left foot first.

Exiting the Passenger’s SideIMPORTANT: Do not attempt to exit the cabwhile carrying any items in your hands. Placethem in an accessible location on the seat orcab floor and make sure they will not get in yourway as you exit, then retrieve them after youhave exited the cab.

CAUTIONAlways face in when exiting the cab. Do not at-tempt to exit with your back to the cab, as youwould going down a flight of stairs. It is easier toslip or lose your balance. If you slip when exitingin this way, there is a greater likelihood of per-sonal injury.

1. Grasp the A-pillar grab handle with both hands,then place your right foot on the top step whilefacing inward. See Fig. 2.4.


3. Move your left hand to the B-pillar grab handle.


5. Move your right hand to the lower door pocket.


Back-of-Cab AccessWhen trailer air and electrical connections cannot bereached conveniently from the ground, Federal MotorCarrier Safety Regulations require that tractors haveadequate back-of-cab access. Grab handles are typi-cally located on the backwall of the cab or sleeper, oron the inside of the cab extender, if equipped. A grabhandle may also be provided on the exhaust stack.Steps may be mounted on the fuel tank(s), battery ortool box(es), or on metal brackets secured to theframe rail. A deck plate is mounted across the top ofthe frame rails. All other areas are not meant to sup-port back-of-cab access

CAUTIONFollow these rules for back-of-cab access. Failingto follow these rules could lead to a fall, and pos-sible personal injury.

Never step on any exterior part unless it has aslip-resistant surface meant for safe stepping. Ifthe surface is movable, such as a battery boxcover with a slip-resistant surface, be certain it isfirmly secured.

Be careful not to trip on items such as chains orair lines in the back-of-cab area.

Always follow safety procedures for back-of-cabaccess, maintaining three-point contact—bothhands and one foot, or both feet and one hand—

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1

2

34

1. B-Pillar Grab Handle2. Door Latch3. A-Pillar Grab Handle

4. Upper Door Pocket5. Lower Door Pocket

Fig. 2.4, Passenger-Side Cab Access

Vehicle Access

2.3

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 greatlyincrease the chance of slipping or falling. If yourshoes or the contact areas are wet or dirty, cleanand dry them as much as possible before ac-cessing the back of cab area, and be especiallycareful when climbing or standing on the vehicle.

Never jump onto, or off of, a vehicle; doing socreates a very high likelihood of a fall and per-sonal injury.

IMPORTANT: Climb onto, and down from, be-hind the cab while facing in toward the vehicle,as you would on a ladder. Do not climb up ordown facing out away from the vehicle.

Accessing Back-of-Cab Area

WARNINGExternal surfaces of the exhaust system remainhot after the engine has been shut down. Whenaccessing the back of the cab or sleeper, do nottouch any part of the exhaust system other thanthe exhaust-mounted grab handle, if equipped, orsevere burns could occur.

1. Facing the deck plate, grasp the grab handlewith both hands. Reach up as far as is comfort-able.

2. Place one foot on the bottom step and pull your-self up.

3. Place your other foot on the top step.

4. Move your lower hand to a higher position on thegrab handle.

5. Step onto the deck plate.

Exiting Back-of-Cab Area1. Face the center of the vehicle and grasp the

sidewall grab handle with both hands.

2. Place one foot at a time on the top step.

3. Move your upper hand to a lower position on thegrab handle.

4. Move one foot to the bottom step.

5. Step to the ground with your upper foot first.

Hood Opening and ClosingThe hood can be raised to a full-open position. Tilt-assist struts help you to raise the hood, and to lowerit to the operating position. In the operating position,the hood is secured to the cab-mounted cowl by ahold-down latch on each side.

Opening the Hood1. Release both hood hold-down latches by pulling

the handles outward.

2. Slowly tilt the hood with both hands on the grabhandle.

3. As the hood starts to open, walk backwards asyou pull. The hood will stop in the full-openposition.

Closing the Hood1. Grasp and lift the grab handle to tilt the hood

toward the closed position.

2. As the hood goes over center, slowly lower thehood with both hands on the grab handle.

IMPORTANT: Make sure that both latches arefully engaged before operating the vehicle.

3. Make sure the hood is flush with the cowl, thensecure the hood by engaging both hood hold-down latches.

Vehicle Access

2.4

3

InstrumentsInstrumentation Control Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.1Warning and Indicator Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.2Instruments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.6Driver Message Center . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.11Overhead Instrument Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.15

Instrumentation Control UnitsThe instrumentation control unit (ICU) provides thedriver with engine and vehicle information. It is com-prised of standard and optional gauges, an audiblewarning, a driver message center, and a lightbar con-taining warning and indicator lamps (also known astelltales). Warning and indicator lamps illuminate inred (danger), amber (caution), green (status advi-sory), or blue (high-beam headlights active).

Western Star 5700 vehicles are equipped with anICU4Me. See Fig. 3.1 for a typical ICU layout.

The following headings in this chapter provide addi-tional information and operating instructions for ICUcomponents:

• "Warning and Indicator Lights"

• "Instruments"

• "Driver Message Center"

Ignition SequenceWhen the ignition is turned on, the ICU runs a self-check. See Fig. 3.2. Observing the ignition sequenceis a good way to ensure the ICU is functioning prop-erly.

IMPORTANT: Do not crank the engine until theICU self-check is complete.

NOTE: Primary and secondary air pressuregauges are the only air gauges that complete asweep of their dials during the ignition se-quence.

When the ignition is turned on, the following actionsshould occur:

• electronic gauges complete a full sweep oftheir dials

12/11/2014 f611244

1

2

3

4

5

6

7

8

9

10 11

12

13

14

15

1. Voltmeter2. Turbocharger Boost Pressure Gauge3. Trailer Air Supply Gauge4. Engine Oil Temperature Gauge5. Transmission Oil Temperature Gauge6. Tachometer and Coolant Temperature Gauge7. Fuel/DEF Level Gauge8. Speedometer and Engine Oil Pressure Gauge

9. Suspension Air Pressure Gauge10. Forward Drive-Axle Temperature Gauge11. Rear Drive-Axle Temperature Gauge12. Trailer Suspension Air Pressure Gauge13. Secondary Air Pressure Gauge14. Primary Air Pressure Gauge15. Driver Message Center

Fig. 3.1, ICU4Me Instrument Cluster

Instruments

3.1

• warning and indicator lamps illuminate, thenare extinguished

• audible alert sounds for approximately fourseconds or until sufficient air pressure buildsup in the primary and secondary air systems

• DEF level indicator illuminates all segmentsgreen, then turns them off one at a time beforeturning the leftmost segment amber and thenred

• Western Star logo displays on the ICU4Medriver message center for two seconds.

• software revision level of the ICU is displayedon the driver message center, followed by anyactive faults

IMPORTANT: If any red or amber warning andindicator lamps do not illuminate during the ICUself-check or do not go out after the self-checkcompletes, take the action outlined in Table 3.1,then take the vehicle to an authorized WesternStar service facility as soon as possible.

NOTE: If active faults are present, take the ve-hicle to an authorized Western Star service facil-ity as soon as possible.

If the ICU receives active fault codes, it displaysthem one after the other until the parking brake isreleased or the ignition is turned off. Once the park-ing brake is completely released, the ICU displaysthe home screen. If there are no active faults, theICU displays the home screen after the self-checkcompletes.

Audible AlertsAn audible alert sounds during the ignition sequenceand whenever one of the following conditions exists:

• Engine oil pressure falls below the minimumpreset value.

• Coolant temperature rises above the maximumpreset value.

• Air pressure falls below approximately 70 psi(483 kPa).

• Parking brake is set with the vehicle movingfaster than two miles per hour.

• System voltage falls below 11.9 volts.

• Door is open or the headlights are on, with theparking brake off.

• Driver seat belt is not fastened with the parkingbrake off (optional).

• Outside temperature falls below 35°F (1.7°C)(optional).

Warning and Indicator LightsThe ICU has three or four rows of warning and indi-cator lights with icon symbols, depending on the ICUconfiguration. The positions of the lights may vary,but the telltales are standard for all applications. SeeTable 3.1 for a listing of standard and commonlyused warning and indicator lamps.

Warning and indicator lamps illuminate in red (dan-ger), amber (caution), green (status advisory), orblue (high-beam headlights active).

IMPORTANT: Depending upon local jurisdic-tional emissions guidelines, vehicles and/or en-gines that are domiciled outside of the U.S. andCanada may not be compliant with EPA07,EPA10, GHG14, or GHG17 regulations. Non-compliant vehicles may not be equipped with allof the lamps shown in Table 3.1.

IGNITION SWITCH

PARKING BRAKERELEASED

IF NO FAULTSWERE DETECTED

IF FAULT DETECTED

APU 190123456.7

12.3 VOLTS

123456.7

12.3 VOLTS

MI

MI

01/18/2012 f040420c


TURNED TO ON

ICU PERFORMSSELF−TEST

Fig. 3.2, ICU Ignition Sequence

Instruments

3.2

Common Warning and Indicator LampsLamp Description Color

STOP STOP Engine*

Indicates a serious fault that requires engine shutdownimmediately. The engine protection system will reduce themaximum engine torque and speed, and, if the conditiondoes not improve, will shut down the engine within 30 to 60seconds.

Safely bring the vehicle to a stop on the side of the roadand shut down the engine as soon as the red light is seen.If the engine shuts down while the vehicle is in ahazardous location, turn the key to the OFF position fora few seconds, then restart the engine and move thevehicle to a safer location.

Red

High Coolant Temperature Indicates the coolant temperature is above the maximumallowable temperature. Red

BRAKE

Low Air Pressure (EPA10and Newer)

Indicates air pressure in the primary or secondary reservoirhas dropped below approximately 70 psi (483 kPa). Red

Low Engine Oil Pressure Indicates the engine oil pressure is below the minimumallowable pressure. Red

Transmission Overheat Indicates high transmission temperature. Red

Transmission Fluid Level Indicates low transmission fluid level. Safely bring thevehicle to a stop as soon as possible. Red

PARK

P Parking Brake (EPA10and Newer) Indicates the parking brake is engaged. Red

Low Battery Voltage Indicates that battery voltage is 11.9 volts or less. Red

Unfastened Seat Belt

Activates with an audible alert when the system detects thatthe parking brake is off and the driver seat belt is notfastened on some vehicles. On other vehicles, this lampilluminates for 15 seconds when the ignition is first turnedon.

Red

Check ECAS Indicates Electronically Controlled Air Suspension (ECAS)active fault. Red

CHECK CHECK Engine*

Indicates an engine condition (low oil pressure, low coolantlevel, high coolant temperature, high DPF soot level, oruncontrolled DPF regeneration) that requires correction.Correct the condition as soon as possible. If the conditionworsens, the STOP engine lamp will illuminate.

Amber

Instruments

3.3


High Exhaust SystemTemperature (HEST)*

Slow (10-second) flashing indicates a regeneration (regen)is in progress.

IMPORTANT: When the HEST lamp is illuminated, donot park the vehicle near flammable material.

Solid illumination indicates high exhaust temperatures at theoutlet of the tail pipe when speed is below 5 mph (8 km/h).

Amber

Diesel Particulate Filter(DPF) Status

Solid illumination indicates a regen is required. Change to amore challenging duty cycle (such as highway driving ) toraise exhaust temperatures for at least twenty minutes, orperform a parked regen.

Blinking indicates that a parked regen is requiredimmediately. An engine derate and shutdown will occur.

Amber

Malfunction IndicatorLamp (MIL)

Indicates an emissions-related fault. See the engineoperation manual for details. Amber

Vehicle ABS

Momentary illumination indicates the vehicle ABS isengaged.

Solid illumination indicates a problem with the vehicle ABS.Repair the ABS immediately to ensure full brakingcapability.

Amber

Trailer ABS

Momentary illumination indicates the trailer ABS is engaged.

Solid illumination indicates a problem with the trailer ABS.Repair the ABS immediately to ensure full brakingcapability.

Amber

NOCHARGE No Charge Indicates the alternator is not properly powering the

electrical system. Amber

Water in Fuel Indicates the fuel may contain water. Drain any watercollected in the fuel/water separators. Amber

Fuel Filter Restriction Indicates the fuel filter is clogged and requires service. Amber

Check Transmission Indicates an undesirable transmission condition. Amber

START

BLOCKEDStart Blocked (GHG14only)

Indicates that the system is preventing the starter fromcranking. This can occur when the ignition switch is turnedto START before the gauge sweep has completed.

NOTE: Illumination of the Start Blocked lamp does notindicate a problem with the starter.

Turn the ignition switch back to ON, wait for the lamp to goout, then turn the ignition switch to START again.

Amber

Instruments

3.4


WHEELSPIN Wheel Spin

Flashing indicates the ATC system is active, or the ATCbutton has been pressed to allow wheel slip.

Solid illumination indicates a problem with the ATC system.Repair the ATC system immediately to ensure full brakingcapability.

Amber

Roll Stability

Momentary illumination indicates that a stability event hasoccurred.

On vehicles that are also equipped with ATC, flashingindicates the ATC button has been pressed to allow wheelslip.

Amber

Hill Start Aid (HSA)Override

Indicates the HSA switch has been pressed to override thehill start assist feature. Amber

Outside Normal RideHeight

Indicates the current rear suspension height is not at thenormal ride height. This light will turn off once the vehiclereturns to normal ride height.

Amber

Engine Brake Indicates the engine brake is enabled. Green

Left-Turn Signal Flashing indicates the outside left-turn signal lights areactivated. Green

Right-Turn Signal Flashing indicates the outside right-turn signal lights areactivated. Green

Cruise Control

Indicates the cruise control is enabled.

NOTE: The ICU4Me does not have a green cruise controltelltale.

Green

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

* See Fig. 3.3 for an explanation of the aftertreatment system (ATS) warning indicators, and actions required to avoid further engine protection steps.

Table 3.1, Common Warning and Indicator Lamps

Engine Protection System

WARNINGWhen the red STOP engine lamp illuminates,most engines are programmed to shut down au-tomatically within 30 seconds. The driver mustimmediately move the vehicle to a safe locationat the side of the road to prevent causing a haz-ardous situation that could cause bodily injury,property damage, or severe damage to the en-gine.

See Fig. 3.3 for an explanation of the aftertreatmentsystem (ATS) warning indicators, and actions re-quired to avoid further engine protection steps.

The STOP engine lamp illuminates when the engineprotection system is activated in one of two ways. Onsome engines, the engine protection system will der-ate the engine, allowing it to run at lower rpm andslower vehicle speed. Drive the vehicle to a safe lo-cation or to a service facility.

Instruments

3.5

IMPORTANT: Safely bring the vehicle to a stopon the side of the road and shut down the en-gine as soon as the red light is seen. If the en-gine shuts down while the vehicle is in a haz-ardous location, turn the key to the OFF positionfor a few seconds, then restart the engine andmove the vehicle to a safer location.

On other engines, the engine protection system willshut down the engine. It will first derate the engine,then shut it down completely 30 to 60 seconds afterthe indicator illuminates (depending on the criticalfault type) if the condition does not improve. Bringthe vehicle to a stop on the side of the road beforethe engine shuts down.

Some vehicles may have a shutdown-overrideswitch, which may be used to momentarily overridethe shutdown sequence. See Chapter 10 for detailedinformation regarding the shutdown process.

IMPORTANT: Do not attempt to restart the en-gine while the vehicle is moving. Bring the ve-hicle to a safe stop, then restart the engine.

To restart the engine, turn the ignition to OFF, leaveit there a few seconds, then turn the ignition toSTART. The engine will run for a short period andshut down again if the condition does not improve.

InstrumentsThe instruments are listed here in alphabetical order,to make the information easier to find.

NOTE: Some of the listed instruments are op-tional, and not found in every vehicle.

Air Intake Restriction GaugeThe air intake restriction gauge indicates the vacuumon the engine side of the air cleaner. On standardinstallations, it is mounted on the air intake duct inthe engine compartment, and has a go/no-go restric-tion indicator without graduations. See Fig. 3.4. Asan option, a graduated indicator (Fig. 3.5) on the airintake duct or, for easier viewing, a dash-mountedrestriction gauge may be installed.

Air intake restriction vacuum is measured in inchesof water (inH2O). For vehicles equipped with agraduated indicator or a restriction gauge on thedash, check the gauge with the engine off. If the yel-low signal stays locked in the red zone once the en-gine is shut down, or is at or above 18 inH2O (forDetroit engines), the air cleaner element needs to bereplaced.

f080156

EXHAUST AFTERTREATMENT SYSTEM INFORMATION

Switch.

Level 1 Level 3Level 2 Level 4Filter RegenerationRecommended.

Filter is reaching

Bring vehicle tohighway speeds to

Filter Regeneration

Filter is nowreaching maximumcapacity.

To avoid enginederate, bring vehicle

Parked RegenerationRequired − EngineDerate

Filter has reachedmaximum capacity.

Vehicle must beparked, and a Parked

Service Regeneration Required.Engine Derate To Idle Only.

Filter has exceeded maximumcapacity.

Vehicle must be parked, and aService Regeneration must be

(Solid) (Flashing) (Flashing)

CHECKINDICATORLAMP(S)

Indicator LampMessage(s)

Diesel ParticulateFilter Condition

Required Action

capacity.

STOP

allow for an AutomaticRegeneration orperform a Parked

to highway speedsto allow for anAutomaticRegeneration, orperform a ParkedRegeneration assoon as possible.

Regeneration mustbe performed.Engine will beginderate.

performed. Check engineoperator’s manual for details.Engine will shut down.

For a driver performed Parked Regeneration, vehicle must be equipped with a dash mounted Regeneration Switch.

02/20/2009

WARNING

HEST (High ExhaustSystem Temperature)

Exhaust componentsand exhaust gas are athigh temperature. Whenstationary, keep awayfrom people andflammable materials orvapors.

A regeneration is inprogress.

Flashing

Solid

Regeneration.

Necessary

Fig. 3.3, ATS Warning Lamps

Instruments

3.6

NOTE: Rain or snow can wet the filter andcause a temporary high reading.

Application Air Pressure GaugeAn application air pressure gauge (Fig. 3.6) registersthe air pressure being used to apply the brakes, andshould be used for reference only. The gauge will notregister air pressure until the foot brake pedal is de-pressed or the trailer hand brake is applied.

Coolant Temperature Gauge

NOTICEA sudden increase in coolant temperature mayindicate engine or cooling system failure. Bringthe vehicle to a safe stop and investigate thecause to prevent further damage. Do not operatethe engine until the cause has been determinedand corrected.

During normal engine operation, the coolant tem-perature gauge (Fig. 3.7) should read 175 to 195°F(79 to 91°C). If the temperature remains below 160°F(71°C), inspect the cooling system to determine thecause.

For Detroit engines, if coolant temperature risesabove 215°F (101°C), the CHECK engine lamp willilluminate. If the condition does not improve, theSTOP engine lamp will also illuminate and an audiblewarning will sound. The engine will then derate or

04/08/2005 f090431

Fig. 3.4, Manual-Reset Air Restriction Indicator, Go/No-Go

02/12/2015 f090514

Fig. 3.5, Air Intake Restriction Indicator, Graduated

08/07/2014 f611267

Fig. 3.6, Application Air Pressure Gauge

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Fig. 3.7, Tachometer and Coolant Temperature Gauge

Instruments

3.7

shut down, depending on the type of engine protec-tion system installed.

Drive Axle Oil Temperature Gauges

NOTICEA sudden increase in oil temperature that is notcaused by a load increase may indicate mechani-cal failure. Bring the vehicle to a safe stop andinvestigate the cause to prevent further damage.Do not operate the vehicle until the cause hasbeen determined and corrected.

During normal operation, drive axle oil temperaturegauges (Fig. 3.8) should read as follows:

• 160 to 220°F (71 to 104°C) for Detroit™ andMeritor™ drive axles

• 180 to 200°F (82 to 93°C) for Dana Spicer®drive axles

Under heavy loads, such as when climbing steepgrades, temperatures that exceed the normal oil tem-perature range for a short period are not unusual. Ifthe temperature returns to normal when the load de-creases, there is no problem.

Engine Oil Pressure Gauge

NOTICEA sudden decrease or absence of oil pressuremay indicate mechanical failure. Bring the vehicle

to a safe stop and investigate the cause to pre-vent further damage. Do not operate the engineuntil the cause has been determined and cor-rected.

The engine oil pressure gauge, as shown in Fig. 3.9,displays the current engine oil pressure. If engine oilpressure falls below the minimum levels shown inTable 3.2, the CHECK engine lamp will illuminate. Ifthe condition does not improve, the STOP enginelamp will also illuminate and an audible warning willsound. The engine will then derate or shut down, de-pending on the type of engine protection system in-stalled.

NOTE: Oil pressures in Table 3.2 are given withthe engine at operating temperature. With theengine cold, oil pressure may be higher. Indi-vidual engines may vary from the listed pres-sures; observe and record pressures when theengine is new to create a guide for checkingengine condition.

Minimum Oil Pressure

Engine ModelAt Idle Speed:

psi (kPa)At Rated RPM:

psi (kPa)Detroit 14 (97) 55 (350)

Table 3.2, Minimum Engine Oil Pressure

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Fig. 3.8, Drive Axle Oil Temperature Gauge (rear driveaxle gauge shown)

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Fig. 3.9, Speedometer and Engine Oil Pressure Gauge

Instruments

3.8

Engine Oil Temperature Gauge

NOTICEA sudden increase in oil temperature that is notcaused by a load increase may indicate mechani-cal failure. Bring the vehicle to a safe stop andinvestigate the cause to prevent further damage.Do not operate the engine until the cause hasbeen determined and corrected.

During normal operation, the optional engine oil tem-perature gauge (Fig. 3.10) should read in the follow-ing temperature range:

• 200 to 260°F (93 to 126°C) for Detroit engines


Fuel/Diesel Exhaust Fluid (DEF)GaugeFor engines that are EPA10-compliant or newer, thefuel and DEF levels are measured in a dual purposefuel/DEF level gauge. See Fig. 3.11.

The diesel fuel level is indicated at the top of thegauge, with a low-fuel warning lamp that illuminatesamber when the diesel fuel level registers 1/8th ofcapacity.

The DEF level is indicated in a four-segment lightbaron the lower portion of the gauge. There is a low

DEF level warning lamp that illuminates amber whenthe DEF level reaches 10% of capacity. See Chap-ter 12 for details of the DEF gauge functions.

Primary and Secondary Air PressureGauges

WARNINGIf air pressure falls below minimum pressure, thebraking ability of the vehicle will be limited. Slowthe vehicle down and bring it to a gradual stop.Do not attempt to move the vehicle until air pres-sure has risen above the minimum level. Movinga vehicle without adequate braking power couldcause an accident resulting in property damage,personal injury, or death.

Air pressure gauges (Fig. 3.12) register the pressurein the primary and secondary air systems. Normalpressure, with the engine running, is 100 to 120 psi(689 to 827 kPa) in both systems.

A low-air-pressure warning light and audible alert,connected to both the primary and secondary sys-tems, activate when air pressure in either systemdrops below approximately 70 psi (483 kPa).

When the engine is started, the warning light andaudible warning remain on until air pressure in bothsystems exceeds minimum pressure.

07/29/2014 f611251

Fig. 3.10, Engine Oil Temperature Gauge

10/08/2014 f611246

1

2

3

4

1. Diesel Fuel Level Indicator2. DEF Level Indicator3. Low DEF Warning Lamp (amber below 10% DEF)4. Low Fuel Warning Lamp (amber at 1/8 tank of fuel)

Fig. 3.11, Fuel/DEF Gauge, EPA10 and Newer

Instruments

3.9

SpeedometerTwo speedometer options are available. The U.S.version of the speedometer (Fig. 3.9) registers speedin both miles per hour (mph) and kilometers per hour(km/h), with mph in larger numbers. The metric ver-sion of the speedometer face reverses this arrange-ment, with km/h in larger numbers.

Suspension Air Pressure GaugeA suspension air pressure gauge (Fig. 3.13) registersthe air pressure applied to the vehicle airsuspension.

TachometerThe tachometer (Fig. 3.7) indicates engine speed inrevolutions per minute (rpm) and serves as a guidefor shifting the transmission and keeping the enginein the appropriate rpm range. For low idle and ratedrpm, see the engine identification plate.

Transmission Fluid TemperatureGaugeThe transmission fluid temperature gauge, shown inFig. 3.14, measures the transmission lubricant oper-ating temperature. Temperatures vary by application,but the transmission fluid temperature gauge readingshould not exceed 250°F (121°C).

NOTICEA sudden increase in transmission fluid tempera-ture that is not caused by a load increase mayindicate mechanical failure. Bring the vehicle to asafe stop and investigate the cause to preventfurther damage. Do not operate the vehicle untilthe cause has been determined and corrected.


Turbocharger Boost Pressure GaugeA turbocharger boost pressure gauge (Fig. 3.15) indi-cates the pressure in the intake manifold, in excess

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Fig. 3.12, Air Pressure Gauge (primary shown)

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Fig. 3.13, Suspension Air Pressure Gauge

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Fig. 3.14, Transmission Fluid Temperature Gauge

Instruments

3.10

of atmospheric pressure, being created by theturbocharger.

VoltmeterThe voltmeter indicates the vehicle charging systemvoltage when the engine is running and the batteryvoltage when the engine is off. By monitoring thevoltmeter, the driver can stay aware of potential bat-tery charging problems and have them fixed beforethe batteries discharge enough to create starting diffi-culties. A digital voltage display is integrated withdriver message center. An optional voltmeter gauge(Fig. 3.16) may be installed.

The voltmeter will normally show approximately 13.7to 14.1 volts when the engine is running. The voltage

of a fully charged battery is 12.7 to 12.8 volts whenthe engine is off. Battery voltage under 12.0 volts isconsidered a low battery, and a completely dis-charged battery will produce only about 11.0 volts.

If the voltmeter shows an undercharged or over-charged condition for an extended period, have thecharging system and batteries checked at an autho-rized Western Star service facility.

On a vehicle equipped with a battery isolator system,the voltmeter measures the average voltage of all thebatteries when the engine is running. When the en-gine is off, the voltmeter shows only the isolated bat-tery voltage and does not indicate the voltage of theengine-starting batteries.

Driver Message CenterICU4MeFunctionsICU4Me settings and the driver message center arecontrolled using the switches mounted in the left-hand switch pod of the steering wheel. SeeFig. 3.17.

The driver message center is divided into four sec-tions. The odometer and cruise control status field

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Fig. 3.15, Turbocharger Boost Pressure Gauge

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Fig. 3.16, Voltmeter

12/11/2014 f611255a

1

23

4

5

6

7

NOTE: To reset values in the ICU4Me driver messagecenter, press and hold the RIGHT navigation switch.1. Volume Up Switch2. Volume Down Switch3. Headlight Interrupt Switch4. UP Navigation Switch5. RIGHT Navigation Switch6. DOWN Navigation Switch7. LEFT Navigation Switch

Fig. 3.17, Steering Wheel-Mounted Switches, Left-HandSwitch Pod

Instruments

3.11

are displayed along the bottom of the message cen-ter. When cruise control is active, the cruise controlstatus field displays relevant cruise control icons andthe set speed. If the vehicle is equipped with amanual transmission, time and temperature are dis-played in the top left corner of the driver messagecenter. The message field displays the drivingscreens and alert messages. See Fig. 3.18.

If the vehicle is equipped with an automated trans-mission, the gear display is located in the top leftcorner of the driver message center. Time and tem-perature are displayed in the message field, unlessan alert message is active or a driving screen hasbeen selected. The odometer and cruise control sta-tus field are displayed along the bottom of the mes-sage center. See Fig. 3.19. For information abouttransmission display options, see Chapter 15.

Alert MessagesAlert messages are displayed in the message field tonotify the driver when certain conditions occur. Theyinclude warnings, cautions, and other messages thatrequire the driver’s attention. Not all alert messagesare critical to the operation of the vehicle. More im-portant messages take priority over less importantmessages.

NOTE: All alert messages follow the formatshown in Fig. 3.20.

Press the OK button on the left-hand steering wheelpod to acknowledge alert messages and revert to thepreviously displayed driving screen. The followingalert messages will repeat intermittently until the con-dition is eliminated:

• turn signal on

• low voltage

• no datalink

• low transmission air pressure (Detroit transmis-sions only)

Driving ScreensWith the parking brake off, only the driving screensare available. Use the UP and DOWN navigationswitches on the steering wheel to scroll through thedriving screens; see Fig. 3.21. To reset any values,press and hold the RIGHT navigation switch.

• Temperature

• MPG information

• Trip information

• Leg information

• Gauge display (if selected)

• Predictive Cruise Control (optional)

• Enter parked menus

06/26/2012 f611166

5555555 mi

1/7NW

77° F

Trip MPG: 5.6

0 155

1 2

34

10

65 mph

1. Temperature and Compass2. Message Field3. Cruise Control Status Field4. Odometer

Fig. 3.18, Driver Message Center Without Gear Display,ICU4Me

1/7NW

77 °F

06/26/2012 f611165

10A econ

5555555 mi

1 2

34

65 mph

1. Gear Display2. Temperature and Compass3. Cruise Control Status Field4. Odometer

Fig. 3.19, Driver Message Center with Gear Display,ICU4Me

Park Brake On!

06/12/2012 f611192

10A econ

5555555 mi

Fig. 3.20, Parking Brake Alert Message

Instruments

3.12

Parked Screens/MenusPark the vehicle and set the parking brake to accessthe parked menus and submenus. See Fig. 3.22. Toreset values in any of the menus, press and hold theRIGHT navigation switch.


• Fuel information

• Engine information

• Diagnostics

• Service information

• Settings

• ICU Information

A small numerical fraction is displayed in the upperright-hand corner of each screen to indicate the num-ber of available screens or options to scroll through.See Fig. 3.23. Press the OK button on the left-handsteering wheel pod to select a menu choice. Pressthe LEFT navigation switch to back out of a selectedmenu or submenu. Use the UP navigation switch toscroll up, and the DOWN navigation switch to scrolldown.

Time &Temperature

MPGInformation

TripInformation

Enter toStationary

Menu

GaugeDisplayScreens

LegInformation

PredictiveCruise

Control (opt)

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(if selected)

Use the UP and DOWN navigation switches on thesteering wheel to navigate through the driving screens.

Fig. 3.21, Driving Screen Navigation, ICU4Me

02/23/2015 f040824a

Trip Info

Fuel Info

Engine Info Diagnostics Service

Settings

ICU Info

Use the UP and DOWN navigation switches on thesteering wheel to navigate through the parked menus.

Fig. 3.22, Parked Menus, ICU4Me

1/3Miles:Gallons:

Menu

Avg. MPG:Trip Info

Trip

123456.7123456.7

123.4

1/2TripLeg

Menu

Trip Info

1/7Trip InfoFuel Info

Menu

Engine Info

12/11/2014 f611193a

OK

OK

Fig. 3.23, Parked Menu Navigation, ICU4Me

Instruments

3.13

When navigating the parked menus, the left side ofthe driver message center displays a "breadcrumbmenu" to show the order of menus and submenusthat have been selected during the current naviga-tion.

Trip InformationThe ICU can record data for one trip segment andone leg segment. When trip information is reset, allthe leg information is reset as well.

Fuel InformationUsing this menu, the driver can view the total fuelused since the last reset, the total idle gallons usedsince the last reset, and the average MPG since thelast reset.

Engine InformationUsing this menu, the driver can view engine miles,engine hours, gallons used, PTO hours, and PTOgallons. Engine oil level is optional for Detroit en-gines. The information contained in the Engine Infor-mation screens cannot be reset.

DiagnosticsActive faults are displayed in the diagnostics menu.See Fig. 3.24. If there are any active faults, the totalnumber of faults is displayed in parenthesis next tothe affected controller. To view specific active faults,press the OK button on the left-hand steering wheelpod. Press the OK button to toggle between the textdescription and the failure code for each selectedfault.

Service InformationUsing this menu, the driver can enable, disable, andset service intervals for engine miles or enginehours. After enabling service intervals, select intervalunit (miles or hours), and the interval duration.

SettingsThe settings menu contains the controls for the fol-lowing settings:

• Display (includes brightness, display light, andnight mode settings)

• Gauge select

• Language

• Temperature warning enable/disable

• Units

The Gauge Select submenu allows the driver to se-lect certain gauge values for display in the messagefield while driving. See Fig. 3.25. Use the UP andDOWN navigation switches on the steering wheel toscroll through the list of available gauges, then pressthe OK button to select a desired gauge. The OKbutton can also be used to uncheck boxes ifnecessary.

ICU InformationThe ICU Information screen displays the part num-bers for the instrument cluster and software.

1/3Accelerator PedalProblem Detected

Diagnostics

Active

Engine (3)

1/3ABS (1)Engine (3)

1/2Active (12)Historic (0)

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Menu

Diagnostics

MSF (1)

Menu

Diagnostics

Active

OK

OK

Fig. 3.24, Diagnostics Menu Navigation, ICU4Me

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1/6Axle TempAir Pressure

Engine Oil Temp

Menu

Settings

Gauge Disp. x

Fig. 3.25, Selecting Gauges to Display, ICU4Me

Instruments

3.14

Overhead Instrument PanelThe overhead instrument panel typically holds a citi-zen’s band (C/B) radio, an AM/FM radio, a digitalclock, and storage areas with netting. The undersideof the overhead console also holds the sun visorsand the dome/reading light assembly. For more infor-mation on the dome/reading light assembly, seeChapter 8.

Instruments

3.15

4

Driver ControlsControl Panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1Ignition Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1Lighting Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2Horn Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.5Powertrain Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.5Cruise Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.8Dash-Mounted Brake Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.10Windshield Wiper and Washer Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.12Suspension/Trailer Connection Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.13Adjustable Steering Column Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.15Radio/Bluetooth Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.16Climate Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.16Seat Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.16

Control PanelsNOTE: Western Star vehicles are offered withvarious chassis and body components. Becauseof the various options, the information containedin this chapter may not apply to every vehicle.

The right-hand dash control panel contains a facevent, the majority of the driver switch controls, auto-mated and automatic transmission controls, and theOnGuard display module, if equipped.

The ignition switch control panel (below the right-hand dash panel) contains the ignition switch, ciga-rette lighter, and climate controls.

The instrument cluster is located behind the steeringwheel.

Fig. 4.1 shows a typical dash control panel layout.

Ignition SwitchThe ignition switch has four positions: OFF, ACCES-SORY, ON, and START. See Fig. 4.2.

In the OFF position, the key slot is vertical. The keycan be inserted and removed only in the OFF posi-tion.

The following functions are operable when the igni-tion switch is in the OFF position (regardless ofwhether the key is inserted):

• high-beam headlights

• taillights

• brake lights

• road lights

• dome lights

• clearance lights

• turn signals

• hazard warning lights

• utility and baggage lights

• spotlights

• electric horn

• clock

• refrigerator

• television

Turn the key counterclockwise to the ACCESSORYposition. In addition to all the functions that are oper-able with the ignition switch in the OFF position, thefollowing functions are operable when the switch is inthe ACCESSORY position:

• radio/stereo system

• heater and A/C fan

• mirror defog

• windshield wipers

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1

2

3

5

6

4

NOTE: Control locations may vary from those showndepending on vehicle options.

1. Lighting Switches2. Parking Brake3. Trailer Air Supply4. Axle and Fifth Wheel

Switches

5. Trailer Brake Lever6. OnGuard

Fig. 4.1, Dash Control Panel

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2

1. Ignition Switch 2. Cigarette Lighter

Fig. 4.2, Ignition Switch and Cigarette Lighter

Driver Controls

4.1

• beacons

• power windows

• windshield washer

• outside air temperature display

Turn the key clockwise past the OFF position to theON position. With the switch in the ON position, thewarning and indicator lamps illuminate. Wait for threeseconds before starting the engine.

Turn the key clockwise past the ON position to theSTART position and start the engine. Do not operatethe starter longer than thirty seconds, and wait atleast two minutes between starting attempts to allowthe starter to cool. Release the key the moment theengine starts.

Switching on the ignition and releasing the parkingbrake automatically activates the daytime runninglights, if equipped. The daytime running lights willoperate until the parking brake is applied or theheadlights are turned on.

Lighting ControlsIMPORTANT: Unless otherwise noted below,press the upper half of the switch to activate thedesired light(s). Press the lower half of theswitch to turn the light(s) off.

Exterior Lighting ControlsExterior light controls are listed here in alphabeticalorder. See Fig. 4.3 for exterior light locations. At therear of the vehicle there are taillights, brake lightswith turn signals, backup lights, and optional utilitylights.

See Fig. 4.4 for exterior and interior light switches.

Backup LightsBackup lights are activated automatically when thevehicle is in reverse, and are designed to be usedwhile backing up at night.

Clearance LightsPress the upper half of the clearance lights switch toactivate all clearance lamps including back-of-sleeperand mirrors.

Driving LightsDriving lights are designed to extend the range of thehigh-beam headlights, and can only be activated

when the headlight high-beams are on. When head-lights are dimmed, the driving lights automaticallyturn off.

Fog LightsFog lights are designed to reduce glare in foggy con-ditions. The headlights must be on and set on lowbeam for the fog lights to activate.

Hazard Warning LightsPress the upper half of the hazard light switch to ac-tivate all of the turn signal lights. Both of the telltaleson the instrument cluster will flash. To cancel thehazard lights, press the lower half of the switch.

HeadlightsThe headlight switch is operated by pushing theupper half of the switch once for the parking lights,illuminating the taillights and side marker lamps onboth the tractor and trailer. Pressing the upper half ofthe switch a second time activates the headlights. Anaudible warning will sound if the lights are left onwhen the ignition is turned off and the driver-sidedoor is open.

High-Beam HeadlightsWith the low-beam headlights on, push the turn-signal lever away from you to turn on the high-beamheadlights. See Fig. 4.5. To turn off the high-beamheadlights, pull the lever to the middle position.

With the low-beam headlights on, pull the lever to-wards you to flash the high-beam headlights momen-tarily.

When the high-beam headlights are on, a blue tell-tale illuminates on the instrument cluster.

Headlight InterruptThe headlight interrupt switch is located on the left-hand switch pod of the steering wheel. See Fig. 4.6.When the headlight interrupt switch is activated, thedaytime running lights blink. The headlight interruptswitch only operates when the headlights are on.

Turn SignalsThe turn-signal lever is mounted on the left-handside of the steering column. Pulling the turn-signallever up activates the right-turn signal; pushing it

Driver Controls

4.2

down activates the left-turn signal. The lever is typi-cally a non-canceling combination turn-signal, wind-shield wiper/washer switch, and headlight controlunit. See Fig. 4.5.

When a turn signal is activated, a green telltale lightflashes on the instrument panel.

On a self-canceling turn signal lever, the lever auto-matically returns to the neutral position when thesteering wheel returns to the straight-ahead positionafter a turn.

Trailer Clearance LightsThe trailer clearance lights switch activates the trailerclearance lamps independent of the tractor lamps.

Utility LightsUtility lights can be swivel-mounted on the upper halfof the cab, or flush-mounted on the back of the cabor sleeper. Press the upper half of the switch to acti-vate it. Press the lower half of the switch to turn itoff.

Interior Lighting ControlsThe cab is equipped with door-activated dome lampson the ceiling and under the overhead console, andcourtesy lights on the bottom edge of each door andunder the dash. Depending on vehicle configuration,there may also be LH and RH reading/map lamps.

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45678910

1. Clearance Light2. Identification Lights3. Mirror Marker Light4. Clearance Light

5. Side Marker Light6. Front Turn Signal7. Headlight, Low Beam

8. Combination Fog/Driving Light9. Headlight, High Beam10. LED Accent Light

Fig. 4.3, Exterior Lights

Driver Controls

4.3

When the instrument panel lights are on, most switchicons are backlit with a colored light to allow thedriver to find switches more easily in the dark. Whena switch is activated, an LED on the switch is illumi-nated.

FOGLIGHTS

DRIVINGLIGHTS

CL / IDLIGHTS

HEADLIGHTS

CL / IDLIGHTS

SLEEPERLIGHTS

DASHLIGHTS

TRAILER

UTILITYLIGHTS

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9 8 7 6

2 3 4 5

f611257

1. Headlights Switch2. Tractor Clearance Lights Switch3. Driving Lights Switch

4. Fog Lights Switch5. Utility Lights Switch6. Hazard Flasher Switch

7. Trailer Clearance Lights Switch8. Sleeper Lights Switch9. Dash Lights Switch

Fig. 4.4, Exterior and Interior Light Switches

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32

4

1. Headlight ControlSymbols

2. Windshield WiperSwitch

3. Windshield WasherSwitch

4. Turn Signal Symbol

Fig. 4.5, Steering Column-Mounted Turn Signal Lever

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23

4

1. Volume Up Switch2. Volume Down Switch3. Headlight Interrupt Switch4. ICU4Me Navigation Switches

Fig. 4.6, Left-Hand Steering Wheel Switches

Driver Controls

4.4

For sleeper and baggage compartment lights, seeChapter 8.

Dash LightsThe dash lights are controlled by the dash lightsswitch (Fig. 4.4, item 9). With the headlight switch inposition 1 (marker lights on) or position 2 (headlightson), tapping the upper half of the dash lights switchincreases the instrument cluster and switch backlight-ing incrementally. Note that tapping the switch pastthe maximum setting also activates the dome lampsand courtesy lights. Tapping the lower half of theswitch dims the dash lights.

Cab Dome Lamps and Courtesy LightsThe dome lamps on the cab ceiling and overheadconsole, and the courtesy lights on the cab doorsand under the dash are activated when a cab door isopened. Closing the doors will cause the lights to beturned off after 30 seconds. If a cab door is left open,a timer turns the lights off after 15 minutes.

Both the ceiling and overhead console dome lampscan be activated using the dash lights switch(Fig. 4.4, item 9) when the headlight switch is in po-sition 1 (marker lights on) or position 2 (headlightson). Tap the top half of the dash lights switch untilthe dome lamps are activated. Tap the bottom half ofthe switch to turn the dome lamps off.

Overhead Console Dome/Reading LampsThe overhead console dome/reading lamps (Fig. 4.7)are powered by both the ECC module and the bat-tery. When powered by the ECC module, they arecontrolled together with the cab dome lamps (see"Cab Dome Lamps and Courtesy Lights" above).They can also be operated individually (when notpowered by the ECC module) by pushing on thelens.

Red Map LampsThe red map lamps (Fig. 4.7) on the overhead con-sole are operated by pushing on the lens.

Horn ControlsAir HornThe air horn is controlled by a wire lanyard hangingfrom the center of the overhead console. Pull downon the lanyard to sound the air horn.

Electric HornThe electric horn control is located in the center ofthe steering wheel. To sound the horn, press downon the top of the steering wheel center pad. Thehorn will sound for the duration that the buttonpressed, up to 60 seconds.

Powertrain ControlsAftertreatment System RegenSwitchesNOTE: See Chapter 12 for detailed informationabout the operation of the regeneration (regen)switches and the aftertreatment system (ATS).

The regen request switch is used to initiate a parkedregen. See Fig. 4.8.

Some vehicles are equipped with an optional regenrequest/inhibit switch. To request a parked regen,press the upper half of the switch. To stop a regen inprogress or prevent the start of a regen, press thelower half of the switch. Regen will not occur until theswitch is no longer active.

Axle SwitchesAxle switch controls are listed here in alphabeticalorder. See Fig. 4.9.

NOTE: See Chapter 17 for detailed informationabout drive axle functions.

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1 2 2 1

1. Red Map Lamp2. Clear Dome/Reading

Lamp

Fig. 4.7, Overhead Console Lamps

Driver Controls

4.5

Differential Lock SwitchThe differential lock switch provides maximum trac-tion for slippery conditions by forcing the wheels oneach drive axle governed by the switch to rotate to-gether. Engagement can be at any speed, providedthe wheels are not slipping or spinning.

Interaxle Lock SwitchThe interaxle lock switch allows the driver to lock thedrive axles together, causing the drive axle shafts torotate together. Use this feature only under adverseroad conditions where greater traction is needed.

Leave the control in the UNLOCK position for normalhighway operation. When a spinning or slipping ac-tion occurs at any of the drive wheels, press theupper half of the switch to LOCK the differential andprevent the wheels from spinning.

NOTICEDo not shift into LOCK while the rear wheels arespinning. Come to a halt before engaging to pre-vent damage to the interaxle and main differen-tials.

Do not permit rear wheels to spin freely for morethan ten seconds when traction is lost. Shift intoLOCK to prevent damage to the interaxle andmain differentials.

Lift Axle SwitchThe lift axle switch controls the lift axle operation.Pushing the upper half of the switch will lower the liftaxle.

Engine Brake SwitchesNOTE: See Chapter 13 for detailed informationabout engine brake operation.

Whenever vehicle braking is required on good roadconditions, the engine brake may be used in con-junction with the service brakes. There is no timelimit for operation of the engine brake. However, anengine brake does not provide the precise control of,and is not a substitute for, service brakes.

The engine brake control is located on the right-handsteering-column-mounted lever. At the top position,the engine brake is off, and at the three lower posi-tions, the brake is on and the intensity (low, medium,high) increases with each step down. See Fig. 4.10

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1. Regen Request Switch2. Regen Request/Inhibit Switch

Fig. 4.8, Aftertreatment System Regen Switches

LIFTAXLE

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1. Rear Drive Axle Differential Lock Switch2. Forward Drive Axle Differential Lock Switch3. Interaxle Lock Switch4. Lift Axle Switch

Fig. 4.9, Axle Switches

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0

1

2

3

0. Off1. Low

2. Medium3. High

Fig. 4.10, Engine Brake Positions

Driver Controls

4.6

Engine Fan SwitchPress the upper half of the engine fan switch to over-ride the automatic fan control and cause the enginefan to run continuously. See Fig. 4.11, item 1. Thisswitch is intended for temporary use, or if the auto-matic fan control fails. Press the lower half of theswitch to return to automatic fan control.

Shutdown Override SwitchSome vehicles may have a shutdown overrideswitch, which can be used to momentarily overridethe shutdown sequence. This switch resets the shut-down timer, restoring power to the level before thederate. The switch must be pressed again after fiveseconds to obtain a subsequent override. SeeFig. 4.11, item 2.

NOTICEWhen the derate process begins, immediately getthe vehicle serviced in order to prevent severedamage to the engine.

Hill Start Aid Override SwitchSome vehicles are equipped with a Hill Start Aid(HSA) feature to prevent the vehicle from rollingwhile on steep grades and to allow for a controlledlaunch. HSA is "on" by default. It can be turned offby pressing and releasing the HSA override switchon the dash (see Fig. 4.12).

Power Takeoff ControlsEngine power takeoffs (PTO) are devices used to tapinto engine power to run auxiliary devices, such ashydraulic pumps that power additional equipment.The following instructions are general guidelines foroperating a PTO.

1. Set the parking brake and put the transmission inneutral.

2. Press the PTO switch. See Fig. 4.13. When thelight is steadily illuminated, the PTO is engagedand ready to operate. In stationary mode, thevehicle must remain in neutral with the parkingbrake set.

3. To activate the mobile mode, shift from neutral toreverse, 1st, or 2nd gear. The clutch will openand the PTO will disengage for a moment.

4. Touch the accelerator pedal to close the clutchand engage the PTO in mobile mode. The PTOmay be operated with the transmission in re-verse, neutral, 1st, or 2nd gear only.

NOTE: Do not attempt to change gears whilethe vehicle is moving. The transmission will ig-nore the request.

5. To end the mobile mode, bring the vehicle to astop. The clutch will open and shut down powerto the PTO.

6. To resume stationary mode, shift to neutral. ThePTO will engage.

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SHUTDOWNOVERRIDE

ENGINEFAN

Fig. 4.11, Engine Switches

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HSAOVR

Fig. 4.12, Hill Start Aid Override Switch

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AUXPTO

Fig. 4.13, PTO Switch

Driver Controls

4.7

7. To end stationary mode, press the PTO switch.When the light in the switch goes out, power tothe PTO is shut off.

Transmission ControlsDetroit™ Automated Transmissions

NOTE: See Chapter 15 for complete Detroitautomated transmission operating instructions.

Vehicles with Detroit transmissions use the multifunc-tion control shown in Fig. 4.14. This control moves intwo directions and has two switches. It is used torequest manual shifts, change shift mode, set enginebrake levels, and control specialty engine brake func-tions during cruise control operation.

Manual Transmissions

NOTE: See Chapter 16 for complete manualtransmission operating instructions.

if equipped, the transmission range control and split-ter valves are attached to the gear shift knob.

To operate a range-shift transmission, move the shiftknob through all the low-range gear positions andthen pull the range-preselection lever up to move intothe high-range ratios. Use the same shift knob posi-tions in both the low and high ranges.

Dependent on the transmission model, some ratioscan be split using the splitter-control button (locatedon the side of the shift knob).

Cruise Control

WARNINGDo not use the cruise control system when driv-ing conditions do not permit maintaining a con-stant speed, such as in heavy traffic or on roadsthat are winding, icy, snow-covered, slippery, orroads with a loose driving surface. Failure to fol-low this precaution could cause a collision orloss of vehicle control, possibly resulting in per-sonal injury or property damage.

NOTICEWhen the cruise control is engaged, do not at-tempt to shift gears without using the clutchpedal. Failure to follow this precaution will resultin a temporarily uncontrolled increase in engine

speed. Transmission damage and gear strippingcould result.

B

2

3

1

( + )

( − )

4

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A

C

A. Front ViewB. Shift RequestsC. Four positions for engine brake settings1. Engine Brake Symbol2. D/N/R Switch3. Mode Switch4. Gear Shift Symbol

Fig. 4.14, Detroit Multifunction Control

Driver Controls

4.8

NOTE: If the vehicle is equipped with a Detroitmultifunction control, setting the cruise controlwith the engine brake on will activate DescentControl Mode. Moving the lever to the top posi-tion will resume the set cruise speed. Movingthe lever down to engage the engine brake afterthe cruise control has been set will activate De-celeration Mode. See "Descent Control and De-celeration Modes, Detroit™ Automated Transmis-sions" in this chapter.

The cruise control is operated by four buttonsmounted in the right-hand switch pod of the steeringwheel. See Fig. 4.15.

• Cruise On/Off Button—Press to turn cruisecontrol on or off. When cruise control is on, theICU message center displays relevant cruisecontrol icons and the set speed. The speedmemory will be retained until the cruise controlis disabled with the ON/OFF button, or the igni-tion is turned off.

• Cruise Accelerate/SET Button—Press to setthe cruise speed while the vehicle is travelingat the desired speed. Press and hold to in-crease the set cruise speed.

• CNCL Button —Press to pause the cruise con-trol, while retaining the speed setting inmemory. The cruise control can also be disen-gaged, while retaining the speed memory, bydepressing the brake or clutch pedals.

• Cruise Decelerate/RES Button—Press to re-sume the set speed. Press and hold to de-crease the set cruise speed.

1. To cruise at a particular speed:

1.1 Press the on/off button to turn cruise con-trol on.

1.2 Depress the accelerator pedal until thespeedometer reaches the desired speed.

NOTE: Cruise control is cancelled if thebrake or clutch pedal is depressed, or ve-hicle speed drops below the minimum cruisecontrol speed.

1.3 Press the cruise accelerate/SET button toset the desired speed.

NOTE: The speed memory is lost whenever theignition switch is turned to OFF, or cruise controlis turned off.

2. To disengage the cruise control, do one of thefollowing:

• Press the CNCL button in the center of theright-hand control pod.

• Depress the brake pedal.

• Depress the clutch pedal (on a manualtransmission only).

3. To resume a preselected cruise speed:

3.1 Ensure cruise control is on.

3.2 Press the cruise decelerate/RES button.Cruise will return to the last set speed.

NOTE: If vehicle speed drops below theminimum cruise control speed, cruise controlwill disengage. To resume to the preselectedcruise speed, increase vehicle speed toabove minimum cruise control speed andpress the cruise decelerate/RES button.

4. To increase cruise speed, press the cruiseaccelerate/SET button until the vehicle acceler-ates to the desired speed.

5. To decrease cruise speed, press the cruisedecelerate/RES button until the vehicle deceler-ates to the desired speed.

Cruise Control ("CC") LimiterOn vehicles equipped with a CC limiter switch (seeFig. 4.16), the cruise control limiter allows the vehicleto exceed the set cruise control speed before enginebraking is applied. The CC limiter switch provides

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234

5

67

1. Cruise Accelerate/SET2. Marker Interrupt3. Cruise Decelerate/

Resume

4. Bluetooth—End Call5. Mute6. Bluetooth—Start Call7. Cruise On/Off

Fig. 4.15, Right-Hand Steering Wheel Switches

Driver Controls

4.9

more flexibility to the existing cruise control limit func-tion, allowing the driver to tune the cruise function tobetter suit driving preferences and conditions. To se-lect a limit, use the three-position CC Limiter switchon the dash. See Table 4.1 for switch settings.

CC Limiter Switch SettingsPosition Approximate Overrun Setting

Top in 3 mph (5 km/h)Middle 6 mph (9 km/h)

Bottom in Unlimited

Table 4.1, CC Limiter Switch Settings

Descent Control and DecelerationModes, Detroit™ AutomatedTransmissionsOn vehicles equipped with a Detroit multifunctioncontrol (Fig. 4.17), the functions of the lever posi-tions for engine brake control change when cruisecontrol is set. Two distinct modes can be activated:

• Descent Control Mode—engine braking keepsthe speed below cruise set speed; throttle isnot automatically applied.

• Deceleration Mode—engine braking activatesto reduce vehicle speed (with no lower limit) ata constant rate.

Descent Control ModeDescent Control Mode keeps the vehicle speedbelow the set cruise speed on a downhill.

To activate Descent Control Mode, set the cruisecontrol speed with the engine brake on (Fig. 4.17,positions 1, 2, or 3). In this mode, all three levels ofengine braking will be employed to to keep thespeed below the set cruise speed. This mode will notkeep the speed above the lower limit of the set

speed, so it is possible to eventually coast to a stop,unless the lever is moved to "engine brake off" (posi-tion 0), or throttle is applied. After throttle application,the Descent Control Mode is resumed.

Moving the lever to "engine brake off" (position 0)cancels Descent Control Mode and resumes cruisespeed. To reactivate Descent Control Mode, reset thecruise control speed with the lever in position 1, 2, or3.

Deceleration ModeDeceleration Mode reduces the vehicle speed at aconstant rate.

With the cruise control speed set, activate Decelera-tion Mode by moving the lever to engine brake on(Fig. 4.18, position 1, 2, or 3). This mode engagesone of the engine brake levels, depending on thelever position. The vehicle will decelerate at a con-stant rate until the vehicle comes to a stop, unlessthrottle applied to override the deceleration, or thelever is moved to "engine brake off" (position 0).

Moving the lever to position 0 resumes the previouslyset cruise control speed.

Dash-Mounted Brake ControlsNOTE: See Chapter 13 for detailed informationabout brake systems.

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CCLIMIT

Fig. 4.16, CC Limiter Switch

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0

1

2

3

0. Resume cruise control set speed.1, 2, 3. Descent Control maintains set speed.

Fig. 4.17, Descent Control Mode Positions, DetroitMultifunction Control

Driver Controls

4.10

Parking Brake Control Valve

NOTICEDo not step on the service brake pedal while theparking brakes are applied. To do so can causedamage to the brake mechanisms.

The yellow diamond-shaped knob operates the park-ing brake valve. See Fig. 4.19. Pull the knob out toapply both the tractor and the trailer spring parkingbrakes. Push the knob in to release the tractor andtrailer spring parking brakes. Before the spring park-ing brakes can be released, the air pressure in eitherair brake system must be at least 65 psi (447 kPa).

If the trailer is not equipped with spring parkingbrakes, pull the parking brake valve out to apply thetractor parking brakes and the trailer service brakes.

Trailer Air Supply ValveThe red octagonal-shaped knob operates the trailerair supply valve, which charges the trailer air supplysystem and releases the trailer spring parkingbrakes. See Fig. 4.19.

After the vehicle and its air hoses are connected to atrailer and the pressure in the air system is at least65 psi (447 kPa), push the trailer air supply valveknob in (and leave it in) to charge the trailer air sup-ply system and release the trailer spring parkingbrakes. Pull the trailer air supply valve out beforedisconnecting a trailer or when operating a vehiclewithout a trailer.

Trailer Brake LeverThe trailer brake lever is used to apply the trailer ser-vice brakes without applying the truck or tractor ser-vice brakes. It is usually mounted on the right-handcontrol panel. See Fig. 4.20. The valve can be par-tially or fully applied, but in any partially on position itwill be overridden by a full application of the servicebrake pedal. Move the lever down to apply the trailerbrakes; move the lever up to release the trailerbrakes. The lever will automatically return to the upposition when it is released.

Antilock Braking SystemThe Meritor™ WABCO® Antilock Braking System(ABS) passively monitors vehicle wheel speed at alltimes, and controls wheel speed during emergencystops or wheel lock situations.

During emergency or reduced-traction stops, fullydepress the brake pedal until the vehicle comes to asafe stop. Do not pump the brake pedal. With thebrake pedal fully depressed, the ABS will control all

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0

1

2

3

0. Resume cruise controlset speed.

1. Low

2. Medium3. High

Fig. 4.18, Deceleration Mode Positions, DetroitMultifunction Control

f61029102/02/2017

12

1. Trailer Air Supply Valve (red knob)2. Parking Brake Control Valve (yellow knob)

Fig. 4.19, Brake Valve Control Knobs

f61059102/03/2017

Fig. 4.20, Trailer Brake Lever

Driver Controls

4.11

wheels to provide steering control and a reducedbraking distance.

The ABS is designed to communicate with a trailerABS, if they are compatible. Compatibility will resultin the illumination of the trailer ABS lamp during ve-hicle start-up and fault detection. The trailer ABSlamp will not illuminate unless a compatible trailer isconnected to the tractor.

Vehicles with ABS may have Automatic Traction Con-trol (ATC). On these vehicles, the ATC system auto-matically limits wheel spin during reduced-tractionsituations. In normal braking applications, the stan-dard air brake system is in effect.

ATC includes a deep snow and mud option to in-crease available traction on extra-soft surfaces likesnow, mud, or gravel. A switch labeled ATC will belocated on the dash. See Fig. 4.21. Press the switchto temporarily allow more drive wheel spin. The acti-vation of the deep snow and mud option is indicatedby a flashing WHEEL SPIN lamp. Press the switchagain to cycle the system back to normal operation.

NOTICEThe deep snow and mud option is intended to beused under specific slippery conditions that re-quire momentary increased wheel spin. Usingthis option for an extended period of time maydamage the brake system.

Windshield Wiper and WasherControls

NOTICEDo not attempt to manually move the windshieldwiper arms. Wiper motor damage will occur if thearms are forcibly moved.

The windshield wipers and washer controls are onthe multi-function turn signal lever on the left-handside of the steering column. See Fig. 4.22.

The wipers are operated by a rotary switch on theturn signal lever. There are five settings, marked onthe dial by symbols for off, two intermittent settings,and two continuous speeds.

Turn the wipers on by rotating the rotary switch up.Rotate the switch further to increase the speed of thewipers through the two intermittent settings, then tolow and high speeds. Rotate the switch down to slowthe wipers down. Rotate the switch as far down as itwill go to turn the wipers off.

For wiper intermittent operation, there are two set-tings. The first intermittent setting has a default inter-val of 6 seconds, but the interval is programmablefrom 1 to 25 seconds. To program the interval, rotatethe switch from the first intermittent position to theOFF position, wait for the desired interval betweenwipes to lapse (between 1 and 25 seconds), andthen move the switch back to the first intermittentposition. If the switch is kept in the OFF position formore than 50 seconds, the interval changes back tothe default of 6 seconds. The second intermittent set-ting has an interval of 1 second, and is not program-mable.

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DEEP MUDAND SNOW

ATC

Fig. 4.21, ATC Switch

f61126402/17/2017

1

32

4





Fig. 4.22, Windshield Wiper/Washer Controls

Driver Controls

4.12

The windshield washer button is located at the endof the turn signal lever. Momentarily press the wind-shield washer button to initiate a single wipe withoutactivating the washer pump. The wipers will swipeone full cycle and return to the inactive position.

To operate the windshield washers, press and holdthe button in. After a short delay, the washer willpump windshield washer fluid onto the windshield foras long as the washer button is pressed. The wind-shield wipers will turn on at low speed while thewasher button is pressed. After the button is re-leased, the wipers will continue to operate for one toseveral wipe cycles, depending on how long thewash button was pressed initially.

Suspension/Trailer ConnectionControlsAir Suspension Height Control Switch

NOTICEDo not operate the vehicle over uneven groundsuch as ramps, speed bumps, curbs, etc. withthe air springs deflated. Doing this may lead toair bag separation from the piston, preventing thesuspension air springs from re-inflating.

The air suspension height control switch is used toadjust the vehicle height to aid in coupling or uncou-pling from a trailer. See Fig. 4.23. Setting the switchto DOWN deflates the air springs to lower the rear ofthe vehicle. In the UP position, the air springs inflateto raise the rear of the vehicle to normal ride height.

NOTICENever exhaust air from the suspension whiledriving. When the air is exhausted, the suspen-sion will not absorb road shocks, and compo-nents may be damaged.

A red LED in the switch is illuminated when the sus-pension is deflated.

ECAS Dash SwitchesVehicles with Electronically Controlled Air Suspension(ECAS) may be equipped with either dash switches(Fig. 4.24) or a remote control unit, not both.

LOAD XFER (Load Transfer)This switch controls the ECAS Manual Load Transferfunction by adjusting suspension air pressure. Usethis function to minimize wheel slippage in road con-ditions where traction may be a concern.

The ECAS Load Transfer feature applies the maxi-mum available vehicle load on the drive axle, up tothe maximum allowable limit, determined by thegross axle weight rating (GAWR). In bobtail or with aloaded trailer less than the GAWR, the tag axle sup-ports a negligible load while the drive axle supportsnearly the full weight. Above the GAWR, the driveaxle is loaded with approximately the maximum al-lowable load and the tag supports the remainder.

Load transfer mode can be deactivated by holding upon the dash switch for 4 seconds. Load transfermode will automatically deactivate when the vehiclereaches 45 mph (72 kmh).07/22/2011 f545805

Fig. 4.23, Air Suspension Height Control Switch

11/19/2014 f6112791 2

LOADXFER

SUSPHGT

1. Load Transfer 2. Suspension Height

Fig. 4.24, ECAS Dash Switches

Driver Controls

4.13

When Load Transfer mode is active, "Load Transfer"will display in the message field of the driver mes-sage center. See Figure 4.25.

SUSP HGT (Suspension Height)If the suspension is at normal height:

• each up press increases the suspension heightan increment, unless the suspension is atmaximum height

• a down press lowers the suspension to its low-est set-point (usually axle stops)

If the suspension is below normal height:

• an up press increases the suspension height tonormal ride height

• a down press does nothing; the suspension isalready at its lowest point

If the suspension is above normal height:


• a down press lowers the suspension to normalride height

Messages about the ride height status will display inthe message field of the driver message center. SeeFigure 4.26.

If the suspension is outside normal ride height(amber lamp on), the ECAS system will automaticallyreturn the suspension to normal ride height whenvehicle speed reaches or exceeds a set speed (usu-ally set to 5 mph).

ECAS Standby Mode, Dash SwitchOnce the key is turned off, the ECAS will enterStandby mode, remaining powered and adjusting tolevel and load changes for 1 hour. To cancel Standbymode on vehicles with ECAS dash switches, turn thekey from OFF to ON to OFF in less than 1.5 sec-onds. Confirm the deactivation of standby mode bypressing the SUSP HGT switch, which should notadjust the suspension.

ECAS Remote Control UnitSome vehicles equipped with Electronically Con-trolled Air Suspension (ECAS) have a remote controlunit to lower and raise the rear suspension. SeeTable 4.2 for keys and functions.


Messages about the ride height status will display inthe message field of the driver message center.

ECAS Standby Mode, Remote ControlOnce the key is turned off, the ECAS will enterStandby mode, remaining powered and adjusting tolevel and load changes for 1 hour. To cancel Standbymode on vehicles with a remote control, turn on theremote control then hold the STOP key on the re-mote for 2 seconds. Confirm the deactivation ofstandby mode by attempting to turn the remote onand adjust the suspension, which should not be pos-sible.

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Fig. 4.25, Load Transfer Notification

02/04/2015 f611287

Fig. 4.26, Example of Ride Height Message

Driver Controls

4.14

ECAS Remote Control Keys and Functions

f61121102/03/2017

Key Function

Remote Control On/Off. The middlelight will remain lit while the remote is

active.

Memory keys. Pressing the Stop keyand a memory key simultaneously willstore the current height. Once stored,

pressing the key will adjust thevehicle to the stored height.

Normal height key. This key willreturn the vehicle to normal ride

height.

Lift and lower keys. These keys willraise or lower the rear suspension

height.

The Stop key. Pressing the Stop keywill interrupt and stop all adjustments

being made by the remote control.When the key is off, holding the Stopkey for 2 seconds will cancel the 1

hour Standby mode.

Table 4.2, ECAS Remote Control Keys and Functions

Fifth Wheel Slide Control Switch

NOTICEDo not activate the fifth wheel slide control valvewhile the vehicle is in motion. To do so couldcause damage to the fifth wheel member, thekingpin, the cab or trailer, and ultimately to thedrivetrain.

The fifth wheel air slide switch permits repositioningof the sliding fifth wheel from inside the cab. SeeFig. 4.27. Moving the air slide control valve switch tothe lock position deactivates the control valve andlocks the fifth wheel to the baseplate. Moving theswitch to the unlock position activates the controlvalve and unlocks the fifth wheel slide mechanism,allowing changes to the total length of the tractor-trailer and changes to axle loads to comply with vary-ing jurisdictional laws. For detailed operating instruc-tions for fifth wheel slide, coupling, and uncouplingprocedures, refer to Chapter 18.

Trailer Auxiliary SwitchTrailers that are equipped with pneumatic brakes andused in North America or South America are gener-ally equipped with power for the trailer lights. Theconnection is passed from the vehicle to the trailervia the primary receptacle, controlled by a dashswitch.

Press the top of the switch to activate the trailer aux-iliary function. Press the bottom of the switch to turntrailer auxiliary function off. See Fig. 4.28.

Adjustable Steering ColumnControlsTo unlock the steering column to adjust it, pull thesteering column locking lever out and away from thecolumn. See Fig. 4.29. With the column unlocked,the steering wheel can be adjusted up-and-down andtilted fore-and-aft. Once the wheel is in the desired

07/22/2011 f545806

Fig. 4.27, Fifth Wheel Slide Control Switch

Driver Controls

4.15

position, lock the position by pushing the lever in to-ward the column until it goes no further and is paral-lel to the column itself.

WARNINGMake sure that the steering column is locked be-fore driving the vehicle. Never attempt to adjustthe column while driving the vehicle. Doing socould cause loss of vehicle control, personal in-jury, and property damage.

Radio/Bluetooth ControlsBluetooth controls are located on the steering wheel.Volume up and down buttons are on the left-handswitch pod. Start call, end call, and mute buttons areon the right-hand switch pod. See Fig. 4.30. For ad-ditional radio operating instructions, see the radiomanufacturer’s manual.

Climate ControlsNOTE: See Chapter 6 for detailed climate con-trol panel operating instructions.

The climate control panel allows you to control theheating, ventilating, defrosting, and air conditioningfunctions. See Fig. 4.31. Western Star vehicles haveseveral heater and air conditioner options.

Options for the cab include:

• heater only

• heater and air conditioner

• heater and air conditioner with automatic tem-perature control (ATC)

Options for a sleeper unit include:

• no heater or air conditioner

• heater only


• heater and air conditioner with ATC

The ATC feature automatically controls the heatingand cooling system to maintain the cab and sleeperair temperature close to the temperature set by theuser. The ATC adjusts the air temperature blownthrough the air outlets to maintain the selected tem-perature.

Seat ControlsNOTE: See Chapter 7 for detailed informationabout seat controls and adjustments.

WARNINGKeep hands, tools, and other objects away fromthe scissor points under the seats. Failure to doso could cause personal injury.

The following is a description of adjustments that canbe made to various Western Star seats. Not all seats

11/19/2014 f611261

TRAILERAUX

Fig. 4.28, Trailer Auxiliary Switch

08/19/2014 f462249

A

A. To unlock the steering column for adjustment, pullthe lever out and away from the column.

Fig. 4.29, Steering Column Locking Lever

Driver Controls

4.16

have all of the adjustments listed below. SeeFig. 4.32.

1. Backrest Tilt: This adjustment enables the back-rest to pivot forward or backward.

2. Lumbar Support: Lumbar support changes theshape of the seat back to give more or less sup-port to the occupant’s lumbar (lower back) area.This adjustment is either mechanical or air con-

trolled, depending on make and model of theseat.

3. Isolator: This feature reduces the amount of roadshock by isolating the occupant from the motionof the vehicle, and allowing the upper seat tomove in a simple pendulum motion. A lockoutfeature is used whenever the isolator is not de-sired.

5

4

08/14/2014 f611271

1

3

2

1. Bluetooth—Start Call2. Mute

3. Bluetooth—End Call4. Volume Down

5. Volume Up

Fig. 4.30, Radio/Bluetooth Controls on the Steering Wheel

f610640

A/CBUNK

1

2 3 4

6 5702/10/2003

1. Fan Off Position2. Fan Switch3. Temperature Control Switch

4. Mode Control Switch5. Air Conditioner Switch

6. Bunk Switch7. Indicator

Fig. 4.31, Cab Climate Control Panel, No ATC

Driver Controls

4.17

4. Height Adjustment: This adjustment moves theentire seat up or down. The adjustment is eithermanually- or air-controlled, depending on themake of the seat.

5. Bottom Cushion Angle, or Fore-and-Aft BottomCushion Height: This adjustment enables the oc-cupant to raise or lower the front or back of thebottom cushion. This adjustment is easier to per-form when all weight is removed from the seat.

6. Fore-and-Aft Seat Slide, or Seat Track Adjust-ment: This adjustment moves the entire seat for-ward or backward on its track.

7. Seat Tilt: This adjustment allows the seat assem-bly (back and bottom cushions) to tilt forward orbackward.

8. Headrest Adjustment: This adjustment changesthe angle of the upper part of the backrest toprovide head and upper back support.

f910149a02/03/2017

1

2

3 4

56 7

8

1. Backrest Tilt2. Lumbar Support3. Isolator Feature4. Height Adjustment

5. Bottom Cushion Angle (fore-and-aft cushion height)

6. Fore-and-Aft Seat Slide (seattrack adjustment)

7. Seat Tilt8. Headrest Adjustment

Fig. 4.32, General Seat Adjustments

Driver Controls

4.18

5

Driver Assistance FeaturesOnGuard™ Collision Safety System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1Lane Departure Warning Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.4OnLane™ Lane Departure Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.5Roll Stability System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.6Enhanced Stability Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.8

OnGuard™ Collision SafetySystemMeritor WABCO OnGuard is a forward-looking radar-based safety system. The system includes forwardcollision warning, adaptive cruise control (ACC), andcollision mitigation.

OnGuard equipped vehicles have antilock brakes(ABS) and automatic traction control (ATC), and ei-ther roll stability control (RSC) or electronic stabilitycontrol (ESC). These systems work together to en-hance control of the vehicle. Depending on the situa-tion, any of these features may apply throttle control,engine brakes, and/or service brakes, as needed.

The front-looking antenna assembly transmits radarsignals to, and receives them back from, objectsahead of the vehicle. To be detected, vehicles mustbe within the radar field of view and provide a sur-face area that can reflect the radar. The distance,speed, and angle of the vehicle ahead is calculated,and the driver is warned of potentially dangeroussituations. The system also warns of stationary ob-jects to alert the driver of potential obstructionsahead in their lane.

WARNINGThe Meritor WABCO OnGuard™ Collision SafetySystem is intended solely as an aid for an alertand conscientious professional driver. It is notintended to be relied upon to operate a vehicle.Use the system in conjunction with rearview mir-rors and other instruments to safely operate thevehicle. Operate a vehicle equipped with the On-Guard in the same safe manner as if the CMSwere not present.

The OnGuard Collision Safety System is not asubstitute for safe, normal driving procedures,nor will it compensate for any driver impairmentsuch as drugs, alcohol, or fatigue.

Failure to drive safely and use the system prop-erly could result in personal injury and/or deathand severe property damage.

System LimitationsThe OnGuard Collision Safety System may providelittle or no warning of hazards such as pedestrians,animals, oncoming vehicles, or cross traffic.

OnGuard CMS only brakes for lead vehicles locateddirectly in front of your vehicle, and does not operatewhen vehicle speed is less than 15 mph (25 km/h).

Due to these limitations, the system:

• will not react and alert the operator to objectscrossing in front of the vehicle or oncomingtraffic;

• should not be relied on to track lead vehicleswhen traveling through a severe curve in theroad. Because of this, ACC is not recom-mended for use on winding roads;

• will alert, but not actively brake, on stationaryobjects;

• should not be relied upon to track smaller ob-jects like motorcycles, mopeds, bicycles, orpedestrians;

• should not be relied on to alert drivers to ve-hicles in an adjacent lane.

OnGuard Display UnitThe OnGuard system controls are located in the dis-play unit. The display provides visual and audiblewarnings and messages, as well as verification ofcorrect system operation and faults. Menu selectionsare made by pressing the up and down arrows, andthe MODE button. See Fig. 5.1 .

The display includes:

• an internal speaker

• a graphic display

• buttons to scroll and select options

f61127702/17/2017

12

3

4

1. Mode2. Day/Night Mode

3. Up4. Down

Fig. 5.1, OnGuard Display Unit

Driver Assistance Features

5.1

• day/night display mode

Collision Mitigation System (CMS)The CMS provides the driver with audible and visualalerts when the vehicle’s following distance couldresult in a rear-end collision. The OnGuard displayunit shows a graphic of the condition, enhanced by ascreen color relevant to the intensity of the situation.See Table 5.1. If a potential rear-end collision is im-minent, OnGuard’s active braking automatically ap-plies the engine and service brakes to slow the ve-hicle. The active braking application is intended onlyto provide early braking; the driver is still required torecognize and react to all driving situations.

IMPORTANT: CMS and active braking are notoperational at vehicle speeds below 15 mph (25km/h).

OnGuard Display Screen Background ColorsScreen Color Description

Blue General operation; no lead vehiclesdetected.

Green Lead vehicle detected.

Yellow Following distance alert, accompaniedby an audible alert.

RedCollision warning, stationary objectwarning. Accompanied with audiblealert.

Amber Data Error

Table 5.1, OnGuard Display Screen BackgroundColors

StandbyWhen no lead vehicle is detected, the display showsthat the CMS is on and the radar is searching. SeeFig. 5.2.

A Vehicle is DetectedWhen a lead vehicle is detected in the lane ahead,the display shows that the CMS is on and the radar

is tracking a lead vehicle at the speed shown. SeeFig. 5.3.

If the following distance between the vehicle and thelead vehicle is too close, the CMS will emit an au-dible alert and the display background will turn yel-low. The alert will end when the vehicle speed dropsbelow the lead vehicle speed and the following dis-tance is increased.

Collision WarningWhen a lead vehicle is detected traveling slower thanyour vehicle, or the gap between them becomes tooclose, the CMS warns of an impending collision byemitting an urgent audible alert and displaying thecollision warning symbol with a red background. SeeFig. 5.4.

Adaptive Cruise Control (ACC)ACC works in conjunction with conventional cruisecontrol to maintain a minimum following distancewhen a lead vehicle is being tracked. The minimumfollowing distance is maintained by automatically de-celerating the vehicle using throttle, engine, and ser-vice brakes without driver intervention. When the

CMS12/18/2014 f611143c

Fig. 5.2, CMS Standby (blue)

CMS

12/18/2014 f611143b

55 MPH

230FT

Fig. 5.3, CMS Lead Vehicle Detected (green)

12/18/2014 f611144a

CMS 15 MPH

15 FT

Fig. 5.4, CMS Collision Warning (red)


5.2

lead vehicle is no longer being tracked, the set cruisecontrol speed resumes automatically.

StandbyWhen no lead vehicle is detected, OnGuard ACCoperates similarly to conventional cruise control. Thecruise control set speed is shown on the OnGuarddisplay unit. See Fig. 5.5.

Lead Vehicle DetectedWhen a lead vehicle is detected in the lane ahead,the display shows that ACC is on and the radar istracking it. See Fig. 5.6.

If the driver uses the accelerator pedal to overridethe cruise control and approach a vehicle too closely,the ACC will emit an audible alert and the displaybackground will turn yellow. The alert will end whenvehicle speed drops below the lead vehicle’s speedand the following distance is increased.

NOTE: The following distance alert does notoperate at speeds below 15 mph (25 km/h).

Collision WarningIf the lead vehicle is traveling slower than the driver’svehicle, the CMS warns of an impending collision byemitting an urgent audible alert and displaying thecollision warning symbol with a red background. SeeFig. 5.7.

The braking control will activate and slow the vehicle.The driver must also initiate braking.

Error ScreensIMPORTANT: The OnGuard collision safety sys-tem is not operational when an error screen isdisplayed. If a fault occurs or OnGuard fails toproperly track a vehicle, take the vehicle in forservice as soon as possible. Standard cruisecontrol will not function with an active OnGuardsystem fault.

If a system fault is detected, the OnGuard displayunit will immediately display an error screen asshown in Fig. 5.8. The first error code transmittedwill be displayed first; additional faults (if any) can beviewed using the up or down buttons. The displaydoes not show stored fault codes.

Refer to the OnGuard Collision Safety System Main-tenance Manual MM-0951 for a full list of faults(www.meritorwabco.com).

Additional FeaturesPress the MODE button to access the OnGuard dis-play unit additional features from the CMS or ACCmain operating screen. Press the up and down ar-rows to scroll through each menu, then press theMODE button to select the value to be changed. Inedit mode, press the up or down arrows to change a

f61114502/17/2017

Set: 60 MPH

Fig. 5.5, ACC Standby (blue)

f61114602/17/2017Set: 60 MPH 55 MPH

230 FT

Fig. 5.6, ACC Lead Vehicle Detected (green)

f61114702/17/2017

Set: 60 MPH15 MPH

15 FT

Fig. 5.7, ACC Collision Warning (red)

f61114802/17/2017

ACC1 Link Error

DATA ERROR

Fig. 5.8, OnGuard Error Screen (amber)


5.3

www.meritorwabco.com

value setting, then press the MODE button to savethe setting. Pressing MODE in each feature screenadvances the display to the next feature.

The Display Control menu allows adjustment of thealarm volume, LCD brightness, LCD contrast, andU.S./metric unit conversion. See Fig. 5.9.

The component test menu provides verification ofsystem component operation and acts as a valuableOnGuard system diagnostic tool. The header will dis-play either COMPONENT TEST or ACC FUNCTION,depending on the software release version of the On-Guard system. The component test screen shown inFig. 5.10 provides access to the following compo-nents (press the up or down arrows to scroll throughthe menu):

• brake pedal position

• EBS brake switch

• CCVS brake switch

• clutch switch

• park brake switch

• accelerator pedal position

• driveline engaged

• cruise control enable

• cruise control set speed switch

• cruise control coast switch

• cruise control resume switch

• cruise control accelerate switch

• cruise control pause switch

Lane Departure WarningControlsThe lane departure warning system monitors the ve-hicle’s position within the roadway lane markings andsounds a warning in the cab when the vehicle isabout to stray outside its lane, provided the turn sig-nal is not on and the vehicle is traveling at least 37mph (60 km/h). The system includes a digital cameramounted high near the center of the windshield in-side the cab and speakers that emit a sound similarto a rumble strip. The sound is made on the side ofthe vehicle it’s straying toward, prompting the driverto respond and steer away from the sound and backinto the center of the correct lane.

WARNINGThe lane departure warning system is intendedonly as an aid for a conscientious and alertdriver. The system may not indicate lane depar-tures under certain conditions. Read the informa-tion in this manual to understand the circum-stances under which this system may notprovide adequate lane departure warnings. Donot rely solely on the system to safely operatethe vehicle. The system does not warn of all pos-sible hazards. For example, the system cannotprevent an accident if the driver is impaired ornot driving safely.

The lane departure warning system is not a sub-stitute for safe driving procedures.


The lane departure warning system powers up eachtime the ignition is turned to ON. The system con-ducts a self test, and initiates test tones from the leftspeaker and then the right speaker. Once the vehicleis started and the system is ready, the LED in theswitch illuminates.

Press the LANE ALERT switch to temporarily disablethe lane departure warning system. See Fig. 5.11.Some vehicles are equipped with a timer that auto-matically re-enables the warning system after 15minutes. On all other vehicles, the warning system

f61114902/17/2017

DISPLAY CONTROL

Alarm Volume

Alarm Tone

10

4

LCD Intensity 9

Fig. 5.9, Display Control Menu

f61115102/17/2017

COMPONENT TEST

CCVS Brake Switch

Brake Pedal Position

ON

37%

ON

EBS Brake Switch

Fig. 5.10, Component Test Menu


5.4

will remain disabled until the driver enables the sys-tem by pressing the LANE ALERT switch again, orthe ignition is cycled off and then on.

When the vehicle approaches the lane markings oneither side, the system sense the activation of a turnsignal. If a turn signal has not been activated, thesystem initiates the audible warning to alert the driverthat the vehicle is departing its current lane of travel.

The LANE SRCHNG warning light illuminates to indi-cate the system is not fully functional. When thewarning light is on, the system audible alert may notindicate a lane departure. Conditions that can causethe warning light to illuminate include:

• The system is unable to detect lane markings.

• Vehicle speed is less than 37 mph (60 km/h).

• A system problem is detected.

OnLane™ Lane DepartureWarning

WARNINGOnLane lane departure warning is intended onlyas an aid for a conscientious and alert driver. Thesystem may not indicate lane departures undercertain conditions. Read the information in thismanual to understand the circumstances underwhich this system may not provide adequate lanedeparture warnings. Do not rely solely on thesystem to safely operate the vehicle. The systemdoes not warn of all possible hazards. For ex-ample, the system cannot prevent an accident ifthe driver is impaired or not driving safely.



OnLane is a camera-based warning system thathelps the driver avoid unintentional lane drifting.

The system utilizes a camera mounted near the topcenter of the vehicle windshield, which calculatesvehicle position within the lane. When the vehiclecrosses lane markings without the turn signal beingactivated, OnLane sounds an audible warning.

The Driver Alertness Warning (DAW) system pro-vides a warning when weaving or erratic driving isdetected within the driving lane.

System StartupOnLane is activated when the vehicle ignition isturned on. Lane departure warnings are active onlywhen the vehicle is traveling at 42 mph (68 kph) orabove.

Intentional Lane ChangesThe system identifies intentional lane changes bymonitoring the turn signal, the brake switch, and ve-hicle speed. When a lane change is intentional, theassistance warnings are disabled. The following con-ditions will disable/enable the warnings:

• If brake lights are ON, all warnings are dis-abled

• If the Left Turn Signal is ON, left departurewarnings are disabled

• If the Right Turn Signal is ON, right departurewarnings are disabled

• If the vehicle’s speed is under 42 mph (68kph), all warnings are disabled

• If the hazard lights are ON, all warnings areenabled

Unintentional Lane DepartureThe system constantly monitors and calculates thevehicle’s position within the lane. In the event of anunintentional lane change, the system provides anaudible warning (rumble strip noise). The audiblewarning will terminate once the vehicle is guidedback into the lane.

08/07/2014 f611266

LANEALERT

Fig. 5.11, Lane Departure Warning System DisableSwitch


5.5

Driver Alertness WarningThe system detects erratic driving based on weavingbehavior within the driving lane. OnLane computes a"Driver Alertness Index" based on driving perfor-mance, and alerts the driver when it falls below acertain threshold. DAW warns the driver by providingan intermittent warning tone when it detects erraticdriving or weaving within the driving lane. The alertterminates when driving performance improves, orwhen the key is cycled.

Temporarily Disabling the SystemThe system can be temporarily disabled by pressingthe OnLane switch. This disables warnings for 15minutes. Warnings can be enabled by pressing theOnLane switch again.

Roll Stability SystemThe roll stability system may include the roll stabilityadvisor (RSA) only, or it may also include the roll sta-bility control (RSC).

A decal (Fig. 5.12) on the auxiliary dash panel, andan amber-colored dash indicator light (Fig. 5.13), in-dicate that the vehicle is equipped with roll stabilitysystem components.

Roll Stability AdvisorIMPORTANT: This is not an advance warningsystem. The roll stability advisor displays a mes-sage only after the driving maneuver is com-pleted.

The roll stability system uses a lateral-accelerationsensor that monitors rollover risk. Shortly after acurve, lane change, or other driving maneuver thatresults in a rollover-risk detection, a dash warninglight illuminates, an audible tone sounds, and a driveradvisory message is displayed in the driver messagecenter. The purpose is to advise the driver that theprevious maneuver produced a rollover risk.

The roll stability advisor displays different text mes-sages depending on the severity of the risk of eachoccurrence of risky driving. From the highest risklevel to the lowest risk level, the system will soundan audible alert, and display a message, as shown inFig. 5.14.

NOTE: The system will calculate and recom-mend a speed reduction value. It may be differ-ent than the values shown here.

Bring the vehicle to an authorized service facility if asystem failure message is displayed.

Roll Stability Control

WARNINGThe Roll Stability Control system is intended onlyas an aid for a conscientious and alert driver.Carefully read the information in this manual tounderstand this system and its limitations. TheRoll Stability Control system is not a substitutefor safe driving procedures. Failure to drivesafely, and use the system properly, could resultin personal injury and/or death and propertydamage.

The roll stability control system automatically reducesengine 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 rollingover. The control can intervene even before an advi-sory message is displayed.

The dash indicator light illuminates whenever the rollstability control system intervenes.

lamp indicates tractionOR roll control event.Follow instructions indriver’s manual.

24−01204−000

07/11/2003 f080125

SAFETY INSTRUCTIONS

Fig. 5.12, Roll Stability Decal

f60212802/03/2017

Fig. 5.13, Roll Stability Indicator Lamp


5.6

Hard-Braking AdvisorThe hard-braking advisor uses the information fromthe ABS wheel speed sensors to determine whenbraking is severe enough to produce lockup at one

or more wheels on the tractor, and/or very rapid ve-hicle deceleration. Shortly after a hard-braking eventoccurs, an advisory message is displayed in thedriver message center, indicating that the brakingbehavior was too aggressive for the current road sur-face conditions. This system is not a replacement fora driver’s good judgment. Sometimes it is necessaryto brake hard.

From the highest risk level to the lowest risk level,the system will sound an audible alert, and display amessage, as shown in Fig. 5.14.

Trip/Leg TotalsThe driver message center records the number ofmessages received, and displays the number ofmessages as counts. Roll stability advisor (RSA) andhard-braking event data (HBED) counts can beviewed in the trip advisory screen, and the leg advi-sory screen.

Counts can be reset using the + key on the steeringwheel. Clearing RSA and HBED leg counts will alsoreset the leg miles and leg hours. Clearing RSA andHBED trip counts will also reset trip miles, trip hours,leg miles, leg hours, and leg advisory counts. In ad-dition, resetting leg miles will clear leg counts. Clear-ing trip miles will reset miles, hours, and counts inboth the leg and trip screens.

The TRIP and LEG advisor screens count both theroll stability advisories (ROLL) and hard-brakingevents (BRK). For example, if during a TRIP, thedriver message center recorded the events inTable 5.2, the message center would display asshown in Fig. 5.15.

RSA/HBED CountMessage Received Message Counts

RSA Level 3 2RSA Level 2 3RSA Level 1 7

HBED Level 3 5HBED Level 2 1HBED Level 1 8

Table 5.2, RSA/HBED Count

If the count reaches more than 9 occurrences an up-arrow symbol will appear, to indicate to the driverthat the count has exceeded 9 counts. SeeFig. 5.16.

Message to Display

4 1

MessageMSG

No.

System Fault1WARNING

RAC SYSTEM FAIL

ACTIVE SLOWING

ROLLOVER RISK

4 NoneRSC2

VERY HIGH RISK OF

ROLLOVER DETECTED

REDUCE SPEED

AT LEAST 11 KPH

REDUCE SPEED

AT LEAST 7 MPH

or in metric

19.6 10RSA Level 33

HIGH RISK OF

ROLLOVER DETECTED

REDUCE SPEED

AT LEAST 11 KPH

REDUCE SPEED

AT LEAST 7 MPH

or in metric

14 5RSA Level 24

ROLLOVER RISK

DETECTED

REDUCE SPEED

AT LEAST 11 KPH

or in metric

REDUCE SPEED

AT LEAST 7 MPH

8.4 2RSA Level 15

HARD BRAKING WITH

ABS ACTIVATED

LOOK AHEAD

BRAKE SOONER

14 0.5HBED Level 36

HARD BRAKING

DETECTED

LOOK AHEAD

BRAKE SOONER

14 0.5HBED Level 27

LOSS OF TRACTION

ABS ACTIVATED

ROAD SURFACE

MAY BE POOR

14 0.5HBED Level 18

07/25/2008 f040769

DisplayTime:

Seconds

BuzzerTime:

Seconds

Fig. 5.14, Roll Stability and Hard-Braking Warnings


5.7

Enhanced Stability Control

WARNINGEnhance Stability Control (ESC) is intended onlyas an aid for a conscientious and alert driver.Carefully read the information in this manual tounderstand this system and its limitations. ESCis not a substitute for safe driving procedures.Failure to drive safely, and use the system prop-erly, could result in personal injury and/or deathand property damage.

ESC offers the full capability of RSC (shown above)with the added capability of complete directional sta-bility (yaw control) in oversteer and understeer condi-tions to reduce the likelihood of drift-out or jackknife.The system determines where the driver is attempt-ing to steer the vehicle and how much brake demandis required in order to more precisely control the ve-hicle in an emergency situation.

ESC works by constantly comparing the driver inputwith the vehicle’s actual behavior. The system doesthis by monitoring systems such as wheel speed,steering angle, yaw rate, lateral acceleration, throttleposition, and brake application. A central microcom-puter analyzes the collected data and triggers a re-sponse to keep the vehicle on course when an un-stable condition is detected.

When the system detects that the vehicle is at risk ofoversteering or understeering, it applies individualtractor wheel end brakes and trailer brakes, activatesthe engine retarder (if equipped), and/or cuts enginepower, depending on the severity. As a result, thedriver has full control over the vehicle until the sys-tem detects a potential risk and intervenes accord-ingly. ESC operates automatically; the driver doesnot monitor or activate the system.

07/25/2008

TRIP ADVISORIES

237 ROLL 518 BRK

f040770A B C D E F

A. RSA lev. 3 Count (2)B. RSA lev. 2 Count (3)C. RSA lev. 1 Count (7)

D. HBED lev. 3 Count (5)E. HBED lev. 2 Count (1)F. HBED lev. 1 Count (8)

Fig. 5.15, Trip Advisor Message Screen

07/25/2008

TRIP ADVISORIES

23 ROLL 518 BRK

f040771A

A. RSA Lev. 1 has more than 9 counts.

Fig. 5.16, Trip Advisor Message Screen (more than 9counts)


5.8

6

Climate ControlsClimate Control Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.1Cab Climate Control Panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.1Sleeper Climate Control Panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3Parked HVAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.7Accessory Heaters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.8

Climate Control OptionsThe climate control panel allows you to control theheating, ventilating, defrosting, and air conditioningfunctions. Western Star vehicles have several heaterand air conditioner options.






• heater only




Cab Climate Control PanelsThe standard cab climate control panel has a fanswitch, a temperature control switch, and a modecontrol switch that allows the driver to control heat-ing, cooling, defrosting, and ventilating. The controlpanel may also be equipped with an optional A/Cswitch and/or an optional BUNK switch. See Fig. 6.1.

Vehicles equipped with ATC have an LED display.See Fig. 6.2.

ControlsFan SwitchThe fan switch activates the fan, which forces freshair or recirculated air through the air outlets. The fanswitch has four fan speed settings and an off posi-tion. See Fig. 6.1.

To operate the fan switch, turn the fan switch clock-wise to increase airflow; turn the fan switch counter-clockwise to decrease airflow.

On vehicles equipped with ATC, the AUTO setting onthe fan switch places the heater and air conditionersystem in the automatic fan speed control mode.When the fan switch is set to AUTO, the fan speed

will vary as necessary to maintain the temperatureset by the user.

Temperature Control SwitchTo select the desired temperature:

• Vehicles Without ATC: Turn the switch to theleft (counterclockwise) for cool air, or to theright (clockwise) for hot air.

• Vehicles With ATC: Press and release the rightside of the temperature up/down switch to in-crease the temperature to the desired setting.Press and release the left side of the tempera-ture up/down switch to decrease the tempera-ture to the desired setting. Press and hold thetemperature up/down switch to change the de-sired temperature in large increments.

Mode Control SwitchThe mode control switch allows the driver to controlthe flow of air through the face outlets, the floor out-lets, the defrost (windshield) outlets, or a combinationof these outlets to provide six air selection modes.See Fig. 6.3.

• Face Mode (using recirculating air): Directs allairflow through the face or instrument paneloutlets, using recirculated air.

• Face Mode (using fresh air): Directs all airflowthrough the face or instrument panel outlets,using fresh air.

• Bi-Level Mode: Directs the airflow equally tothe face outlets and the floor outlets.

• Floor Mode: Directs all airflow through the flooroutlets.

• Floor/Defrost Mode: Directs the airflow equallyto the floor outlets and the defrost outlets.

• Defrost Mode: Directs all airflow through thedefrost outlets.

NOTE: The face mode using recirculating air isthe only mode that recirculates the air in thecab. All other modes draw in fresh air from out-side the vehicle.

Bunk SwitchThe optional BUNK switch allows the driver to controlthe sleeper heater and air conditioner from the cab.Press the BUNK switch to turn the sleeper heaterand air conditioner on. When the bunk switch is on,the indicator light is on. The sleeper heater and air

Climate Controls

6.1

conditioner can still be controlled from the sleeperwhen the BUNK switch is on.

Air Conditioner (A/C) SwitchThe air conditioner cools and dehumidifies the airinside the cab. Press the optional A/C switch to turnthe air conditioner on or off. When the air conditioneris on, the A/C switch illuminates.

IMPORTANT: Operate the air conditioner atleast five minutes each month, even during coolweather. This helps prevent drying and crackingof the refrigerant compressor seals and reducesthe chance of refrigerant leaks in the system.

f610640

A/CBUNK

1

2 3 4

6 5702/10/2003





12/13/2002

Automatic Temperature Control

f610628

1

2

3

456

1. Fan Off Position2. LED Display

3. Mode Control Switch4. Bunk Switch (optional)

5. Temperature Up/Down Switch6. Fan Switch

Fig. 6.2, Cab Climate Control Panel With ATC

Climate Controls

6.2

LED Display, Vehicles With ATC OnlyThe LED display shows the temperature to which theheater or air conditioner has been set in degreesFahrenheit or degrees Celsius.

Changing Temperature UnitsThe temperature units can be changed from Fahren-heit (°F) to Celsius (°C) or from Celsius to Fahrenheitby turning the ignition on, turning the fan switch off,and pressing and holding the left side of the tem-perature up/down switch for five seconds. The cur-rent temperature unit will then be shown on the LEDdisplay. Press the left side of the temperature up/down switch again to toggle between °F and °C.Changing the temperature units on the cab climatecontrol panel will also effect the sleeper climate con-trol panel.

Error CodesError codes can be displayed by turning the ignitionon, turning the fan switch off, and pressing and hold-ing the right side of the temperature up/down switchfor five seconds. The current error status will beshown on the LED display. Press the right side of thetemperature up/down switch again repeatedly toscroll the display through any existing error codes. Ifan error code is displayed, contact your Western Stardealer for service.

ModesRecirculation Mode

WARNINGDo not use the recirculation mode when theheater is on and the vehicle is in motion. Drivingwith the recirculation mode on while the heater ison may cause the windows to be obscured bymoisture or ice, which could result in an accidentpossibly causing personal injury or propertydamage.

Do not use the recirculation mode for more than20 minutes at a time because the air inside thecab may become stuffy and the windows maybecome obscured by moisture, which could re-sult in an accident possibly causing personal in-jury or property damage.

When the mode control switch (see Fig. 6.3) isturned to the face mode using recirculating air, theair in the cab is recirculated through the heater andair conditioner system. This is the only mode thatuses recirculated air. Fresh air, or outside air, is cir-culated through the heating and air conditioning sys-tem when any other mode is selected.

The recirculation mode can be used to prevent dustyor smoky air from entering the cab, or to decreasethe time required to cool or heat the cab interior dur-ing extreme outside temperature conditions. Whenthe outside air is clear or the desired cab tempera-ture is reached, change the mode control switch to afresh-air mode. The recirculation mode can be usedwhen the air conditioner is on whether the vehicle ismoving or not.

Defrost ModeThe defrost mode is used to deice, defrost, or defogthe windows.

NOTE: When the defrost mode is on, the airconditioner is on. The air conditioner is used todehumidify the air entering the cab and to re-move the moisture from the windshield.

Sleeper Climate Control PanelsThe standard sleeper climate control panel has a fanswitch, a temperature control switch, and a powerswitch that allow you to control the heating and airconditioning functions in the sleeper. A vehicle with

02/06/2003 f610641

1

2

3 45

6

1. Face Mode (recirculating air)2. Face Mode (fresh air)3. Bi-Level Mode4. Floor Mode5. Floor and Defrost Mode6. Defrost Mode

Fig. 6.3, Mode Control Switch Settings

Climate Controls

6.3

an air conditioner has an air conditioner switch onthe control panel. See Fig. 6.4.

Vehicles with ATC have button controls instead ofswitch controls. See Fig. 6.5.

Controls, Vehicles Without ATCPower Switch and IndicatorThe power switch is used to turn the sleeper heaterand air conditioner on and off. When the heater or airconditioner is on, the indicator illuminates.

Fan SwitchThe fan switch controls the fan speed and forces airthrough the air outlets. The fan switch has threespeed settings and an off position. See Fig. 6.4.

To operate the fan switch, turn the switch clockwiseto increase airflow; turn the fan switch counterclock-wise to decrease airflow.

Temperature Control SwitchTo select the desired temperature, turn the switch tothe left (counterclockwise) for cool air, or to the right(clockwise) for hot air.

Air Conditioner (A/C) SwitchThe air conditioner cools and dehumidifies the airinside the sleeper. Press the optional A/C switch toturn the air conditioner on or off.

Controls, Vehicles With ATCThe controls for the sleeper heater and air condi-tioner are located on the right side of the ATCsleeper control panel. See Fig. 6.5.

Power Switch and IndicatorTurn the sleeper heater and air conditioner on bypressing the ON button. The current set temperatureis displayed for five seconds, after which it returns tothe time display. When the heater or air conditioneris on, the indicator illuminates. To turn the sleeperheater and air conditioner off, press the OFF button.

Fan SwitchTo operate the fan switch, press the fan up or fandown button repeatedly to incrementally increase ordecrease the fan speed. Press either button for atleast two seconds to continuously increase or de-

crease the fan speed. The fan speed setting is dis-played on the sleeper control panel in 10 percentincrements. When the highest or lowest fan speed isselected, HI or LO is displayed. The display returnsto the time display five seconds after a fan up/downbutton is pressed and released.

In the ATC mode, fan speed is determined by thesystem as required. The fan speed is based on thedifference between the set point temperature and theactual sleeper cab temperature. The greater the dif-ference, the greater the fan speed. The AUTO fan

f610642a

1 2 3

5 402/04/2015

POWER

A/C HEAT

1. Fan Switch2. Power Switch

3. Indicator4. Temperature Control Switch

5. Air Conditioner Switch

Fig. 6.4, Sleeper Climate Control Panel, No ATC

Climate Controls

6.4

function is disabled when either the fan up or fandown button is pressed.

Temperature Control SwitchTemperature is displayed with a three-digit annotationand can be displayed either in degrees Celsius ordegrees Fahrenheit. A capital "C" or "F" is displayedfor the appropriate temperature scale.

To select the desired temperature, press the tem-perature up or temperature down button repeatedlyto incrementally increase or decrease the set tem-perature. Press either button for at least two secondsto continuously increase or decrease the set tem-perature. The temperature setting is displayed on thesleeper control panel. The display returns to the timedisplay five seconds after a temperature up/downbutton is pressed and released.

The temperature units can be changed from °F to °Cor from °C to °F by pressing the temperature up andtemperature down buttons simultaneously. Changingthe temperature units on the ATC sleeper controlpanel will also change the temperature units on theATC cab control panel.

Auto ButtonPress the AUTO button to enable automatic controlof the fan speed. The display will show the currentset temperature for five seconds, then return to thetime display. When in the automatic mode, the fanspeed can vary to maintain the temperature set bythe user. When automatic control is turned on, theindicator above the AUTO button illuminates.

Alarm ButtonMomentarily press the ALARM button to turn thealarm on and to illuminate the alarm indicator abovethe ALARM button. Momentarily press the buttonagain to deactivate the alarm.

When pressing the ALARM button, the display showsthe alarm time setting for five seconds before return-ing to the current time display. If the ALARM buttonis pressed and held down continuously for more thanone second, the alarm time setting can be viewedwithout changing the state of the alarm indicator. Ifeither the SET+ or SET– buttons are pressed simul-taneously with the ALARM button held down, thealarm time setting will increase or decrease. Whenthe ALARM button is released after changing the

01/14/2003


f610629

ALARM

SET −

TIME

SET +

ON

OFF

AUTO

PM

DISP

1

2 3 4 5

6

7

8910

1. Alarm Button2. Time Button3. Fan Up Button4. Heater and Air Conditioner On Button5. Heater and Air Conditioner Off Button

6. Temperature Up Button7. Temperature Down Button8. Automatic Fan Button9. Fan Down Button10. Display Button

Fig. 6.5, Sleeper Climate Control Panel With ATC

Climate Controls

6.5

alarm time, the alarm will be turned on and the indi-cator will be illuminated. When the ALARM is sound-ing, press the ALARM button to turn the alarm offand to reset the alarm for the next 24-hour cycle.

To set the snooze function, press any button on thecontrol panel, except the ALARM button, when thealarm is sounding. The alarm will sound again afterseven minutes. The alarm indicator flashes when thesnooze function is set.

To cancel the snooze function, press the ALARM but-ton. This will also reset the alarm for the next 24-hour cycle.

Time ButtonThe clock controls are located on the left side of theATC sleeper control panel under the display. The dis-play will show the clock time as the default mode.

Press the TIME button to display the current time. Ifthe TIME button is held down and either the SET+ orSET– buttons are pressed simultaneously with theTIME button, the clock setting will increase or de-crease.

Display ButtonPress the DISP button to allow the display and illumi-nation of the control panel to scroll through three illu-mination levels: bright, dim, and off. If you want thealarm, time, or temperature setting to be displayedwhen the display is in the off mode, press theALARM, TIME, or temperature up/down buttons todisplay the corresponding display for five seconds.After five seconds, the display will turn off. If thealarm sounds while in the display off mode, the cur-rent time will be displayed simultaneously. The dis-play will remain on for five minutes, then turn off.

When the vehicle ignition is not powered, the sleeperclimate control panel is in a power-saving mode andthe display and illumination of the control panel willbe off. All clock functions, including the alarm, willcontinue to work internally.

Temperature Slave Mode FeatureThe temperature slave mode allows the set tempera-ture of the cab heater and air conditioner to be auto-matically tied to the sleeper heater and air condi-tioner. In this mode, the set temperature in thevehicle will be the same whether the set temperatureis changed on the cab climate control panel or thesleeper climate control panel. To enable the tempera-ture slave mode, press the SET+ and SET– buttons

simultaneously. The display will read S–ON when thetemperature slave mode is enabled.

To disable the temperature slave mode, press theSET+ and SET– buttons simultaneously. The displaywill read S–OFF indicating that the temperature slavemode is disabled. When disabled, the temperaturesfor the cab and sleeper can be changed indepen-dently for separate temperature control. If you wishto maintain a temperature in the sleeper that is differ-ent than the temperature in the front of the cab, it isrecommended that a curtain be used between thesleeper and the front of the cab.

Turning on the Sleeper Air ConditionerWhen the Cab Air Conditioner is OffThe sleeper ATC control panel can turn on the airconditioner even if the cab HVAC unit is turned offbut the engine is running. By pressing the ON button,the ATC sleeper control panel will turn on the cabunit and the bunk indicator light on the cab controlpanel will be illuminated. If cooling is needed in thesleeper, the cab HVAC unit will switch on to a lowblower fan setting and the A/C compressor clutch willengage. If cooling is no longer required in thesleeper or if heat is needed, the cab unit fan and thecompressor clutch will be turned off after a five-minute delay.

Accessory HeatersOptional accessary heaters are available from thefactory in several configurations. Familiarize yourselfwith the equipment on your specific vehicle, and fol-low the manufacturer’s operating and maintenanceinstructions.

WARNINGDo not operate fuel-operated heaters in an areawhere flammable vapors, including gasoline ordiesel fumes, are present, such as at filling sta-tions and tank farms. Turn off a fuel-operatedheater and allow it shut down completely beforeentering an area where flammable gases or liq-uids are present. Heaters continue to operate forup to three minutes after being turned off.

Failure to observe these precautions could causean explosion or fire, resulting in serious propertydamage, and personal injury or death.

Climate Controls

6.6

Parked HVACThe Bergstrom NITE parked HVAC system consistsof a compact electrical 3000-BTU air-conditioningsystem, and a diesel-fired heater unit. It is completelyself-contained, and runs on 12-volt deep-cycle batter-ies located between the frame rails. The parkedHVAC batteries are isolated from the vehicle-startingbatteries, to prevent the starting batteries from beingdrawn down during HVAC operation.

The A/C system is designed to maintain cool air inthe sleeper interior without having the engine run-ning. However, the parked A/C unit will not cool downa hot sleeper that has been sitting in the sun withoutthe vehicle A/C running. If the interior temperature ishigher than desired, start the engine and run the ve-hicle A/C system until the desired sleeper tempera-ture is achieved. This will help cool the sleeper to atemperature that the parked A/C system can main-tain. For optimal operation, the curtain between thecab and the sleeper should be closed when usingthe Parked HVAC A/C system.

The A/C unit is located under the lower bunk in thesleeper compartment, and intakes air through a grillelocated on the front panel of the lower bunk. The out-let ducting runs from the left side of the unit to anoutlet on the back wall of the sleeper.

The heater unit is located next to the A/C unit. It in-takes air through a grille located on the right side ofthe front panel of the lower bunk. The outlet ductingruns from the back of the unit to a grille on the leftside of the front panel of the lower bunk.



IMPORTANT: Blocked vents will hamper the op-eration of the unit. Keep the area around the airintake grilles clear of objects that may block airflow, or emit objectionable odors into the HVACsystem.

Parked-HVAC ControlsThe control panel for the parked HVAC is located onthe left side of the rear wall, in the sleeper. It has atemperature-control dial, and a 4-position modeswitch. Turn the temperature-control dial to the leftfor cooling, and to the right for heat. See Fig. 6.6.See Table 6.1 for a description of the mode func-tions.

After using the system, turn the mode switch to theOFF position, even if the unit is not running, or thebatteries may not charge properly.

Parked-HVAC Mode OperationMode FunctionOFF Turns the unit OFF.

AUTO

Allows the unit to automatically heat orcool the sleeper, depending on thetemperature setting and the sleepertemperature. Adjusts the compressor,heater, and fans to keep temperatureconstant.

Heat OnlyAllows only the heat portion of the systemto run. Adjusts the heater only to keep thetemperature constant.

AUTO

08/29/2007 f831760

1

2

3

4

5

6

1. Temperature-ControlDial

2. Mode Switch3. A/C Only

4. Heat Only5. AUTO6. OFF

Fig. 6.6, Parked-HVAC Control Panel

Climate Controls

6.7

Parked-HVAC Mode OperationMode Function

A/C OnlyAllows only the A/C portion of the systemto run. Adjusts compressor and fans onlyto keep the temperature constant.

Table 6.1, Parked-HVAC Mode Operation




NOTICEAlways ensure that air inlet and outlet grilles arenot restricted. Restriction of any air inlet or outletports could result in damage to the auxiliaryheater.

IMPORTANT: To maintain reliable performance,run the accessory heater for at least 15 minutesevery month to prevent fuel from degrading.

Accessory heaters function when the ignition switchis in the off position and the cab load disconnectswitch is on, if equipped.

IMPORTANT: Wait three minutes after shuttingdown an accessory heater before turning thecab load disconnect switch (CLDS) to OFF.

NOTE: The low voltage disconnect (LVD) controlprevents a heater from draining the batteriesbelow starting voltage.

Espar HeaterRefer to the Espar website, www.espar.com, for ad-ditional information.

Espar Mini-ControllerTo turn the heat on, press the heat button. SeeFig. 6.7. The red indicator will illuminate when heatmode is activated. Adjust the desired temperaturewith the control knob; rotate the temperature controlknob clockwise for warmer air, or counterclockwisefor cooler air. To turn the heat off, press the offbutton.

To turn the fan on, press the fan button. The blueindicator will illuminate when ventilation mode is acti-vated. To turn the fan off, press the off button.

Espar Digi-ControllerVehicles built after December 8, 2011 with the Digi-Controller and D2 air heaters are equipped with aninternal LVD in the Digi-Controller that prevents theheater from draining battery voltage below 12.0 volts.

To turn heat mode on, press the heat button and theheater will begin its start-up cycle. See Fig. 6.8. ON

02/06/2012 f61116112

3

4

56

1. Temperature Control Knob2. Fan Button3. Fan Indicator (blue)4. Off Button5. Heat Indicator (red)6 Heat Button

Fig. 6.7, Espar Mini-Controller

Climate Controls

6.8

http://www.espar.com

will display briefly followed by the ambient tempera-ture, and the green indicator will illuminate. Ambientdisplay temperature range is 41°F to 90°F.

To adjust the desired temperature, press the up ordown arrow buttons. The desired temperature willdisplay briefly, followed by the ambient temperature.The desired temperature will remain in the modulatormemory when the heater is not in operation. Tem-perature adjustment range is from 41°F to 90°F.

To turn heat mode off, press the heat button again.The heater will initiate a 3-minute cooling cycle.

To turn the fan on, press and hold the fan button untilthe blue indicator illuminates and the display showsactive rotating digits. To turn the fan off, press thefan button again.

NOTE: The Digi-Controller also has a program-mable run timer that will automatically shut theheater off after the set time limit. The defaulttime limit setting is 10 hours.

Webasto HeaterTo turn the heater on, rotate the heater control knobclockwise until the indicator light illuminates. See

Fig. 6.9. The Webasto heater requires one to twominutes to warm up before warm air is delivered.

To set the desired temperature, rotate the heatercontrol knob clockwise for warmer air, or counter-clockwise for cooler air.

To turn the heater off, rotate the heater control coun-terclockwise until it clicks and the indicator light isextinguished. The heater will initiate a two-minutecooling cycle.

Refer to the Webasto website, techwebasto.com,for additional information.

02/06/2012 f611160

Espar

81

2

3

4 5

6

7

1. Ambient Temperature Sensor2. Down Arrow Button3. Fan Button4. Fan Indicator (blue)5. Heat Indicator (green)6 Heat On/Off Button7. Up Arrow Button8. Ambient Temperature Display

Fig. 6.8, Espar Digi-Controller

10/24/2014 f611162

1

2

1. Off Position2. Heater On Indicator Light

Fig. 6.9, Webasto Heater Control Knob

Climate Controls

6.9

http://techwebasto.com

7

Seats and RestraintsSeats, General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.1Western Star High-Back Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.2Seat Belts and Tether Belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.3Sleeper Compartment Restraints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.6

Seats, General InformationUnless otherwise noted, all seat adjustments shouldbe made while seated and before the engine isstarted.

Due to the maximum adjustability of mid- and high-back air suspension seats, it is possible to combinethe seat back recline adjustment and the seat slideadjustment so that the seat back contacts the back-wall. It is the responsibility of the driver to adjust theseat to prevent damage to the seat and the cabinterior.


The following is a description of adjustments that canbe made to various Western Star seats. Not all seatshave all of the adjustments listed below. SeeFig. 7.1.


2. Lumbar Support: Lumbar support changes theshape of the seat back to give more or less sup-port to the occupant’s lumbar (lower back) area.This adjustment is either mechanical or air con-trolled, depending on make and model of theseat.


4. Height Adjustment: This adjustment moves theentire seat up or down. The adjustment is eithermanual or air-controlled, depending on the makeof the seat.



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Seats and Restraints

7.1



Western Star High-Back SeatSee Fig. 7.2 for seat adjustment controls. Not allmodels of the seat have all the adjustments listedbelow.

1. Rear Cushion Height: To adjust the height of therear of the seat cushion, remove your weightfrom the seat and turn the rear cushion adjust-ment knob to one of three positions.

2. Fore/Aft Isolator: To engage the isolator, turn theisolator knob rearward to the unlocked position.Turn the isolator knob forward to the locked posi-tion when the isolator feature is not desired.

3. Front Cushion Height: To adjust the height of thefront of the cushion, remove your weight from theseat, then turn the adjustment knob toward thefront of the seat (clockwise) to increase cushionheight. To lower the cushion height, turn the ad-justment knob toward the rear of the seat (coun-terclockwise).

4. Bottom Cushion Extension: To adjust the fore-and-aft position of the seat cushion, remove yourweight from the seat, then lift up and pull forwardon the cushion adjustment handle. To return the

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NOTE: Not all models of the seat have all the adjustment controls shown.

1. Rear Cushion Height AdjustmentKnob

2. Fore/Aft Isolator3. Front Cushion Height Adjustment

Knob

4. Bottom Cushion Extension Handle5. Fore/Aft Seat Slide Lever6. Backrest Tilt Knob7. Heater Button

8. Shock Absorber Lever9. Height Adjustment Switch10 Lumbar Support Switches

Fig. 7.2, Western Star High-Back Seat


7.2

cushion to the aft position, lift up and push rear-ward.

5. Fore/Aft Seat Slide: To adjust the fore-and-aftposition of the entire seat, move the fore-and-aftseat adjustment lever to the left and slide theseat forward or backward to the desired position.Move the lever back to its original position tolock the seat in place.

6. Backrest Tilt: To tilt the backrest, lean forwardslightly to remove pressure from the cushion,then turn the knob forward or rearward toachieve the desired position.

7. Heater: To turn on the heat option, press the but-ton. To turn off the heat option, press the buttonagain.

8. Shock Absorber: To adjust the amount of damp-ing the shock absorber provides, move the leverup to increase damping; move the lever down todecrease damping.

9. Height Adjustment: To raise or lower the heightof the seat, use the height adjustment switch onthe side of the seat.

10. Lumbar Support: To adjust the lumbar support,use the lumbar support switches on the side ofthe seat.

Seat Belts and Tether BeltsSeat belt assemblies are designed to secure personsin the vehicle to help reduce the chance of injury orthe amount of injury resulting from accidents or sud-den stops. For this reason, Daimler Trucks NorthAmerica LLC (DTNA) urges that the driver and allpassengers, regardless of age or physical condition,use seat belts when riding in the vehicle.

WARNINGAlways use the vehicle’s seat belt system whenoperating the vehicle. Failure to do so can resultin severe personal injury or death.

Seat belt assemblies in DTNA vehicles meet FederalMotor Vehicle Safety Standard 209, "Type 1" and"Type 2" requirements.

When transporting a child, always use a child re-straint system or the vehicle seat belts as appropri-ate. To determine whether a child restraint system isrequired, review and comply with applicable stateand local laws. Any child restraint used must complywith Federal Motor Vehicle Safety Standard 213,

"Child Restraint Systems." When providing a childrestraint system, always carefully read and follow allinstructions pertaining to installation and usage forthe child. Make certain the child remains in the re-straint system at all times when the vehicle is inmotion.

In addition to seat belt assemblies, tether belts areinstalled on suspension-type seats. Tether belts helpsecure the seat to the floor and are intended to re-strain the seat and seat belt in case of an accident orsudden stop.

IMPORTANT: Seat belts have a finite life whichmay be much shorter than the life of the vehicle.Regular inspections and replacement as neededare the only assurance of adequate seat beltsecurity over the life of the vehicle.

Seat Belt Inspection

WARNINGInspect and maintain seat belts. When any part ofa seat belt system needs replacement, the entireseat belt must be replaced, both retractor andbuckle side. Any time a vehicle is involved in anaccident, and the seat belt system was in use,the entire vehicle seat belt system must be re-placed before operating the vehicle. Do not at-tempt to modify the seat belt system; doing socould change the effectiveness of the system.Failure to replace worn or damaged seat belts, ormaking any modifications to the system, may re-sult in personal injury or death.

Inspect the seat belts and tether belts (if soequipped).

1. Check the web for fraying, cuts, extreme dirt anddust, or for severe fading from exposure to sun-light, especially near the buckle latch plate and inthe D-loop guide area.

2. Check operation of the buckle, latch, KomfortLatch or Sliding Komfort Latch (if equipped), webretractor, and upper seat belt mount on the doorpillar. Check all visible components for wear ordamage.

3. Check the seat belt and tether belt connectionpoints and tighten any that are loose.


7.3

Seat Belt OperationThree-Point Seat Belt

NOTE: For vehicles equipped with the KomfortLatch or the Sliding Komfort Latch, see the seatbelt operation under the heading Seat Belt WithKomfort Latch or Sliding Komfort Latch.

WARNINGWear three-point seat belts only as describedbelow. Three-point seat belts are designed to beworn by one person at a time. In case of an acci-dent or sudden stop, personal injury or deathcould result from misuse.

Fasten the seat belts before driving. Fastening athree-point seat belt while driving creates a haz-ard.

1. Slowly pull the link end of the three-point seatbelt out of the retractor and pull it across yourlap (from outboard to inboard) far enough to en-gage the buckle. If the retractor locks too soon,allow the belt to retract slightly, then slowly pull itout again.

2. Fasten the seat belt by pushing the latch into thebuckle. Listen for an audible click. See Fig. 7.3.

3. Tug on the seat belt to make sure it is securelyfastened. If the buckle unlatches, repeat thisstep. If the problem continues, replace the seatbelt.

4. Snug the seat belt to your waist.

5. Position the shoulder strap diagonally acrossyour chest with the adjustable D-loop bracket (ifequipped). The shoulder strap must be centeredon your shoulder and chest, away from your faceand neck. See Fig. 7.4.

6. To unbuckle the seat belt, press the release but-ton on the buckle. See Fig. 7.5.

NOTE: Make sure the seat belt is completelyretracted when it is not in use.

Seat Belt With Komfort Latch or SlidingKomfort Latch

NOTE: For vehicles not equipped with the Kom-fort Latch or the Sliding Komfort Latch, see the

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Fig. 7.3, Fastening the Three-Point Belt

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A B C

A. Correct—Belt is centered shoulder and chest, awayfrom face and neck.

B. Wrong—Belt must not rub against face or neck.C. Wrong—Belt must not hang off shoulder.

Fig. 7.4, Proper Shoulder Strap Fit

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Fig. 7.5, Releasing the Three-Point Seat Belt


7.4

seat belt operation under the heading Three-Point Seat Belt.



When engaged and used properly, the Komfort Latch(Fig. 7.6) and the Sliding Komfort Latch (Fig. 7.7)introduce a small amount of slack into the seat belt,resulting in a more comfortable ride.

1. Slowly pull the link end of the seat belt out of theretractor and pull it across your lap (from out-board to inboard) far enough to engage thebuckle. If the retractor locks too soon, allow thebelt to retract slightly, then slowly pull it outagain.




WARNINGBefore activating the Komfort Latch or the Slid-ing Komfort Latch, make sure the amount ofslack in the shoulder strap is set as describedbelow. 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 acrossyour chest with the adjustable D-loop bracket (ifequipped). The shoulder strap must be centeredon your shoulder and chest, away from your faceand neck. See Fig. 7.4. If desired, engage theKomfort Latch or Sliding Komfort Latch as fol-lows.

If equipped with a Sliding Komfort Latch, makesure that the shoulder strap is snug against yourchest. Without loosening the shoulder strap,push the Sliding Komfort Latch switch to the"ON" position. See Fig. 7.7. To activate the latchlean forward until you hear a click. This will allowfor approximately 1 inch (2.5 cm) of slack be-tween your chest and the shoulder harness.Once engaged, the latch will allow you to leanforward about 5 inches (13 cm) without having to

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A. Disengaged B. Engaged

Fig. 7.6, Komfort Latch

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Fig. 7.7, Sliding Komfort Latch


7.5

reset the latch. Leaning forward more than 5inches (13 cm) will disengage the Sliding Kom-fort Latch, requiring it to be reset.

If equipped with a Komfort Latch, pull on theshoulder strap to lessen the pressure of the strapon your shoulder and chest. Allow no more than1 inch (2.5 cm) of slack between your chest andthe shoulder harness. More slack can signifi-cantly reduce the seat belt effectiveness in anaccident or a sudden stop. While holding the beltslack, press the Komfort Latch lever up, clamp-ing the seat belt webbing (Fig. 7.8 and Fig. 7.9).

6. Unbuckle the seat belt and release the KomfortLatch or the Sliding Komfort Latch as follows.

If equipped with a Sliding Komfort Latch, un-buckle the seat belt (Fig. 7.5), then tug on theshoulder belt to release the Sliding KomfortLatch, or press the Sliding Komfort latch to the"OFF" position, then unbuckle the seat belt.

If equipped with a Komfort Latch, unbuckle theseat belt (Fig. 7.5), then release the KomfortLatch by giving the shoulder belt a quick tug. Ifyou lean forward against the shoulder belt, theKomfort Latch will automatically release, and willneed to be reset.

NOTE: Neither the Komfort Latch nor the SlidingKomfort Latch need to be manually released inan emergency situation. Each will release byitself under rough road or other abnormal condi-tions. Make sure the seat belt is completely re-tracted when it is not in use.

Sleeper CompartmentRestraintsOn vehicles equipped with a sleeper compartment,bunk restraints should be used whenever the sleepercompartment is occupied and the vehicle is moving.Restraints are designed to lessen the chance of in-jury or the amount of injury resulting from accidentsor sudden stops.

Bunk Restraint Adjustment1. Make sure the belt is attached to the bunk sup-

port and sleeper wall.

2. To lengthen the belt, tip the link end downwardand pull the link until it connects with the buckle.

3. After the belt is connected, shorten it by pullingon the loose end until the belt is snug, but com-fortable. Be sure the belts are not twisted. SeeFig. 7.10.

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A. 1 Inch (2.5 cm) Maximum

Fig. 7.8, Adjusting Shoulder Harness Clearance,Komfort Latch

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Fig. 7.9, Locking the Komfort Latch


7.6

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A. Pull on the loose end to shorten the belt.1. Belt2. Connector

3. Release Buckle

Fig. 7.10, Bunk Restraint Adjustment


7.7

8

Cab and Sleeper FeaturesWindows and Mirrors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.1Cab Amenities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.1Sleeper Amenities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.3

Windows and MirrorsPower MirrorsThe outside mirrors are mounted on the cab. Thereis a primary rear view mirror and a convex mirror onboth the driver and passenger sides. The mirrors arecontrolled by a switch pad located on the overheadconsole. See Fig. 8.1.

One or both outside mirrors may be heated to clearfog, frost, or ice. To defog the mirrors, press theupper half of the mirror defog switch (MIRRORDEFOG). See Fig. 8.2. When the mirror defog switchis on, the status bar illuminates. To turn off heat tothe mirror(s), press the lower half of the switch.

Down-View MirrorA down-view mirror is installed on the door frame toprovide the driver a view of the area adjacent to theside of the cab. See Fig. 8.3.

WindowsPower windows are operated by switches (POWERWINDOW) located on the door. See Fig. 8.4.

To raise the window, press the upper half of theswitch. To lower the window, press the lower half ofthe switch.

Cab AmenitiesWestern Star vehicles are available with many op-tional features. The following are some of thoseoptions.

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Fig. 8.1, Power Mirror Switch Pad

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MIRRORDEFOG

To defog the mirror(s), press the upper half of the switch.To turn off heat to the mirror(s), press the lower half ofthe switch.

Fig. 8.2, Mirror Defog Switch

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f602531

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Fig. 8.3, Down-View Mirror

Cab and Sleeper Features

8.1

Cigar Lighter/Accessory PlugsThe cigar lighter/accessory plug (Fig. 8.5) is locatedon the lower right-hand dash panel, above the igni-tion switch. The ash tray is located to the left of thecigar lighter. Optional 12V receptacles may be lo-cated on the dash.

To activate the cigar lighter, push in the elementknob. It will pop out when heated. Grasp the elementknob and pull it out of the socket.

To remove the ash tray, push down on the centerbar, and swing outwards. To install the ash tray, in-sert in the opening then swing upwards until the barsnaps into place.

Cup HoldersA dual cup holder with a cell phone holder, standardin the sleeper cab and optional in the day cab, is lo-cated below the right-hand dash control panel.

Glove BoxThe glove box (Fig. 8.6) is located on the right sideof the dash face, and is equipped with a lock. To lockthe latch, insert the key in the lock, and turn it 1/2-turn clockwise. Remove the key. To unlock the latch,insert the key in the lock, and turn it 1/2-turn counter-clockwise.

The glove box door is hinged at the bottom. To openthe unlocked door, push the button in with yourthumb and pull gently on the tang-style latch. Thedoor will swing downwards, then stop in the openposition. To close the door, swing it upwards, and putgentle pressure on the latch. The door will be se-cured, but not locked.

Electronic Device MountSome vehicles may be equipped with an optionalelectronic device mounting station and 12-volt outleton the dash. The standard bolt pattern allows themounting of a variety of devices including navigationsystems, cell phone holders, portable music players,and other electronic devices. Mounting systems canbe found at www.ram-mount.com.

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1. Door Lock Switch2. Right-Hand Power Window Switch3. Left-Hand Power Window Switch

Fig. 8.4, Door Lock and Power Window Switches

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1. Ash Tray 2. Cigar Lighter

Fig. 8.5, Ash Tray and Lighter

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1. Glove Box 2. Fuse/Relay Panel

Fig. 8.6, Passenger-Side Dash Panels


8.2

http://www.ram-mount.com

Cab LightingSee Chapter 4 for detailed information regarding cablighting controls.

Storage AreasSome vehicles may have a storage bin and a glovebox located on the right-hand side of the overheadconsole (Fig. 8.7). The storage bin has an elasticmesh cover to keep objects in place. Map pocketsare molded into the lower portion of the driver andpassenger doors.

Sleeper AmenitiesWestern Star sleepers are available with many op-tional features. The following are some of thoseoptions.

NOTE: See Chapter 6 for detailed informationregarding sleeper climate controls and the digi-tal clock.

Baggage Compartment DoorsTo unlock, insert the baggage door key in the lockand turn counterclockwise 1/4-turn. Push the button,and the latch will spring open. To lock, press thelatch in, turn the key clockwise 1/4-turn, then removethe key. If the baggage compartment door is un-locked, it can be opened simply by pushing thebutton.

Sleeper LightingThe sleeper is equipped with two dome lamps, afloor courtesy light, and swivel reading lamps. Thebaggage compartment is equipped with LH and RHcompartment lights. Depending on vehicle configura-tion, the sleeper may also be equipped with domelamps under the rear shelf, a swivel task lampmounted on the cabinet, and a pull-out desk lamp.See Fig. 8.8.

Dome Lamps and Sleeper Courtesy LightThe ceiling dome lamps and the floor courtesy lightare operated by the sleeper lights switches on thesleeper control panel and the dash. The under-shelfdome lamps are operated by pushing on the lens.

Reading LampsThe swivel reading lamps are operated with a rockerswitch on the lamp.

Baggage Compartment LightsThe baggage compartment lights are activated byopening or closing the baggage compartment door,raising and lowering the bunk, or toggling the switchon the sleeper control panel (if equipped).

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Fig. 8.7, Overhead Console Area 05/19/2015 f602557

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1. Dome Lamps2. Task Lamp3. Reading Lamp

4. Under-Shelf DomeLamps

Fig. 8.8, Sleeper Lighting


8.3

Task LampThe task lamp is operated by rotating the end of thelamp canister.

Sleeper DoorNOTE: The sleeper door is not intended forentry or exit. The door is intended only as aconvenient means to stow or remove personalbelongings in the sleeper area.

To open the sleeper door, reach behind the latchcover at the rear upper corner, locate the flat handle,and push down.

IMPORTANT: The sleeper doors have two-stagelatching. When closing the doors, ensure thatthey are completely latched to prevent windnoise and water intrusion.

Sliding Side WindowThe sliding side window is locked with an over-centertoggle lever. When unlocked, the window may beadjusted to suit.

VentThe air vent is operated using a simple, over-centerlatch. The vent will open in two directions. Push theknob firmly forward or back to open. The center posi-tion is closed.


8.4

9

Electrical SystemVehicle Power Distribution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.1Battery Disconnect Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.1Battery Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.2Low Voltage Disconnect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.2Inverter/Charger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.3

Vehicle Power DistributionThere are three standard power distribution modules(PDMs) on vehicles that are compliant with EPA10and newer regulations: the dash electrical panel, thepowertrain PDM, and the powernet distribution box(PNDB). See Fig. 9.1 for the typical location of thepowertrain PDM located in the engine compartment.

IMPORTANT: The cover on the powertrain PDMunit must be in place to protect against watersplash and dust intrusion.

The powertrain PDM houses many of the fuses andrelays for the engine, transmission, and aftertreat-ment system (ATS). There is a label on the cover ofthe powertrain PDM identifying the fuses and relays.

The PNDB houses up to three MIDI fuses and fourATO fuses. A label on the cover of the PNDB identi-fies the fuses.

Vehicles may also be equipped with a secondaryPNDB. The secondary PNDB sources power to anyof 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 truckbody equipment)

The main PDMs are located inboard of thepassenger-side glove box. Access to the PDMs isachieved by removing the four screws that securethe panel cover. See Fig. 9.2and Fig. 9.3.

Battery Disconnect SwitchYour Western Star vehicle may be equipped with acab load disconnect switch (CLDS).

The optional CLDS (Fig. 9.4) is used to minimizedraw on the battery, and should be set to OFF whenthe vehicle is parked for an extended period of time.

When the CLDS is set to OFF, it signals the PNDB todisconnect battery power to the circuits powered bythe MIDI fuses.

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1. Powertrain PDM

Fig. 9.1, Powertrain PDM Location

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1. Glove Box 2. PDM Cover Panel


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1. PDM 1 2. PDM 2

Fig. 9.3, Main PDMs

Electrical System

9.1

The CLDS is mounted on the underdash cover, out-board of the steering column.

IMPORTANT: The ignition should be turned OFFbefore using the CLDS.

Battery AccessThe batteries on a Western Star vehicle may be lo-cated in a variety of locations, including under thepassenger seat, under the cab, behind the cab, orunder the sleeper bunk, if equipped. Some vehiclesmay have two batteries in the step compartments onboth sides of the vehicle.

Low Voltage DisconnectThe Low Voltage Disconnect (LVD) system protectsthe batteries from excessive discharge by discon-necting certain isolated circuits from battery powersupply if necessary. See Table 9.1. This allows thebatteries to maintain acceptable charge to restart thevehicle. The LVD is integrated into PDM 1. SeeFig. 9.3.

Isolated CircuitsFunction Key Position

PDM 112V Power Receptacle 1, Dash OFF/ACC/IGN*

12V Power Receptacle 2, Dash OFF/ACC/IGN12V Power Receptacle 1, Sleeper OFF/ACC/IGNCB Radio OFF/ACC/IGN*

Dome Lamp, Cab, Dome/Reading OFF/ACC/IGNDome Lamp, Sleeper OFF/ACC/IGNDome Lamp, Floor Lamp, Sleeper OFF/ACC/IGN


Fuel Water Separator Heater Element IGNMirror Heat, Driver IGNMirror Heat, Hood-Mounted IGNSpare Power Feed 1 IGNSpare Power Feed 2 IGNUtility Lamp OFF/ACC/IGN

PDM 212V Power Receptacle 2, Sleeper OFF/ACC/IGN12V Power Receptacle 3, Sleeper OFF/ACC/IGNAir Dryer ACCAmplifier Power ACCSleeper/Cab Auxiliary Heater/ParkedHVAC OFF/ACC/IGN*

Auxillary Circulation Fan, Windshield ACCAuxilliary/Thermo Coolant Heater OFF/ACC/IGN*

Heated Seat ACCNavigation System ACCOptional Switch 1 OFF/BAT/IGN†

Optional Switch 2 OFF/ACC/IGN†









Radio ACCRefrigerator OFF/ACC/IGN*

Sleeper HVAC Controller, Wake-Up ACCSleeper HVAC Fan Motor ACCSpare Power Feed 3 ACCSpare Power Feed 4 OFF/ACC/IGN* Option to move fuse to remove the function from the LVD bus.† Option to move fuse to BAT to remove the function from the LVD bus.

Table 9.1, Isolated Circuits

If battery voltage drops to the trip point (12.3 or 12.1volts, determined by the vehicle configuration), theLVD system implements a shut-down. At 70 secondsbefore the disconnect, an alarm beeps and the lowbattery indicator light on PDM 1 flashes green. Thealarm beeps again at 9 and 3 seconds before thedisconnect. If no action is taken, the LVD system willshut off power to the circuits, and a red low batteryindicator remains lighted.

These circuits will remain off until the LVD systemmeasures 13.0 volts applied to the system, which

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Fig. 9.4, Cab Load Disconnect Switch

Electrical System

9.2

can be achieved by starting the engine. After the en-gine is started, the system will reset.

Vehicles are equipped with an LVD label on thedrivers-side sun visor, indicating the presence of thesystem.

Inverter/ChargerThe optional Freedom HF Inverter/Charger powerssmall appliances and other electric equipment. It islocated in the driver-side luggage compartment. SeeFig. 9.5. The unit has one three-pin GFIC OUT con-nector, one three-pin GFIC IN connector, and two ACpower outlets.

There are two models available for the Western Star:

• 1000W: 1000 watt, 20-amp

• 1500W: 1500 watt, 40-amp

DANGERDo not store gasoline, flammable material, or anycomponent with a connection to the fuel systemin the storage compartment with the inverter/charger. The unit contains equipment that mayproduce sparks. Storing flammable or electricalequipment in proximity to the unit could result infire or explosion hazards, which could result inserious injury or death.

The display on the sleeper control panel providesinformation about the operation of the unit. SeeFig. 9.6. Refer to Table 9.2 for details on the displaypanel.

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Fig. 9.5, Inverter/Charger

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543

7

2

6

1. Power2. LED Display3. Select4. Input Voltage LED

5. Input Current LED6. Output Power LED7. Status LED

Fig. 9.6, Inverter/Charger Display Panel (1000W shown)

Electrical System

9.3

Display Panel FunctionsNumber Name Function

1 Power

Press the power button for one second to turn on the unit.

Press and hold the button for five seconds to enter the feature settings mode, thenpress the button to toggle between the following modes:

• Charging Current Setting

• Inverter Mode Setting

• Alarm Setting

• Shutdown Setting

• Factory Setting

Refer to the owner’s manual for more information.2 LED Display The LED display screen shows status information and fault codes.

3 Select

The Select button changes the display or settings.

Press the Select button to cycle through the setting options. Press and hold theSelect button for five seconds to save the setting. Refer to the owner’s manual formore information.

• In "Inverter Mode Setting" press the button to turn the inverter mode ON orOFF.

• With the inverter mode ON, press the button to choose what appears on theLED display screen: Input Voltage, Input Current, or Output Power. Details areprovided below.

NOTE: The unit is in "Inverter Mode" when shore power is not present and theunit is using the battery to power the appliances connected to it.

• In an alarm condition, press and hold the button for two seconds to disable orenable the audible alarm.

• In "Charging Current Setting" mode, press the button to select the chargercurrent.

4 Input Voltage LED In inverter mode, when Input Voltage is selected, the corresponding LED will light upand the display will show the input voltage.

5 Input Current LED In inverter mode, when Input Current is selected, the corresponding LED will light upand the display will show the input current.

6 Output Power LED In inverter mode, when Output Power is selected, the corresponding LED will light upand the display will show the output power.

Electrical System

9.4


7 Status

The color of the Status light indicates the unit’s mode of operation:

• Green: Utility (Shore Power Mode)

A solid green light indicates that the battery is fully charged.

A flashing green light indicates that the unit is charging the battery.

• Yellow: Battery (Inverter Mode)

A solid yellow light indicates that the unit is using the battery to supply ACpower.

A flashing yellow light indicates that the unit is in inverter mode, but that ACshore power is detected and is transferring to shore power mode within 20seconds.

• Red: Fault Condition

The fault status light indicates a fault condition with the unit. Refer to theowner’s manual for fault code information and troubleshooting procedures.

Table 9.2, Display Panel Functions

For more information about troubleshooting, settings,and other features, refer to the owner’s manual in-cluded with the inverter/charger.

Electrical System

9.5

10

Engine Starting, Operation,and Shutdown

Engine Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.1Engine Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.1Engine Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.3Engine Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.3

Engine StartingThis engine chapter is to serve as a guide for bestpractices only. Each engine model may have operat-ing characteristics that are unique to that particularengine, and will be documented in the engine manu-facturer’s literature. Always refer to specific instruc-tions and recommendations from the engine manu-facturer.

NOTE: Before starting the engine, read Chap-ter 3 for detailed information on how to read theinstruments and see Chapter 4 for detailed in-formation on how to operate the controls. Readthe engine manufacturer’s operating instructionsbefore starting the engine.

WARNINGNever pour fuel or other flammable liquid into theair inlet opening in the air intake in an attempt tostart the vehicle. This could result in a flash firecausing serious personal injury or propertydamage.

1. Before engine start-up, complete the engine pre-trip inspection and maintenance procedures inChapter 23.

2. Set the parking brake.

3. For manual transmissions, place the transmis-sion in neutral and fully depress the clutch pedal.Do not depress the accelerator pedal.

For automatic transmissions, put the transmis-sion in neutral. Do depress the accelerator pedal.

NOTICEIf the warning lights stay on, or do not come onmomentarily after turning on the ignition, do notoperate the engine. To do so may result in enginedamage.

4. Turn the ignition switch to the ON position. Thebuzzer will sound for three seconds.

During cold conditions, the START BLOCKEDlamp may illuminate. Wait until the lamp goes outbefore turning the ignition key to START.

NOTE: The length of time the STARTBLOCKED lamp remains illuminated dependson the ambient temperature. The lower the am-bient temperature, the longer the lamp will beilluminated.

NOTE: The engine electronics supply the cor-rect amount of fuel for starting the engine. Ac-celerator pedal pressure is unnecessary andcould interfere with engine starting.

5. Turn the ignition key to the START position. Donot depress the accelerator pedal.

Release the key the moment the engine starts.

6. Apply load gradually during the warm-up period.

NOTICEDo not rev the engine if the oil pressure gaugeindicates no oil pressure. Shut down the enginewithin approximately ten seconds to avoid enginedamage.

7. Check the oil pressure gauge for any drop in lu-bricating oil pressure or mechanical malfunctionin the lubricating oil system.

Cold-Weather StartingSee the engine manufacturer’s operation manual forstarting aids that are approved for specific engines.

Starting After Extended ShutdownBefore engine start-up, complete the engine pretripinspection and maintenance procedures in Chap-ter 23.

NOTICEFailure to eliminate water-diluted lubricating oilmay lead to serious engine damage at startup.

An engine in storage for an extended period of time(over winter, for example) may accumulate water inthe oil pan through normal condensation of moistureon the internal surfaces of the engine. Oil diluted bywater cannot provide adequate bearing protection atstart-up. For this reason, change the engine oil andfilters after extended storage.

Engine OperationSafety and EnvironmentalConsiderationsAll engines on Western Star vehicles comply with therequirements of the Federal (U.S.) Clean Air Act.

Engine Starting, Operation, and Shutdown

10.1

Once an engine is placed in service, the responsibil-ity for meeting both state and local regulations is withthe owner/operator.

IMPORTANT: Depending upon local jurisdic-tional emissions guidelines, vehicles that aredomiciled outside of the U.S. and Canada maynot have engines and/or emissions aftertreat-ment systems that are compliant with EPA07,EPA10, GHG14, or GHG17 regulations.

NOTICEIt is extremely important that the following guide-lines be followed for engines that comply withEPA07 or newer regulations, or damage mayoccur to the aftertreatment device, and the war-ranty may be compromised.

• Use ultralow-sulfur diesel with 15 ppm sul-fur content or less.

• Do not use fuel blended with used enginelube oil or kerosene.

• Use only engine lube oil with a sulfated ashlevel less than 1.0 wt%; currently referredto as CJ-4 oil.

A Top Tier™ compliant fuel is recommended. Look forthe symbol that denotes a Top Tier compliant fuel;see Fig. 10.1.

Adequate maintenance of the engine and the dieselparticulate filter (DPF) are the responsibility of theowner/operator, and are essential to keep the emis-sion levels low. Good operating practices, regularmaintenance, and correct adjustments are factorsthat will help keep emissions within the regulations.

The driver should be familiar with the vehicle warningsystem in order to bring the vehicle to a safe stop ifthe engine malfunctions. If the driver doesn’t under-stand how the warning system works, an engineshutdown could occur, causing a safety hazard. SeeChapter 11 for more information.

Engine Break-InEach engine must pass a full-load operating test ona dynamometer before shipment, thereby eliminatingthe need for a break-in. Before running the enginefor the first time, follow the instructions in the enginemanufacturer’s operation manual specific to yourengine.

Normal Operation

WARNINGDo not operate the engine in an area where flam-mable vapors such as gasoline or diesel fumesare present. Shut off the engine when in an areawhere flammable liquids or gases are beinghandled. Failure to observe these precautionscould result in serious injury or death.

Every engine has an operating range in which it per-forms most efficiently. The operating range extendsfrom maximum torque rpm at the low end, to enginerated speed at the high end. Most engines deliverbest fuel economy when operated in the low- andmid-speed segments of the efficiency range and pro-duce maximum horsepower at rated speed, which isalso the recommended maximum speed of the en-gine. For further engine-specific information, refer tothe engine manufacturer’s operation manual.

Prolonged idling of engines is not recommended, andis illegal in some states. Idling produces sulfuric acid,that is absorbed by the lubricating oil, and eats intobearings, rings, valve stems, and engine surfaces. Ifyou must idle the engine for cab heat or cooling, usethe high idle function of the cruise control switches.An idle speed of 900 rpm should be enough to pro-vide cab heat in ambient temperatures that areabove freezing.

If the engine is programmed with the idle shutdowntimer, ninety seconds before the preset shutdowntime, the CHECK engine light will begin to flash at arapid rate. If the position of the clutch pedal or ser-vice brake changes during this final ninety secondsthe idle shutdown timer will be disabled until reset.

Cold-Weather OperationSatisfactory performance of a diesel engine operatingin low ambient temperatures requires modification ofthe engine, surrounding equipment, operating prac-tices, and maintenance procedures. The lower thetemperature, the greater the amount of modificationrequired. For service products approved for use in

f47069804/27/2017

Fig. 10.1, Top Tier Fuel Symbol


10.2

cold weather for your engine, see the engine manu-facturer’s engine operation manual.

If satisfactory engine temperature is not maintained,maintenance costs will increase due to greater en-gine wear. If the engine coolant gets too cold, rawfuel will wash the lubricating oil off the cylinder wallsand dilute the crankcase oil, causing all moving partsof the engine to suffer from poor lubrication.

If the engine is in good mechanical condition and theprecautions necessary for cold-weather operation aretaken, ordinary cold weather will not cause difficultyin starting or loss of efficiency.

The following points are important to observe whenoperating in cold weather:

• Check for cracks in the batteries, for corrosionof the terminals, and for tightness of the cableclamps at the terminals.

• Charge the batteries to full capacity. Replacedamaged batteries.

• If equipped, turn off the load disconnect switchafter the engine is shut down, to prevent bat-tery discharge.

• Have the alternator output checked at an au-thorized service provider.

• Check the condition and tension of the drivebelts.

• Refer to the engine manufacturer’s operationmanual for recommended heaters, low-viscosity lubricating oils, winter-grade fuels,and approved coolants.

NOTICEFor Detroit engines, use of a winterfront is notrecommended, as it can cause false fault codeswith the engine and aftertreatment system, andpossible emission component failures.

If using a winterfront, leave at least 25% of the grilleopening exposed in sectioned stripes that run per-pendicular to the charge-air-cooler tube-flow direc-tion. This assures even cooling across each tube,and reduces header-to-tube stress, and possiblechance of component failure.

Using a winterfront can cause excessive fan runtime, increased fuel consumption, and failure of theDEF system heaters to operate correctly, resulting infault codes, poor performance, and power reduction.A winterfront should only be used temporarily in thefollowing situations:

• To improve cab heating while idling in an ex-tremely cold ambient temperature;

• When the ambient temperature remains below-22°F (-30°C) and the engine is unable tomaintain a running coolant temperature of175°F (80°C) during normal over-the-road op-eration.

Engine Shutdown1. With the vehicle stopped, set the parking brake

and place the transmission in neutral.

NOTICEIdle the engine one to two minutes before shut-ting it down. After hard operation, shutting downthe engine without idling may cause damage tothe turbocharger.

2. Allow the engine to idle one to two minutes be-fore shutting it down.

NOTICEExcept in an emergency, do not shut down theengine when the coolant temperature is above194°F (90°C). To do so could damage the engine.

3. Turn off the ignition switch and shut down theengine.

Engine CoolingThe cooling system used on all Western Star ve-hicles is a pressure type system. This raises thecoolant boiling point, permitting higher operating tem-peratures. The coolant supplied in your vehicle willbe a 50/50 mix of antifreeze and water, giving protec-tion down to –35°F (–37°C). It is recommended thatan antifreeze mixture be used at all times, as, in ad-dition to providing frost protection, it is a more effec-tive coolant, and has a higher boiling point than tapwater.

Over-concentration of antifreeze or coolant condi-tioner can cause silicate to precipitate out of thecoolant, forming silica gel on cooling system heattransfer surfaces (fuel coolers, oil coolers, radiators,and heater cores), resulting in reduced coolant flowand overheating.

Hard water (with high levels of calcium and magne-sium ions) encourages formation of silica gel. Do notuse softened water as the salt used to artificially


10.3

soften it is corrosive. Most engine manufacturers pre-fer the use of distilled or de-ionized water to reducethe potential and severity of silicate dropouts.

Never exceed a 60/40 antifreeze-to-water ratio. If thelevel is low, add a 50/50 antifreeze solution to main-tain solution concentrations. Note that checking theengine coolant level is part of the pretrip inspection.See Chapter 23 for more information.


10.4

11

Optional Engine SystemsEngine Protection—Warning and Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.1Engine Idle Limiting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.2Power Takeoff (PTO) Governor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.2

Engine Protection—Warningand ShutdownThe driver should be familiar with the vehicle warningsystem in order to bring the vehicle to a safe stop ifnecessary. If the driver doesn’t understand how thewarning system works, the driver may not be able toutilize the advantage of the advance warning systemto pull over appropriately.

The engine will begin a warning and derate and/orshutdown process if the engine coolant temperature,coolant level, engine oil pressure, or exhaust after-treatment system (ATS) reach preset levels. Onsome engines, the warning process will begin whenthe engine oil temperature, engine coolant tempera-ture, or the intake air temperature reach preset lev-els. Detroit™ engines may also begin the warningand shutdown process if water is detected in the fuel.

See the engine manufacturer’s operation manual forspecific details for your vehicle. See Chapter 12 forthe warning and shutdown modes associated withthe ATS.

Electronic engine protection can be specified as ei-ther SHUTDOWN or WARNING and DERATE.

WARNINGWhen the STOP engine or CHECK engine lampilluminates, most engines are programmed toshut down automatically within 30 seconds. Thedriver must immediately move the vehicle to asafe location at the side of the road to preventcausing a hazardous situation that could causebodily injury, property damage, or severe damageto the engine.

In SHUTDOWN mode, the red STOP engine lampwill illuminate when the problem is serious enough toreduce power or speed. See Fig. 11.1. Engine powerwill ramp down, then the engine will shut down if theproblem continues while in derate mode. The driverhas 30 or 60 seconds (depending on the critical faulttype) after the STOP engine lamp illuminates tomove the vehicle safely off the road. If the vehiclecannot be moved to a safe location within that time,turn the ignition switch to OFF for at least five sec-onds, then restart the engine. Repeat this action untilthe vehicle is safely off the road.

Do not operate the vehicle further until the problemcausing the shutdown has been corrected.

Some vehicles may have a shutdown overrideswitch, which can be used to momentarily overridethe shutdown sequence. This switch resets the shut-down timer, restoring power to the level before thederate. The switch must be pressed again after fiveseconds to obtain a subsequent override. SeeFig. 11.2.


Detroit engines may begin a warning and derate pro-cess if water is detected in the fuel, or if engine cool-ant temperature is high. In WARNING and DERATEmode, the CHECK engine, STOP engine, or MILlamp will illuminate to indicate an engine problemthat requires service and the engine controls willbegin a derate of engine output. Continuing to runthe engine while it is in derate mode could causesevere damage to the engine.

07/09/2009 f6110361 2 3

CHECK STOP

1. Malfunction Indicator Lamp (MIL)2. CHECK Engine Lamp3. STOP Engine Lamp

Fig. 11.1, Engine Warning Lamps

08/19/2014 f611274

SHUTDOWNOVERRIDE

Fig. 11.2, Shutdown Override Switch

Optional Engine Systems

11.1

Engine Idle LimitingIdle Shutdown TimerThis feature is an optional 1- to 100-minute idle shut-down system. Its purpose is to conserve fuel byeliminating excessive idling, and allowing a turbo-charger cool-down period. Idle shutdown timing andparameters are programmable. See the enginemanufacturer’s operation manual for specific detailsfor your vehicle.

The idle shutdown system requires that the transmis-sion be in neutral with the parking brake set.

California Engine Idle LimitingIn order to meet the California Air Resources Board(CARB) engine idle limit, vehicles are equipped withan engine idle shutdown feature. The automatic shut-down feature is required on all California-certifiedengines (with the exception of engines used in spe-cific vehicle types that are exempt from the require-ment). Owners that wish to have the shutdown fea-ture disabled on vehicles operating in Californiashould consult with California authorities to determineif their vehicle qualifies for the exemption.

When the CARB engine idle limiting feature is en-abled, the engine will typically shut down after fiveminutes of continuous idling with the transmission inneutral or park, and the parking brake set. It will alsoshut down after 15 minutes with the transmission inneutral or park, and the parking brake off. See theengine manufacturer’s operation manual for specificdetails for your vehicle.

Changing the position of the brake pedal, clutchpedal, accelerator pedal, shutdown override switch,or parking brake during the final 30 seconds willcause the shutdown timer to reset. After an auto-matic shutdown, the engine may be restarted andoperated normally.

Power Takeoff (PTO) Governor

WARNINGTo avoid injury, do not install a PTO that is notDetroit Diesel approved onto a Detroit™ Trans-mission. Use of a non-Detroit Diesel approvedPTO with a Detroit Transmission could result inunintended operation which could lead to severepersonal injury.

Engine power takeoffs (PTO) tap into engine powerto run auxiliary devices, such as hydraulic pumpsthat power additional equipment. The following aregeneral guidelines for operating a PTO.


2. Press the dash PTO switch. Release the switchwhen the light begins to blink.

When the light illuminates steadily, the PTO isengaged and ready to operate. In stationarymode, the vehicle must remain in neutral with theparking brake set.

3. To activate mobile mode, shift from neutral toreverse, 1st, or 2nd gear. The clutch will openand the PTO will disengage for a moment.

4. Touch the accelerator pedal to close the clutchand engage the PTO in mobile mode. The PTOmay be operated with the transmission in neutralor reverse, and 1st and 2nd gears only.


5. To deactivate mobile mode, bring the vehicle to astop. The clutch will open and shut down powerto the PTO.


7. To deactivate PTO, press the PTO switch again.When the light in the switch goes out, power tothe PTO is shut off.


11.2

12

Emissions and FuelEfficiency

Greenhouse Gas Emissions and Fuel Consumption Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.1EPA-Regulated Emissions Aftertreatment Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.1Diesel Exhaust Fluid and Tank, EPA10 and Newer Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.3

Greenhouse Gas Emissionsand Fuel ConsumptionStandardsVehicles and/or engines manufactured after Decem-ber 31, 2006 and domiciled in the U.S. or Canadaare required to meet all EPA and NHTSA regulationseffective as of the vehicle build date. Engines manu-factured between January 1, 2007 and December 31,2009 meet EPA07 requirements. Engines manufac-tured between January 1, 2010 and December 31,2012 meet EPA10 requirements. Engines manufac-tured from January 1, 2013 meet NHTSA and EPA2014 fuel efficiency and greenhouse gas emissionstandards (GHG14) requirements. Engines manufac-tured from January 1, 2016 meet NHTSA and EPA2017 fuel efficiency and greenhouse gas emissionstandards (GHG17) requirements.

Model year 2013 and later vehicles meet additionalrequirements as specified by GHG14 requirements.Model year 2017 and later vehicles meet similar re-quirements as specified by GHG17 requirements.These vehicles are equipped with components thatincrease fuel efficiency and reduce GHG emissions.Components may include, but are not limited to, low-rolling resistance tires; aerodynamic devices such ashood, cab/sleeper extenders, and fuel tank fairings;vehicle speed limiter; and idle shutdown timer. If re-placement of any drag-reducing component is re-quired, the replacement component must meet orexceed the drag reduction performance of the origi-nally installed component in order to maintain compli-ance with GHG14 and GHG17 requirements.

EPA-Regulated EmissionsAftertreatment SystemsIMPORTANT: Depending on local jurisdictionalguidelines, vehicles that are domiciled outside ofthe U.S. and Canada may not have emissionsaftertreatment systems (ATS) that are compliantwith EPA regulations.

NOTICEFollow these guidelines for engines that complywith EPA07 or newer regulations, or damage mayoccur to the aftertreatment device (ATD) and thewarranty may be compromised.



• Engine lube oil must have a sulfated ashlevel less than 1.0 wt %; currently referredto as CJ-4 oil.

IMPORTANT: Using non-specification fuels oroils can lead to shortened diesel particulate filter(DPF) cleaning or replacement intervals. Forexample, using CJ-4+ oil with 1.3% sulfated ash(30% more ash content) may result in the needfor DPF cleaning or replacement 20 to 30%sooner than would normally be required.

IMPORTANT: See the engine manufacturer’soperation manual for complete details and op-eration of the ATS.

EPA07 EnginesEngines built between January 1, 2007 and Decem-ber 31, 2009 are required to meet EPA07 guidelinesfor reduced exhaust emissions of particulate matterand nitrogen oxides (NOx). NOx is limited to justover 1 gram per brake horsepower hour (g/bhp-hr),and particulate matter cannot exceed 0.01 g/bhp-hr.

The EPA07 ATS varies according to engine manufac-turer and vehicle configuration, but the exhaust muf-fler is replaced by an aftertreatment device (ATD).Inside the ATD, the exhaust first passes over the die-sel oxidation catalyst (DOC), then passes throughthe diesel particulate filter (DPF), which traps sootparticles. The soot is burned to ash during a processcalled regeneration (regen).

EPA10 and Newer EnginesThe EPA mandates that all engines built after De-cember 31, 2009 must reduce the level of emissionsexhausted by the engine to the following levels:

• Nitrogen Oxides (NOx) – 0.2 g/bhp-hr

• Particulate Matter (PM) – .01 g/bhp-hr

To meet EPA guidelines, engines that are compliantwith EPA10 and newer regulations use an ATS thathas, in addition to a DOC/DPF device like that usedin an EPA07 ATD, a Selective Catalytic Reduction(SCR) devide to reduce NOx downstream of the en-gine. After exhaust gases leave the DPF, a controlledquantity of diesel exhaust fluid (DEF) is injected intothe exhaust stream. In the presence of heat, DEF isconverted to ammonia gas, which reacts with NOx in

Emissions and Fuel Efficiency

12.1

the selective catalyst chamber to yield nitrogen andwater vapor, which exit through the tailpipe.

RegenerationThe harder an engine works, the better it disposes ofsoot. If the exhaust temperature is high enough, aprocess called passive regeneration (regen) occursas the vehicle is driven normally. However, if the en-gine isn’t running hot enough, the electronic controlsmay initiate an active regen, whereby extra fuel isinjected into the exhaust stream to superheat andreduce the soot trapped in the DPF to ash. Activeregen happens only when the vehicle is movingabove a certain speed, determined by the enginemanufacturer. See your engine operation manual forcomplete details. Both active and passive regen hap-pen automatically, without driver input.

WARNINGActive regeneration can occur automatically any-time the vehicle is moving. The exhaust gas tem-perature could reach 1500°F (800°C), which is hotenough to cause a fire, heat damage to objectsor materials, or personal injury to persons nearthe exhaust outlet. The exhaust temperature canremain 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 maybe damaged or injured by exposure to high heat.

See Regen Switches, below, for instructions onpreventing automatic regen if necessary.

When operating conditions do not allow for ATD filtercleaning by active or passive regen, the vehicle mayrequire a driver-activated parked regen. When thisoccurs, the DPF lamp illuminates, indicating that aregen is required. The driver must either bring thevehicle up to highway speed to increase the load(thus starting an active regen), or park the vehicleand initiate a parked regen. See Regen Switches,below, for instructions on initiating a parked regen.

Regen SwitchesThe regen request switch, located on the dash, isused to initiate a parked regen. See Fig. 12.1, item1. The function of the switch varies by the enginemake and model in the vehicle. See the engine op-eration manual for switch operation details.

Some vehicles may be equipped with a regenrequest/inhibit switch. See Fig. 12.1, item 2. To stopa regen in progress or prevent the start of a regen,press the lower half of the switch. Regen is then de-layed until the switch is no longer active.

NOTE: The regen switch can initiate a parkedregen only when the DPF lamp is illuminated.

WARNINGDuring parked regen, exhaust temperatures arevery high and could cause a fire, heat damage toobjects or materials, or personal injury to per-sons near the exhaust outlet.

Before initiating a parked regen, make certain theexhaust outlets are directed away from struc-tures, trees, vegetation, flammable materials, andanything else that may be damaged or injured byprolonged exposure to high heat.

To initiate a parked regen, perform the followingsteps.

1. Park the vehicle away from all flammable materi-als, put the transmission in neutral, and set theparking brake.

2. Start and warm the engine until the coolant tem-perature is at least 150°F (66°C).

3. Press and hold the regen switch for five sec-onds. The engine will increase rpm and initiatethe regen process. As the regen process is initi-ated, engine rpm increases and the HEST lampilluminates to indicate extremely high exhausttemperatures.

08/07/2014 f6112581 2




12.2

IMPORTANT: The driver must remain with thevehicle during the entire regen cycle.

4. The regen cycle will finish after 20 to 60 minutes,at which time engine idle speed drops to normaland the vehicle can be driven normally. TheHEST lamp is extinguished when vehicle speedexceeds 5 mph (8 km/h) or the system hascooled to normal operating temperature.

5. To stop a parked regen at any time during theprocess:

• depress the clutch pedal, brake pedal, oraccelerator pedal;

• press and hold the regen inhibit switch untilidle returns to normal;

• shut down the engine.

ATS Warning LampsThere are three warning lamps that alert the driver ofhigh exhaust temperature, the need to perform aparked regen or service the DPF, or of an enginefault that affects emissions. A decal attached to thedriver’s sun visor explains the ATS warning lamps.See Fig. 12.2.

See Fig. 12.3 for an explanation of the ATS warn-ings, and actions required to avoid engine protectionsequences.

Malfunction Indicator Lamp (MIL)A steadily illuminated yellow malfunction indicatorlamp (MIL) indicates an engine fault that affects theemissions. See Fig. 12.4.

DPF LampWhen soot accumulates in the DPF and the DPF sta-tus lamp illuminates, see Fig. 12.5, perform a parkedregen or bring the vehicle up to highway speed toincrease the load (thus starting an active regen).

If the DPF status lamp blinks while the CHECK en-gine lamp is illuminated, initiate a parked regen im-mediately in order to prevent an engine derate.

If the red STOP engine lamp illuminates with theblinking DPF lamp and the CHECK engine lamp,begin a parked regen in order to prevent an engineshutdown. Park the vehicle and perform a parkedregen.

High Exhaust System Temperature(HEST) LampSlow (10-second) flashing of the high exhaust sys-tem temperature (HEST) lamp indicates that aparked regen is in progress, and the engine’s highidle speed is being controlled by the engine software,not the vehicle driver.

Steady illumination of the HEST lamp alerts thedriver of high exhaust temperature during the regenprocess if the vehicle speed is below 5 mph (8 km/h), or during a parked regen. See Fig. 12.6.

MaintenanceAuthorized service facilities must perform any DPFservice. For warranty purposes, maintain a recordthat includes:

• date of cleaning or replacement;

• vehicle mileage;

• particulate filter part number and serial number.

Diesel Exhaust Fluid and Tank,EPA10 and Newer EnginesDiesel Exhaust FluidDiesel exhaust fluid (DEF) is used in the ATS tolower NOx in the exhaust stream. DEF is colorlessand close to odorless (it may have a slightly pungentodor similar to ammonia). It is nontoxic, nonflam-mable, and biodegradable. It is mildly corrosive toaluminum, but does not affect the strength or struc-ture of the aluminum.

White crystals may be noticeable around compo-nents that come into contact with DEF. The crystalsare easily removed with water.

DEF consumption varies depending on ambient con-ditions and vehicle application.

Freezing ConditionsDEF freezes to slush at around 12°F (-11°C). It is notdamaged or destroyed if frozen, and is fully usablewhen thawed. The DEF in the tank is allowed tofreeze while a vehicle is non-operational. At start-up,normal operation of the vehicle is not inhibited if theDEF 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.


12.3

DEF TankEngines that are compliant with EPA10 and newerregulations are equipped with a DEF tank located onthe driver’s side of the vehicle behind the battery boxor forward of the fuel tank. See Fig. 12.7. The DEFtank has a 19 mm filler neck inlet that prevents thehose from a diesel outlet from being inserted, andhas a blue cap for easy identification.

Fuel/DEF GaugeThe diesel fuel and DEF levels are measured in adual-purpose gauge. See Fig. 12.8.

Fuel level is indicated at the top of the gauge. Belowthe fuel level, a low fuel warning lamp illuminatesamber when the fuel level drops below 1/8th of thecapacity.

The lower portion of the gauge has a DEF warninglamp that illuminates amber when the DEF tank isnear empty, and a lightbar that indicates the level ofDEF in the tank. The DEF light bar illuminates as fol-lows.

• Four bars illuminated green—Between 75%and 100% full

• Three bars illuminated green—Between 50%and 75% full

• Two bars illuminated green—Between 25%and 50% full

• One bar illuminated green—Between approxi-mately 10% and 25% full

• One bar illuminated amber—DEF very low, re-fill DEF

• One bar flashing red—DEF empty, refill DEF

DEF Warnings and Engine LimitsIMPORTANT: Ignoring the DEF warning lightsresults in limited engine power, with the applica-tion of a 5 mph (8 km/h) speed limit.

DPF Regen Needed

Hot Exhaust

DEF Refill Needed







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

IMPORTANT

DEF

11/30/2010 f080161

1

2

3

Fig. 12.2, Warning Lamp Decal, Sun Visor


12.4

DEF Level Low—Initial WarningWhen the DEF level is low, the following lamps notifythe driver. See Fig. 12.9. Refill the DEF tank in orderto cancel the warning sequence.

• One bar of the DEF level indicator illuminatesamber—DEF very low, refill DEF.

• The DEF warning lamp illuminates solid amber.

DEF EmptyWhen the DEF level reads empty, the followinglamps notify the driver. See Fig. 12.10.

f080147


Switch.

Level 1 Level 3Level 2 Level 4Filter RegenerationRecommended

Filter is reaching


Filter RegenerationNecessary


To avoid enginederate bring vehicle



Vehicle must beparked and a Parked

Parked Regeneration Required −Engine Shut Down

Filter has exceededmaximum capacity

Vehicle must be parked and aParked Regeneration or Service


CHECK CHECK

(Flashing)

INDICATORLAMP(S)



Required Action

capacity. .

STOP

See Engine Operator’s Manual for complete Regeneration Instructions.

allow for an AutomaticRegeneration orperform a ParkedRegeneration.

to highway speedsto allow for anAutomaticRegeneration orperform a ParkedRegeneration assoon as possible.

Regeneration mustbe performed −engine will beginderate.

Regeneration must be performed.Check engine operator’s manualfor details −engine will shut down.


06/29/2009

24−01583−000B

WARNING


Exhaust Componentsand exhaust gas areat high temperature. When stationary, keepaway from people andflammable materialsor vapors.


Flashing

Solid


09/25/2006 f610814a

Fig. 12.4, Malfunction Indicator Lamp (MIL)

09/25/2006 f610815a

Fig. 12.5, Diesel Particulate Filter (DPF) Status Lamp

09/25/2006 f610816a

Fig. 12.6, High Exhaust System Temperature (HEST)Lamp


12.5

• One bar of the DEF level indicator flashesred—DEF empty, refill DEF.

• The DEF warning lamp flashes amber.

• The MIL lamp illuminates.

Power is limited with progressively harsher enginepower limits applied.

DEF Tank Empty and IgnoredIf the empty warning is ignored and the DEF tank isnot refilled, the red STOP engine lamp illuminates inaddition to the MIL lamp and CHECK engine lamp

(on vehicles with a Cummins ISB or ISC/L engine.)See Fig. 12.11.

If the DEF is not refilled, a 5 mph (8 km/h) speed

limit is applied after the next engine shutdown, whileparked and idling, or if a fuel refill is detected.

DEF Contamination or SCR Tampering

NOTICEOnce contaminated DEF or tampering has beendetected, the vehicle must be taken to an autho-rized service facility to check the SCR system fordamage and to deactivate the warning lights andengine limits.

10/01/2014 f490495

1

1. DEF Fill Cap

Fig. 12.7, DEF Tank Location

11/08/2010 f611037

B

1/2ULTRA LOW SULFURDIESEL FUEL ONLY

E F

DEF

FE


E F

DEF

FE


E F

DEF

FE

A C

1 2

A. Green bars—DEF level indicatorsB. One bar illuminated amber—DEF very low, refill DEF

C. One bar flashing red—DEF empty, refill DEF

1. Low Fuel Warning Lamp 2. DEF Warning Lamp

Fig. 12.8, Fuel/DEF Gauge

A

B

07/09/2009 f470537

A. DEF Warning Lamp (illuminated)B. DEF Lightbar (one bar amber)

Fig. 12.9, DEF Level Low Initial Warning


12.6

If contaminated DEF or tampering with the ATS isdetected, the DEF warning light flashes and the MILlamp illuminates to warn the driver. The CHECK en-gine lamp also illuminates on vehicles with a Cum-mins ISB or ISC/L engine. See Fig. 12.11.

• Detroit engines: Engine power is limited withprogressively harsher limits applied. If the faultis 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, whileparked and idling, or if a fuel refill is detected.

• Cummins engines: Engine power is limited withprogressively harsher limits applied. If the faultis 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 whileparked and idling.

A

B

11/08/2010 f470539a

NOTE: MIL illuminates. CHECK engine lamp illuminatesif Cummins ISB or ISC/L engine. Engine power is lim-ited.A. DEF Warning Lamp (flashing)B. DEF Lightbar (one bar flashing red)

Fig. 12.10, DEF Empty Warning

A

B

11/08/2010 f470540a

NOTE: STOP engine light and MIL illuminate, enginepower is limited, speed limit of 5 mph (8 km/h)A. DEF Warning Lamp (flashing)B. DEF Lightbar (one bar flashing red)

Fig. 12.11, DEF Empty and Ignored Warning


12.7

13

Brake SystemsAir Brake System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.1Meritor WABCO® Antilock Braking System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.4Engine Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.5

Air Brake SystemBrake System General InformationA dual air brake system consists of two independentair systems that use a single set of brake controls.Each system has its own reservoirs, plumbing, andbrake chambers. The primary system operates theservice brakes on the rear axle; the secondary sys-tem operates the service brakes on the front axle.Service brake signals from both systems are sent tothe trailer.

WARNINGDo not operate the vehicle with the front brakesbacked off or disconnected. Backing off or dis-connecting the front brakes will not improve ve-hicle handling and may lead to loss of vehiclecontrol, resulting in property damage or personalinjury.

Brake System ComponentsThe warning light and buzzer come on if air pressuredrops below approximately 70 psi (483 kPa) in eithersystem. See Table 13.1. If this happens, check theair pressure gauges to determine which system haslow air pressure. Although the vehicle’s speed can bereduced using the foot brake control pedal, either thefront or rear service brakes will not be operating atfull capacity, causing a longer stopping distance.Bring the vehicle to a safe stop and have the air sys-tem repaired before continuing.

IMPORTANT: In the event of a total loss of ser-vice brakes with full system air pressure, usethe parking brake control valve (yellow knob) tobring the vehicle to a complete stop in the saf-est location possible.

Brake System Warning and Indicator LampsLamp Description Color

Low Air Pressure Indicates air pressure in the primary or secondary reservoirhas dropped below approximately 70 psi (483 kPa). Red

Parking Brake Indicates the parking brake is engaged. Red

Vehicle ABS



Amber

Trailer ABS



Amber




Amber


Table 13.1, Brake System Warning and Indicator Lamps

Brake Systems

13.1

Before a vehicle with insufficient system air pressurecan be moved, the spring parking brakes must bereleased by applying an external air source at thegladhands, or by manually caging the parking brakesprings.

WARNINGDo not release the spring parking brakes andthen drive the vehicle. There would be no meansof stopping the vehicle, which could result in se-rious personal injury or vehicle damage. Beforereleasing the spring parking brakes, make theconnection to a towing vehicle or chock the tires.

After correcting the brake system problem, uncagethe spring parking brakes before resuming normalvehicle operation.

Primary Air Brake SystemLoss of air pressure in the primary air system causesthe rear service brakes to become inoperative. Thesecondary air system will continue to operate thefront brakes and the trailer brakes (if equipped).

Secondary Air SystemLoss of air pressure in the secondary air systemcauses the front service brakes to become inopera-tive. The primary air system will continue to operatethe rear service brakes and the trailer brakes (ifequipped).

Brake System OperationBefore driving your vehicle, allow time for the aircompressor to build up a minimum of 100 psi (689kPa) pressure in both the primary and secondarysystems. Monitor the air pressure system by observ-ing the air pressure gauges and the low-air-pressurewarning light and buzzer. The warning light andbuzzer shut off when air pressure in both systemsreaches approximately 70 psi (483 kPa).

IMPORTANT: Before driving the vehicle, secure allloose items in the cab so that they will not fly forwardduring a full brake application. Make sure all passen-gers are wearing seat belts.

During normal brake stops, depress the foot brakecontrol pedal until braking action slows down the ve-hicle. Increase or decrease the pressure on thepedal so that the vehicle comes to a smooth, safestop. Apply the spring parking brakes if the vehicle isto be parked.

IMPORTANT: An air brake proportioning systemmay be used in tractor air brake systems whenthe vehicle is not equipped with an antilockbraking system (ABS). When operating in bob-tail mode, the rear brake chambers (on whichthe axle load has been greatly reduced) receivereduced (proportional) air pressure, while thefront axle brake chambers receive full (normal)air pressure. This results in a different brakepedal "feel," as the pedal seems to require moretravel and/or effort to slow or stop the vehicle.However, the air brake proportioning systemactually improves vehicle control when the trac-tor is in bobtail mode. When the tractor is tow-ing a trailer, the rear brake chambers will re-ceive full (normal) application air pressure.

When parking a vehicle attached to a trailer thatdoes not have spring parking brakes, apply the trac-tor parking brakes. Chock the trailer tires before dis-connecting the vehicle from the trailer.

WARNINGIf a trailer or combination vehicle is not equippedwith 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 causingan unattended runaway vehicle.

NOTICENever apply the service and spring parkingbrakes simultaneously. To do so transmits exces-sive input force to the brake components, whichcould damage or cause eventual failure of brakeactuating components.

Brake ControlsThe trailer brake lever (hand control valve) is usedfor applying the trailer brakes without applying thetruck or tractor service brakes. It is usually mountedon the right-hand control panel. See Fig. 13.1. Thevalve can be partially or fully applied, but in any par-tially on position it will be overridden by a full applica-tion of the service brake pedal. Moving the leverdown applies the trailer brakes, while moving it upreleases the trailer brakes. The lever will automati-cally return to the up position when it is released.

Brake Systems

13.2

WARNINGDo not use the trailer service brakes for parking;they are not designed for this purpose. If airbleeds out of the trailer air tank during parking,the vehicle could roll, causing serious personalinjury or property damage.

The red octagonal-shaped knob in the control panelactuates the trailer air supply valve. See Fig. 13.2.After the vehicle’s air hoses are connected to atrailer and the pressure in both air systems is at least65 psi (448 kPa), the trailer air supply valve must bepushed in. It should stay in to charge the trailer airsupply system and to release the trailer spring park-ing brakes.

Pull the trailer air supply valve out before disconnect-ing a trailer or when operating a vehicle without atrailer. If pressure in both air systems drops to 35 to45 psi (241 to 310 kPa), the trailer air supply valveautomatically pops out, exhausting the trailer air sup-ply, and applying the trailer service or spring parkingbrakes.

The yellow diamond-shaped knob in the controlpanel actuates the parking brake valve. SeeFig. 13.2. Pulling out the parking brake valve appliesboth the tractor and trailer spring parking brakes andautomatically causes the trailer air supply valve topop out.

NOTICEDo not use the spring parking brakes if the ser-vice brakes are hot, such as after descending asteep grade. To do so could damage the brakes.Allow hot brakes to cool before using the springparking brakes.

Do not use the spring parking brakes duringfreezing temperatures if the service brakes arewet. To do so could cause them to freeze. If thebrakes are wet, drive the vehicle in low gear andlightly apply the brakes to heat and dry them.

If the trailer is not equipped with spring parkingbrakes, pulling out the parking brake valve appliesthe tractor spring parking brakes and the trailer ser-vice brakes. When the tractor and trailer parkingbrakes (or trailer service brakes) are both applied,the trailer brakes are released by pushing in thetrailer air supply valve, leaving the tractor parkingbrakes applied. Air pressure in the primary or sec-ondary reservoir must be at least 65 psi (448 kPa)before the tractor spring parking brakes, or the trailerservice or spring parking brakes, can be released.

Automatic Slack AdjustersAutomatic slack adjusters should never be manuallyadjusted except during routine maintenance of thefoundation brakes (e.g., replacing shoes), duringslack adjuster installation, or in an emergency situa-tion.

When the brake pushrod stroke exceeds the legalbrake adjustment limit on a vehicle, there is likely amechanical problem with the foundation brake com-ponents or the adjuster is improperly installed.

Visit a repair facility as soon as possible whenbrakes equipped with automatic slack adjusters aredetermined to be out of adjustment.

WARNINGManually adjusting an automatic slack adjuster tobring the pushrod stroke within legal limits islikely masking a mechanical problem. Adjustmentis not a repair. Before adjusting an automatic

f61059102/03/2017


f61029102/02/2017

12

1. Trailer Air-Supply-Valve Knob2. Parking-Brake-Valve Knob

Fig. 13.2, Brake Valve Knobs

Brake Systems

13.3

slack adjuster, troubleshoot the foundation brakesystem and inspect it for worn or damaged com-ponents. Improperly maintaining the vehicle brak-ing system may lead to brake failure, resulting inproperty damage, personal injury, or death.

Meritor WABCO® AntilockBraking SystemThe Meritor WABCO Antilock Braking System (ABS)is an electronic wheel speed monitoring and controlsystem that works with the standard air brake sys-tem. ABS passively monitors vehicle wheel speed atall times, and controls wheel speed during emer-gency stops.

IMPORTANT: For proper ABS system operation,do not change tire sizes. The sizes of the tiresinstalled during production are programmed intothe electronic control unit. Installing different-sized tires could result in a reduced brakingforce, leading to longer stopping distances.

ABS includes signal-generating tone wheels and sen-sors located in the wheel hubs of each sensedwheel. The sensors transmit vehicle wheel speedinformation to an electronic control unit (located be-hind the center dash). The control unit’s main circuitinterprets the speed sensor signals and calculateswheel speed, wheel retardation, and a vehicle refer-ence speed. If the calculations indicate wheel lockup,the main circuit signals the appropriate modulatorvalve to reduce braking pressure. During emergencybraking, the modulator valve alternately reduces, in-creases, or maintains air pressure supply in thebrake chamber to prevent front and rear wheellockup.

The electronic control unit (ECU) also has a safetycircuit that constantly monitors the wheel sensors,traction control valve (if equipped), modulator valves,and the electrical circuitry.

The Meritor WABCO ABS combines one front-axlecontrol channel with one rear-axle control channel toform one control circuit. For example, the sensor andmodulator valve on the left-front axle form a controlcircuit with the sensor and modulator valve on theright-rear axle. If, during vehicle operation, the safetycircuit senses a failure in any part of the ABS, thevehicle ABS warning lamp (see Table 13.1) illumi-nates and the control circuit where the failure oc-curred is switched to normal braking action. The re-maining control circuit will retain the ABS effect. Evenif the ABS is completely inoperative, normal braking

ability is maintained. An exception would be if amodulator valve (or combination modulator valve) isdamaged and inoperative. As these components arean integral part of the air brake system, normal brak-ing may be impaired or inoperative.

During emergency or reduced-traction stops, fullydepress the brake pedal until the vehicle comes to asafe stop. Do not pump the brake pedal. With thebrake pedal fully depressed, the ABS will control allwheels to provide steering control and a reducedbraking distance.

Although the ABS improves vehicle control duringemergency braking situations, the driver still has theresponsibility to change driving styles depending onexisting traffic and road conditions. For example, theABS cannot prevent an accident if the driver isspeeding or following too closely.

Trailer ABS CompatibilityThe Meritor WABCO ABS is designed to communi-cate with a trailer ABS, if they are compatible. Com-patibility will result in the illumination of the TRAILERABS lamp (see Table 13.1) during vehicle start-upand fault detection.

The TRAILER ABS lamp will not illuminate unless acompatible trailer is connected to the tractor. Thedash-mounted lamp will operate as follows when acompatible trailer is properly connected to the tractor:

• When the ignition key is turned to the ON posi-tion, the TRAILER ABS lamp will illuminate mo-mentarily, then turn off.

• If the lamp illuminates momentarily during ve-hicle operation, then shuts off, a fault was de-tected and corrected.

• If the lamp illuminates and stays on during ve-hicle operation, there is a fault with the trailerABS. Repair the trailer ABS system immedi-ately to ensure full antilock braking capability.

IMPORTANT: If a compatible trailer is con-nected, and the lamp is not illuminating momen-tarily when the ignition key is turned to the ONposition, it is possible that the lamp is burnt out.

Automatic Traction ControlVehicles with electronic engines and ABS may haveAutomatic Traction Control (ATC). On these vehicles,the ATC system automatically limits wheel spin dur-ing reduced-traction situations. In normal braking ap-plications, the standard air brake system is in effect.

Brake Systems

13.4

An additional solenoid valve is installed. Duringreduced-traction situations, the ATC solenoid valvecontrols air pressure to the modulator valves andthey in turn increase, hold, or reduce pressure to theappropriate brake chambers to provide better tractionwhenever wheel spin occurs.

When the ATC system is in the NORMAL mode, itwill apply gentle braking to the spinning wheel, tofeed power to the wheel(s) with better traction. Ifboth wheels are spinning, the system will signal theengine to reduce power.

ATC includes a deep snow and mud option to in-crease available traction on extra soft surfaces likesnow, mud, or gravel. A rocker switch labeled ATCwill be located on the dash. See Fig. 13.3. Pressingthe switch will temporarily allow more drive wheelspin. The activation of the deep snow and mud op-tion is indicated by a flashing WHEEL SPIN lamp.See Table 13.1. Pressing the switch again will cyclethe system back to normal operation.

NOTICEThe deep snow and mud option is intended to beused under specific slippery conditions that re-quire momentary increased wheel spin. Usingthis option for an extended period of time maydamage the vehicle brake system.

After the ignition switch is turned on, the vehicle ABSlamp and the WHEEL SPIN indicator lamp come onfor about three seconds. After three seconds, thewarning lights go out if all of the tractor’s ABS com-ponents are working.

IMPORTANT: If any of the ABS warning lightsdo not work as described above, or come onwhile driving, repair the ABS immediately to en-sure full antilock braking capability.

ECAS Automatic Load Transfer(ECAS only)On vehicles equipped with Electronically ControlledAir Suspension (ECAS), ECAS works in conjunctionwith ABS. When wheel slippage is detected by theABS, the ECAS system transfers weight from the tagaxle to the drive axle by changing air pressures inthe suspension air bellows, increasing drive wheeltraction.

The ECAS Load Transfer feature is optimized toapply the maximum available vehicle load on thedrive axle, up to the maximum allowable limit, deter-mined by the gross axle weight rating (GAWR). Inbobtail or with a loaded trailer less than the GAWR,the tag axle supports a negligible load while the driveaxle supports nearly the full weight. Above theGAWR, the drive axle is loaded with approximatelythe maximum allowable load and the tag supportsthe remainder.


Load transfer mode will automatically deactivatewhen the vehicle reaches 45 mph (72 kmh).

Engine BrakeEach engine manufacturer uses a specific enginebrake for their engine. Regardless of the manufac-turer, the engine brake is operated with the principlesoutlined here. Refer to the engine manufacturer’soperation manual for details of their particular enginebrake product.

WARNINGTo avoid injury from loss of vehicle control, donot activate the engine brake system under thefollowing conditions:

• on wet or slippery pavement, unless thevehicle is equipped with antilock braking

08/08/2014 f611262

DEEP MUDAND SNOW

ATC


02/04/2015 f611291


Brake Systems

13.5

system (ABS) and you have had prior expe-rience driving under these conditions;

• when driving without a trailer or pulling anempty trailer;

• if the tractor drive wheels begin to lock, orthere is fishtail motion after the enginebrake is activated.

NOTE: When the engine brake is enabled, theengine brake lamp illuminates in the instrumentpanel. See Table 13.1.


WARNINGUsage of the engine brake as the primary brakingsystem can cause unpredictable stopping dis-tances, that could result in personal injury orproperty damage. Service brakes are the primaryvehicle braking system.

Since the engine brake is most effective at rated en-gine speed, gear selection is very important. Gearingdown the vehicle within the limits of the rated enginespeed makes the engine brake more effective. Rec-ommended engine braking speed is above 1800 rpmand below the rated speed.

WARNINGThe engine brake must be disengaged whenshifting gears using the clutch pedal. If the en-gine brake is engaged when the transmission isin neutral, the braking power of the engine brakecan stall the engine, which could result in loss ofvehicle control, possibly causing personal injuryand property damage.

"Control speed" is the speed at which the enginebrake performs 100 percent of the required downhillbraking, resulting in a constant speed of descent.The control speed varies, depending on vehicleweight and the downhill grade.

For faster descent, select a higher gear than thatused for control speed. Service brakes must then beused intermittently to prevent engine overspeed andto maintain desired vehicle speed.

For slower descent, select a lower gear, being care-ful not to overspeed the engine. Occasional deactiva-tion of the engine brake may be necessary to main-tain the designated road speed under theseconditions.

If the engine is equipped with both cruise control andan engine brake, the engine brake can operate auto-matically while cruise control is activated. The maxi-mum amount of braking is selected with the enginebrake control. When the vehicle returns to the setcruise speed, the engine brake will turn off.

The engine brake will only operate when the accel-erator and clutch pedals are fully released.

Vehicles equipped with ABS have the ability to turnthe engine brake off if wheel slip is detected. Theengine brake will automatically turn back on oncewheel slip is no longer detected.

Engine Brake Operation

NOTICEDo not allow the engine to exceed its governedspeed, or serious engine damage could result.

NOTE: Depending on the brake type, the enginebrake may be disabled when engine tempera-ture falls below a set level.

The engine brake control is located on the right-handsteering column lever. At the top position, the enginebrake is off, and at the three lower positions, the en-gine brake is on and the intensity (low, medium,high) increases with each step down. See Fig. 13.5.

NOTE: On vehicles equipped with a Detroit au-tomated transmission, setting the engine brakewith the cruise control set activates DecelerationMode. Setting the cruise control while the en-gine brake is on activates Descent ControlMode. For information on these modes, see"Cruise Control" in Chapter 4.

Brake Systems

13.6

f270164a02/17/2017

0

1

2

3

0. Off1. Low

2. Medium3. High

Fig. 13.5, Engine Brake Positions, Detroit MultifunctionControl

Brake Systems

13.7

14

Steering SystemPower Steering System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.1

Power Steering SystemThe power steering system includes the power steer-ing gear, hydraulic hoses, power steering pump, res-ervoir, steering wheel and column, and other compo-nents.

The power steering pump, driven by the engine, pro-vides the power assist for the steering system. If theengine is not running, there is no power assist.

WARNINGDriving the vehicle without the power-assist fea-ture of the steering system requires much greatereffort, especially in sharp turns or at low speeds,which could result in an accident and possibleinjury.

If the power-assist feature does not work due to hy-draulic fluid loss, steering pump damage, or anothercause, bring the vehicle to a safe stop. Do not drivethe vehicle until the cause of the problem has beencorrected.

NOTICENever steam clean or high-pressure wash thesteering gear. Internal damage to gear seals, andultimately the steering gear, can result.

Drivers should carefully use the power available witha power steering system. If the front tires becomelodged in a deep hole or rut, drive the vehicle outinstead of using the steering system to lift the tiresout of the hole.

NOTICEAvoid turning the tires when they are against acurb, as this places a heavy load on steeringcomponents and could damage them.

Steering Wheel AdjustmentWhen there is no load on the vehicle and the fronttires are pointed straight ahead, the standard steer-ing wheel spokes should be at the 3 o’clock and 9o’clock positions or within 10 degrees of these posi-tions. See Fig. 14.1.

10°

10°

1 2

10°

10°

08/19/2014 f462250

1. 9 o’Clock 2. 3 o’Clock

Fig. 14.1, Steering Wheel Centered

Steering System

14.1

15

Automated TransmissionsDetroit™ Automated Transmissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.1

Detroit™ AutomatedTransmissionsDetroit transmissions have twelve forward gears andup to four reverse gears that can be shifted automati-cally or manually. Shifting and clutch actuation arecomputer controlled, and there is no clutch pedalneeded to operate the vehicle. Automatic shifts areselected for fuel economy or engine power. Manualshifts can be requested with the shift control and thetransmission ECU grants them when conditions per-mit. In all cases, shifts depend on the following fac-tors: engine speed, accelerator pedal position, ser-vice brake usage, engine brake operation, vehicleload status, and road conditions.

NOTE: To avoid potential engine stall risk or un-expected shifting, use the interaxle differentiallock when the vehicle is operated in slipperyconditions. See Chapter 17 for informationabout the interaxle differential lock.

Detroit™ Multifunction ControlVehicles with Detroit transmissions use the controlshown in Fig. 15.1. This control can be used to re-quest manual shifts, change driving mode, and setengine brake levels. See Table 15.1 for an overviewof control functionality.

D/N/R SwitchUse the "D/N/R Switch" to request drive (D), neutral(N), or reverse (R).

Mode SwitchThe driving mode can be changed using the Modeswitch on the shift control (see Fig. 15.1). To activatethe manual drive mode, press and hold the switchbriefly. Press the switch quickly to activate the auto-matic drive mode or change between AutomaticEconomy and Automatic Performance modes.

Upshifting and DownshiftingGear shifts can be requested manually; push thelever away to request a downshift, or pull the levertoward you to request an upshift. See Table 15.1 formore information about upshift and downshiftrequests.

B

2

3

1

( + )

( − )

4

05/30/2012 f270163a

A

C

See Table 15.1 for a description of control functionality.A. Front ViewB. Shift RequestsC. Four positions for engine brake settings1. Engine Brake Symbol2. D/N/R Switch3. Mode Switch4. Gear Shift Symbol


Automated Transmissions

15.1

Functionality, Detroit Multifunction ControlFunction/Switch Action/Position Request

D/N/RD Forward gearsN NeutralR Reverse gears

ModeDepress switch and release it quickly Activate the automatic drive mode, or switch between

Automatic Economy and Automatic Performance.Depress switch and hold it briefly Activate the manual drive mode.

Upshifting andDownshifting

Pull the lever toward you momentarily Upshift, single gearPull the lever toward you in quick repetitions Upshift, multiple gearsPush the lever away momentarily Downshift, single gearPush the lever away in quick repetitions Downshift, multiple gears

Engine Brake*

Lever at position 0 (top) Engine brake offLever at position 1 Low intensityLever at position 2 Medium intensityLever at position 3 (bottom) High intensity

* For functions with cruise control active, see Chapter 4.

Table 15.1, Functionality, Detroit Multifunction Control

Engine BrakeThe engine brake is controlled by the lever position(as shown in Fig. 15.1, Ref. C). At the top position,the engine brake is off, and at the three lower posi-tions, the engine brake is on and the intensity (low,medium, high) increases with each step down. Formore information about using the engine brake, seeChapter 13.

NOTE: Setting the cruise control with the enginebrake on will activate Descent Control Mode.Moving the lever down to engage the enginebrake after the cruise control has been set willactivate Deceleration Mode. For information onthese modes, see "Cruise Control" in Chap-ter 4.

Power Up and Shift into Gear1. With the parking brake set and Neutral (N) se-

lected on the shift control, turn the ignition switchto the ON position.

2. Start the engine.

3. Apply the service brake.

4. Select the desired starting gear.

5. Release the parking brake.

6. Release the service brake and apply the accel-erator.

Gear Display WindowThe gear display window shows the current transmis-sion gear and driving mode. See Fig. 15.2.

Driving ModesThere are three driving modes: Manual, AutomaticEconomy, and Automatic Performance.

In Automatic Economy mode, gear shifts are de-signed for saving fuel. In Automatic Performancemode, gear shifts are designed for higher perfor-mance and are made at higher engine speeds. Inmanual mode, gear shifts are requested manually.See Chapter 4 for more information about upshiftingand downshifting using the control.

5A econ

07/23/2015 f611187

1

2

N70 °F

1. Driving Mode2. Current Gear

Fig. 15.2, Gear Display Window


15.2

NOTE: In Automatic Performance mode, thetransmission will automatically change to Auto-matic Economy mode if it hasn’t received a re-quest for more power in several minutes, unlesscurrent road conditions require higher engineperformance.

Selected GearIf the selected gear is different than the current gearfor longer than a half second, the current gear dis-play will flash and the selected gear value will beshown. Once the current gear and selected gearmatch, the selected gear display disappears and thecurrent gear display stops flashing. See Fig. 15.3.

Suggested ShiftIn Manual mode only, a suggested shift is displayedto indicate the most economical gear available. Thesuggested shift is the number of up or down arrowsfrom the current gear with a maximum of three up ordown arrows. See Fig. 15.4.

eCoastThe eCoast feature can improve driving economy.When conditions permit, the transmission control au-

tomatically shifts the transmission to neutral to coastat speeds of approximately 22 mph (35 km/h) andabove. An "E" shows in the gear display windowwhen eCoast is in effect. See Fig. 15.5.

The eCoast function is not active when any of thefollowing occur:

• the accelerator pedal is pressed.

• vehicle acceleration rate is exceeded.

• the service brake pedal is pressed.

• the engine brake is in use.

• cruise control brakes or accelerates.

• vehicle speed exceeds the cruise control setspeed by more than approximately 4 mph (6km/h).

• the speed limiter is active and the maximumspeed set is exceeded.

• diesel particulate filter (DPF) regeneration oc-curs.

The eCoast function cannot be deactivated when theAutomatic Economy mode is active.

NOTE: To disable eCoast, see an authorizedWestern Star service facility.

Creep ModeCreep mode allows the vehicle to be maneuvered atvery slow speeds. To activate Creep mode for thefirst time within the current driving cycle, press theaccelerator pedal to launch the vehicle, thereby fullyengaging the clutch. Following this and for the dura-tion of the current driving cycle, Creep mode is ac-tive.

Once the vehicle is stopped via the service brakes,the vehicle will begin to creep again, without the ac-celerator pedal actuation, as soon as the servicebrakes are released.

07/23/2015 f611188

1

2

7

A econ

5 N70 °F

1. Selected Gear2. Current Gear

Fig. 15.3, Selected Gear Display

Manual

07/23/2015 f611189

12

5 N70 °F

1. Suggested Shift Arrows2. Current Gear

Fig. 15.4, Suggested Shift

E

07/23/2015 f611190

A econ

N70 °F

NOTE: Upshift and downshift arrows are not shownwhen "E" is shown in the gear display window.

Fig. 15.5, eCoast Display


15.3

To begin using Creep mode (once active) from aparked position, shift from neutral to either drive orreverse, release the service brakes, and briefly de-press the accelerator pedal. The vehicle’s urge tomove can then be felt.

If creep is active and no acceleration is achievedwithin five seconds, then Creep mode will abort. Adisplay message notifies the operator when Creepmode is about to be aborted.

IMPORTANT: When slowing down from higherspeeds in drive or reverse, remember thatCreep mode will be in effect at lower speeds.Use the service brakes to stop the vehicle.

Clutch Abuse ProtectionA vehicle equipped with a Detroit transmission doesnot have a clutch pedal, but still has a clutch that isoperated automatically and can be damaged by abu-sive driver actions. To protect the clutch, the vehiclehas a clutch abuse protection system that alerts thedriver and restricts functionality when needed. Ex-tended periods in Creep Mode, slipping the clutch(using the accelerator pedal to hold the vehicle on ahill, for example), and high clutch temperatures canactivate the clutch abuse protection system. A displaymessage notifies the operator when the protectionsare needed.

NOTICETo hold the vehicle stationary on an uphill slope,use the service brakes, not the accelerator pedal.

Using the accelerator pedal can overheat anddamage the clutch. To start moving, use the ac-celerator pedal and release the brakes as the ve-hicle begins to move.

There are three clutch abuse protection levels. Ateach, the driver is alerted and functionality is modi-fied; see Table 15.2.

To avoid overheating the clutch, follow these tips:

• To hold the vehicle stationary on an uphillslope, use the service brakes, not the accel-erator pedal.

• To start moving on an uphill slope, use the ac-celerator pedal and release the brakes as thevehicle begins to move.

• When hooking up to a trailer, ensure the traileris high enough to back under, and use firstgear reverse.

• Avoid starting in higher gears, and start in firstgear when a trailer is attached.

• Ensure trailer brakes have had time to com-pletely release prior to starting.

• Do not use Creep mode for an extended pe-riod. Stop or adjust the vehicle speed whenwarned to deactivate Creep mode.

Clutch Abuse Alerts and Protections

Alert Level AlertProtections

Highest Start Gear Creep Mode Clutch Function1 Heavy clutch load message 1 No restriction Normal function2 Heavy clutch load message 1 Disabled Normal function

3 Clutch overload message andbuzzer 1 Disabled

If the accelerator pedal isdepressed, the clutch closesat fixed rate.

If the accelerator pedal isreleased, the clutch opens atfixed rate.

Table 15.2, Clutch Abuse Alerts and Protections

Engine Overspeed AlertsTo help protect the engine, the system has displaymessages to notify the operator when the engine has

exceeded certain thresholds and needs to be sloweddown before significant engine damage occurs.There are two warnings, one at about 2400 rpm and


15.4

another at 2500 rpm, indicated with messages and afault code.

Low Transmission Air WarningPneumatic controls are used to shift the transmis-sion. If there is inadequate air pressure, a warning isdisplayed and the quality of gear shifts may be de-graded. Wait for air pressure to build before operat-ing the vehicle.

IMPORTANT: If the low transmission air warningindicator appears while the vehicle is in opera-tion, safely pull the vehicle off the road, and cor-rect the problem.


15.5

16

Manual Transmissions andClutch

Eaton® Fuller® Transmission Operation Tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.1Eaton Fuller 13-Speed and 18-Speed Splitter and Range-Shift Transmissions . . . . . . . . . . . . . . . 16.1Eaton Fuller 10-Speed Range-Shift Transmissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.4Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.5

Eaton® Fuller® TransmissionOperation TipsNOTE: Refer to the Eaton website (www.road-ranger.com) for additional information.

Follow these important operation principles:

• For all conditions, use the highest gear that isstill low enough to start the vehicle moving withthe engine at or near idle speed, and withoutslipping the clutch excessively.

When operating on-highway with no load orunder ideal conditions, use 1st gear to start thevehicle moving forward.

When operating off-road or under adverse con-ditions, use LOW gear to start the vehicle mov-ing forward.

• Use the clutch brake to stop gear rotationwhen shifting into LOW or reverse while thevehicle is stationary. The clutch brake is actu-ated by depressing the clutch pedal all the wayto the floor.

• Partially disengage the clutch to break enginetorque during normal gear shifts.

• Double-clutch between all upshifts and down-shifts that require movement of the shift knob.Splitting of gears does not require movementof the shift knob.

• Never push the range-preselection lever downinto low range while operating in high range,except when downshifting from 5th gear to 4thgear.

• Do not shift from high range to low range athigh vehicle speeds.

• Never make a range shift or a splitter shiftwhile the vehicle is in reverse.

• Never move the range-preselection lever withthe transmission in neutral while the vehicle ismoving.

• Skip ratios while shifting only when operatingconditions permit, depending on the load,grade, and road speed.

• Never coast with the transmission in neutral.

Eaton Fuller 13-Speed and 18-Speed Splitter and Range-ShiftTransmissionsNOTE: Refer to the Eaton website for additionalinformation, www.roadranger.com.

General Information, Eaton FullerSplitter and Range-ShiftTransmissionsCombination splitter and range-shift transmissionsallow the choice of two splitter ratios in each leverposition as well as the additional ratio provided ineach lever position after shifting to the other range.

IMPORTANT: Not all lever positions are used ineach range and the shift patterns vary betweentransmissions. Be sure to read the shift patterndecal for the specific transmission installed inyour vehicle. The shift pattern decal may befound on the shift knob, the dash, or the visor.

13-Speed RTLO ModelsEaton Fuller 13-speed transmissions have thirteenforward speeds and two reverse speeds. Each trans-mission consists of a 5-speed front section, and a3-speed auxiliary section. The auxiliary section con-tains low- and high-range ratios, plus an overdrivesplitter gear. See Fig. 16.1 for the shift pattern.

All of the 13 speeds are controlled with one shiftlever. A range preselection lever and a splitter control

f260044a02/03/2017

R1 3

2 4LOW

Dir OD

5 5

Dir OD

Dir OD Dir OD

7 7

6 6 8 8

Hi

Lo

A

B

C D

1

N

A. High RangeB. Low Range

C. Overdrive (forward)D. Direct Drive (rearward)

1. Splitter Control Button

Fig. 16.1, Eaton Fuller 13-Speed Transmission ShiftPattern

Manual Transmissions and Clutch

16.1

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button are built into the shift knob. The range prese-lection lever controls range selection and the splittercontrol button (located on the side of the shift knob)controls gear splits.

Low gear in the front section is used only as a start-ing ratio. The remaining four forward positions areused once in the low range and once in the highrange. However, each of the four high range gearpositions can be split with the underdrive ratio (RTmodels), or overdrive ratio (RTO models) of the split-ter gear. Ratios cannot be split while the transmis-sion is in low range.

18-Speed RTLO Splitter and Range-ShiftModelsEaton Fuller 18-speed transmissions have 18 forwardspeeds and four reverse speeds. These transmis-sions consisting of a 5-speed front section and a3-speed auxiliary section. The auxiliary section con-tains low and high range ratios, plus an overdrivesplitter gear.

One ratio in the front section (low) is used as a start-ing ratio; it is never used when the transmission is inhigh range. Low gear can be split to provide both adirect and an overdrive ratio.

The other four ratios in the front section are usedonce in low range and once again in high range;however, each of the five ratios (low–1–2–3–4) in lowrange and each of the four ratios (5–6–7–8) in highrange can be split with the overdrive splitter gear.

All of the 18 speeds are controlled with one shiftlever. A range preselection lever and a splitter controlbutton are built into the shift knob. The range prese-lection lever controls range selection and the splittercontrol button (located on the side of the shift knob)controls gear splits.

Operation, Eaton Fuller Splitter andRange-Shift TransmissionsIMPORTANT: The shifter knob has an interlockfeature that prevents the splitter control buttonfrom being moved forward when the range pre-selection lever is down (in low range); when inhigh range and the splitter control button is inthe forward position, the range preselectionlever cannot be moved down.

Upshifting1. Position the gear shift lever in neutral. Start the

engine, and bring the air system pressure up to100 to 120 psi (689 to 827 kPa).

2. Position the range preselection lever down, intolow range. See Fig. 16.2.

3. Make sure the splitter control button is in the di-rect (rearward) position. See Fig. 16.2.

4. For 13-speed transmissions:

Press the clutch to the floor, shift into low or 1stgear; then engage the clutch, with the engine ator near idle speed, to start the vehicle moving.Accelerate to 80 percent of engine governedspeed.

For 18-speed transmissions:

Press the clutch to the floor, shift into low; thenengage the clutch, with the engine at or near idlespeed, to start the vehicle moving.

To shift from low direct to low overdrive, movethe splitter control button into the overdrive (for-ward) position, then immediately release the ac-celerator. Press and release the clutch pedal.After releasing the clutch, accelerate again.


Shift upward from low to 1st gear, 2nd, etc. until4th gear, double-clutching between shifts, andaccelerating to 80 percent of engine governedspeed. See Fig. 16.1.


f260157a02/03/2017

N

R 1Dir

5Dir

5OD1

OD3

Dir

7Dir

7OD3

OD

2Dir

6Dir

6OD2

OD4

Dir

8Dir

8OD4

OD

LOWDir

LOWOD

A

B

C D

1






16.2

Shift upward from low overdrive to 1st direct byfirst moving the splitter control button into thedirect (rearward) position (Fig. 16.2). Move theshift lever, double-clutching, to the 1st gear posi-tion.

Continue upshifting through the shift pattern.Double-clutch during lever shifts (1st to 2nd to3rd to 4th); single-clutch during split shifts (1stdirect to 1st overdrive, etc.).

6. When in 4th gear (13-speed transmissions) or4th overdrive (18-speed transmissions) andready to shift up to 5th gear, use the range shiftlever as follows:


While in 4th gear, pull the range shift preselec-tion lever up, into high range. The transmissionwill automatically shift from low to high range asthe shift lever passes through neutral. Then, dis-engage the clutch; double-clutch through neutral;move the shift lever to 5th gear; engage theclutch, and accelerate the engine.


While in 4th overdrive, pull the range shift prese-lection lever up, into high range. The transmis-sion will automatically shift from low to highrange as the shift lever passes through neutral.

Move the shift lever, double-clutching, to the 5thgear position. Just before making final clutch en-gagement, move the splitter control button to thedirect (rearward) position; then engage the clutchand accelerate. Do not move the control buttonwhile the shift lever is in neutral.

7. Shift up through the high range gears as follows:


To shift from 5th direct to 5th overdrive, move thesplitter control button (Fig. 16.1) into the over-drive (forward) position, then immediately releasethe accelerator. Press and release the clutchpedal. After releasing the clutch, accelerateagain.

Continue upshifting through the shift pattern.Double-clutch during lever shifts (6th to 7th to8th); single-clutch during split shifts (6th direct to6th overdrive, etc.).


To shift from 5th direct to 5th overdrive, move thesplitter control button (Fig. 16.2) into the over-drive (forward) position, then immediately release

the accelerator. Press and release the clutchpedal. After releasing the clutch, accelerateagain.


Downshifting1. Downshift from 8th overdrive to 8th direct without

moving the shift lever. Flip the splitter control but-ton to the direct (rearward) position, then imme-diately release the accelerator, and disengagethe clutch. Engage the clutch, and accelerate theengine only after the transmission has shifted.

2. Start the downshift from 8th direct to 7th over-drive by flipping the splitter control button to theoverdrive (forward) position; then, immediatelydouble-clutch through neutral, moving the shiftlever from 8th to 7th gear.

3. Shift downward through each of the high rangegears, alternating the procedures in steps 1 and2, above, until reaching 5th direct.

4. While in 5th direct and ready for the downshift to4th (13-speed transmissions) or 4th overdrive(18-speed transmissions), push the range prese-lection lever down. Then, double-clutch throughneutral and move the shift lever to the 4th gearposition. On 18-speed transmissions, move thesplitter control button to the overdrive (forward)position before engaging the clutch. Do not movethe control button while the shift lever is in neu-tral.

5. Continue downshifting from 4th to 1st as follows:


Downshift through the low range gears as condi-tions require.


Continue downshifting from 4th overdrive to 4thdirect, then 4th direct to 3rd overdrive, 3rd over-drive to 3rd direct, etc. Single-clutch when splitshifting (direct to overdrive, overdrive to direct).Double-clutch when making lever shifts (4th to3rd, 3rd to 2nd, etc.).

IMPORTANT: Never use the clutch brake whendownshifting, or as a brake to slow the vehicle.


16.3

Eaton Fuller 10-Speed Range-Shift TransmissionsNOTE: Refer to the Eaton website for additionalinformation, www.roadranger.com.

General Information, Eaton FullerRange-ShiftTo operate a range-shift transmission, move the shiftlever through all the low gear positions and then acti-vate a range switch to provide an additional set ofratios in the high range. Using the same shift leverpositions as in low range, move the shift leverthrough each position as before. On some models,the initial low gear is often used only in low range.

IMPORTANT: Not all lever positions are used in eachrange and the shift patterns vary between transmis-sions. Be sure to read the shift pattern decal for thespecific transmission installed in your vehicle. Theshift pattern decal may be found on the shift knob,the dash, or the visor.

10-Speed FR/FRO and RT/RTO/RTXModelsEaton Fuller 10-speed transmissions have 10 selec-tive, evenly spaced forward ratios. Each transmissionhas a 5-speed front section and a 2-speed rearrange section. The 10 forward speeds are obtainedby twice using a 5-speed shift pattern: the first timein low range, the second time in high range. SeeFig. 16.3 for the shift patterns.

NOTE: The 4th/9th and the 5th/10th shift posi-tions in the RT (direct ratio) and RTX (overdrive

ratio) transmissions are directly opposite in theRTO (overdrive ratio) transmissions

Operation, Eaton Fuller Range-ShiftUpshifting1. Position the gear shift lever in neutral. Start the


2. Position the range preselection lever down, intolow range.

3. Press the clutch pedal to the floor; shift into lowor 1st gear (Table 16.1), then engage the clutch,with the engine at or near idle speed, to start thevehicle moving. Accelerate to 80 percent of en-gine governed speed.

Eaton Fuller Shift Progressions

TRANS.MODEL

LOW RANGE HIGHRANGEOff-Highway On-Highway

10-SpeedDirect orOverdrive

(RT orRTX)

2

3

4

1f260329

R

5

2

3

4

1f260329

R

5

9

8 10

7

f260330

R

6

Table 16.1, Eaton Fuller Range-Shift ShiftProgressions

4. Shift progressively upward from low or 1st gear,to the top gear in low range (Table 16.1),double-clutching between shifts, and acceleratingto 80 percent of engine governed speed.

5. While in the top gear of the low range shift pat-tern, and ready for the next upshift, flip the rangepreselection lever up into high range. Double-clutch through neutral, and shift into the bottomgear in high range (Table 16.1). As the shift leverpasses through neutral, the transmission will au-tomatically shift from low range to high range.

6. With the transmission in high range, shift pro-gressively upward through each of the highrange gears (Table 16.1), double-clutching be-tween shifts.

Downshifting1. With the transmission in high range, shift pro-

gressively downward to the bottom gear in highrange, double-clutching between shifts.

2. When in the bottom gear of the high range shiftpattern, and ready for the next downshift, push

f26105302/03/2017

4

N

7

2

9

6

1

8

3

10

5

R

HI

LO

A

B

A. High Range B. Low Range

Fig. 16.3, Eaton Fuller 10-Speed Transmission ShiftPatterns


16.4

www.roadranger.com

the range preselection lever down into low range.Double-clutch through neutral, and shift into thetop gear of the low range shift pattern. As theshift lever passes through neutral, the transmis-sion will automatically shift from high range tolow range.

3. With the transmission in low range, downshiftthrough the low range gears as conditions re-quire.


ClutchGeneral InformationThe hydraulic clutch control system consists of apedal unit and a slave cylinder, connected by a hy-draulic hose and fastened with quick-disconnectclamps. The components of the system have beenspecially designed to use DOT 4 brake fluid. Thepedal unit includes a hydraulic subassembly, com-posed of the master cylinder and reservoir, whichcan be removed from the pedal unit for service pur-poses. When the clutch pedal is depressed, the fluidin the master cylinder is forced through a hydraulicline to the slave cylinder. The fluid pressure movesthe slave cylinder piston, pushing the plunger rodand clutch release lever, which disengages theclutch. The hydraulic system is self-adjusting.

Clutches are designed to absorb and dissipate moreheat than encountered in typical operation. The tem-peratures developed in typical operation will notbreak down the clutch friction surfaces. However, if aclutch is slipped excessively, or asked to do the jobof a fluid coupling, high temperatures develop quicklyand destroy the clutch. Temperatures generated be-tween the flywheel, driven discs, and pressure platescan be high enough to cause the metal to flow andthe friction facing material to char and burn.

Heat and wear are practically nonexistent when aclutch is fully engaged. But during the moment ofengagement, when the clutch is picking up the load,it generates considerable heat. An improperly ad-justed or slipping clutch will rapidly generate suffi-cient heat to destroy itself.

To ensure long service life of the clutch, start in theright gear, be alert to clutch malfunctions, and knowwhen to adjust the clutch.

Clutch OperationClutch Break-InWith a new or newly installed clutch, the clutch mayslip for a short time while the friction surfaces break-in. However, allowing the clutch to slip for more thantwo seconds can severely damage the clutch disc,pressure plate, and the flywheel.

During initial operation of a new vehicle or a vehiclewith a new clutch, check for clutch slippage duringacceleration. If the clutch slips, decelerate until theclutch does not slip. Allow the clutch to cool 15 to 30seconds, and then gradually accelerate again. If theclutch continues to slip, repeat the procedure. If nec-essary, repeat the procedure up to five times. If theclutch slips after five attempts, stop the vehicle. Allowthe clutch to cool for at least one hour. Notify yourWestern Star dealer of the problem.

NOTICEDo not allow sustained slippage of the clutch;this could severely damage the clutch disc, pres-sure plate, or flywheel. Damage caused by clutchslippage due to improper break-in is not warrant-able.

Moving the Vehicle in the Proper GearAn empty truck can be started in a higher transmis-sion gear than can a partially or fully loaded truck. Agood rule of thumb for the driver to follow is to selectthe gear combination that allows the vehicle to startmoving with an idling engine, or, if necessary, justenough throttle to prevent stalling the engine. Afterthe clutch is fully engaged, the engine can be accel-erated to the correct rpm for the upshift into the nexthigher gear.

Gear Shifting TechniquesShift into the next higher gear when the vehiclespeed allows the transmission input shaft speed tomatch the flywheel speed when engaging the clutch.This technique results in the smallest speed differ-ence between the clutch disc and the flywheel andcauses the least heat and wear on the clutch assem-bly. When downshifting, the input shaft speed mustbe increased by slightly revving the engine to matchthe flywheel speed for smooth clutch engagement.For transmission operating instructions, refer to thetransmission headings in this manual.


16.5

Vehicle LoadingClutches are designed for specific vehicle applica-tions and loads. These weight limitations should notbe exceeded.

NOTICEExceeding vehicle load limits can not only resultin damage to the clutch, but can also damage theentire powertrain.

Using the ClutchThe clutch pedal must be used only to start the ve-hicle moving or while shifting. To start the vehiclemoving, depress the clutch pedal all the way to thefloor plate (see "Using the Clutch Brake") and shiftfrom neutral to a low gear. Slowly raise your foot untilthe clutch starts to engage. In this position the clutchis starting to connect the transmission input shaft tothe flywheel and is causing the most heat and wear.Slightly increase the engine speed and smoothlyallow the clutch pedal to return to its at rest position.Do not allow the clutch to remain in the partially en-gaged position any longer than necessary to obtain asmooth start.

To shift gears while the vehicle is moving, push theclutch pedal most of the way (but not all of the way)to the floor plate. Shift the transmission into neutraland fully release the clutch pedal. If upshifting, waitlong enough for the engine speed to decrease to theroad speed. If downshifting, increase the enginespeed to match the road speed. Again, push downthe clutch pedal part way and then move the shiftlever to the next gear position. Fully release theclutch pedal after completing the shift.

Slightly depressing the clutch pedal while driving isdamaging to the clutch, because partial clutch en-gagement causes slippage and heat. Resting yourfoot on the clutch pedal will also put a constant thrustload on the release bearing, thinning the bearing lu-bricant and increasing the wear on the bearing.

Using the Clutch BrakeThe clutch brake is applied by depressing the clutchpedal past the fully released clutch position, almostto the floor plate. The last part of the clutch pedaltravel will compress the clutch brake plates together,stopping the transmission input shaft. The purpose ofthe clutch brake is to stop the transmission gearsfrom rotating in order to quickly engage a transmis-sion gear after idling in neutral.

NOTICENever apply the clutch brake when the vehicle ismoving. If the clutch brake is applied when thevehicle is moving, the clutch brake will try tostop or decelerate the vehicle, causing rapidwear of the clutch brake friction discs. Consider-able heat will be generated, causing damage tothe release bearings and the transmission frontbearings.

Holding the Vehicle on an InclineAlways use the vehicle service brakes to prevent thevehicle from rolling backwards while stopped on ahill. Slipping the clutch on a hill to maintain the ve-hicle position will quickly damage the clutch assem-bly.

CoastingCoasting with the clutch pedal depressed and thetransmission in a low gear can cause high drivendisc speed. The clutch speed can be much higherunder these conditions than when the engine is driv-ing the clutch. This condition creates a hazardoussituation due to the lack of vehicle control and due tothe high clutch disc speed. Engaging the clutchunder these conditions can cause component dam-age because of the shock loads to the clutch anddrivetrain.

WARNINGAlways shift into the gear that is correct for thetraveling speed of the vehicle and engage theclutch. Coasting with the clutch disengaged canprevent engagement of the correct transmissiongear which can cause loss of vehicle control,possibly resulting in personal injury or propertydamage.

High clutch disc speeds while coasting can alsocause the clutch facing to be thrown off the disc.Flying debris from the clutch can cause injury topersons in the cab.

Clutch MaintenanceClutch AdjustmentEaton Fuller Solo clutches are adjustment-free. Asthe clutch wears, its wear-adjusting technology moni-tors clutch components and makes any necessaryadjustments. The wear adjusting technology comes


16.6

from two sliding cams, which rotate to maintain theproper adjustment. Atop the upper cam, a wear indi-cating tab mirrors the cam’s movement, letting youknow when it’s time to replace the clutch.

NOTICEOperating the vehicle with incorrect free pedalcould result in clutch damage.

Hydraulic Clutch Fluid ReservoirCheckingMake sure that the clutch fluid reservoir is full. SeeFig. 16.4. The reservoir is full when the fluid level isup to the "max" mark. The fluid level must always beabove the "min" mark. Use only heavy-duty brakefluid, DOT 4, in the clutch hydraulic system.

06/05/2007 f250664

Fig. 16.4, Clutch Fluid Reservoir


16.7

17

Drive AxlesDifferential Lock, Drive Axles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.1Interaxle Lock, Tandem Axles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.2

Differential Lock, Drive AxlesThe driver-controlled differential lock feature (side-to-side wheel lock, traction control, or traction equalizer)is available on vehicles with single- or tandem-driveaxles.

The differential lock provides maximum traction forslippery conditions by forcing the wheels on eachdrive axle governed by the switch to rotate together.When the differential lock is engaged, the clutch col-lar completely locks the differential case, gearing,and axle shafts together, maximizing the traction ofboth wheels.

Differential Lock SwitchEach differential lock is controlled by a switch on thedash. See Fig. 17.1.

Differential Lock Operation

WARNINGLocking the wheels when the vehicle is travelingdown steep grades or when the wheels are slip-ping could damage the differential and/or lead toloss of vehicle control, causing personal injuryand property damage.

NOTICEEngage the differential lock only when the ve-hicle is stopped or moving slowly at low speed,less than 5 mph (8 km/h). Engaging the differen-

tial lock at high speeds can cause internal axledamage.

NOTE: On some vehicles, the differential locksystem is connected through the low speedrange of the transmission. If this system is used,the transmission must be in the low speedrange for the wheels to fully lock. In addition,shifting out of low speed range will also disen-gage the differential lock.

NOTE: If the differential lock is engaged whenthe engine is shut down, the differential lock willdisengage.

1. With the engine running, press the upper half ofthe differential lock switch to engage the differen-tial lock.

2. If the vehicle is moving, briefly let up on the ac-celerator to relieve torque on the gearing, allow-ing the differential to fully lock.

WARNINGBe especially careful when driving under slipperyconditions with the differential locked. Thoughforward traction is improved, the vehicle can stillslip sideways, causing possible loss of vehiclecontrol, personal injury, and property damage.

3. Drive cautiously and do not exceed 25 mph (40km/h). When the differential is fully locked, theturning radius will increase because the vehicleundersteers. See Fig. 17.2.

LIFTAXLE

08/07/2014 f6112591 2 3 4



f350079a02/03/2017

A

B

A. Turning Radius When the Differential Lock isEngaged (understeer condition)

B. Turning Radius When the Differential Lock isDisengaged

Fig. 17.2, Turning Radii

Drive Axles

17.1

4. Press the lower half of the differential lock switchto disengage the differential lock after leavingpoor road conditions.

5. If the vehicle is moving, briefly let up on the ac-celerator to allow the wheels to fully unlock, thenresume driving at normal speed.

Single Drive Axles with TractionEqualizerSome single drive axles are equipped with a tractionequalizer that is a load-sensing, self-actuating fea-ture. A traction equalizer provides normal differentialaction where traction is good. When one wheel be-gins to spin faster than the other, clutch plates in thedifferential housing automatically engage, deliveringpower to both wheels. There is no operator controlwith this feature.

NOTICETire sizes on both rear wheels should be thesame on axles equipped with a traction equalizer.If not, excessive wear may occur in the tractionequalizer.

Interaxle Lock, Tandem AxlesThe interaxle lock (axle lock, interaxle differentiallockout) feature causes the drive axle shafts to rotatetogether, and is recommended for use under adverseroad conditions where greater traction is needed.

When engaged, the interaxle lock essentially makesthe driveshaft a solid connection between the driveaxles. Power entering the forward axle is transmittedstraight through to the rearmost axle(s). Drivelinetorque is now delivered equally and the drive axles,and wheels, turn together at the same speed. Theinteraxle lock increases drivetrain and tire wear andshould be used only when improved traction isrequired.

See the axle manufacturer’s website for more infor-mation.

Interaxle Lock SwitchThe interaxle lock switch (see Fig. 17.1, item 3) al-lows the driver to lock the drive axles together.

Interaxle Lock Operation

NOTICEThe interaxle lock should not be engaged on avehicle with obviously spinning wheels. Engage-ment at high speed or power can damage theaxle(s).

NOTE: If the interaxle lock is engaged when theengine is turned off, the interaxle lock will disen-gage.

1. With the engine running, press the upper half ofthe interaxle lock switch to engage the interaxlelock. Do not wait until traction is lost and the tiresare spinning before engaging the interaxle lock.

2. If the vehicle is moving, briefly let up on the ac-celerator until the interaxle lock engages. Thered interaxle indicator light illuminates on thedash message center when interaxle lock is en-gaged.

NOTICEDo not operate the vehicle continuously with theinteraxle locked during extended good road con-ditions. To do so could result in damage to theaxle gearing and excessive driveline and tirewear.

3. Proceed over poor road conditions with caution.

4. Press the lower half of the interaxle lock switchto disengage the interaxle lock after leaving poorroad conditions.

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 theinteraxle lock disengages, the indicator light willgo off.

Drive Axles

17.2

18

Fifth WheelsFifth Wheels, General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.1Fifth Wheel Coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.1Fifth Wheel Uncoupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.4Fifth Wheel Slide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.7

Fifth Wheels, GeneralInformation

WARNINGDo not use any fifth wheel that fails to operateproperly. Doing so may cause loss of vehiclecontrol, possibly resulting in severe personal in-jury or death.

Air Suspension Height Control Switch


The air suspension height control switch may beused to adjust the vehicle height to aid in coupling oruncoupling from a trailer. See Fig. 18.1. Setting theswitch to DOWN deflates the air springs to lower therear of the vehicle. In the UP position, the air springsinflate to raise the rear of the vehicle to normal rideheight.



Fifth Wheel Lubrication

WARNINGKeep the fifth wheel plate lubricated to preventbinding between the tractor and trailer. A bindingfifth wheel could cause erratic steering and lossof vehicle control, possibly resulting in personalinjury or death.

The standard fifth wheel plate must be kept well lu-bricated with chassis grease to prevent friction andbinding between the vehicle fifth wheel plate and thetrailer.

For a low-lube fifth wheel plate, inspect the conditionof the low-lube pads. There should be no damagedor missing pieces. Slight puckering at the outsideedges is normal.

For lubrication instructions, see Group 31 of theWestern Star Maintenance Manual.

Fifth Wheel CouplingFifth wheel coupling is activated with the lock controlhandle located on either the right or left side of thefifth wheel. Coupling is complete when the kingpinhas been forced into the jaws and the lock controlhandle has moved to the locked position.

NOTICESome fifth wheels may be mounted on slidingrails. Before attempting to couple a trailer to asliding fifth wheel, the slide feature must belocked to prevent the top plate from sliding rap-idly forward or rearward, causing damage to thefifth wheel or kingpin.

Coupling, Fontaine and Holland FifthWheelsNOTE: For a tractor equipped with a Jost fifthwheel, see the heading Coupling, Jost FifthWheel below.

1. Chock the front and rear trailer tires.

2. Ensure the fifth wheel jaw is fully open and theoperating rod is in the unlocked position. SeeFig. 18.2 or Fig. 18.3.

07/22/2011 f545805


Fifth Wheels

18.1

3. Make sure the fifth wheel top plate is tilted so theramps are as low as possible.

4. Position the tractor so that the center of the fifthwheel is in line with the trailer kingpin. The king-pin should be in a position to enter the throat ofthe locking mechanism.

NOTICEAttempting to couple at the wrong height maycause improper coupling, which could result indamage to the fifth wheel or kingpin.

5. Adjust the trailer height if required.

For a standard fifth wheel plate, the trailershould contact the fifth wheel approximately 4 to8 inches (10 to 20 cm) behind the fifth wheelpivot. See Fig. 18.4.

For a low-lube fifth wheel plate, the fifth wheelmust slide freely under the trailer, and the trailershould contact the fifth wheel at the pivot. SeeFig. 18.5.

6. With the fifth wheel lock opening aligned with thetrailer kingpin, back the tractor slowly toward the

trailer. After sliding under the trailer, stop to avoidhitting the kingpin too hard, then resume backingslowly until the fifth wheel locks.

For a standard fifth wheel plate, the fifth wheelmust lift the trailer.

For a low-lube fifth wheel plate, do not lift thetrailer as this may damage the fifth wheel plate.

f310110a04/06/2017

1

1

2

2

A

B

NOTE: Make sure the safety latch is down when thecontrol handle is locked.

A. Unlocked B. Locked1. Safety Latch 2. Lock Control Handle

Fig. 18.2, Fontaine Locking Mechanism

f31044704/19/2017

1

1

2

3

1. Safety Latch2. Operating Rod

(locked)

3. Operating Rod(unlocked)

Fig. 18.3, Holland Simplex SE Locking Mechanism

f31112404/28/2017

A

B

C

D

A. Fifth wheel must lift trailerB. Adjust trailer heightC. Ramps tilted downD. 4 to 8 inches (10 to 20 cm)

Fig. 18.4, Trailer Connection Point, Standard FifthWheel Plate

Fifth Wheels

18.2

7. Set the tractor parking brake.

WARNINGA visual inspection is required by law. Some im-proper couplings can pass a pull test. Sound isnot reliable. Get out of the cab and look. Incor-rect coupling could cause the trailer to discon-nect, possibly resulting in serious personal injuryor death.

8. Perform a coupling inspection, checking thatthere is no gap between the bottom of the trailerand the fifth wheel, and that the kingpin is se-curely locked. See Fig. 18.6.

When lockup has occurred, the fifth wheel con-trol handle moves to the locked position. Makesure that the safety latch is down over the lockcontrol handle to hold the control handle in thelocked position (the safety latch will only rotatedown if the operating rod is fully retracted in thelocked position). See Fig. 18.2 or Fig. 18.3.

9. Release the tractor parking brake. Test for king-pin lockup by slowly inching the tractor forward,pulling on the trailer against the chocks.

10. After lockup is completed, connect the tractor-to-trailer air system lines and the electrical cable tothe trailer. Take care to prevent dirt or foreignmaterial from entering the air system lines.

NOTICEAlways make sure the connection hanger keepsthe trailer air hoses and electrical cables posi-tioned so that they do not rub on anything. Rub-bing may wear through hoses or cables, resultingin air leaks, or exposed or broken wires, poten-tially affecting trailer brake or electrical systems.

11. Charge the air brake system and check that theair connections do not leak.

WARNINGIncorrect fifth wheel lock adjustment could causethe trailer to disconnect, possibly resulting in se-rious personal injury or death.

12. With the trailer tires chocked and the brakes set,check for clearance between the kingpin and thefifth wheel jaws by moving the tractor forwardand backward against the locked kingpin. If slackis present, uncouple the trailer and have the fifthwheel inspected and adjusted by a certifiedtechnician.

Coupling, Jost Fifth WheelNOTE: For a tractor equipped with a Fontaineor Holland fifth wheel, see the heading Cou-pling, Fontaine and Holland Fifth Wheelsabove.

1. Tilt the ramp down.

2. Open the kingpin locks. See Fig. 18.7.

3. Back the tractor close to the trailer, centering thekingpin on the fifth wheel.

4. Chock the trailer tires.

5. Connect the air lines and electrical cable.

6. Ensure that the trailer air supply valve (trailerbrake) is pulled out, and that the trailer parkingbrakes are set. See Fig. 18.8.

f31112504/28/2017

A

B

A. Adjust trailer height B. Ramps tilted down

Fig. 18.5, Trailer Connection Point, Low-Lube FifthWheel Plate

f31112604/28/2017

A B

A. No gap between trailerand fifth wheel

B. Kingpin inside lock

Fig. 18.6, Coupling Inspection

Fifth Wheels

18.3


7. Adjust the trailer height (if required).

For a standard fifth wheel plate, the trailershould contact the fifth wheel approximately 4 to8 inches (10 to 20 cm) behind the pivot. SeeFig. 18.4.


8. Back the tractor under the trailer.



9. After sliding under the trailer, stop to avoid hittingthe kingpin too hard, then resume backing slowlyuntil the fifth wheel locks.



11. Perform a physical check for positive kingpinlockup, ensuring that there is no gap betweenthe trailer and the fifth wheel. See Fig. 18.6.

12. Ensure that the release handle is in the lockedposition adjacent to the casting. See Fig. 18.9.

13. Release the tractor parking brake and test forkingpin lockup by slowly moving the tractor for-ward, pulling on the trailer against the chocks.

Fifth Wheel UncouplingManual Uncoupling1. Set the tractor and trailer parking brakes.

2. Chock the trailer rear wheels.

3. Lower the trailer landing gear until the weight isremoved from the fifth wheel.

4. Disconnect the tractor-to-trailer air system linesand electrical cable. Plug the air lines to preventdirt or foreign material from entering the lines.

5. Verify that both the parking brake and trailer airsupply knobs are out (see Fig. 18.8), the tractorand trailer parking brakes are set, and that thetrailer is prepared for uncoupling.

6. Release the kingpin locking mechanism followingthe instructions for each manufacturer listedbelow.

6.1 Fontaine: Lift the safety latch and pull thelock control handle to the unlocked posi-tion. See Fig. 18.2.

6.2 Holland: In the locked position the safetyindicator swings freely over the operatingrod. See Fig. 18.10, View A.

f31112804/28/2017

A

A. Lock held open by catch mechanism

Fig. 18.7, Jost Release Handle Unlocked

f61029102/02/2017

12

1. Trailer Air Supply Valve Knob2. Parking Brake Valve Knob


Fifth Wheels

18.4

To unlock the mechanism, manually rotatethe safety indicator toward the rear of thefifth wheel. See Fig. 18.10, View B.

Pull the operating rod out. When theupper operating rod shoulder is outsidethe slot, raise the handle and place theshoulder of the upper rod against the platecasting, above the slot. See Fig. 18.10,View C.

The fifth wheel is now in the lock positionand is ready for uncoupling. As the tractorpulls away from the trailer the kingpinforces the jaw to rotate, contacting thelock. Continued rotation of the jaw forcesthe lock to move outward, and drops theupper rod back into the slot. SeeFig. 18.10, View D. The wheel is nowready for coupling.

6.3 Jost: Pull the retractable handle out, thensecure it in the open position with thecatch. See Fig. 18.7.

7. Release the tractor parking brake, then drive for-ward slowly, allowing the trailer to slide down thefifth wheel and pick-up ramps.

Air-Actuated UncouplingAn air-actuated kingpin release valve is optional withall fifth wheels. See Fig. 18.11.

NOTE: In the event of an air system failure, air-actuated kingpins can be manually released fol-lowing the instructions for manual unlocking.

WARNINGOnce the kingpin release valve has been pulledthe kingpin lock is released. The vehicle MUSTNOT be driven with the trailer until the trailer hasbeen uncoupled and coupled again. Failure to doso may result in separation of the trailer from thetractor, possibly causing serious personal injuryor death.

Preparing the Trailer for UncouplingBefore using the air valve to unlock a fifth wheelkingpin, prepare the trailer as follows.

1. Set the tractor and trailer parking brakes.

2. Chock the rear trailer tires.


4. Disconnect the tractor-to-trailer air lines and elec-trical cable. Plug the air lines to prevent dirt orforeign material from entering the lines.

Air-Activated Kingpin Unlock, Fontaineand Holland Fifth Wheels1. Verify that both the parking brake and trailer-air

supply knobs are out (see Fig. 18.8), the tractor

f31112704/28/2017

OK OK

Fig. 18.9, Jost Release Handle Locked

Fifth Wheels

18.5

and trailer parking brakes are set, and that thetrailer is prepared for uncoupling.

NOTE: If the tractor parking brake is not set, theair-actuated kingpin-release valve will not acti-vate.

2. Pull and hold the kingpin release valve(Fig. 18.11) until the kingpin lock mechanismopens and locks in place.

3. Let go of the kingpin release valve.

4. Release the tractor parking brake.

5. Drive out from under the trailer.

Air-Activated Kingpin Unlock, Jost FifthWheels1. Verify that both the parking brake and trailer air


11/02/2010 f311133

A

B

C

D

1

2

3

4

A. Locked PositionB. 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 Indicator2. Operating Rod

3. Upper Rod4. Plate Casting

Fig. 18.10, Holland Kingpin Locking Mechanism

Fifth Wheels

18.6


NOTE: If the trailer parking brake is not set, theair-actuated valve will not activate.


3. Pull and hold the kingpin release valve, thendrive forward slowly.

4. After the trailer has slid down the fifth wheel andpick-up ramps, let go of the kingpin releasevalve.

Fifth Wheel Slide

WARNINGAdjust the fifth wheel slide correctly, and do notoverload any tractor axle by incorrectly loadingthe trailer. Incorrect slide adjustment or improperaxle loading could cause erratic steering andloss of vehicle control, possibly resulting in seri-ous personal injury or death.

On sliding fifth wheel assemblies, the fifth wheelplate 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 areevenly spaced along the slide rails, and retractablewedges are positioned through the slots to hold thefifth wheel in the desiposition.

The amount of load distribution on the front steeringaxle and rear drive axle(s) will have a direct effect onthe steering control of the tractor. Determine the frontand rear axle weights by weighing the tractor onscales designed for this purpose.

The maximum axle weight ratings are shown on theFederal Motor Vehicle Safety Standard (FMVSS)label or Canadian Motor Vehicle Safety Standard(CMVSS) label attached to the driver-side doorframe. The desired load on the axle is no less than80 percent of the maximum axle weight rating, but inno instances should the axle load exceed the maxi-mum axle weight rating given on the FMVSS orCMVSS label.

Manual Slide OperationUse the following procedure to manually slide thefifth wheel. See Fig. 18.12.

1. Stop the tractor and trailer in a straight line onlevel ground. Pull the trailer air supply knob toset the trailer parking brakes.

2. Set the tractor parking brake, then release thesliding mechanism using the appropriate methodfor the fifth wheel manufacturer.

2.1 Fontaine: Lift the slide release pull handleto disengage it from the guide plate. Then,pull out the handle until it is in the un-locked position and can be positionedagainst the guide plate to hold it out. Thehandle will stay in the unlocked positionuntil it is manually disengaged from theguide plate. See Fig. 18.13.

10/26/2010 f611102

Fig. 18.11, Air-Actuated Kingpin Release Valve

07/25/95 f310190

1

2

1. Locking Wedge2. Slide Release Pull Handle

Fig. 18.12, Manual Release Sliding Fifth Wheel,Fontaine

Fifth Wheels

18.7

2.2 Holland: Pull the operating rod out. Makesure both side plungers have released.See Fig. 18.14.

3. Lower the trailer landing gear just enough to re-move the weight from the tractor.

4. Chock the front and rear trailer tires to preventthe trailer from moving.

NOTICEWhen moving the fifth wheel to the desiposition,be sure the trailer landing gear will not at anytime come in contact with the tractor frame orother components. Make sure that the front ofthe trailer will not come in contact with the rearof the cab or with other components if they ex-tend beyond the rear of the cab.

5. Release the tractor parking brake, then slowlymove the tractor forward or backward until thefifth wheel is in the desilocation.

WARNINGCheck that the locking wedges have seated in theslots. Failure to achieve complete lockup mayallow disengagement of the tractor from thetrailer, 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 followingmethods:

6.1 Fontaine: Disengage the slide releasepull handle from the guide plate. The sliderelease pull handle is spring-loaded in thelocked position and will seek the lockedposition when disengaged from the guideplate. After the slide release pull handlereturns to the fully locked position, visuallyand physically check the locking wedgesto make sure they are fully inserted intothe slots in the slide rails. Make sure thehandle is locked in position against theguide plate.

6.2 Holland: Raise the operating rod so that itis free to move inward. Make sure that thelock pins have seated in the base platerail holes and the operating rod movesinto the locked position.

NOTE: The fifth wheel may need to be movedslightly to enable the locking wedges to enterthe fully locked position.

Air Slide OperationThe slide feature may be operated with a dash-mounted switch that operates an air cylinder thatlocks and unlocks the slide.

f31005005/05/2017

Fig. 18.13, Sliding Fifth Wheel Manual Release,Fontaine

f31044505/05/2017

1

2

3

45

6

3

7

8

1. Baseplate2. Bolted Stop3. Baseplate Rail4. Fifth Wheel Mount

5. Slider Saddle Plate6. Safety Latch7. Operating Rod8. Operating Lever

Fig. 18.14, Sliding Fifth Wheel Manual Release, HollandSimplex

Fifth Wheels

18.8

1. Press the top half of the air-slide switch to en-able the air-slide feature. See Fig. 18.15.

Ensure the locking plungers have released. SeeFig. 18.16.

For Jost fifth wheels, the mechanism activates asshown in Fig. 18.17.


3. Pull the trailer air supply knob to set the trailerparking brakes.

4. Slowly move the tractor forward or backwarduntil the fifth wheel is in the desilocation.

NOTICEEnsure the trailer landing gear does not come incontact with the tractor frame or other compo-nents, and that the front of the trailer will notcome in contact with the rear of the cab or othercomponents if they extend beyond the rear of thecab.



6. Press the lower half of the air-slide switch to dis-able the air-slide feature. Visually inspect thelocking wedges or plungers to make sure thatthey are fully inserted in the slide rail slots. Verifythat the plungers have engaged by tugging the

07/22/2011 f545806

Fig. 18.15, Air Slide Switch

07/25/95 f310189

1

2

1. Locking Wedge 2. Air Cylinder

Fig. 18.16, Air-Operated Sliding Fifth Wheel, Fontaine

09/10/2010 f311131

A

B

A. Unlocked B. Locked

Fig. 18.17, Jost Sliding Fifth Wheel

Fifth Wheels

18.9

tractor forward while the trailer brakes are lockedand the tires are chocked.

NOTE: The fifth wheel may need to be movedslightly to enable the locking wedges to fullylock.

Fifth Wheels

18.10

19

Trailer CouplingsHolland Trailer Coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.1

Holland Trailer CouplingGeneral InformationIMPORTANT: Refer to the Holland web site(www.hollandhitch.com) for additional informa-tion.

The Holland trailer coupling is designed for use withtrailers having a maximum gross weight of 10,000 lb.(4540 kg) for Holland PH-10RP41 and PH-10RP51,or 30,000 lb. (13,610 kg) for Holland PH-30RP41 andPH-30RP51. It is a rigid-type pintle hook, used onlyon tractor applications, and is fastened to the rearclosing crossmember of the vehicle. It is a non-air-adjusted coupling. See Fig. 19.1.

Trailer Hookup1. Chock the front and rear tires of the trailer.

2. Remove the lock pin (if equipped), then lift thelock handle and raise the latch.

3. Back up the vehicle until the drawbar eye is overthe pintle hook.

4. Lower the trailer, until the drawbar eye rests onthe pintle hook.

5. Push the latch closed, then insert the lock pin (ifequipped).


6. Connect the trailer electrical and air lines.

Trailer Release1. Apply the tractor and trailer parking brakes.

WARNINGDo not use the trailer air supply for parking trail-ers not equipped with spring parking brakes.This applies the trailer service brakes only. As airbleeds from the trailer brake system, brake appli-cation is lost. This could allow the unattendedvehicle to roll away, possibly resulting in seriouspersonal injury or death.

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 off thepintle hook.

5. Open the latch by removing the lock pin (ifequipped), then lift up the lock and raise thelatch.

6. Slowly drive the vehicle away from the trailer.

f31117602/17/2017

21

3

4

1. Lock2. Cotter Pin

3. Latch4. Pintle Hook

Fig. 19.1, Holland Trailer Coupling (typical)

Trailer Couplings

19.1

www.hollandhitch.com

20

Headlight AimingPreliminary Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20.1Checking Headlight Aim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20.1Adjusting Headlight Aim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20.1

Preliminary ChecksBefore checking or adjusting the headlight aim, com-plete the following inspection:

• Check that the hood is closed and latched.

• Remove any large amounts of mud or ice fromthe underside of the fenders.

• Check the springs for sagging or brokenleaves.

• Check the suspension for proper functioning ofthe leveling mechanism. On cabs with air sus-pensions, make sure that the height is properlyadjusted.

• Check for damage to the hood and hinge as-sembly. Repair as necessary.

• With the vehicle unloaded, check that the tiresare inflated to the recommended air pressure.

• Clean the headlight lenses. Use a soft clothwith mild, non-caustic soap or detergent, andwater.

Checking Headlight Aim1. Park the vehicle on a level surface, 25 ft (7.6 m)

away from, and perpendicular to, a verticalscreen or wall. Shut down the engine and set theparking brake. Chock the tires.

2. On each headlight, find the low-beam bulb cen-ter, marked by a small transparent ring on theinside of the headlight lens.

3. Measure the distance from the ground to thecenter of each headlight bulb (Fig. 20.1, Item A).Note those distances.

4. On the screen or wall, mark the locations of eachlow-beam headlight bulb center using the dis-tances found in step 3. See Fig. 20.1, Items 2and 3.

5. Turn on the low-beam headlights.

6. Check the vertical adjustment of the low beams.The center of each beam projection should fallon or near the marks made during step 4. SeeFig. 20.2.

7. Use Table 20.1 to determine the maximum verti-cal distance allowable between the marks on thewall and the center of each beam projection.

If the distance between either projection centerand the mark made on the wall or screen is

greater than the maximum distance given inTable 20.1, adjust the vertical positioning of thatheadlight.

IMPORTANT: The zone of high-intensity lightfrom a low-beam lamp should not project abovethe low-beam angle upper limit. See Fig. 20.3for an example of correctly aimed headlights.

Adjusting Headlight AimHeadlight adjustment is made on the bottom of theheadlight assembly, accessible through the wheelwell when the hood is closed. Using a Phillips #2screwdriver inserted through the slot in the hood-mounted splash shield (Fig. 20.4), turn the adjustingscrew clockwise to raise the beam and counterclock-wise to lower it, until the beam pattern meets the ac-ceptable standard.

Headlight Aiming

20.1

f545850h10/21/2014

B

B

1

23

25 ft (7.6 m)

AA

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 Wall2. Center of Right-Hand Headlight Projection

3. Center of Left-Hand Headlight Projection

Fig. 20.1, Headlight Aiming Screen/Wall

10/20/2014 f545851h

A

12

3

A. Measurement: 25 ft (7.6 m)1. Low-Beam Angle Upper Limit2. Ideal Low-Beam Projection

3. Low-Beam Angle Lower Limit

Fig. 20.2, Vertical Low-Beam Headlight Variation Limits

Headlight Aiming

20.2

Vertical Low-Beam Headlight Variation LimitsDistance Between Ground

and Headlight: in (mm)Desired Variation (Fig. 20.2,

Item 2) : in (mm)Upper Limit (Fig. 20.2, Item

1): in (mm) upLower Limit (Fig. 20.2, Item

3): in (mm) down22–36 (560–900) 0 3.9 (100) 3.9 (100)

36–48 (900–1200) 2 (50) down 2 (50) 6 (150)48–54 (1200–1400) 3.9 (100) down 1.6 (40) 6.5 (165)

Table 20.1, Vertical Low-Beam Headlight Variation Limits

02/09/2015 f546133

1

23 3

1. Ground2. Low-Beam Angle

Upper Limit

3. Low-Beam VerticalCenter Line

Fig. 20.3, Beam Projection of Correctly AimedHeadlights

02/04/2015 f546104a

Fig. 20.4, Headlight Adjustment Slot (shown with thehood open)

Headlight Aiming

20.3

21

Vehicle Appearance andCare

Cab Washing and Polishing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.1Care of Fiberglass Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.1Care of Chrome Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.1Care of Exterior Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.1Dashboard and Instrument Panel Care . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.2Vinyl Upholstery Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.2Velour Upholstery Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.3

Cab Washing and PolishingIMPORTANT: Carefully read all instructions be-fore using or applying any cleaner or product onthe vehicle or components. Failure to followmanufacturers’ recommendations can result indamage to the finish.

To protect the finish of your new vehicle, follow theseguidelines carefully.

• During the first 30 days, rinse your vehicle fre-quently with water. If the vehicle is dirty, use amild liquid soap. Do not use detergent.

• During the first 30 days, do not use anythingabrasive on your vehicle. Brushes, chemicals,and cleaners may scratch the finish.

• During the first 120 days, do not wax yourvehicle.

To extend the life of your vehicle’s finish, follow theseguidelines.

• Avoid washing your vehicle in the hot sun.

• Always use water. After the cab is completelywashed, dry it with a towel or chamois.

• Do not dust painted surfaces with a dry cloth,as this will scratch the paint.

• Do not remove ice or snow from a painted sur-face with a scraper of any sort.

• To prevent damage to the finish, wax it regu-larly. Before waxing, if the finish has becomedull, remove oxidized paint using a cleanerspecifically designed for this purpose. Removeall road tar and tree sap before waxing. West-ern Star Trucks recommends using a highquality brand of cleaner or cleaner-polish andpolishing wax.

• Do not let diesel fuel or antifreeze stand on apainted surface. If either should occur, rinsethe surface off with water.

• To prevent rust, have any nicks or other dam-age on the finish touched up as soon as pos-sible.

• Park your vehicle in a sheltered area wheneverpossible.

To prevent delamination and deterioration of labelsand stickers on the cab, follow these guidlines care-fully:

• Do not pressure wash the label or sticker orsurfaces near it.

• Do not use strong alkaline soaps on or nearthe label or sticker.

Care of Fiberglass PartsWash unpainted fiberglass air fairings and shieldsmonthly with a mild detergent, such as dishwashingliquid. Avoid strong alkaline cleansers.

Apply a wax specifically designed for fiberglass.

Care of Chrome PartsTo prevent rust, keep chrome parts clean and pro-tected at all times. This is especially important duringwinter driving and in coastal areas where there isexposure to salt air.

When cleaning chrome parts, use clean water and asoft cloth or sponge. A mild detergent may also beused.

Sponge gently, then rinse. If necessary, use a non-abrasive chrome cleaner to remove stubborn rust orother material. Do not use steel wool.

To help protect the chrome after cleaning, apply acoat of polishing wax to the surface. Never use waxon parts that are exposed to high heat, such as ex-haust pipes.

Care of Exterior LightsClean the headlight lenses by hand only. Use a flan-nel cloth with mild, non-caustic soap or detergent,and water.

NOTICEDo not use a power buffer, paper towels, chemi-cal solvents, or abrasive cleaners on the head-light lens, all of which can remove the UV coatingfrom the surface, and result in yellowing of thelens.

Vehicle Appearance and Care

21.1

Dashboard and InstrumentPanel Care

NOTICEWhen cleaning the dashboard, instrument panel,or gauge lens covers, do not use Armor-All Pro-tectant®, STP Son-of-a-Gun®, window cleaner, orother equivalent treatments. These cleaners con-tain vinyl plasticizers which can cause stresscrazing in the interior plastic panels and can re-sult in cracking of the panels. Some cleaners canalso have an adverse effect on the clear plasticof instrument panels and gauge lens covers, re-sulting in a foggy or cloudy appearance. Thistype of damage is not covered by vehicle war-ranty.

To clean the dashboard, instrument panel, and gaugelens covers, use a cloth dampened with warm soapywater. Make certain to wring the cloth out well beforecleaning, as excess water will damage the electricalcomponents.

Vinyl Upholstery CleaningTo prevent soiling, frequent vacuuming or light brush-ing to remove dust and dirt is recommended. Harshcleaning agents can cause permanent damage tovinyl upholstery.

To preserve the upholstery and prevent damage,carefully review the following sections for recom-mended cleaning procedures. Waxing or refinishingimproves soil resistance and cleanability for all vinyls.Use any hard wax, such as that used on automo-biles.

Ordinary DirtWash the upholstery with warm water and mild soap,such as saddle or oil soap. Apply soapy water to alarge area and allow to soak for a few minutes, thenrub briskly with a cloth to remove the dirt. Repeatseveral times, as necessary.

If dirt is deeply imbedded, use a soft bristle brushafter applying the soap.

If dirt is extremely difficult to remove, use a wall-washing preparation such as those normally foundaround the home. Powdered cleaners, such as thoseused for sinks and tiles, are abrasive and must beused with caution as they can scratch the vinyl orgive it a permanent dull appearance.

Chewing GumHarden the gum with an ice cube wrapped in a plas-tic bag, then scrape it off with a dull knife. Removeany remaining traces of gum with an all-purpose lightoil (peanut butter will also work). Wipe off the gumand oil substance.

Tars, Asphalts, and CreosoteEach of these items stains vinyl after prolonged con-tact. Wipe any of these items off immediately andcarefully clean the area using a cloth dampened withnaphtha.

Paint, Shoe Heel MarksRemove paint immediately. Do not use paint removeror liquid-type brush cleaner on vinyl. An unprintedcloth, dampened with naphtha or turpentine may beused. Use care to prevent contact with parts of theupholstery that are not vinyl.

Sulfide StainsSulfide compounds, such as those found in eggs andsome canned goods, can stain after prolonged con-tact with vinyl. Remove these stains by placing aclean, unprinted piece of cloth over the spotted areaand pouring a liberal amount of 6 percent hydrogenperoxide onto the cloth. Allow the saturated cloth toremain on the spot for 30 to 60 minutes. For stub-born spots, allow the hydrogen-peroxide saturatedcloth to remain on the area overnight. Use caution toprevent the solution from seeping into the seams,where it can weaken the cotton thread.

Nail Polish and Nail Polish RemoverProlonged contact with these substances causes per-manent damage to vinyl. Careful blotting immediatelyafter contact minimizes damage. Do not spread theliquid during removal.

Shoe PolishMost shoe polishes contain dyes which penetratevinyl and stain it permanently. Wipe shoe polish offas quickly as possible using naphtha or lighter fluid.If staining occurs, try the procedure used for sulfidestains.


21.2

Ball Point InkRub ball point ink immediately with a damp cloth,using water or rubbing alcohol. If this does not work,try the procedure used for sulfide stains.

MiscellaneousIf stains do not respond to any of the treatments de-scribed above, it is sometimes helpful to expose thevinyl to direct sunlight for up to 30 hours. Mustard,ball point ink, certain shoe polishes, and dyes oftenbleach out in direct sunlight, leaving the vinyl undam-aged.

Velour Upholstery CleaningTo prevent soiling, frequent vacuuming or light brush-ing to remove dust and dirt is recommended. Spotclean with a mild solvent or an upholstery shampoo,or the foam from a mild detergent. When using a sol-vent or a dry-cleaning product, follow the instructionscarefully, and clean only in a well-ventilated area.Avoid any product that contains carbon tetrachlorideor other toxic materials. With either method, pretest asmall area before proceeding. Use a professionalupholstery cleaning service when extensive cleaningis needed.

Grease and Oil-Based StainsDampen a small absorbent cloth with dry-cleaningsolvent or spot remover. Apply the cloth carefully tothe spot from the outer edge to the center. Pat andblot the spot with a clean, dry cloth. Repeat severaltimes, as necessary, turning the cloths so that thestain does not redeposit on the fabric.

Sugar and Water-Based StainsApply water-based detergent or cleaner, working incircular motions. Pat and blot as dry as possible. Re-peat, if necessary, before drying thoroughly.

Chewing Gum or WaxHarden the gum or wax with an ice cube wrapped ina plastic bag, then scrape it off with a dull knife. Ab-sorb excess wax by placing a thick white blotter overthe wax and heating with a warm (not hot) iron. Re-move the remainder by using the procedure forgrease and oil-based stains.

MildewBrush the dry fabric with a soft brush. Sponge withdetergent, and blot. If the fabric is colorfast, dilute ateaspoon of bleach in one quart (one liter) of coolwater. Apply with a swab, directly on the mildewstain. Dab repeatedly with clear, cool water, and blotdry.


21.3

22

Pre- and Post-TripChecklists

Periodic Inspections and Maintenance, General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22.1Checklists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22.1Fluids Added . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22.2

Periodic Inspections andMaintenance, GeneralInformationRegulations in Canada and the U.S. clearly indicatethat it is the driver’s responsibility to perform an in-spection, and ensure the complete road-worthinessof a vehicle, before placing it into service. Commer-cial vehicles may be subject to inspection by autho-rized inspectors, and an unsafe vehicle can be taken"out of service" until the driver or owner repairs it.

Use the following checklists to ensure that vehiclecomponents are in good working condition beforeeach trip. Careful inspections eliminate stops later tofix overlooked or forgotten items.

The checklists in this chapter can be copied and keptas a record that the procedures have been com-pleted. For details on how to inspect each item onthe checklists, see the corresponding procedure(step number) in Chapter 23.

ChecklistsNOTE: Checklists in this chapter correspondwith the procedures and steps in Chapter 23,Pre- and Post-Trip Inspections and Mainte-nance. Your vehicle may not be equipped withall components listed below.

Daily Pretrip Inspection ChecklistsSee the following tables for a list of procedures thatshould be performed daily, before the first trip. Placea check mark in the complete (Comp.) column toindicate a procedure has been performed.

Inspector Date

Suspension and Slack Adjusters Comp.1 Suspension components2 Slack adjusters

Wheels and Tires Comp.1 Wheel covers2 Tire condition3 Tire inflation4 Rims and wheel components5 Wheel bearing oil seals and lubrication levels6 Mud Flaps

Saddle Tank Areas Comp.

1 Drain air reservoirs (without automatic drainvalves)

2 Fuel tank(s) secure3 Frame rails and crossmembers4 Visible exhaust components

Engine Compartment Comp.1 Leakage under engine2 Air intake system3 Engine oil level4 Power steering reservoir level5 Engine coolant level6 Visible engine wiring7 Frame rails

Cab Comp.

1 Reset dash-mounted air intake restrictionindicator

2 Air-pressure warning systems3 Air governor cut-in and cut-out pressures4 Air pressure build-up time5 Air system leakage6 Air pressure reserve7 Mirrors, windows, windshield8 Horn, windshield wipers, windshield washers9 Heater and defroster10 Interior lights11 Exterior lights12 Seat belts and tether belts13 Fuel level14 Mirror adjustment15 Service brakes16 Backup alarm

Weekly Post-trip Inspection ChecklistSee the following table for procedures that should beperformed weekly, post-trip. Place a check mark inthe complete (Comp.) column to indicate a proce-dure has been performed.

Inspector Date

Engine Compartment Comp.1 Windshield washer reservoir level2 Air intake restriction indicator3 Water evacuation components

Pre- and Post-Trip Checklists

22.1

Engine Compartment Comp.4 Automatic transmission fluid level5 Water in fuel/water separator6 Steering components7 Serpentine drive belts

Monthly Post-trip InspectionChecklistsSee the following tables for procedures that shouldbe performed monthly, post-trip. Place a check markin the complete (Comp.) column to indicate a proce-dure has been performed.

Inspector Date

Brake Components Comp.1 Brake system components2 Brake chambers3 Air brake lines4 Flex air hoses5 Brake linings and brake drums6 Brake lining thickness


1 Drain air reservoirs (with automatic drainvalves)

2 Batteries (location may vary)3 Aerodynamic components

Engine Compartment Comp.1 Hood and bumper2 Hydraulic clutch reservoir3 Radiator and heater hoses4 Steering wheel play

Fluids AddedUse the following table to note any fluids that wereadded during the inspection and maintenance proce-dures.

Fluids Added During InspectionFluid Amount Added

Wheel Bearing LubricantEngine OilPower Steering FluidEngine CoolantWindshield Washer Fluid


Automatic TransmissionFluidHydraulic Clutch Fluid (DOT4 brake fluid)


22.2

23

Pre- and Post-TripInspections and

MaintenanceSafety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23.1Daily Pretrip Inspections and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23.1Weekly Post-Trip Inspections and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23.8Monthly Post-Trip Inspections and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23.10

Safety Precautions

DANGERWhen working on the vehicle, shut down the en-gine, set the parking brake, and chock the tires.Before working under the vehicle, always placejack stands under the frame rails to ensure thevehicle can not drop. Failure to follow thesesteps could result in serious personal injury ordeath.

Daily Pretrip Inspections andMaintenanceComplete the following inspection and maintenanceprocedures to ensure that vehicle components are ingood working condition before each trip. A driver whois familiar with the vehicle and drives it regularly canperform the daily inspections, then add the weeklyand monthly post-trip inspections as scheduled.

If the driver does not operate the vehicle on a con-sistent basis, all daily, weekly, and monthly inspec-tion and maintenance procedures should be per-formed before the trip.

IMPORTANT: The pre- and post-trip checklists,inspections, and maintenance procedures de-tailed in this chapter are not all-inclusive.Refer to other component and body manufactur-ers’ instructions for specific inspection andmaintenance instructions, as well as local, state,and federal guidelines.

NOTE: If any system or component does notpass this inspection, it must be corrected beforeoperating the vehicle. Whenever equipment re-quires adjustment, replacement, and/or repair,see the Western Star Workshop Manual for pro-cedures and specifications.

Suspension and Slack AdjusterInspectionWalk around the vehicle and visually inspect suspen-sion and slack adjuster components.

1. Inspect the following suspension components forsigns of structural damage, cracks, or wear.

• springs

• spring hangers

• shocks

• suspension arms

• suspension brackets

• axle seats

• bushings

2. Inspect slack adjusters for signs of damage. SeeFig. 23.1, Fig. 23.2, or Fig. 23.3.

• Inspect slack adjuster boots, if equipped,for cuts or tears.

• Inspect anchor straps, if equipped, fordamage.

• Look for worn clevis pins on brake cham-ber pushrods.

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1. Grease Fitting (if equipped)2. Slack Adjuster Housing3. Brake Chamber Pushrod4. Clevis5. Clevis Pin (large)6. Clevis Pin (small)7. Actuator Rod8. Boot9. Manual Adjusting Nut10. Camshaft Splines

Fig. 23.1, Meritor Automatic Slack Adjuster

Pre- and Post-Trip Inspections and Maintenance

23.1

• Look for missing or damaged cotter pinson the clevis pins.

• Ensure chamber piston rods are in linewith the slack adjusters.

Wheel and Tire InspectionWalk around the vehicle and visually inspect eachwheel and tire assembly.

IMPORTANT: Wheel covers decrease drag forceas a vehicle moves, thereby improving fuel effi-ciency. If replacement of a wheel cover is nec-essary, the replacement cover must meet or ex-ceed the drag reduction performance of theoriginally installed cover in order to maintaincompliance with greenhouse gas and fuel effi-ciency regulations (GHG14).

1. If the vehicle was originally equipped with wheelcovers, ensure all wheel covers are present. In-spect wheel covers for damage or wear. Removewheel covers from rear drive wheels, if equipped,prior to inspecting the tires and wheel compo-nents.

NOTE: During wheel cover installation, ensurethe V-notch in the liner inner retaining ring iscentered on the valve stem. The inner and outerretaining rings should be uniformly aligned toeach other and to the wheel rim. The outer re-taining ring of the liner is equipped with twocanvas flaps. When installing the face cover,make sure the cover retaining ring is insertedbetween the two canvas flaps on the liner outerretaining ring so that the Velcro strips line upbetween the face cover and the liner. Make cer-tain the detachable view cover is centered onthe face cover, and the Velcro strips arepressed firmly in place.

2. Inspect each tire for the following:

• valve stem caps on every tire, screwed onfinger-tight

• bulges, cracks, cuts, and penetrations

• oil contamination (petroleum derivatives willsoften the rubber and destroy the tire)

• tread depth—if tread is less than 4/32 inch(3 mm) on any front tire, or less than 2/32inch (1.5 mm) on any rear tire, replace thetire

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1. 7/16-inch Adjusting Nut2. Grease Fitting3. Boot4. Link5. Brake Chamber Piston Rod6. Clevis7. 1/2-inch Clevis Pin8. 1/4-inch Clevis Pin9. Grease Relief Opening10. Slack Adjuster Spline

Fig. 23.2, Gunite Automatic Slack Adjuster

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1. Clevis2. Slack Adjuster3. Clevis Pin4. Manual Adjusting Nut5. Control Arm

6. Control-Arm Washersand Nut

7. Anchor Strap Slot8. Anchor Strap9. Brake Chamber

Fig. 23.3, Haldex Automatic Slack Adjuster


23.2

• debris lodged between duel tire sets

IMPORTANT: Low-rolling resistance (LRR) tiresminimize wasted energy as a tire rolls, therebydecreasing rolling effort and improving fuel effi-ciency. If tire replacement is necessary, replace-ment tires must meet or exceed the rolling resis-tance of the originally installed tires in order tomaintain compliance with greenhouse gas andfuel efficiency regulations (GHG14).

Contact your tire manufacturer/supplier to deter-mine the rolling resistance of the originally in-stalled tires. Visit www.epa.gov/smartway foradditional information and resources.

3. Check tire inflation.

For inflation pressures and maximum loads, seethe tire manufacturer’s guidelines. Inflate the tiresto the applicable pressures if needed.

If a tire has been run flat or under-inflated, checkthe wheel and tire for damage before adding air.

Keep compressed air reservoirs and lines dryduring tire inflation. Use well-maintained inlinemoisture traps and service them regularly.

WARNINGDo not operate the vehicle with underinflated oroverinflated tires. Incorrect inflation can stressthe tires and make the tires and rims more sus-ceptible to damage, possibly leading to rim ortire failure and loss of vehicle control, resultingin serious personal injury or death.

NOTICEA weekly pressure loss of 4 psi (28 kPa) or morein a tire may indicate damage. The tire should beinspected and, if necessary, repaired or replacedby a qualified tire service facility.

IMPORTANT: The load and cold inflation pres-sure must not exceed the rim or wheel manu-facturer’s recommendations, even though thetire may be approved for a higher load inflation.Consult the rim or wheel manufacturer for thecorrect tire inflation pressure for the vehicleload.

4. Examine each rim and wheel component.

4.1 Remove all dirt and debris from the as-sembly. Rust streaks or metal build-uparound stud holes, or out-of-round or wornstud holes, may be caused by loose wheelnuts.

WARNINGHave any worn or damaged wheel componentsreplaced by a qualified person using the wheelmanufacturer’s instructions and the wheel indus-try’s standard safety precautions and equipment.Otherwise a vehicle or workshop accident couldoccur, possibly resulting in serious personal in-jury or death.

4.2 Inspect for broken, cracked, badly worn,bent, rusty, or sprung rings and rims.

NOTICEUse the recommended torque values and followthe proper tightening sequence. Insufficientwheel nut torque can cause wheel shimmy, re-sulting in wheel damage, stud breakage, and ex-treme tire tread wear. Excessive wheel nut torquecan break studs, damage threads, and crackdiscs in the stud hole area.

4.3 Make sure all wheel nuts are tightened. Iftightening is necessary, use the tighteningpattern in Fig. 23.4 to initially tighten theflange nuts to 50 to 100 lbf·ft (68 to 136N·m). Then tighten the flange nuts to 450to 500 lbf·ft (610 to 678 N·m).

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Fig. 23.4, Tightening Pattern, 10-Hole Wheels


23.3

www.epa.gov/smartway

5. Inspect the outboard side of all wheel hubs andthe hub oil seal area on the inboard side of eachwheel for signs of oil leakage. If any oil is foundon wheel and tire or brake components, removethe vehicle from service until the leak has beenfixed.

If needed, fill the hubs to the level indicated onthe hub cap. See Group 35 of the Western StarMaintenance Manual for recommended lubri-cants.

6. Check that mud flaps are undamaged and hang10 inches (25.4 cm) or less from the ground.

Saddle Tank Areas Inspection

WARNINGWhen draining the air reservoir, do not look intothe air jets or direct them toward anyone. Dirt orsludge particles may be in the airstream andcould cause injury.

NOTICEIf the water drained from the air reservoirs iscloudy or oily, it may indicate a problem with thecompressor. If oil is allowed to contaminate theair dryer, it will not remove the water from the airbrake system, which could adversely affect brak-ing.

1. Drain the brake system air reservoirs (reservoirswithout automatic drain valves only).

WARNINGNever operate the engine with the fuel tank shut-off valves partially closed. This could damage thefuel pump, causing sudden loss of engine power,possibly resulting in serious personal injury dueto reduced vehicle control.

2. Ensure fuel tanks are secured to their mountingbrackets and that the mounting brackets are se-cured to the frame.

If equipped with fuel tank shutoff valves, be surethe valves are fully open.

3. Inspect visible frame rails for missing bolts, shinyareas, or rust streaks. Check all visible cross-members for damage or signs of looseness.

4. Inspect visible components of the exhaust sys-tem to ensure connections are tight.

Inspect upstream of the aftertreatment device(ATD), if equipped, for cracking or signs of leaks,such as soot trails. Inspect downstream of theATD for signs of exhaust leaks, such as blister-ing or warping of nearby components.

Engine Compartment Inspection1. Check the ground underneath the engine for fuel,

oil, or coolant leaks.

2. Inspect the air intake system for leaks or dam-age.

NOTICEFailure to maintain a sealed air intake systemcould allow the entry of dirt and contaminantsinto the engine. This could adversely affect en-gine performance and result in engine damage.

2.1 Push the reset button on the air intakerestriction indicator located on the aircleaner, if equipped.

2.2 Check the air intake duct from the aircleaner to the engine intake. Make surethe duct components are secure and air-tight.

3. Check the engine oil level.

NOTICEOperating the engine with the oil level below theminimum fill (or "add") mark or above the maxi-mum fill (or "full") mark could result in enginedamage.

3.1 Check the oil level with the vehicle parkedon a level surface. See the engine manu-facturer’s guidelines for engine shutdowntime requirements prior to checking the oillevel.

IMPORTANT: On engines that comply withEPA07 or newer regulations, use CJ-4 en-gine oil with less than 1% sulfated ash. Fail-ure to use CJ-4 oil may void the warranty onemission aftertreatment components.

3.2 If the oil level is at or below the minimumfill (or "add") mark on the dipstick, addenough oil to maintain the level betweenthe minimum and maximum fill marks. Seethe engine operation manual for recom-mended lubricants.


23.4

4. Check the power steering reservoir fluid level.

The power steering fluid level should be betweenthe MIN COLD mark and the middle mark justabove it. See Fig. 23.5. If needed, fill the reser-voir with automatic transmission fluid that meetsDexron III or TES-389 specifications.

NOTICELow coolant could result in engine overheating,which could cause engine damage.

IMPORTANT: The surge tank must be cool tocheck the coolant level.

5. Check the engine coolant level in the radiatorsurge tank. See Fig. 23.6.

NOTICECoolant must be filled to the COLD MAX line ofthe surge tank. Low coolant could result in en-gine overheating, which could cause engine dam-age.

5.1 If the coolant is low, fill the surge tank tothe MAX line with a 50/50 mixture of waterand the type of antifreeze currently in-stalled in your vehicle.

5.2 If the surge tank was empty, start the en-gine after refilling and check the levelagain when the engine is at operatingtemperature.

6. Inspect visible engine wiring for damage orlooseness. Check for loose wiring, chafed insula-tion, and damaged or loose hold-down clamps.

7. Inspect visible frame rails for missing bolts, shinyareas, or rust streaks.

Cab Inspection1. Push the reset button on the dash-mounted air

intake restriction indicator, if equipped.

2. With the ignition switch in the OFF position,check the air-pressure warning system.

2.1 If not previously drained, drain the air res-ervoirs using moderate brake applicationsuntil pressure in both reservoirs is lessthan 70 psi (483 kPa).

2.2 Turn the ignition to the ON position. TheICU will complete a full gauge sweep andbulb check, and an audible warning willsound. Ensure the low air pressure lamp(BRAKE AIR) remains illuminated and anaudible warning continues to sound afterthe gauge sweep is complete.

3. Check air governor cut-in and cut-out pressures.

3.1 Start the engine and ensure the BRAKEAIR lamp goes out and the buzzer si-lences when pressure reaches approxi-mately 70 psi (483 kPa) in both air reser-voirs.

The air governor should cut out at ap-proximately 120 psi (827 kPa). For ve-hicles with an optional dryer reservoirmodule (DRM), the cut-out pressure isapproximately 130 psi (896 kPa).

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Fig. 23.5, Power Steering Fluid Reservoir

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1. Pressure Relief Cap2. Filler Cap3. COLD MAX Fill Line

4. COLD MIN Fill Line5. Coolant Level Sensor

Fig. 23.6, Coolant Surge Tank


23.5

3.2 With the engine idling, apply the brakepedal several times. The air governorshould cut in when pressure in the primaryair reservoir (top air gauge) reaches ap-proximately 100 psi (689 kPa).

4. Check air pressure build-up time.

4.1 With the air system fully charged, makeone full brake application and note the airpressure reading on the primary airgauge.

4.2 Further reduce air pressure using moder-ate brake applications, then run the en-gine at governed rpm.

4.3 Note the time that the pressure reachesthe previously noted reading on the pri-mary air gauge, then note the time thatthe air pressure reaches cut-out pressure.

4.4 If it takes longer than 30 seconds to reachcut-out pressure after the primary airgauge passes the previously noted pres-sure (noted after one full brake applica-tion), eliminate any leaks or replace the aircompressor before operating the vehicle.

5. Check air leakage in the system.

5.1 With the parking brake applied, the trans-mission out of gear, and the air systemfully charged, release the service brakesand shut down the engine.

5.2 Wait one minute and note the air pressuredrop in psi (kPa) per minute from the pri-mary air reservoir.

If the pressure drop exceeds the limitsshown in Table 23.1, eliminate any leaksbefore operating the vehicle.

6. Check the air pressure reserve.

With the engine still off, make one full brake ap-plication and observe the pressure drop on theprimary air gauge. If pressure drops more than25 psi (172 kPa), eliminate any leaks before op-erating the vehicle.

Maximum Allowable Air Leakage

DescriptionPressure Drop:

psi (kPa) Per MinuteReleased Applied

Truck or Tractor Only 2 (14) 3 (21)Truck or Tractor w/Single Trailer 3 (21) 4 (28)




Truck or Tractor w/Two Trailers 5 (35) 6 (42)

Table 23.1, Maximum Allowable Air Leakage

WARNINGWhen cleaning windshields and windows, alwaysstand on the ground or on a secure ladder orplatform. Use a long-handled window cleaner. Donot use the cab steps, tires, fenders, fuel tanks,engine, or under-hood components to access thewindshield or windows. Doing so could cause afall and result in an injury.

7. Inspect the mirrors, window glass, and wind-shield for cracks or other damage.

8. Ensure that the horn, windshield wipers, andwindshield washers are operating properly.These devices must be in good working order forsafe vehicle operation.

9. Ensure the heater and defroster are operatingproperly.

10. Check the operation of all interior lights.

10.1 Turn on the headlights and leave them on.Ensure all equipped gauge bulbs illumi-nate in the dash message center.

10.2 Ensure all equipped driver controlswitches illuminate.

10.3 Ensure both turn signal indicator bulbsilluminate in the dash message centerwhen the turn signal switch is activated.

11. Check the operation of all exterior lights. SeeFig. 23.7.

11.1 Activate the high-beam headlights andhazard warning lights.

11.2 Exit the cab and check that all exteriorlights and reflectors are clean and intact.

11.3 Check that the brake lights, taillights,headlights, turn signals, marker lights,identification lights, and clearance lightsare working properly.


23.6

12. Inspect the seat belts and tether belts.


12.1 Check the web for fraying, cuts, extremedirt and dust, or for severe fading fromexposure to sunlight, especially near thebuckle latch plate and in the D-loop guidearea.

12.2 Check operation of the buckle, latch, Kom-fort Latch or Sliding Komfort Latch (ifequipped), web retractor, and upper seatbelt mount on the door pillar. Check allvisible components for wear or damage.

12.3 Check the seat belt and tether belt con-nection points and tighten any that areloose.

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23.7

WARNINGNever fill fuel tanks to more than 95 percent oftheir liquid capacity. This could make them morelikely to rupture from impact, possibly causingfire and resulting in serious personal injury ordeath by burning.

Do not mix gasoline or alcohol with diesel fuel.This mixture could cause an explosion, possiblyresulting in serious personal injury or death. Donot fill the fuel tanks in the presence of sparks,open flames, or intense heat. These could ignitethe fuel, possibly causing severe burns.

IMPORTANT: On engines that comply withEPA07 or newer regulations, use ultralow-sulfurdiesel (ULSD) with 15 ppm sulfur content orless. Failure to use ULSD fuel may void thewarranty on emission components.

13. Check the fuel level in the fuel tank(s). To keepcondensation to a minimum, fuel tanks should befilled at the end of each day.

14. Adjust the rearview and down view mirrors asnecessary.

15. Test the service brakes.

15.1 With the engine running and air systemfully charged, set the parking brake.

15.2 Put the vehicle in the lowest gear andgently attempt to move it forward. The ve-hicle should not move.

If the vehicle moves, the parking brakesare not operating correctly and must berepaired before the vehicle is operated.

16. Test the backup alarm.

16.1 Release the parking brake and put thetransmission in reverse.

16.2 Move the vehicle slightly backward to en-sure that the backup alarm is operatingcorrectly.

Weekly Post-Trip Inspectionsand MaintenanceEngine Compartment Inspection

WARNINGWasher fluids may be flammable and poisonous.Do not expose washer fluid to an open flame orany burning material, such as a cigarette. Alwayscomply with the washer fluid manufacturer’s rec-ommended safety precautions.

1. Check the windshield washer reservoir fluid level.The reservoir is usually located near the left-hand hood support. See Fig. 23.8.

2. After resetting the air intake restriction indicatorduring the daily pretrip inspection, check the indi-cator again with the engine off.

2.1 For an indicator with graduations, check tosee if air restriction exceeds 18 inH2O.

For a go/no-go indicator without gradua-tions, check to see if the colored barshows through the clear window.

2.2 If air restriction exceeds the maximum al-lowable value, operate the vehicle for onemore day, making sure not to run the en-gine over rated rpm. Refer to the engineoperation manual for more information onrated rpm for your engine.

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Fig. 23.8, Windshield Washer Reservoir


23.8

2.3 If air restriction exceeds the maximumvalue again, replace the air cleaner. Forinstructions, refer to Group 09 of theWestern Star Workshop Manual.

3. Inspect water evacuation components.

3.1 Inspect the vacuator valve(s). Make surethe lips of each valve are undamaged andpliable, free of debris, and remain closedduring inspection.

3.2 Inspect the rain tray installed at the baseof the windshield. Ensure that the seal onthe forward edge of the rain tray is ingood condition.

4. If the vehicle is equipped with an Allison auto-matic transmission, check the automatic trans-mission fluid level.

5. Check for water in the fuel/water separator, ifequipped.

IMPORTANT: When draining fluid from afuel/water separator, drain the fluid into anappropriate container and dispose of it prop-erly. Many jurisdictions now issue fines fordraining fuel/water separators onto theground.

5.1 Place a suitable container under the fuel/water separator.

NOTE: A hose may be used to direct waterinto the container. Use a hose with a ½-inchpipe thread on DAVCO models.

5.2 If the engine is equipped with a built-inwater separator, loosen the drain valve,and allow the water to run out. Close thedrain valve, taking care not to overtightenit.

5.3 Alliance/Racor Models: Turn the drain plugcounterclockwise to open it. SeeFig. 23.9.

DAVCO Models: Remove the vent capand open the drain. See Fig. 23.10.

5.4 Stop draining fluid when fuel begins todrain out.

Alliance/Racor Models: turn the drain plugclockwise to close it.

DAVCO Models: close the drain valve.Install and hand-tighten the vent cap.

6. Inspect the steering components.

6.1 Inspect tie rods, steering arms, and thedrag link for signs of looseness (i.e., shinyspots or rust tracks). See Fig. 23.11.

6.2 Check the steering gear mounting boltsand pitman arm pinch bolt and nut forsigns of looseness.

6.3 Check the drag link nuts for missing cotterpins.

6.4 Inspect the steering intermediate shaft andend yokes for excessive looseness orother damage.

NOTICEDo not drive with a drive belt that is visibly wornor damaged. If it fails, the lack of coolant flowcould rapidly cause damage to engine compo-nents.

7. Inspect the serpentine drive belts for signs ofglazing, frayed edges, breaks, cracks, or oil con-tamination.

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1. Washers (qty 2)2. Nuts (qty 2)3. Frame Rail4. Fuel Outlet Port5. Fuel Inlet Port6. Priming Pump

7. Mounting Head8. Mounting Bolts (qty 2)9. Filter Element10. Sight Bowl11. Drain Plug

Fig. 23.9, Alliance Fuel/Water Separator Assembly andInstallation


23.9

Monthly Post-Trip Inspectionsand MaintenanceBrake Component InspectionWalk around the vehicle and inspect brake systemcomponents for visible damage.

1. Inspect all visible brake system components formissing fasteners or signs of looseness, such asrust tracks.

NOTICEIf the external breather tube or breather cap ismissing or incorrectly installed, road dirt and de-bris can adversely affect the operation of thebrake chamber. Once inside of the chamber, dirtand debris can cause the internal parts of thechamber to deteriorate faster.

2. Inspect the exterior surfaces of brake chambersfor damage. Make sure that breather holes areopen and free of debris.

NOTE: Do not route air brake lines on top ofanything likely to be stepped on.

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1. Inlet Port/Check Valve2. Lower Housing3. Bypass Valve4. Filter Element5. Spring6. Cover O-Ring7. Clear Cover

8. Vent Cap O-Ring9. Vent Cap10. Collar11. 120VAC Pre-Heater12. 12VDC Pre-Heater13. Drain Valve

Fig. 23.10, DAVCO Fuel/Water Separator (Fuel Pro 482shown)

f46191605/16/2017

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1. Steering Gear Mounting Bolts2. Pitman Arm Pinch Bolt Nut3. Drag Link Nut

Fig. 23.11, Integral Steering Gear Fasteners


23.10

3. Inspect air brake lines for dents, swelling, kinks,twisting, abrasion, and damage, especially nearmoving parts.

4. Inspect flex air lines for deterioration or signs ofabrasion.

5. Inspect for cracked, worn, or oil-contaminatedbrake linings and brake drums (or rotors).

6. Check the thickness of the brake linings. Re-place brake linings on all brake assemblies onthe axle if any brake linings are worn to less thanapproximately 1/4 inch (6.4 mm) at the thinnestpoint.




1. Drain the brake system air reservoirs (reservoirswith automatic drain valves only).

NOTE: Battery locations vary between vehicles.

2. Inspect the batteries.

WARNINGBattery posts, terminals, and related accessoriescontain lead and lead compounds, chemicalsknown to the State of California to cause cancerand reproductive harm. To prevent possible per-sonal injury, always wash your hands after han-dling battery parts and related accessories.

2.1 Remove the battery box cover and inspectall visible battery cables for loose wiring ordamage.

2.2 Check that the battery hold-down is se-cure.

IMPORTANT: Aerodynamic components de-crease drag force as a vehicle moves, therebyimproving fuel efficiency. If replacement of anaerodynamic component is necessary, replace-ment components must meet or exceed thedrag reduction performance of the originally in-stalled component in order to maintain compli-ance with greenhouse gas and fuel efficiencyregulations (GHG14).

3. Inspect the following aerodynamic components, ifequipped, for structural damage, cracks, or wear.

• Chassis fairings

• Roof fairing/deflector

• Side skirts

• Cab/sleeper extenders

• Battery access cover

Engine Compartment Inspection andAdjustmentsIMPORTANT: If replacement of the hood orbumper is necessary, the replacement compo-nent must meet or exceed the drag reductionperformance of the originally installed item inorder to maintain compliance with greenhousegas and fuel efficiency regulations (GHG14).

1. Inspect the bumper and hood for structural dam-age, cracks, or wear.

2. Check the hydraulic clutch reservoir, if equipped.If necessary, add DOT 4 brake fluid.

3. Inspect the radiator and heater hoses, includingthe clamps and support brackets.

3.1 Inspect the radiator and charge air coolerfor damage and accumulated debris.Straighten bent or damaged fins to permitairflow across all areas of the cores.

NOTE: When traveling through areas of highinsect concentration, it may be necessary toclean the exterior of the radiator or thecharge air cooler core as often as every 200miles (320 km).

3.2 Make sure the radiator inlet and outlethoses are pliable and are not cracking orballooning.


23.11

3.3 Make sure the heater hoses are pliableand are not cracking or ballooning.

3.4 Tighten hose clamps as necessary.

IMPORTANT: Do not overtighten hoseclamps, as hose life can be adversely af-fected.

3.5 Ensure hose support brackets are se-curely fastened. Make sure hoses are notlocated near sources of wear, abrasion, orhigh heat.

IMPORTANT: When replacing hoses, installservice-type knitted or braided yarn-reinforcedneoprene hose. Extended-service-life siliconehoses may also be used. See the Alliance PartsCatalog at www.alliancebrandparts.com orcontact your Western Star Dealer.

4. Check the steering wheel for excessive play.

4.1 Start the engine. With the front tiresstraight ahead, turn the steering wheeluntil motion is observed at the frontwheels.

4.2 Align a reference mark on the steeringwheel to a rule, then slowly turn the steer-ing wheel in the opposite direction untilmotion is again detected at the wheels.

4.3 Measure the lash (free play) at the rim ofthe steering wheel. Excessive lash existsif steering wheel movement exceeds 2-1/2inches (64 mm) with a 20-inch (508-mm)steering wheel, or 2-1/4 inches (57 mm)with an 18-inch (450-mm) steering wheel.

4.4 If there is excessive lash, check the steer-ing system for wear or incorrect adjust-ment before operating the vehicle.


23.12

www.alliancebrandparts.com

24

In An EmergencyHazard Warning Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24.1Fire Extinguisher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24.1Emergency Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24.1Emergency Filter Replacement, DAVCO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24.1Emergency Starting With Jumper Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24.2Towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24.4Fire in the Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24.6

Hazard Warning LightsThe hazard warning light switch (Fig. 24.1) is locatedon the right-hand dash panel. To operate the hazardlights, press the upper half of the switch. To cancelthe hazard warning lights, press the lower half of theswitch.

Fire ExtinguisherAn optional factory-installed fire extinguisher may belocated in the cab by the driver’s door, between theseats, or in the sleeper baggage compartment, ifequipped.

Emergency KitAn optional emergency reflector kit containing threetriangular reflectors may be supplied in the cab.

WARNINGUse extreme care when placing flares in emer-gency situations that involve exposure to flam-mable substances such as fuel. An explosion orfire could occur causing serious personal injury.

If there is an emergency while driving, cautiously pulloff the road. Turn on the hazard warning lights. Placethe reflectors and flares along the side of the road toalert other drivers that an emergency situation exists.

Emergency FilterReplacement, DAVCOIf the filter cover on the DAVCO fuel/water separatoris 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 web site for additional informa-tion, www.davcotec.com.

WARNINGFluid circulated through the fuel/water separatorto heat the fuel may be diesel fuel returned fromthe engine, or engine coolant. Drain the fuel/water separator only when the engine and fluidshave cooled. Draining it when the engine is hotcould cause severe personal injury due to scald-ing.

If returning fuel is released into the atmosphere,its vapors can ignite in the presence of any igni-tion source. Do not expose the fuel to, or workwith the fuel system near, open flame or intenseheat. To do so could cause fire, possibly result-ing in serious personal injury or property dam-age.

1. Shut down the engine, apply the parking brake,and chock the tires.

2. Put a clean receptacle under the fuel/water sepa-rator and attach a piece of hose to the drainvalve, to direct fuel into the receptacle.

NOTE: The drain valve on the Fuel Pro 382 hasa 1/2-inch (12.7-mm) opening; use a hose witha 1/2-inch pipe thread to fit correctly.

3. Remove the vent cap (Fig. 24.2, Item 9) andopen the drain valve (Fig. 24.2, Item 13) to drainthe fuel to just below the collar level, then closethe drain valve.

4. Using a DAVCO collar wrench (Fig. 24.3), re-move the clear cover and collar.

NOTE: Broken vent cap and collar warrantyclaims will not be accepted if any tool other thana DAVCO collar wrench, p/n 482017, is used forremoval. During installation, the vent cap andcollar are to be hand-tightened only, not tight-ened with a wrench.

5. Remove the filter and dispose of it in an environ-mentally acceptable manner.

6. Clean all threads and sealing surfaces very thor-oughly. Even a small amount of dirt will preventthe fuel/water separator from sealing, and an airleak will result.

7. Ensure that the drain valve is closed.

10/01/2014 f611275

Fig. 24.1, Hazard Warning Light Switch

In An Emergency

24.1

www.davcotec.com

8. Remove the filter grommet from the filter stud, ifequipped.

9. Fill the housing to the top with clean diesel fuel.

10. Install a standard fuel filter element on the filterstud. If a standard filter element is not available,install a spin-on fuel filter element (part numberFF105 or equivalent).

11. Install the cover O-ring, clear cover, and the col-lar. Hand-tighten the collar.

12. Install and hand-tighten the vent cap O-ring andvent cap.

13. Start the engine. When the lubricating oilreaches its normal operating pressure, increaseengine speed to high idle for one to two minutesto purge air from the system.

Emergency Starting WithJumper CablesWhen using jumper cables, follow the instructionsbelow.

WARNINGBatteries release explosive gas. Do not smokewhen working around batteries. Put out all flamesand remove all sources of sparks or intense heatin the vicinity of the battery. Do not allow the ve-hicles to touch each other. Do not lean over thebatteries when making connections, and keep allother persons away from the batteries. Failure tofollow these precautions could lead to severepersonal injury as a result of an explosion oracid burns.

NOTICEMake sure both electrical systems are the samevoltage. Electronic devices on both vehicles can

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02/16/2009 f470277

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FOR REMOVAL OF TOP COLLAR ONLY

Fig. 24.3, DAVCO Collar Wrench

In An Emergency

24.2

be damaged when connected to a vehicle with adifferent operating voltage.

1. Apply the parking brakes and turn off all lightsand other electrical devices. Ensure that the ve-hicles are not touching and both ignition switchesare turned to the OFF position.

IMPORTANT: Do not attempt to jump start adamaged battery.

2. Remove the battery box cover.

NOTE: The batteries on a Western Star vehiclemay be located in a variety of locations, includ-ing under the passenger seat, under the cab,behind the cab, or under the sleeper bunk, ifequipped. Some vehicles may have two batter-ies in the step compartments on both sides ofthe vehicle.

NOTICEAlways connect the batteries and jumper cablescorrectly (positive-to-positive and negative-to-negative). Connecting a charging device back-wards (positive-to-negative) can severely damagethe vehicle electrical content and cause non-warrantable failures.

IMPORTANT: On vehicles equipped with op-tional jump start posts, connect to these postsinstead of the battery terminals. Jump startposts may be installed in various locations onthe vehicle. See Fig. 24.4.

3. Connect the positive (+) jumper cable to thepositive terminal or jump start post on the dis-charged battery. See Fig. 24.5.

4. Connect the other end of the positive jumpercable to the positive terminal or jump start poston the booster battery providing the charge.

WARNINGDo the next step exactly as instructed and do notallow the clamps of one cable to touch theclamps of the other cable. Otherwise, a sparkcould occur near a battery, possibly resulting insevere personal injury from explosion or acidburns.

5. Connect the negative (-) jumper cable to thenegative terminal or jump start post on thebooster battery.

6. Connect the other end of the negative jumpercable to the negative ground stud on the vehiclerequiring the jump start.

7. Start the engine of the vehicle providing the jumpstart and let the engine run a few minutes tocharge the batteries of the other vehicle.

8. Attempt to start the engine of the vehicle receiv-ing the jump. Do not operate the starter longerthan 30 seconds, and wait at least two minutesbetween starting attempts to allow the starter tocool.

9. When the engine starts, let it idle a few minutes.


10. Disconnect the negative jumper cable from thenegative cable stud on the jump started vehicle.

11. Disconnect the negative jumper cable from thebooster battery.

12. Disconnect the positive cable from the boosterbattery.

NEG JUMP

START STUD

POS JUMPSTART STUD

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1. Frame Rail2. Negative Jump Start Post3. Positive Jump Start Post

Fig. 24.4, Possible Jump Start Post Location(passenger-side engine compartment)

In An Emergency

24.3

13. Disconnect the other end of the positive jumpercable from the jump started vehicle.

14. Install the battery box cover; be sure it is posi-tioned properly before fastening the latch.

TowingWhen it is necessary to tow the vehicle, make surethe instructions below are closely followed to preventdamage to the vehicle.

WARNINGDo not tow an unbraked vehicle if the combinedweight of both vehicles is more than the sum ofthe gross axle weight ratings (GAWR) of the tow-ing vehicle. Otherwise brake capacity will be in-adequate, which could result in personal injury ordeath.

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Disconnect jumper cables in the REVERSE order that they were connected.

A. Discharged BatteryB. Negative Ground Stud

C. Positive Jumper CableD. Negative Jumper Cable

E. Booster Battery

1. 1st Connection: Positive Jumper Cable to Discharged Battery2. 2nd Connection: Positive Jumper Cable to Booster Battery3. 3rd Connection: Negative Jumper Cable to Booster Battery4. 4th Connection: Negative Jumper Cable to Negative Ground Stud (discharged battery)

Fig. 24.5, Jumper Connections

In An Emergency

24.4

Front Towing Hookup1. Disconnect the batteries at the negative termi-

nals.

NOTICEFailure to remove the driveline(s) or the driveaxle shafts when towing the vehicle with the rearwheels on the ground could result in damage tothe transmission and other parts.

2. Remove the driveline and the interaxle driveline(if equipped), or the axle shafts for each axle thatmay touch the ground during the towing process.

3. For any axle shaft that has been removed, coverthe ends of the hubs with metal plates or ply-wood cut to fit the axle opening, and drilled to fitthe axle shaft studs. This prevents lubricant fromleaking out and will keep contaminants from get-ting into and damaging the wheel bearings andaxle lubricant.

If the driveline(s) were removed, ensure theU-joint caps are secure so they will not come off.

NOTICEFailure to protect the frame rails from the chainscould cause damage, leading to eventual framefailure.

4. If a vehicle with tandem rear axles is to be liftedand towed, chain the forward rear-axle assemblyto the vehicle frame. This will prevent the forwardrear-axle assembly from dropping and keep itswheels off the ground while being towed.

Use protection to keep the chains from damagingthe frame.

5. Remove the bumper end caps and chrome bum-per, if equipped.

NOTICEDo not pass a sling (for example, a rope or chain)from one tow hook to another to fasten for tow-ing. Known as reeving, this practice is not per-missible in most industrial applications of towingand hoisting. Reeving can overload the hooksand result in damage to the vehicle.

6. Attach the towing device.

NOTE: Due to the many variables that exist intowing, positioning the lifting and towing deviceis the sole responsibility of the towing-vehicleoperator.

7. Lift the vehicle and secure the safety chains. Ifextra towing clearance is needed, remove thefront wheels.

8. Connect the clearance lights, taillights, and sig-nal lights. Connect any special towing lights re-quired by local regulations.

WARNINGFailure to chock the tires or connect the towtruck’s air brake system before releasing thespring parking brakes could allow the disabledvehicle to suddenly roll. This could cause prop-erty damage or personal injury.

9. Chock the tires on the disabled vehicle and con-nect the towing vehicle’s air brake system to thevehicle being towed. Then, release the springparking brakes and remove the chocks.

Rear Towing Hookup

NOTICEUsing a rear towing hookup on a vehicleequipped with a roof fairing could cause damageto the cab structure.

If reverse towing at speeds above 45 mph (70kph) is necessary, hold down the cab with ten-sion straps looped over the cab shocks andunder the frame rails. Failure to do so couldallow the wind load to lift the cab unexpectedly,resulting in damage to the air springs and othercomponents.

1. If the vehicle is equipped with cab air suspen-sion, and reverse towing at speeds above 45mph (70 kph) is necessary, hold down the cab asfollows:

1.1 Drain the air from the cab air springs.

1.2 Loop a 2-inch (5-cm) ratchet-style tensionstrap (rated 2000 lb [900 kg] minimumwork load) over the top of the cab shockand under the frame rail. Tighten the strapfor a snug fit. If the cab is equipped withtwo or more shocks, restrain the aftmostshock on each side of the vehicle.

In An Emergency

24.5

2. Place the front tires straight forward and securethe steering wheel in this position.

3. Disconnect the battery ground cables.


4. On dual drive axles, using protection to keep thechains from damaging the vehicle frame, chainthe forward-rear drive axle to the frame.



6. Lift the vehicle and secure the safety chains. Ifextra clearance is needed, remove the bumperextension if equipped.

7. Connect the clearance lights, taillights, and sig-nal lights. Also connect any special towing lightsrequired by local regulations.

Fire in the CabThe incidence of fire in trucks is rare, according todata from the National Highway Traffic Safety Admin-istration. Federal Motor Vehicle Safety Standard#302 limits the flammability of specified materialsused inside the cab, but despite this, most materialswill burn. The cab of this vehicle contains urethanefoam, which is of concern in this respect.

WARNINGUrethane foam is flammable! Do not allow anyflames, sparks, or other heat sources such ascigarettes or light bulbs to contact urethanefoam. Urethane foam in contact with such heatsources could cause a serious, rapid fire, whichcould result in death, severe burns, or gas poi-soning, as well as damage to the vehicle.

In Case of a Cab FireAs quickly as possible, bring the vehicle to a safestop, apply the parking brake, turn off the ignition,and get out of the vehicle.

In An Emergency

24.6

25

Telematics DataTerms of Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.1

Terms of UseYour vehicle ("Vehicle") may be equipped with one ormore devices that gather information describedbelow regarding the Vehicle and the environment inwhich it may be operating ("Telematics Information").The devices may periodically send Telematics Infor-mation to Daimler Trucks North America LLC("DTNA"). Additionally, DTNA and its dealers maymanually retrieve Telematics Information from thedevices for the purposes described below.

Telematics Information We Collectand Why We Collect ItThe Telematics Information we collect may in-clude, but is not limited to, information regardingthe performance, operation, location, speed,trips, travel history, stop and idle times, fuel con-sumption, fault codes and diagnostic information,steering and braking performance, air bag de-ployment and seatbelt use, decelerations, andother information relating to the performance,operation, health and safety of your Vehicle.DTNA gathers this information in order to improvethe performance, operation, health and safety of yourVehicle and other DTNA vehicles and products, inthe following ways, among others:

• To enable your subscription services. DTNAand other third party service providers havedeveloped a variety of applications and ser-vices that are now available to you to optimizethe performance, use, reliability and safe op-eration of your Vehicle. These services are en-abled by the Telematics Information we receivefrom your Vehicle and will likely be made moreeffective in the future by the use of that Telem-atics Information and similar information wereceive from other DTNA vehicles.

• To make your Vehicle safer and to improveits performance. Depending on the type ofdevice installed on your Vehicle, DTNA mayperiodically update your Vehicle’s on-boardsoftware to improve the performance and safeuse of the Vehicle. We may need to obtain cer-tain Telematics Information to ensure the effec-tiveness of these updates.

• To monitor and manage the health and effi-ciency of your Vehicle. Telematics Informa-tion from your Vehicle may be used by DTNAand its affiliates, dealers and service providersto diagnose and resolve problems with your

Vehicle more effectively and to help you main-tain it.

• To improve your customer service experi-ence. Telematics Information may be used byDTNA and its affiliates, dealers and serviceproviders to provide you a more efficient andeffective customer service experience in con-junction with Vehicle service, maintenance,field service campaigns and recalls.

• For product development and product im-provement. Telematics Information may beanalyzed and used to identify and resolve per-formance and safety issues and to developimprovements to our products that will benefityou and our future customers.

• To develop more meaningful product mar-keting. Telematics Information may be used toprovide more customized and meaningful infor-mation to our customers regarding productsand services that best satisfy their operationalrequirements and improve the performance oftheir businesses.

• To help match our customers with the rightproducts. Telematics Information may be usedto develop future products and services thatbest satisfy the operational requirements of ourcustomers.

What We Do with TelematicsInformation and Who We Share ItWithDTNA may use Telematics Information for any pur-pose allowed by law, including but not limited tousing the information for any of the purposes de-scribed in this chapter. DTNA may share TelematicsInformation with its service providers, affiliates, sub-sidiaries, dealers and distributors, but only for lawfulbusiness purposes. This may include third partieswho process information on behalf of DTNA, thirdparties who you authorize directly to receive informa-tion from us, and law enforcement agencies pursuantto applicable law.

DTNA may also combine Telematics Information itobtains from your Vehicle with data from others, ano-nymize and de-identify that aggregated data ("Aggre-gated Data"), and use and disclose that AggregatedData and derivatives of it indefinitely and for any pur-pose whatsoever, including sharing it with third par-ties for any purpose without restriction. You will not

Telematics Data

25.1

have any rights in any Aggregated Data or any de-rivatives or proceeds of it. DTNA will be the exclusiveowner of all rights, title and interests in and to all Ag-gregated Data. DTNA shall not have any obligation toprovide any Aggregated Data to you or to compen-sate you for any use or disclosure of any AggregatedData.

Collection MethodThe Telematics Information may be transmitted auto-matically or manually from the devices on your Ve-hicle to DTNA or Detroit Diesel Corporation (DDC)through diagnostic tools, including but not limited toDDC DiagnosticLink.

SafeguardsDTNA will use reasonable data security systems andprocedures in an effort to protect Telematics Informa-tion from unauthorized use, access, disclosure, distri-bution, loss or alteration. We do this through physi-cal, electronic and procedural safeguards that aredesigned to protect the confidentiality, integrity andavailability of Telematics Information. However, nosecurity system is perfect. DTNA cannot guaranteethat Telematics Information will not be hacked, de-leted, intercepted or altered. DTNA will also requireother parties to whom Telematics Information is dis-closed to take reasonable steps to protect the Telem-atics Information from unauthorized use, access, dis-closure, distribution, loss or alteration.

Your ConsentBy continuing to provide to us, or allowing us to re-ceive or retrieve, Telematics Information through thedevices on your Vehicle, you consent to its collectionand use as described in this chapter. Although someinformation may be transferred to and processed incountries without laws providing the same level ofdata protection as your country, our use and disclo-sure of your information is subject to these terms ofuse regardless of where your information is trans-ferred. If you have subscribed to a subscriptionservice such as Virtual Technician or Detroit Ana-lytics, the Telematics Terms and Conditions forthat service will apply to DTNA’s collection, stor-age, use and sharing of the data covered bythose Terms and Conditions.

Your RightsYou may ask DTNA to discontinue receiving and re-trieving Telematics Information from the devices onyour Vehicle. If you do so, you will be unable to re-

ceive telematics subscription services relating to yourVehicle and unable to remotely receive important Ve-hicle software updates, among other things. If youare interested in that option, please contact DTNA at:[email protected].

Privacy Statement ChangesDTNA reserves the right to amend these terms ofuse from time to time. Changes will be reflected inthe online version of this document found at: https://cmspublish-dtna.prd.freightliner.com/content/public/dtnaconnect---daimler-trucks-north-america.html. By continuing to provide to us, orallowing us to receive or retrieve, Telematics In-formation through the devices on your Vehicle,you consent to and accept those changes.

NOTE: These terms of use do not apply to after-market telematics devices that may be providedby others or configured to send information tosomeone other than DTNA or its affiliates,dealers or service providers.

Telematics Data

25.2

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Subject Page

AAccessory Heaters . . . . . . . . . . . . . . . . . . . . . . . . 6.8

Espar Heater . . . . . . . . . . . . . . . . . . . . . . . . . 6.8Webasto Heater . . . . . . . . . . . . . . . . . . . . . . . 6.9

Adjustable Steering ColumnControls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.15

Adjusting Headlight Aim . . . . . . . . . . . . . . . . . . . 20.1Air Brake System . . . . . . . . . . . . . . . . . . . . . . . . 13.1

Automatic Slack Adjusters . . . . . . . . . . . . . . . . 13.3Brake System Components . . . . . . . . . . . . . . . 13.1Brake System General

Information . . . . . . . . . . . . . . . . . . . . . . . . . 13.1Brake System Operation . . . . . . . . . . . . . . . . . 13.2

BBack-of-Cab Access . . . . . . . . . . . . . . . . . . . . . . . 2.3

Accessing Back-of-Cab Area . . . . . . . . . . . . . . . 2.4Exiting Back-of-Cab Area . . . . . . . . . . . . . . . . . 2.4

Battery Access . . . . . . . . . . . . . . . . . . . . . . . . . . 9.2Battery Disconnect Switch . . . . . . . . . . . . . . . . . . . 9.1

CCab Amenities . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.1

Cab Lighting . . . . . . . . . . . . . . . . . . . . . . . . . . 8.3Cigar Lighter/Accessory

Plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.2Cup Holders . . . . . . . . . . . . . . . . . . . . . . . . . . 8.2Electronic Device Mount . . . . . . . . . . . . . . . . . . 8.2Glove Box . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.2Storage Areas . . . . . . . . . . . . . . . . . . . . . . . . . 8.3

Cab Climate Control Panels . . . . . . . . . . . . . . . . . . 6.1Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.1Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3

Cab Washing and Polishing . . . . . . . . . . . . . . . . . 21.1Canadian Motor Vehicle Safety

Standard Labels . . . . . . . . . . . . . . . . . . . . . . . . 1.2Care of Chrome Parts . . . . . . . . . . . . . . . . . . . . . 21.1Care of Exterior Lights . . . . . . . . . . . . . . . . . . . . 21.1Care of Fiberglass Parts . . . . . . . . . . . . . . . . . . . 21.1Checking Headlight Aim . . . . . . . . . . . . . . . . . . . 20.1Checklists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22.1

Daily Pretrip InspectionChecklists . . . . . . . . . . . . . . . . . . . . . . . . . 22.1

Monthly Post-trip InspectionChecklists . . . . . . . . . . . . . . . . . . . . . . . . . 22.2

Weekly Post-trip InspectionChecklist . . . . . . . . . . . . . . . . . . . . . . . . . . 22.1

Climate Control Options . . . . . . . . . . . . . . . . . . . . 6.1Climate Controls . . . . . . . . . . . . . . . . . . . . . . . . 4.16Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.5

Subject Page

Clutch Maintenance . . . . . . . . . . . . . . . . . . . . 16.6Clutch Operation . . . . . . . . . . . . . . . . . . . . . . 16.5General Information . . . . . . . . . . . . . . . . . . . . 16.5

Component GWR Label . . . . . . . . . . . . . . . . . . . . 1.2Component Information Label . . . . . . . . . . . . . . . . 1.1Control Panels . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1Cruise Control . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.8

Cruise Control ("CC") Limiter . . . . . . . . . . . . . . . 4.9Descent Control and

Deceleration Modes,Detroit™ AutomatedTransmissions . . . . . . . . . . . . . . . . . . . . . . . 4.10

DDaily Pretrip Inspections and

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . 23.1Cab Inspection . . . . . . . . . . . . . . . . . . . . . . . 23.5Engine Compartment

Inspection . . . . . . . . . . . . . . . . . . . . . . . . . 23.4Saddle Tank Areas

Inspection . . . . . . . . . . . . . . . . . . . . . . . . . 23.4Suspension and Slack

Adjuster Inspection . . . . . . . . . . . . . . . . . . . 23.1Wheel and Tire Inspection . . . . . . . . . . . . . . . . 23.2

Dashboard and InstrumentPanel Care . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.2

Dash-Mounted Brake Controls . . . . . . . . . . . . . . . 4.10Antilock Braking System . . . . . . . . . . . . . . . . . 4.11Parking Brake Control Valve . . . . . . . . . . . . . . . 4.11Trailer Air Supply Valve . . . . . . . . . . . . . . . . . . 4.11Trailer Brake Lever . . . . . . . . . . . . . . . . . . . . . 4.11

Detroit™ AutomatedTransmissions . . . . . . . . . . . . . . . . . . . . . . . . . 15.1Clutch Abuse Protection . . . . . . . . . . . . . . . . . 15.4Creep Mode . . . . . . . . . . . . . . . . . . . . . . . . . 15.3Detroit™ Multifunction

Control . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.1Driving Modes . . . . . . . . . . . . . . . . . . . . . . . . 15.2eCoast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.3Engine Overspeed Alerts . . . . . . . . . . . . . . . . . 15.4Gear Display Window . . . . . . . . . . . . . . . . . . . 15.2Low Transmission Air

Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.5Power Up and Shift into

Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.2Selected Gear . . . . . . . . . . . . . . . . . . . . . . . . 15.3Suggested Shift . . . . . . . . . . . . . . . . . . . . . . . 15.3

Diesel Exhaust Fluid and Tank,EPA10 and Newer Engines . . . . . . . . . . . . . . . . 12.3DEF Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.4DEF Warnings and Engine

Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.4Diesel Exhaust Fluid . . . . . . . . . . . . . . . . . . . . 12.3

Index

I-1

Subject Page

Fuel/DEF Gauge . . . . . . . . . . . . . . . . . . . . . . 12.4Differential Lock, Drive Axles . . . . . . . . . . . . . . . . 17.1

Differential Lock Operation . . . . . . . . . . . . . . . . 17.1Differential Lock Switch . . . . . . . . . . . . . . . . . . 17.1Single Drive Axles with

Traction Equalizer . . . . . . . . . . . . . . . . . . . . 17.2Door Locks and Handles . . . . . . . . . . . . . . . . . . . . 2.1

Remote Keyless Entry . . . . . . . . . . . . . . . . . . . 2.1Driver Message Center . . . . . . . . . . . . . . . . . . . . 3.11

ICU4Me . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.11

EEaton Fuller 10-Speed Range-

Shift Transmissions . . . . . . . . . . . . . . . . . . . . . 16.4General Information, Eaton

Fuller Range-Shift . . . . . . . . . . . . . . . . . . . . 16.4Operation, Eaton Fuller

Range-Shift . . . . . . . . . . . . . . . . . . . . . . . . 16.4Eaton Fuller 13-Speed and 18-

Speed Splitter and Range-Shift Transmissions . . . . . . . . . . . . . . . . . . . . . 16.1General Information, Eaton

Fuller Splitter and Range-Shift Transmissions . . . . . . . . . . . . . . . . . . . 16.1

Operation, Eaton FullerSplitter and Range-ShiftTransmissions . . . . . . . . . . . . . . . . . . . . . . . 16.2

Eaton® Fuller® TransmissionOperation Tips . . . . . . . . . . . . . . . . . . . . . . . . 16.1

Emergency Filter Replacement,DAVCO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24.1

Emergency Kit . . . . . . . . . . . . . . . . . . . . . . . . . . 24.1Emergency Starting With

Jumper Cables . . . . . . . . . . . . . . . . . . . . . . . . 24.2Emissions Labels . . . . . . . . . . . . . . . . . . . . . . . . . 1.2

Aftertreatment SystemIndicators Label . . . . . . . . . . . . . . . . . . . . . . 1.2

Certified Clean Idle Label . . . . . . . . . . . . . . . . . 1.3EPA Noise Emission Control

Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2Vehicle Emission Control

Information Label . . . . . . . . . . . . . . . . . . . . . 1.3Engine Brake . . . . . . . . . . . . . . . . . . . . . . . . . . 13.5

Engine Brake Operation . . . . . . . . . . . . . . . . . 13.6Engine Cooling . . . . . . . . . . . . . . . . . . . . . . . . . 10.3Engine Idle Limiting . . . . . . . . . . . . . . . . . . . . . . 11.2

California Engine IdleLimiting . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.2

Idle Shutdown Timer . . . . . . . . . . . . . . . . . . . . 11.2Engine Operation . . . . . . . . . . . . . . . . . . . . . . . . 10.1

Cold-Weather Operation . . . . . . . . . . . . . . . . . 10.2Engine Break-In . . . . . . . . . . . . . . . . . . . . . . . 10.2Normal Operation . . . . . . . . . . . . . . . . . . . . . . 10.2

Subject Page

Safety and EnvironmentalConsiderations . . . . . . . . . . . . . . . . . . . . . . 10.1

Engine Protection—Warningand Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . 11.1

Engine Shutdown . . . . . . . . . . . . . . . . . . . . . . . . 10.3Engine Starting . . . . . . . . . . . . . . . . . . . . . . . . . 10.1

Cold-Weather Starting . . . . . . . . . . . . . . . . . . . 10.1Starting After Extended

Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . 10.1Enhanced Stability Control . . . . . . . . . . . . . . . . . . 5.8EPA-Regulated Emissions

Aftertreatment Systems . . . . . . . . . . . . . . . . . . . 12.1ATS Warning Lamps . . . . . . . . . . . . . . . . . . . . 12.3EPA07 Engines . . . . . . . . . . . . . . . . . . . . . . . 12.1EPA10 and Newer Engines . . . . . . . . . . . . . . . 12.1Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . 12.3Regeneration . . . . . . . . . . . . . . . . . . . . . . . . 12.2

FFederal Motor Vehicle Safety

Standard Labels . . . . . . . . . . . . . . . . . . . . . . . . 1.1Fifth Wheel Coupling . . . . . . . . . . . . . . . . . . . . . 18.1

Coupling, Fontaine andHolland Fifth Wheels . . . . . . . . . . . . . . . . . . 18.1

Coupling, Jost Fifth Wheel . . . . . . . . . . . . . . . . 18.3Fifth Wheel Slide . . . . . . . . . . . . . . . . . . . . . . . . 18.7

Air Slide Operation . . . . . . . . . . . . . . . . . . . . . 18.8Manual Slide Operation . . . . . . . . . . . . . . . . . . 18.7

Fifth Wheel Uncoupling . . . . . . . . . . . . . . . . . . . . 18.4Air-Actuated Uncoupling . . . . . . . . . . . . . . . . . 18.5Manual Uncoupling . . . . . . . . . . . . . . . . . . . . . 18.4

Fifth Wheels, GeneralInformation . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.1Air Suspension Height

Control Switch . . . . . . . . . . . . . . . . . . . . . . . 18.1Fifth Wheel Lubrication . . . . . . . . . . . . . . . . . . 18.1

Fire Extinguisher . . . . . . . . . . . . . . . . . . . . . . . . 24.1Fire in the Cab . . . . . . . . . . . . . . . . . . . . . . . . . 24.6

In Case of a Cab Fire . . . . . . . . . . . . . . . . . . . 24.6Fluids Added . . . . . . . . . . . . . . . . . . . . . . . . . . . 22.2

GGrab Handles and Access

Steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1Entering the Driver’s Side . . . . . . . . . . . . . . . . . 2.2Entering the Passenger’s

Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2Exiting the Driver’s Side . . . . . . . . . . . . . . . . . . 2.2Exiting the Passenger’s Side . . . . . . . . . . . . . . . 2.3

Index

I-2

Subject PageGreenhouse Gas Emissions

and Fuel ConsumptionStandards . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.1

HHazard Warning Lights . . . . . . . . . . . . . . . . . . . . 24.1Holland Trailer Coupling . . . . . . . . . . . . . . . . . . . 19.1

General Information . . . . . . . . . . . . . . . . . . . . 19.1Trailer Hookup . . . . . . . . . . . . . . . . . . . . . . . . 19.1Trailer Release . . . . . . . . . . . . . . . . . . . . . . . 19.1

Hood Opening and Closing . . . . . . . . . . . . . . . . . . 2.4Closing the Hood . . . . . . . . . . . . . . . . . . . . . . . 2.4Opening the Hood . . . . . . . . . . . . . . . . . . . . . . 2.4

Horn Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.5Air Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.5Electric Horn . . . . . . . . . . . . . . . . . . . . . . . . . . 4.5

IIgnition Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1Instrumentation Control Units . . . . . . . . . . . . . . . . . 3.1

Audible Alerts . . . . . . . . . . . . . . . . . . . . . . . . . 3.2Ignition Sequence . . . . . . . . . . . . . . . . . . . . . . 3.1

Instruments . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.6Air Intake Restriction Gauge . . . . . . . . . . . . . . . 3.6Application Air Pressure

Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.7Coolant Temperature Gauge . . . . . . . . . . . . . . . 3.7Drive Axle Oil Temperature

Gauges . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.8Engine Oil Pressure Gauge . . . . . . . . . . . . . . . . 3.8Engine Oil Temperature

Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.9Fuel/Diesel Exhaust Fluid

(DEF) Gauge . . . . . . . . . . . . . . . . . . . . . . . . 3.9Primary and Secondary Air

Pressure Gauges . . . . . . . . . . . . . . . . . . . . . 3.9Speedometer . . . . . . . . . . . . . . . . . . . . . . . . 3.10Suspension Air Pressure

Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.10Tachometer . . . . . . . . . . . . . . . . . . . . . . . . . . 3.10Transmission Fluid

Temperature Gauge . . . . . . . . . . . . . . . . . . . 3.10Turbocharger Boost

Pressure Gauge . . . . . . . . . . . . . . . . . . . . . 3.10Voltmeter . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.11

Interaxle Lock, Tandem Axles . . . . . . . . . . . . . . . . 17.2Interaxle Lock Operation . . . . . . . . . . . . . . . . . 17.2Interaxle Lock Switch . . . . . . . . . . . . . . . . . . . 17.2

Inverter/Charger . . . . . . . . . . . . . . . . . . . . . . . . . 9.3

Subject Page

LLane Departure Warning

Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.4Lighting Controls . . . . . . . . . . . . . . . . . . . . . . . . . 4.2

Exterior Lighting Controls . . . . . . . . . . . . . . . . . 4.2Interior Lighting Controls . . . . . . . . . . . . . . . . . . 4.3

Low Voltage Disconnect . . . . . . . . . . . . . . . . . . . . 9.2

MMeritor WABCO® Antilock

Braking System . . . . . . . . . . . . . . . . . . . . . . . . 13.4Automatic Traction Control . . . . . . . . . . . . . . . . 13.4ECAS Automatic Load

Transfer (ECAS only) . . . . . . . . . . . . . . . . . . 13.5Trailer ABS Compatibility . . . . . . . . . . . . . . . . . 13.4

Monthly Post-Trip Inspectionsand Maintenance . . . . . . . . . . . . . . . . . . . . . . 23.10Brake Component Inspection . . . . . . . . . . . . . 23.10Engine Compartment

Inspection andAdjustments . . . . . . . . . . . . . . . . . . . . . . . 23.11

Saddle Tank AreasInspection . . . . . . . . . . . . . . . . . . . . . . . . . 23.11

OOnGuard™ Collision Safety

System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1Adaptive Cruise Control

(ACC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.2Additional Features . . . . . . . . . . . . . . . . . . . . . 5.3Collision Mitigation System

(CMS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.2Error Screens . . . . . . . . . . . . . . . . . . . . . . . . . 5.3OnGuard Display Unit . . . . . . . . . . . . . . . . . . . . 5.1System Limitations . . . . . . . . . . . . . . . . . . . . . . 5.1

OnLane™ Lane DepartureWarning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.5Driver Alertness Warning . . . . . . . . . . . . . . . . . . 5.6Intentional Lane Changes . . . . . . . . . . . . . . . . . 5.5System Startup . . . . . . . . . . . . . . . . . . . . . . . . 5.5Temporarily Disabling the

System . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.6Unintentional Lane

Departure . . . . . . . . . . . . . . . . . . . . . . . . . . 5.5Overhead Instrument Panel . . . . . . . . . . . . . . . . . 3.15

PParked HVAC . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.7

Parked-HVAC Controls . . . . . . . . . . . . . . . . . . . 6.7

Index

I-3

Subject PagePeriodic Inspections and

Maintenance, GeneralInformation . . . . . . . . . . . . . . . . . . . . . . . . . . . 22.1

Power Steering System . . . . . . . . . . . . . . . . . . . . 14.1Steering Wheel Adjustment . . . . . . . . . . . . . . . 14.1

Power Takeoff (PTO) Governor . . . . . . . . . . . . . . . 11.2Powertrain Controls . . . . . . . . . . . . . . . . . . . . . . . 4.5

Aftertreatment SystemRegen Switches . . . . . . . . . . . . . . . . . . . . . . 4.5

Axle Switches . . . . . . . . . . . . . . . . . . . . . . . . . 4.5Engine Brake Switches . . . . . . . . . . . . . . . . . . . 4.6Engine Fan Switch . . . . . . . . . . . . . . . . . . . . . . 4.7Hill Start Aid Override Switch . . . . . . . . . . . . . . . 4.7Power Takeoff Controls . . . . . . . . . . . . . . . . . . . 4.7Shutdown Override Switch . . . . . . . . . . . . . . . . 4.7Transmission Controls . . . . . . . . . . . . . . . . . . . 4.8

Preliminary Checks . . . . . . . . . . . . . . . . . . . . . . . 20.1

RRadio/Bluetooth Controls . . . . . . . . . . . . . . . . . . . 4.16Roll Stability System . . . . . . . . . . . . . . . . . . . . . . . 5.6

Hard-Braking Advisor . . . . . . . . . . . . . . . . . . . . 5.7Roll Stability Advisor . . . . . . . . . . . . . . . . . . . . . 5.6Roll Stability Control . . . . . . . . . . . . . . . . . . . . . 5.6Trip/Leg Totals . . . . . . . . . . . . . . . . . . . . . . . . 5.7

SSafety Precautions . . . . . . . . . . . . . . . . . . . . . . . 23.1Seat Belts and Tether Belts . . . . . . . . . . . . . . . . . . 7.3

Seat Belt Inspection . . . . . . . . . . . . . . . . . . . . . 7.3Seat Belt Operation . . . . . . . . . . . . . . . . . . . . . 7.4

Seat Controls . . . . . . . . . . . . . . . . . . . . . . . . . . 4.16Seats, General Information . . . . . . . . . . . . . . . . . . 7.1Sleeper Amenities . . . . . . . . . . . . . . . . . . . . . . . . 8.3

Baggage CompartmentDoors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.3

Sleeper Door . . . . . . . . . . . . . . . . . . . . . . . . . 8.4Sleeper Lighting . . . . . . . . . . . . . . . . . . . . . . . 8.3Sliding Side Window . . . . . . . . . . . . . . . . . . . . 8.4Vent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.4

Sleeper Climate Control Panels . . . . . . . . . . . . . . . 6.3Accessory Heaters . . . . . . . . . . . . . . . . . . . . . . 6.6Controls, Vehicles With ATC . . . . . . . . . . . . . . . 6.4Controls, Vehicles Without

ATC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.4Sleeper Compartment

Restraints . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.6Bunk Restraint Adjustment . . . . . . . . . . . . . . . . 7.6

Suspension/Trailer ConnectionControls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.13

Subject Page

Air Suspension HeightControl Switch . . . . . . . . . . . . . . . . . . . . . . . 4.13

ECAS Dash Switches . . . . . . . . . . . . . . . . . . . 4.13ECAS Remote Control Unit . . . . . . . . . . . . . . . 4.14Fifth Wheel Slide Control

Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.15Trailer Auxiliary Switch . . . . . . . . . . . . . . . . . . 4.15

TTerms of Use . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.1

Collection Method . . . . . . . . . . . . . . . . . . . . . 25.2Privacy Statement Changes . . . . . . . . . . . . . . . 25.2Safeguards . . . . . . . . . . . . . . . . . . . . . . . . . . 25.2Telematics Information We

Collect and Why WeCollect It . . . . . . . . . . . . . . . . . . . . . . . . . . 25.1

What We Do with TelematicsInformation and Who WeShare It With . . . . . . . . . . . . . . . . . . . . . . . 25.1

Your Consent . . . . . . . . . . . . . . . . . . . . . . . . 25.2Your Rights . . . . . . . . . . . . . . . . . . . . . . . . . . 25.2

Towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24.4Front Towing Hookup . . . . . . . . . . . . . . . . . . . 24.5Rear Towing Hookup . . . . . . . . . . . . . . . . . . . 24.5

VVehicle Power Distribution . . . . . . . . . . . . . . . . . . . 9.1Velour Upholstery Cleaning . . . . . . . . . . . . . . . . . 21.3

Chewing Gum or Wax . . . . . . . . . . . . . . . . . . . 21.3Grease and Oil-Based Stains . . . . . . . . . . . . . . 21.3Mildew . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.3Sugar and Water-Based

Stains . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.3Vinyl Upholstery Cleaning . . . . . . . . . . . . . . . . . . 21.2

Ball Point Ink . . . . . . . . . . . . . . . . . . . . . . . . . 21.3Chewing Gum . . . . . . . . . . . . . . . . . . . . . . . . 21.2Miscellaneous . . . . . . . . . . . . . . . . . . . . . . . . 21.3Nail Polish and Nail Polish

Remover . . . . . . . . . . . . . . . . . . . . . . . . . . 21.2Ordinary Dirt . . . . . . . . . . . . . . . . . . . . . . . . . 21.2Paint, Shoe Heel Marks . . . . . . . . . . . . . . . . . 21.2Shoe Polish . . . . . . . . . . . . . . . . . . . . . . . . . 21.2Sulfide Stains . . . . . . . . . . . . . . . . . . . . . . . . 21.2Tars, Asphalts, and Creosote . . . . . . . . . . . . . . 21.2

WWarning and Indicator Lights . . . . . . . . . . . . . . . . . 3.2

Engine Protection System . . . . . . . . . . . . . . . . . 3.5Weekly Post-Trip Inspections

and Maintenance . . . . . . . . . . . . . . . . . . . . . . . 23.8

Index

I-4

Subject Page

Engine CompartmentInspection . . . . . . . . . . . . . . . . . . . . . . . . . 23.8

Western Star High-Back Seat . . . . . . . . . . . . . . . . . 7.2Windows and Mirrors . . . . . . . . . . . . . . . . . . . . . . 8.1

Down-View Mirror . . . . . . . . . . . . . . . . . . . . . . 8.1Power Mirrors . . . . . . . . . . . . . . . . . . . . . . . . . 8.1Windows . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.1

Windshield Wiper and WasherControls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.12

Index

I-5

IntroductionThis manual provides information needed to operateand understand the vehicle and its components.More detailed information is contained in the Owner’sWarranty Information for North America booklet andin the vehicle’s workshop and maintenance manuals.

Custom-built Western Star vehicles are equippedwith various chassis and cab components. Not all ofthe information contained in this manual applies toevery vehicle. For details about components in yourvehicle, refer to the chassis specification pages in-cluded in all new vehicles and to the vehicle specifi-cation decal located inside the vehicle.

For your reference, keep this manual in the vehicleat all times.

IMPORTANT: Descriptions and specifications inthis manual were in effect at the time of printing.Western Star Trucks reserves the right to dis-continue models and to change specifications ordesign at any time without notice and withoutincurring obligation. Descriptions and specifica-tions contained in this publication provide nowarranty, expressed or implied, and are subjectto revisions and editions without notice.

Environmental Concerns andRecommendationsWhenever you see instructions in this manual to dis-card materials, you should first attempt to reclaimand recycle them. To preserve our environment, fol-low appropriate environmental rules and regulationswhen disposing of materials.

Event Data RecorderThis vehicle is equipped with one or more devicesthat record specific vehicle data. The type andamount of data recorded varies depending on howthe vehicle is equipped (such as the brand of engine,if an air bag is installed, or if the vehicle features acollision avoidance system, etc.).

This vehicle is equipped with an event data recorder(EDR). The main purpose of an EDR is to recorddata in certain crash or near-crash situations, suchas air bag deployment or hitting a road obstacle, thatwill assist in understanding how a vehicle’s systems

performed. The EDR is designed to record data re-lated to vehicle dynamics and safety systems for ap-proximately 60 seconds. This data can help providea better understanding of the circumstances in whichcrashes and injuries occur. Data recorded includesthe following items:

• how various systems in the vehicle were oper-ating

• engine system information

• how far (if at all) the driver was depressing theaccelerator

• if the driver was depressing the brake pedal

• how fast the vehicle was traveling

NOTE: Data is not recorded by the EDR undernormal driving conditions. Personal data suchas name, gender, age, and crash location arenot recorded. However, other parties such aslaw enforcement could combine the EDR datawith the type of personally identifying data rou-tinely acquired during a crash investigation.

To read data recorded by an EDR, special equipmentis required, and access to the vehicle or the EDR isneeded. In addition to the vehicle manufacturer, otherparties that have the special equipment, such as lawenforcement, can read the information if they haveaccess to the vehicle or the EDR.

Emissions and Fuel EfficiencyComplianceThis vehicle must be regularly inspected and main-tained as indicated in the Western Star MaintenanceManual, and in the Pre- and Post-Trip Inspectionsand Maintenance chapter in this manual, in order tocontinue satisfactory performance and ensure cover-age of the vehicle under the manufacturer’s warranty.Many maintenance procedures ensure that the ve-hicle and engine continue to comply with applicableemissions standards. Maintenance procedures, usingcomponents engineered to comply with greenhousegas emissions and fuel efficiency regulations, may beperformed by an authorized Daimler Trucks NorthAmerica dealer, an independent outlet, or the vehicleowner or operator.

The vehicle owner is responsible for determining thesuitability of replacement components to maintain

Foreword

STI-499-6 (7/17)A24-01858-000

Printed in U.S.A.

compliance with federal and local jurisdictional regu-lations. Components including, but not limited to,tires, cab/sleeper side extenders, chassis fairings,bumper, hood, vehicle speed limiters, and idle reduc-tion timers are specifically designed and manufac-tured to exacting standards for regulatory fuel effi-ciency and greenhouse gas emissions compliance. Itis important that these components are always re-placed with components that meet or exceed the per-formance of the originally installed components.

Customer Assistance CenterHaving trouble finding service? For over-the-roadbreakdown assistance, customer concerns, literaturerequests, and the location of the nearest dealer, call1-866-850-STAR (7827). Call night or day, weekdaysor weekends. Our people are knowledgeable, profes-sional, and committed to following through to helpyou keep your truck moving.

Reporting Safety DefectsIf you believe that your vehicle has a defect whichcould cause a crash or could cause injury ordeath, you should immediately inform the NationalHighway Traffic Safety Administration (NHTSA) inaddition to notifying Western Star Trucks.

If the NHTSA receives similar complaints, it mayopen an investigation, and if it finds that a safetydefect exists in a group of vehicles, it may order arecall and remedy campaign. However, NHTSAcannot become involved in individual problemsbetween you, your dealer, or Western Star Trucks.

To contact NHTSA, you may call the VehicleSafety Hotline toll-free at 1-888-327-4236 (TTY:1-800-424-9153); go to www.safercar.gov; orwrite to: Administrator, NHTSA, 1200 New JerseyAvenue, SE, Washington, DC 20590. You can alsoobtain other information about motor vehicle safetyfrom 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-freehotline 1-800-333-0510, or contact TransportCanada by mail at: Transport Canada, ASFAD,

Place de Ville Tower C, 330 Sparks Street, Ot-tawa, Ontario, Canada K1A 0N5.

For additional road safety information, please visitthe Road Safety website at: www.tc.gc.ca/roadsafety.

© 2017 Daimler Trucks North America LLC. All rights reserved. Daimler Trucks North America LLC is a Daimler com-

pany.

No part of this publication, in whole or part, may be translated, reproduced, stored in a retrieval system, or transmittedin 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 NorthAmerica LLC, Service Systems and Documentation, P.O. Box 3849, Portland OR 97208–3849 U.S.A. or refer towww.Daimler-TrucksNorthAmerica.com and www.WesternStarTrucks.com.

Foreword

www.safercar.gov

www.safercar.gov



http://www.Daimler-TrucksNorthAmerica.com

www.WesternStarTrucks.com

ContentsChapter Page

Introduction, Environmental Concerns and Recommendations,Event Data Recorder, Emissions and Fuel Efficiency Compliance,Customer Assistance Center, Reporting Safety Defects . . . . . . . . . . . . . . . . . . . . Foreword

1 Vehicle Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.12 Vehicle Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.13 Instruments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.14 Driver Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.15 Driver Assistance Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.16 Climate Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.17 Seats and Restraints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.18 Cab and Sleeper Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.19 Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.1

10 Engine Starting, Operation, and Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.111 Optional Engine Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.112 Emissions and Fuel Efficiency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.113 Brake Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.114 Steering System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.115 Automated Transmissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.116 Manual Transmissions and Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.117 Drive Axles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.118 Fifth Wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.119 Trailer Couplings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.120 Headlight Aiming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20.121 Vehicle Appearance and Care . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.122 Pre- and Post-Trip Checklists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22.123 Pre- and Post-Trip Inspections and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23.124 In An Emergency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24.125 Telematics Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.1

Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I.1

1

Vehicle IdentificationComponent Information Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1Federal Motor Vehicle Safety Standard Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1Canadian Motor Vehicle Safety Standard Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2Component GWR Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2Emissions Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2

Component Information LabelNOTE: Labels shown in this chapter are ex-amples only. Actual specifications may vary fromvehicle to vehicle.

The component information label lists the vehiclemodel, identification number, and major componentmodels. It also lists the major assemblies and instal-lations shown on the chassis specification sheet.One copy of the component information label is at-tached to the inside of the glove box; another copy isinside the rear cover of the Owner’s Warranty Infor-mation for North America booklet. An illustration ofthe label is shown in Fig. 1.1.

Federal Motor Vehicle SafetyStandard LabelsNOTE: Due to the variety of Federal Motor Ve-hicle Safety Standard (FMVSS) certification re-quirements, not all of the labels shown will applyto your vehicle.

Tractors with or without fifth wheels purchased in theU.S. are marked as certified by means of an FMVSScertification label. See Fig. 1.2. This label is attachedto the driver-side B-pillar, as shown in Fig. 1.3.

The tire and rim portion of the FMVSS certificationlabel certifies suitable tire and rim combinations that

can be installed on the vehicle, for the given grossaxle weight rating. Tires and rims installed on thevehicle at the time of manufacture may have a higherload capacity than that certified by the tire and rimlabel. If the tires and rims currently on the vehiclehave a lower load capacity than that shown on thetire and rim label, then the tires and rims determinethe load limitations on each of the axles.

Trucks built without a cargo body that are intendedfor service in the U.S. have an incomplete vehiclecertification label attached by the final-stage manu-facturer. See Fig. 1.4. This label will be attached tothe incomplete vehicle document included with thevehicle, and certifies that the vehicle conforms to all

applicable FMVSS regulations in effect on the date ofcompletion.

06/28/2011 f080173

Fig. 1.1, Component Information Label

06/28/2011 f080175

Fig. 1.2, Vehicle Certification Label

01/30/2015 f080186

1

2

1. Certification Label2. Noise Emission Label

Fig. 1.3, Label Locations


1.1

Canadian Motor Vehicle SafetyStandard LabelsIn Canada, tractors with fifth wheels are marked ascertified by means of a statement of compliance labelwith the Canadian National Safety Mark attached tothe driver-side door frame B-pillar. See Fig. 1.5.

Trucks built without a cargo body and tractors builtwithout a fifth wheel that are intended for service inCanada have an incomplete vehicle certification label(similar to Fig. 1.4) attached to the driver-sideB-pillar. After completion of the vehicle, a completecertification label must be attached by the final-stagemanufacturer to certify that the vehicle conforms toall applicable Canada Motor Vehicle Safety Standard(CMVSS) regulations in effect on the date ofcompletion.

Component GWR LabelThe component GWR label is located on the A-pillarof the driver-side door frame. The label providesmaximum GWR ratings for each component.

See Fig. 1.6 for a typical component GWR label.

Emissions LabelsAftertreatment System IndicatorsLabelEngines and vehicles manufactured after December31, 2006 and domiciled in the U.S. or Canada arerequired to meet all EPA regulations effective as ofthe vehicle build date, and are equipped with anemission aftertreatment system (ATS). Vehicles do-miciled outside of the U.S. and Canada may nothave aftertreatment equipment, depending upon localstatutory emissions guidelines. See Table 1.1.

A warning label on the driver-side visor contains im-portant warning indicators in the instrument clusterthat pertain to the ATS. See Fig. 1.7.

It is a violation of U.S. federal law to alter exhaustplumbing, ATS, or other components in any way thatwould bring the engine/vehicle out of compliance withcertification requirements [Ref: 42 U.S.C. S7522(a)(3)]. It is the owner’s responsibility to maintain thevehicle so that it conforms to EPA regulations.

EPA Noise Emission Control LabelA vehicle noise emission control label (Fig. 1.8) islocated on the driver-side B-pillar as shown inFig. 1.3. It is the owner’s responsibility to maintainthe vehicle so that it conforms to EPA regulations.

IMPORTANT: Certain Western Star incompletevehicles may be produced with incomplete noisecontrol hardware. Such vehicles will not have avehicle noise emission control information label.For such vehicles, it is the final-stage manufac-turer’s responsibility to complete the vehicle inconformity to U.S. EPA regulations (40 CFR Part205) and label it for compliance.

06/28/2011 f080174

Fig. 1.4, Incomplete Vehicle Certification Label

f08002410/10/2006

Fig. 1.5, Canadian National Safety Mark


1.2

Applicable Emissions System Based on Build Date and EPA RegulationsBuild Date Regulation: Emissions Components

January 1, 2010–December 31,2012

EPA10 (reduce NOx emissions to 0.2 g/bhp-hr): Aftertreatment device (ATD)containing a diesel particulate filter that traps soot and ash, with selective catalystreduction (SCR) technology that utilizes diesel exhaust fluid (DEF) to convert NOx tonitrogen and water vapor.

From March 5, 2012–December31, 2015

GHG14: Aerodynamic and fuel efficiency components including, but not limited to,tires, cab/sleeper side extenders, chassis fairings, bumper, hood, vehicle speedlimiters, and idle reduction timers specifically designed to meet regulatory fuelefficiency and greenhouse gas emissions standards.

From January 1, 2016GHG17: GHG14 components plus OBD16 instrumentation and sensor upgrades, andcomponent technology that meets NHTSA and EPA 2017 fuel efficiency andgreenhouse gas emission standards (GHG17) requirements.

Table 1.1, Applicable Emissions System Based on Build Date and EPA Regulations

Vehicle Emission Control InformationLabelModel year 2013 and later vehicles meet additionalrequirements as specified by federal greenhouse gasand fuel efficiency regulations (GHG14). Model year2017 and later vehicles meet similar requirements asspecified by GHG17 requirements. These vehiclesare equipped with components that increase fuel effi-ciency and reduce GHG emissions. Componentsmay include, but are not limited to, low rolling resis-tance tires; aerodynamic devices such as hood, cabside extenders, and fuel tank fairings; vehicle speedlimiters; and idle shutdown timers.

A Vehicle Emission Control Information Label is lo-cated on the driver-side door. See Fig. 1.9. It is theowner’s responsibility to maintain the vehicle so thatit conforms to EPA and NHTSA regulations.

Certified Clean Idle LabelThe California Air Resources Board (CARB) requiresmodel year 2008 and newer heavy-duty diesel en-gines to be equipped with a non-programmable en-gine shutdown system that automatically shuts down

the engine after five minutes of idling in order to limitemissions of particulate matter and NOx.

Certified vehicles are equipped with a label placednear the bottom edge of the driver-side door. SeeFig. 1.10.

06/28/2011 f080172

Fig. 1.6, Component GWR Label


1.3

DPF Regen Needed

Hot Exhaust

DEF Refill Needed







24−01656−000

IMPORTANT

DEF

11/30/2010 f080162

See operator’s manual for complete instructions.

Fig. 1.7, ATS Indicators

06/28/2011 f080171

Fig. 1.8, Vehicle Noise Emission Control Label

f08018403/06/2012

MANUFACTURED BY:VIN:VEH FAMILY CD:GVWR−KGGVWR−LBS

REGULATORY CLASS:

EMISSION CONTROL IDENTIFIERS:

DATE OF MANUFACTURE:VEHICLE EMISSION CONTROL INFORMATION

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

Fig. 1.9, Vehicle Emission Control Information Label

CERTIFIEDCLEAN IDLE

02/20/2012 f080179

Fig. 1.10, CARB Clean Idle Label


1.4

2

Vehicle AccessDoor Locks and Handles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1Grab Handles and Access Steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1Back-of-Cab Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3Hood Opening and Closing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4

Door Locks and HandlesTo unlock either door from outside the cab, insert thekey in the lock and turn it one-quarter turn towardsthe front of the vehicle. See Fig. 2.1. Turn the keyback to the original position to remove it. Pull out onthe paddle latch to open the door.

To lock either door from outside the cab, insert thekey in the lock and turn it one-quarter turn towardsthe rear of the vehicle. Turn the key back to the origi-nal position to remove it. If the door is closed, it willnow be locked. If the door is open, close the doorfirmly.

To lock either door from inside the cab, push the lockbutton down. Pull the lock button up to unlock thedoor from the inside.

To open either door from inside the cab, pull the lockbutton up, then pull the interior door latch out andpush the door outwards.

Remote Keyless EntryRemote keyless entry is optional on Western Starvehicles. The remote entry key fob can be used tounlock the doors from outside the cab.

To unlock both doors, press the unlock button. Tolock both doors, press the lock button. See Fig. 2.2.

Key Fob ProgrammingA maximum of four fobs can be programmed to workon one vehicle. Whenever a new fob will be used, allexisting fobs must be reprogrammed at the same

time. Any existing fobs that were previously pro-grammed will no longer work on the vehicle unlessthey are all reprogrammed at the same time.

To have the key fobs programmed, take the vehicleto an authorized Western Star dealer or service facil-ity.

Grab Handles and AccessStepsThe grab handles, access steps, and steering wheelare all part of the cab access system. Use these"helping hands" when getting into or out of the cab.They will increase your security and comfort.

CAUTIONSlipping or falling from the vehicle can result inpersonal injury or propert damage.

Wet or dirty shoes greatly increase the chance ofslipping or falling. If your shoes are wet or dirty,be especially careful when entering or exiting thevehicle.

10/20/2014 f720394a

1

2

1. Lock 2. Paddle Latch

Fig. 2.1, Exterior Door Handle

11/02/2011 f545852

1

2

1. Unlock Button 2. Lock Button

Fig. 2.2, Key Fob

Vehicle Access

2.1

Always maintain three-point contact with the ve-hicle when entering or exiting the cab. Three-point contact means both feet and one hand, orboth hands and one foot.

When steps are mounted on battery box covers,make sure that the cover is latched and securebefore using the steps.

Do not step on the fuel tank, battery box, frame,etc. unless adequate slip resistant surfaces andhandholds are provided.

Do not jump from the vehicle.

For ease of entry and exit, there are multiple grabhandles: a handle on the A-pillar (optional on thedriver’s side), handles on the inside of the door, andhandles on the B-pillar. In addition, the steeringwheel may be used to provide a secure handhold.There are at least two access steps to provide se-cure footholds.

Entering the Driver’s Side1. Open the driver-side door and place anything

that you are carrying in the cab.

2. Grasp the B-pillar grab handle with your righthand. See Fig. 2.3.

3. Grasp the lower door pocket with your left hand.

4. Place your right foot on the bottom step, and pullyourself up.


6. Grasp the steering wheel or A-pillar grab handle,if equipped, with your left hand.

7. Step into the cab with your right foot first, andgrasp the steering wheel with your right hand.

Exiting the Driver’s SideIMPORTANT: Do not attempt to exit the cabwhile carrying any items in your hands. Placethem in an accessible location on the seat orcab floor and make sure they will not get in yourway as you exit, then retrieve them after youhave exited the cab.

CAUTIONAlways face in when exiting the cab. Do not at-tempt to exit with your back to the cab, as youwould going down a flight of stairs. It is easier toslip or lose your balance. If you slip when exiting

in this way, there is a greater likelihood of per-sonal injury.

1. Grasp the steering wheel with both hands, placeyour left foot on the top step, and stand on thethreshold, facing into the cab.

2. Grasp the B-pillar grab handle with your righthand. See Fig. 2.3, item 5.


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


Entering the Passenger’s Side1. Open the passenger-side door and place any-

thing that you are carrying in the cab.

2. Grasp the B-pillar grab handle with your lefthand. See Fig. 2.4.

10/20/2014 f720729a1

2

3 4

5

1. Lower Door Pocket2. Upper Door Pocket3. Door Latch

4. Steering Wheel5. B-Pillar Grab Handle

Fig. 2.3, Driver-Side Cab Access

Vehicle Access

2.2

3. Grasp the lower door pocket with your righthand.

4. Place your left foot on the bottom step.

5. Place your right foot on the top step and moveyour right hand to the A-pillar grab handle.

6. Place your left foot on the top step, then moveyour left hand to the A-pillar grab handle.

7. Step into the cab with your left foot first.

Exiting the Passenger’s SideIMPORTANT: Do not attempt to exit the cabwhile carrying any items in your hands. Placethem in an accessible location on the seat orcab floor and make sure they will not get in yourway as you exit, then retrieve them after youhave exited the cab.

CAUTIONAlways face in when exiting the cab. Do not at-tempt to exit with your back to the cab, as youwould going down a flight of stairs. It is easier toslip or lose your balance. If you slip when exitingin this way, there is a greater likelihood of per-sonal injury.

1. Grasp the A-pillar grab handle with both hands,then place your right foot on the top step whilefacing inward. See Fig. 2.4.


3. Move your left hand to the B-pillar grab handle.


5. Move your right hand to the lower door pocket.


Back-of-Cab AccessWhen trailer air and electrical connections cannot bereached conveniently from the ground, Federal MotorCarrier Safety Regulations require that tractors haveadequate back-of-cab access. Grab handles are typi-cally located on the backwall of the cab or sleeper, oron the inside of the cab extender, if equipped. A grabhandle may also be provided on the exhaust stack.Steps may be mounted on the fuel tank(s), battery ortool box(es), or on metal brackets secured to theframe rail. A deck plate is mounted across the top ofthe frame rails. All other areas are not meant to sup-port back-of-cab access

CAUTIONFollow these rules for back-of-cab access. Failingto follow these rules could lead to a fall, and pos-sible personal injury.

Never step on any exterior part unless it has aslip-resistant surface meant for safe stepping. Ifthe surface is movable, such as a battery boxcover with a slip-resistant surface, be certain it isfirmly secured.

Be careful not to trip on items such as chains orair lines in the back-of-cab area.

Always follow safety procedures for back-of-cabaccess, maintaining three-point contact—bothhands and one foot, or both feet and one hand—

10/20/2014 f720728a5

1

2

34

1. B-Pillar Grab Handle2. Door Latch3. A-Pillar Grab Handle

4. Upper Door Pocket5. Lower Door Pocket

Fig. 2.4, Passenger-Side Cab Access

Vehicle Access

2.3

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 greatlyincrease the chance of slipping or falling. If yourshoes or the contact areas are wet or dirty, cleanand dry them as much as possible before ac-cessing the back of cab area, and be especiallycareful when climbing or standing on the vehicle.

Never jump onto, or off of, a vehicle; doing socreates a very high likelihood of a fall and per-sonal injury.

IMPORTANT: Climb onto, and down from, be-hind the cab while facing in toward the vehicle,as you would on a ladder. Do not climb up ordown facing out away from the vehicle.

Accessing Back-of-Cab Area

WARNINGExternal surfaces of the exhaust system remainhot after the engine has been shut down. Whenaccessing the back of the cab or sleeper, do nottouch any part of the exhaust system other thanthe exhaust-mounted grab handle, if equipped, orsevere burns could occur.

1. Facing the deck plate, grasp the grab handlewith both hands. Reach up as far as is comfort-able.

2. Place one foot on the bottom step and pull your-self up.

3. Place your other foot on the top step.

4. Move your lower hand to a higher position on thegrab handle.

5. Step onto the deck plate.

Exiting Back-of-Cab Area1. Face the center of the vehicle and grasp the

sidewall grab handle with both hands.

2. Place one foot at a time on the top step.

3. Move your upper hand to a lower position on thegrab handle.

4. Move one foot to the bottom step.

5. Step to the ground with your upper foot first.

Hood Opening and ClosingThe hood can be raised to a full-open position. Tilt-assist struts help you to raise the hood, and to lowerit to the operating position. In the operating position,the hood is secured to the cab-mounted cowl by ahold-down latch on each side.

Opening the Hood1. Release both hood hold-down latches by pulling

the handles outward.

2. Slowly tilt the hood with both hands on the grabhandle.

3. As the hood starts to open, walk backwards asyou pull. The hood will stop in the full-openposition.

Closing the Hood1. Grasp and lift the grab handle to tilt the hood

toward the closed position.

2. As the hood goes over center, slowly lower thehood with both hands on the grab handle.

IMPORTANT: Make sure that both latches arefully engaged before operating the vehicle.

3. Make sure the hood is flush with the cowl, thensecure the hood by engaging both hood hold-down latches.

Vehicle Access

2.4

3

InstrumentsInstrumentation Control Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.1Warning and Indicator Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.2Instruments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.6Driver Message Center . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.11Overhead Instrument Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.15

Instrumentation Control UnitsThe instrumentation control unit (ICU) provides thedriver with engine and vehicle information. It is com-prised of standard and optional gauges, an audiblewarning, a driver message center, and a lightbar con-taining warning and indicator lamps (also known astelltales). Warning and indicator lamps illuminate inred (danger), amber (caution), green (status advi-sory), or blue (high-beam headlights active).

Western Star 5700 vehicles are equipped with anICU4Me. See Fig. 3.1 for a typical ICU layout.

The following headings in this chapter provide addi-tional information and operating instructions for ICUcomponents:

• "Warning and Indicator Lights"

• "Instruments"

• "Driver Message Center"

Ignition SequenceWhen the ignition is turned on, the ICU runs a self-check. See Fig. 3.2. Observing the ignition sequenceis a good way to ensure the ICU is functioning prop-erly.

IMPORTANT: Do not crank the engine until theICU self-check is complete.

NOTE: Primary and secondary air pressuregauges are the only air gauges that complete asweep of their dials during the ignition se-quence.

When the ignition is turned on, the following actionsshould occur:

• electronic gauges complete a full sweep oftheir dials

12/11/2014 f611244

1

2

3

4

5

6

7

8

9

10 11

12

13

14

15

1. Voltmeter2. Turbocharger Boost Pressure Gauge3. Trailer Air Supply Gauge4. Engine Oil Temperature Gauge5. Transmission Oil Temperature Gauge6. Tachometer and Coolant Temperature Gauge7. Fuel/DEF Level Gauge8. Speedometer and Engine Oil Pressure Gauge

9. Suspension Air Pressure Gauge10. Forward Drive-Axle Temperature Gauge11. Rear Drive-Axle Temperature Gauge12. Trailer Suspension Air Pressure Gauge13. Secondary Air Pressure Gauge14. Primary Air Pressure Gauge15. Driver Message Center

Fig. 3.1, ICU4Me Instrument Cluster

Instruments

3.1

• warning and indicator lamps illuminate, thenare extinguished

• audible alert sounds for approximately fourseconds or until sufficient air pressure buildsup in the primary and secondary air systems

• DEF level indicator illuminates all segmentsgreen, then turns them off one at a time beforeturning the leftmost segment amber and thenred

• Western Star logo displays on the ICU4Medriver message center for two seconds.

• software revision level of the ICU is displayedon the driver message center, followed by anyactive faults

IMPORTANT: If any red or amber warning andindicator lamps do not illuminate during the ICUself-check or do not go out after the self-checkcompletes, take the action outlined in Table 3.1,then take the vehicle to an authorized WesternStar service facility as soon as possible.

NOTE: If active faults are present, take the ve-hicle to an authorized Western Star service facil-ity as soon as possible.

If the ICU receives active fault codes, it displaysthem one after the other until the parking brake isreleased or the ignition is turned off. Once the park-ing brake is completely released, the ICU displaysthe home screen. If there are no active faults, theICU displays the home screen after the self-checkcompletes.

Audible AlertsAn audible alert sounds during the ignition sequenceand whenever one of the following conditions exists:

• Engine oil pressure falls below the minimumpreset value.

• Coolant temperature rises above the maximumpreset value.

• Air pressure falls below approximately 70 psi(483 kPa).

• Parking brake is set with the vehicle movingfaster than two miles per hour.

• System voltage falls below 11.9 volts.

• Door is open or the headlights are on, with theparking brake off.

• Driver seat belt is not fastened with the parkingbrake off (optional).

• Outside temperature falls below 35°F (1.7°C)(optional).

Warning and Indicator LightsThe ICU has three or four rows of warning and indi-cator lights with icon symbols, depending on the ICUconfiguration. The positions of the lights may vary,but the telltales are standard for all applications. SeeTable 3.1 for a listing of standard and commonlyused warning and indicator lamps.

Warning and indicator lamps illuminate in red (dan-ger), amber (caution), green (status advisory), orblue (high-beam headlights active).

IMPORTANT: Depending upon local jurisdic-tional emissions guidelines, vehicles and/or en-gines that are domiciled outside of the U.S. andCanada may not be compliant with EPA07,EPA10, GHG14, or GHG17 regulations. Non-compliant vehicles may not be equipped with allof the lamps shown in Table 3.1.

IGNITION SWITCH


IF NO FAULTSWERE DETECTED

IF FAULT DETECTED

APU 190123456.7

12.3 VOLTS

123456.7

12.3 VOLTS

MI

MI

01/18/2012 f040420c


TURNED TO ON

ICU PERFORMSSELF−TEST

Fig. 3.2, ICU Ignition Sequence

Instruments

3.2


STOP STOP Engine*

Indicates a serious fault that requires engine shutdownimmediately. The engine protection system will reduce themaximum engine torque and speed, and, if the conditiondoes not improve, will shut down the engine within 30 to 60seconds.

Safely bring the vehicle to a stop on the side of the roadand shut down the engine as soon as the red light is seen.If the engine shuts down while the vehicle is in ahazardous location, turn the key to the OFF position fora few seconds, then restart the engine and move thevehicle to a safer location.

Red

High Coolant Temperature Indicates the coolant temperature is above the maximumallowable temperature. Red

BRAKE

Low Air Pressure (EPA10and Newer)

Indicates air pressure in the primary or secondary reservoirhas dropped below approximately 70 psi (483 kPa). Red

Low Engine Oil Pressure Indicates the engine oil pressure is below the minimumallowable pressure. Red

Transmission Overheat Indicates high transmission temperature. Red

Transmission Fluid Level Indicates low transmission fluid level. Safely bring thevehicle to a stop as soon as possible. Red

PARK

P Parking Brake (EPA10and Newer) Indicates the parking brake is engaged. Red

Low Battery Voltage Indicates that battery voltage is 11.9 volts or less. Red

Unfastened Seat Belt

Activates with an audible alert when the system detects thatthe parking brake is off and the driver seat belt is notfastened on some vehicles. On other vehicles, this lampilluminates for 15 seconds when the ignition is first turnedon.

Red

Check ECAS Indicates Electronically Controlled Air Suspension (ECAS)active fault. Red

CHECK CHECK Engine*

Indicates an engine condition (low oil pressure, low coolantlevel, high coolant temperature, high DPF soot level, oruncontrolled DPF regeneration) that requires correction.Correct the condition as soon as possible. If the conditionworsens, the STOP engine lamp will illuminate.

Amber

Instruments

3.3


High Exhaust SystemTemperature (HEST)*

Slow (10-second) flashing indicates a regeneration (regen)is in progress.

IMPORTANT: When the HEST lamp is illuminated, donot park the vehicle near flammable material.

Solid illumination indicates high exhaust temperatures at theoutlet of the tail pipe when speed is below 5 mph (8 km/h).

Amber

Diesel Particulate Filter(DPF) Status

Solid illumination indicates a regen is required. Change to amore challenging duty cycle (such as highway driving ) toraise exhaust temperatures for at least twenty minutes, orperform a parked regen.

Blinking indicates that a parked regen is requiredimmediately. An engine derate and shutdown will occur.

Amber

Malfunction IndicatorLamp (MIL)

Indicates an emissions-related fault. See the engineoperation manual for details. Amber

Vehicle ABS



Amber

Trailer ABS



Amber

NOCHARGE No Charge Indicates the alternator is not properly powering the

electrical system. Amber

Water in Fuel Indicates the fuel may contain water. Drain any watercollected in the fuel/water separators. Amber

Fuel Filter Restriction Indicates the fuel filter is clogged and requires service. Amber

Check Transmission Indicates an undesirable transmission condition. Amber

START

BLOCKEDStart Blocked (GHG14only)

Indicates that the system is preventing the starter fromcranking. This can occur when the ignition switch is turnedto START before the gauge sweep has completed.

NOTE: Illumination of the Start Blocked lamp does notindicate a problem with the starter.

Turn the ignition switch back to ON, wait for the lamp to goout, then turn the ignition switch to START again.

Amber

Instruments

3.4





Amber

Roll Stability

Momentary illumination indicates that a stability event hasoccurred.

On vehicles that are also equipped with ATC, flashingindicates the ATC button has been pressed to allow wheelslip.

Amber

Hill Start Aid (HSA)Override

Indicates the HSA switch has been pressed to override thehill start assist feature. Amber

Outside Normal RideHeight

Indicates the current rear suspension height is not at thenormal ride height. This light will turn off once the vehiclereturns to normal ride height.

Amber


Left-Turn Signal Flashing indicates the outside left-turn signal lights areactivated. Green

Right-Turn Signal Flashing indicates the outside right-turn signal lights areactivated. Green

Cruise Control

Indicates the cruise control is enabled.

NOTE: The ICU4Me does not have a green cruise controltelltale.

Green

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

* See Fig. 3.3 for an explanation of the aftertreatment system (ATS) warning indicators, and actions required to avoid further engine protection steps.

Table 3.1, Common Warning and Indicator Lamps

Engine Protection System

WARNINGWhen the red STOP engine lamp illuminates,most engines are programmed to shut down au-tomatically within 30 seconds. The driver mustimmediately move the vehicle to a safe locationat the side of the road to prevent causing a haz-ardous situation that could cause bodily injury,property damage, or severe damage to the en-gine.

See Fig. 3.3 for an explanation of the aftertreatmentsystem (ATS) warning indicators, and actions re-quired to avoid further engine protection steps.

The STOP engine lamp illuminates when the engineprotection system is activated in one of two ways. Onsome engines, the engine protection system will der-ate the engine, allowing it to run at lower rpm andslower vehicle speed. Drive the vehicle to a safe lo-cation or to a service facility.

Instruments

3.5

IMPORTANT: Safely bring the vehicle to a stopon the side of the road and shut down the en-gine as soon as the red light is seen. If the en-gine shuts down while the vehicle is in a haz-ardous location, turn the key to the OFF positionfor a few seconds, then restart the engine andmove the vehicle to a safer location.

On other engines, the engine protection system willshut down the engine. It will first derate the engine,then shut it down completely 30 to 60 seconds afterthe indicator illuminates (depending on the criticalfault type) if the condition does not improve. Bringthe vehicle to a stop on the side of the road beforethe engine shuts down.

Some vehicles may have a shutdown-overrideswitch, which may be used to momentarily overridethe shutdown sequence. See Chapter 10 for detailedinformation regarding the shutdown process.

IMPORTANT: Do not attempt to restart the en-gine while the vehicle is moving. Bring the ve-hicle to a safe stop, then restart the engine.

To restart the engine, turn the ignition to OFF, leaveit there a few seconds, then turn the ignition toSTART. The engine will run for a short period andshut down again if the condition does not improve.

InstrumentsThe instruments are listed here in alphabetical order,to make the information easier to find.

NOTE: Some of the listed instruments are op-tional, and not found in every vehicle.

Air Intake Restriction GaugeThe air intake restriction gauge indicates the vacuumon the engine side of the air cleaner. On standardinstallations, it is mounted on the air intake duct inthe engine compartment, and has a go/no-go restric-tion indicator without graduations. See Fig. 3.4. Asan option, a graduated indicator (Fig. 3.5) on the airintake duct or, for easier viewing, a dash-mountedrestriction gauge may be installed.

Air intake restriction vacuum is measured in inchesof water (inH2O). For vehicles equipped with agraduated indicator or a restriction gauge on thedash, check the gauge with the engine off. If the yel-low signal stays locked in the red zone once the en-gine is shut down, or is at or above 18 inH2O (forDetroit engines), the air cleaner element needs to bereplaced.

f080156


Switch.

Level 1 Level 3Level 2 Level 4Filter RegenerationRecommended.

Filter is reaching


Filter Regeneration


To avoid enginederate, bring vehicle



Vehicle must beparked, and a Parked

Service Regeneration Required.Engine Derate To Idle Only.

Filter has exceeded maximumcapacity.

Vehicle must be parked, and aService Regeneration must be


CHECKINDICATORLAMP(S)



Required Action

capacity.

STOP

allow for an AutomaticRegeneration orperform a Parked

to highway speedsto allow for anAutomaticRegeneration, orperform a ParkedRegeneration assoon as possible.

Regeneration mustbe performed.Engine will beginderate.

performed. Check engineoperator’s manual for details.Engine will shut down.


02/20/2009

WARNING


Exhaust componentsand exhaust gas are athigh temperature. Whenstationary, keep awayfrom people andflammable materials orvapors.


Flashing

Solid

Regeneration.

Necessary


Instruments

3.6

NOTE: Rain or snow can wet the filter andcause a temporary high reading.

Application Air Pressure GaugeAn application air pressure gauge (Fig. 3.6) registersthe air pressure being used to apply the brakes, andshould be used for reference only. The gauge will notregister air pressure until the foot brake pedal is de-pressed or the trailer hand brake is applied.

Coolant Temperature Gauge

NOTICEA sudden increase in coolant temperature mayindicate engine or cooling system failure. Bringthe vehicle to a safe stop and investigate thecause to prevent further damage. Do not operatethe engine until the cause has been determinedand corrected.

During normal engine operation, the coolant tem-perature gauge (Fig. 3.7) should read 175 to 195°F(79 to 91°C). If the temperature remains below 160°F(71°C), inspect the cooling system to determine thecause.

For Detroit engines, if coolant temperature risesabove 215°F (101°C), the CHECK engine lamp willilluminate. If the condition does not improve, theSTOP engine lamp will also illuminate and an audiblewarning will sound. The engine will then derate or

04/08/2005 f090431

Fig. 3.4, Manual-Reset Air Restriction Indicator, Go/No-Go

02/12/2015 f090514

Fig. 3.5, Air Intake Restriction Indicator, Graduated

08/07/2014 f611267

Fig. 3.6, Application Air Pressure Gauge

07/29/2014 f611254

Fig. 3.7, Tachometer and Coolant Temperature Gauge

Instruments

3.7

shut down, depending on the type of engine protec-tion system installed.

Drive Axle Oil Temperature Gauges

NOTICEA sudden increase in oil temperature that is notcaused by a load increase may indicate mechani-cal failure. Bring the vehicle to a safe stop andinvestigate the cause to prevent further damage.Do not operate the vehicle until the cause hasbeen determined and corrected.

During normal operation, drive axle oil temperaturegauges (Fig. 3.8) should read as follows:

• 160 to 220°F (71 to 104°C) for Detroit™ andMeritor™ drive axles

• 180 to 200°F (82 to 93°C) for Dana Spicer®drive axles


Engine Oil Pressure Gauge

NOTICEA sudden decrease or absence of oil pressuremay indicate mechanical failure. Bring the vehicle

to a safe stop and investigate the cause to pre-vent further damage. Do not operate the engineuntil the cause has been determined and cor-rected.

The engine oil pressure gauge, as shown in Fig. 3.9,displays the current engine oil pressure. If engine oilpressure falls below the minimum levels shown inTable 3.2, the CHECK engine lamp will illuminate. Ifthe condition does not improve, the STOP enginelamp will also illuminate and an audible warning willsound. The engine will then derate or shut down, de-pending on the type of engine protection system in-stalled.

NOTE: Oil pressures in Table 3.2 are given withthe engine at operating temperature. With theengine cold, oil pressure may be higher. Indi-vidual engines may vary from the listed pres-sures; observe and record pressures when theengine is new to create a guide for checkingengine condition.

Minimum Oil Pressure

Engine ModelAt Idle Speed:

psi (kPa)At Rated RPM:

psi (kPa)Detroit 14 (97) 55 (350)

Table 3.2, Minimum Engine Oil Pressure

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Fig. 3.8, Drive Axle Oil Temperature Gauge (rear driveaxle gauge shown)

07/29/2014 f611245

Fig. 3.9, Speedometer and Engine Oil Pressure Gauge

Instruments

3.8

Engine Oil Temperature Gauge

NOTICEA sudden increase in oil temperature that is notcaused by a load increase may indicate mechani-cal failure. Bring the vehicle to a safe stop andinvestigate the cause to prevent further damage.Do not operate the engine until the cause hasbeen determined and corrected.

During normal operation, the optional engine oil tem-perature gauge (Fig. 3.10) should read in the follow-ing temperature range:

• 200 to 260°F (93 to 126°C) for Detroit engines


Fuel/Diesel Exhaust Fluid (DEF)GaugeFor engines that are EPA10-compliant or newer, thefuel and DEF levels are measured in a dual purposefuel/DEF level gauge. See Fig. 3.11.

The diesel fuel level is indicated at the top of thegauge, with a low-fuel warning lamp that illuminatesamber when the diesel fuel level registers 1/8th ofcapacity.

The DEF level is indicated in a four-segment lightbaron the lower portion of the gauge. There is a low

DEF level warning lamp that illuminates amber whenthe DEF level reaches 10% of capacity. See Chap-ter 12 for details of the DEF gauge functions.

Primary and Secondary Air PressureGauges

WARNINGIf air pressure falls below minimum pressure, thebraking ability of the vehicle will be limited. Slowthe vehicle down and bring it to a gradual stop.Do not attempt to move the vehicle until air pres-sure has risen above the minimum level. Movinga vehicle without adequate braking power couldcause an accident resulting in property damage,personal injury, or death.

Air pressure gauges (Fig. 3.12) register the pressurein the primary and secondary air systems. Normalpressure, with the engine running, is 100 to 120 psi(689 to 827 kPa) in both systems.

A low-air-pressure warning light and audible alert,connected to both the primary and secondary sys-tems, activate when air pressure in either systemdrops below approximately 70 psi (483 kPa).

When the engine is started, the warning light andaudible warning remain on until air pressure in bothsystems exceeds minimum pressure.

07/29/2014 f611251

Fig. 3.10, Engine Oil Temperature Gauge

10/08/2014 f611246

1

2

3

4

1. Diesel Fuel Level Indicator2. DEF Level Indicator3. Low DEF Warning Lamp (amber below 10% DEF)4. Low Fuel Warning Lamp (amber at 1/8 tank of fuel)

Fig. 3.11, Fuel/DEF Gauge, EPA10 and Newer

Instruments

3.9

SpeedometerTwo speedometer options are available. The U.S.version of the speedometer (Fig. 3.9) registers speedin both miles per hour (mph) and kilometers per hour(km/h), with mph in larger numbers. The metric ver-sion of the speedometer face reverses this arrange-ment, with km/h in larger numbers.

Suspension Air Pressure GaugeA suspension air pressure gauge (Fig. 3.13) registersthe air pressure applied to the vehicle airsuspension.

TachometerThe tachometer (Fig. 3.7) indicates engine speed inrevolutions per minute (rpm) and serves as a guidefor shifting the transmission and keeping the enginein the appropriate rpm range. For low idle and ratedrpm, see the engine identification plate.

Transmission Fluid TemperatureGaugeThe transmission fluid temperature gauge, shown inFig. 3.14, measures the transmission lubricant oper-ating temperature. Temperatures vary by application,but the transmission fluid temperature gauge readingshould not exceed 250°F (121°C).

NOTICEA sudden increase in transmission fluid tempera-ture that is not caused by a load increase mayindicate mechanical failure. Bring the vehicle to asafe stop and investigate the cause to preventfurther damage. Do not operate the vehicle untilthe cause has been determined and corrected.


Turbocharger Boost Pressure GaugeA turbocharger boost pressure gauge (Fig. 3.15) indi-cates the pressure in the intake manifold, in excess

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Fig. 3.12, Air Pressure Gauge (primary shown)

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Fig. 3.13, Suspension Air Pressure Gauge

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Fig. 3.14, Transmission Fluid Temperature Gauge

Instruments

3.10

of atmospheric pressure, being created by theturbocharger.

VoltmeterThe voltmeter indicates the vehicle charging systemvoltage when the engine is running and the batteryvoltage when the engine is off. By monitoring thevoltmeter, the driver can stay aware of potential bat-tery charging problems and have them fixed beforethe batteries discharge enough to create starting diffi-culties. A digital voltage display is integrated withdriver message center. An optional voltmeter gauge(Fig. 3.16) may be installed.

The voltmeter will normally show approximately 13.7to 14.1 volts when the engine is running. The voltage

of a fully charged battery is 12.7 to 12.8 volts whenthe engine is off. Battery voltage under 12.0 volts isconsidered a low battery, and a completely dis-charged battery will produce only about 11.0 volts.

If the voltmeter shows an undercharged or over-charged condition for an extended period, have thecharging system and batteries checked at an autho-rized Western Star service facility.

On a vehicle equipped with a battery isolator system,the voltmeter measures the average voltage of all thebatteries when the engine is running. When the en-gine is off, the voltmeter shows only the isolated bat-tery voltage and does not indicate the voltage of theengine-starting batteries.

Driver Message CenterICU4MeFunctionsICU4Me settings and the driver message center arecontrolled using the switches mounted in the left-hand switch pod of the steering wheel. SeeFig. 3.17.

The driver message center is divided into four sec-tions. The odometer and cruise control status field

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Fig. 3.15, Turbocharger Boost Pressure Gauge

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Fig. 3.16, Voltmeter

12/11/2014 f611255a

1

23

4

5

6

7

NOTE: To reset values in the ICU4Me driver messagecenter, press and hold the RIGHT navigation switch.1. Volume Up Switch2. Volume Down Switch3. Headlight Interrupt Switch4. UP Navigation Switch5. RIGHT Navigation Switch6. DOWN Navigation Switch7. LEFT Navigation Switch

Fig. 3.17, Steering Wheel-Mounted Switches, Left-HandSwitch Pod

Instruments

3.11

are displayed along the bottom of the message cen-ter. When cruise control is active, the cruise controlstatus field displays relevant cruise control icons andthe set speed. If the vehicle is equipped with amanual transmission, time and temperature are dis-played in the top left corner of the driver messagecenter. The message field displays the drivingscreens and alert messages. See Fig. 3.18.

If the vehicle is equipped with an automated trans-mission, the gear display is located in the top leftcorner of the driver message center. Time and tem-perature are displayed in the message field, unlessan alert message is active or a driving screen hasbeen selected. The odometer and cruise control sta-tus field are displayed along the bottom of the mes-sage center. See Fig. 3.19. For information abouttransmission display options, see Chapter 15.

Alert MessagesAlert messages are displayed in the message field tonotify the driver when certain conditions occur. Theyinclude warnings, cautions, and other messages thatrequire the driver’s attention. Not all alert messagesare critical to the operation of the vehicle. More im-portant messages take priority over less importantmessages.

NOTE: All alert messages follow the formatshown in Fig. 3.20.

Press the OK button on the left-hand steering wheelpod to acknowledge alert messages and revert to thepreviously displayed driving screen. The followingalert messages will repeat intermittently until the con-dition is eliminated:

• turn signal on

• low voltage

• no datalink

• low transmission air pressure (Detroit transmis-sions only)

Driving ScreensWith the parking brake off, only the driving screensare available. Use the UP and DOWN navigationswitches on the steering wheel to scroll through thedriving screens; see Fig. 3.21. To reset any values,press and hold the RIGHT navigation switch.

• Temperature

• MPG information


• Leg information

• Gauge display (if selected)

• Predictive Cruise Control (optional)

• Enter parked menus

06/26/2012 f611166

5555555 mi

1/7NW

77° F

Trip MPG: 5.6

0 155

1 2

34

10

65 mph

1. Temperature and Compass2. Message Field3. Cruise Control Status Field4. Odometer

Fig. 3.18, Driver Message Center Without Gear Display,ICU4Me

1/7NW

77 °F

06/26/2012 f611165

10A econ

5555555 mi

1 2

34

65 mph

1. Gear Display2. Temperature and Compass3. Cruise Control Status Field4. Odometer

Fig. 3.19, Driver Message Center with Gear Display,ICU4Me

Park Brake On!

06/12/2012 f611192

10A econ

5555555 mi

Fig. 3.20, Parking Brake Alert Message

Instruments

3.12

Parked Screens/MenusPark the vehicle and set the parking brake to accessthe parked menus and submenus. See Fig. 3.22. Toreset values in any of the menus, press and hold theRIGHT navigation switch.


• Fuel information

• Engine information

• Diagnostics

• Service information

• Settings

• ICU Information

A small numerical fraction is displayed in the upperright-hand corner of each screen to indicate the num-ber of available screens or options to scroll through.See Fig. 3.23. Press the OK button on the left-handsteering wheel pod to select a menu choice. Pressthe LEFT navigation switch to back out of a selectedmenu or submenu. Use the UP navigation switch toscroll up, and the DOWN navigation switch to scrolldown.

Time &Temperature

MPGInformation

TripInformation

Enter toStationary

Menu

GaugeDisplayScreens

LegInformation

PredictiveCruise

Control (opt)

12/11/2014 f040823b

(if selected)

Use the UP and DOWN navigation switches on thesteering wheel to navigate through the driving screens.

Fig. 3.21, Driving Screen Navigation, ICU4Me

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Trip Info

Fuel Info

Engine Info Diagnostics Service

Settings

ICU Info

Use the UP and DOWN navigation switches on thesteering wheel to navigate through the parked menus.

Fig. 3.22, Parked Menus, ICU4Me

1/3Miles:Gallons:

Menu

Avg. MPG:Trip Info

Trip

123456.7123456.7

123.4

1/2TripLeg

Menu

Trip Info

1/7Trip InfoFuel Info

Menu

Engine Info

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OK

OK

Fig. 3.23, Parked Menu Navigation, ICU4Me

Instruments

3.13

When navigating the parked menus, the left side ofthe driver message center displays a "breadcrumbmenu" to show the order of menus and submenusthat have been selected during the current naviga-tion.

Trip InformationThe ICU can record data for one trip segment andone leg segment. When trip information is reset, allthe leg information is reset as well.

Fuel InformationUsing this menu, the driver can view the total fuelused since the last reset, the total idle gallons usedsince the last reset, and the average MPG since thelast reset.

Engine InformationUsing this menu, the driver can view engine miles,engine hours, gallons used, PTO hours, and PTOgallons. Engine oil level is optional for Detroit en-gines. The information contained in the Engine Infor-mation screens cannot be reset.

DiagnosticsActive faults are displayed in the diagnostics menu.See Fig. 3.24. If there are any active faults, the totalnumber of faults is displayed in parenthesis next tothe affected controller. To view specific active faults,press the OK button on the left-hand steering wheelpod. Press the OK button to toggle between the textdescription and the failure code for each selectedfault.

Service InformationUsing this menu, the driver can enable, disable, andset service intervals for engine miles or enginehours. After enabling service intervals, select intervalunit (miles or hours), and the interval duration.

SettingsThe settings menu contains the controls for the fol-lowing settings:

• Display (includes brightness, display light, andnight mode settings)

• Gauge select

• Language

• Temperature warning enable/disable

• Units

The Gauge Select submenu allows the driver to se-lect certain gauge values for display in the messagefield while driving. See Fig. 3.25. Use the UP andDOWN navigation switches on the steering wheel toscroll through the list of available gauges, then pressthe OK button to select a desired gauge. The OKbutton can also be used to uncheck boxes ifnecessary.

ICU InformationThe ICU Information screen displays the part num-bers for the instrument cluster and software.

1/3Accelerator PedalProblem Detected

Diagnostics

Active

Engine (3)

1/3ABS (1)Engine (3)

1/2Active (12)Historic (0)

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Menu

Diagnostics

MSF (1)

Menu

Diagnostics

Active

OK

OK

Fig. 3.24, Diagnostics Menu Navigation, ICU4Me

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1/6Axle TempAir Pressure

Engine Oil Temp

Menu

Settings

Gauge Disp. x

Fig. 3.25, Selecting Gauges to Display, ICU4Me

Instruments

3.14

Overhead Instrument PanelThe overhead instrument panel typically holds a citi-zen’s band (C/B) radio, an AM/FM radio, a digitalclock, and storage areas with netting. The undersideof the overhead console also holds the sun visorsand the dome/reading light assembly. For more infor-mation on the dome/reading light assembly, seeChapter 8.

Instruments

3.15

4

Driver ControlsControl Panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1Ignition Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1Lighting Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2Horn Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.5Powertrain Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.5Cruise Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.8Dash-Mounted Brake Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.10Windshield Wiper and Washer Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.12Suspension/Trailer Connection Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.13Adjustable Steering Column Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.15Radio/Bluetooth Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.16Climate Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.16Seat Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.16

Control PanelsNOTE: Western Star vehicles are offered withvarious chassis and body components. Becauseof the various options, the information containedin this chapter may not apply to every vehicle.

The right-hand dash control panel contains a facevent, the majority of the driver switch controls, auto-mated and automatic transmission controls, and theOnGuard display module, if equipped.

The ignition switch control panel (below the right-hand dash panel) contains the ignition switch, ciga-rette lighter, and climate controls.

The instrument cluster is located behind the steeringwheel.

Fig. 4.1 shows a typical dash control panel layout.

Ignition SwitchThe ignition switch has four positions: OFF, ACCES-SORY, ON, and START. See Fig. 4.2.

In the OFF position, the key slot is vertical. The keycan be inserted and removed only in the OFF posi-tion.

The following functions are operable when the igni-tion switch is in the OFF position (regardless ofwhether the key is inserted):

• high-beam headlights

• taillights

• brake lights

• road lights

• dome lights

• clearance lights

• turn signals

• hazard warning lights

• utility and baggage lights

• spotlights

• electric horn

• clock

• refrigerator

• television

Turn the key counterclockwise to the ACCESSORYposition. In addition to all the functions that are oper-able with the ignition switch in the OFF position, thefollowing functions are operable when the switch is inthe ACCESSORY position:

• radio/stereo system

• heater and A/C fan

• mirror defog

• windshield wipers

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1

2

3

5

6

4

NOTE: Control locations may vary from those showndepending on vehicle options.

1. Lighting Switches2. Parking Brake3. Trailer Air Supply4. Axle and Fifth Wheel

Switches

5. Trailer Brake Lever6. OnGuard

Fig. 4.1, Dash Control Panel

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2

1. Ignition Switch 2. Cigarette Lighter

Fig. 4.2, Ignition Switch and Cigarette Lighter

Driver Controls

4.1

• beacons

• power windows

• windshield washer

• outside air temperature display

Turn the key clockwise past the OFF position to theON position. With the switch in the ON position, thewarning and indicator lamps illuminate. Wait for threeseconds before starting the engine.

Turn the key clockwise past the ON position to theSTART position and start the engine. Do not operatethe starter longer than thirty seconds, and wait atleast two minutes between starting attempts to allowthe starter to cool. Release the key the moment theengine starts.

Switching on the ignition and releasing the parkingbrake automatically activates the daytime runninglights, if equipped. The daytime running lights willoperate until the parking brake is applied or theheadlights are turned on.

Lighting ControlsIMPORTANT: Unless otherwise noted below,press the upper half of the switch to activate thedesired light(s). Press the lower half of theswitch to turn the light(s) off.

Exterior Lighting ControlsExterior light controls are listed here in alphabeticalorder. See Fig. 4.3 for exterior light locations. At therear of the vehicle there are taillights, brake lightswith turn signals, backup lights, and optional utilitylights.

See Fig. 4.4 for exterior and interior light switches.

Backup LightsBackup lights are activated automatically when thevehicle is in reverse, and are designed to be usedwhile backing up at night.

Clearance LightsPress the upper half of the clearance lights switch toactivate all clearance lamps including back-of-sleeperand mirrors.

Driving LightsDriving lights are designed to extend the range of thehigh-beam headlights, and can only be activated

when the headlight high-beams are on. When head-lights are dimmed, the driving lights automaticallyturn off.

Fog LightsFog lights are designed to reduce glare in foggy con-ditions. The headlights must be on and set on lowbeam for the fog lights to activate.

Hazard Warning LightsPress the upper half of the hazard light switch to ac-tivate all of the turn signal lights. Both of the telltaleson the instrument cluster will flash. To cancel thehazard lights, press the lower half of the switch.

HeadlightsThe headlight switch is operated by pushing theupper half of the switch once for the parking lights,illuminating the taillights and side marker lamps onboth the tractor and trailer. Pressing the upper half ofthe switch a second time activates the headlights. Anaudible warning will sound if the lights are left onwhen the ignition is turned off and the driver-sidedoor is open.

High-Beam HeadlightsWith the low-beam headlights on, push the turn-signal lever away from you to turn on the high-beamheadlights. See Fig. 4.5. To turn off the high-beamheadlights, pull the lever to the middle position.

With the low-beam headlights on, pull the lever to-wards you to flash the high-beam headlights momen-tarily.

When the high-beam headlights are on, a blue tell-tale illuminates on the instrument cluster.

Headlight InterruptThe headlight interrupt switch is located on the left-hand switch pod of the steering wheel. See Fig. 4.6.When the headlight interrupt switch is activated, thedaytime running lights blink. The headlight interruptswitch only operates when the headlights are on.

Turn SignalsThe turn-signal lever is mounted on the left-handside of the steering column. Pulling the turn-signallever up activates the right-turn signal; pushing it

Driver Controls

4.2

down activates the left-turn signal. The lever is typi-cally a non-canceling combination turn-signal, wind-shield wiper/washer switch, and headlight controlunit. See Fig. 4.5.

When a turn signal is activated, a green telltale lightflashes on the instrument panel.

On a self-canceling turn signal lever, the lever auto-matically returns to the neutral position when thesteering wheel returns to the straight-ahead positionafter a turn.

Trailer Clearance LightsThe trailer clearance lights switch activates the trailerclearance lamps independent of the tractor lamps.

Utility LightsUtility lights can be swivel-mounted on the upper halfof the cab, or flush-mounted on the back of the cabor sleeper. Press the upper half of the switch to acti-vate it. Press the lower half of the switch to turn itoff.

Interior Lighting ControlsThe cab is equipped with door-activated dome lampson the ceiling and under the overhead console, andcourtesy lights on the bottom edge of each door andunder the dash. Depending on vehicle configuration,there may also be LH and RH reading/map lamps.

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1

3

45678910





Driver Controls

4.3

When the instrument panel lights are on, most switchicons are backlit with a colored light to allow thedriver to find switches more easily in the dark. Whena switch is activated, an LED on the switch is illumi-nated.

FOGLIGHTS

DRIVINGLIGHTS

CL / IDLIGHTS

HEADLIGHTS

CL / IDLIGHTS

SLEEPERLIGHTS

DASHLIGHTS

TRAILER

UTILITYLIGHTS

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9 8 7 6

2 3 4 5

f611257

1. Headlights Switch2. Tractor Clearance Lights Switch3. Driving Lights Switch

4. Fog Lights Switch5. Utility Lights Switch6. Hazard Flasher Switch

7. Trailer Clearance Lights Switch8. Sleeper Lights Switch9. Dash Lights Switch

Fig. 4.4, Exterior and Interior Light Switches

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32

4





Fig. 4.5, Steering Column-Mounted Turn Signal Lever

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23

4

1. Volume Up Switch2. Volume Down Switch3. Headlight Interrupt Switch4. ICU4Me Navigation Switches

Fig. 4.6, Left-Hand Steering Wheel Switches

Driver Controls

4.4

For sleeper and baggage compartment lights, seeChapter 8.

Dash LightsThe dash lights are controlled by the dash lightsswitch (Fig. 4.4, item 9). With the headlight switch inposition 1 (marker lights on) or position 2 (headlightson), tapping the upper half of the dash lights switchincreases the instrument cluster and switch backlight-ing incrementally. Note that tapping the switch pastthe maximum setting also activates the dome lampsand courtesy lights. Tapping the lower half of theswitch dims the dash lights.

Cab Dome Lamps and Courtesy LightsThe dome lamps on the cab ceiling and overheadconsole, and the courtesy lights on the cab doorsand under the dash are activated when a cab door isopened. Closing the doors will cause the lights to beturned off after 30 seconds. If a cab door is left open,a timer turns the lights off after 15 minutes.

Both the ceiling and overhead console dome lampscan be activated using the dash lights switch(Fig. 4.4, item 9) when the headlight switch is in po-sition 1 (marker lights on) or position 2 (headlightson). Tap the top half of the dash lights switch untilthe dome lamps are activated. Tap the bottom half ofthe switch to turn the dome lamps off.

Overhead Console Dome/Reading LampsThe overhead console dome/reading lamps (Fig. 4.7)are powered by both the ECC module and the bat-tery. When powered by the ECC module, they arecontrolled together with the cab dome lamps (see"Cab Dome Lamps and Courtesy Lights" above).They can also be operated individually (when notpowered by the ECC module) by pushing on thelens.

Red Map LampsThe red map lamps (Fig. 4.7) on the overhead con-sole are operated by pushing on the lens.

Horn ControlsAir HornThe air horn is controlled by a wire lanyard hangingfrom the center of the overhead console. Pull downon the lanyard to sound the air horn.

Electric HornThe electric horn control is located in the center ofthe steering wheel. To sound the horn, press downon the top of the steering wheel center pad. Thehorn will sound for the duration that the buttonpressed, up to 60 seconds.

Powertrain ControlsAftertreatment System RegenSwitchesNOTE: See Chapter 12 for detailed informationabout the operation of the regeneration (regen)switches and the aftertreatment system (ATS).

The regen request switch is used to initiate a parkedregen. See Fig. 4.8.

Some vehicles are equipped with an optional regenrequest/inhibit switch. To request a parked regen,press the upper half of the switch. To stop a regen inprogress or prevent the start of a regen, press thelower half of the switch. Regen will not occur until theswitch is no longer active.

Axle SwitchesAxle switch controls are listed here in alphabeticalorder. See Fig. 4.9.

NOTE: See Chapter 17 for detailed informationabout drive axle functions.

05/19/2015 f602556

1 2 2 1

1. Red Map Lamp2. Clear Dome/Reading

Lamp

Fig. 4.7, Overhead Console Lamps

Driver Controls

4.5

Differential Lock SwitchThe differential lock switch provides maximum trac-tion for slippery conditions by forcing the wheels oneach drive axle governed by the switch to rotate to-gether. Engagement can be at any speed, providedthe wheels are not slipping or spinning.

Interaxle Lock SwitchThe interaxle lock switch allows the driver to lock thedrive axles together, causing the drive axle shafts torotate together. Use this feature only under adverseroad conditions where greater traction is needed.

Leave the control in the UNLOCK position for normalhighway operation. When a spinning or slipping ac-tion occurs at any of the drive wheels, press theupper half of the switch to LOCK the differential andprevent the wheels from spinning.

NOTICEDo not shift into LOCK while the rear wheels arespinning. Come to a halt before engaging to pre-vent damage to the interaxle and main differen-tials.

Do not permit rear wheels to spin freely for morethan ten seconds when traction is lost. Shift intoLOCK to prevent damage to the interaxle andmain differentials.

Lift Axle SwitchThe lift axle switch controls the lift axle operation.Pushing the upper half of the switch will lower the liftaxle.

Engine Brake SwitchesNOTE: See Chapter 13 for detailed informationabout engine brake operation.


The engine brake control is located on the right-handsteering-column-mounted lever. At the top position,the engine brake is off, and at the three lower posi-tions, the brake is on and the intensity (low, medium,high) increases with each step down. See Fig. 4.10

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LIFTAXLE

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f270164a02/17/2017

0

1

2

3

0. Off1. Low

2. Medium3. High

Fig. 4.10, Engine Brake Positions

Driver Controls

4.6

Engine Fan SwitchPress the upper half of the engine fan switch to over-ride the automatic fan control and cause the enginefan to run continuously. See Fig. 4.11, item 1. Thisswitch is intended for temporary use, or if the auto-matic fan control fails. Press the lower half of theswitch to return to automatic fan control.

Shutdown Override SwitchSome vehicles may have a shutdown overrideswitch, which can be used to momentarily overridethe shutdown sequence. This switch resets the shut-down timer, restoring power to the level before thederate. The switch must be pressed again after fiveseconds to obtain a subsequent override. SeeFig. 4.11, item 2.


Hill Start Aid Override SwitchSome vehicles are equipped with a Hill Start Aid(HSA) feature to prevent the vehicle from rollingwhile on steep grades and to allow for a controlledlaunch. HSA is "on" by default. It can be turned offby pressing and releasing the HSA override switchon the dash (see Fig. 4.12).

Power Takeoff ControlsEngine power takeoffs (PTO) are devices used to tapinto engine power to run auxiliary devices, such ashydraulic pumps that power additional equipment.The following instructions are general guidelines foroperating a PTO.


2. Press the PTO switch. See Fig. 4.13. When thelight is steadily illuminated, the PTO is engagedand ready to operate. In stationary mode, thevehicle must remain in neutral with the parkingbrake set.

3. To activate the mobile mode, shift from neutral toreverse, 1st, or 2nd gear. The clutch will openand the PTO will disengage for a moment.

4. Touch the accelerator pedal to close the clutchand engage the PTO in mobile mode. The PTOmay be operated with the transmission in re-verse, neutral, 1st, or 2nd gear only.


5. To end the mobile mode, bring the vehicle to astop. The clutch will open and shut down powerto the PTO.


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SHUTDOWNOVERRIDE

ENGINEFAN

Fig. 4.11, Engine Switches

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HSAOVR

Fig. 4.12, Hill Start Aid Override Switch

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AUXPTO

Fig. 4.13, PTO Switch

Driver Controls

4.7

7. To end stationary mode, press the PTO switch.When the light in the switch goes out, power tothe PTO is shut off.

Transmission ControlsDetroit™ Automated Transmissions

NOTE: See Chapter 15 for complete Detroitautomated transmission operating instructions.

Vehicles with Detroit transmissions use the multifunc-tion control shown in Fig. 4.14. This control moves intwo directions and has two switches. It is used torequest manual shifts, change shift mode, set enginebrake levels, and control specialty engine brake func-tions during cruise control operation.

Manual Transmissions

NOTE: See Chapter 16 for complete manualtransmission operating instructions.

if equipped, the transmission range control and split-ter valves are attached to the gear shift knob.

To operate a range-shift transmission, move the shiftknob through all the low-range gear positions andthen pull the range-preselection lever up to move intothe high-range ratios. Use the same shift knob posi-tions in both the low and high ranges.

Dependent on the transmission model, some ratioscan be split using the splitter-control button (locatedon the side of the shift knob).

Cruise Control

WARNINGDo not use the cruise control system when driv-ing conditions do not permit maintaining a con-stant speed, such as in heavy traffic or on roadsthat are winding, icy, snow-covered, slippery, orroads with a loose driving surface. Failure to fol-low this precaution could cause a collision orloss of vehicle control, possibly resulting in per-sonal injury or property damage.

NOTICEWhen the cruise control is engaged, do not at-tempt to shift gears without using the clutchpedal. Failure to follow this precaution will resultin a temporarily uncontrolled increase in engine

speed. Transmission damage and gear strippingcould result.

B

2

3

1

( + )

( − )

4

05/30/2012 f270163a

A

C

A. Front ViewB. Shift RequestsC. Four positions for engine brake settings1. Engine Brake Symbol2. D/N/R Switch3. Mode Switch4. Gear Shift Symbol


Driver Controls

4.8

NOTE: If the vehicle is equipped with a Detroitmultifunction control, setting the cruise controlwith the engine brake on will activate DescentControl Mode. Moving the lever to the top posi-tion will resume the set cruise speed. Movingthe lever down to engage the engine brake afterthe cruise control has been set will activate De-celeration Mode. See "Descent Control and De-celeration Modes, Detroit™ Automated Transmis-sions" in this chapter.

The cruise control is operated by four buttonsmounted in the right-hand switch pod of the steeringwheel. See Fig. 4.15.

• Cruise On/Off Button—Press to turn cruisecontrol on or off. When cruise control is on, theICU message center displays relevant cruisecontrol icons and the set speed. The speedmemory will be retained until the cruise controlis disabled with the ON/OFF button, or the igni-tion is turned off.

• Cruise Accelerate/SET Button—Press to setthe cruise speed while the vehicle is travelingat the desired speed. Press and hold to in-crease the set cruise speed.

• CNCL Button —Press to pause the cruise con-trol, while retaining the speed setting inmemory. The cruise control can also be disen-gaged, while retaining the speed memory, bydepressing the brake or clutch pedals.

• Cruise Decelerate/RES Button—Press to re-sume the set speed. Press and hold to de-crease the set cruise speed.

1. To cruise at a particular speed:

1.1 Press the on/off button to turn cruise con-trol on.

1.2 Depress the accelerator pedal until thespeedometer reaches the desired speed.

NOTE: Cruise control is cancelled if thebrake or clutch pedal is depressed, or ve-hicle speed drops below the minimum cruisecontrol speed.

1.3 Press the cruise accelerate/SET button toset the desired speed.

NOTE: The speed memory is lost whenever theignition switch is turned to OFF, or cruise controlis turned off.

2. To disengage the cruise control, do one of thefollowing:

• Press the CNCL button in the center of theright-hand control pod.

• Depress the brake pedal.

• Depress the clutch pedal (on a manualtransmission only).

3. To resume a preselected cruise speed:

3.1 Ensure cruise control is on.

3.2 Press the cruise decelerate/RES button.Cruise will return to the last set speed.

NOTE: If vehicle speed drops below theminimum cruise control speed, cruise controlwill disengage. To resume to the preselectedcruise speed, increase vehicle speed toabove minimum cruise control speed andpress the cruise decelerate/RES button.

4. To increase cruise speed, press the cruiseaccelerate/SET button until the vehicle acceler-ates to the desired speed.

5. To decrease cruise speed, press the cruisedecelerate/RES button until the vehicle deceler-ates to the desired speed.

Cruise Control ("CC") LimiterOn vehicles equipped with a CC limiter switch (seeFig. 4.16), the cruise control limiter allows the vehicleto exceed the set cruise control speed before enginebraking is applied. The CC limiter switch provides

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234

5

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1. Cruise Accelerate/SET2. Marker Interrupt3. Cruise Decelerate/

Resume

4. Bluetooth—End Call5. Mute6. Bluetooth—Start Call7. Cruise On/Off

Fig. 4.15, Right-Hand Steering Wheel Switches

Driver Controls

4.9

more flexibility to the existing cruise control limit func-tion, allowing the driver to tune the cruise function tobetter suit driving preferences and conditions. To se-lect a limit, use the three-position CC Limiter switchon the dash. See Table 4.1 for switch settings.

CC Limiter Switch SettingsPosition Approximate Overrun Setting

Top in 3 mph (5 km/h)Middle 6 mph (9 km/h)

Bottom in Unlimited

Table 4.1, CC Limiter Switch Settings

Descent Control and DecelerationModes, Detroit™ AutomatedTransmissionsOn vehicles equipped with a Detroit multifunctioncontrol (Fig. 4.17), the functions of the lever posi-tions for engine brake control change when cruisecontrol is set. Two distinct modes can be activated:

• Descent Control Mode—engine braking keepsthe speed below cruise set speed; throttle isnot automatically applied.

• Deceleration Mode—engine braking activatesto reduce vehicle speed (with no lower limit) ata constant rate.

Descent Control ModeDescent Control Mode keeps the vehicle speedbelow the set cruise speed on a downhill.

To activate Descent Control Mode, set the cruisecontrol speed with the engine brake on (Fig. 4.17,positions 1, 2, or 3). In this mode, all three levels ofengine braking will be employed to to keep thespeed below the set cruise speed. This mode will notkeep the speed above the lower limit of the set

speed, so it is possible to eventually coast to a stop,unless the lever is moved to "engine brake off" (posi-tion 0), or throttle is applied. After throttle application,the Descent Control Mode is resumed.

Moving the lever to "engine brake off" (position 0)cancels Descent Control Mode and resumes cruisespeed. To reactivate Descent Control Mode, reset thecruise control speed with the lever in position 1, 2, or3.

Deceleration ModeDeceleration Mode reduces the vehicle speed at aconstant rate.

With the cruise control speed set, activate Decelera-tion Mode by moving the lever to engine brake on(Fig. 4.18, position 1, 2, or 3). This mode engagesone of the engine brake levels, depending on thelever position. The vehicle will decelerate at a con-stant rate until the vehicle comes to a stop, unlessthrottle applied to override the deceleration, or thelever is moved to "engine brake off" (position 0).

Moving the lever to position 0 resumes the previouslyset cruise control speed.

Dash-Mounted Brake ControlsNOTE: See Chapter 13 for detailed informationabout brake systems.

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CCLIMIT

Fig. 4.16, CC Limiter Switch

f270164a02/17/2017

0

1

2

3

0. Resume cruise control set speed.1, 2, 3. Descent Control maintains set speed.

Fig. 4.17, Descent Control Mode Positions, DetroitMultifunction Control

Driver Controls

4.10

Parking Brake Control Valve

NOTICEDo not step on the service brake pedal while theparking brakes are applied. To do so can causedamage to the brake mechanisms.

The yellow diamond-shaped knob operates the park-ing brake valve. See Fig. 4.19. Pull the knob out toapply both the tractor and the trailer spring parkingbrakes. Push the knob in to release the tractor andtrailer spring parking brakes. Before the spring park-ing brakes can be released, the air pressure in eitherair brake system must be at least 65 psi (447 kPa).

If the trailer is not equipped with spring parkingbrakes, pull the parking brake valve out to apply thetractor parking brakes and the trailer service brakes.

Trailer Air Supply ValveThe red octagonal-shaped knob operates the trailerair supply valve, which charges the trailer air supplysystem and releases the trailer spring parkingbrakes. See Fig. 4.19.

After the vehicle and its air hoses are connected to atrailer and the pressure in the air system is at least65 psi (447 kPa), push the trailer air supply valveknob in (and leave it in) to charge the trailer air sup-ply system and release the trailer spring parkingbrakes. Pull the trailer air supply valve out beforedisconnecting a trailer or when operating a vehiclewithout a trailer.

Trailer Brake LeverThe trailer brake lever is used to apply the trailer ser-vice brakes without applying the truck or tractor ser-vice brakes. It is usually mounted on the right-handcontrol panel. See Fig. 4.20. The valve can be par-tially or fully applied, but in any partially on position itwill be overridden by a full application of the servicebrake pedal. Move the lever down to apply the trailerbrakes; move the lever up to release the trailerbrakes. The lever will automatically return to the upposition when it is released.

Antilock Braking SystemThe Meritor™ WABCO® Antilock Braking System(ABS) passively monitors vehicle wheel speed at alltimes, and controls wheel speed during emergencystops or wheel lock situations.

During emergency or reduced-traction stops, fullydepress the brake pedal until the vehicle comes to asafe stop. Do not pump the brake pedal. With thebrake pedal fully depressed, the ABS will control all

f270164a02/17/2017

0

1

2

3

0. Resume cruise controlset speed.

1. Low

2. Medium3. High

Fig. 4.18, Deceleration Mode Positions, DetroitMultifunction Control

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12

1. Trailer Air Supply Valve (red knob)2. Parking Brake Control Valve (yellow knob)

Fig. 4.19, Brake Valve Control Knobs

f61059102/03/2017


Driver Controls

4.11

wheels to provide steering control and a reducedbraking distance.

The ABS is designed to communicate with a trailerABS, if they are compatible. Compatibility will resultin the illumination of the trailer ABS lamp during ve-hicle start-up and fault detection. The trailer ABSlamp will not illuminate unless a compatible trailer isconnected to the tractor.

Vehicles with ABS may have Automatic Traction Con-trol (ATC). On these vehicles, the ATC system auto-matically limits wheel spin during reduced-tractionsituations. In normal braking applications, the stan-dard air brake system is in effect.

ATC includes a deep snow and mud option to in-crease available traction on extra-soft surfaces likesnow, mud, or gravel. A switch labeled ATC will belocated on the dash. See Fig. 4.21. Press the switchto temporarily allow more drive wheel spin. The acti-vation of the deep snow and mud option is indicatedby a flashing WHEEL SPIN lamp. Press the switchagain to cycle the system back to normal operation.

NOTICEThe deep snow and mud option is intended to beused under specific slippery conditions that re-quire momentary increased wheel spin. Usingthis option for an extended period of time maydamage the brake system.

Windshield Wiper and WasherControls

NOTICEDo not attempt to manually move the windshieldwiper arms. Wiper motor damage will occur if thearms are forcibly moved.

The windshield wipers and washer controls are onthe multi-function turn signal lever on the left-handside of the steering column. See Fig. 4.22.

The wipers are operated by a rotary switch on theturn signal lever. There are five settings, marked onthe dial by symbols for off, two intermittent settings,and two continuous speeds.

Turn the wipers on by rotating the rotary switch up.Rotate the switch further to increase the speed of thewipers through the two intermittent settings, then tolow and high speeds. Rotate the switch down to slowthe wipers down. Rotate the switch as far down as itwill go to turn the wipers off.

For wiper intermittent operation, there are two set-tings. The first intermittent setting has a default inter-val of 6 seconds, but the interval is programmablefrom 1 to 25 seconds. To program the interval, rotatethe switch from the first intermittent position to theOFF position, wait for the desired interval betweenwipes to lapse (between 1 and 25 seconds), andthen move the switch back to the first intermittentposition. If the switch is kept in the OFF position formore than 50 seconds, the interval changes back tothe default of 6 seconds. The second intermittent set-ting has an interval of 1 second, and is not program-mable.

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DEEP MUDAND SNOW

ATC


f61126402/17/2017

1

32

4





Fig. 4.22, Windshield Wiper/Washer Controls

Driver Controls

4.12

The windshield washer button is located at the endof the turn signal lever. Momentarily press the wind-shield washer button to initiate a single wipe withoutactivating the washer pump. The wipers will swipeone full cycle and return to the inactive position.

To operate the windshield washers, press and holdthe button in. After a short delay, the washer willpump windshield washer fluid onto the windshield foras long as the washer button is pressed. The wind-shield wipers will turn on at low speed while thewasher button is pressed. After the button is re-leased, the wipers will continue to operate for one toseveral wipe cycles, depending on how long thewash button was pressed initially.

Suspension/Trailer ConnectionControlsAir Suspension Height Control Switch


The air suspension height control switch is used toadjust the vehicle height to aid in coupling or uncou-pling from a trailer. See Fig. 4.23. Setting the switchto DOWN deflates the air springs to lower the rear ofthe vehicle. In the UP position, the air springs inflateto raise the rear of the vehicle to normal ride height.



ECAS Dash SwitchesVehicles with Electronically Controlled Air Suspension(ECAS) may be equipped with either dash switches(Fig. 4.24) or a remote control unit, not both.

LOAD XFER (Load Transfer)This switch controls the ECAS Manual Load Transferfunction by adjusting suspension air pressure. Usethis function to minimize wheel slippage in road con-ditions where traction may be a concern.

The ECAS Load Transfer feature applies the maxi-mum available vehicle load on the drive axle, up tothe maximum allowable limit, determined by thegross axle weight rating (GAWR). In bobtail or with aloaded trailer less than the GAWR, the tag axle sup-ports a negligible load while the drive axle supportsnearly the full weight. Above the GAWR, the driveaxle is loaded with approximately the maximum al-lowable load and the tag supports the remainder.

Load transfer mode can be deactivated by holding upon the dash switch for 4 seconds. Load transfermode will automatically deactivate when the vehiclereaches 45 mph (72 kmh).07/22/2011 f545805


11/19/2014 f6112791 2

LOADXFER

SUSPHGT

1. Load Transfer 2. Suspension Height

Fig. 4.24, ECAS Dash Switches

Driver Controls

4.13


SUSP HGT (Suspension Height)If the suspension is at normal height:


• a down press lowers the suspension to its low-est set-point (usually axle stops)

If the suspension is below normal height:

• an up press increases the suspension height tonormal ride height

• a down press does nothing; the suspension isalready at its lowest point

If the suspension is above normal height:


• a down press lowers the suspension to normalride height

Messages about the ride height status will display inthe message field of the driver message center. SeeFigure 4.26.


ECAS Standby Mode, Dash SwitchOnce the key is turned off, the ECAS will enterStandby mode, remaining powered and adjusting tolevel and load changes for 1 hour. To cancel Standbymode on vehicles with ECAS dash switches, turn thekey from OFF to ON to OFF in less than 1.5 sec-onds. Confirm the deactivation of standby mode bypressing the SUSP HGT switch, which should notadjust the suspension.

ECAS Remote Control UnitSome vehicles equipped with Electronically Con-trolled Air Suspension (ECAS) have a remote controlunit to lower and raise the rear suspension. SeeTable 4.2 for keys and functions.


Messages about the ride height status will display inthe message field of the driver message center.

ECAS Standby Mode, Remote ControlOnce the key is turned off, the ECAS will enterStandby mode, remaining powered and adjusting tolevel and load changes for 1 hour. To cancel Standbymode on vehicles with a remote control, turn on theremote control then hold the STOP key on the re-mote for 2 seconds. Confirm the deactivation ofstandby mode by attempting to turn the remote onand adjust the suspension, which should not be pos-sible.

02/04/2015 f611291


02/04/2015 f611287

Fig. 4.26, Example of Ride Height Message

Driver Controls

4.14

ECAS Remote Control Keys and Functions

f61121102/03/2017

Key Function

Remote Control On/Off. The middlelight will remain lit while the remote is

active.

Memory keys. Pressing the Stop keyand a memory key simultaneously willstore the current height. Once stored,

pressing the key will adjust thevehicle to the stored height.

Normal height key. This key willreturn the vehicle to normal ride

height.

Lift and lower keys. These keys willraise or lower the rear suspension

height.

The Stop key. Pressing the Stop keywill interrupt and stop all adjustments

being made by the remote control.When the key is off, holding the Stopkey for 2 seconds will cancel the 1

hour Standby mode.

Table 4.2, ECAS Remote Control Keys and Functions

Fifth Wheel Slide Control Switch

NOTICEDo not activate the fifth wheel slide control valvewhile the vehicle is in motion. To do so couldcause damage to the fifth wheel member, thekingpin, the cab or trailer, and ultimately to thedrivetrain.

The fifth wheel air slide switch permits repositioningof the sliding fifth wheel from inside the cab. SeeFig. 4.27. Moving the air slide control valve switch tothe lock position deactivates the control valve andlocks the fifth wheel to the baseplate. Moving theswitch to the unlock position activates the controlvalve and unlocks the fifth wheel slide mechanism,allowing changes to the total length of the tractor-trailer and changes to axle loads to comply with vary-ing jurisdictional laws. For detailed operating instruc-tions for fifth wheel slide, coupling, and uncouplingprocedures, refer to Chapter 18.

Trailer Auxiliary SwitchTrailers that are equipped with pneumatic brakes andused in North America or South America are gener-ally equipped with power for the trailer lights. Theconnection is passed from the vehicle to the trailervia the primary receptacle, controlled by a dashswitch.

Press the top of the switch to activate the trailer aux-iliary function. Press the bottom of the switch to turntrailer auxiliary function off. See Fig. 4.28.

Adjustable Steering ColumnControlsTo unlock the steering column to adjust it, pull thesteering column locking lever out and away from thecolumn. See Fig. 4.29. With the column unlocked,the steering wheel can be adjusted up-and-down andtilted fore-and-aft. Once the wheel is in the desired

07/22/2011 f545806

Fig. 4.27, Fifth Wheel Slide Control Switch

Driver Controls

4.15

position, lock the position by pushing the lever in to-ward the column until it goes no further and is paral-lel to the column itself.

WARNINGMake sure that the steering column is locked be-fore driving the vehicle. Never attempt to adjustthe column while driving the vehicle. Doing socould cause loss of vehicle control, personal in-jury, and property damage.

Radio/Bluetooth ControlsBluetooth controls are located on the steering wheel.Volume up and down buttons are on the left-handswitch pod. Start call, end call, and mute buttons areon the right-hand switch pod. See Fig. 4.30. For ad-ditional radio operating instructions, see the radiomanufacturer’s manual.

Climate ControlsNOTE: See Chapter 6 for detailed climate con-trol panel operating instructions.

The climate control panel allows you to control theheating, ventilating, defrosting, and air conditioningfunctions. See Fig. 4.31. Western Star vehicles haveseveral heater and air conditioner options.


• heater only





• heater only




Seat ControlsNOTE: See Chapter 7 for detailed informationabout seat controls and adjustments.


The following is a description of adjustments that canbe made to various Western Star seats. Not all seats

11/19/2014 f611261

TRAILERAUX

Fig. 4.28, Trailer Auxiliary Switch

08/19/2014 f462249

A

A. To unlock the steering column for adjustment, pullthe lever out and away from the column.

Fig. 4.29, Steering Column Locking Lever

Driver Controls

4.16

have all of the adjustments listed below. SeeFig. 4.32.


2. Lumbar Support: Lumbar support changes theshape of the seat back to give more or less sup-port to the occupant’s lumbar (lower back) area.This adjustment is either mechanical or air con-

trolled, depending on make and model of theseat.


5

4

08/14/2014 f611271

1

3

2

1. Bluetooth—Start Call2. Mute

3. Bluetooth—End Call4. Volume Down

5. Volume Up

Fig. 4.30, Radio/Bluetooth Controls on the Steering Wheel

f610640

A/CBUNK

1

2 3 4

6 5702/10/2003





Driver Controls

4.17

4. Height Adjustment: This adjustment moves theentire seat up or down. The adjustment is eithermanually- or air-controlled, depending on themake of the seat.





f910149a02/03/2017

1

2

3 4

56 7

8






Driver Controls

4.18

5

Driver Assistance FeaturesOnGuard™ Collision Safety System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1Lane Departure Warning Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.4OnLane™ Lane Departure Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.5Roll Stability System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.6Enhanced Stability Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.8

OnGuard™ Collision SafetySystemMeritor WABCO OnGuard is a forward-looking radar-based safety system. The system includes forwardcollision warning, adaptive cruise control (ACC), andcollision mitigation.

OnGuard equipped vehicles have antilock brakes(ABS) and automatic traction control (ATC), and ei-ther roll stability control (RSC) or electronic stabilitycontrol (ESC). These systems work together to en-hance control of the vehicle. Depending on the situa-tion, any of these features may apply throttle control,engine brakes, and/or service brakes, as needed.

The front-looking antenna assembly transmits radarsignals to, and receives them back from, objectsahead of the vehicle. To be detected, vehicles mustbe within the radar field of view and provide a sur-face area that can reflect the radar. The distance,speed, and angle of the vehicle ahead is calculated,and the driver is warned of potentially dangeroussituations. The system also warns of stationary ob-jects to alert the driver of potential obstructionsahead in their lane.

WARNINGThe Meritor WABCO OnGuard™ Collision SafetySystem is intended solely as an aid for an alertand conscientious professional driver. It is notintended to be relied upon to operate a vehicle.Use the system in conjunction with rearview mir-rors and other instruments to safely operate thevehicle. Operate a vehicle equipped with the On-Guard in the same safe manner as if the CMSwere not present.

The OnGuard Collision Safety System is not asubstitute for safe, normal driving procedures,nor will it compensate for any driver impairmentsuch as drugs, alcohol, or fatigue.


System LimitationsThe OnGuard Collision Safety System may providelittle or no warning of hazards such as pedestrians,animals, oncoming vehicles, or cross traffic.

OnGuard CMS only brakes for lead vehicles locateddirectly in front of your vehicle, and does not operatewhen vehicle speed is less than 15 mph (25 km/h).

Due to these limitations, the system:

• will not react and alert the operator to objectscrossing in front of the vehicle or oncomingtraffic;

• should not be relied on to track lead vehicleswhen traveling through a severe curve in theroad. Because of this, ACC is not recom-mended for use on winding roads;

• will alert, but not actively brake, on stationaryobjects;

• should not be relied upon to track smaller ob-jects like motorcycles, mopeds, bicycles, orpedestrians;

• should not be relied on to alert drivers to ve-hicles in an adjacent lane.

OnGuard Display UnitThe OnGuard system controls are located in the dis-play unit. The display provides visual and audiblewarnings and messages, as well as verification ofcorrect system operation and faults. Menu selectionsare made by pressing the up and down arrows, andthe MODE button. See Fig. 5.1 .

The display includes:

• an internal speaker

• a graphic display

• buttons to scroll and select options

f61127702/17/2017

12

3

4

1. Mode2. Day/Night Mode

3. Up4. Down

Fig. 5.1, OnGuard Display Unit


5.1

• day/night display mode

Collision Mitigation System (CMS)The CMS provides the driver with audible and visualalerts when the vehicle’s following distance couldresult in a rear-end collision. The OnGuard displayunit shows a graphic of the condition, enhanced by ascreen color relevant to the intensity of the situation.See Table 5.1. If a potential rear-end collision is im-minent, OnGuard’s active braking automatically ap-plies the engine and service brakes to slow the ve-hicle. The active braking application is intended onlyto provide early braking; the driver is still required torecognize and react to all driving situations.

IMPORTANT: CMS and active braking are notoperational at vehicle speeds below 15 mph (25km/h).

OnGuard Display Screen Background ColorsScreen Color Description

Blue General operation; no lead vehiclesdetected.

Green Lead vehicle detected.

Yellow Following distance alert, accompaniedby an audible alert.

RedCollision warning, stationary objectwarning. Accompanied with audiblealert.

Amber Data Error

Table 5.1, OnGuard Display Screen BackgroundColors

StandbyWhen no lead vehicle is detected, the display showsthat the CMS is on and the radar is searching. SeeFig. 5.2.

A Vehicle is DetectedWhen a lead vehicle is detected in the lane ahead,the display shows that the CMS is on and the radar

is tracking a lead vehicle at the speed shown. SeeFig. 5.3.

If the following distance between the vehicle and thelead vehicle is too close, the CMS will emit an au-dible alert and the display background will turn yel-low. The alert will end when the vehicle speed dropsbelow the lead vehicle speed and the following dis-tance is increased.

Collision WarningWhen a lead vehicle is detected traveling slower thanyour vehicle, or the gap between them becomes tooclose, the CMS warns of an impending collision byemitting an urgent audible alert and displaying thecollision warning symbol with a red background. SeeFig. 5.4.

Adaptive Cruise Control (ACC)ACC works in conjunction with conventional cruisecontrol to maintain a minimum following distancewhen a lead vehicle is being tracked. The minimumfollowing distance is maintained by automatically de-celerating the vehicle using throttle, engine, and ser-vice brakes without driver intervention. When the

CMS12/18/2014 f611143c

Fig. 5.2, CMS Standby (blue)

CMS

12/18/2014 f611143b

55 MPH

230FT

Fig. 5.3, CMS Lead Vehicle Detected (green)

12/18/2014 f611144a

CMS 15 MPH

15 FT

Fig. 5.4, CMS Collision Warning (red)


5.2

lead vehicle is no longer being tracked, the set cruisecontrol speed resumes automatically.

StandbyWhen no lead vehicle is detected, OnGuard ACCoperates similarly to conventional cruise control. Thecruise control set speed is shown on the OnGuarddisplay unit. See Fig. 5.5.

Lead Vehicle DetectedWhen a lead vehicle is detected in the lane ahead,the display shows that ACC is on and the radar istracking it. See Fig. 5.6.

If the driver uses the accelerator pedal to overridethe cruise control and approach a vehicle too closely,the ACC will emit an audible alert and the displaybackground will turn yellow. The alert will end whenvehicle speed drops below the lead vehicle’s speedand the following distance is increased.

NOTE: The following distance alert does notoperate at speeds below 15 mph (25 km/h).

Collision WarningIf the lead vehicle is traveling slower than the driver’svehicle, the CMS warns of an impending collision byemitting an urgent audible alert and displaying thecollision warning symbol with a red background. SeeFig. 5.7.

The braking control will activate and slow the vehicle.The driver must also initiate braking.

Error ScreensIMPORTANT: The OnGuard collision safety sys-tem is not operational when an error screen isdisplayed. If a fault occurs or OnGuard fails toproperly track a vehicle, take the vehicle in forservice as soon as possible. Standard cruisecontrol will not function with an active OnGuardsystem fault.

If a system fault is detected, the OnGuard displayunit will immediately display an error screen asshown in Fig. 5.8. The first error code transmittedwill be displayed first; additional faults (if any) can beviewed using the up or down buttons. The displaydoes not show stored fault codes.

Refer to the OnGuard Collision Safety System Main-tenance Manual MM-0951 for a full list of faults(www.meritorwabco.com).

Additional FeaturesPress the MODE button to access the OnGuard dis-play unit additional features from the CMS or ACCmain operating screen. Press the up and down ar-rows to scroll through each menu, then press theMODE button to select the value to be changed. Inedit mode, press the up or down arrows to change a

f61114502/17/2017

Set: 60 MPH

Fig. 5.5, ACC Standby (blue)

f61114602/17/2017Set: 60 MPH 55 MPH

230 FT

Fig. 5.6, ACC Lead Vehicle Detected (green)

f61114702/17/2017

Set: 60 MPH15 MPH

15 FT

Fig. 5.7, ACC Collision Warning (red)

f61114802/17/2017

ACC1 Link Error

DATA ERROR

Fig. 5.8, OnGuard Error Screen (amber)


5.3

www.meritorwabco.com

value setting, then press the MODE button to savethe setting. Pressing MODE in each feature screenadvances the display to the next feature.

The Display Control menu allows adjustment of thealarm volume, LCD brightness, LCD contrast, andU.S./metric unit conversion. See Fig. 5.9.

The component test menu provides verification ofsystem component operation and acts as a valuableOnGuard system diagnostic tool. The header will dis-play either COMPONENT TEST or ACC FUNCTION,depending on the software release version of the On-Guard system. The component test screen shown inFig. 5.10 provides access to the following compo-nents (press the up or down arrows to scroll throughthe menu):

• brake pedal position

• EBS brake switch

• CCVS brake switch

• clutch switch

• park brake switch

• accelerator pedal position

• driveline engaged

• cruise control enable

• cruise control set speed switch

• cruise control coast switch

• cruise control resume switch

• cruise control accelerate switch

• cruise control pause switch

Lane Departure WarningControlsThe lane departure warning system monitors the ve-hicle’s position within the roadway lane markings andsounds a warning in the cab when the vehicle isabout to stray outside its lane, provided the turn sig-nal is not on and the vehicle is traveling at least 37mph (60 km/h). The system includes a digital cameramounted high near the center of the windshield in-side the cab and speakers that emit a sound similarto a rumble strip. The sound is made on the side ofthe vehicle it’s straying toward, prompting the driverto respond and steer away from the sound and backinto the center of the correct lane.

WARNINGThe lane departure warning system is intendedonly as an aid for a conscientious and alertdriver. The system may not indicate lane depar-tures under certain conditions. Read the informa-tion in this manual to understand the circum-stances under which this system may notprovide adequate lane departure warnings. Donot rely solely on the system to safely operatethe vehicle. The system does not warn of all pos-sible hazards. For example, the system cannotprevent an accident if the driver is impaired ornot driving safely.



The lane departure warning system powers up eachtime the ignition is turned to ON. The system con-ducts a self test, and initiates test tones from the leftspeaker and then the right speaker. Once the vehicleis started and the system is ready, the LED in theswitch illuminates.

Press the LANE ALERT switch to temporarily disablethe lane departure warning system. See Fig. 5.11.Some vehicles are equipped with a timer that auto-matically re-enables the warning system after 15minutes. On all other vehicles, the warning system

f61114902/17/2017

DISPLAY CONTROL

Alarm Volume

Alarm Tone

10

4

LCD Intensity 9

Fig. 5.9, Display Control Menu

f61115102/17/2017

COMPONENT TEST

CCVS Brake Switch

Brake Pedal Position

ON

37%

ON

EBS Brake Switch

Fig. 5.10, Component Test Menu


5.4

will remain disabled until the driver enables the sys-tem by pressing the LANE ALERT switch again, orthe ignition is cycled off and then on.

When the vehicle approaches the lane markings oneither side, the system sense the activation of a turnsignal. If a turn signal has not been activated, thesystem initiates the audible warning to alert the driverthat the vehicle is departing its current lane of travel.

The LANE SRCHNG warning light illuminates to indi-cate the system is not fully functional. When thewarning light is on, the system audible alert may notindicate a lane departure. Conditions that can causethe warning light to illuminate include:

• The system is unable to detect lane markings.

• Vehicle speed is less than 37 mph (60 km/h).

• A system problem is detected.

OnLane™ Lane DepartureWarning

WARNINGOnLane lane departure warning is intended onlyas an aid for a conscientious and alert driver. Thesystem may not indicate lane departures undercertain conditions. Read the information in thismanual to understand the circumstances underwhich this system may not provide adequate lanedeparture warnings. Do not rely solely on thesystem to safely operate the vehicle. The systemdoes not warn of all possible hazards. For ex-ample, the system cannot prevent an accident ifthe driver is impaired or not driving safely.



OnLane is a camera-based warning system thathelps the driver avoid unintentional lane drifting.

The system utilizes a camera mounted near the topcenter of the vehicle windshield, which calculatesvehicle position within the lane. When the vehiclecrosses lane markings without the turn signal beingactivated, OnLane sounds an audible warning.

The Driver Alertness Warning (DAW) system pro-vides a warning when weaving or erratic driving isdetected within the driving lane.

System StartupOnLane is activated when the vehicle ignition isturned on. Lane departure warnings are active onlywhen the vehicle is traveling at 42 mph (68 kph) orabove.

Intentional Lane ChangesThe system identifies intentional lane changes bymonitoring the turn signal, the brake switch, and ve-hicle speed. When a lane change is intentional, theassistance warnings are disabled. The following con-ditions will disable/enable the warnings:

• If brake lights are ON, all warnings are dis-abled

• If the Left Turn Signal is ON, left departurewarnings are disabled

• If the Right Turn Signal is ON, right departurewarnings are disabled

• If the vehicle’s speed is under 42 mph (68kph), all warnings are disabled

• If the hazard lights are ON, all warnings areenabled

Unintentional Lane DepartureThe system constantly monitors and calculates thevehicle’s position within the lane. In the event of anunintentional lane change, the system provides anaudible warning (rumble strip noise). The audiblewarning will terminate once the vehicle is guidedback into the lane.

08/07/2014 f611266

LANEALERT

Fig. 5.11, Lane Departure Warning System DisableSwitch


5.5

Driver Alertness WarningThe system detects erratic driving based on weavingbehavior within the driving lane. OnLane computes a"Driver Alertness Index" based on driving perfor-mance, and alerts the driver when it falls below acertain threshold. DAW warns the driver by providingan intermittent warning tone when it detects erraticdriving or weaving within the driving lane. The alertterminates when driving performance improves, orwhen the key is cycled.

Temporarily Disabling the SystemThe system can be temporarily disabled by pressingthe OnLane switch. This disables warnings for 15minutes. Warnings can be enabled by pressing theOnLane switch again.

Roll Stability SystemThe roll stability system may include the roll stabilityadvisor (RSA) only, or it may also include the roll sta-bility control (RSC).

A decal (Fig. 5.12) on the auxiliary dash panel, andan amber-colored dash indicator light (Fig. 5.13), in-dicate that the vehicle is equipped with roll stabilitysystem components.

Roll Stability AdvisorIMPORTANT: This is not an advance warningsystem. The roll stability advisor displays a mes-sage only after the driving maneuver is com-pleted.

The roll stability system uses a lateral-accelerationsensor that monitors rollover risk. Shortly after acurve, lane change, or other driving maneuver thatresults in a rollover-risk detection, a dash warninglight illuminates, an audible tone sounds, and a driveradvisory message is displayed in the driver messagecenter. The purpose is to advise the driver that theprevious maneuver produced a rollover risk.

The roll stability advisor displays different text mes-sages depending on the severity of the risk of eachoccurrence of risky driving. From the highest risklevel to the lowest risk level, the system will soundan audible alert, and display a message, as shown inFig. 5.14.

NOTE: The system will calculate and recom-mend a speed reduction value. It may be differ-ent than the values shown here.

Bring the vehicle to an authorized service facility if asystem failure message is displayed.

Roll Stability Control

WARNINGThe Roll Stability Control system is intended onlyas an aid for a conscientious and alert driver.Carefully read the information in this manual tounderstand this system and its limitations. TheRoll Stability Control system is not a substitutefor safe driving procedures. Failure to drivesafely, and use the system properly, could resultin personal injury and/or death and propertydamage.

The roll stability control system automatically reducesengine 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 rollingover. The control can intervene even before an advi-sory message is displayed.

The dash indicator light illuminates whenever the rollstability control system intervenes.

lamp indicates tractionOR roll control event.Follow instructions indriver’s manual.

24−01204−000

07/11/2003 f080125

SAFETY INSTRUCTIONS

Fig. 5.12, Roll Stability Decal

f60212802/03/2017

Fig. 5.13, Roll Stability Indicator Lamp


5.6

Hard-Braking AdvisorThe hard-braking advisor uses the information fromthe ABS wheel speed sensors to determine whenbraking is severe enough to produce lockup at one

or more wheels on the tractor, and/or very rapid ve-hicle deceleration. Shortly after a hard-braking eventoccurs, an advisory message is displayed in thedriver message center, indicating that the brakingbehavior was too aggressive for the current road sur-face conditions. This system is not a replacement fora driver’s good judgment. Sometimes it is necessaryto brake hard.

From the highest risk level to the lowest risk level,the system will sound an audible alert, and display amessage, as shown in Fig. 5.14.

Trip/Leg TotalsThe driver message center records the number ofmessages received, and displays the number ofmessages as counts. Roll stability advisor (RSA) andhard-braking event data (HBED) counts can beviewed in the trip advisory screen, and the leg advi-sory screen.

Counts can be reset using the + key on the steeringwheel. Clearing RSA and HBED leg counts will alsoreset the leg miles and leg hours. Clearing RSA andHBED trip counts will also reset trip miles, trip hours,leg miles, leg hours, and leg advisory counts. In ad-dition, resetting leg miles will clear leg counts. Clear-ing trip miles will reset miles, hours, and counts inboth the leg and trip screens.

The TRIP and LEG advisor screens count both theroll stability advisories (ROLL) and hard-brakingevents (BRK). For example, if during a TRIP, thedriver message center recorded the events inTable 5.2, the message center would display asshown in Fig. 5.15.

RSA/HBED CountMessage Received Message Counts

RSA Level 3 2RSA Level 2 3RSA Level 1 7

HBED Level 3 5HBED Level 2 1HBED Level 1 8

Table 5.2, RSA/HBED Count

If the count reaches more than 9 occurrences an up-arrow symbol will appear, to indicate to the driverthat the count has exceeded 9 counts. SeeFig. 5.16.

Message to Display

4 1

MessageMSG

No.

System Fault1WARNING

RAC SYSTEM FAIL

ACTIVE SLOWING

ROLLOVER RISK

4 NoneRSC2

VERY HIGH RISK OF

ROLLOVER DETECTED

REDUCE SPEED

AT LEAST 11 KPH

REDUCE SPEED

AT LEAST 7 MPH

or in metric

19.6 10RSA Level 33

HIGH RISK OF

ROLLOVER DETECTED

REDUCE SPEED

AT LEAST 11 KPH

REDUCE SPEED

AT LEAST 7 MPH

or in metric

14 5RSA Level 24

ROLLOVER RISK

DETECTED

REDUCE SPEED

AT LEAST 11 KPH

or in metric

REDUCE SPEED

AT LEAST 7 MPH

8.4 2RSA Level 15

HARD BRAKING WITH

ABS ACTIVATED

LOOK AHEAD

BRAKE SOONER

14 0.5HBED Level 36

HARD BRAKING

DETECTED

LOOK AHEAD

BRAKE SOONER

14 0.5HBED Level 27

LOSS OF TRACTION

ABS ACTIVATED

ROAD SURFACE

MAY BE POOR

14 0.5HBED Level 18

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DisplayTime:

Seconds

BuzzerTime:

Seconds

Fig. 5.14, Roll Stability and Hard-Braking Warnings


5.7

Enhanced Stability Control

WARNINGEnhance Stability Control (ESC) is intended onlyas an aid for a conscientious and alert driver.Carefully read the information in this manual tounderstand this system and its limitations. ESCis not a substitute for safe driving procedures.Failure to drive safely, and use the system prop-erly, could result in personal injury and/or deathand property damage.

ESC offers the full capability of RSC (shown above)with the added capability of complete directional sta-bility (yaw control) in oversteer and understeer condi-tions to reduce the likelihood of drift-out or jackknife.The system determines where the driver is attempt-ing to steer the vehicle and how much brake demandis required in order to more precisely control the ve-hicle in an emergency situation.

ESC works by constantly comparing the driver inputwith the vehicle’s actual behavior. The system doesthis by monitoring systems such as wheel speed,steering angle, yaw rate, lateral acceleration, throttleposition, and brake application. A central microcom-puter analyzes the collected data and triggers a re-sponse to keep the vehicle on course when an un-stable condition is detected.

When the system detects that the vehicle is at risk ofoversteering or understeering, it applies individualtractor wheel end brakes and trailer brakes, activatesthe engine retarder (if equipped), and/or cuts enginepower, depending on the severity. As a result, thedriver has full control over the vehicle until the sys-tem detects a potential risk and intervenes accord-ingly. ESC operates automatically; the driver doesnot monitor or activate the system.

07/25/2008

TRIP ADVISORIES

237 ROLL 518 BRK

f040770A B C D E F

A. RSA lev. 3 Count (2)B. RSA lev. 2 Count (3)C. RSA lev. 1 Count (7)

D. HBED lev. 3 Count (5)E. HBED lev. 2 Count (1)F. HBED lev. 1 Count (8)

Fig. 5.15, Trip Advisor Message Screen

07/25/2008

TRIP ADVISORIES

23 ROLL 518 BRK

f040771A

A. RSA Lev. 1 has more than 9 counts.

Fig. 5.16, Trip Advisor Message Screen (more than 9counts)


5.8

6

Climate ControlsClimate Control Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.1Cab Climate Control Panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.1Sleeper Climate Control Panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3Parked HVAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.7Accessory Heaters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.8

Climate Control OptionsThe climate control panel allows you to control theheating, ventilating, defrosting, and air conditioningfunctions. Western Star vehicles have several heaterand air conditioner options.






• heater only




Cab Climate Control PanelsThe standard cab climate control panel has a fanswitch, a temperature control switch, and a modecontrol switch that allows the driver to control heat-ing, cooling, defrosting, and ventilating. The controlpanel may also be equipped with an optional A/Cswitch and/or an optional BUNK switch. See Fig. 6.1.

Vehicles equipped with ATC have an LED display.See Fig. 6.2.

ControlsFan SwitchThe fan switch activates the fan, which forces freshair or recirculated air through the air outlets. The fanswitch has four fan speed settings and an off posi-tion. See Fig. 6.1.

To operate the fan switch, turn the fan switch clock-wise to increase airflow; turn the fan switch counter-clockwise to decrease airflow.

On vehicles equipped with ATC, the AUTO setting onthe fan switch places the heater and air conditionersystem in the automatic fan speed control mode.When the fan switch is set to AUTO, the fan speed

will vary as necessary to maintain the temperatureset by the user.

Temperature Control SwitchTo select the desired temperature:

• Vehicles Without ATC: Turn the switch to theleft (counterclockwise) for cool air, or to theright (clockwise) for hot air.

• Vehicles With ATC: Press and release the rightside of the temperature up/down switch to in-crease the temperature to the desired setting.Press and release the left side of the tempera-ture up/down switch to decrease the tempera-ture to the desired setting. Press and hold thetemperature up/down switch to change the de-sired temperature in large increments.

Mode Control SwitchThe mode control switch allows the driver to controlthe flow of air through the face outlets, the floor out-lets, the defrost (windshield) outlets, or a combinationof these outlets to provide six air selection modes.See Fig. 6.3.

• Face Mode (using recirculating air): Directs allairflow through the face or instrument paneloutlets, using recirculated air.

• Face Mode (using fresh air): Directs all airflowthrough the face or instrument panel outlets,using fresh air.

• Bi-Level Mode: Directs the airflow equally tothe face outlets and the floor outlets.

• Floor Mode: Directs all airflow through the flooroutlets.

• Floor/Defrost Mode: Directs the airflow equallyto the floor outlets and the defrost outlets.

• Defrost Mode: Directs all airflow through thedefrost outlets.

NOTE: The face mode using recirculating air isthe only mode that recirculates the air in thecab. All other modes draw in fresh air from out-side the vehicle.

Bunk SwitchThe optional BUNK switch allows the driver to controlthe sleeper heater and air conditioner from the cab.Press the BUNK switch to turn the sleeper heaterand air conditioner on. When the bunk switch is on,the indicator light is on. The sleeper heater and air

Climate Controls

6.1

conditioner can still be controlled from the sleeperwhen the BUNK switch is on.

Air Conditioner (A/C) SwitchThe air conditioner cools and dehumidifies the airinside the cab. Press the optional A/C switch to turnthe air conditioner on or off. When the air conditioneris on, the A/C switch illuminates.

IMPORTANT: Operate the air conditioner atleast five minutes each month, even during coolweather. This helps prevent drying and crackingof the refrigerant compressor seals and reducesthe chance of refrigerant leaks in the system.

f610640

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1. Fan Off Position2. LED Display

3. Mode Control Switch4. Bunk Switch (optional)

5. Temperature Up/Down Switch6. Fan Switch

Fig. 6.2, Cab Climate Control Panel With ATC

Climate Controls

6.2

LED Display, Vehicles With ATC OnlyThe LED display shows the temperature to which theheater or air conditioner has been set in degreesFahrenheit or degrees Celsius.

Changing Temperature UnitsThe temperature units can be changed from Fahren-heit (°F) to Celsius (°C) or from Celsius to Fahrenheitby turning the ignition on, turning the fan switch off,and pressing and holding the left side of the tem-perature up/down switch for five seconds. The cur-rent temperature unit will then be shown on the LEDdisplay. Press the left side of the temperature up/down switch again to toggle between °F and °C.Changing the temperature units on the cab climatecontrol panel will also effect the sleeper climate con-trol panel.

Error CodesError codes can be displayed by turning the ignitionon, turning the fan switch off, and pressing and hold-ing the right side of the temperature up/down switchfor five seconds. The current error status will beshown on the LED display. Press the right side of thetemperature up/down switch again repeatedly toscroll the display through any existing error codes. Ifan error code is displayed, contact your Western Stardealer for service.

ModesRecirculation Mode

WARNINGDo not use the recirculation mode when theheater is on and the vehicle is in motion. Drivingwith the recirculation mode on while the heater ison may cause the windows to be obscured bymoisture or ice, which could result in an accidentpossibly causing personal injury or propertydamage.

Do not use the recirculation mode for more than20 minutes at a time because the air inside thecab may become stuffy and the windows maybecome obscured by moisture, which could re-sult in an accident possibly causing personal in-jury or property damage.

When the mode control switch (see Fig. 6.3) isturned to the face mode using recirculating air, theair in the cab is recirculated through the heater andair conditioner system. This is the only mode thatuses recirculated air. Fresh air, or outside air, is cir-culated through the heating and air conditioning sys-tem when any other mode is selected.

The recirculation mode can be used to prevent dustyor smoky air from entering the cab, or to decreasethe time required to cool or heat the cab interior dur-ing extreme outside temperature conditions. Whenthe outside air is clear or the desired cab tempera-ture is reached, change the mode control switch to afresh-air mode. The recirculation mode can be usedwhen the air conditioner is on whether the vehicle ismoving or not.

Defrost ModeThe defrost mode is used to deice, defrost, or defogthe windows.

NOTE: When the defrost mode is on, the airconditioner is on. The air conditioner is used todehumidify the air entering the cab and to re-move the moisture from the windshield.

Sleeper Climate Control PanelsThe standard sleeper climate control panel has a fanswitch, a temperature control switch, and a powerswitch that allow you to control the heating and airconditioning functions in the sleeper. A vehicle with

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1. Face Mode (recirculating air)2. Face Mode (fresh air)3. Bi-Level Mode4. Floor Mode5. Floor and Defrost Mode6. Defrost Mode

Fig. 6.3, Mode Control Switch Settings

Climate Controls

6.3

an air conditioner has an air conditioner switch onthe control panel. See Fig. 6.4.

Vehicles with ATC have button controls instead ofswitch controls. See Fig. 6.5.

Controls, Vehicles Without ATCPower Switch and IndicatorThe power switch is used to turn the sleeper heaterand air conditioner on and off. When the heater or airconditioner is on, the indicator illuminates.

Fan SwitchThe fan switch controls the fan speed and forces airthrough the air outlets. The fan switch has threespeed settings and an off position. See Fig. 6.4.

To operate the fan switch, turn the switch clockwiseto increase airflow; turn the fan switch counterclock-wise to decrease airflow.

Temperature Control SwitchTo select the desired temperature, turn the switch tothe left (counterclockwise) for cool air, or to the right(clockwise) for hot air.

Air Conditioner (A/C) SwitchThe air conditioner cools and dehumidifies the airinside the sleeper. Press the optional A/C switch toturn the air conditioner on or off.

Controls, Vehicles With ATCThe controls for the sleeper heater and air condi-tioner are located on the right side of the ATCsleeper control panel. See Fig. 6.5.

Power Switch and IndicatorTurn the sleeper heater and air conditioner on bypressing the ON button. The current set temperatureis displayed for five seconds, after which it returns tothe time display. When the heater or air conditioneris on, the indicator illuminates. To turn the sleeperheater and air conditioner off, press the OFF button.

Fan SwitchTo operate the fan switch, press the fan up or fandown button repeatedly to incrementally increase ordecrease the fan speed. Press either button for atleast two seconds to continuously increase or de-

crease the fan speed. The fan speed setting is dis-played on the sleeper control panel in 10 percentincrements. When the highest or lowest fan speed isselected, HI or LO is displayed. The display returnsto the time display five seconds after a fan up/downbutton is pressed and released.

In the ATC mode, fan speed is determined by thesystem as required. The fan speed is based on thedifference between the set point temperature and theactual sleeper cab temperature. The greater the dif-ference, the greater the fan speed. The AUTO fan

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POWER

A/C HEAT

1. Fan Switch2. Power Switch

3. Indicator4. Temperature Control Switch

5. Air Conditioner Switch

Fig. 6.4, Sleeper Climate Control Panel, No ATC

Climate Controls

6.4

function is disabled when either the fan up or fandown button is pressed.

Temperature Control SwitchTemperature is displayed with a three-digit annotationand can be displayed either in degrees Celsius ordegrees Fahrenheit. A capital "C" or "F" is displayedfor the appropriate temperature scale.

To select the desired temperature, press the tem-perature up or temperature down button repeatedlyto incrementally increase or decrease the set tem-perature. Press either button for at least two secondsto continuously increase or decrease the set tem-perature. The temperature setting is displayed on thesleeper control panel. The display returns to the timedisplay five seconds after a temperature up/downbutton is pressed and released.

The temperature units can be changed from °F to °Cor from °C to °F by pressing the temperature up andtemperature down buttons simultaneously. Changingthe temperature units on the ATC sleeper controlpanel will also change the temperature units on theATC cab control panel.

Auto ButtonPress the AUTO button to enable automatic controlof the fan speed. The display will show the currentset temperature for five seconds, then return to thetime display. When in the automatic mode, the fanspeed can vary to maintain the temperature set bythe user. When automatic control is turned on, theindicator above the AUTO button illuminates.

Alarm ButtonMomentarily press the ALARM button to turn thealarm on and to illuminate the alarm indicator abovethe ALARM button. Momentarily press the buttonagain to deactivate the alarm.

When pressing the ALARM button, the display showsthe alarm time setting for five seconds before return-ing to the current time display. If the ALARM buttonis pressed and held down continuously for more thanone second, the alarm time setting can be viewedwithout changing the state of the alarm indicator. Ifeither the SET+ or SET– buttons are pressed simul-taneously with the ALARM button held down, thealarm time setting will increase or decrease. Whenthe ALARM button is released after changing the

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f610629

ALARM

SET −

TIME

SET +

ON

OFF

AUTO

PM

DISP

1

2 3 4 5

6

7

8910

1. Alarm Button2. Time Button3. Fan Up Button4. Heater and Air Conditioner On Button5. Heater and Air Conditioner Off Button

6. Temperature Up Button7. Temperature Down Button8. Automatic Fan Button9. Fan Down Button10. Display Button

Fig. 6.5, Sleeper Climate Control Panel With ATC

Climate Controls

6.5

alarm time, the alarm will be turned on and the indi-cator will be illuminated. When the ALARM is sound-ing, press the ALARM button to turn the alarm offand to reset the alarm for the next 24-hour cycle.

To set the snooze function, press any button on thecontrol panel, except the ALARM button, when thealarm is sounding. The alarm will sound again afterseven minutes. The alarm indicator flashes when thesnooze function is set.

To cancel the snooze function, press the ALARM but-ton. This will also reset the alarm for the next 24-hour cycle.

Time ButtonThe clock controls are located on the left side of theATC sleeper control panel under the display. The dis-play will show the clock time as the default mode.

Press the TIME button to display the current time. Ifthe TIME button is held down and either the SET+ orSET– buttons are pressed simultaneously with theTIME button, the clock setting will increase or de-crease.

Display ButtonPress the DISP button to allow the display and illumi-nation of the control panel to scroll through three illu-mination levels: bright, dim, and off. If you want thealarm, time, or temperature setting to be displayedwhen the display is in the off mode, press theALARM, TIME, or temperature up/down buttons todisplay the corresponding display for five seconds.After five seconds, the display will turn off. If thealarm sounds while in the display off mode, the cur-rent time will be displayed simultaneously. The dis-play will remain on for five minutes, then turn off.

When the vehicle ignition is not powered, the sleeperclimate control panel is in a power-saving mode andthe display and illumination of the control panel willbe off. All clock functions, including the alarm, willcontinue to work internally.

Temperature Slave Mode FeatureThe temperature slave mode allows the set tempera-ture of the cab heater and air conditioner to be auto-matically tied to the sleeper heater and air condi-tioner. In this mode, the set temperature in thevehicle will be the same whether the set temperatureis changed on the cab climate control panel or thesleeper climate control panel. To enable the tempera-ture slave mode, press the SET+ and SET– buttons

simultaneously. The display will read S–ON when thetemperature slave mode is enabled.

To disable the temperature slave mode, press theSET+ and SET– buttons simultaneously. The displaywill read S–OFF indicating that the temperature slavemode is disabled. When disabled, the temperaturesfor the cab and sleeper can be changed indepen-dently for separate temperature control. If you wishto maintain a temperature in the sleeper that is differ-ent than the temperature in the front of the cab, it isrecommended that a curtain be used between thesleeper and the front of the cab.

Turning on the Sleeper Air ConditionerWhen the Cab Air Conditioner is OffThe sleeper ATC control panel can turn on the airconditioner even if the cab HVAC unit is turned offbut the engine is running. By pressing the ON button,the ATC sleeper control panel will turn on the cabunit and the bunk indicator light on the cab controlpanel will be illuminated. If cooling is needed in thesleeper, the cab HVAC unit will switch on to a lowblower fan setting and the A/C compressor clutch willengage. If cooling is no longer required in thesleeper or if heat is needed, the cab unit fan and thecompressor clutch will be turned off after a five-minute delay.




Climate Controls

6.6

Parked HVACThe Bergstrom NITE parked HVAC system consistsof a compact electrical 3000-BTU air-conditioningsystem, and a diesel-fired heater unit. It is completelyself-contained, and runs on 12-volt deep-cycle batter-ies located between the frame rails. The parkedHVAC batteries are isolated from the vehicle-startingbatteries, to prevent the starting batteries from beingdrawn down during HVAC operation.

The A/C system is designed to maintain cool air inthe sleeper interior without having the engine run-ning. However, the parked A/C unit will not cool downa hot sleeper that has been sitting in the sun withoutthe vehicle A/C running. If the interior temperature ishigher than desired, start the engine and run the ve-hicle A/C system until the desired sleeper tempera-ture is achieved. This will help cool the sleeper to atemperature that the parked A/C system can main-tain. For optimal operation, the curtain between thecab and the sleeper should be closed when usingthe Parked HVAC A/C system.

The A/C unit is located under the lower bunk in thesleeper compartment, and intakes air through a grillelocated on the front panel of the lower bunk. The out-let ducting runs from the left side of the unit to anoutlet on the back wall of the sleeper.

The heater unit is located next to the A/C unit. It in-takes air through a grille located on the right side ofthe front panel of the lower bunk. The outlet ductingruns from the back of the unit to a grille on the leftside of the front panel of the lower bunk.



IMPORTANT: Blocked vents will hamper the op-eration of the unit. Keep the area around the airintake grilles clear of objects that may block airflow, or emit objectionable odors into the HVACsystem.

Parked-HVAC ControlsThe control panel for the parked HVAC is located onthe left side of the rear wall, in the sleeper. It has atemperature-control dial, and a 4-position modeswitch. Turn the temperature-control dial to the leftfor cooling, and to the right for heat. See Fig. 6.6.See Table 6.1 for a description of the mode func-tions.

After using the system, turn the mode switch to theOFF position, even if the unit is not running, or thebatteries may not charge properly.

Parked-HVAC Mode OperationMode FunctionOFF Turns the unit OFF.

AUTO

Allows the unit to automatically heat orcool the sleeper, depending on thetemperature setting and the sleepertemperature. Adjusts the compressor,heater, and fans to keep temperatureconstant.

Heat OnlyAllows only the heat portion of the systemto run. Adjusts the heater only to keep thetemperature constant.

AUTO

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1. Temperature-ControlDial

2. Mode Switch3. A/C Only

4. Heat Only5. AUTO6. OFF

Fig. 6.6, Parked-HVAC Control Panel

Climate Controls

6.7

Parked-HVAC Mode OperationMode Function

A/C OnlyAllows only the A/C portion of the systemto run. Adjusts compressor and fans onlyto keep the temperature constant.

Table 6.1, Parked-HVAC Mode Operation




NOTICEAlways ensure that air inlet and outlet grilles arenot restricted. Restriction of any air inlet or outletports could result in damage to the auxiliaryheater.

IMPORTANT: To maintain reliable performance,run the accessory heater for at least 15 minutesevery month to prevent fuel from degrading.

Accessory heaters function when the ignition switchis in the off position and the cab load disconnectswitch is on, if equipped.

IMPORTANT: Wait three minutes after shuttingdown an accessory heater before turning thecab load disconnect switch (CLDS) to OFF.

NOTE: The low voltage disconnect (LVD) controlprevents a heater from draining the batteriesbelow starting voltage.

Espar HeaterRefer to the Espar website, www.espar.com, for ad-ditional information.

Espar Mini-ControllerTo turn the heat on, press the heat button. SeeFig. 6.7. The red indicator will illuminate when heatmode is activated. Adjust the desired temperaturewith the control knob; rotate the temperature controlknob clockwise for warmer air, or counterclockwisefor cooler air. To turn the heat off, press the offbutton.

To turn the fan on, press the fan button. The blueindicator will illuminate when ventilation mode is acti-vated. To turn the fan off, press the off button.

Espar Digi-ControllerVehicles built after December 8, 2011 with the Digi-Controller and D2 air heaters are equipped with aninternal LVD in the Digi-Controller that prevents theheater from draining battery voltage below 12.0 volts.

To turn heat mode on, press the heat button and theheater will begin its start-up cycle. See Fig. 6.8. ON

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1. Temperature Control Knob2. Fan Button3. Fan Indicator (blue)4. Off Button5. Heat Indicator (red)6 Heat Button

Fig. 6.7, Espar Mini-Controller

Climate Controls

6.8

http://www.espar.com

will display briefly followed by the ambient tempera-ture, and the green indicator will illuminate. Ambientdisplay temperature range is 41°F to 90°F.

To adjust the desired temperature, press the up ordown arrow buttons. The desired temperature willdisplay briefly, followed by the ambient temperature.The desired temperature will remain in the modulatormemory when the heater is not in operation. Tem-perature adjustment range is from 41°F to 90°F.

To turn heat mode off, press the heat button again.The heater will initiate a 3-minute cooling cycle.

To turn the fan on, press and hold the fan button untilthe blue indicator illuminates and the display showsactive rotating digits. To turn the fan off, press thefan button again.

NOTE: The Digi-Controller also has a program-mable run timer that will automatically shut theheater off after the set time limit. The defaulttime limit setting is 10 hours.

Webasto HeaterTo turn the heater on, rotate the heater control knobclockwise until the indicator light illuminates. See

Fig. 6.9. The Webasto heater requires one to twominutes to warm up before warm air is delivered.

To set the desired temperature, rotate the heatercontrol knob clockwise for warmer air, or counter-clockwise for cooler air.

To turn the heater off, rotate the heater control coun-terclockwise until it clicks and the indicator light isextinguished. The heater will initiate a two-minutecooling cycle.

Refer to the Webasto website, techwebasto.com,for additional information.

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Espar

81

2

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4 5

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7

1. Ambient Temperature Sensor2. Down Arrow Button3. Fan Button4. Fan Indicator (blue)5. Heat Indicator (green)6 Heat On/Off Button7. Up Arrow Button8. Ambient Temperature Display

Fig. 6.8, Espar Digi-Controller

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1. Off Position2. Heater On Indicator Light

Fig. 6.9, Webasto Heater Control Knob

Climate Controls

6.9

http://techwebasto.com

7

Seats and RestraintsSeats, General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.1Western Star High-Back Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.2Seat Belts and Tether Belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.3Sleeper Compartment Restraints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.6

Seats, General InformationUnless otherwise noted, all seat adjustments shouldbe made while seated and before the engine isstarted.

Due to the maximum adjustability of mid- and high-back air suspension seats, it is possible to combinethe seat back recline adjustment and the seat slideadjustment so that the seat back contacts the back-wall. It is the responsibility of the driver to adjust theseat to prevent damage to the seat and the cabinterior.


The following is a description of adjustments that canbe made to various Western Star seats. Not all seatshave all of the adjustments listed below. SeeFig. 7.1.


2. Lumbar Support: Lumbar support changes theshape of the seat back to give more or less sup-port to the occupant’s lumbar (lower back) area.This adjustment is either mechanical or air con-trolled, depending on make and model of theseat.


4. Height Adjustment: This adjustment moves theentire seat up or down. The adjustment is eithermanual or air-controlled, depending on the makeof the seat.



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Western Star High-Back SeatSee Fig. 7.2 for seat adjustment controls. Not allmodels of the seat have all the adjustments listedbelow.

1. Rear Cushion Height: To adjust the height of therear of the seat cushion, remove your weightfrom the seat and turn the rear cushion adjust-ment knob to one of three positions.

2. Fore/Aft Isolator: To engage the isolator, turn theisolator knob rearward to the unlocked position.Turn the isolator knob forward to the locked posi-tion when the isolator feature is not desired.

3. Front Cushion Height: To adjust the height of thefront of the cushion, remove your weight from theseat, then turn the adjustment knob toward thefront of the seat (clockwise) to increase cushionheight. To lower the cushion height, turn the ad-justment knob toward the rear of the seat (coun-terclockwise).

4. Bottom Cushion Extension: To adjust the fore-and-aft position of the seat cushion, remove yourweight from the seat, then lift up and pull forwardon the cushion adjustment handle. To return the

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NOTE: Not all models of the seat have all the adjustment controls shown.

1. Rear Cushion Height AdjustmentKnob

2. Fore/Aft Isolator3. Front Cushion Height Adjustment

Knob

4. Bottom Cushion Extension Handle5. Fore/Aft Seat Slide Lever6. Backrest Tilt Knob7. Heater Button

8. Shock Absorber Lever9. Height Adjustment Switch10 Lumbar Support Switches

Fig. 7.2, Western Star High-Back Seat


7.2

cushion to the aft position, lift up and push rear-ward.

5. Fore/Aft Seat Slide: To adjust the fore-and-aftposition of the entire seat, move the fore-and-aftseat adjustment lever to the left and slide theseat forward or backward to the desired position.Move the lever back to its original position tolock the seat in place.

6. Backrest Tilt: To tilt the backrest, lean forwardslightly to remove pressure from the cushion,then turn the knob forward or rearward toachieve the desired position.

7. Heater: To turn on the heat option, press the but-ton. To turn off the heat option, press the buttonagain.

8. Shock Absorber: To adjust the amount of damp-ing the shock absorber provides, move the leverup to increase damping; move the lever down todecrease damping.

9. Height Adjustment: To raise or lower the heightof the seat, use the height adjustment switch onthe side of the seat.

10. Lumbar Support: To adjust the lumbar support,use the lumbar support switches on the side ofthe seat.

Seat Belts and Tether BeltsSeat belt assemblies are designed to secure personsin the vehicle to help reduce the chance of injury orthe amount of injury resulting from accidents or sud-den stops. For this reason, Daimler Trucks NorthAmerica LLC (DTNA) urges that the driver and allpassengers, regardless of age or physical condition,use seat belts when riding in the vehicle.

WARNINGAlways use the vehicle’s seat belt system whenoperating the vehicle. Failure to do so can resultin severe personal injury or death.

Seat belt assemblies in DTNA vehicles meet FederalMotor Vehicle Safety Standard 209, "Type 1" and"Type 2" requirements.

When transporting a child, always use a child re-straint system or the vehicle seat belts as appropri-ate. To determine whether a child restraint system isrequired, review and comply with applicable stateand local laws. Any child restraint used must complywith Federal Motor Vehicle Safety Standard 213,

"Child Restraint Systems." When providing a childrestraint system, always carefully read and follow allinstructions pertaining to installation and usage forthe child. Make certain the child remains in the re-straint system at all times when the vehicle is inmotion.

In addition to seat belt assemblies, tether belts areinstalled on suspension-type seats. Tether belts helpsecure the seat to the floor and are intended to re-strain the seat and seat belt in case of an accident orsudden stop.

IMPORTANT: Seat belts have a finite life whichmay be much shorter than the life of the vehicle.Regular inspections and replacement as neededare the only assurance of adequate seat beltsecurity over the life of the vehicle.

Seat Belt Inspection


Inspect the seat belts and tether belts (if soequipped).

1. Check the web for fraying, cuts, extreme dirt anddust, or for severe fading from exposure to sun-light, especially near the buckle latch plate and inthe D-loop guide area.

2. Check operation of the buckle, latch, KomfortLatch or Sliding Komfort Latch (if equipped), webretractor, and upper seat belt mount on the doorpillar. Check all visible components for wear ordamage.

3. Check the seat belt and tether belt connectionpoints and tighten any that are loose.


7.3

Seat Belt OperationThree-Point Seat Belt

NOTE: For vehicles equipped with the KomfortLatch or the Sliding Komfort Latch, see the seatbelt operation under the heading Seat Belt WithKomfort Latch or Sliding Komfort Latch.



1. Slowly pull the link end of the three-point seatbelt out of the retractor and pull it across yourlap (from outboard to inboard) far enough to en-gage the buckle. If the retractor locks too soon,allow the belt to retract slightly, then slowly pull itout again.




5. Position the shoulder strap diagonally acrossyour chest with the adjustable D-loop bracket (ifequipped). The shoulder strap must be centeredon your shoulder and chest, away from your faceand neck. See Fig. 7.4.

6. To unbuckle the seat belt, press the release but-ton on the buckle. See Fig. 7.5.

NOTE: Make sure the seat belt is completelyretracted when it is not in use.

Seat Belt With Komfort Latch or SlidingKomfort Latch

NOTE: For vehicles not equipped with the Kom-fort Latch or the Sliding Komfort Latch, see the

01/18/95 f910004a

Fig. 7.3, Fastening the Three-Point Belt

f91063402/03/2017

A B C

A. Correct—Belt is centered shoulder and chest, awayfrom face and neck.

B. Wrong—Belt must not rub against face or neck.C. Wrong—Belt must not hang off shoulder.

Fig. 7.4, Proper Shoulder Strap Fit

01/18/95 f910049a

Fig. 7.5, Releasing the Three-Point Seat Belt


7.4

seat belt operation under the heading Three-Point Seat Belt.



When engaged and used properly, the Komfort Latch(Fig. 7.6) and the Sliding Komfort Latch (Fig. 7.7)introduce a small amount of slack into the seat belt,resulting in a more comfortable ride.

1. Slowly pull the link end of the seat belt out of theretractor and pull it across your lap (from out-board to inboard) far enough to engage thebuckle. If the retractor locks too soon, allow thebelt to retract slightly, then slowly pull it outagain.




WARNINGBefore activating the Komfort Latch or the Slid-ing Komfort Latch, make sure the amount ofslack in the shoulder strap is set as describedbelow. 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 acrossyour chest with the adjustable D-loop bracket (ifequipped). The shoulder strap must be centeredon your shoulder and chest, away from your faceand neck. See Fig. 7.4. If desired, engage theKomfort Latch or Sliding Komfort Latch as fol-lows.

If equipped with a Sliding Komfort Latch, makesure that the shoulder strap is snug against yourchest. Without loosening the shoulder strap,push the Sliding Komfort Latch switch to the"ON" position. See Fig. 7.7. To activate the latchlean forward until you hear a click. This will allowfor approximately 1 inch (2.5 cm) of slack be-tween your chest and the shoulder harness.Once engaged, the latch will allow you to leanforward about 5 inches (13 cm) without having to

03/11/2010 f910620

A B

A. Disengaged B. Engaged

Fig. 7.6, Komfort Latch

11/18/2010 f910621a

Fig. 7.7, Sliding Komfort Latch


7.5

reset the latch. Leaning forward more than 5inches (13 cm) will disengage the Sliding Kom-fort Latch, requiring it to be reset.

If equipped with a Komfort Latch, pull on theshoulder strap to lessen the pressure of the strapon your shoulder and chest. Allow no more than1 inch (2.5 cm) of slack between your chest andthe shoulder harness. More slack can signifi-cantly reduce the seat belt effectiveness in anaccident or a sudden stop. While holding the beltslack, press the Komfort Latch lever up, clamp-ing the seat belt webbing (Fig. 7.8 and Fig. 7.9).

6. Unbuckle the seat belt and release the KomfortLatch or the Sliding Komfort Latch as follows.

If equipped with a Sliding Komfort Latch, un-buckle the seat belt (Fig. 7.5), then tug on theshoulder belt to release the Sliding KomfortLatch, or press the Sliding Komfort latch to the"OFF" position, then unbuckle the seat belt.

If equipped with a Komfort Latch, unbuckle theseat belt (Fig. 7.5), then release the KomfortLatch by giving the shoulder belt a quick tug. Ifyou lean forward against the shoulder belt, theKomfort Latch will automatically release, and willneed to be reset.

NOTE: Neither the Komfort Latch nor the SlidingKomfort Latch need to be manually released inan emergency situation. Each will release byitself under rough road or other abnormal condi-tions. Make sure the seat belt is completely re-tracted when it is not in use.

Sleeper CompartmentRestraintsOn vehicles equipped with a sleeper compartment,bunk restraints should be used whenever the sleepercompartment is occupied and the vehicle is moving.Restraints are designed to lessen the chance of in-jury or the amount of injury resulting from accidentsor sudden stops.

Bunk Restraint Adjustment1. Make sure the belt is attached to the bunk sup-

port and sleeper wall.

2. To lengthen the belt, tip the link end downwardand pull the link until it connects with the buckle.

3. After the belt is connected, shorten it by pullingon the loose end until the belt is snug, but com-fortable. Be sure the belts are not twisted. SeeFig. 7.10.

f910048a02/03/2017

A

A. 1 Inch (2.5 cm) Maximum

Fig. 7.8, Adjusting Shoulder Harness Clearance,Komfort Latch

01/06/95 f910006a

Fig. 7.9, Locking the Komfort Latch


7.6

08/18/2011 f910472

1

3

A

2

A. Pull on the loose end to shorten the belt.1. Belt2. Connector

3. Release Buckle

Fig. 7.10, Bunk Restraint Adjustment


7.7

8

Cab and Sleeper FeaturesWindows and Mirrors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.1Cab Amenities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.1Sleeper Amenities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.3

Windows and MirrorsPower MirrorsThe outside mirrors are mounted on the cab. Thereis a primary rear view mirror and a convex mirror onboth the driver and passenger sides. The mirrors arecontrolled by a switch pad located on the overheadconsole. See Fig. 8.1.

One or both outside mirrors may be heated to clearfog, frost, or ice. To defog the mirrors, press theupper half of the mirror defog switch (MIRRORDEFOG). See Fig. 8.2. When the mirror defog switchis on, the status bar illuminates. To turn off heat tothe mirror(s), press the lower half of the switch.

Down-View MirrorA down-view mirror is installed on the door frame toprovide the driver a view of the area adjacent to theside of the cab. See Fig. 8.3.

WindowsPower windows are operated by switches (POWERWINDOW) located on the door. See Fig. 8.4.

To raise the window, press the upper half of theswitch. To lower the window, press the lower half ofthe switch.

Cab AmenitiesWestern Star vehicles are available with many op-tional features. The following are some of thoseoptions.

08/18/2014 f610523a

1

2

1. Mirror Select Switch 2. Keypad

Fig. 8.1, Power Mirror Switch Pad

08/18/2011 f545813

MIRRORDEFOG

To defog the mirror(s), press the upper half of the switch.To turn off heat to the mirror(s), press the lower half ofthe switch.

Fig. 8.2, Mirror Defog Switch

08/18/2014

1

f602531

1. Down-View Mirror (passenger side shown)

Fig. 8.3, Down-View Mirror


8.1

Cigar Lighter/Accessory PlugsThe cigar lighter/accessory plug (Fig. 8.5) is locatedon the lower right-hand dash panel, above the igni-tion switch. The ash tray is located to the left of thecigar lighter. Optional 12V receptacles may be lo-cated on the dash.

To activate the cigar lighter, push in the elementknob. It will pop out when heated. Grasp the elementknob and pull it out of the socket.

To remove the ash tray, push down on the centerbar, and swing outwards. To install the ash tray, in-sert in the opening then swing upwards until the barsnaps into place.

Cup HoldersA dual cup holder with a cell phone holder, standardin the sleeper cab and optional in the day cab, is lo-cated below the right-hand dash control panel.

Glove BoxThe glove box (Fig. 8.6) is located on the right sideof the dash face, and is equipped with a lock. To lockthe latch, insert the key in the lock, and turn it 1/2-turn clockwise. Remove the key. To unlock the latch,insert the key in the lock, and turn it 1/2-turn counter-clockwise.

The glove box door is hinged at the bottom. To openthe unlocked door, push the button in with yourthumb and pull gently on the tang-style latch. Thedoor will swing downwards, then stop in the openposition. To close the door, swing it upwards, and putgentle pressure on the latch. The door will be se-cured, but not locked.

Electronic Device MountSome vehicles may be equipped with an optionalelectronic device mounting station and 12-volt outleton the dash. The standard bolt pattern allows themounting of a variety of devices including navigationsystems, cell phone holders, portable music players,and other electronic devices. Mounting systems canbe found at www.ram-mount.com.

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1

23

1. Door Lock Switch2. Right-Hand Power Window Switch3. Left-Hand Power Window Switch

Fig. 8.4, Door Lock and Power Window Switches

03/21/2001 f610479

12

1. Ash Tray 2. Cigar Lighter

Fig. 8.5, Ash Tray and Lighter

08/19/2014 f611272

12

1. Glove Box 2. Fuse/Relay Panel



8.2

http://www.ram-mount.com

Cab LightingSee Chapter 4 for detailed information regarding cablighting controls.

Storage AreasSome vehicles may have a storage bin and a glovebox located on the right-hand side of the overheadconsole (Fig. 8.7). The storage bin has an elasticmesh cover to keep objects in place. Map pocketsare molded into the lower portion of the driver andpassenger doors.

Sleeper AmenitiesWestern Star sleepers are available with many op-tional features. The following are some of thoseoptions.

NOTE: See Chapter 6 for detailed informationregarding sleeper climate controls and the digi-tal clock.

Baggage Compartment DoorsTo unlock, insert the baggage door key in the lockand turn counterclockwise 1/4-turn. Push the button,and the latch will spring open. To lock, press thelatch in, turn the key clockwise 1/4-turn, then removethe key. If the baggage compartment door is un-locked, it can be opened simply by pushing thebutton.

Sleeper LightingThe sleeper is equipped with two dome lamps, afloor courtesy light, and swivel reading lamps. Thebaggage compartment is equipped with LH and RHcompartment lights. Depending on vehicle configura-tion, the sleeper may also be equipped with domelamps under the rear shelf, a swivel task lampmounted on the cabinet, and a pull-out desk lamp.See Fig. 8.8.

Dome Lamps and Sleeper Courtesy LightThe ceiling dome lamps and the floor courtesy lightare operated by the sleeper lights switches on thesleeper control panel and the dash. The under-shelfdome lamps are operated by pushing on the lens.

Reading LampsThe swivel reading lamps are operated with a rockerswitch on the lamp.

Baggage Compartment LightsThe baggage compartment lights are activated byopening or closing the baggage compartment door,raising and lowering the bunk, or toggling the switchon the sleeper control panel (if equipped).

10/16/2015 f602569

1 2

33

1. Glove Box2. Storage Bin3. Dome/Reading Lamp

Fig. 8.7, Overhead Console Area 05/19/2015 f602557

1

2

3

4

1. Dome Lamps2. Task Lamp3. Reading Lamp

4. Under-Shelf DomeLamps

Fig. 8.8, Sleeper Lighting


8.3

Task LampThe task lamp is operated by rotating the end of thelamp canister.

Sleeper DoorNOTE: The sleeper door is not intended forentry or exit. The door is intended only as aconvenient means to stow or remove personalbelongings in the sleeper area.

To open the sleeper door, reach behind the latchcover at the rear upper corner, locate the flat handle,and push down.

IMPORTANT: The sleeper doors have two-stagelatching. When closing the doors, ensure thatthey are completely latched to prevent windnoise and water intrusion.

Sliding Side WindowThe sliding side window is locked with an over-centertoggle lever. When unlocked, the window may beadjusted to suit.

VentThe air vent is operated using a simple, over-centerlatch. The vent will open in two directions. Push theknob firmly forward or back to open. The center posi-tion is closed.


8.4

9

Electrical SystemVehicle Power Distribution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.1Battery Disconnect Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.1Battery Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.2Low Voltage Disconnect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.2Inverter/Charger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.3

Vehicle Power DistributionThere are three standard power distribution modules(PDMs) on vehicles that are compliant with EPA10and newer regulations: the dash electrical panel, thepowertrain PDM, and the powernet distribution box(PNDB). See Fig. 9.1 for the typical location of thepowertrain PDM located in the engine compartment.

IMPORTANT: The cover on the powertrain PDMunit must be in place to protect against watersplash and dust intrusion.

The powertrain PDM houses many of the fuses andrelays for the engine, transmission, and aftertreat-ment system (ATS). There is a label on the cover ofthe powertrain PDM identifying the fuses and relays.

The PNDB houses up to three MIDI fuses and fourATO fuses. A label on the cover of the PNDB identi-fies the fuses.

Vehicles may also be equipped with a secondaryPNDB. The secondary PNDB sources power to anyof 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 truckbody equipment)

The main PDMs are located inboard of thepassenger-side glove box. Access to the PDMs isachieved by removing the four screws that securethe panel cover. See Fig. 9.2and Fig. 9.3.

Battery Disconnect SwitchYour Western Star vehicle may be equipped with acab load disconnect switch (CLDS).

The optional CLDS (Fig. 9.4) is used to minimizedraw on the battery, and should be set to OFF whenthe vehicle is parked for an extended period of time.

When the CLDS is set to OFF, it signals the PNDB todisconnect battery power to the circuits powered bythe MIDI fuses.

08/19/2014 f546090

1

1. Powertrain PDM

Fig. 9.1, Powertrain PDM Location

08/19/2014 f611272

12

1. Glove Box 2. PDM Cover Panel


12/09/2014 f546093

12

1. PDM 1 2. PDM 2

Fig. 9.3, Main PDMs

Electrical System

9.1

The CLDS is mounted on the underdash cover, out-board of the steering column.

IMPORTANT: The ignition should be turned OFFbefore using the CLDS.

Battery AccessThe batteries on a Western Star vehicle may be lo-cated in a variety of locations, including under thepassenger seat, under the cab, behind the cab, orunder the sleeper bunk, if equipped. Some vehiclesmay have two batteries in the step compartments onboth sides of the vehicle.

Low Voltage DisconnectThe Low Voltage Disconnect (LVD) system protectsthe batteries from excessive discharge by discon-necting certain isolated circuits from battery powersupply if necessary. See Table 9.1. This allows thebatteries to maintain acceptable charge to restart thevehicle. The LVD is integrated into PDM 1. SeeFig. 9.3.


PDM 112V Power Receptacle 1, Dash OFF/ACC/IGN*

12V Power Receptacle 2, Dash OFF/ACC/IGN12V Power Receptacle 1, Sleeper OFF/ACC/IGNCB Radio OFF/ACC/IGN*

Dome Lamp, Cab, Dome/Reading OFF/ACC/IGNDome Lamp, Sleeper OFF/ACC/IGNDome Lamp, Floor Lamp, Sleeper OFF/ACC/IGN


Fuel Water Separator Heater Element IGNMirror Heat, Driver IGNMirror Heat, Hood-Mounted IGNSpare Power Feed 1 IGNSpare Power Feed 2 IGNUtility Lamp OFF/ACC/IGN

PDM 212V Power Receptacle 2, Sleeper OFF/ACC/IGN12V Power Receptacle 3, Sleeper OFF/ACC/IGNAir Dryer ACCAmplifier Power ACCSleeper/Cab Auxiliary Heater/ParkedHVAC OFF/ACC/IGN*

Auxillary Circulation Fan, Windshield ACCAuxilliary/Thermo Coolant Heater OFF/ACC/IGN*

Heated Seat ACCNavigation System ACCOptional Switch 1 OFF/BAT/IGN†










Radio ACCRefrigerator OFF/ACC/IGN*

Sleeper HVAC Controller, Wake-Up ACCSleeper HVAC Fan Motor ACCSpare Power Feed 3 ACCSpare Power Feed 4 OFF/ACC/IGN* Option to move fuse to remove the function from the LVD bus.† Option to move fuse to BAT to remove the function from the LVD bus.

Table 9.1, Isolated Circuits

If battery voltage drops to the trip point (12.3 or 12.1volts, determined by the vehicle configuration), theLVD system implements a shut-down. At 70 secondsbefore the disconnect, an alarm beeps and the lowbattery indicator light on PDM 1 flashes green. Thealarm beeps again at 9 and 3 seconds before thedisconnect. If no action is taken, the LVD system willshut off power to the circuits, and a red low batteryindicator remains lighted.

These circuits will remain off until the LVD systemmeasures 13.0 volts applied to the system, which

08/19/2014 f546091

Fig. 9.4, Cab Load Disconnect Switch

Electrical System

9.2

can be achieved by starting the engine. After the en-gine is started, the system will reset.

Vehicles are equipped with an LVD label on thedrivers-side sun visor, indicating the presence of thesystem.

Inverter/ChargerThe optional Freedom HF Inverter/Charger powerssmall appliances and other electric equipment. It islocated in the driver-side luggage compartment. SeeFig. 9.5. The unit has one three-pin GFIC OUT con-nector, one three-pin GFIC IN connector, and two ACpower outlets.

There are two models available for the Western Star:

• 1000W: 1000 watt, 20-amp

• 1500W: 1500 watt, 40-amp

DANGERDo not store gasoline, flammable material, or anycomponent with a connection to the fuel systemin the storage compartment with the inverter/charger. The unit contains equipment that mayproduce sparks. Storing flammable or electricalequipment in proximity to the unit could result infire or explosion hazards, which could result inserious injury or death.

The display on the sleeper control panel providesinformation about the operation of the unit. SeeFig. 9.6. Refer to Table 9.2 for details on the displaypanel.

11/05/2014 f546114

Fig. 9.5, Inverter/Charger

11/18/2014 f546067

1

543

7

2

6

1. Power2. LED Display3. Select4. Input Voltage LED

5. Input Current LED6. Output Power LED7. Status LED

Fig. 9.6, Inverter/Charger Display Panel (1000W shown)

Electrical System

9.3


1 Power

Press the power button for one second to turn on the unit.

Press and hold the button for five seconds to enter the feature settings mode, thenpress the button to toggle between the following modes:

• Charging Current Setting

• Inverter Mode Setting

• Alarm Setting

• Shutdown Setting

• Factory Setting

Refer to the owner’s manual for more information.2 LED Display The LED display screen shows status information and fault codes.

3 Select

The Select button changes the display or settings.

Press the Select button to cycle through the setting options. Press and hold theSelect button for five seconds to save the setting. Refer to the owner’s manual formore information.

• In "Inverter Mode Setting" press the button to turn the inverter mode ON orOFF.

• With the inverter mode ON, press the button to choose what appears on theLED display screen: Input Voltage, Input Current, or Output Power. Details areprovided below.

NOTE: The unit is in "Inverter Mode" when shore power is not present and theunit is using the battery to power the appliances connected to it.

• In an alarm condition, press and hold the button for two seconds to disable orenable the audible alarm.

• In "Charging Current Setting" mode, press the button to select the chargercurrent.

4 Input Voltage LED In inverter mode, when Input Voltage is selected, the corresponding LED will light upand the display will show the input voltage.

5 Input Current LED In inverter mode, when Input Current is selected, the corresponding LED will light upand the display will show the input current.

6 Output Power LED In inverter mode, when Output Power is selected, the corresponding LED will light upand the display will show the output power.

Electrical System

9.4


7 Status

The color of the Status light indicates the unit’s mode of operation:

• Green: Utility (Shore Power Mode)

A solid green light indicates that the battery is fully charged.

A flashing green light indicates that the unit is charging the battery.

• Yellow: Battery (Inverter Mode)

A solid yellow light indicates that the unit is using the battery to supply ACpower.

A flashing yellow light indicates that the unit is in inverter mode, but that ACshore power is detected and is transferring to shore power mode within 20seconds.

• Red: Fault Condition

The fault status light indicates a fault condition with the unit. Refer to theowner’s manual for fault code information and troubleshooting procedures.

Table 9.2, Display Panel Functions

For more information about troubleshooting, settings,and other features, refer to the owner’s manual in-cluded with the inverter/charger.

Electrical System

9.5

10

Engine Starting, Operation,and Shutdown

Engine Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.1Engine Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.1Engine Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.3Engine Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.3

Engine StartingThis engine chapter is to serve as a guide for bestpractices only. Each engine model may have operat-ing characteristics that are unique to that particularengine, and will be documented in the engine manu-facturer’s literature. Always refer to specific instruc-tions and recommendations from the engine manu-facturer.

NOTE: Before starting the engine, read Chap-ter 3 for detailed information on how to read theinstruments and see Chapter 4 for detailed in-formation on how to operate the controls. Readthe engine manufacturer’s operating instructionsbefore starting the engine.

WARNINGNever pour fuel or other flammable liquid into theair inlet opening in the air intake in an attempt tostart the vehicle. This could result in a flash firecausing serious personal injury or propertydamage.

1. Before engine start-up, complete the engine pre-trip inspection and maintenance procedures inChapter 23.

2. Set the parking brake.

3. For manual transmissions, place the transmis-sion in neutral and fully depress the clutch pedal.Do not depress the accelerator pedal.

For automatic transmissions, put the transmis-sion in neutral. Do depress the accelerator pedal.

NOTICEIf the warning lights stay on, or do not come onmomentarily after turning on the ignition, do notoperate the engine. To do so may result in enginedamage.

4. Turn the ignition switch to the ON position. Thebuzzer will sound for three seconds.

During cold conditions, the START BLOCKEDlamp may illuminate. Wait until the lamp goes outbefore turning the ignition key to START.

NOTE: The length of time the STARTBLOCKED lamp remains illuminated dependson the ambient temperature. The lower the am-bient temperature, the longer the lamp will beilluminated.

NOTE: The engine electronics supply the cor-rect amount of fuel for starting the engine. Ac-celerator pedal pressure is unnecessary andcould interfere with engine starting.

5. Turn the ignition key to the START position. Donot depress the accelerator pedal.

Release the key the moment the engine starts.

6. Apply load gradually during the warm-up period.

NOTICEDo not rev the engine if the oil pressure gaugeindicates no oil pressure. Shut down the enginewithin approximately ten seconds to avoid enginedamage.

7. Check the oil pressure gauge for any drop in lu-bricating oil pressure or mechanical malfunctionin the lubricating oil system.

Cold-Weather StartingSee the engine manufacturer’s operation manual forstarting aids that are approved for specific engines.

Starting After Extended ShutdownBefore engine start-up, complete the engine pretripinspection and maintenance procedures in Chap-ter 23.

NOTICEFailure to eliminate water-diluted lubricating oilmay lead to serious engine damage at startup.

An engine in storage for an extended period of time(over winter, for example) may accumulate water inthe oil pan through normal condensation of moistureon the internal surfaces of the engine. Oil diluted bywater cannot provide adequate bearing protection atstart-up. For this reason, change the engine oil andfilters after extended storage.

Engine OperationSafety and EnvironmentalConsiderationsAll engines on Western Star vehicles comply with therequirements of the Federal (U.S.) Clean Air Act.


10.1

Once an engine is placed in service, the responsibil-ity for meeting both state and local regulations is withthe owner/operator.

IMPORTANT: Depending upon local jurisdic-tional emissions guidelines, vehicles that aredomiciled outside of the U.S. and Canada maynot have engines and/or emissions aftertreat-ment systems that are compliant with EPA07,EPA10, GHG14, or GHG17 regulations.

NOTICEIt is extremely important that the following guide-lines be followed for engines that comply withEPA07 or newer regulations, or damage mayoccur to the aftertreatment device, and the war-ranty may be compromised.



• Use only engine lube oil with a sulfated ashlevel less than 1.0 wt%; currently referredto as CJ-4 oil.

A Top Tier™ compliant fuel is recommended. Look forthe symbol that denotes a Top Tier compliant fuel;see Fig. 10.1.

Adequate maintenance of the engine and the dieselparticulate filter (DPF) are the responsibility of theowner/operator, and are essential to keep the emis-sion levels low. Good operating practices, regularmaintenance, and correct adjustments are factorsthat will help keep emissions within the regulations.

The driver should be familiar with the vehicle warningsystem in order to bring the vehicle to a safe stop ifthe engine malfunctions. If the driver doesn’t under-stand how the warning system works, an engineshutdown could occur, causing a safety hazard. SeeChapter 11 for more information.

Engine Break-InEach engine must pass a full-load operating test ona dynamometer before shipment, thereby eliminatingthe need for a break-in. Before running the enginefor the first time, follow the instructions in the enginemanufacturer’s operation manual specific to yourengine.

Normal Operation

WARNINGDo not operate the engine in an area where flam-mable vapors such as gasoline or diesel fumesare present. Shut off the engine when in an areawhere flammable liquids or gases are beinghandled. Failure to observe these precautionscould result in serious injury or death.

Every engine has an operating range in which it per-forms most efficiently. The operating range extendsfrom maximum torque rpm at the low end, to enginerated speed at the high end. Most engines deliverbest fuel economy when operated in the low- andmid-speed segments of the efficiency range and pro-duce maximum horsepower at rated speed, which isalso the recommended maximum speed of the en-gine. For further engine-specific information, refer tothe engine manufacturer’s operation manual.

Prolonged idling of engines is not recommended, andis illegal in some states. Idling produces sulfuric acid,that is absorbed by the lubricating oil, and eats intobearings, rings, valve stems, and engine surfaces. Ifyou must idle the engine for cab heat or cooling, usethe high idle function of the cruise control switches.An idle speed of 900 rpm should be enough to pro-vide cab heat in ambient temperatures that areabove freezing.

If the engine is programmed with the idle shutdowntimer, ninety seconds before the preset shutdowntime, the CHECK engine light will begin to flash at arapid rate. If the position of the clutch pedal or ser-vice brake changes during this final ninety secondsthe idle shutdown timer will be disabled until reset.

Cold-Weather OperationSatisfactory performance of a diesel engine operatingin low ambient temperatures requires modification ofthe engine, surrounding equipment, operating prac-tices, and maintenance procedures. The lower thetemperature, the greater the amount of modificationrequired. For service products approved for use in

f47069804/27/2017

Fig. 10.1, Top Tier Fuel Symbol


10.2

cold weather for your engine, see the engine manu-facturer’s engine operation manual.

If satisfactory engine temperature is not maintained,maintenance costs will increase due to greater en-gine wear. If the engine coolant gets too cold, rawfuel will wash the lubricating oil off the cylinder wallsand dilute the crankcase oil, causing all moving partsof the engine to suffer from poor lubrication.

If the engine is in good mechanical condition and theprecautions necessary for cold-weather operation aretaken, ordinary cold weather will not cause difficultyin starting or loss of efficiency.

The following points are important to observe whenoperating in cold weather:

• Check for cracks in the batteries, for corrosionof the terminals, and for tightness of the cableclamps at the terminals.

• Charge the batteries to full capacity. Replacedamaged batteries.

• If equipped, turn off the load disconnect switchafter the engine is shut down, to prevent bat-tery discharge.

• Have the alternator output checked at an au-thorized service provider.

• Check the condition and tension of the drivebelts.

• Refer to the engine manufacturer’s operationmanual for recommended heaters, low-viscosity lubricating oils, winter-grade fuels,and approved coolants.

NOTICEFor Detroit engines, use of a winterfront is notrecommended, as it can cause false fault codeswith the engine and aftertreatment system, andpossible emission component failures.

If using a winterfront, leave at least 25% of the grilleopening exposed in sectioned stripes that run per-pendicular to the charge-air-cooler tube-flow direc-tion. This assures even cooling across each tube,and reduces header-to-tube stress, and possiblechance of component failure.

Using a winterfront can cause excessive fan runtime, increased fuel consumption, and failure of theDEF system heaters to operate correctly, resulting infault codes, poor performance, and power reduction.A winterfront should only be used temporarily in thefollowing situations:

• To improve cab heating while idling in an ex-tremely cold ambient temperature;

• When the ambient temperature remains below-22°F (-30°C) and the engine is unable tomaintain a running coolant temperature of175°F (80°C) during normal over-the-road op-eration.

Engine Shutdown1. With the vehicle stopped, set the parking brake

and place the transmission in neutral.

NOTICEIdle the engine one to two minutes before shut-ting it down. After hard operation, shutting downthe engine without idling may cause damage tothe turbocharger.

2. Allow the engine to idle one to two minutes be-fore shutting it down.

NOTICEExcept in an emergency, do not shut down theengine when the coolant temperature is above194°F (90°C). To do so could damage the engine.

3. Turn off the ignition switch and shut down theengine.

Engine CoolingThe cooling system used on all Western Star ve-hicles is a pressure type system. This raises thecoolant boiling point, permitting higher operating tem-peratures. The coolant supplied in your vehicle willbe a 50/50 mix of antifreeze and water, giving protec-tion down to –35°F (–37°C). It is recommended thatan antifreeze mixture be used at all times, as, in ad-dition to providing frost protection, it is a more effec-tive coolant, and has a higher boiling point than tapwater.

Over-concentration of antifreeze or coolant condi-tioner can cause silicate to precipitate out of thecoolant, forming silica gel on cooling system heattransfer surfaces (fuel coolers, oil coolers, radiators,and heater cores), resulting in reduced coolant flowand overheating.

Hard water (with high levels of calcium and magne-sium ions) encourages formation of silica gel. Do notuse softened water as the salt used to artificially


10.3

soften it is corrosive. Most engine manufacturers pre-fer the use of distilled or de-ionized water to reducethe potential and severity of silicate dropouts.

Never exceed a 60/40 antifreeze-to-water ratio. If thelevel is low, add a 50/50 antifreeze solution to main-tain solution concentrations. Note that checking theengine coolant level is part of the pretrip inspection.See Chapter 23 for more information.


10.4

11

Optional Engine SystemsEngine Protection—Warning and Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.1Engine Idle Limiting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.2Power Takeoff (PTO) Governor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.2

Engine Protection—Warningand ShutdownThe driver should be familiar with the vehicle warningsystem in order to bring the vehicle to a safe stop ifnecessary. If the driver doesn’t understand how thewarning system works, the driver may not be able toutilize the advantage of the advance warning systemto pull over appropriately.

The engine will begin a warning and derate and/orshutdown process if the engine coolant temperature,coolant level, engine oil pressure, or exhaust after-treatment system (ATS) reach preset levels. Onsome engines, the warning process will begin whenthe engine oil temperature, engine coolant tempera-ture, or the intake air temperature reach preset lev-els. Detroit™ engines may also begin the warningand shutdown process if water is detected in the fuel.

See the engine manufacturer’s operation manual forspecific details for your vehicle. See Chapter 12 forthe warning and shutdown modes associated withthe ATS.

Electronic engine protection can be specified as ei-ther SHUTDOWN or WARNING and DERATE.

WARNINGWhen the STOP engine or CHECK engine lampilluminates, most engines are programmed toshut down automatically within 30 seconds. Thedriver must immediately move the vehicle to asafe location at the side of the road to preventcausing a hazardous situation that could causebodily injury, property damage, or severe damageto the engine.

In SHUTDOWN mode, the red STOP engine lampwill illuminate when the problem is serious enough toreduce power or speed. See Fig. 11.1. Engine powerwill ramp down, then the engine will shut down if theproblem continues while in derate mode. The driverhas 30 or 60 seconds (depending on the critical faulttype) after the STOP engine lamp illuminates tomove the vehicle safely off the road. If the vehiclecannot be moved to a safe location within that time,turn the ignition switch to OFF for at least five sec-onds, then restart the engine. Repeat this action untilthe vehicle is safely off the road.

Do not operate the vehicle further until the problemcausing the shutdown has been corrected.

Some vehicles may have a shutdown overrideswitch, which can be used to momentarily overridethe shutdown sequence. This switch resets the shut-down timer, restoring power to the level before thederate. The switch must be pressed again after fiveseconds to obtain a subsequent override. SeeFig. 11.2.


Detroit engines may begin a warning and derate pro-cess if water is detected in the fuel, or if engine cool-ant temperature is high. In WARNING and DERATEmode, the CHECK engine, STOP engine, or MILlamp will illuminate to indicate an engine problemthat requires service and the engine controls willbegin a derate of engine output. Continuing to runthe engine while it is in derate mode could causesevere damage to the engine.

07/09/2009 f6110361 2 3

CHECK STOP

1. Malfunction Indicator Lamp (MIL)2. CHECK Engine Lamp3. STOP Engine Lamp

Fig. 11.1, Engine Warning Lamps

08/19/2014 f611274

SHUTDOWNOVERRIDE

Fig. 11.2, Shutdown Override Switch


11.1

Engine Idle LimitingIdle Shutdown TimerThis feature is an optional 1- to 100-minute idle shut-down system. Its purpose is to conserve fuel byeliminating excessive idling, and allowing a turbo-charger cool-down period. Idle shutdown timing andparameters are programmable. See the enginemanufacturer’s operation manual for specific detailsfor your vehicle.

The idle shutdown system requires that the transmis-sion be in neutral with the parking brake set.

California Engine Idle LimitingIn order to meet the California Air Resources Board(CARB) engine idle limit, vehicles are equipped withan engine idle shutdown feature. The automatic shut-down feature is required on all California-certifiedengines (with the exception of engines used in spe-cific vehicle types that are exempt from the require-ment). Owners that wish to have the shutdown fea-ture disabled on vehicles operating in Californiashould consult with California authorities to determineif their vehicle qualifies for the exemption.

When the CARB engine idle limiting feature is en-abled, the engine will typically shut down after fiveminutes of continuous idling with the transmission inneutral or park, and the parking brake set. It will alsoshut down after 15 minutes with the transmission inneutral or park, and the parking brake off. See theengine manufacturer’s operation manual for specificdetails for your vehicle.

Changing the position of the brake pedal, clutchpedal, accelerator pedal, shutdown override switch,or parking brake during the final 30 seconds willcause the shutdown timer to reset. After an auto-matic shutdown, the engine may be restarted andoperated normally.

Power Takeoff (PTO) Governor

WARNINGTo avoid injury, do not install a PTO that is notDetroit Diesel approved onto a Detroit™ Trans-mission. Use of a non-Detroit Diesel approvedPTO with a Detroit Transmission could result inunintended operation which could lead to severepersonal injury.

Engine power takeoffs (PTO) tap into engine powerto run auxiliary devices, such as hydraulic pumpsthat power additional equipment. The following aregeneral guidelines for operating a PTO.


2. Press the dash PTO switch. Release the switchwhen the light begins to blink.

When the light illuminates steadily, the PTO isengaged and ready to operate. In stationarymode, the vehicle must remain in neutral with theparking brake set.

3. To activate mobile mode, shift from neutral toreverse, 1st, or 2nd gear. The clutch will openand the PTO will disengage for a moment.

4. Touch the accelerator pedal to close the clutchand engage the PTO in mobile mode. The PTOmay be operated with the transmission in neutralor reverse, and 1st and 2nd gears only.


5. To deactivate mobile mode, bring the vehicle to astop. The clutch will open and shut down powerto the PTO.


7. To deactivate PTO, press the PTO switch again.When the light in the switch goes out, power tothe PTO is shut off.


11.2

12

Emissions and FuelEfficiency

Greenhouse Gas Emissions and Fuel Consumption Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.1EPA-Regulated Emissions Aftertreatment Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.1Diesel Exhaust Fluid and Tank, EPA10 and Newer Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.3

Greenhouse Gas Emissionsand Fuel ConsumptionStandardsVehicles and/or engines manufactured after Decem-ber 31, 2006 and domiciled in the U.S. or Canadaare required to meet all EPA and NHTSA regulationseffective as of the vehicle build date. Engines manu-factured between January 1, 2007 and December 31,2009 meet EPA07 requirements. Engines manufac-tured between January 1, 2010 and December 31,2012 meet EPA10 requirements. Engines manufac-tured from January 1, 2013 meet NHTSA and EPA2014 fuel efficiency and greenhouse gas emissionstandards (GHG14) requirements. Engines manufac-tured from January 1, 2016 meet NHTSA and EPA2017 fuel efficiency and greenhouse gas emissionstandards (GHG17) requirements.

Model year 2013 and later vehicles meet additionalrequirements as specified by GHG14 requirements.Model year 2017 and later vehicles meet similar re-quirements as specified by GHG17 requirements.These vehicles are equipped with components thatincrease fuel efficiency and reduce GHG emissions.Components may include, but are not limited to, low-rolling resistance tires; aerodynamic devices such ashood, cab/sleeper extenders, and fuel tank fairings;vehicle speed limiter; and idle shutdown timer. If re-placement of any drag-reducing component is re-quired, the replacement component must meet orexceed the drag reduction performance of the origi-nally installed component in order to maintain compli-ance with GHG14 and GHG17 requirements.

EPA-Regulated EmissionsAftertreatment SystemsIMPORTANT: Depending on local jurisdictionalguidelines, vehicles that are domiciled outside ofthe U.S. and Canada may not have emissionsaftertreatment systems (ATS) that are compliantwith EPA regulations.

NOTICEFollow these guidelines for engines that complywith EPA07 or newer regulations, or damage mayoccur to the aftertreatment device (ATD) and thewarranty may be compromised.



• Engine lube oil must have a sulfated ashlevel less than 1.0 wt %; currently referredto as CJ-4 oil.

IMPORTANT: Using non-specification fuels oroils can lead to shortened diesel particulate filter(DPF) cleaning or replacement intervals. Forexample, using CJ-4+ oil with 1.3% sulfated ash(30% more ash content) may result in the needfor DPF cleaning or replacement 20 to 30%sooner than would normally be required.

IMPORTANT: See the engine manufacturer’soperation manual for complete details and op-eration of the ATS.

EPA07 EnginesEngines built between January 1, 2007 and Decem-ber 31, 2009 are required to meet EPA07 guidelinesfor reduced exhaust emissions of particulate matterand nitrogen oxides (NOx). NOx is limited to justover 1 gram per brake horsepower hour (g/bhp-hr),and particulate matter cannot exceed 0.01 g/bhp-hr.

The EPA07 ATS varies according to engine manufac-turer and vehicle configuration, but the exhaust muf-fler is replaced by an aftertreatment device (ATD).Inside the ATD, the exhaust first passes over the die-sel oxidation catalyst (DOC), then passes throughthe diesel particulate filter (DPF), which traps sootparticles. The soot is burned to ash during a processcalled regeneration (regen).

EPA10 and Newer EnginesThe EPA mandates that all engines built after De-cember 31, 2009 must reduce the level of emissionsexhausted by the engine to the following levels:

• Nitrogen Oxides (NOx) – 0.2 g/bhp-hr

• Particulate Matter (PM) – .01 g/bhp-hr

To meet EPA guidelines, engines that are compliantwith EPA10 and newer regulations use an ATS thathas, in addition to a DOC/DPF device like that usedin an EPA07 ATD, a Selective Catalytic Reduction(SCR) devide to reduce NOx downstream of the en-gine. After exhaust gases leave the DPF, a controlledquantity of diesel exhaust fluid (DEF) is injected intothe exhaust stream. In the presence of heat, DEF isconverted to ammonia gas, which reacts with NOx in


12.1

the selective catalyst chamber to yield nitrogen andwater vapor, which exit through the tailpipe.

RegenerationThe harder an engine works, the better it disposes ofsoot. If the exhaust temperature is high enough, aprocess called passive regeneration (regen) occursas the vehicle is driven normally. However, if the en-gine isn’t running hot enough, the electronic controlsmay initiate an active regen, whereby extra fuel isinjected into the exhaust stream to superheat andreduce the soot trapped in the DPF to ash. Activeregen happens only when the vehicle is movingabove a certain speed, determined by the enginemanufacturer. See your engine operation manual forcomplete details. Both active and passive regen hap-pen automatically, without driver input.

WARNINGActive regeneration can occur automatically any-time the vehicle is moving. The exhaust gas tem-perature could reach 1500°F (800°C), which is hotenough to cause a fire, heat damage to objectsor materials, or personal injury to persons nearthe exhaust outlet. The exhaust temperature canremain 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 maybe damaged or injured by exposure to high heat.

See Regen Switches, below, for instructions onpreventing automatic regen if necessary.

When operating conditions do not allow for ATD filtercleaning by active or passive regen, the vehicle mayrequire a driver-activated parked regen. When thisoccurs, the DPF lamp illuminates, indicating that aregen is required. The driver must either bring thevehicle up to highway speed to increase the load(thus starting an active regen), or park the vehicleand initiate a parked regen. See Regen Switches,below, for instructions on initiating a parked regen.

Regen SwitchesThe regen request switch, located on the dash, isused to initiate a parked regen. See Fig. 12.1, item1. The function of the switch varies by the enginemake and model in the vehicle. See the engine op-eration manual for switch operation details.

Some vehicles may be equipped with a regenrequest/inhibit switch. See Fig. 12.1, item 2. To stopa regen in progress or prevent the start of a regen,press the lower half of the switch. Regen is then de-layed until the switch is no longer active.

NOTE: The regen switch can initiate a parkedregen only when the DPF lamp is illuminated.

WARNINGDuring parked regen, exhaust temperatures arevery high and could cause a fire, heat damage toobjects or materials, or personal injury to per-sons near the exhaust outlet.

Before initiating a parked regen, make certain theexhaust outlets are directed away from struc-tures, trees, vegetation, flammable materials, andanything else that may be damaged or injured byprolonged exposure to high heat.

To initiate a parked regen, perform the followingsteps.

1. Park the vehicle away from all flammable materi-als, put the transmission in neutral, and set theparking brake.

2. Start and warm the engine until the coolant tem-perature is at least 150°F (66°C).

3. Press and hold the regen switch for five sec-onds. The engine will increase rpm and initiatethe regen process. As the regen process is initi-ated, engine rpm increases and the HEST lampilluminates to indicate extremely high exhausttemperatures.

08/07/2014 f6112581 2




12.2

IMPORTANT: The driver must remain with thevehicle during the entire regen cycle.

4. The regen cycle will finish after 20 to 60 minutes,at which time engine idle speed drops to normaland the vehicle can be driven normally. TheHEST lamp is extinguished when vehicle speedexceeds 5 mph (8 km/h) or the system hascooled to normal operating temperature.

5. To stop a parked regen at any time during theprocess:

• depress the clutch pedal, brake pedal, oraccelerator pedal;

• press and hold the regen inhibit switch untilidle returns to normal;

• shut down the engine.

ATS Warning LampsThere are three warning lamps that alert the driver ofhigh exhaust temperature, the need to perform aparked regen or service the DPF, or of an enginefault that affects emissions. A decal attached to thedriver’s sun visor explains the ATS warning lamps.See Fig. 12.2.

See Fig. 12.3 for an explanation of the ATS warn-ings, and actions required to avoid engine protectionsequences.

Malfunction Indicator Lamp (MIL)A steadily illuminated yellow malfunction indicatorlamp (MIL) indicates an engine fault that affects theemissions. See Fig. 12.4.

DPF LampWhen soot accumulates in the DPF and the DPF sta-tus lamp illuminates, see Fig. 12.5, perform a parkedregen or bring the vehicle up to highway speed toincrease the load (thus starting an active regen).

If the DPF status lamp blinks while the CHECK en-gine lamp is illuminated, initiate a parked regen im-mediately in order to prevent an engine derate.

If the red STOP engine lamp illuminates with theblinking DPF lamp and the CHECK engine lamp,begin a parked regen in order to prevent an engineshutdown. Park the vehicle and perform a parkedregen.

High Exhaust System Temperature(HEST) LampSlow (10-second) flashing of the high exhaust sys-tem temperature (HEST) lamp indicates that aparked regen is in progress, and the engine’s highidle speed is being controlled by the engine software,not the vehicle driver.

Steady illumination of the HEST lamp alerts thedriver of high exhaust temperature during the regenprocess if the vehicle speed is below 5 mph (8 km/h), or during a parked regen. See Fig. 12.6.

MaintenanceAuthorized service facilities must perform any DPFservice. For warranty purposes, maintain a recordthat includes:

• date of cleaning or replacement;

• vehicle mileage;

• particulate filter part number and serial number.

Diesel Exhaust Fluid and Tank,EPA10 and Newer EnginesDiesel Exhaust FluidDiesel exhaust fluid (DEF) is used in the ATS tolower NOx in the exhaust stream. DEF is colorlessand close to odorless (it may have a slightly pungentodor similar to ammonia). It is nontoxic, nonflam-mable, and biodegradable. It is mildly corrosive toaluminum, but does not affect the strength or struc-ture of the aluminum.

White crystals may be noticeable around compo-nents that come into contact with DEF. The crystalsare easily removed with water.

DEF consumption varies depending on ambient con-ditions and vehicle application.

Freezing ConditionsDEF freezes to slush at around 12°F (-11°C). It is notdamaged or destroyed if frozen, and is fully usablewhen thawed. The DEF in the tank is allowed tofreeze while a vehicle is non-operational. At start-up,normal operation of the vehicle is not inhibited if theDEF 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.


12.3

DEF TankEngines that are compliant with EPA10 and newerregulations are equipped with a DEF tank located onthe driver’s side of the vehicle behind the battery boxor forward of the fuel tank. See Fig. 12.7. The DEFtank has a 19 mm filler neck inlet that prevents thehose from a diesel outlet from being inserted, andhas a blue cap for easy identification.

Fuel/DEF GaugeThe diesel fuel and DEF levels are measured in adual-purpose gauge. See Fig. 12.8.

Fuel level is indicated at the top of the gauge. Belowthe fuel level, a low fuel warning lamp illuminatesamber when the fuel level drops below 1/8th of thecapacity.

The lower portion of the gauge has a DEF warninglamp that illuminates amber when the DEF tank isnear empty, and a lightbar that indicates the level ofDEF in the tank. The DEF light bar illuminates as fol-lows.

• Four bars illuminated green—Between 75%and 100% full

• Three bars illuminated green—Between 50%and 75% full

• Two bars illuminated green—Between 25%and 50% full

• One bar illuminated green—Between approxi-mately 10% and 25% full

• One bar illuminated amber—DEF very low, re-fill DEF

• One bar flashing red—DEF empty, refill DEF

DEF Warnings and Engine LimitsIMPORTANT: Ignoring the DEF warning lightsresults in limited engine power, with the applica-tion of a 5 mph (8 km/h) speed limit.

DPF Regen Needed

Hot Exhaust

DEF Refill Needed







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

IMPORTANT

DEF

11/30/2010 f080161

1

2

3

Fig. 12.2, Warning Lamp Decal, Sun Visor


12.4

DEF Level Low—Initial WarningWhen the DEF level is low, the following lamps notifythe driver. See Fig. 12.9. Refill the DEF tank in orderto cancel the warning sequence.

• One bar of the DEF level indicator illuminatesamber—DEF very low, refill DEF.

• The DEF warning lamp illuminates solid amber.

DEF EmptyWhen the DEF level reads empty, the followinglamps notify the driver. See Fig. 12.10.

f080147


Switch.

Level 1 Level 3Level 2 Level 4Filter RegenerationRecommended

Filter is reaching


Filter RegenerationNecessary


To avoid enginederate bring vehicle



Vehicle must beparked and a Parked

Parked Regeneration Required −Engine Shut Down

Filter has exceededmaximum capacity

Vehicle must be parked and aParked Regeneration or Service


CHECK CHECK

(Flashing)

INDICATORLAMP(S)



Required Action

capacity. .

STOP

See Engine Operator’s Manual for complete Regeneration Instructions.

allow for an AutomaticRegeneration orperform a ParkedRegeneration.

to highway speedsto allow for anAutomaticRegeneration orperform a ParkedRegeneration assoon as possible.

Regeneration mustbe performed −engine will beginderate.

Regeneration must be performed.Check engine operator’s manualfor details −engine will shut down.


06/29/2009

24−01583−000B

WARNING


Exhaust Componentsand exhaust gas areat high temperature. When stationary, keepaway from people andflammable materialsor vapors.


Flashing

Solid


09/25/2006 f610814a

Fig. 12.4, Malfunction Indicator Lamp (MIL)

09/25/2006 f610815a

Fig. 12.5, Diesel Particulate Filter (DPF) Status Lamp

09/25/2006 f610816a

Fig. 12.6, High Exhaust System Temperature (HEST)Lamp


12.5

• One bar of the DEF level indicator flashesred—DEF empty, refill DEF.

• The DEF warning lamp flashes amber.

• The MIL lamp illuminates.

Power is limited with progressively harsher enginepower limits applied.

DEF Tank Empty and IgnoredIf the empty warning is ignored and the DEF tank isnot refilled, the red STOP engine lamp illuminates inaddition to the MIL lamp and CHECK engine lamp

(on vehicles with a Cummins ISB or ISC/L engine.)See Fig. 12.11.

If the DEF is not refilled, a 5 mph (8 km/h) speed

limit is applied after the next engine shutdown, whileparked and idling, or if a fuel refill is detected.

DEF Contamination or SCR Tampering

NOTICEOnce contaminated DEF or tampering has beendetected, the vehicle must be taken to an autho-rized service facility to check the SCR system fordamage and to deactivate the warning lights andengine limits.

10/01/2014 f490495

1

1. DEF Fill Cap

Fig. 12.7, DEF Tank Location

11/08/2010 f611037

B


E F

DEF

FE


E F

DEF

FE


E F

DEF

FE

A C

1 2

A. Green bars—DEF level indicatorsB. One bar illuminated amber—DEF very low, refill DEF

C. One bar flashing red—DEF empty, refill DEF

1. Low Fuel Warning Lamp 2. DEF Warning Lamp

Fig. 12.8, Fuel/DEF Gauge

A

B

07/09/2009 f470537

A. DEF Warning Lamp (illuminated)B. DEF Lightbar (one bar amber)

Fig. 12.9, DEF Level Low Initial Warning


12.6

If contaminated DEF or tampering with the ATS isdetected, the DEF warning light flashes and the MILlamp illuminates to warn the driver. The CHECK en-gine lamp also illuminates on vehicles with a Cum-mins ISB or ISC/L engine. See Fig. 12.11.

• Detroit engines: Engine power is limited withprogressively harsher limits applied. If the faultis 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, whileparked and idling, or if a fuel refill is detected.

• Cummins engines: Engine power is limited withprogressively harsher limits applied. If the faultis 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 whileparked and idling.

A

B

11/08/2010 f470539a

NOTE: MIL illuminates. CHECK engine lamp illuminatesif Cummins ISB or ISC/L engine. Engine power is lim-ited.A. DEF Warning Lamp (flashing)B. DEF Lightbar (one bar flashing red)

Fig. 12.10, DEF Empty Warning

A

B

11/08/2010 f470540a

NOTE: STOP engine light and MIL illuminate, enginepower is limited, speed limit of 5 mph (8 km/h)A. DEF Warning Lamp (flashing)B. DEF Lightbar (one bar flashing red)

Fig. 12.11, DEF Empty and Ignored Warning


12.7

13

Brake SystemsAir Brake System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.1Meritor WABCO® Antilock Braking System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.4Engine Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.5

Air Brake SystemBrake System General InformationA dual air brake system consists of two independentair systems that use a single set of brake controls.Each system has its own reservoirs, plumbing, andbrake chambers. The primary system operates theservice brakes on the rear axle; the secondary sys-tem operates the service brakes on the front axle.Service brake signals from both systems are sent tothe trailer.

WARNINGDo not operate the vehicle with the front brakesbacked off or disconnected. Backing off or dis-connecting the front brakes will not improve ve-hicle handling and may lead to loss of vehiclecontrol, resulting in property damage or personalinjury.

Brake System ComponentsThe warning light and buzzer come on if air pressuredrops below approximately 70 psi (483 kPa) in eithersystem. See Table 13.1. If this happens, check theair pressure gauges to determine which system haslow air pressure. Although the vehicle’s speed can bereduced using the foot brake control pedal, either thefront or rear service brakes will not be operating atfull capacity, causing a longer stopping distance.Bring the vehicle to a safe stop and have the air sys-tem repaired before continuing.

IMPORTANT: In the event of a total loss of ser-vice brakes with full system air pressure, usethe parking brake control valve (yellow knob) tobring the vehicle to a complete stop in the saf-est location possible.

Brake System Warning and Indicator LampsLamp Description Color

Low Air Pressure Indicates air pressure in the primary or secondary reservoirhas dropped below approximately 70 psi (483 kPa). Red

Parking Brake Indicates the parking brake is engaged. Red

Vehicle ABS



Amber

Trailer ABS



Amber




Amber


Table 13.1, Brake System Warning and Indicator Lamps

Brake Systems

13.1

Before a vehicle with insufficient system air pressurecan be moved, the spring parking brakes must bereleased by applying an external air source at thegladhands, or by manually caging the parking brakesprings.

WARNINGDo not release the spring parking brakes andthen drive the vehicle. There would be no meansof stopping the vehicle, which could result in se-rious personal injury or vehicle damage. Beforereleasing the spring parking brakes, make theconnection to a towing vehicle or chock the tires.

After correcting the brake system problem, uncagethe spring parking brakes before resuming normalvehicle operation.

Primary Air Brake SystemLoss of air pressure in the primary air system causesthe rear service brakes to become inoperative. Thesecondary air system will continue to operate thefront brakes and the trailer brakes (if equipped).

Secondary Air SystemLoss of air pressure in the secondary air systemcauses the front service brakes to become inopera-tive. The primary air system will continue to operatethe rear service brakes and the trailer brakes (ifequipped).

Brake System OperationBefore driving your vehicle, allow time for the aircompressor to build up a minimum of 100 psi (689kPa) pressure in both the primary and secondarysystems. Monitor the air pressure system by observ-ing the air pressure gauges and the low-air-pressurewarning light and buzzer. The warning light andbuzzer shut off when air pressure in both systemsreaches approximately 70 psi (483 kPa).

IMPORTANT: Before driving the vehicle, secure allloose items in the cab so that they will not fly forwardduring a full brake application. Make sure all passen-gers are wearing seat belts.

During normal brake stops, depress the foot brakecontrol pedal until braking action slows down the ve-hicle. Increase or decrease the pressure on thepedal so that the vehicle comes to a smooth, safestop. Apply the spring parking brakes if the vehicle isto be parked.

IMPORTANT: An air brake proportioning systemmay be used in tractor air brake systems whenthe vehicle is not equipped with an antilockbraking system (ABS). When operating in bob-tail mode, the rear brake chambers (on whichthe axle load has been greatly reduced) receivereduced (proportional) air pressure, while thefront axle brake chambers receive full (normal)air pressure. This results in a different brakepedal "feel," as the pedal seems to require moretravel and/or effort to slow or stop the vehicle.However, the air brake proportioning systemactually improves vehicle control when the trac-tor is in bobtail mode. When the tractor is tow-ing a trailer, the rear brake chambers will re-ceive full (normal) application air pressure.

When parking a vehicle attached to a trailer thatdoes not have spring parking brakes, apply the trac-tor parking brakes. Chock the trailer tires before dis-connecting the vehicle from the trailer.

WARNINGIf a trailer or combination vehicle is not equippedwith 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 causingan unattended runaway vehicle.

NOTICENever apply the service and spring parkingbrakes simultaneously. To do so transmits exces-sive input force to the brake components, whichcould damage or cause eventual failure of brakeactuating components.

Brake ControlsThe trailer brake lever (hand control valve) is usedfor applying the trailer brakes without applying thetruck or tractor service brakes. It is usually mountedon the right-hand control panel. See Fig. 13.1. Thevalve can be partially or fully applied, but in any par-tially on position it will be overridden by a full applica-tion of the service brake pedal. Moving the leverdown applies the trailer brakes, while moving it upreleases the trailer brakes. The lever will automati-cally return to the up position when it is released.

Brake Systems

13.2

WARNINGDo not use the trailer service brakes for parking;they are not designed for this purpose. If airbleeds out of the trailer air tank during parking,the vehicle could roll, causing serious personalinjury or property damage.

The red octagonal-shaped knob in the control panelactuates the trailer air supply valve. See Fig. 13.2.After the vehicle’s air hoses are connected to atrailer and the pressure in both air systems is at least65 psi (448 kPa), the trailer air supply valve must bepushed in. It should stay in to charge the trailer airsupply system and to release the trailer spring park-ing brakes.

Pull the trailer air supply valve out before disconnect-ing a trailer or when operating a vehicle without atrailer. If pressure in both air systems drops to 35 to45 psi (241 to 310 kPa), the trailer air supply valveautomatically pops out, exhausting the trailer air sup-ply, and applying the trailer service or spring parkingbrakes.

The yellow diamond-shaped knob in the controlpanel actuates the parking brake valve. SeeFig. 13.2. Pulling out the parking brake valve appliesboth the tractor and trailer spring parking brakes andautomatically causes the trailer air supply valve topop out.

NOTICEDo not use the spring parking brakes if the ser-vice brakes are hot, such as after descending asteep grade. To do so could damage the brakes.Allow hot brakes to cool before using the springparking brakes.

Do not use the spring parking brakes duringfreezing temperatures if the service brakes arewet. To do so could cause them to freeze. If thebrakes are wet, drive the vehicle in low gear andlightly apply the brakes to heat and dry them.

If the trailer is not equipped with spring parkingbrakes, pulling out the parking brake valve appliesthe tractor spring parking brakes and the trailer ser-vice brakes. When the tractor and trailer parkingbrakes (or trailer service brakes) are both applied,the trailer brakes are released by pushing in thetrailer air supply valve, leaving the tractor parkingbrakes applied. Air pressure in the primary or sec-ondary reservoir must be at least 65 psi (448 kPa)before the tractor spring parking brakes, or the trailerservice or spring parking brakes, can be released.

Automatic Slack AdjustersAutomatic slack adjusters should never be manuallyadjusted except during routine maintenance of thefoundation brakes (e.g., replacing shoes), duringslack adjuster installation, or in an emergency situa-tion.

When the brake pushrod stroke exceeds the legalbrake adjustment limit on a vehicle, there is likely amechanical problem with the foundation brake com-ponents or the adjuster is improperly installed.

Visit a repair facility as soon as possible whenbrakes equipped with automatic slack adjusters aredetermined to be out of adjustment.

WARNINGManually adjusting an automatic slack adjuster tobring the pushrod stroke within legal limits islikely masking a mechanical problem. Adjustmentis not a repair. Before adjusting an automatic

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12

1. Trailer Air-Supply-Valve Knob2. Parking-Brake-Valve Knob


Brake Systems

13.3

slack adjuster, troubleshoot the foundation brakesystem and inspect it for worn or damaged com-ponents. Improperly maintaining the vehicle brak-ing system may lead to brake failure, resulting inproperty damage, personal injury, or death.

Meritor WABCO® AntilockBraking SystemThe Meritor WABCO Antilock Braking System (ABS)is an electronic wheel speed monitoring and controlsystem that works with the standard air brake sys-tem. ABS passively monitors vehicle wheel speed atall times, and controls wheel speed during emer-gency stops.

IMPORTANT: For proper ABS system operation,do not change tire sizes. The sizes of the tiresinstalled during production are programmed intothe electronic control unit. Installing different-sized tires could result in a reduced brakingforce, leading to longer stopping distances.

ABS includes signal-generating tone wheels and sen-sors located in the wheel hubs of each sensedwheel. The sensors transmit vehicle wheel speedinformation to an electronic control unit (located be-hind the center dash). The control unit’s main circuitinterprets the speed sensor signals and calculateswheel speed, wheel retardation, and a vehicle refer-ence speed. If the calculations indicate wheel lockup,the main circuit signals the appropriate modulatorvalve to reduce braking pressure. During emergencybraking, the modulator valve alternately reduces, in-creases, or maintains air pressure supply in thebrake chamber to prevent front and rear wheellockup.

The electronic control unit (ECU) also has a safetycircuit that constantly monitors the wheel sensors,traction control valve (if equipped), modulator valves,and the electrical circuitry.

The Meritor WABCO ABS combines one front-axlecontrol channel with one rear-axle control channel toform one control circuit. For example, the sensor andmodulator valve on the left-front axle form a controlcircuit with the sensor and modulator valve on theright-rear axle. If, during vehicle operation, the safetycircuit senses a failure in any part of the ABS, thevehicle ABS warning lamp (see Table 13.1) illumi-nates and the control circuit where the failure oc-curred is switched to normal braking action. The re-maining control circuit will retain the ABS effect. Evenif the ABS is completely inoperative, normal braking

ability is maintained. An exception would be if amodulator valve (or combination modulator valve) isdamaged and inoperative. As these components arean integral part of the air brake system, normal brak-ing may be impaired or inoperative.

During emergency or reduced-traction stops, fullydepress the brake pedal until the vehicle comes to asafe stop. Do not pump the brake pedal. With thebrake pedal fully depressed, the ABS will control allwheels to provide steering control and a reducedbraking distance.

Although the ABS improves vehicle control duringemergency braking situations, the driver still has theresponsibility to change driving styles depending onexisting traffic and road conditions. For example, theABS cannot prevent an accident if the driver isspeeding or following too closely.

Trailer ABS CompatibilityThe Meritor WABCO ABS is designed to communi-cate with a trailer ABS, if they are compatible. Com-patibility will result in the illumination of the TRAILERABS lamp (see Table 13.1) during vehicle start-upand fault detection.

The TRAILER ABS lamp will not illuminate unless acompatible trailer is connected to the tractor. Thedash-mounted lamp will operate as follows when acompatible trailer is properly connected to the tractor:

• When the ignition key is turned to the ON posi-tion, the TRAILER ABS lamp will illuminate mo-mentarily, then turn off.

• If the lamp illuminates momentarily during ve-hicle operation, then shuts off, a fault was de-tected and corrected.

• If the lamp illuminates and stays on during ve-hicle operation, there is a fault with the trailerABS. Repair the trailer ABS system immedi-ately to ensure full antilock braking capability.

IMPORTANT: If a compatible trailer is con-nected, and the lamp is not illuminating momen-tarily when the ignition key is turned to the ONposition, it is possible that the lamp is burnt out.

Automatic Traction ControlVehicles with electronic engines and ABS may haveAutomatic Traction Control (ATC). On these vehicles,the ATC system automatically limits wheel spin dur-ing reduced-traction situations. In normal braking ap-plications, the standard air brake system is in effect.

Brake Systems

13.4

An additional solenoid valve is installed. Duringreduced-traction situations, the ATC solenoid valvecontrols air pressure to the modulator valves andthey in turn increase, hold, or reduce pressure to theappropriate brake chambers to provide better tractionwhenever wheel spin occurs.

When the ATC system is in the NORMAL mode, itwill apply gentle braking to the spinning wheel, tofeed power to the wheel(s) with better traction. Ifboth wheels are spinning, the system will signal theengine to reduce power.

ATC includes a deep snow and mud option to in-crease available traction on extra soft surfaces likesnow, mud, or gravel. A rocker switch labeled ATCwill be located on the dash. See Fig. 13.3. Pressingthe switch will temporarily allow more drive wheelspin. The activation of the deep snow and mud op-tion is indicated by a flashing WHEEL SPIN lamp.See Table 13.1. Pressing the switch again will cyclethe system back to normal operation.

NOTICEThe deep snow and mud option is intended to beused under specific slippery conditions that re-quire momentary increased wheel spin. Usingthis option for an extended period of time maydamage the vehicle brake system.

After the ignition switch is turned on, the vehicle ABSlamp and the WHEEL SPIN indicator lamp come onfor about three seconds. After three seconds, thewarning lights go out if all of the tractor’s ABS com-ponents are working.

IMPORTANT: If any of the ABS warning lightsdo not work as described above, or come onwhile driving, repair the ABS immediately to en-sure full antilock braking capability.

ECAS Automatic Load Transfer(ECAS only)On vehicles equipped with Electronically ControlledAir Suspension (ECAS), ECAS works in conjunctionwith ABS. When wheel slippage is detected by theABS, the ECAS system transfers weight from the tagaxle to the drive axle by changing air pressures inthe suspension air bellows, increasing drive wheeltraction.

The ECAS Load Transfer feature is optimized toapply the maximum available vehicle load on thedrive axle, up to the maximum allowable limit, deter-mined by the gross axle weight rating (GAWR). Inbobtail or with a loaded trailer less than the GAWR,the tag axle supports a negligible load while the driveaxle supports nearly the full weight. Above theGAWR, the drive axle is loaded with approximatelythe maximum allowable load and the tag supportsthe remainder.


Load transfer mode will automatically deactivatewhen the vehicle reaches 45 mph (72 kmh).

Engine BrakeEach engine manufacturer uses a specific enginebrake for their engine. Regardless of the manufac-turer, the engine brake is operated with the principlesoutlined here. Refer to the engine manufacturer’soperation manual for details of their particular enginebrake product.

WARNINGTo avoid injury from loss of vehicle control, donot activate the engine brake system under thefollowing conditions:

• on wet or slippery pavement, unless thevehicle is equipped with antilock braking

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DEEP MUDAND SNOW

ATC


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Brake Systems

13.5

system (ABS) and you have had prior expe-rience driving under these conditions;

• when driving without a trailer or pulling anempty trailer;

• if the tractor drive wheels begin to lock, orthere is fishtail motion after the enginebrake is activated.

NOTE: When the engine brake is enabled, theengine brake lamp illuminates in the instrumentpanel. See Table 13.1.


WARNINGUsage of the engine brake as the primary brakingsystem can cause unpredictable stopping dis-tances, that could result in personal injury orproperty damage. Service brakes are the primaryvehicle braking system.

Since the engine brake is most effective at rated en-gine speed, gear selection is very important. Gearingdown the vehicle within the limits of the rated enginespeed makes the engine brake more effective. Rec-ommended engine braking speed is above 1800 rpmand below the rated speed.

WARNINGThe engine brake must be disengaged whenshifting gears using the clutch pedal. If the en-gine brake is engaged when the transmission isin neutral, the braking power of the engine brakecan stall the engine, which could result in loss ofvehicle control, possibly causing personal injuryand property damage.

"Control speed" is the speed at which the enginebrake performs 100 percent of the required downhillbraking, resulting in a constant speed of descent.The control speed varies, depending on vehicleweight and the downhill grade.

For faster descent, select a higher gear than thatused for control speed. Service brakes must then beused intermittently to prevent engine overspeed andto maintain desired vehicle speed.

For slower descent, select a lower gear, being care-ful not to overspeed the engine. Occasional deactiva-tion of the engine brake may be necessary to main-tain the designated road speed under theseconditions.

If the engine is equipped with both cruise control andan engine brake, the engine brake can operate auto-matically while cruise control is activated. The maxi-mum amount of braking is selected with the enginebrake control. When the vehicle returns to the setcruise speed, the engine brake will turn off.

The engine brake will only operate when the accel-erator and clutch pedals are fully released.

Vehicles equipped with ABS have the ability to turnthe engine brake off if wheel slip is detected. Theengine brake will automatically turn back on oncewheel slip is no longer detected.

Engine Brake Operation

NOTICEDo not allow the engine to exceed its governedspeed, or serious engine damage could result.

NOTE: Depending on the brake type, the enginebrake may be disabled when engine tempera-ture falls below a set level.

The engine brake control is located on the right-handsteering column lever. At the top position, the enginebrake is off, and at the three lower positions, the en-gine brake is on and the intensity (low, medium,high) increases with each step down. See Fig. 13.5.

NOTE: On vehicles equipped with a Detroit au-tomated transmission, setting the engine brakewith the cruise control set activates DecelerationMode. Setting the cruise control while the en-gine brake is on activates Descent ControlMode. For information on these modes, see"Cruise Control" in Chapter 4.

Brake Systems

13.6

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0

1

2

3

0. Off1. Low

2. Medium3. High

Fig. 13.5, Engine Brake Positions, Detroit MultifunctionControl

Brake Systems

13.7

14

Steering SystemPower Steering System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.1

Power Steering SystemThe power steering system includes the power steer-ing gear, hydraulic hoses, power steering pump, res-ervoir, steering wheel and column, and other compo-nents.

The power steering pump, driven by the engine, pro-vides the power assist for the steering system. If theengine is not running, there is no power assist.

WARNINGDriving the vehicle without the power-assist fea-ture of the steering system requires much greatereffort, especially in sharp turns or at low speeds,which could result in an accident and possibleinjury.

If the power-assist feature does not work due to hy-draulic fluid loss, steering pump damage, or anothercause, bring the vehicle to a safe stop. Do not drivethe vehicle until the cause of the problem has beencorrected.

NOTICENever steam clean or high-pressure wash thesteering gear. Internal damage to gear seals, andultimately the steering gear, can result.

Drivers should carefully use the power available witha power steering system. If the front tires becomelodged in a deep hole or rut, drive the vehicle outinstead of using the steering system to lift the tiresout of the hole.

NOTICEAvoid turning the tires when they are against acurb, as this places a heavy load on steeringcomponents and could damage them.

Steering Wheel AdjustmentWhen there is no load on the vehicle and the fronttires are pointed straight ahead, the standard steer-ing wheel spokes should be at the 3 o’clock and 9o’clock positions or within 10 degrees of these posi-tions. See Fig. 14.1.

10°

10°

1 2

10°

10°

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1. 9 o’Clock 2. 3 o’Clock

Fig. 14.1, Steering Wheel Centered

Steering System

14.1

15

Automated TransmissionsDetroit™ Automated Transmissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.1

Detroit™ AutomatedTransmissionsDetroit transmissions have twelve forward gears andup to four reverse gears that can be shifted automati-cally or manually. Shifting and clutch actuation arecomputer controlled, and there is no clutch pedalneeded to operate the vehicle. Automatic shifts areselected for fuel economy or engine power. Manualshifts can be requested with the shift control and thetransmission ECU grants them when conditions per-mit. In all cases, shifts depend on the following fac-tors: engine speed, accelerator pedal position, ser-vice brake usage, engine brake operation, vehicleload status, and road conditions.

NOTE: To avoid potential engine stall risk or un-expected shifting, use the interaxle differentiallock when the vehicle is operated in slipperyconditions. See Chapter 17 for informationabout the interaxle differential lock.

Detroit™ Multifunction ControlVehicles with Detroit transmissions use the controlshown in Fig. 15.1. This control can be used to re-quest manual shifts, change driving mode, and setengine brake levels. See Table 15.1 for an overviewof control functionality.

D/N/R SwitchUse the "D/N/R Switch" to request drive (D), neutral(N), or reverse (R).

Mode SwitchThe driving mode can be changed using the Modeswitch on the shift control (see Fig. 15.1). To activatethe manual drive mode, press and hold the switchbriefly. Press the switch quickly to activate the auto-matic drive mode or change between AutomaticEconomy and Automatic Performance modes.

Upshifting and DownshiftingGear shifts can be requested manually; push thelever away to request a downshift, or pull the levertoward you to request an upshift. See Table 15.1 formore information about upshift and downshiftrequests.

B

2

3

1

( + )

( − )

4

05/30/2012 f270163a

A

C

See Table 15.1 for a description of control functionality.A. Front ViewB. Shift RequestsC. Four positions for engine brake settings1. Engine Brake Symbol2. D/N/R Switch3. Mode Switch4. Gear Shift Symbol



15.1

Functionality, Detroit Multifunction ControlFunction/Switch Action/Position Request

D/N/RD Forward gearsN NeutralR Reverse gears

ModeDepress switch and release it quickly Activate the automatic drive mode, or switch between

Automatic Economy and Automatic Performance.Depress switch and hold it briefly Activate the manual drive mode.

Upshifting andDownshifting

Pull the lever toward you momentarily Upshift, single gearPull the lever toward you in quick repetitions Upshift, multiple gearsPush the lever away momentarily Downshift, single gearPush the lever away in quick repetitions Downshift, multiple gears

Engine Brake*

Lever at position 0 (top) Engine brake offLever at position 1 Low intensityLever at position 2 Medium intensityLever at position 3 (bottom) High intensity

* For functions with cruise control active, see Chapter 4.

Table 15.1, Functionality, Detroit Multifunction Control

Engine BrakeThe engine brake is controlled by the lever position(as shown in Fig. 15.1, Ref. C). At the top position,the engine brake is off, and at the three lower posi-tions, the engine brake is on and the intensity (low,medium, high) increases with each step down. Formore information about using the engine brake, seeChapter 13.

NOTE: Setting the cruise control with the enginebrake on will activate Descent Control Mode.Moving the lever down to engage the enginebrake after the cruise control has been set willactivate Deceleration Mode. For information onthese modes, see "Cruise Control" in Chap-ter 4.

Power Up and Shift into Gear1. With the parking brake set and Neutral (N) se-

lected on the shift control, turn the ignition switchto the ON position.

2. Start the engine.

3. Apply the service brake.

4. Select the desired starting gear.

5. Release the parking brake.

6. Release the service brake and apply the accel-erator.

Gear Display WindowThe gear display window shows the current transmis-sion gear and driving mode. See Fig. 15.2.

Driving ModesThere are three driving modes: Manual, AutomaticEconomy, and Automatic Performance.

In Automatic Economy mode, gear shifts are de-signed for saving fuel. In Automatic Performancemode, gear shifts are designed for higher perfor-mance and are made at higher engine speeds. Inmanual mode, gear shifts are requested manually.See Chapter 4 for more information about upshiftingand downshifting using the control.

5A econ

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1

2

N70 °F

1. Driving Mode2. Current Gear

Fig. 15.2, Gear Display Window


15.2

NOTE: In Automatic Performance mode, thetransmission will automatically change to Auto-matic Economy mode if it hasn’t received a re-quest for more power in several minutes, unlesscurrent road conditions require higher engineperformance.

Selected GearIf the selected gear is different than the current gearfor longer than a half second, the current gear dis-play will flash and the selected gear value will beshown. Once the current gear and selected gearmatch, the selected gear display disappears and thecurrent gear display stops flashing. See Fig. 15.3.

Suggested ShiftIn Manual mode only, a suggested shift is displayedto indicate the most economical gear available. Thesuggested shift is the number of up or down arrowsfrom the current gear with a maximum of three up ordown arrows. See Fig. 15.4.

eCoastThe eCoast feature can improve driving economy.When conditions permit, the transmission control au-

tomatically shifts the transmission to neutral to coastat speeds of approximately 22 mph (35 km/h) andabove. An "E" shows in the gear display windowwhen eCoast is in effect. See Fig. 15.5.

The eCoast function is not active when any of thefollowing occur:

• the accelerator pedal is pressed.

• vehicle acceleration rate is exceeded.

• the service brake pedal is pressed.

• the engine brake is in use.

• cruise control brakes or accelerates.

• vehicle speed exceeds the cruise control setspeed by more than approximately 4 mph (6km/h).

• the speed limiter is active and the maximumspeed set is exceeded.

• diesel particulate filter (DPF) regeneration oc-curs.

The eCoast function cannot be deactivated when theAutomatic Economy mode is active.

NOTE: To disable eCoast, see an authorizedWestern Star service facility.

Creep ModeCreep mode allows the vehicle to be maneuvered atvery slow speeds. To activate Creep mode for thefirst time within the current driving cycle, press theaccelerator pedal to launch the vehicle, thereby fullyengaging the clutch. Following this and for the dura-tion of the current driving cycle, Creep mode is ac-tive.

Once the vehicle is stopped via the service brakes,the vehicle will begin to creep again, without the ac-celerator pedal actuation, as soon as the servicebrakes are released.

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1

2

7

A econ

5 N70 °F

1. Selected Gear2. Current Gear

Fig. 15.3, Selected Gear Display

Manual

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12

5 N70 °F

1. Suggested Shift Arrows2. Current Gear

Fig. 15.4, Suggested Shift

E

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A econ

N70 °F

NOTE: Upshift and downshift arrows are not shownwhen "E" is shown in the gear display window.

Fig. 15.5, eCoast Display


15.3

To begin using Creep mode (once active) from aparked position, shift from neutral to either drive orreverse, release the service brakes, and briefly de-press the accelerator pedal. The vehicle’s urge tomove can then be felt.

If creep is active and no acceleration is achievedwithin five seconds, then Creep mode will abort. Adisplay message notifies the operator when Creepmode is about to be aborted.

IMPORTANT: When slowing down from higherspeeds in drive or reverse, remember thatCreep mode will be in effect at lower speeds.Use the service brakes to stop the vehicle.

Clutch Abuse ProtectionA vehicle equipped with a Detroit transmission doesnot have a clutch pedal, but still has a clutch that isoperated automatically and can be damaged by abu-sive driver actions. To protect the clutch, the vehiclehas a clutch abuse protection system that alerts thedriver and restricts functionality when needed. Ex-tended periods in Creep Mode, slipping the clutch(using the accelerator pedal to hold the vehicle on ahill, for example), and high clutch temperatures canactivate the clutch abuse protection system. A displaymessage notifies the operator when the protectionsare needed.

NOTICETo hold the vehicle stationary on an uphill slope,use the service brakes, not the accelerator pedal.

Using the accelerator pedal can overheat anddamage the clutch. To start moving, use the ac-celerator pedal and release the brakes as the ve-hicle begins to move.

There are three clutch abuse protection levels. Ateach, the driver is alerted and functionality is modi-fied; see Table 15.2.

To avoid overheating the clutch, follow these tips:

• To hold the vehicle stationary on an uphillslope, use the service brakes, not the accel-erator pedal.

• To start moving on an uphill slope, use the ac-celerator pedal and release the brakes as thevehicle begins to move.

• When hooking up to a trailer, ensure the traileris high enough to back under, and use firstgear reverse.

• Avoid starting in higher gears, and start in firstgear when a trailer is attached.

• Ensure trailer brakes have had time to com-pletely release prior to starting.

• Do not use Creep mode for an extended pe-riod. Stop or adjust the vehicle speed whenwarned to deactivate Creep mode.

Clutch Abuse Alerts and Protections

Alert Level AlertProtections

Highest Start Gear Creep Mode Clutch Function1 Heavy clutch load message 1 No restriction Normal function2 Heavy clutch load message 1 Disabled Normal function

3 Clutch overload message andbuzzer 1 Disabled

If the accelerator pedal isdepressed, the clutch closesat fixed rate.

If the accelerator pedal isreleased, the clutch opens atfixed rate.

Table 15.2, Clutch Abuse Alerts and Protections

Engine Overspeed AlertsTo help protect the engine, the system has displaymessages to notify the operator when the engine has

exceeded certain thresholds and needs to be sloweddown before significant engine damage occurs.There are two warnings, one at about 2400 rpm and


15.4

another at 2500 rpm, indicated with messages and afault code.

Low Transmission Air WarningPneumatic controls are used to shift the transmis-sion. If there is inadequate air pressure, a warning isdisplayed and the quality of gear shifts may be de-graded. Wait for air pressure to build before operat-ing the vehicle.

IMPORTANT: If the low transmission air warningindicator appears while the vehicle is in opera-tion, safely pull the vehicle off the road, and cor-rect the problem.


15.5

16

Manual Transmissions andClutch

Eaton® Fuller® Transmission Operation Tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.1Eaton Fuller 13-Speed and 18-Speed Splitter and Range-Shift Transmissions . . . . . . . . . . . . . . . 16.1Eaton Fuller 10-Speed Range-Shift Transmissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.4Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.5

Eaton® Fuller® TransmissionOperation TipsNOTE: Refer to the Eaton website (www.road-ranger.com) for additional information.

Follow these important operation principles:

• For all conditions, use the highest gear that isstill low enough to start the vehicle moving withthe engine at or near idle speed, and withoutslipping the clutch excessively.

When operating on-highway with no load orunder ideal conditions, use 1st gear to start thevehicle moving forward.

When operating off-road or under adverse con-ditions, use LOW gear to start the vehicle mov-ing forward.

• Use the clutch brake to stop gear rotationwhen shifting into LOW or reverse while thevehicle is stationary. The clutch brake is actu-ated by depressing the clutch pedal all the wayto the floor.

• Partially disengage the clutch to break enginetorque during normal gear shifts.

• Double-clutch between all upshifts and down-shifts that require movement of the shift knob.Splitting of gears does not require movementof the shift knob.

• Never push the range-preselection lever downinto low range while operating in high range,except when downshifting from 5th gear to 4thgear.

• Do not shift from high range to low range athigh vehicle speeds.

• Never make a range shift or a splitter shiftwhile the vehicle is in reverse.

• Never move the range-preselection lever withthe transmission in neutral while the vehicle ismoving.

• Skip ratios while shifting only when operatingconditions permit, depending on the load,grade, and road speed.

• Never coast with the transmission in neutral.

Eaton Fuller 13-Speed and 18-Speed Splitter and Range-ShiftTransmissionsNOTE: Refer to the Eaton website for additionalinformation, www.roadranger.com.

General Information, Eaton FullerSplitter and Range-ShiftTransmissionsCombination splitter and range-shift transmissionsallow the choice of two splitter ratios in each leverposition as well as the additional ratio provided ineach lever position after shifting to the other range.

IMPORTANT: Not all lever positions are used ineach range and the shift patterns vary betweentransmissions. Be sure to read the shift patterndecal for the specific transmission installed inyour vehicle. The shift pattern decal may befound on the shift knob, the dash, or the visor.

13-Speed RTLO ModelsEaton Fuller 13-speed transmissions have thirteenforward speeds and two reverse speeds. Each trans-mission consists of a 5-speed front section, and a3-speed auxiliary section. The auxiliary section con-tains low- and high-range ratios, plus an overdrivesplitter gear. See Fig. 16.1 for the shift pattern.

All of the 13 speeds are controlled with one shiftlever. A range preselection lever and a splitter control

f260044a02/03/2017

R1 3

2 4LOW

Dir OD

5 5

Dir OD

Dir OD Dir OD

7 7

6 6 8 8

Hi

Lo

A

B

C D

1

N






16.1

www.roadranger.com

www.roadranger.com

www.roadranger.com

button are built into the shift knob. The range prese-lection lever controls range selection and the splittercontrol button (located on the side of the shift knob)controls gear splits.

Low gear in the front section is used only as a start-ing ratio. The remaining four forward positions areused once in the low range and once in the highrange. However, each of the four high range gearpositions can be split with the underdrive ratio (RTmodels), or overdrive ratio (RTO models) of the split-ter gear. Ratios cannot be split while the transmis-sion is in low range.

18-Speed RTLO Splitter and Range-ShiftModelsEaton Fuller 18-speed transmissions have 18 forwardspeeds and four reverse speeds. These transmis-sions consisting of a 5-speed front section and a3-speed auxiliary section. The auxiliary section con-tains low and high range ratios, plus an overdrivesplitter gear.

One ratio in the front section (low) is used as a start-ing ratio; it is never used when the transmission is inhigh range. Low gear can be split to provide both adirect and an overdrive ratio.

The other four ratios in the front section are usedonce in low range and once again in high range;however, each of the five ratios (low–1–2–3–4) in lowrange and each of the four ratios (5–6–7–8) in highrange can be split with the overdrive splitter gear.

All of the 18 speeds are controlled with one shiftlever. A range preselection lever and a splitter controlbutton are built into the shift knob. The range prese-lection lever controls range selection and the splittercontrol button (located on the side of the shift knob)controls gear splits.

Operation, Eaton Fuller Splitter andRange-Shift TransmissionsIMPORTANT: The shifter knob has an interlockfeature that prevents the splitter control buttonfrom being moved forward when the range pre-selection lever is down (in low range); when inhigh range and the splitter control button is inthe forward position, the range preselectionlever cannot be moved down.

Upshifting1. Position the gear shift lever in neutral. Start the


2. Position the range preselection lever down, intolow range. See Fig. 16.2.

3. Make sure the splitter control button is in the di-rect (rearward) position. See Fig. 16.2.


Press the clutch to the floor, shift into low or 1stgear; then engage the clutch, with the engine ator near idle speed, to start the vehicle moving.Accelerate to 80 percent of engine governedspeed.


Press the clutch to the floor, shift into low; thenengage the clutch, with the engine at or near idlespeed, to start the vehicle moving.

To shift from low direct to low overdrive, movethe splitter control button into the overdrive (for-ward) position, then immediately release the ac-celerator. Press and release the clutch pedal.After releasing the clutch, accelerate again.


Shift upward from low to 1st gear, 2nd, etc. until4th gear, double-clutching between shifts, andaccelerating to 80 percent of engine governedspeed. See Fig. 16.1.


f260157a02/03/2017

N

R 1Dir

5Dir

5OD1

OD3

Dir

7Dir

7OD3

OD

2Dir

6Dir

6OD2

OD4

Dir

8Dir

8OD4

OD

LOWDir

LOWOD

A

B

C D

1






16.2

Shift upward from low overdrive to 1st direct byfirst moving the splitter control button into thedirect (rearward) position (Fig. 16.2). Move theshift lever, double-clutching, to the 1st gear posi-tion.

Continue upshifting through the shift pattern.Double-clutch during lever shifts (1st to 2nd to3rd to 4th); single-clutch during split shifts (1stdirect to 1st overdrive, etc.).

6. When in 4th gear (13-speed transmissions) or4th overdrive (18-speed transmissions) andready to shift up to 5th gear, use the range shiftlever as follows:


While in 4th gear, pull the range shift preselec-tion lever up, into high range. The transmissionwill automatically shift from low to high range asthe shift lever passes through neutral. Then, dis-engage the clutch; double-clutch through neutral;move the shift lever to 5th gear; engage theclutch, and accelerate the engine.


While in 4th overdrive, pull the range shift prese-lection lever up, into high range. The transmis-sion will automatically shift from low to highrange as the shift lever passes through neutral.

Move the shift lever, double-clutching, to the 5thgear position. Just before making final clutch en-gagement, move the splitter control button to thedirect (rearward) position; then engage the clutchand accelerate. Do not move the control buttonwhile the shift lever is in neutral.

7. Shift up through the high range gears as follows:


To shift from 5th direct to 5th overdrive, move thesplitter control button (Fig. 16.1) into the over-drive (forward) position, then immediately releasethe accelerator. Press and release the clutchpedal. After releasing the clutch, accelerateagain.



To shift from 5th direct to 5th overdrive, move thesplitter control button (Fig. 16.2) into the over-drive (forward) position, then immediately release

the accelerator. Press and release the clutchpedal. After releasing the clutch, accelerateagain.


Downshifting1. Downshift from 8th overdrive to 8th direct without

moving the shift lever. Flip the splitter control but-ton to the direct (rearward) position, then imme-diately release the accelerator, and disengagethe clutch. Engage the clutch, and accelerate theengine only after the transmission has shifted.

2. Start the downshift from 8th direct to 7th over-drive by flipping the splitter control button to theoverdrive (forward) position; then, immediatelydouble-clutch through neutral, moving the shiftlever from 8th to 7th gear.

3. Shift downward through each of the high rangegears, alternating the procedures in steps 1 and2, above, until reaching 5th direct.

4. While in 5th direct and ready for the downshift to4th (13-speed transmissions) or 4th overdrive(18-speed transmissions), push the range prese-lection lever down. Then, double-clutch throughneutral and move the shift lever to the 4th gearposition. On 18-speed transmissions, move thesplitter control button to the overdrive (forward)position before engaging the clutch. Do not movethe control button while the shift lever is in neu-tral.

5. Continue downshifting from 4th to 1st as follows:


Downshift through the low range gears as condi-tions require.


Continue downshifting from 4th overdrive to 4thdirect, then 4th direct to 3rd overdrive, 3rd over-drive to 3rd direct, etc. Single-clutch when splitshifting (direct to overdrive, overdrive to direct).Double-clutch when making lever shifts (4th to3rd, 3rd to 2nd, etc.).



16.3