Western Star 47X 2020 User manual

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

Foreword
When performed on a regular basis, lubricating the parts of your vehicle is the least costly way of obtaining safe and
reliable vehicle operation. Added benefits and savings occur when you check that the engine, undercarriage, and
noise emission control parts are in good working order during lubrication.
IMPORTANT: The maintenance operations in this manual are not all-inclusive. Also refer to other
component and body manufacturers’ instructions for specific inspection and maintenance instructions.
Perform the operations in this maintenance manual at scheduled intervals based upon distance traveled or hours
of operation. Perform daily, pretrip inspection and maintenance as outlined in the Western Star 47X and 49X
Driver’s Manual.
IMPORTANT: Descriptions and specifications in this manual were in effect at the time of printing. Western
Star Trucks reserves the right to discontinue models and to change specifications or design at any time
without notice and without incurring obligation. Descriptions and specifications contained in this
publication provide no warranty, expressed or implied, and are subject to revision and editions without
notice.
Refer to www.Daimler-TrucksNorthAmerica.com and www.WesternStarTrucks.com for more information, or
contact Daimler Trucks North America LLC at the address below.
Environmental and Safety Concerns and Recommendations
Whenever you see instructions in this manual to discard materials, you should attempt to reclaim and recycle them.
To preserve our environment, follow appropriate environmental rules and regulations when disposing of materials.
Servicing vehicles may result in contact with items known to the state of California to cause harm.
WARNING
Breathing diesel engine exhaust exposes you to chemicals known to the State of California to cause can-
cer and birth defects or other reproductive harm.
Always start and operate the engine in a well-ventilated area. If in an enclosed are, vent the exhaust to the
outside. Do not modify or tamper with the exhaust system. Do not idle the engine except as necessary.
For more information go to www.P65warnings.ca.gov/diesel.
WARNING
Cancer and Reproductive Harm www.P65warnings.ca.gov/diesel.
NOTICE: Parts Replacement Considerations
Do not replace suspension, axle, or steering parts (such as springs, wheels, hubs, and steering gears) with used
parts. Used parts may have been subjected to collisions or improper use and have undetected structural damage.

© 2020–2022 Daimler Trucks North America LLC
All rights reserved. No part of this publication, in whole or in part, may be translated, reproduced, stored in a retrieval
system, or transmitted in any form by any means, electronic, mechanical, photocopying, recording, or otherwise,
without the prior written permission of Daimler Trucks North America LLC. Daimler Trucks North America LLC is a
Daimler company.
Daimler Trucks North America LLC
Service Systems and Documentation (CVI-SSD)
P.O. Box 3849
Portland, OR 97208–3849

Daimler Trucks North America LLC distributes the following major service publications in paper and electronic
formats. Refer to www.DTNAConnect.com.
Workshop/Service
Manual
Workshop/service manuals contain service and repair information for all vehicle
systems and components, except for major components such as engines, trans-
missions, and rear axles. Each workshop/service manual section is divided into
subjects that can include general information, principles of operation, removal,
disassembly, assembly, installation, and specifications.
Maintenance Manual Maintenance manuals contain routine maintenance procedures and intervals for
vehicle components and systems. They have information such as lubrication
procedures and tables, fluid replacement procedures, fluid capacities, specifica-
tions, and procedures for adjustments and for checking the tightness of fasten-
ers. Maintenance manuals do not contain detailed repair or service information.
Driver’s/Operator’s
Manual
Driver’s/operator’s manuals contain information needed to enhance the driver’s
understanding of how to operate and care for the vehicle and its components.
Each manual contains a chapter that covers pre-trip and post-trip inspections,
and daily, weekly, and monthly maintenance of vehicle components.
Driver’s/operator’s manuals do not contain detailed repair or service information.
Service Bulletins Service bulletins provide the latest service tips, field repairs, product improve-
ments, and related information. Some service bulletins are updates to informa-
tion in the workshop/service manual. These bulletins take precedence over
workshop/service manual information, until the latter is updated; at that time, the
bulletin is usually canceled. The service bulletins manual is available only to
dealers. When doing service work on a vehicle system or part, check for a valid
service bulletin for the latest information on the subject.
IMPORTANT: Before using a particular service bulletin, check the current
service bulletin validity list to be sure the bulletin is valid.
Parts Technical Bulletins Parts technical bulletins provide information on parts. These bulletins contain
lists of parts and BOMs needed to do replacement and upgrade procedures.
Web-based repair, service, and parts documentation can be accessed using the following applications on the
www.DTNAConnect.com website.
DTNAConnect DTNAConnect provides Web-based access to the most up-to-date versions of
the publications listed above. In addition, the Service Solutions feature provides
diagnostic assistance with Symptoms Search, by connecting to a large knowl-
edge base gathered from technicians and service personnel. Search results for
both documents and service solutions can be narrowed by initially entering ve-
hicle identification data.
PartsPro PartsPro® is an electronic parts catalog system, showing the specified vehicle’s
build record.
EZWiring EZWiring™makes Western Star, Freightliner, Freightliner Custom Chassis Cor-
poration, Sterling, and Thomas Built Buses products’ wiring drawings and float-
ing pin lists available online for viewing and printing. EZWiring can also be ac-
cessed from within PartsPro.
Introduction
Descriptions of Service Publications
47X and 49X Maintenance Manual, I–1

Warranty-related service information available on the www.DTNAConnect.com website includes the following
documentation.
Recall Campaigns Recall campaigns cover situations that involve service work or replacement of
parts in connection with a recall notice. These campaigns pertain to matters of
vehicle safety. All recall campaigns are distributed to dealers; customers receive
notices that apply to their vehicles.
Field Service Campaigns Field service campaigns are concerned with non-safety-related service work or
replacement of parts. All field service campaigns are distributed to dealers; cus-
tomers receive notices that apply to their vehicles.
Introduction
Descriptions of Service Publications
I–2 47X and 49X Maintenance Manual,

For an example of a Western Star Maintenance Manual page, see Fig. 1.
f020178
CB
ED
35
35/1
Rear Axle
A
Western Star Maintenance Manual, November 2011
1. Park the vehicle on a level surface, shut down
the engine, and set the parking brake. Chock the
NOTICE
Fig. 1, Freightliner Tandem Axle (forward axle shown)
the possibility of dirt and road grime entering the
assembly. Remove the plug, and check the oil
level. If low, add fluid using the same lubricant
recommended for the drive axle.
35−01 Drive Axle Lubricant
Failure to keep the rear axle filled to the proper
level with the recommended lubricant can result in
rear axle damage.
Fig. 3.
2. Breather Hose
4. Oil Fill Plug
B. Rear View
A. Front View
1. Axle Breather
3. Temperature Sensor Port
1
2
43
2
B
A
12/07/2010 f350509a
Level Check
tires.
2. If the vehicle has just been driven, allow a few
minutes for the lubricant to settle.
3. Clean the oil fill hole plug (located in the carrier
or the side of the axle housing) and the area sur−
rounding it, then remove the plug. For Freight−
liner axles, see
; for Dana Spicer axles, see
Fig. 1 Fig.; for Meritor axles, see
2
09/13/2011
4. Check the level of the lubricant. The lubricant
must be level with the bottom of the oil fill hole
(see
For Freightliner axles, see Table 1 for approved
Fig. 4). If low, add lubricant.
axle lubricants and lubricant capacities.
For Meritor axles, see for approved axle
lubricants, and
Table 2
Table 3 Table 4and for axle ca−
pacities.
For Dana Spicer axles, see for approved
axle lubricants, and
Table 5
Table 6 for axle capacities.
5. Install the oil fill hole plug and tighten it per the
following:
6. On non−drive axles using oil−lubricated wheel
bearings, clean the hub cap and plug to minimize
For Dana Spicer axles: 50 lbf·ft (68 N·m).
For Freightliner axles: 37 lbf·ft (50 N·m).
For Meritor axles: 35 lbf·ft (47 N·m).
NOTE: Some Freightliner and Meritor axles
IMPORTANT: A lubricant level close enough to
must not be used as a fill or level hole.
below the housing oil fill hole. This smaller hole
have a small tapped and plugged hole located
is for the lubricant temperature sensor only and
level with the bottom of the fill hole.
be seen or touched is not sufficient. It must be
A. Maintenance Operation Number consists of the Group Number followed by the Sequence Number
B. Group Title
C. Group Number
D. Release Date
E. Group Number/Page Number
Fig. 1, Example Page
Introduction
Page Description
47X and 49X Maintenance Manual, I–3

Group No. Group Title
00...................... General Information
09.............................. AirIntake
13 ......................... AirCompressor
15................... Alternators and Starters
20................... Engine Cooling/Radiator
25................................ Clutch
26........................... Transmission
31 ............. Frame and Frame Components
32............................ Suspension
33 ............................. Front Axle
35 ............................. Rear Axle
40........................ Wheels and Tires
41 .............................. Driveline
42................................ Brakes
46............................... Steering
47 ................................. Fuel
49............................... Exhaust
54.......... Electrical, Instruments, and Controls
60 .................................. Cab
83................. Heater and Air Conditioner
Introduction
Maintenance Manual Contents
I–4 47X and 49X Maintenance Manual,

Title of Maintenance Operation (MOP) MOP Number
Determining Scheduled Maintenance Intervals.............................................00–01
Initial Maintenance (IM) Operations.....................................................00–04
M1 Maintenance Interval Operations....................................................00–05
M2 Maintenance Interval Operations....................................................00–06
M3 Maintenance Interval Operations....................................................00–07
Maintenance Operation Sets Table ..................................................... 00–08
Noise Emission Controls Maintenance...................................................00–09
Service Schedule Table ............................................................. 00–02
Vehicle Maintenance Schedule Table ................................................... 00–03
Verification of Inspections Log.........................................................00–10
General Information 00
Index, Alphabetical
47X and 49X Maintenance Manual, October 2020

Determining Scheduled
Maintenance Intervals
Performing regular maintenance on your Western
Star vehicle will help ensure that your vehicle deliv-
ers safe reliable service and optimum performance
for years to come. Failure to follow a regular mainte-
nance program can result in inefficient operation and
unscheduled down time.
To determine the correct maintenance intervals for
your vehicle you must first determine the type of ser-
vice or conditions the vehicle will be operating in.
Generally, over-the-road vehicles operate under con-
ditions that fall within one of the two types of service
described. Before placing your new vehicle in ser-
vice, determine the type of service (Service Schedule
I or II) that applies to the intended use of the vehicle.
After determining the vehicle’s type of service, refer
to the service schedule table or the vehicle mainte-
nance schedule table, to determine how often main-
tenance should be performed.
When the vehicle reaches the distance given for a
maintenance interval, see the Maintenance Interval
Operation Table for a list of the maintenance opera-
tions to be performed at that maintenance interval.
Use the maintenance operation reference numbers to
find detailed instructions in the manual on each op-
eration.
Types of Service
Service Schedule I (short-haul transport) applies to
vehicles that annually travel less than 60,000 miles
(100 000 kilometers) and operate under normal con-
ditions. Examples of Schedule I usage are: operation
primarily in cities and densely populated areas; local
transport with infrequent freeway travel; or high per-
centage of stop-and-go travel.
Service Schedule II (long-haul transport) is for ve-
hicles that annually travel more than 60,000 miles
(100 000 kilometers) with minimal city or stop-and-go
operation. Examples of Schedule II usage are: re-
gional delivery that is mostly freeway miles; interstate
transport; or any road operation with high annual
mileage.
NOTE: Maintenance instructions in this manual
are based on average vehicle use and normal
operating conditions. Unusual vehicle operating
conditions may require service at more frequent
intervals.
General Information 00
Determining Scheduled Maintenance Intervals: 00–01
47X and 49X Maintenance Manual, October 2020 00/1

Service Schedule Maintenance Interval Operation Maintenance Interval
Frequency Miles km
Schedule I
(Short-Haul Transport)
vehicles that annually travel less than 60,000
miles (100 000 km)
Initial Maintenance (IM) first 10,000 16 000
Maintenance 1 (M1) every 10,000 16 000
Maintenance 2 (M2) every 50,000 80 000
Maintenance 3 (M3) every 150,000 240 000
Schedule II
(Long-Haul Transport)
vehicles that annually travel over 60,000
miles (100 000 km)
Initial Maintenance (IM) first 25,000 40 000
Maintenance 1 (M1) every 25,000 40 000
Maintenance 2 (M2) every 100,000 161 000
Maintenance 3 (M3) every 300,000 483 000
Table 1, Service Schedule
General Information00
Service Schedule Table: 00–02
47X and 49X Maintenance Manual, October 202000/2

Maintenance for Service Schedule I
Maint. No. Maintenance
Interval
Service
Date
Service Schedule I
Miles km
1st IM and M1 10,000 16 000
2nd M1 20,000 32 000
3rd M1 30,000 48 000
4th M1 40,000 64 000
5th M1 and M2 50,000 80 000
6th M1 60,000 96 000
7th M1 70,000 112 000
8th M1 80,000 128 000
9th M1 90,000 144 000
10th M1 and M2 100,000 160 000
11th M1 110,000 176 000
12th M1 120,000 192 000
13th M1 130,000 208 000
14th M1 140,000 224 000
15th M1, M2, and M3 150,000 240 000
16th M1 160,000 256 000
17th M1 170,000 272 000
18th M1 180,000 288 000
19th M1 190,000 304 000
20th M1 and M2 200,000 320 000
21st M1 210,000 336 000
22nd M1 220,000 352 000
23rd M1 230,000 368 000
24th M1 240,000 384 000
25th M1 and M2 250,000 400 000
26th M1 260,000 416 000
27th M1 270,000 432 000
28th M1 280,000 448 000
29th M1 290,000 464 000
30th M1, M2, and M3 300,000 480 000
31st M1 310,000 496 000
32nd M1 320,000 512 000
33rd M1 330,000 528 000
34th M1 340,000 544 000
35th M1 and M2 350,000 560 000
General Information 00
Vehicle Maintenance Schedule Table: 00–03
47X and 49X Maintenance Manual, October 2020 00/3

Maintenance for Service Schedule I
Maint. No. Maintenance
Interval
Service
Date
Service Schedule I
Miles km
36th M1 360,000 576 000
37th M1 370,000 592 000
38th M1 380,000 608 000
39th M1 390,000 624 000
40th M1 and M2 400,000 640 000
41st M1 410,000 656 000
42nd M1 420,000 672 000
43rd M1 430,000 688 000
44th M1 440,000 704 000
45th M1, M2, and M3 450,000 720 000
46th M1 460,000 736 000
47th M1 470,000 752 000
48th M1 480,000 768 000
49th M1 490,000 784 000
50th M1 and M2 500,000 800 000
51st M1 510,000 820 000
52nd M1 520,000 837 000
53rd M1 530,000 853 000
54th M1 540,000 869 000
55th M1 and M2 550,000 885 000
56th M1 560,000 901 000
57th M1 570,000 917 000
58th M1 580,000 933 000
59th M1 590,000 949 000
60th M1, M2, and M3 600,000 965 000
61st M1 610,000 982 000
62nd M1 620,000 998 000
63rd M1 630,000 1 014 000
64th M1 640,000 1 030 000
65th M1 and M2 650,000 1 046 000
66th M1 660,000 1 062 000
67th M1 670,000 1 078 000
68th M1 680,000 1 094 000
69th M1 690,000 1 110 000
70th M1 and M2 700,000 1 127 000
General Information00
Vehicle Maintenance Schedule Table: 00–03
47X and 49X Maintenance Manual, October 202000/4

Maintenance for Service Schedule I
Maint. No. Maintenance
Interval
Service
Date
Service Schedule I
Miles km
71st M1 710,000 1 143 000
72nd M1 720,000 1 159 000
73rd M1 730,000 1 175 000
74th M1 740,000 1 191 000
75th M1, M2, and M3 750,000 1 207 000
76th M1 760,000 1 223 000
77th M1 770,000 1 239 000
78th M1 780,000 1 255 000
79th M1 790,000 1 271 000
80th M1 and M2 800,000 1 287 000
81st M1 810,000 1 304 000
82nd M1 820,000 1 320 000
83rd M1 830,000 1 340 000
84th M1 840,000 1 352 000
85th M1 and M2 850,000 1 370 000
86th M1 860,000 1 384 000
87th M1 870,000 1 400 000
88th M1 880,000 1 416 000
89th M1 890,000 1 432 000
90th M1, M2, and M3 900,000 1 448 000
91st M1 910,000 1 465 000
92nd M1 920,000 1 481 000
93rd M1 930,000 1 500 000
94th M1 940,000 1 513 000
95th M1 and M2 950,000 1 530 000
96th M1 960,000 1 550 000
97th M1 970,000 1 561 000
98th M1 980,000 1 577 000
99th M1 990,000 1 593 000
100th M1 and M2 1,000,000 1 609 000
Table 2, Maintenance for Service Schedule I
General Information 00
Vehicle Maintenance Schedule Table: 00–03
47X and 49X Maintenance Manual, October 2020 00/5

Maintenance for Service Schedule II
Maint. No. Maintenance Interval Service
Date
Service Schedules II
Miles km
1 IM and M1 25,000 40 000
2 M1 50,000 80 000
3 M1 75,000 121 000
4 M1 and M2 100,000 161 000
5 M1 125,000 201 000
6 M1 150,000 241 000
7 M1 175,000 281 000
8 M1 and M2 200,000 322 000
9 M1 225,000 362 000
10 M1 250,000 402 000
11 M1 275,000 443 000
12 M1, M2, and M3 300,000 483 000
13 M1 325,000 523 000
14 M1 350,000 563 000
15 M1 375,000 604 000
16 M1 and M2 400,000 644 000
17 M1 425,000 684 000
18 M1 450,000 724 000
19 M1 475,000 764 000
20 M1 and M2 500,000 805 000
21 M1 525,000 845 000
22 M1 550,000 885 000
23 M1 575,000 925 000
24 M1, M2, and M3 600,000 966 000
25 M1 625,000 1 005 800
26 M1 650,000 1 046 000
27 M1 675,000 1 086 000
28 M1 and M2 700,000 1 127 000
29 M1 725,000 1 167 000
30 M1 750,000 1 207 000
31 M1 775,000 1 248 000
32 M1 and M2 800,000 1 287 000
33 M1 825,000 1 328 000
34 M1 850,000 1 368 000
35 M1 875,000 1 408 000
General Information00
Vehicle Maintenance Schedule Table: 00–03
47X and 49X Maintenance Manual, October 202000/6

Maintenance for Service Schedule II
Maint. No. Maintenance Interval Service
Date
Service Schedules II
Miles km
36 M1, M2, and M3 900,000 1 448 000
37 M1 925,000 1 490 000
38 M1 950,000 1 529 000
39 M1 975,000 1 569 000
40 M1 and M2 1,000,000 1 609 000
Table 3, Maintenance for Service Schedule II
General Information 00
Vehicle Maintenance Schedule Table: 00–03
47X and 49X Maintenance Manual, October 2020 00/7

The Initial Maintenance table lists all maintenance
operations that are to be performed at the initial
maintenance (IM) interval. Maintenance operation
numbers are reference numbers used to help you
find detailed instructions in this manual on the main-
tenance operations to be performed. All operations
listed in the table, along with the operations listed in
the applicable M1 maintenance interval table, must
be performed to complete the initial maintenance
(IM).
Maintenance
Operation Number Initial Maintenance (IM) Operations for Service Schedules I and II Check
00–05 Perform all M1 Operations
31–03 Frame Fastener Torque Check
32–02 Suspension U-Bolt Torque Check
33–04 All-Axle Alignment Check
42–12 Bendix Automatic Drain Valve Operating and Leakage Tests*
47–03 Fuel Tank Band-Nut Tightening
*The automatic drain valve should be inspected every 6 months or 1500 operating hours, whichever comes first.
Table 4, Initial Maintenance (IM) Operations for Service Schedules I and II
General Information00
Initial Maintenance (IM) Operations: 00–04
47X and 49X Maintenance Manual, October 202000/8

The M1 Maintenance Interval Operations tables list
all maintenance operations that are to be performed
at the M1 maintenance interval. Maintenance opera-
tion numbers are reference numbers used to help
you find detailed instructions in this manual on the
maintenance operations to be performed.
IMPORTANT: After performing all operations listed in
this table, perform all daily, weekly, and monthly
maintenance operations listed in the Pre- and Post-
Trip Inspections and Maintenance chapter of the
Western Star 47X and 49X Driver’s Manual.
Maintenance
Operation Number M1 Maintenance Interval Operations for Service Schedules I and II Check
13–01 Air Compressor Inspection
25–01 Clutch Release Bearing Lubrication*
31–01 Fifth Wheel Inspection
31–02 Fifth Wheel Lubrication
33–05 Steer Axle Hub Cap Vent Plug Inspection
40–01 Wheel Nut Check
40–02 Tire Check
41–01 Driveline Inspection
41–02 Driveline Lubrication
42–02 Bendix Air Dryer Desiccant Replacement (with an oil-coalescing desiccant cartridge)†
42–05 Brake Inspection
42–06 Dana Spicer, Haldex, and Gunite Slack Adjuster Lubrication
42–07 Meritor Camshaft Bracket Lubrication
42–10 WABCO System Saver Air Dryer Desiccant Cartridge Replacement
42–11 Versajust Slack Adjuster Inspection and Lubrication‡
42–12 Bendix Automatic Drain Valve Operating and Leakage Tests§
47–01 Fuel Filter Replacement
47–02 Fuel/Water Separator Element Checking and Replacement
49–01 Exhaust System Inspection (noise emission control)
60–02 Cab Shock Absorber Bracket Torque Check
60–03 Aerodynamic Component Inspection
83–03 Battery-Powered HVAC System (BPHS) Inspection
*On vehicles equipped with Detroit transmissions, the release bearing does not need to be lubricated. On vehicles equipped with Eaton Fuller UltraShift PLUS
transmissions, lubricate the release bearing every 50,000 miles (80 000 km) or 3 months.
†If equipped with an oil-coalescing desiccant cartridge, replace the cartridge once a year, regardless of mileage. Otherwise use the M3 maintenance interval.
‡Complete this procedure every 25,000 miles (40 225 km), 3 months, or 500 operating hours, whichever comes first.
§The automatic drain valve should be inspected every 6 months or 1500 operating hours, whichever comes first.
Table 5, M1 Maintenance Interval Operations for Service Schedules I and II
General Information 00
M1 Maintenance Interval Operations: 00–05
47X and 49X Maintenance Manual, October 2020 00/9

The M2 Maintenance Interval Operations tables list
all maintenance operations that are to be performed
at the M2 maintenance interval. Maintenance opera-
tion numbers are reference numbers used to help
you find detailed instructions in this manual on the
maintenance operations to be performed. Perform all
M1 maintenance interval operations at the M2 main-
tenance interval.
Maintenance
Operation Number M2 Maintenance Interval Operations for Service Schedules I and II Check
00–05 Perform All M1 Operations
15–01 Alternator, Battery, and Starter Check
20–01 Pressure Relief Cap Check
20–03 Fan Clutch Check (noise emission control)
25–02 Fluid Level Check, Hydraulic Clutch Control
26–01 Detroit™Automated Transmission Fluid Change and Magnetic Plug Cleaning
26–02 Detroit™Automated Transmission Fluid Level Inspection
26–04 Eaton Fuller Transmission Fluid Level Inspection
26–05 Eaton Fuller Manual Transmission Air Filter/Regulator Check, Cleaning, or
Replacement
32–01 Suspension Inspection
32–02 Suspension U-Bolt Torque Check
33–01 Knuckle Pin Lubrication*
33–02 Tie Rod Inspection
33–03 Tie Rod Lubrication*
35–02 Axle Breather and Axle Lubricant Level Inspection
42–01 Air Brake System Valve Inspection
42–03 Air Dryer Inspection
42–04 Alcohol Evaporator Cleaning and Inspection
42–08 Meritor Slack Adjuster Lubrication
46–01 Drag Link Inspection
46–03 Power Steering Fluid Level Inspection
46–04 Power Steering Gear Lubrication
54–01 Trailer Cable Inspection and Cleaning
60–01 Mirror Folding Check
60–04 Baggage Door and Sleeper Access Door Release Cable and Latch Lubrication
83–01 Air Conditioner Inspection
83–02 Air Filter Replacement
*For Schedule I vehicles with Detroit axles, complete this procedure once a year or every 25,000 miles (40 000 km), whichever comes first.
Table 6, M2 Maintenance Interval Operations for Service Schedules I and II
General Information00
M2 Maintenance Interval Operations: 00–06
47X and 49X Maintenance Manual, October 202000/10