Western Star Trucks Bodybuilder Book Manual

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This manual is a source of basic information for body and equipment manufacturers, and dealers who install their products on Western Star Heavy Duty truck chassis. Information on brake systems, electrical circuits, and chassis layout are included. This information is not intended for use by anyone who does not have substantial technical expertise in the design and manufacture of motor vehicles and motor vehicle equipment.

TABLE OF CONTENTS :

01-A. Air & Electrical Systems
01-B. Technical Schematics
01-C. Front Wall Pinout Charts
01-D. Engine Interfacing Systems
02. Exhaust Systems
03. Frame Components
04. Powertrain
05. Chassis Components
06-A. 4700-4800 Model
06-B. 4900 Model
06-C. 4900-6900XD Model
06-D. CAD Data
07. Cab Information
08. Suspension Systems
09. General Information

MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
Total Pages : 265

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Western Star Bodybuilder Book (Revision 3.1)

01-A. Air & Electrical Systems
Electrical Harness Information 1A-2
Dash Mount Device Prep 1A-3
Backup Camera and Backup Radar 1A-4
Power Cutoff Switches 1A-5
PNDB Power Net Distribution Box 1A-6
Power Train – Power Distribution Module 1A-7
WST Gauges & RX Module 1A-8
2007 Star Gauge System 1A-9
2010 Star Gauge System All LHD Models 1A-10
2010 J1939 Connection All LHD Models 1A-11
Fuse and Relay Blocks 1A-12
4700 In Cab Body Builder Connections 1A-13
4700 SF/SB Cab Passthrough & Floor Track 1A-14
Dash Switches 1A-15
Switch Options – All Models
Specific Switch Types 1A-16
Specific Switch Labels – Actuators 1A-17
Specific Switch Labels – Lighting 1A-18
Specific Switch Labels – Body 1A-19
Utility Lights – Model Specific Availability 1A-20
Lighting Mods and Harness Repair – All Models 1A-21
Daytime Running Lights – Discon/Recon 1A-22
4800/4900/6900 Tail Light Configurations 1A-23
4800/4900/6900 Tail Lights 1A-24
4700 DCC Tail Lights 1A-25
WST Air System – All Models 1A-26
4800/4900/6900 Airline Numbering 1A-27
Air System – In Cab Lines – All Models 1A-28

01-B. Technical Schematics
Frequently Asked Electrical Questions 1B-2
Harness/Schematic Location Information 1B-3
47/48/49/69 Main Chassis Harness Schematic 1B-4
Chassis Harness Break Out Locations 1B-5
Chassis Max Complexity Harness
All LHD EPA 2010 Models: Front Wall Fwd 1B-6
All LHD EPA 2010 Models: Under Cab Rear 1B-7
4700/4800/4900/6900 Main Cab Schematic 1B-8
4700/4800/4900 LHD PTO Schematic 1B-9
4800/4900 LHD PTO Schematic 1B-10
4800/4900 Remote Fast Idle 1B-11
4800/4900 Remote Start Stop 1B-12
48/49/69 Engine Remote Interface – EOF
End of Frame Engine Remote Interface – 148-071 1B-13
End of Frame Engine Remote Interface – 148-035 1B-14
Exterior Cab Body Builder Connections 1B-15
4800/4900/6900 Plow Light Prep 1B-16
4700 10 AMP Switches & In Cab Connections 1B-17
4700 Body Builder Cab Access Port 1B-18
4700 Body Builder Interface 1B-19
Speed Sensor Connections Interface 1B-20

01-C. Front Wall Pinout Charts
FNT Wall Pin Out Chart Overview 1C-2
LHD 2014 48/49/6900 Main Chassis Bulkhead 1C-3
LHD 2014 48/49/69 FNT Wall 76 Pin Bulkhead 1C-4
LHD 2014 48/49/69 Engine 76 Pin Bulkhead
Detroit HDEP 1C-5
Cummins ISX 1C-6
LHD 2014 4700 Main Chassis 76 Pin Bulkhead 1C-7
LHD 2014 4700 FNT Wall 76 Bulkhead 1C-8
LHD 2014 4700 Engine 76 Pin Bulkhead 1C-9
LHD 2014 4700 Options 76 Bulkhead 1C-10
LHD 2014 4700 Engine 76 Pin Bulkhead 1C-11
LHD ‘06-‘12 48/49/69 Main Chassis Bulkhead 1C-12
LHD ’06-’12 48/49/69 FNT Wall 76 Pin Bulkhead 1C-13
LHD ’06-’12 48/49/69 Engine 76 Pin Bulkhead 1C-14
RHD 2011 ADR11 Main Chassis 76 Pin Bulkhead 1C-15
RHD 2011 ADR11 Front Wall 76 Bulkhead 1C-16
RHD 2011 484969 ADR11 Engine 76 Pin Bulkhead
Detroit HDEP 1C-17
Cummins ISL 1C-18
RHD 2014 4700 Main Chassis 76 Pin Bulkhead 1C-19
RHD 2014 4700 Front Wall 76 Pin Bulkhead 1C-20
RHD 2014 4700 Engine 76 Pin Bulkhead
Detroit HDEP 1C-21
Cummins ISL 1C-22

01-D. Engine Interfacing Systems
Additional Switches (SC 329)
Not Wired All Models 1D-2
Routed In Chassis All Models 1D-3
Prewired in Floor Track 4700 Models Only 1D-4
RPM Control (SC 148) 1D-5
Engine Remote Interface Location (SC 163) 1D-6
Speed Limiters
Maximum Road Speed Limiting (SC 79A) 1D-7
Cruise Control (SC 79B) 1D-8
Driver Fuel Economy Incentive (SC 79C) 1D-9
Engine Control
Low Range Torque Protect (SC 79E) 1D-10
Idle Shut Down (SC 79G) 1D-12
PTO Shutdown (SC 79J) 1D-14
PTO Mode Engine RPM Limit & Throttle Override (SC 79K) 1D-15
PTO Mode Brake Override & PTO Mode Clutch Override (SC 79M) 1D-16
PTO RPM with Cruise Set Switch (SC 79P) 1D-17
PTO RPM with Cruise Resume Switch (SC 79Q) 1D-18
PTO Mode Cooling Fan Enable & PTO Mode Cruise-RPM Increment (SC 79R) 1D-19
PTO Mode Cancel-Vehicle Speed & PTO Governor Ramp Rate (SC 79S) 1D-20
PTO Mode DPF Regeneration & Remote PTO Number of Speeds (SC 79W) 1D-21
Remote PTO Speed Setting 1 & 2 (SC 79X & 79Y) 1D-22
Remote PTO Speed 3 Setting (SC 79Z) 1D-23
Alternate Road Speed Limit 1 & 2 (SC 80A & 80B) 1D-24
Engine Brake With Cruise Control (SC 80C) 1D-25
Dynamic Fan Braking & PTO Mode Minimum RPM (SC 80E & 80G) 1D-26
Auto Elevate (SC 80L-001) 1D-27

02. Exhaust Systems
Detroit Diesel ATS Availability by Model 2-2
Cummins ATS Availability by Model 2-3
Exhaust System per Vehicle Service 2-4
Right Hand Under Step Single Vertical Outlet
016-1C1 – Daycab 2-5
016-1C2 – Daycab 4800/4900 DD13/15/16 2-6
016-1C2 & 016-1E2 – Daycab 4700 DD13 2-7
4700/4900 Cummins 16-1C2 DAYCAB 2-8
Right Hand Under Step Horizontal Outlets
4700/4800/4900 016-1C3 DAYCAB 2-9
016-1C3 DAYCAB 2-10
Right Hand Under Step Dual Vertical Outlets
4900SF 016-1C4 Daycab Cummins and DDC 2-11
4900 “Lowmax” 016-1D9 DAYCAB 6″ Outlets 2-12
Right Hand Vertical ATS with Vertical Outlets 2-13
RH Frame Mounted Horizontal/Vertical 2-14
Cummins Horizontal RH Discharge Tail Pipe 2-15
RH Horizontal Mid Chassis Mount 2-16
Cummins LH or RH Discharge Tail Pipe 2-17
RH Horizontal/Horizontal 2-18
GHG17 Cummins Exhaust Installations
4700SF – 016-1C2, 016-1C3 New! 2-19
4700SB – 016-1C0, 016-1C2, 016-1C3 New! 2-20
4900SF – 016-1C2, 016-1C3, 016-1C4 New! 2-21
4900SB – 016-1C2, 016-1C4 New! 2-22
4900SB Tandem Steer – 016-1DH New! 2-23

03. Frame Components
4700 Main Frame Rail 3-2
4800/4900/6900 Main Frame Rail 3-3
4800/4900/6900 Frame Inner & Outer Liners 3-4
All Models Frame Height Calculation 3-5
All Models Frame Slope Calculation 3-6
Basic 4700 Design Parameters 3-7
Basic 4800 Design Parameters 3-8
Basic 4900 Design Parameters 3-9
Basic 4900XD Design Parameters 3-10
Basic 6900XD Design Parameters 3-11
4700 Front Frame Options
4700 SF Cast Drop Frame 3-12
4700 SB Stamped Front Frame 3-13
4700 SB Bolt-on Front Frame 3-14
4700 SF/SB Front Frame Extensions 3-15
4800/4900/6900 Front Frame Options
SF/SB Drop Frame Non Logger 3-16
4800/4900 SF/SB – Drop Cast Logger Bumper & Flush Mount Tow Pin 3-17
4800/4900 Non Logger Front Frame Extensions
Frame Extensions 12” and Under 3-18
Frame Extensions Over 12” 3-19
48/4900 SB Snow Plow Reinforcement 605-043 3-20
All Models Basic Crossmember Layout 3-21
Midship Crossmembers
4700 SF/SB 3-22
4800/4900/6900 SF/SB 3-23
End of Frame Crossmembers
4700 SF/SB Standard Rear Crossmembers 3-24
4700 SF/SB Clevis Tow Crossmembers 3-25
4700 SF/SB Drop Centre Towing Crossmembers 3-26
4800/4900/6900 SF/SB Standard Rear Crossmembers 3-27
4800/4900/6900 SF/SB Drop Centre Towing Crossmembers 3-28
4800/4900/6900 SF/SB C-Channel Crossmembers 3-29

04. Powertrain
Engine Cooling Charts 4-2
PTO Selection Guide
Sizing, Mounting, Locations, Output & Drive Options 4-3
Power/Torque Calculations & Application Recommendations 4-4
Speed Control Via Engine 4-5
Engagement and Disengagement Control 4-6
DD13 GHG17 Curve 4-7
PTO Compatibility Criteria 4-8
Transmission PTO Compatibility Matrix
4700 SF/SB – Allison 4-9
4700 SF/SB – Eaton Fuller 4-10
4800/4900SB AWD – Allison & Eaton Fuller 4-11
4900SB – Allison & Eaton Fuller 4-12
4900SF – Allison & Eaton Fuller 4-13
4900XD – Allison & Eaton Fuller 4-14
4900SF/SB – Allison & Eaton Fuller With Front Frame Extension 4-15
6900XD – Allison & Eaton Fuller 4-16

05. Chassis Components
Chassis Frame Grid 5-2
WST Chassis Air Tanks Overview 5-3
WST Chassis Air Tanks – 4800/4900/6900 5-5
DCC Chassis Air Tanks – 4700 5-6
Fuel/Hydraulic Tanks – 4700/4800/4900/6900 5-7
4800/4900 SF/SB DEF & Fuel Tank Locations 5-8
4800/4900 DEF Tank Mounting 5-9
4700 SF/SB 13 Gallon DEF Tanks 5-10
4700 SF/SB 6 Gallon DEF Tank Locations 5-11
4700 DEF Tank Relocation Prep 5-12
4700 Rectangular Fuel Tanks 5-13
2010 EPA – 48/49/69 Batt/Tool Box Configs 5-14
2010 EPA – 4800/4900 Battery/Tool Box 5-15
4700/4800/4900/6900 In Cab Battery Box
290-1AC Single and Double Person Box Mounting 5-16
2 Person Passenger seat battery box vented to outside of cab 5-17
Pre-2010 EPA – Battery/Tool Box 5-18

06-A. 4700-4800 Model
4700SF – 110 BBC – Standard Cab 6A-2
4700SB – 110 BBC – Standard Cab 6A-3
4700SB AWD – 110 BBC – Raised Cab New! 6A-4
4800SF – 109 BBC – Standard Cab 6A-5
4800SB – 109 BBC – Standard Cab 6A-6
4800SB – 109 BBC – Raised Cab 6A-7
4800SB AWD – 109 BBC – Raised Cab New! 6A-8
4800SB TS – 109 Tandem Steer Standard Cab 6A-9
4800SF TS – 109 Tandem Steer Raised Cab 6A-10

06-B. 4900 Model
4900SF – 123 BBC 6B-2
4900SB – 123 BBC 6B-3
4900SB TS – 123 BBC 6B-4
4900SF LowMax – 123 BBC Car Hauler 6B-5
4900SF EX – 132 BBC 6B-6

06-C. 4900-6900XD Model
4900XD – 123 BBC
Butterfly Hood & On Road Aluminum Fenders (644-037) 6C-2
Fiberglass Hood with Tier 3 Steel Fenders (644-037) 6C-3
6900XD – 141 BBC
Tilt Hood (644-037) 6C-4
Butterfly Hood (644-043) 6C-5
Tandem Steer 6C-6

06-D. CAD Data
2D Bodybuilder Diagram – Serial Specific 6D-2
3D Bodybuilder Model – Serial Specific 6D-3
2D & 3D Generic Bodybuilders 6D-4
SWAN Account 6D-5
SWAN Usage 6D-6

07. Cab Information
Interior Cab Dimensions 7-2
Seat Measurements 7-3
Sleeper Interior Dimensions 7-4
Glass Dimensions 7-5
Cab Exterior Dimensions 7-6
Sleeper Exterior Dimension 7-7
Cab Height/Engine/Radiator Combinations 7-8

08. Suspension Systems
Front Axles Beam Drop All Models 8-2
Front Suspension Ride Heights
4700 DDC Chassis 8-3
4800/4900/6900 WST Chassis 8-4
Rear Suspensions
Airliner 23k# Single With Chain Clearance 622-126 8-5
Airliner Tandem 622-005/199/218 8-6
Airliner 46k# Tandem With Chain Clearance 622-108 8-7
Airliner 69k# Tridem 622-223 8-8
Chalmers 854 Series 40k# Tandem 622-080/251 8-9
Chalmers 854 Series 46k# Tandem 622-060/248 8-10
Haulmax 40k# & 46k# Tandem 622-1E8/1E7 8-11
Hendrickson HN 46K# Tandem 622-269 8-12
Hendrickson Primaax 46k# Tandem 622-1H2 8-13
Hendrickson R650 65k# Tandem 622-1EB 8-14
Hendrickson RS463 46k# Tandem 622-1CE 8-15
Hendrickson RT-Series 40k#-50k# 622-1CH/1CN/1CJ/1CP/1CK/1CR 8-16
Hendrickson RT650 65k# Tandem 622-051 8-17
Hendrickson RS650 Walking Beam 65k# Tandem 622-052 8-18
Hendrickson Haulmaxx 40k# & 46k# Tandem 622-1E7/1E8 8-19
Neway AD252 Air Ride 23k#-78k# 622-189/188/231/1FT/195/1D9 8-20
Reyco Spring 23k#-31k# Single 622-138/079/139/1B7 8-21
TufTrac 40k#-50k# Tandem 622-1E3/286/1A1 8-22
Pusher/Tag Axle Frame Space 8-23
Pusher/Tag Suspensions
Hendrickson HLUC2 035-067/061 8-24
Watson & Chalin SL-800 8k# 035-064 8-25
Watson & Chalin RSL-1100 Reversible Tru-Track 13.2k# 035-016 8-26

09. General Information
General Disclaimer 9-2
EPA Emissions 9-3
Label Location and Attachment Requirements 9-5
FMVSS and CMVSS Requirements 9-6
Western Star VIN Coding 9-9
Center of Gravity and Air Accessories 9-10
Vehicle Rollover Stability 9-11
Truck and Body Equipment Installation 9-12
Truck and Body Mounting Methods 9-16
Corporate Support Contact Information 9-19

 

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Western Star Trucks Bodybuilder Book Manual.pdf

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