01Air-Elect Feb2015 PDF
01Air-Elect Feb2015 PDF
01Air-Elect Feb2015 PDF
1A
Power Distribution Module (PNDB) 1A-5
RX Module 1A-6
2007 Star Gauges 1A-7
2010 Star Gauges 1A-8
2010 J1939 Connections 1A-9
Fuse & Relay Blocks 1A-10
In Cab Body Builder Connections 4700 with PDM 1A-11
4700 Cab Electrical Pass Through Details 1A-12
Additional Switch Package 1A-13
Optional Switch Types 1A-14
Optional Switch Facings
Air and Electrical WST Air System
1A-17
1A-18
Air Line Numbering
Systems Air System - In Cab Schematic All LHD
1A-20
1A-21
Utility Lights 1A-22
Version - Rev (2.3) Lighting Modifications 1A-23
WST Tail Light Configurations 48/49/6900 1A-25
WST Tail Light Configurations 4700 1A-26
This guide is to be used as a reference document only. Please consult your Western Star CAE representative
on specific specing needs as the information contained in this document can change without notice.
AXLE
WIRING
INTERLOCK
MOD 87B
AXLE TEMP
MOD 865
FRONTWALL
HARNESS
MOD 321
TRAILER
ENGINE HARNESS WIRING
MODULE PRIMARY
286 / 283 TRAILER CBL
MOD 296
ADDITIONAL
LIGHTING MAIN CHASSIS PRIMARY
HARNESS
EXT. LIGHTS MOD 303
MOD 288
MOD 318 / 31J SUPPLEMENTAL
CABLE
BEACON MOD 308
LIGHTS
MOD 327 ADDITIONAL
SUPPLEMENTAL
FORWARD MOD 334
CHASSIS &
POWER WIRING Power Net Distribution PTO
SIGNAL Box (PNDB)
312 / 314 MOD 372 / 885
ALTERNATOR BATTERY
315 / 310 ROUTINGS CABLES
MOD 125 MOD 291
POWER JUMPSTART
WIRING MOD 295
MOD 29A BATT
CAB POWER SHUTOFF
MOD 926 MOD 293
Page 1A-1
Rev (2.3) - Feb 2015
Dash Mount Device Prep
1U1-001 TOP OF DASH NAVIGATION PREP WITH POWER AND GROUND
Western Star now offers a Top dash mount Navigation Prep. This new option provides
a standard bolt pattern in the dash for a 1 RAM ball mount system or other camera mount equipment.
These mountings allow customers to quickly mount a variety of electrical devices ranging from navigation
systems to cell phone holders in a road legal and easily accessible location without drilling the dash.
Mounting solutions for most devices can be found on the RAM websit.
Navigation and Camera systems can be consistently mounted to factory installed mounts with no cab modifications.
This industry leading solution allows customers to easily upgrade to new systems as fast as they become available
to the market.
The Nav prep system is superior to in dash navigation as it allows owners or drivers to easily add their own
devices such as Iphones for hands free and navigation or full navigation and backup systems. Todays technolodgy
is moving quicker than in dash systems can keep up with. Using the Western Star Navigation prep your equipment
can be easily upgraded to the latest hardware in minutes.
1 7/8 dia
22.8mm dia
120
Dash Mounted
Power Receptical
Mates to Main
Fuse Block
Exterior battery mounted switches will be offered in the locking configuration only.
Cutoff switches are equipped with red LED lights, which are illuminated when power is on.
X1, Main PNDB
Trucks equipped with the body builder auxiliary power system will have an additional LED light on the switch.
Note:
1. Both PNDB units will be deactivated when the switch is in the off position.
2. Positive disconnect switches do not isolate the starter.
MIDI Fuse
Output
300Amp Max
ATC Fuses
Power Net Distribution Box (PNDB)
ATC -D
The PNDB is a new power delivery system for the ATC -C
WST and is designed to deliver more consistent and better ATC -B Primary
protected battery power to the other components ATC -A Solenoid
on the truck. for Cut off
Switch
ATC Fuse
The PNDB also has protected keep alive circuits that will Output
maintain power even with the cutoff switch in the off position.
The primary reason for this change is to provide power to the Battery
2010 DEF purge system which drains urea from the delivery Input
Primary Solenoid
system and prevents the system from freezing during cold Cut Off Switch
conditions. Connection
Page 1A-5
Rev (2.3) - Feb 2015
Power Train Power Distribution Module (PT-PDM)
Module 286
The power which supplies the PT-PDM is sourced from the Power Net Distribution Box (PNDB).
This power is protected by a 175A fuse. It is important to note that the PNDB holds the bi-stable
relay, which disconnects the battery when the relay is turned off power at the PNDB output.
PT-PDM power is not maintained by the alternator if the disconnect switch is "thrown".
therefore the engine ignition relay, in the PT-PDM will fall out and the engine will turn off.
The source of the ignition signal, on a WST, is Fuse F33_LD which is in the optional fuse
block in the dash of the Western Star.
The sole purpose of this line is to turn on the PT-PDM relay which then powers ignition
for all the engine related ignition circuits.
Page 1A-6
Rev (2.3) - Feb 2015
RX Module
3
WST Star Gauge System 87340-4403
Data Star
Beginning in April 2005, the PX and PX-A modules
Star Gauges 2
were replaced by air lines that are routed to each
individual Star Gauge. These gauges convert the air 87340-4404
pressure into an electrical signal. The Star Gauge
databus supplies power, ground, and backlighting Star Gauges are secured in place with a lock ring,
information for these gauges. which can be removed easily using a removal key
that fits into the lock ring. These tools can be ordered
Beginning with EPA10 vehicles, the engine controller through your WS dealership
no longer offers a J1587 databus. The engine,
transmission, ABS, and most of the other optional 2 Gauge removal tool 87340-4404
electronic devices on the vehicle now communicate using 3 Gauge removal tool 87340-4403
J1939 protocol.
24 to 12 Volt Converter
Star Gauges
Electronic Control Center(ECC) Function slave Gauges read information
supplied by Speedometer outputs
and display information to driver
Page 1A-8
Rev (2.3) - Feb 2015
2010 Star Gauge System All LHD Models
Electrical Star Gauges
Function slave Gauges read information
supplied by Speedometer outputs
and display information to driver
Air Line
J1939
2010 Resistive (RX) Module
2010 RX Module acts as a gateway to
convert J1939 engine and system inputs
J1939 into WST Star Gauge databus signal
J1939
Air Line
J1939
Page 1A-9
Rev (2.3) - Feb 2015
2010 J1939 Connection All LHD Models
The J1939 Datalink
J1939 Connections
Tying into the J1939 backbone is accomplished by tapping into the system
using the terminating resistor tees located at each end of the backbone
Front Wall
The Chassis terminating resistor is located in a tee along the left frame
Engine connection rail, usually behind the cab.
40 pin 48/49/6900
76 pin 4700 The cab terminating resistor is located in the dash tapped 10 back from the
Front Wall engine plug harness under the dash (shown on the left).
The correct datlink resistence measured at any device, or at the diagnostic
plug should be 60 ohmes with the battery disconnected.
IMPORTANT:
Resistor Receptor - It is essential that both terminating resistors remain
Part FTL# 23-13303-902 connected to the ends of the J1939 backbone to dampen feedback signals.
Deutsch # DTM04 - 2P - EP10 Numerous J1939 problems can be attributed to terminated resistors are
missing or disconnected.
- If connections under dash become disconnected. Connections should
never be reconnected back together directly IE ABS with ABS as this creates an
independent circuit in the system that is not connected to the backbone.
Page 1A-10
Rev (2.3) - Feb 2015
Fuse and Relay Blocks
Fuse Fuze
Wire Code LN Function
Location Rating
F1 10A BA3H-10 Start Switch
F2 20A Bus Bar Par Lights R - 15 R - 14
F3 8A BA03Y-10 Headlight Switch LN LD LN LD LN LD
F4 10A BA03K-10 Radio 21 11 1 Relays
The WST Fuse panel is equipped with 30 fuses,14 relays and 18
power jumpers. The fuse and relay locations are standard as F5 20A BA03N-10 ECC Flasher R-7 R-1
shown buy may be changed by engineering to accommodate new F6 20A BA03K-10 Interior Lights Accesory 212 12 2 Ignition
designs. Refer to the Main Cab Harness schematic in Mod 320 F7 20A BA03N-10 Wiper Motor Power
to find the specific information on these items. The fuse panel Power
F8 30A BA03U-10 Brake Light
23 30 3
jumper slots provide for 18 additional power jumpers; R-2
which provide power. F9 10A BA25A-12 Electric Horn R - 127
Heater 24 146 4 Horn
F10 30A BA03T-10 Option Battery Fuse Relay Fuses
Relay
F11 15A BA03U-10 Tractor Markers 25 44 5
Relay F12 30A BA03B-10 Trailer Markers
R-9 R-3
Battery 27 45 6 Tractor
F30 5A Bus Bar ECC Battery Signal Marker
F146 15A Bus Bar DRL Power Release 18 15 17 Lights
F44 15A BA25A-12 ABS ECU Batt Power R - 10 R-4
19 16 8 Trailer
Fuse F45 10A IG03H-10 ABS ECU Ign Power High Marker
F15 20A IG03K-10 Backup Lamp Beams Lights
29 47 9
F16 30A IG03B-10 Option Ing Power R-5
Jumper Harness R - 11
F47 20A IG03H-10 Air Dryer 28 20 10 Spare or
used with optional Low Fog
Fuse Pannel F20 5A IG03J-12 ECC Lightbar Beams 16 13 10 7 4 1 Lights
F21 15A AC02A-10 Radio
F212 25A Bus Bar Sleeper R-6 17 14 11 8 5 2 R--
F23 20A AC02B-10 Htd Mirror/lighter Park Spare
F24 5A Bus Bar Wiper Switch Lights 18 15 12 9 6 3
Main Fuse Panel F25 20A AC02B-10 Opt Accessory Fus
F27 30A Bus Bar Cab Heater Jumpers
Optional Fuse/Relay Panel
F18 10A Bus Bar RHS Low Beam
Optional fuse panels are used to support additional switches and F19 10A Bus Bar LHS Low Beam Main Fuse/Relay Pannel
other custom options. The WST system is designed to support up F29 15A Bus Bar RHS High Beam
to 20 Fuses and 11 relays. Additional fuse blocks and switches
can be ordered for customer use, see the Switch page for more F28 15A Bus Bar LHS High Beam
information.
Mounting Hole
10-24
Fuse block quantity Relay
Fuse Cavity
will change based Qty (4)
on the amount of
extra switches
ordered
Page 1A-12
Rev (2.3) - Feb 2015
4700 SF/SB In Cab Floor Track System and Cab Passthrough Connections
Included with 329-1AU, 329-1AV, 329-1AW, 329-1AX, 329-064
329-068, 329-072, 329-076 and 353-060 Options
**See section 1B page 1B-17 for installtion tips and schematics**
In dash
interface harness
connections
Air Lines
Cab floor
access panel
C
L Cab
In Cab
Cab Floor access PDM Unit 353-060
Pre cut Vehicle interface
Easy Access Unit
floor mats
Floor Plate
Page 1A-13
Rev (2.3) - Feb 2015
Additional Switch Package Options
Indicat Indicat
Part Switch Graphics Part Switch Graphics
Label Description or type Label Description or type
Specific Switch Labels: Number
Light
Type yes/No Number
Light
Type yes/No
Page 1A-16
Rev (2.3) - Feb 2015
Optional Switch Facings
Lighting Application Switches All Models
Part Indicator Switch Graphics Part Indicator Switch Graphics Part Indicator Switch Graphics
Label Description Type Label Description Type Label Description Type
Number Light Type Yes/No Number Light Type Yes/No Number Light Type Yes/No
7830-7006 CHUTE UNLOCK/LOCK/REMOTE Yes 3 N Body 7830-3447 PUP PIN Yes 2 N Body 06-74457-000 SHUTDOWN OVERRIDE No 2 Body
7830-7035 DOLLY LOCK Yes 2 N Body 7830-7013 SANDER DOOR Yes 2 N Body
06-73289-000 DUMP REAR Yes 2 N Body 7830-3474 TAIL GATE Yes 2 N Body
Simple Text 7830-7041 GROUND SPEED Yes 2 N Body 7830-7026 TRUCK T/GATE No 2 N Body
Switch 7830-3494 SANDER FRONT Yes 2 N Body 7830-7024 TRUCK TARP No 2 N Body
7830-3495 SANDER REAR Yes 2 N Body 7830-7060 TURNTBL LOCK IN/OUT Yes 2 N Body
Page 1A-18
Rev (2.3) - Feb 2015
WST Air System All Models
880
140
H
in dash manifold 7A
8
8A
9
CHAMBER, SERVICE, WEDGE
CHAMBER, SERVICE, PARK , CAM
CHAMBER, SERVICE, PARK WEDGE
880
141
H
B S D E
21
10
880 ... B
RELAY VALVE DUAL SUPPLY ( 5.5 PSI CRACK )
149 EXH
11 RELAY VALVE DUAL SUPPLY ( 4.0 PSI CRACK ) B
880
manifold 16
17
18
TEE
AXLE TEE
PARK CONTROL VALVE SYSTEM
S
B
SYSTEM
S
S
871
D D
19 TPV CONTROL - TRAILER AIR SUPPLY
20 TPV (TRACTOR PROTECTION VALVE) S
S 42
Item Number 21
22
23
HAND CONTROL VALVE
SPRING BRAKE / INVERSION VALVE D
A
SYSTEM D
S
138
ABS PMV ( PRESSURE MODULATION VALVE )
24 ATC ( ABS ANTISPIN VALVE )
43/27 42
27 DRAIN COCK
N.STREHL 06/28/05
TO ASME STA NDARD Y1 4.5M-1994, WITH
EXCEPTIONS PER FREIGHTLINER EOSM 09E0K17. A
IF PASS THROUGH IS FULLY POPULATED
728B1-3509
1/8 NONE 06/28/05 B.BAER 06/28/05
41 BP-R1 ( BOBTAIL VALVE ) 2 TO PRESSURE PROTECTED AIR SUPPLY
M.MAHLER
DESCRIPTION
ITEM NUMBER
DESCRIPTION
5/32 WST MODELS,CAB AIR PIPING
728B1-3509 B 1 OF 1
8 7 6 5 4 3 2 1
Lighting Harnnes
Page 1A-19
Rev (2.3) - Feb 2015
4800/4900/6900 Airline Numbering Circuits 1 to 100
the colored air lines will have no number labels. Where 12 (BC Air only) - brake valve supply to front chamber
61
62
(BC Air only) - park brake control D to pressure holding valve
(BC Air only) - park brake control D to tractor park brake control
a black line is used number labels are used to identify 13 (BC Air only) - front axle quick release valve supply to frame 63 (BC Air only) - dry tank B supply to brake valve
which lines go to different places on the chassis these 14 Supply - deep reduction control 64 (BC Air only) - control rear-rear axle relay
numbers correspond to the circuit numbers in the 15 Trailer service 65 (BC Air only) - front axle drop lines to brake chambers
schematic drawings. All black and wire braid lines 16 Trailer emergency 66 (BC Air only) - supply to reservoir gauge & wig wag
connecting to the cab will be labeled with a line number 17 (BC Air only) - forward rear axle tee supply to service chamber 67 (BC Air only) - supply to front brake application gauge
on both the cab sides and the chassis line in an area 18 (BC Air only) - relay valve supply to rear axle quick release valve 68 (BC Air only) - pressure holding valve to tractor protection valve S
where no paint or over spray will cover them up. 19 (BC Air only) - rear-rear axle tee supply to service chamber 69 Not yet assigned
20 (BC Air only) - cab manifold to control valve - dry 70 Not yet assigned
21 (BC Air only) - hand control valve to trailer service 71 Not yet assigned
22 (BC Air only) - tractor protection control supply to trailer emergency 72 Not yet assigned
Color designated Lines 23 (BC Air only) - park control supply to frame tee 73 Not yet assigned
74 Not yet assigned
will not have line numbers 24 (BC Air only) - quick release valve to park brake chamber
25 Differential lock-out control supply to axle 75 Not yet assigned
see color/size column for more information
White 25A Differential lock-out control supply to axle
Airline Airline
Airline Number Description Airline Airline
Color/Size Number Airline Number Description
Color/Size Number
26 Deep reduction control supply to transmission
76 Not yet assigned
27 Front brake limiting control to limiting va lve
Airline numbers Supply to fifth wheel lock
77 Not yet assigned
28
on black lines 29 Supply to air shift 2-speed axle
78 Not yet assigned
79 Not yet assigned
30 Supply to air seat
80 Not yet assigned
31 Supply to windshield wiper
81 Not yet assigned
32 Supply to air horn
82 Not yet assigned
33 Supply to reservoir pressure gauge 83 Not yet assigned
34 Supply to wig wag 84 Not yet assigned
35 Signal to stop lamp switch 85 Not yet assigned
Under cab line connections 36 (BC Air only) - rear axle wedge chamber to wedge chamber 86 Not yet assigned
37 Supply to front wheel limiting control 87 Not yet assigned
38 Not yet assigned 88 Not yet assigned
39 (BC Air only) - park brake drop lines 89 Not yet assigned
40 C supply to pusher / tag relay valve 90 Not yet assigned
41 B delivery to pusher / tag relay control 91 Not yet assigned
42 Not yet assigned 92 Not yet assigned
43 Not yet assigned
Additional air line 44 Not yet assigned
93 Not yet assigned
94 Not yet assigned
ports are provided 45 Not yet assigned 95 Not yet assigned
for easy addition 46 Not yet assigned 96 Not yet assigned
(BC Air only) - low pressure governor supply
of body builder 47 97 Not yet assigned
48 (BC Air only) - emergency dump valve to tractor protection valve
controls 49 (BC Air only) - signal to trailer emergency pressure gauge
98 Not yet assigned
99 Not yet assigned
50 (BC Air only) - signal to trailer service gauge Compressor discharge
100
Cab pass through manifold
located behind driver side
dead pedal Page 1A-20
Rev (2.3) - Feb 2015
4800/4900/6900 Airline Numbering Circuits 101 to 256
LED Lighting
New LED Package Description
Mirror Arm 31K-001 (2) Chrome LED utility lights with stainless steel anti-glare shields mounted on mirror arms
Mounting pos 318-1D9 (2) Chrome swivel LED utility lights mounted LH and RH high on painted brackets back of cab
318-1E0 (2) Chrome swivel LED utility lights mounted low inboard on side extenders
High Mount 318-1E1 (2) Chrome swivel LED utility lights mounted LH and RH high on stainless steel brackets back of sleeper
Pos 318-1E2 (2) Chrome swivel LED utility lights mounted high inboard on side extenders
318-1E3 (2) Swivel LED utility lights high inboard on side extenders and (2) flush mounted back of cab/sleeper
(2) Chrome swivel LED utility lights mounted low inboard on side extenders and
318-1E4 (2) flush incandescent utility lights mounted back of cab/sleeper
(4) Utility lights: (2) chrome swivel LED mounted LH and RH high on stainless steel brackets back of sleeper and
318-1E5 (2) flush mounted incandescent back of sleeper
(3) Chrome swivel LED utility lights: (2) mounted high on painted brackets LH and RH back of cab and
High Inboard 318-1E6 (1) mounted low on painted bracket back of cab LH side
Mount Pos 318-1E7 (1) Chrome swivel LED utility light mounted LH high on painted bracket back of cab
318-1E8 (1) Chrome swivel LED utility light mounted RH high on painted bracket back of cab
Low Inboard
Mount Pos
Flush Mount
BOS pos
Page 1A-23
Rev (2.3) - Feb 2015
Lighting Modifications All Models
1. Shut down the engine, set the parking brake, and chock the tires.
2. Disconnect the negative leads from the batteries.
3. Remove the four screws that secure the instrument panel, then pull the
top of the panel forward to access instrument panel wiring.
3A. On vehicles with fixed steering columns, remove the bolts that hold the
steering column to the dash assembly to lower the steering column for access.
Turn Signal and Brake Override Circuit Elimination 4. Disconnect the light gray PECV connector from the left-hand side of the
Electronic Control Center (ECC).
Western Star Trucks turn signal switches are equipped with a brake override circuit.
This circuit is designed to deactivate the 4-way flashers when the brakes are applied. 5. Find wire labeled LB08A in cavity A10, and remove it using a connector tool.
In some vocations, customers prefer that the 4-way flashers remain flashing during 6. Tag the wire with that location for future reinstallation.
use of the service brakes. To disable this feature, the red jumper wire located in the 7. Heat shrink or wrap the terminal end of the wire with electrical tape to prevent
turn signal switch housing, used to activate this circuit needs simply to be cut and unintended connection, then secure the wire back to the harness with a tie-strap.
the ends taped or heat shrunk to remove this function. 7. Connect the PECV connector to the left-hand side of the ECC.
Both methods of wiring comply fully with Canada and USA regulations. 8. Disconnect the dark gray PECP connector from the left-hand side of the ECC.
9. Find wire labeled HL08H (this wire may also be labeled HL05B in later models)
located in in cavity G, and tag the wire with that location for future reinstallation.
Red Jumper 10. Remove the wire from the connector, wrap the terminal of the wire with
Wire electrical tape to prevent unintended connection, then secure the wire back
to the harness with a tie-strap.
11. Connect the PECP connector to the left-hand side of the ECC.
12. Position the instrument panel and install the screws. If the steering column
was lowered, position it into place, and tighten the steering column
capscrews 17 lbfft (23 Nm).
13. Connect the batteries.
14. Verify correct operation of the lights.
PECV
Connector
(Blue)
Spl -3
Black - Amber LED Panel Black Park lite Power
Page 1A-24
Rev (2.3) - Feb 2015
4800/4900/6900 Tail Lights
Fully Protected Tail lights Mounted Outside of Frame
Taillight units are fully boxed in on all sides by a
simple sturdy box housing mounted on the outside of the frame
6.5
294-054 Vsm dual sealed logger light bar mounted stop/tail/turn/backup lights
12.5
34.13 4.0
4.00
0.5
6.5
25.6 4.0
Page 1A-25
Rev (2.3) - Feb 2015
4800/4900/6900 Tail Light Configurations
Partially protected Single Unit Tail lights mounted Outside of Frame
Taillight units are protected on three sides by a
simple open box housing mounted on the outside of the frame
7.38
Vsm dual sealed inboard of rail
294-052 mounted stop/tail/turn/backup lights
Flush mounted stop/tail/backup lights
294-032 mounted below rear most crossmember Boxed tail light assembly (stop/tail/
294-1AC backup) mounted outboard of rails
Boxed tail light assembly with LED stop/tail/license and inset 4" from end of frame
294-1AJ plate lights and incandescent backup lights mounted
below rear most Crossmember
8.0
Partially protected Single Unit Tail lights mounted Under Frame LED stop/tail with separate backup lights
Taillight units are protected on three sides by a
294-060 mounted on polished aluminum plate end
of frame
simple open box housing Mounted under the end of frame
Vsm dual sealed polished aluminum
294-063 plate mounted stop/tail/turn/backup lights
294-040 Boxed tail light (stop/tail/backup) mounted below the rails
4.0
7.38
25.63 2.0
8.0
7.0
Page 1A-26
Rev (2.3) - Feb 2015
4700 DCC Tail Lights
20.6 4.7
10.3
C
L Chassis 3.0
C Frame
L
12.3
16.8
20.6
294-001 Integral stop / tail / backup lights with Deep V EOF 294-001 Integral stop / tail / backup lights with STD EOF
100mm
11.1
4.25
C Frame
L 8.5 5.0
Page 1A-27
Rev (2.3) - Feb 2015