Western Star Bodybuilder Book: Revision 3.

Table of Contents
1A
P. 1A-1

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
Section Power Train - Power Distribution Module 1A-7
WST Gauges & RX Module 1A-8

1A
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

Air & Electrical Systems Specific Switch Labels - Actuators

Specific Switch Labels - Lighting
1A-17
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

This guide is to be used as a reference document only.

Please consult your Western Star CAE representative on
specific spec’ing needs as the information contained in
this document can change without notice.
 Western Star Bodybuilder Book: Revision 3.1

Electrical Harness Information

1A
P. 1A-2

TRANSMISSION
WIRING
Engine and ABS MODULE
34B
Front Wall/ Sleeper TRANSFER CASE
MODULE
376
Main Chassis MAIN CAB HARNESS AUXILIARY
Harness MODULE TRANSMISSION
320 MODULE EOF LIGHTING
34C / 352
MOD 294

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
 Western Star Bodybuilder Book: Revision 3.1

Dash Mount Device Prep

1A
P. 1A-3

Std RAM ball

Top of dash navigation prep with power and ground mount pattern 12V power
1U1-001 - Dash Mount Device Prep

Western Star now offers a Top dash mount Navigation Prep. 1 7/8” dia
This new option provides a standard bolt pattern in the dash 22.8mm dia

120°
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
3/16” dia 50 mm dia
systems to cell phone holders in a road legal and easily
accessible location without drilling the dash. Mounting 10-32
solutions for most devices can be found on the RAM websit. 3/16” dia
Navigation and Camera systems can be consistently 10-32
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.

AWTI Camera Mounted using

common mounting pattern

Nav System Mounted using RAM Mounting

Adapters Shown Below

Dash Power Schematic

RAM B-202CHU
RAM B-201CHU

Dash Mounted
Power Receptical

Mates to Main
Fuse Block

Mates to Front Wall RAM B-202U

Ground Stud Plate
RAM B-201
 Western Star Bodybuilder Book: Revision 3.1

Backup Camera and Backup Radar

1AP. 1A-4

Camera and Radar Systems

Western Star now offers factory PDI installed camera and radar packages for
improved safety and efficiency on the job site. Chose from three different
systems using the data codes below or custom order your own configuration
from Daimler Custom Truck. All camera systems have built in looping DVR
recorders that constantly record drivers actions and surrounding environment.
Radar systems use proximity radar and tell operator how close the object is and
giv an audible alarm if objects move in to path without the drivers notice.

73H-004 PDI Installed AWTI 1 Back Up Camera With Radar System

73H-005 PDI Installed AWTI 3 Camera System ( 1 backup and 2 side cameras)
73H-006 PDI Installed AWTI 4 Camera With Radar System ( 1 Forward 1 backup and 2 side cameras)
*Note used in combination with 1U1-001to provide mounting for backup camera.
AWT07MLEDSD Dash Monitor
– 7” Heavy Duty Built-in SD Card
DVR recorder ( up to 32GB)
LED Monitor – Quad Screen Capable

AWT5000HCR-20 Radar/Camera AWT1020T Front or Rear Camera AWT2149SC36 Side Camera 42' / 10' Cable: Co-Ax Cable
– 4” Grommet Hybrid – Heavy Duty Universal Color Camera – Adjustable Side Mount Color Camera (both sides threaded)
Radar w/integrated Camera - 1/3” Sony CCD color camera w/IR for Night Vision – 1/4” Sony CCD Color Camera w/IR can be used for extension
(fits in standard 4” light cutout) – 150˚ Lens Angle
 Western Star Bodybuilder Book: Revision 3.1

Power Cutoff Switches

1A
P. 1A-5

Main Cab PNDB

Positive Disconnect Switch Connector Plug
#23-13153-307
The disconnect switch system for 2010 has been reconfigured to provide better application coverage and
provide for two levels of power disconnect based on the options ordered with the truck.

In-cab disconnect switches are offered in “locking” or “non-locking” configuration.

Exterior battery mounted switches will be offered in the locking configuration only. 1
3 2
Cutoff switches are equipped with red LED lights, which are illuminated when power is on. 4

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.
X1, Main PNDB
Negative Disconnect Switch

The negative disconnect switch option is for use in emergency and dangerous goods applications only. This
option provides a battery box disconnect between the starter and the batteries. This option is currently only
available with Detroit Diesel engine configurations.
293-058 POSITIVE LOAD DISCONNECT W/CAB MOUNTED CONTROL SWITCH MOUNTED OUTBOARD DR SEAT
293-060 POSITIVE LOAD DISCONNECT W/CAB MTD CONTROL SW W/LOCKING PROVISION MOUNTED OUTBOARD DR SEAT Lockout Tab
293-061 POSITIVE LOAD DISCONNECT W/BATTERY BOX CONTROL SWITCH WITH LOCKING PROVISION
293-057 NEGATIVE LOAD DISCONNECT FOR DDC ENGINES WITH BATTERY BOX DISCONNECT SWITCH
Auxiliary Power
and Main Power
LED

Axillary Body Builder Standard

293-058/-060/-061 Positive Disconnect Switch Cutoff Switch Cutoff Switch

293-057 Negative Battery Box Switch Standard Power LED

 Western Star Bodybuilder Book: Revision 3.1

PNDB Power Net Distribution Box

1A
P. 1A-6

Fuse Cover
Power Net Distribution Box (PNDB) and label

The PNDB is a new power delivery system for the WST and is
designed to deliver more consistent and better protected
battery power to the other components on the truck. MIDI Fuse
Output
300Amp Max
The PNDB also has protected “keep alive” circuits that will
maintain power even with the cutoff switch in the off position. ATC Fuses
The primary reason for this change is to provide power to the
2010 DEF purge system which drains urea from the delivery ATC -D
system and prevents the system from freezing during cold ATC -C
conditions. ATC -B Primary
ATC -A Solenoid
for Cut off
The PNDB located at the lower LH front wall area is equipped Switch
with three MIDI fuses which supply power to the Main Power ATC Fuse
Distribution Module. These fuse connections have been Output
relocated from the battery in 2010 to prevent corrosion and
Battery
improve the trucks reliability in severe conditions.
Input
Primary Solenoid
Cut Off Switch
Connection

INSTALLATION WITHOUT INSTALLATION WITH

DISCONNECT SWITCH DISCONNECT SWITCH
CONNECTOR PIN DESCRIPTION
1 AFTER TREATMENT ECU
X2 2 EMERGENCY POWER
KEEP ALIVE RADIO AND CLOCK
3
CIRCUIT 3 2 1
4 ALTERNATOR REMOTE SENSE
A GROUND
B SIGNAL OFF
X1 D C B A D C B A
Disconnect C LED INDICATOR
through solenoid D SIGNAL ON
control E SIGNAL RETURN
F GROUND

Fuse Description Function Rating Max. Fuse Allowed

ATC-A Keep Alive Power After Treatment ECU 30 AMPS 30 AMPS
ATC-B Keep Alive Power Emergency Power 20 AMPS 30 AMPS 1 2 3 4 A B C
ATC-C Keep Alive Power Radio and Clock 5 AMPS 30 AMPS X2
ATC-D Keep Alive Power Alternator Remote Sense 5 AMPS 30 AMPS A B C D ATC Fuse output D E F
MIDI-1 (Fuse 1) High AMP Fuse 175 AMPS 200 AMPS keeps power on
MIDI-2 (Fuse 2) High AMP Fuse 125 AMPS 200 AMPS after disconnect
MIDI-3 (Fuse 3) High AMP Fuse 125 AMPS 200 AMPS X1
Mating connector Solenoid
23-13153-410 Control
 Western Star Bodybuilder Book: Revision 3.1

Power Train - Power Distribution Module

1A
P. 1A-7

Power Train (PT-PDM) Module 286

The PT-PDM holds all of the power train related fuses and relays.

Ÿ All engine fuses/relays

Ÿ All transmission fuses/relays
Ÿ All after treatment fuses/relays except DCU main battery feed (located in PNDB)
Ÿ Sleeper power

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.
 Western Star Bodybuilder Book: Revision 3.1

WST Gauges & RX Module

1A
P. 1A-8

WST Star Gauge System

Beginning in April 2005, the PX and PX-A modules were replaced by
air lines that are routed to each individual Star Gauge. These
gauges convert the air pressure into an electrical signal. The Star
Gauge databus supplies power, ground, and backlighting information 3”
Data Star 87340-4403
for these gauges.
Star Gauges
Beginning with EPA10 vehicles, the engine controller no longer
offers a J1587 databus. The engine, transmission, ABS, and most of 2”
the other optional electronic devices on the vehicle now 87340-4404
communicate using J1939 protocol.
Star Gauges are secured in place with a lock ring,
which can be removed easily using a removal key
that fits into the lock ring. These tools can be ordered
The EPA10 RX module through your WS dealership
This new redesigned module, incorporates the functions of the
2” Gauge removal tool 87340-4404
earlier RX and PX modules in one unit that also performs a gateway
3” Gauge removal tool 87340-4403
function. The EPA10 RX module performs the following functions.

Ÿ Converts sensor and voltage inputs into J1587 (PI bus) data.
EPA 2007 PX Module
Ÿ Converts four air pressure inputs into J1587 (PI bus) data.

Ÿ Gateway Function converts J1939 data that is required for the

DataStar and the Star Gauges into J1587 protocol (PI bus) data. EPA 2007 RX Module

NOTE: The J1587 data network is also called the PI bus in some ECC
instances. The speedometer uses the J1587 data from the RX
module as the source of data for the Star Gauges.

The Datastar is also on the J1587 (PI bus) network and uses this
data. The RX gateway module is located on the underside of the cab
below the steering shaft, near the clutch linkage.

24 to 12 Volt Converter 2010 RX

Module
The 24 to 12 volt converter is used on vehicles with 24 volt electrical
systems. It is connected between the speedometer and the dash
wiring harness and reduces voltage to 13.5 volts which is needed by
the Starguage and Datastar system.
Western Star Bodybuilder Book: Revision 3.1

2007 Star Gauge System

1AP. 1A-9

Star Gauges
Electronic Control Center(ECC) Function slave Gauges read information
supplied by Speedometer outputs
and display information to driver
 Western Star Bodybuilder Book: Revision 3.1

2010 Star Gauge System All LHD Models

1A
P. 1A-10

Electrical Star Gauges

Function slave Gauges read information
supplied by Speedometer outputs
and display information to driver

Air Line

Air pressurel Star Gauges

Air system components feed air
pressure directly to designated air
gauges in dash

J1939

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

Air Line
J1939
 Western Star Bodybuilder Book: Revision 3.1

2010 J1939 Connection All LHD Models

1A
P. 1A-11

The J1939 Datalink

ABS TRANS ICU ENG

120 Ohm 120 Ohm

Terminating Terminating
Resistor Resistor
Cab resistor
located in dash
10” back from frontwall
engine connection
RXM DIAG
Branch
Backbone Circuit
WST J1939 System Connections

J1939 Connections

Tying into the J1939 backbone is accomplished by tapping into the system using the terminating resistor tee’s located
at each end of the backbone.
Front Wall
Engine connection The Chassis terminating resistor is located in a tee along the left frame 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.

2015 and older western star units have a 250kb data rate interface at both the diagnostic plug and the center tie in
points.

Resistor Receptor 2016 and newer units have a new 500kb J1939 interface for the diagnostic plug and main engin/transmission signals.
Part FTL# 23-13303-902 A 250kb gateway is provided for connecting to the system and is located at the center of the dash console near the RH
Deutsch # DTM04 - 2P - EP10 side of the steering column.

IMPORTANT:
Ÿ It is essential that both terminating resistors remain connected to the ends of the J1939 backbone to dampen
feedback signals. Numerous J1939 problems can be attributed to terminated resistors are missing or disconnected.
Ÿ 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.

J1939 Connections for Body Builders

To connect easily to J1939 at dash location
order the following parts:

(1) Tee and Jumper FTL# A06-37868-000

(1) Jumper Plug # DUFDTM06 2S E004
(2) Female Pins DUFWM2SB
 Western Star Bodybuilder Book: Revision 3.1

Fuse and Relay Blocks

1A
P. 1A-12

WST Fuse panel Fuse Fuze

Wire Code LN Function
Location Rating
R - 15 R - 14 The WST Fuse panel is equipped with 30 fuses,14 relays and 18 F1 10A BA3H-10 Start Switch
LN LD LN LD LN LD power jumpers. The fuse and relay locations are standard as shown F2 20A Bus Bar Par Lights
21 11 1 Relay’s buy may be changed by engineering to accommodate new designs. F3 8A BA03Y-10 Headlight Switch
R-7 R-1 Refer to the ‘Main Cab Harness’ schematic in Mod 320 to find the
F4 10A BA03K-10 Radio
Accesory 212 12 2 Ignition specific information on these items. The fuse panel jumper slots
F5 20A BA03N-10 ECC Flasher
Power Power provide for 18 additional power jumpers; which provide power.
23 30 3 F6 20A BA03K-10 Interior Lights
R - 127 R-2 Relay
F7 20A BA03N-10 Wiper Motor
Heater 24 146 4 Horn F8 30A BA03U-10 Brake Light
Relay Fuse’s
Relay F9 10A BA25A-12 Electric Horn
25 44 5 F10 30A BA03T-10 Option Battery Fuse
R-9 R-3
Battery 27 45 6 Tractor F11 15A BA03U-10 Tractor Markers
Signal Marker Fuse F12 30A BA03B-10 Trailer Markers
Release 18 15 17 Lights
F30 5A Bus Bar ECC Battery
R - 10 R-4
Trailer Jumper Harness F146 15A Bus Bar DRL Power
High 19 16 8
Marker used with optional F44 15A BA25A-12 ABS ECU Batt Power
Beams 29 47 9 Lights Fuse Pannel F45 10A IG03H-10 ABS ECU Ign Power
R - 11 R-5 F15 20A IG03K-10 Backup Lamp
28 20 10 Spare or
Low Fog F16 30A IG03B-10 Option Ing Power
Beams 16 13 10 7 4 1 Lights F47 20A IG03H-10 Air Dryer
R-6 17 14 11 8 5 2 R-- Main Fuse Panel F20 5A IG03J-12 ECC Lightbar
F21 15A AC02A-10 Radio
Park Spare Optional Fuse/Relay Panel
Lights 18 15 12 9 6 F212 25A Bus Bar Sleeper
3
Optional fuse panels are used to support additional switches and other F23 20A AC02B-10 Htd Mirror/lighter
custom options. The WST system is designed to support up to 20 F24 5A Bus Bar Wiper Switch
Jumpers
Fuses and 11 relays. Additional fuse blocks and switches can be F25 20A AC02B-10 Opt Accessory Fus
ordered for customer use, see the Switch page for more information. F27 30A Bus Bar Cab Heater
Main Fuse/Relay Pannel F18 10A Bus Bar RHS Low Beam
F19 10A Bus Bar LHS Low Beam
F29 15A Bus Bar RHS High Beam
Mounting Hole
Fuse block quantity Relay F28 15A Bus Bar LHS High Beam
10-24
will change based
Fuse Cavity
Qty (4) on the amount of
extra switches
ordered

Fuse max 20A

Harness: PN# A06-62104-AC1
Fuse Block PN# 7642-3402

Additional Jumpers can be added to the Option Panel

Optional Fuse Panel
 Western Star Bodybuilder Book: Revision 3.1

4700 In Cab Body Builder Connections

1A
P. 1A-13

In Cab Body Builder PDM

Ÿ Dedicated raceway to route wiring for body install Note: The fuze panel option is not required in cases
Ÿ Floor Tray accommodates (6) 1/2” bundles where Body Upfitters are installing their own PDM
Ÿ Raceway system provides access cover to route wires systems. If you are in doubt call ahead and check
Ÿ Cab access through access floor plate 4” pass-thru in cab floor before ordering.
Ÿ In-cab body builder fuse and relay system isolates body controls from truck system for a If a PDM system will be installed order the
simple and more reliable truck and Body integration operation

Body Builder PDM is Mandatory with the following high amperage switch options
the PDM unit can be omitted in certain cases with these combinations where the body builder is
supplying their own PDM (engineering review required)

329-068 - (4) 20 amp switches wired behind passenger seat 353-060 - Body lighting interface blunt cut wiring with fuse panel
329-072 - (6) 20 amp switches wired behind passenger seat wire mounted between driver and passenger seats
329-076 - (10) 20 amp switches wired behind passenger seat 353-061 - Body lighting interface blunt cut wiring with fuse panel
wire mounted between driver and passenger seats with
additional 150 amp service
353-062 - 150 amp service for body builder installed components
driver and passenger seats
AUXILIARY PNDB
Module 33P

Body Lighting PDM

Module 353
Cab Floor Harness
Module 287

Mounting Bracket
Module 33M
Power Distribution
Module 33M

Blunt cut switch connections

Pre wired to dash switches and
Cab Aux lighting PDM see schematic
Power Cable Section 1 Page (1-31)
Module 33M Module 329
 Western Star Bodybuilder Book: Revision 3.1

4700 SF/SB Cab Passthrough & Floor Track

1A
P. 1A-14

Included with 329-1AU, 329-1AV, 329-1AW, 329-1AX, 329-064 In dash

interface harness
329-068, 329-072, 329-076 and 353-060 Options connections
Air Lines
**See section 1B page 1B-17 for installtion tips and schematics**

In floor tray cover

In cab easy access

harness tray

Cab floor
access panel

Blunt cut switch In dash

wires coiled interface harness
5.9" behind driver seat connections
In Floor Tray Cover 4.9" Pre wired Switches Air Lines
Easy access 1/4” NC 3.9"
electrical tray makes
adding cab harnesses
easy in the field In floor tray cover
3.9"
2.9"
5.9"

C
L Cab

In cab easy access

harness tray
Cab floor
access panel

Cab Floor access Pre cut In Cab

Easy Access PDM Unit 353-060
floor mats Vehicle interface
Floor Plate Unit
 Western Star Bodybuilder Book: Revision 3.1

Dash Switches
1A
P. 1A-15

Durable and Flexible Marine Grade Switches

Western Star dash switches are designed for the long haul and all
weather conditions these marine grade switches provide long term
durability and dependability for customers and flexibility to body builders.
Switch faces can be easily replaced and we have many custom options
set up for you to create the finished professional operator controls.

Pre Labeled Additional Switch Options

Ÿ WST offers many customized switch options to help the body builder
add functionality and body controls.
Ÿ Western Star marine grade high current switches are designed for
long term duty cycles under severe conditions.
Ÿ Listed to the right are some of the common switch options available
that provide pre installed dash switches and wiring depending on the
option selected.
Ÿ Switches are designed with a separate facing that attaches to the
switch body.
Ÿ Custom switch facings can be selected and factory installed using the
following switch label pages.
Ÿ Wiring schematics for these options are also located in this chapter
see Index.

Custom Switch Facing

New solutions can be created for multiple

order units. If you do not see what you are
looking for in the next few pages or need
more information contact your WST Dealer
Sales contact and we can work
with you to create a custom solution. For detailed switch option Information see Section 1D
Complex Switch
with Icon
 Western Star Bodybuilder Book: Revision 3.1

Switch Options - All Models

1A
P. 1A-16

Specific Switch Types

Mod 329 optional switch packages (p. can be customized with the following
predefined switch bodies by adding a line note to the sales order.

Step 1
Select the 329-XXX option to drive the number of extra switches you require

Step 2
Have the dealer salesmen add the part numbers for the spare switch types from the
choices on the this page that you would like pre installed.

The addition of the line note will drive a demand and the factory will install the
corresponding switch bodies in lieu of standard switch normally installed in the truck.

Note:
Switches will come pre-wired as per the current optional switch data codes but will
not be pre-wired to the locations defined by the switch label.

12V Switches
Type

Type A Type B Type C Type D

Type E Type F Type G Type H

Type J Type K Type L Type M

Type N Type P Type R Type S

 Western Star Bodybuilder Book: Revision 3.1

Switch Options - All Models

1A
P. 1A-17

Specific Switch Labels - Actuators Part

Indicat
Switch Graphics Part
Indicat
Switch Graphics
Label Description or type Label Description or type
Mod 329 optional switch packages can be customized Number Type yes/No Number Type yes/No
Light Light
with the following predefined switch labels by adding a
line note to the sales order. 7830-3454 MOBILE PHONE Yes 2 N Cab/sleeper
06-77236-000 BACKUP CAMERA Yes 2 N Cab/sleeper 7830-3518 FRIDGE Yes 2 Cab/sleeper
Step 1 7830-7030 FAN HIGH/OFF/LOW No 3 N Cab/sleeper
Select the 329-XXX option to drive the number of extra 7830-3555 REAR CAM Yes 2 N Cab/sleeper
switches you require 7830-3449 SPARE Yes 2 N Spare 7830-3461 QUALCOM Yes 2 Cab/sleeper
7830-3563 SPARE #1 Yes 2 N Spare
Step 2
7830-3564 SPARE#2 Yes 2 N Spare
Have the dealer salesmen add the part numbers for the
7830-3516 #1 Yes 2 N Spare 7830-3524 LIFT AXLE Yes 2 Suspension
spare switches from the choices on the this page that
you would like pre installed. 7830-3517 #2 Yes 2 N Spare
7830-3529 ACC 1 Yes 2 N Spare
The addition of the line note will drive a demand and the 7830-3530 ACC 2 Yes 2 N Spare 7830-3534 LIFT AXLE A Yes 2 Suspension
factory will install the corresponding switch facing in lieu 7830-3443 AUX Yes 2 N Spare
of standard OPT switches in the truck.
7830-3507 AUX #2 Yes 2 N Spare
7830-3535 LIFT AXLE B Yes 2 Suspension
Note: 7830-3421 BLANK Yes 2 N Spare
7830-3427 BLANK No 2 N Spare
Switches will come pre-wired as per the current optional 7830-3525 MISC Yes N Spare
7830-7027 PUP LIFT AXLE No Suspension
switch data codes but will not be pre-wired to the 7830-3548 AXLE1 Yes 2 N Suspension
locations defined by the switch label. 7830-3549 AXLE2 Yes 2 N Suspension
06-69691-000 AXLE3 Yes 2 N Suspension
7830-7009 PUSHER AXLE Yes 2 Suspension
7830-7055 FRONT AXLE Yes 2 N Suspension
7830-3540 TRAILER Yes 2 N Trailer
7830-3490 TRAILER AUX Yes 2 N Trailer
7830-7010 TAG AXLE Yes 2 Suspension
Text Graphics 7830-3448 TRAILER BACKUP Yes 2 N Trailer
Area with light Area 7830-7032 TRAILER DOOR Yes 2 N Trailer
7830-3457 TRAILER DUMP Yes 2 N Trailer
7830-3597 AUTO SUSP LOWER REST/DISBL No 3 Suspension
7830-3444 TRAILER GATE Yes 2 N Trailer
7830-7036 TRAILER LOCK Yes 2 N Trailer
TRAILER 7830-3484 TRAILER PIN Yes 2 N Trailer 7830-3430 TRAILER 3RD AXLE LIFT Yes 2 Trailer
LOCK
06-74626-000 TRAILER POWER Yes 2 N Trailer
06-71939-000 TRAILER POWER FRONT Yes 2 N Trailer
LIFT AXLE
06-71940-000 TRAILER POWER REAR Yes 2 N Trailer 7830-3481 TRAILER 4TH AXLE LIFT Yes 2 Trailer
7830-7034 TRAILER SUSP Yes 2 N Trailer
7830-7056 TRAILER AXLE 1 Yes 2 N Trailer

Graphic Icon 7830-7057 TRAILER AXLE 2 Yes 2 N Trailer 7830-7049 TRAILER LIFT AXLE Yes 2 Trailer
Simple Text
Switch Switch 7830-7059 HOIST TRAILER UP/DOWN No 2 N Trailer
 Western Star Bodybuilder Book: Revision 3.1

Switch Options - All Models

1A
P. 1A-18

Part Indicator Switch Graphics Part Indicator Switch Graphics Part Indicator Switch Graphics
Label Description Type Label Description Type Label Description Type
Specific Switch Number Light Type Yes/No Number Light Type Yes/No Number Light Type Yes/No

Labels - Lighting 7830-3552

7830-3551
REAR BEACON
FRONT BEACON
Yes
Yes
2
2
N
N
Light
Light
7830-7038 MIRROR BACKUP LIGHTS Yes 2 Light 7830-3439 LOAD LIGHT Yes 2 Light

7830-3522 BACKUP LIGHT #1 Yes 2 N Light

7830-3523 BACKUP LIGHT #2 Yes 2 N Light
7830-3422 BEACON Yes 2 Light 7830-3498 REAR WORK LAMPS Yes 2 Light
06-69939-000 BLADE LIGHT Yes 2 N Light
7830-3558 BLUE FLASHER Yes 2 N Light
7830-3466 BODY LIGHTS Yes 2 N Light
7830-3509 BEACON #2 Yes 2 Light 7830-3431 SPOT LIGHT Yes 2 Light
7830-3476 BOOM LIGHTS Yes 2 N Light
06-69940-000 BOX LIGHT Yes 2 N Light
7830-3546 BUD LIGHTS Yes 2 N Light
06-74094-000 BUMPER LIGHTS Yes 2 N Light 7830-3406 BACKUP LIGHTS Yes 2 Light 7830-7022 STROBE No 2 Light
7830-7048 CL LIGHTS Yes 2 N Light
Graphics 7830-3562 DECK LIGHTS Yes 2 N Light
7830-3520 DOCK LIGHTS Yes 2 N Light 7830-3584 BACKUP LIGHTS STEP Yes 2 Light 7830-3567 TRAILER LOAD LIGHT Yes 2 Light
Area
7830-3589 EXIT LIGHTS Yes 2 N Light
7830-3527 EXTRA LIGHTS Yes 2 N Light
7830-7042 FLOOD LIGHT Yes 2 N Light 7830-3595 ALTERN FLASHERS Yes 2 Light 7830-3566 TRUCK LOAD LIGHT Yes 2 Light
7830-7047 ID LIGHTS Yes 2 N Light
7830-3532 LEFT LIGHT Yes 2 N Light
7830-7012 LOADER LIGHTS Yes 2 N Light 7830-3492 BULL LIGHTS Yes 2 Light 7830-3596 UNDERBODY LIGHT Yes 2 Light
7830-3550 NEON Yes 2 N Light
7830-3456 O/O LIGHTS Yes 2 N Light
BACKUP 7830-3542 OD LIGHT Yes 2 N Light 7830-3594 CARGO BOX LIGHT Yes 2 Light 7830-7039 UTILITY LIGHTS Yes 2 Light
LIGHTS 7830-7054 OFF ROAD LIGHTS Yes 2 N Light
7830-3526 PICKER LIGHTS Yes 2 N Light
7830-3559 PLOW LIGHTS Yes 2 N Light 7830-3547 CHAINUP LIGHTS Yes 2 Light 7830-7044 TOP STROBE Yes 2 Light
7830-3446 RACK LIGHTS Yes 2 N Light
7830-3469 REAR FLOOD LTS Yes 2 N Light
Graphic Icon 7830-3533 RIGHT LIGHT Yes 2 N Light 7830-3402 CL / ID LIGHTS Yes 2 Light 7830-3582 WING MARKER LIGHT Yes 2 Light
Switch 7830-3553 SANDER LIGHT Yes 2 N Light
7830-7016 SANDER LIGHT FRONT Yes 2 N Light
7830-7017 SANDER LIGHT REAR Yes 2 N Light DRIVING LIGHTS Yes 2 Light 7830-3438 WORK LIGHTS Yes 2 Light
7830-3404 M
7830-3554 SCRAPER LIGHT Yes 2 N Light
Text 7830-3560 SPINNER LIGHT Yes 2 N Light
Area with light 7830-3437 TANK LIGHTS Yes 2 N Light
7830-3528 EXT. LIGHTS Yes 2 Light 7830-3512 FRONT FLOOD Yes 2 Light
7830-7040 TIRE LIGHTS Yes 2 N Light
7830-7033 TRAILER LIGHT Yes 2 N Light
7830-3556 WINCH LIGHTS Yes 2 N Light
7830-3405 FOG LIGHTS Yes 2 Light 7830-3414 HI/LOW No 2 Light
7830-7050 TOOL LIGHTS Yes 2 N Light
7830-3545 WING LIGHTS Yes 2 N Light
RACK 7830-3561 YELLOW FLASHER Yes 2 N Light
7830-7043 FRONT STROBE Yes 2 Light 7830-3413 HI/MED/LOW No 2 Light
LIGHTS 7830-3539 CRTSY Yes 2 N Light
7830-3543 DAYTIME Yes 2 N Light
7830-3451 FENDER MARKER Yes 2 N Light
7830-3497 FRONT WORK LAMPS Yes 2 Light 7830-3513 REAR FLOOD Yes 2 Light
7830-3504 FLASH Yes 2 N Light
7830-3478 FLOOD Yes 2 N Light
7830-7045 FRONT Yes 2 N Light
7830-3471 FRONT TARP Yes 2 N Light 7830-3496 HEADLAMP REMOTE NORMAL Yes 2 Light 7830-3515 REAR STROBE Yes 2 Light
7830-3479 MARKER Yes 2 N Light
Simple Text 7830-3538 MOOSE Yes 2 N Light
7830-3472 REAR TARP Yes 2 N Light 7830-3503 HOOK UP LIGHTS Yes 2 Light 7830-3565 TRUCK BACK-UP Yes 2 Light
Switch
7830-3510 TOOL BOX Yes 2 N Light
7830-3541 TRUCK Yes 2 N Light
06-73290-000 UTILITY Yes 2 N Light 7830-3583 HOPPER LIGHT Yes 2 Light 7830-3511 SIDE FLOOD Yes 2 Light
7830-3460 WIDE LOAD Yes 2 N Light
 Western Star Bodybuilder Book: Revision 3.1

Switch Options - All Models

1A
P. 1A-19

Specific Switch Labels - Body Part

Number
Label Description
Indicator Switch
Light Type
Graphics
yes/No
type
Part
Number
Label Description
Indicator Switch
Light Type
Graphics
yes/No
type

7830-7003 BED Yes 2 N Body 7830-7058 HOIST TRUCK UP/DOWN No 2 N Body

7830-3455 ALARM Yes 2 N Body 7830-3579 HOPPER UP/DOWN/REMOTE Yes 3 N Body

7830-3477 BACKUP ALARM Yes 2 N Body 7830-3499 HYD COOLER Yes 2 N Body

7830-7051 BOOM UP/DOWN No 2 N Body 7830-7028 HYD FAN No 2 N Body

Part Indicator Switch Graphics 06-77769-000 AIR GATE Yes 2 N Body 7830-3468 HYD. PUMP Yes 2 N Body
Label Description type
Number Light Type yes/No
06-77770-000 AIR TARP Yes 2 N Body 7830-3441 LOADER Yes 2 N Body

7830-3418 LH/RH TANK No 2 Body 7830-3598 AUX RANGE HIGH/LOW Yes 2 N Body 7830-3502 MASTER Yes 2 N Body

7830-3486 BELLY DUMP Yes 2 N Body 7830-3574 MIXER MIX/DISCHARGE No 2 N Body

7830-3436 POWER TAKE OFF No 2 Body 7830-3465 BLOWER Yes 2 N Body 7830-3576 MIXER STOP/RESUME/REMOTE No 3 N Body

7830-3569 BOOM Yes 2 N Body 7830-3442 PIN LOCK Yes 2 N Body

06-74457-000 SHUTDOWN OVERRIDE No 2 Body 7830-7052 BOOM IN/OUT No 2 N Body 7830-3544 PLOW Yes 2 N Body

7830-7014 CHAIN Yes 2 N Body 06-73287-000 POWER Yes 2 N Body

7830-7007 TRANSFER CASE LOCK Yes 2 Body
7830-7015 CHAIN 2-SPEED Yes 2 N Body 7830-3580 PTO Yes 2 N Body

7830-3577 CHUTE RAISE/LOWER No 2 N Body 06-77891-000 PUMP Yes 2 N Body

7830-3485 VIBRATOR Yes 2 Body
7830-7006 CHUTE UNLOCK/LOCK/REMOTE Yes 3 N Body 7830-3447 PUP PIN Yes 2 N Body

7830-3531 CONTROL Yes 2 N Body 7830-7025 PUP T/GATE No 2 N Body

Text 7830-3489 CRANE Yes 2 N Body 7830-7023 PUP TARP No 2 N Body

Graphics
Area with light Area 7830-3440 RACK Yes 2 N Body
7830-3508 DIVERTER Yes 2 N Body

7830-3467 DIVIDER BOX Yes 2 N Body 7830-3571 REAR Yes 2 N Body

7830-3570 DOLLY Yes 2 N Body 7830-3500 REMOTE Yes 2 N Body

7830-7035 DOLLY LOCK Yes 2 N Body 7830-7013 SANDER DOOR Yes 2 N Body
BELLY
DUMP
7830-3475 DUMP Yes 2 N Body 7830-3557 SENSOR Yes 2 N Body

LH/RH 06-73288-000 DUMP FRONT Yes 2 N Body 7830-3483 SHUTDOWN Yes 2 N Body
TANK 7830-3474 TAIL GATE Yes 2 N Body
06-73289-000 DUMP REAR Yes 2 N Body

7830-3572 FRONT/REAR THROTTLE CONTRL Yes 2 N Body 7830-7019 TARP No 2 N Body

7830-3590 GATE ONE Yes 2 N Body 7830-7029 TARP Yes 2 N Body

Simple Text Graphic Icon
Switch 7830-3591 GATE TWO Yes 2 N Body 7830-7053 TILT UP/DOWN No 2 N Body
Switch
7830-3470 GENERATOR Yes 2 N Body 7830-3453 TIRE CHAINS Yes 2 N Body

7830-7041 GROUND SPEED Yes 2 N Body 7830-7026 TRUCK T/GATE No 2 N Body

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
 Western Star Bodybuilder Book: Revision 3.1

Utility Lights - Model Specific Availability

1A
P. 1A-20

Mirror Arm Std. Incandescent Lighting

Mounting pos
Incandessent Package Description
31K-1A1 (2) Chrome incandescent utility lights with stainless steel anti-glare shields mounted on mirror arms
High Mount 318-1BY (2) Chrome swivel incandescent utility lights mounted LH and RH high on painted brackets back of cab
BOC pos 318-096 (2) Chrome swivel incandescent utility lights mounted low inboard on side extenders
318-1B0 (2) Chrome swivel incandescent utility lights mounted LH and RH high on stainless steel brackets back of sleeper
318-052 (2) Chrome swivel incandescent utility lights mounted high inboard on side extenders
Flush Mount
(2) Swivel incandescent utility lights high inboard on side extenders and
BOC pos (2) flush mounted incandescent back of cab/sleeper
318-085
(2) Chrome swivel incandescent utility lights mounted low inboard on side extenders and
Low Mount 318-1AB (2) flush incandescent utility lights mounted back of cab/sleeper
BOC pos (4) Utility lights: (2) chrome swivel incandescent mounted LH and RH high on stainless steel brackets back of sleeper and
318-1CG (2) flush mounted incandescent back of sleeper
(3) Chrome swivel incandescent utility lights: (2) mounted high on painted brackets LH and RH back of cab and
318-1BX (1) incandescent mounted low on painted bracket back of cab LH side
318-1CK (1) Chrome swivel incandescent utility light mounted LH high on painted bracket back of cab
318-1CR (1) Chrome swivel incandescent utility light mounted RH high on painted bracket back of cab
318-003 (1) Flush utility light mounted LH back of cab/sleeper
318-004 (2) Flush utility lights mounted back of cab/sleeper

Mirror Arm
LED Lighting
Mounting pos New LED Package Description
31K-001 (2) Chrome LED utility lights with stainless steel anti-glare shields mounted on mirror arms
High Mount 318-1D9 (2) Chrome swivel LED utility lights mounted LH and RH high on painted brackets back of cab
Pos 318-1E0 (2) Chrome swivel LED utility lights mounted low inboard on side extenders
318-1E1 (2) Chrome swivel LED utility lights mounted LH and RH high on stainless steel brackets back of sleeper
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
High Inboard (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
Mount Pos
(3) Chrome swivel LED utility lights: (2) mounted high on painted brackets LH and RH back of cab and
318-1E6 (1) mounted low on painted bracket back of cab LH side
Low Inboard 318-1E7 (1) Chrome swivel LED utility light mounted LH high on painted bracket back of cab
Mount Pos 318-1E8 (1) Chrome swivel LED utility light mounted RH high on painted bracket back of cab

Flush Mount
BOS pos
 Western Star Bodybuilder Book: Revision 3.1

Lighting Mods and Harness Repair - All Models

1A P. 1A-21

Guidline For Repairing or Replacing a Harness

Turn Signal and Brake Override Circuit Elimination
Repair Replace
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. Less than 20% of the harness is damaged. If the wire
In some vocations, customers prefer that the 4-way flashers remain flashing during damage is greater than 6 inches (15 cm), an overlay More than 20% of the harness
use of the service brakes. To disable this feature, the red jumper wire located in the harness can be added to replace the section of damaged
turn signal switch housing, used to activate this circuit needs simply to be cut and
is damaged.
the ends taped or heat shrunk to remove this function. wire.
Both methods of wiring comply fully with Canada and USA regulations.
Wire is smaller than 12-gauge. Wire is 12-gauge or larger.
The harness is not readily available, or shipping will take The harness can be obtained in less
Red Jumper
Wire longer than one week. than a week.
Wire insulation is cracked due to excessive heat from
an external source. Repair is recommended if the
damage isisolated to one section of the wire.
There is a clean cut to the wire, corrosion is wicked no
Wire insulation is cracked due to age, or
more than 1 inch (2.5 cm) from the terminal end. If the
damage is extensive and spread
damaged area is over 6 inches (15 cm), the harness
throughout the wire.
can be repaired by adding overlay wiring over the
damaged area.
NOTE: If damage exceeds 1 inch (2.5 cm) from the
terminal end, a quality repair may require adding a
Installing Aftermarket LED Tail lights jumper wire to end, a quality repair may require adding
a jumper wire to create enough slack in the wire. If
Adding LED Tail Lights requires the addition of a 2 W 560 OHM resistor adding extra splices stretches the wire too tightly it
to ensure that the system consumes enough amperage for the system can degrade the integrity of the harness.
to function properly. Use the splice instructions below for installation of the
aftermarket resistor.
Two harnesses are affected. For example, M2 24 pin The harness is proprietary, such as a
Spl -1
White - Amber LED Panel RED LED Panel lever lock connector (23-13144-010 and 23-13144-009) datalink with sheathing over a twisted
2W 560 OHM
Brown - RED LED Panel RED LED Panel is corroded on both sides. Also, if the harness has pair, or a WABCO sensor and solenoid
White - LED Side Marker Resistor RED Turn Signal Power minimal corrosion wicked up the wire, the connectors wiring.
Green - Ground can be re-pinned
Spl -2

If the damaged area is over 6 inches (15 cm), the Extensive damage to the harness caused
Spl -3
Black - Amber LED Panel Black Park lite Power harness can be repaired by adding overlay wiring by foreign material such as DEF fluid,
over the damaged area. diesel fuel, or road/deicer fluid.
Black - LED Side Marker Black - Red LED Panel
For complete information see Guidelines for Repairing or Replacing an Electrical
Harness - Service Bulletin 54-61in the western Star Service Manual
 Western Star Bodybuilder Book: Revision 3.1

Daytime Running Lights - Discon/Recon

1A
P. 1A-22

General Information PECV

Connector
ECC
Western Star vehicles are built with DRLs enabled. If the vehicle is ordered with data code 311-998 (NO DAYTIME (Blue)
Electronic
RUNNING LIGHTS), the DRLs are disabled during assembly. In most cases, wires are removed from the connector WESTERN STAR TRUCKS
HOLD TO HOLD TO SET
Control
cavities to allow for future connection.
EXPAND

SET CONTRAST 54%

HOLD TO
MORE LESS
HOLD TO SET
Center
PECP
EXPAND

DATA STAR
NOTE: Daytime Running Lights (DRLs) are required by law in Canada. Daimler Trucks North America recommends Connector
keeping DRLs operational in all locations, even where not required by law. The following instructions can be used to (Black)
enable or disable DRLs where it is permissible to operate without day time running lights. IMPORTANT: If disabling
the DRLs, do not cut the wires. Fold back and tape the wires to allow for connection in the future.

Vehicles without Star Gauge Dash, Built Prior to February 2002 Vehicles with Star Gauge Dash, Built Since February 2002
1. Shut down the engine, set the parking brake, and chock the tires. 1. Shut down the engine, set the parking brake, and chock the tires.
2. Disconnect the negative leads from the batteries. 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 3. Remove the four screws that secure the instrument panel, then pull the top of the panel
instrument panel wiring. On vehicles with fixed steering columns, remove the bolts that hold the steering forward to access instrument panel wiring. On vehicles with fixed steering columns, remove
column to the dash assembly to lower the steering column for access. the bolts that hold the steering column to the dash assembly to lower the steering column for
4. Disconnect the blue PECV connector from the left-hand side of the Electronic Control Center (ECC). access.
5. Note the cavity location of wire LB08A, then tag the wire with that location so that the daytime running lights 4. Disconnect the light gray PECV connector from the left-hand side of the Electronic Control
can be easily connected, if necessary. Center (ECC).
6. If connecting the DRLs, locate wire LB08A; the wire should be folded back and taped off in the harness. 5. Find wire LB08A in cavity A10, then tag the wire with that location for possible future
Remove the tape and install the wire into its tagged location, then continue with step 8. If the location is not installation.
tagged and the vehicle uses harness 873b1-3570, install wire LB08A into cavity D1, and continue with step 8. 6. If connecting the DRLs, locate wire LB08A; the wire should be folded back and taped off in
7. If disconnecting the DRLs, remove wire LB08A from the connector, wrap the terminal end of the wire with the harness. Remove the tape and install wire LB08A into cavity A10. Continue with step 8.
electrical tape to prevent unintended connection, then secure the wire back to the harness with a tie-strap. 7. If disconnecting the DRL, remove the wire from the connector, wrap the terminal end of the
8. Connect the blue PECV connector to the ECC. wire with electrical tape to prevent unintended connection, then secure the wire back to the
harness with a tie-strap.
9. Disconnect the black PECP connector from the pigtail on the left-hand side of the ECC. The ECC pigtail to the
black PECP connector has colored wires and mates to a headlamp harness connector with white wires. 8. Connect the PECV connector to the left-hand side of the ECC.
10. On the white-wire headlamp harness side of the connector, note the cavity location of wire HL08 (B, E, or G), 9. Disconnect the dark gray PECP connector from the left-hand side of the ECC.
then tag the wire with that location for possible future installation. 10. Find wire HL08H (this wire may be HL05B in later models) in cavity G, then tag the wire with
11. If connecting the DRLs, locate wire HL08 (B, E, or G); the wire should be folded back and taped off in the that location for future installation, if desired.
harness. Remove the tape and install it into its tagged location. Continue with step 13. If the location is not 11. If connecting DRLs, locate wire HL05H (this wire may be HL05B in later models); the wire
tagged, and the vehicle uses harness 873b1-3570, install wire HL08 (B, E, or G) into cavity C. Continue with should be folded back and taped off in the harness. Remove the tape and install wire HL05H
step 13. or HL05B into cavity G. Continue with step 13.
12. If disconnecting the DRLs, remove the wire from the connector, wrap the terminal of the wire with electrical 12. If disconnecting the DRLs, remove the wire from the connector, wrap the terminal of the wire
tape to prevent unintended connection, then secure the wire back to the harness with a tie-strap. with electrical tape to prevent unintended connection, then secure the wire back to the
13. Connect the PECP connectors. harness with a tie-strap.
14. Position the instrument panel and install the screws. If the steering column was lowered, position it into place, 13. Connect the PECP connector to the left-hand side of the ECC.
and tighten the steering column capscrews 17 lbf·ft (23 N·m). 14. Position the instrument panel and install the screws. If the steering column was lowered,
15. Connect the batteries. position it into place, and tighten the steering column capscrews 17 lbf·ft (23 N·m).
16. Verify correct operation of the lights. 15. Reconnect the batteries.
16. Verify correct operation of the lights.
 Western Star Bodybuilder Book: Revision 3.1

4800/4900/6900 Tail Light Configurations

1A
P. 1A-23

Partially protected Single Unit Tail lights mounted Under Frame Partially protected Single Unit Tail lights
mounted Outside of Frame
Taillight units are protected on three sides by a simple open box housing
Mounted under the end of frame Taillight units are protected on three sides by a
simple open box housing mounted on the outside
294-040 - Boxed tail light (stop/tail/backup) mounted below the rails
of the frame
4.0”

7.38”
294-049 - Boxed tail lights (stop/tail/backup)
mounted outboard of rails
4.0” 294-052 - Vsm dual sealed inboard of rail mounted

7.38”
stop/tail/turn/backup lights
294-1AC - Boxed tail light assembly
(stop/tail/backup) mounted outboard of
rails and inset 4" from end of frame 8.0”

8.0”

Unprotected Single Unit Tail lights

Taillight units are unprotected and mounted off brackets Partially Protected Single Unit Tail Lights Under Frame
located on end of from crossmember Taillight units are supported from a simple angle plate
294-032 - Flush mounted stop/tail/backup lights mounted mounted underend of from crossmember.
below rear most crossmember 294-060 - LED stop/tail with separate backup lights
294-1AJ - Boxed tail light assembly with LED stop/tail/license mounted on polished aluminum plate end of
plate lights and incandescent backup lights frame
mounted below rear most Crossmember 294-063 - Vsm dual sealed polished aluminum plate
mounted stop/tail/turn/backup lights
25.63” 2.0”

7.0”
 Western Star Bodybuilder Book: Revision 3.1

4800/4900/6900 Tail Lights

1A P. 1A-24

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
294-053 - Vsm dual sealed outboard of rail mounted 4.0”
stop/tail/turn/backup lights
294-057 - Grote torsion mount sealed stop/tail/turn lights in boxes
outside of frame Protected Under Frame Vocational Tail lights
294-079 - LED stop/tail with separate backup lights mounted in boxes Taillight units are well protected and mounted under end of from crossmember
outboard of rail
6.5” 294-054 - Vsm dual sealed logger light bar mounted stop/tail/turn/backup lights

12.5”

Fully Protected Separate Tail Lights Mounted Outside of Frame 6.25”

Taillight units are fully boxed in on all sides by a simple sturdy box housing and mounted 4.50” 3.5”
under the end of frame
294-082 - LED stop/tail with separate backup lights mounted in box under end of frame 10.25”

294-055 - Grote torsion mount sealed stop/tail/turn lights in box below tear crossmember

34.13” 4.0”

4.00”

0.5”

6.5”

25.6” 4.0”
 Western Star Bodybuilder Book: Revision 3.1

4700 DCC Tail Lights

1A
P. 1A-25

294-1AV - LED stop/tail with separate led backup lights mounted on painted steel plate end of frame

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”

Ref Sales Codes

Ref Sales Codes -914 / 919
-303 / 331 & 334
Ref Sales Codes
-914 / 919 Ref Sales Codes
-303 / 331 & 334
 Western Star Bodybuilder Book: Revision 3.1

WST Air System - All Models

1A P. 1A-26

Reading WST air schematics

WST Air System Line numbers correspond to
Ÿ The Western Star air system is designed for easy access and adaptability after delivery. Module numbers designate
bill of material items
Ÿ In line air connections to all chassis components are located conveniently under driver’s where parts will be found 8 7 6 5 4 3 2 1

door cab skirt.

REV PUR
No. DESCRIPTION APPLICATION: TRACTOR OR TRUCK/TRACTOR WITH SINGLE DO NOT SCALE DRAWING ORIGINAL CREATED ON WST
RELEASE NUMBER
LTR
ZONE REVISION DESCRIPTION BY DATE
ME
APPD

TECHNICAL ILLUSTRATOR ECO95137 - 2D INITIAL RELEASE WCS 06/28/05 - MIT

1 COMPRESSOR HAND CONTROL VALVE & WITH MV-3 TYPE DASH VALVE ECO92743 A 2D ITM-37/-16 RMVD;LINE138 MVD TO MANF CAS 07/28/97 - -
P27511-05 B 2D REDRAWN IN COREL NHS 06/28/05 BCB M1M
2 GOVERNOR
3 RESERVOIR - SUPPLY "SUPPLY" 18 19
4A RESERVOIR - SUPPLY "A"

Ÿ To aid Body Builder connection access, the floor pass through has extra ports in various
4B RESERVOIR - SUPPLY "B" D D

D 4C S S E D
RESERVOIR - SUPPLY "C"
4D RESERVOIR - SUPPLY "D" 25
5 RESERVOIR "EXTRA"
6 H
BRAKE VALVE 880

sizes. This pass through is located under the dead pedal as shown.
25
7 CHAMBER, SERVICE, CAM 140
7A CHAMBER, SERVICE, WEDGE H
880
8 CHAMBER, SERVICE, PARK , CAM 21
141
8A CHAMBER, SERVICE, PARK WEDGE
9

Ÿ Primary supply air is also available by tapping into the supply manifold located under the
B S D E
10
880 ... B
RELAY VALVE DUAL SUPPLY ( 5.5 PSI CRACK )
149 EXH
11 RELAY VALVE DUAL SUPPLY ( 4.0 PSI CRACK ) B
880
12 SINGLE CHECK VALVE 148 880 880
13 DOUBLE CHECK VALVE 116 122 ... EXHAUST LINE
C C

dash or by using a jumper as show below.

14 QUICK RELEASE VALVE B B EXH THROUGH FIREWALL
15 FRAME TEE B
16 TEE
S S
17 AXLE TEE B S
18 PARK CONTROL VALVE SYSTEM SYSTEM
D D
19 TPV CONTROL - TRAILER AIR SUPPLY
20 TPV (TRACTOR PROTECTION VALVE) S
S 42
21 HAND CONTROL VALVE A S
SYSTEM D
22 SPRING BRAKE / INVERSION VALVE D
D
23 ABS PMV ( PRESSURE MODULATION VALVE )
24 ATC ( ABS ANTISPIN VALVE )
43/27 42

Line sizes noted B

25
25A
26
AIR PRESSUR GAUGE ( DUAL )
AIR PRESSUR GAUGE ( SINGLE )
DRAIN VALVE ( SPITTER VALVE )
IN CAB MANIFOLD
B

Std Air Switch

AIR ACCESSORIES
27

for all schematics

DRAIN COCK
28 STOP LAMP SWITCH
29 AIR DRYER LINE SIZE LEGEND PORT LEGEND
30 QR1-C ( QUICK RELEASE / DOUBLE CHECK VALVE ) SYMBOL NYLON HOSE SYMBOL DESCRIPTION 2 880
31 GLAD HAND A
1/4 #4 S SUPPLY
138
32 PASSTHROUGH MANIFOLD
B 3/8 #6 D DELIVERY 1
33 IN-LINE FITTING QUANTITY ITEM NUMBER DESCRIPTION REF
CAB PASS THRU

AIR SYSTEM PIPING - CAB PIPING

34 FRONT LIMITING VALVE C 1/2 #8 C CONTROL SEE PORT DIAGRAM
WESTERN STAR TRUCKS INC.

35 IN MOD 880 FOR A SUBSIDIARY OF

LLC
R

D HOLE USAGE DETAILS

36 PRESSURE RELIEF VALVE 5/8 #10 E EXHAUST T H E I N F O R M AT I O N C O N TA I N E D H E R E I N I S P R O P R I E TA R Y D ATA , A N D I S N O T F O R
DISSEMINATION OR DISCLOSURE, IN WHOLE OR IN PART, FOR ANY PURPOSE OTHER THAN THAT FOR WHICH
IT IS SUBMITTED, EXCEPT AS AUTHORIZED IN WRITING BY WESTERN STAR TRUCKS.

37 PRESSURE PROTECTION VALVE E

MATERIAL APPROVAL
-
DATE

3/4 #12 R RESERVOIR - UNLESS OTHERWISE NOTED, DIMENSIONS

A 38 ADJUSTABLE PRESSURE REGULATOR DRAWN BY DATE
AND TOLERANCES ARE DEFINED ACCORDING

N.STREHL 06/28/05
TO ASME STA NDARD Y1 4.5M-1994, WITH
EXCEPTIONS PER FREIGHTLINER EOSM 09E0K17. A
39 PRESET PRESSURE REGULATOR IF PASS THROUGH IS FULLY POPULATED CHECKED BY DATE

F #8 TEFLON A ACCESSO
RY 1 I.LEVKIV 06/28/05 THIRD ANGLE PROJECTION UNIT OF
USE FIREWALL DRILLING AND BULKHEAD FITTING RESPONSIBLE ENGINEER DATE
MEASURE

40 CONTROL VALVE M.MAHLER

APPROVED BY
06/28/05
DATE MFG ENGR/PURCH AGENT DATE
NTS
G

728B1-3509
1/8 NONE 06/28/05 B.BAER
41 BP-R1 ( BOBTAIL VALVE ) 2 TO PRESSURE PROTECTED AIR SUPPLY
M.MAHLER
DESCRIPTION
06/28/05

AIR SYSTEM PIPING

42 DC-4 ( DOUBLE CHECK VALVE ) SUPPLEMENTARY DESCRIPTION
H NONE

ITEM NUMBER
5/32

DESCRIPTION
WST MODELS,CAB AIR PIPING
43 DS-2 ( DOUBLE CHECK VALVE ) ITEM/DRAWING NUMBER REVISION LETTER SHEET NUMBER

728B1-3509 B 1 OF 1

8 7 6 5 4 3 2 1

Items numbered for

identification in
description block

Common air switch plumbing

Jumper between
Switches

Supply air from

in dash manifold
In dash Module Number
manifold
871
Item Number
138

WST three port air switch

utilizes a jumper for air common air supply
between option switches which cuts the
air lines required for dash plumbing in half

Lighting Harnnes

Airlines and cab pass In line connections under cab

through are located allow for greater flexibility
under the drivers when connecting or changing
dead pedal air control systems
 Western Star Bodybuilder Book: Revision 3.1

4800/4900/6900 Airline Numbering

1A
P. 1A-27

Circuit From To Line Color Size Area

4800/4900/6900 Airline Numbering Circuits 1 to 100 116 Park Valve-Trac Del
Park Brake-DCV (42)
Park Brake-DCV (42) Black 3/8" Cab
116 Floor Pass-Thru Black 3/8" Cab
The WST air system assigns separate line numbers for each connection line in the air 122 Park Valve-Trlr Del Floor Pass-Thru Orange 3/8" Cab
system design. Most air lines are black but some air lines have been assigned colors and 123 Foot Valve Trailer Brake-DCV (43/28) Green 1/2" Cab
sizes for some common routing and as such the colored air lines will have no number 124 Foot Valve Hand Valve-DCV (42) Red 1/2" Cab
labels. Where a black line is used number labels are used to identify which lines go to 125 Trailer Brake-DCV (43/28) Floor Pass-Thru Black 1/2" Cab
126 Foot Valve Hand Valve-Supply Green 3/8" Cab
different places on the chassis these numbers correspond to the circuit numbers in the Hand Valve-Delivery
127 Hand Valve-DCV (42) Blue 3/8" Cab
schematic drawings. All black and wire braid lines connecting to the cab will be labeled with 138 Accessory Manifold Floor Pass-Thru Yellow 3/8" Cab
a line number on both the cab sides and the chassis line in an area where no paint or over 140 Park Valve-Sec Supply Pressure Gauge-Sec Red 5/32" Cab
spray will cover them up. 141 Park Valve-Pri Supply Pressure Gauge-Pri Green 5/32" Cab
148 Foot Valve Park Valve-Pri Supply Green 3/8" Cab
149 Foot Valve Park Valve-Sec Supply Red 3/8" Cab
229 Foot Valve Park Brake-DCV (42) Green 1/4" Cab
EXH Park Valve-Exhaust Pass-Thru Manifold Silver 3/8" Cab
EXH Hand Valave-Exhaust Pass-Thru Manifold Silver 3/8" Cab
100 Air Dryer Supply Resvr Black 5/8" Charging System
112 Supply Resvr Governor Black 1/4" Charging System
253 Air Dryer Governor Silver 1/4" Charging System
101 Supply Resvr 'A' Reservoir II Green 5/8" Chassis
Color designated Lines 102 Supply Resvr 'B' Reservior Red 5/8" Chassis
will not have line numbers 103 'A' Reservoir Foot Valve Green 5/8" Chassis
see color/size column for more information 104 'B' Reservior Foot Valve Red 5/8" Chassis
105 Foot Valve Rear Combo-Control Green 3/8" Chassis
106 Foot Valve Front Combo-Control Red 1/2" Chassis
107 'A' Reservoir Rear Combo-Supply Green 3/4" Chassis
111 Front Combo-Delivery Bulkhead Fittings Red 1/2" Chassis
116 Floor Pass-Thru Park Relay-Control Black 3/8" Chassis
Airline numbers 117 Park Relay-Delivery Frame Tee Black 1/2" Chassis
on black lines 122 Floor Pass-Thru TPV-Supply Orange 3/8" Chassis
125 Floor Pass-Thru TPV-Delivery Black 1/2" Chassis
134 'A' Reservoir Park System DCV Green 1/2" Chassis
138 Floor Pass-Thru PPV @ 'B' Reservior Yellow 3/8" Chassis
144 Park System DCV Park Relay-Supply Black 1/2" Chassis
249 Undercab Manifold PPV @ 'B' Reservior Yellow 3/8" Chassis
NYL Fan Drive Fan Soleniod White 1/4" Fan Soleniod
Under cab line connections 6642 Cab Manifold Air Horn Valve Yellow 3/8" Air Horn
6641 Air Horn Valve Air Horn Inlet Yellow 1/4" Air Horn
025 Interaxle Lock Switch Floor Pass-Thru White 1/4" Interaxle & DCDL
25B DCDL Switch Floor Pass-Thru Red 1/4" Interaxle & DCDL
271 Accessory Air Manifold Switch Supply Yellow 1/4" Interaxle & DCDL
025 Floor Pass-Thru Interaxle Lock Frame Tee White 1/4" Interaxle & DCDL
25B Floor Pass-Thru Diff Lock Frame Tee Red 1/4" Interaxle & DCDL
Additional air line 1/4"
180 Susp Dump Switch Floor Pass-Thru Blue Suspension Leveling
ports are provided 084 Leveling Valve-Delivery RH Forward Air Bag Blue 3/8" Suspension Leveling
for easy addition 085 RH Forward Air Bag RH Aft Air Bag Blue 3/8" Suspension Leveling
of body builder 086 LH Forward Air Bag LH Aft Air Bag Blue 3/8" Suspension Leveling
controls 087 Leveling Valve-Delivery LH Forward Air Bag Blue 3/8" Suspension Leveling
180 Floor Pass-Thru Leveling Valve-Dump Blue 1/4" Suspension Leveling
181 Press Protection Valve Leveling Valve-Supply Blue 3/8" Suspension Leveling
Cab pass through manifold 028 Air Slide 5th Wheel Switch Floor Pass-Thru Green 1/4" Air Slide Fifth Wheel
located behind driver side 028 Floor Pass-Thru Air Slide 5th Wheel Green 1/4" Air Slide Fifth Wheel
dead pedal
 Western Star Bodybuilder Book: Revision 3.1

Air System - In Cab Lines - All Models

1A
P. 1A-28

No. DESCRIPTION Air systems schematics are located in Mod 880 and 883.
1 COMPRESSOR Refer to individual serial numbers for specific truck information systems using your dealer or service link.
2 GOVERNOR
3 RESERVOIR - SUPPLY "SUPPLY"
4A RESERVOIR - SUPPLY "A"
4B RESERVOIR - SUPPLY "B" Basic Air System for Dual Hand Control Dash Valve
4C RESERVOIR - SUPPLY "C"
4D RESERVOIR - SUPPLY "D"
5 RESERVOIR "EXTRA"
6
18
BRAKE VALVE
7 CHAMBER, SERVICE, CAM
S S
7A CHAMBER, SERVICE, WEDGE
D E
8 CHAMBER, SERVICE, PARK , CAM
8A CHAMBER, SERVICE, PARK WEDGE 25A
9
10 RELAY VALVE DUAL SUPPLY ( 5.5 PSI CRACK ) A
25A
11 RELAY VALVE DUAL SUPPLY ( 4.0 PSI CRACK ) 21
12 SINGLE CHECK VALVE
13 DOUBLE CHECK VALVE S D E

14 QUICK RELEASE VALVE

883
15
880 EXH
FRAME TEE B
141 880 880
16 TEE
H 113 116
17 AXLE TEE ...
18 PARK CONTROL VALVE SYSTEM B EXH
19 TPV CONTROL - TRAILER AIR SUPPLY B
PORT LEGEND
20 TPV (TRACTOR PROTECTION VALVE) SYMBOL DESCRIPTION
21 HAND CONTROL VALVE S SUPPLY
22 SPRING BRAKE / INVERSION VALVE
D DELIVERY
23 ABS PMV ( PRESSURE MODULATION VALVE ) S S
24 ATC ( ABS ANTISPIN VALVE ) C CONTROL
B S
SYSTEM
25 AIR PRESSUR GAUGE ( DUAL ) D D EXHAUST LINE
E EXHAUST THROUGH FIREWALL
25A AIR PRESSUR GAUGE ( SINGLE ) S
S
26 DRAIN VALVE ( SPITTER VALVE ) R RESERVOIR
A S
27 DRAIN COCK A ACCESSORY
D
SYSTEM D
28 STOP LAMP SWITCH D
29 AIR DRYER 42 IN CAB MANIFOLD
30 QR1-C ( QUICK RELEASE / DBLE CHECK VALVE ) AIR ACCESSORIES
31 GLAD HAND LINE SIZE LEGEND
32 PASSTHROUGH MANIFOLD SYMBOL NYLON HOSE 880
33 IN-LINE FITTING
A
1/4 #4 116
34 FRONT LIMITING VALVE B 3/8 #6
2
35
C 1/2 #8
36 PRESSURE RELIEF VALVE
37 D
PRESSURE PROTECTION VALVE 5/8 #10

38 ADJUSTABLE PRESSURE REGULATOR E

3/4 #12
39 PRESET PRESSURE REGULATOR IF PASS THROUGH IS FULLY POPULATED 1
40 F #8 TEFLON 1
CONTROL VALVE USE FIREWALL DRILLING AND BULKHEAD FITTING CAB PASS THRU
41 BP-R1 ( BOBTAIL VALVE ) G 1/8 NONE SEE PORT DIAGRAM
2 TO PRESSURE PROTECTED AIR SUPPLY IN MOD 880 FOR
42 DC-4 ( DOUBLE CHECK VALVE ) HOLE USAGE DETAILS
H 5/32 NONE
43 DS-2 ( DOUBLE CHECK VALVE )