Harness/Schematic Location Information 1B-3 1B - Free Download PDF

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Western Star Bodybuilder Book: Revision 3.1Table of ContentsSection1BTechnical SchematicsThis guide is to be used as a reference document only.Please consult your Western Star CAE representative onspecific spec’ing needs as the information contained inthis document can change without notice.Frequently Asked Electrical QuestionsHarness/Schematic Location Information47/48/49/69 Main Chassis Harness SchematicChassis Harness Break Out LocationsChassis Max Complexity HarnessAll LHD EPA 2010 Models: Front Wall FwdAll LHD EPA 2010 Models: Under Cab Rear4700/4800/4900/6900 Main Cab Schematic4700/4800/4900 LHD PTO Schematic4800/4900 LHD PTO Schematic4800/4900 Remote Fast Idle4800/4900 Remote Start Stop48/49/69 Engine Remote Interface - EOFEnd of Frame Engine Remote Interface - 148-071End of Frame Engine Remote Interface - 148-035Exterior Cab Body Builder Connections4800/4900/6900 Plow Light Prep4700 10 AMP Switches & In Cab Connections4700 Body Builder Cab Access Port4700 Body Builder InterfaceSpeed Sensor Connections Interface1BP. 21B-131B-141B-151B-161B-171B-181B-191B-20

Western Star Bodybuilder Book: Revision 3.1Frequently Asked Electrical QuestionsQuestion: How can I tell from the order if the truck has any body builder connections?Answer: Look at sales code 334 and 353 to determine if supplemental body builder harness optionswhere ordered with your truck.Question: If there is a Body Builder option, what type of interface plug does the option have and wherewill it be located?Answer: The 4700 offers blunt cut wires at the BOC with an access plate in the floor for body builderconnections see page 1A-13/14 and 1B-18/19. The 4800/4900/6900 offer body builderharnesses to the exterior BOC and the End of Frame with std plugs. See page 1B-14 forschematics and details.Question: Where can I find specific transmission information on the truck order and in the Body builderbook?Answer: Truck specific Transmission specifications can be located in the truck order under salescode 342 and schematic information can be found using the sales codes found on page 1B4 of this chapter of the body builder book.Question: Can you obtain wiring diagrams for specific options for serial numbers and any informationon dealer optionally installed features?Answer: Specific schematic information can be obtained by serial number is available to our dealerson line via PartsPro and EZ wiring. Use page 1B-4 of this chapter to locate the modulelocation information.Question: Does Western Star utilize the (J1939) CAN-bus data protocol?Answer: The Western Star dash gauges and driver display (if equipped) are controlled via the J1587data bus. See the star gauge P 1A-6, 1A-7 for more information.Question: Can the day time running lights be deactivated?Answer: The instructions to deactivate the day time running lights are located on page 1A-22.Question: Is there a high amperage option for Plow lights on the 4800/4900/6900 Models?Answer: Yes a plow light package is available using Sales code 329-054 which supplies a separatejunction box mounted to the back wall behind the passenger seat. See details andschematics for this option on page 1B-16.Question: Is there a place I can tie into the tail lights without splicing into the tail light harness?Answer: Yes some trucks will be equipped with a capped plug at the bac of cab LH rail that is labeledsupplemental trailer cable wiring (shown on P 1B-15) if the 388 Mod option has ordered. Ifthis option and plug is not in the harness Pins #20,33,44,57 and 71 can be been accessedin the Main Chassis Bulkhead. The pinout details for this plug can be found in page 1C-4dependant on your model and production year.Question: I have a unit with a Eaton manual transmission. Where would the body builder locate thevehicle speed when installing a salt/sander spreader with a controlled flow rate at differentspeeds on a manual transmission?Answer: The best way to do this is by adding a second speed sensor to the rear bearing cover of thetransmission. see Page 1B-20.1BP. 1B-2Question: Is a J1939 Protocol available? If so, how can I gain access to it?Answer: With the 2010 model year trucks or newer the J1939 protocol is available via the diagnosticconnector located at the lower left hand side of the dash and new nodes can be added atthe end resistors. See Page 1A-10 and 1A-11 for location and connection details.Question: Is there any factory provisions for remote Stop?Answer: Yes remote Stop is available using Option code 162-018 based on the engine configuration.Availability would need to be determined by the Sales and Application Engineering groups.Question: Is there any factory provisions for remote Start/Stop?Answer: Yes remote Start Stop is available using Option code 157-004 for the 4800/4900 models.Customer supplied harness with 4 position switch is supplied by customer for this optionSee Page 1B-12 for more details.Question: How do I get remote Engine Speed Control (ECU)?Answer: This option can be requested on new orders via data code 163-008 or 163-009. If theseoptions are not present, remote engine speed control can also be accessed via the JS19connector located in the engine compartment and is part of the main engine harness A0663518. See Pages 1B-13 to 1B-15 for schematic information.Question: Can you get a fast idle interface on the WST?Answer: Data code 148-035 provides a fast idle switch interface tied to the parking brake Seeschematics on Page 1B-11.Question: Does the 4700 model have the same electrical architecture as the 4800/4900 models?Answer: The 4700 electrical architecture is the same as other WST models but has different pinlocations in the front wall. These differences are defined in the pin out charts in chapter 1Cdependant on your model and production year.Question: Can you deactivate the brake override circuit so that the 4-way flashers stay on when thebrakes are activated?Answer: The instructions to disable the brake override circuit are located on page 1A-21.Question: I have installed aftermarket LED tail lamps to my vehicle but they are not working properly.Answer: The WST electrical turn signal system requires a minimum amperage load from the tail lightsystem. When LED lights are used a resistor needs to be added to increase the load to anacceptable level. See Page 1A-21 for installation information.Question: Does WST offer switches that are ignition controlled that are not rated to 20 amps or relaycontrolled?Answer: Yes WST offers a (6) optional switch option for this application with 329-071 see page 1A15.Question: If I need to stop the truck from starting under specific conditions is there a way I can do this?Answer: Yes, tying into the Neutral Safety switch circuit (located in the front wall PDM, see page 1A7) with a signal controlled relay will stop the truck from starting. the starting schematics canbe found in Mod 156 and are specific for each engine Make.

Western Star Bodybuilder Book: Revision 3.11BHarness/Schematic Location InformationEngine and ABSP. in ChassisHarnessTRANSFER CASEMODULE376AUXILIARYTRANSMISSIONMODULEEPA 2007 Mega Fuse Location34C / 352EOF LIGHTINGMOD 294MAIN CAB HARNESSMODULE320AXLEWIRINGINTERLOCKMOD 87BAXLE TEMPMOD 865FRONTWALLHARNESSMOD 321TRAILERWIRINGENGINE HARNESSMODULEPRIMARYTRAILER CBL286 / 283MOD 296MAIN CHASSISHARNESSLIGHTINGEXT. LIGHTSMOD 288MOD 318 / 31JBEACONLIGHTSMOD 327FORWARDCHASSIS &SIGNAL312 / 314315 / 310ADDITIONALPRIMARYMOD 303SUPPLEMENTALCABLEMOD 308ADDITIONALSUPPLEMENTALMOD 334POWER WIRINGALTERNATOR BATTERYCABLESROUTINGSMOD 125POWERWIRINGMOD 29AMOD 291JUMPSTARTMOD 295CAB POWERBATTSHUTOFFMOD 926MOD 293PTOMOD 372 / 885EPA 2010 Power NetDistribution Box (PNDB)

Western Star Bodybuilder Book: Revision 3.147/48/49/69 Main Chassis Harness Schematic1BP. 1B-4

Western Star Bodybuilder Book: Revision 3.11BChassis Harness Break Out LocationsAll EPA 2010 LHD ModelsP. 1B-5000F000EChassis Harness Max Complexity HarnessNew electrical systems for 2010 will be shown using a Max Complexityharness layout L06-82534. This new diagram system provides allpossible connections that are available on one single diagram. Thisinformation provides the connector part number and the Sales Codeand or Module number that the option and schematic detail can befound.How to use this diagram systemŸ Use the diagram to locate where on the chassis the connections willbe located.Note: Some locations are approximate due to wheelbase differences.Ÿ Not all connections shown in the diagram will be on any one specificvehicle.Note: To order new harnesses for service or repair refer to PartsBulletin 54-018.109A001Z000A000BSPLAY000CBOLT ON108ADROPCASTRear FrameFront WallConnectionsFront EngineCrossmember068BFront108A096ABack of Cab082ABOC Crossmember082A068A051A039A027A015A000ASee diamond indicatorson next page forHarness Breakout Location000D

Western Star Bodybuilder Book: Revision 3.11BChassis Max Complexity HarnessChassis Front Wall (Sleeper Opt)Conn # 23-13153-007Mod 288All LHD EPA 2010 Models: Front Wall FwdChassis Options 3A ForwardConn # 23-13153-004Mod 288Chassis Options 1A ForwardConn # 23-13153-022Mod 288Note: Maximum complexity diagrams show all possible connections.All connections will never be present on any one vehicle.PTO Chassis ForwardConn # 23-13142-407Mod 885Main Chassis Harness JCHAHeadlight RHConn # 23-13153-007Conn # 23-13144-601Mod 288Mod 288Wiring - fog lamp RHConn # 23-13146-200Mod 313Wiring-road/foglampConn # 23-13146-601Wiring - road lamp RHMod 313Conn # 23-13142-215Mod 313Snow Plow LightsConn # 23-13146-601Mod 313Snow Plow Signal LightsPrimary Trailer receptacleConn # 23-13146-601Conn # 23-13153-600Mod 313Mod 296FrontWallWiring - fog lamp LHConn # 23-13146-200Mod 313Wiring - road lamp LHConn # 23-13142-215Mod 313P. 1B-6

Western Star Bodybuilder Book: Revision 3.1Chassis Max Complexity Harness1BP. 1B-7All LHD EPA 2010 Models: Under Cab RearNote: Maximum complexity diagrams show allpossible connections. All connections willnever be present on any one vehicle.Axle Temp SensorConn # 23-13146-402Mod 865Supplemental trailer cable wiringConn # 23-13153-607Mod 308Primary Trailer receptacleConn # 23-13153-601Mod 296Backof CabTail LightsConn # 23-13146-600Mod 294RefDwg L06-82534

Western Star Bodybuilder Book: Revision 3.14700/4800/4900/6900 Main Cab SchematicF60F612007 and Earlier uses aFused connection as shownEPA 2010Jumpers for Option Panel1BP. 1B-8

Western Star Bodybuilder Book: Revision 3.14700/4800/4900 LHD PTO Schematic372-036 Dash mounted electrical PTO switch with indicatorUse with Allison Transmission in combinationwith DDC 13/15/16 /TransmissionHarness BulkheadseeMOD882seeMOD320Ref SchematicG06-795431BP. 1B-9

Western Star Bodybuilder Book: Revision 3.14800/4900 LHD PTO Schematic372-033 Dash mounted PTO controls with indicator light and park brake interlockDDC DD13 / DD15 / DD16 EnginesManual TransmissionCummins PTO InstallationFront wallEngine sideTo be connectedto PTO by customerCab Side1BP. 1B-10

Western Star Bodybuilder Book: Revision 3.11B4800/4900 Remote Fast IdleP. 1B-11Remote Fast Idle CircuitsŸ Wires 440D, 440F & 440E are spliced into the cruise switch wiring in the dash and runthough the front wall at a 40 pin connector pins 11, 9 & 10 respectively.Ÿ Harness P/N A06-74578-000 ties into the 40 pin connector on the engine side of the frontwall and ends in a 6 pin connector with wires 440D, 440F, 440E & 440G. (This harnessis approximately 51" long.)Ÿ Harness WWS 87208-3428-210 connector PS19 0 will connect to the 6 pin connectorand have enough length to route to the end of frame, i.e. this harness is 210" long.148-070 Engine remote interface with preset fast idle 163-008 Engine remote interface at back of cab with blunt cut wires163-009 Engine remote interface at End of Frame with blunt cut wires163-008 Engine remote interface at End of Frame with 6’ extra cableUsed With Cruise control OnlyJumper Harness Installationfor End of Frame RemoteIdle ControlWithoutCruise ControlRef SchematicG06-74072With Cruise ControlSee Sales code 149Ref DrawingD06-57690

Western Star Bodybuilder Book: Revision 3.11B4800/4900 Remote Start StopP. 1B-12157-004 Manual remote engine start/stopThis solution supplies an internal cab harness that terminatedat the Front Wall/Sleeper Harness Bulkhead connection plugsee page 1-8 for pin more details.Front Wall/SleeperHarness BulkheadStart CircuitStart Request SignalCole Hersee956-41244 position ignition switchor equivelentIgnitionaccessoryOptional ignitionfeed Indicator diodeStop EngStop Engine LampCheck EngCheck Engine LampIgnitionCommon GroundBody builder supplied harness from front wall connectionsStart enableswitch ref7830-3401in dashOptional Indicator lightssupplied by Body Builder

Western Star Bodybuilder Book: Revision 3.148/49/69 Engine Remote Interface - EOFEnd of Frame Engine Remote Interface - 148-071148-071 Engine remote interface with increment/decrement 163-008 Engine remote interface at back of cab with blunt cut wires163-009 Engine remote interface at End of Frame with blunt cut wires163-008 Engine remote interface at End of Frame with 6’ extra cableref dwg 872B1-34281BP. 1B-13

Western Star Bodybuilder Book: Revision 3.148/49/69 Engine Remote Interface - EOFEnd of Frame Engine Remote Interface - 148-035148-035 Preset fast idle switch interface for fixed single speed withengine compartment wires and park brake interlock 163-998 No engine opt/rpm controls wiringDash Mounted 70 Pin engine connector PENGFront Wall 40 pin enginetransmission connectionsee Page 1-10 pin 36ref mod 28670 Pins40 Pins1BP. 1B-14

Western Star Bodybuilder Book: Revision 3.1Exterior Cab Body Builder Connections4800/4900/6900 Exterior Cab Body Builder Connections353-053 Vehicle interface wiring with body builder blunt cut wire interface at end of Frame353-054 Vehicle interface wiring with body builder blunt cut wire interface at back of cabRef Dwg G06-796541BP. 1B-15

Western Star Bodybuilder Book: Revision 3.11B4800/4900/6900 Plow Light PrepP. 1B-164800/4900/6900 Plow Light Prep329-054 (5) Extra switches wired to 9 pole junction box mounted behind passenger seatRight Turn Alt FlasherTL06LSW1 AS10BLeft TurnTL05LSpinnerSW2 AS09BMarker LtTL08BTUnderbodySW3 AS08BBackupBL01AYCargo BoxSW4 AS07BGroundGroundGD2MZ/NDGD2MZ/NDJunction Box AssemblyP/N 87330-3438CL Cab21.0”6.0”Junction BoxLocationRef Dwg A06-59428ST/TR/TL LH 39LST/TR/TL RH 39RMarker Lt 46ARH Turn 38RLH Turn 38LTail Lt 237 Way Trlr Stop/Turn 36BBackup 120BseeModule320Left ChasRight ChasMarkersRight TrailerLeft TrailerParkStopReverseseeModule288

Western Star Bodybuilder Book: Revision 3.14700 10 AMP Switches & In Cab 1AU329-1AV329-1AW329-1AX1BP. 1B-17No Wiring-vehicle Interface(2) Ignition Controlled Extra Switches With IndicatorLight, 10 Amps, Wired Between Passenger/driver Seat(4) Ignition Controlled Extra Switches With IndicatorLight, 10 Amps, Wired Between Passenger/driver Seat(6) Ignition Controlled Extra Switches With IndicatorLight, 10 Amps, Wired Between Passenger/driver Seat(10) Ignition Controlled Extra Switches With IndicatorLight, 10 Amps, Wired Between Passenger/driver Seat399A 1A399C 1A399E 1A399G 1A399V 1A400B 1A534L 1A534M 1A534G 1A534H 1A

Western Star Bodybuilder Book: Revision 3.11B4700 Body Builder Cab Access PortP. 1B-18In dashinterface harnessconnectionsPre wired switch harnessescan be ordered using theoption codes found insection 1A page 1A-1313Air LinesIn floor tray coverSwitches can be blunt cut wiresor prewired to an independantrealy box ready for yourbody connections.In cab connections are protectedfrom the weather and corrosion.In cab easy accessharness trayCab flooraccess panelBlunt cut switchwires coiledbehind driver seatAccessing the cab on the 4700 SF and SB is quick and simpleusing the floor access plate at the back of the cab.look for cuts in the floor mat at the center of the cabunder this flap is a cover plate which gives you structurallydesigned access from the chassis into the cab.5.9"4.9"1/4” NCPrewired switches are routedon a tray at the driver side floorboard. this tray allows you tosafely rout wires to the dashinside the cab and eliminatesephosteery and interior damageallong with assembly timePlates can be removed from the unit and mounted ata workbench if desired for better sealing of cab matingharness.Pre wired SwitchesIn dashinterface harnessconnectionsAir Lines3.9"2.9"5.9"In floor tray coverIn cab easy accessharness trayCab flooraccess panel3.9"access openingin floorEasy AccessFloor PlateCab Floor accessPre cutfloor matsIn CabVehicle interfaceUnitPDM Unit 353-060

Western Star Bodybuilder Book: Revision 3.11B4700 Body Builder Interface353-021 Vehicle interface wiring circuit access boxmounted behind/beside passenger seat.353-059 Vehicle interface blunt cut wiring mountedbetween driver and passenger seats.353-060 Vehicle interface blunt cut wiring mountedbetween driver and passenger seats.P. 1B-19Ref SchematicG06-83410Mod 320Ref SchematicG06-83410

Western Star Bodybuilder Book: Revision 3.1Speed Sensor Connections InterfaceSpeed Sensor Connections InterfaceAdding addition equipment such as the vehicle speed when installinga salt/sander spreader with a controlled flow rate at different speedscan be accomplished by adding a second.adding a second speed sensor tothe rear bearing cover of the transmission after delivery.You will need to purchase the following partsP/N FUL K4148 (two wire speed sensor),P/N FUL X8 0801M (mounting screw)P/N A06-26585-000 (adapter harness)to connect this signal to your system simply cut off the access endof the adapter harness and wire to body harness.cut off female end andwire to body harnessconnects maleend to sensorBAdapter harness A06-26585-0001BP. 1B-20

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