2006 T300 Body Builders Manual

T300 Body Builder’s Manual

”Highest in Customer Satisfaction Among Conventional Medium-Duty Trucks”

”Highest in Customer Satisfaction with Medium-Duty Truc Truck k Dealer Service”

Medium Duty Body Builder’s Manual

Model: T300 For Trucks Produced After October 2005

Body Builder’s Manual Contents SECTION 1 - INTRODUCTION SCOPE

1-1

SECTION 2 - SAFETY AND COMPLIANCE SAFETY SIGNALS Warnings, cautions, and notes FEDERAL MOTOR VEHICLE SAFETY STANDARDS COMPLIANCE Incomplete Vehicle Certification Noise and Emissions Requirements

2-1 2-1 2-1 2-2 2-3

SECTION 3 - DIMENSIONS ABBREVIATIONS TURNING RADIUS OVERALL DIMENSIONS Side View — T300 with Single Rear Axle Side View — T300 with Tandem Rear Axle Front and Rear Views — T300 DETAIL VIEWS Side View Detail — T300 Left Side: Step and Cab Floor Height — T300 Right Side: Step and Cab Floor Height — T300 Top of Cab: Roof Mounted Options Back of Cab: Pedestal Mounted Flood Lights Back of Cab: Flush Mounted Flood Lights Crew Cab Conversion Dimensions Extended Cab Dimensions Crossmember Locations: Single Axle Crossmember Locations: Tandem Axle Crossmember Locations: Single Axle, Hydraulic Brakes Fuel Tank Locations COMPONENTS Frame Rail Configurations Battery Box and Air Tank Locations Fuel Tank Dimensions Horizontal Muffler Vertical Tailpipe on Cab Locations, Cummins ISB Vertical Muffler RH Side of Cab, Cummins ISB Transverse Muffler, Cummins ISB Horizontal Muffler Vertical Tailpipe on Cab, Cat C7 & Cummins ISC Vertical Muffler RH Side of Cab, Cat C7 and Cummins ISC Vertical Muffler RH Side of Cab, Cat C7 and Cummins ISC Transverse Muffler, Cat C7 and Cummins ISC

3-1 3-1 3-1 3-2 3-3 3-4 3-5 3-5 3-6 3-7 3-8 3-9 3-10 3-11 3-12 3-13 3-14 3-15 3-16 3-17 3-17 3-18 3-19 3-20 3-21 3-22 3-23 3-24 3-25

SECTION 4 - BODY MOUNTING CRITICAL CLEARANCES Rear Wheels and Cab Chassis with Reinforcements BODY MOUNTING USING BRACKETS Frame Sill Brackets Mounting Holes Frame Drilling BODY MOUNTING USING U–BOLTS Spacers Rear Body Mount

02/06

4-1 4-1 4-2 4-2 4-2 4-3 4-3 4-4 4-4 4-4 4-5

I

Body Builder’s Manual Contents SECTION 5 - FRAME MODIFICATIONS INTRODUCTION DRILLING RAILS Location and Hole Pattern MODIFYING FRAME LENGTH Frame Insert Changing Wheelbase Crossmembers WELDING Precautions

5-1 5-1 5-1 5-1 5-2 5-2 5-4 5-4 5-4

SECTION 6 - ELECTRICAL INTRODUCTION ELECTRICAL CIRCUITS Capacity Additional Spare Circuits for Wiring Optional Body Harness Fuse and Circuit Identification Circuits Wired Through the Ignition Connecting Ignition Circuits Circuits Wired to Battery INSTALLING A THIRD BATTERY WIRING FOR A LIFTGATE Liftgate Power Source Connecting the Liftgate Power ENGINE CONNECTIONS REMOTE PTO/THROTTLE HARNESS

6-1 6-1 6-1 6-1 6-3 6-4 6-5 6-5 6-5 6-6 6-6 6-6 6-7 6-7 6-8

APPENDIX A - VEHICLE IDENTIFICATION VEHICLE IDENTIFICATION NUMBER VIN Location Chassis Number Locations CERTIFICATION LABELS Components and Weights Label Tire/Rim and Weight Rating Data Label Incomplete Vehicle Certification Label Noise Emission Label Paint Identification Label COMPONENT IDENTIFICATION Engine Identification Transmission Identification Front Axle Identification Rear Axle Identification APPENDIX B - WEIGHT DISTRIBUTION INTRODUCTION Abbreviations CALCULATIONS Weight Distribution without Body Weight Distribution with Body Chassis Weights Option Weights COMPLETE (LOADED) VEHICLE Water Level Load Weight Distribution Analysis Body Length INDEX

A-1 A-1 A-1 A-2 A-2 A-2 A-2 A-3 A-3 A-3 A-3 A-4 A-4 A-4 B-1 B-1 B-2 B-2 B-4 B-4 B-5 B-12 B-12 B-13 B-13

II

02/06

Figures Figure 2–1. Figure 2–2. Figure 3–1. Figure 3–2. Figure 3–3. Figure 3–4. Figure 3–5. Figure 3–6. Figure 3–7. Figure 3-8.1 Figure 3-8.2 Figure 3-8.3 Figure 3-8.4 Figure 3-8.5 Figure 3-8.6 Figure 3-8.7 Figure 3–9.1 Figure 3–9.2 Figure 3–9.3 Figure 3–9.4 Figure 3–10. Figure 3–11. Figure 3–12. Figure 3–13. Figure 3–14 Figure 3–15. Figure 3-16 Figure 3-17 Figure 3-18 Figure 3-19 Figure 3-20 Figure 3-21 Figure 3-22 Figure 3-23 Figure 3-24 Figure 4–1. Figure 4–2. Figure 4–3. Figure 4–4. Figure 4–5. Figure 4–6. Figure 4–7. Figure 4–8. Figure 4–9. Figure 4–10. Figure 4–11. Figure 5–1. Figure 5–2. Figure 5–3. Figure 5–4. Figure 5-5 Figure 6–1. Figure 6–2. Figure 6–3. Figure 6–4. Figure 6-5 Figure A–1. Figure A–2. Figure A–3. Figure A–4. Figure A–5. Figure B–1. Figure B–2. Figure B–3. Figure B–4. Figure B–5.

02/06

Incomplete Vehicle Certification Document. Location of Certification Labels - Driver’s Door and Frame T300 W/ Single Rear Axle: Height and Length Measurements. T300 W/ Tandem Rear Axle: Height and Length Measurements. T300 Front View: Width and Ground Clearance Measurements [inches (mm)]. T300 Rear View: Width and Ground Clearance Measurements [inches (mm)]. T300 Detailed Side View: Specific Measurements [inches (mm)]. T300 Battery Box Step and Cab Floor: side view, left side. T300 Fuel Tank Step and Cab Floor: side view, right side. Top of Cab View, Roof Mounted Options Top of Side Cab View, Roof Mounted Options Pedestal Mounted Flood Lamp Locations Pedestal Mounted Flood Lamp Clearance Flush Mounted Flood Lamp Locations Crew Cab Conversion Overall Dimensions Extended Cab Overall Dimensions T300 Crossmember Location and Overall Width with Doors Open, Single Axle. T300 Crossmember Locations, Tandem Axle. T300 Crossmember Location, Single Axle, Hydraulic Brakes. T300 Fuel Tank Locations. T300 10.5 and 10.62–Inch Rail Measurements [Inches (mm)] T300 Battery Box and Air Tank Measurements [Inches (mm)]. T300 Optional 22-inch Fuel Tank Mounting Measurements [Inches (mm)]. T300 Standard Fuel Tank and Horizontal Exhaust Measurements [Inches (mm)]. T300 Vertical Tailpipe on Side of Cab [Inches (mm)]. T300 Vertical Tailpipe on Back of Cab [Inches (mm)]. T300 with 56 Gallon RH Under Cab T300 with 40 Gallon RH Under Cab T300 Transverse Muffler Under Cab T300 Vertical Tailpipe on Side of Cab T300 Vertical Tailpipe on Back of Cab T300 Vertical Muffler for 56 Gallon Fuel Tank RH Under Cab T300 Vertical Muffler for 40 Gallon Fuel Tank RH Under Cab T300 Transverse Muffler for Short Transmissions T300 Transverse Muffler for Long Transmissions Minimum Clearance Between Top of Rear Tires and Body Structure Overhang. Minimum Back–of–Cab Clearance. Air Gap with Frame Rail with Reinforcements Spacer Between Frame Sill and Body Rail — Rubber or Plastic. High Compression Spring Between the Mounting Bolt and Upper Bracket. Rubber Spacer Between Brackets. Hole Location Guidelines for Frame Rail and Bracket. Crossmember–Gusset Hole Pattern Requirements. Acceptable U–Bolt Mounting with Wood and Fabricated Spacers. Clearance Space for Air Lines and Cables. Example of Fishplate Bracket at Rear End of Body, used with U–Bolts. Detail of Frame Extensions and Joint Welding. Frame Insert Comparison of Original, Shortened, and Extended Wheelbases. Crossmember Added When Distance Exceeds 60 Inches (1524mm). Heat Treated Warning Label Location of Optional Body Harness Connection. Prewired Truck and Body Harness (after 3/98) Adding a Third Battery Liftgate Circuit Breaker Inside Battery Box. Remote PTO/Throttle Control Wiring Harness Connector Pin Outs Vehicle Identification Number (VIN). Driver’s Door and Door Frame Labels Engine Identification Plate. Front Axle Identification. Rear Axle Identification Labels. Balanced Load: CGf 100 in. from front axle. Unbalanced Load: CGf 133 in. from front axle. Balanced Body Unloaded: CGf 156 in. (3962 mm) from front axle. Liftgate Example: CGf 246 in. (6248 mm) from front axle. Loaded Vehicle Example: CGf 156 in. (3962 mm) from front axle.

III

2-2 2-2 3-2 3-3 3-4 3-4 3-5 3-6 3-7 3-8 3-8 3-9 3-9 3-10 3-11 3-12 3-13 3-14 3-15 3-16 3-17 3-17 3-18 3-18 3-19 3-19 3-20 3-20 3-21 3-22 3-22 3-23 3-24 3-25 3.25 4-1 4-1 4-2 4-3 4-3 4-3 4-3 4-4 4-5 4-5 4-6 5-2 5-2 5-3 5-4 5-5 6-3 6-4 6-6 6-7 6-8 A-1 A-2 A-3 A-4 A-4 B-2 B-3 B-10 B-10 B-12

Tables

TABLE 3-1. TABLE 3-2. TABLE 3-4. TABLE 3-5. TABLE 3-6. TABLE 3-7. TABLE 3-8. TABLE 3-9.1. TABLE 3-9.2 TABLE 3-9.3 TABLE 3-10 TABLE 3-11 TABLE 6-1.1 TABLE 6-2 TABLE 6-3 TABLE A-1. TABLE B-1. TABLE B-2. TABLE B-3. TABLE B-4. TABLE B-5. TABLE B-6.

Abbreviations Used. Turning Radius-T300 w/single and tandem rear axles T300 w/ Single Rear Axle: Overall Dimensions [inches (mm)]. T300 w/ Tandem Rear Axle: Overall Dimensions [inches (mm)]. T300 Front and Rear Suspension (FS/RS) Centerline (C/L) to Rail Measurements. T300 Battery Box Step and Cab Floor Measurements. T300 Fuel Tank Step and Cab Floor Measurements. T300 Crossmember Locations: Single Axle, Air Brake T300 Crossmember Locations: Tandem Axles, Air Brakes T300 Crossmember Locations: Single Axle, Hydraulic Brakes T300 Fuel Tank and Optional Battery Box Locations for Common WB Configurations Frame Rail Strength Characteristics. Additional Spare Circuits for Wiring Third Battery Installation Parts Remote PTO/Throttle Wiring Harness Model Year Letter (CODE) Designations. T300 Single Rear Axle “Bare” Chassis Tare Weights (no driver, no fuel), lb (kg). T300 Tandem Rear Axle “Bare” Chassis Tare Weights (no driver, no fuel), lb (kg). T300 Typical Options T300 Weight distribution and chassis rating calculation (sample) Recommended T300 Body Lengths (Single Rear Axle). Recommended T300 Body Lengths (Tandem Rear Axle).

IV

3-1 3-1 3-2 3-3 3-5 3-6 3-7 3-13 3-14 3-15 3-16 3-17 6-2 6-6 6-8 A-1 B-4 B-5 B-6 B-13 B-14 B-14

02/06

Section 1 Introduction

This manual was created to provide body builders with appropriate information and guidelines useful in the body planning and installation process. This information will be helpful when installing bodies or other associated equipment. This manual contains appropriate dimensional information, guidelines for mounting bodies, guidelines for modifying frames, electrical wiring information, and other information useful in the body installation process. The intended primary users of this manual are body builders who install bodies and associated equipment on Kenworth T300 Medium Duty vehicles. Dealers who sell and service the vehicle will also find this information useful. This Body Builders’ Manual can be very useful when specifying a vehicle, particularly when the body builder is involved in the vehicle definition and ordering process. Early in the process, professional body builders can often contribute valuable information that reduces the ultimate cost of the body installation. This manual is not a maintenance manual or an operation manual. • For chassis maintenance and repair information consult the Kenworth ServiceNet available in the Service Department of the selling dealer or order a custom shop manual or parts catalog for tyour vehicle through your local dealer. •

For chassis operating information consult the Operator’s Manual, included with each vehicle. They can also be ordered from your local dealer.

1-1

Section 2 Safety & Compliance

SAFETY SIGNALS We’ve put a number of aler ting messages in this book. Please read and follow them. They are there for your protection and information. These alerting messages can help you avoid injury to yourself or others and help prevent costly damage to the vehicle. Key symbols and “signal words” are used to i ndicate what kind of message is going to follow. Pay special attention to comments prefaced by “WARNING”, “CAUTION”, and “NOTE.” Please don’t ignore any of these alerts.

Warnings, cautions, and notes WARNING

When you see this word and symbol, the message that follows is especially vital. It signals a potentially hazardous situation which, if not avoided, could result in death or serious injury. This message will tell you what the hazard is, what can happen if you don’t heed the warning, and how to avoid it.

Example: WARNING! Be sure to use a circuit breaker designed to meet liftgate amperage requirements. An incorrectly specified circuit breaker could result in a electrical overload or fire situation. Follow the liftgate installation instructions and use a circuit breaker with the recommended capacity.

CAUTION

Signals a potentially hazardous situation which, if not avoided, could result in minor or moderate injury or damage to the vehicle.

Example: CAUTION: Never use a torch to make a hole in the rail. Use the appropriate drill bit.

NOTE

Provides general information: for example, the note could warn you on how to avoid damaging your vehicle or how to drive the vehicle more efficiently. Example: Note: Be sure to provide maintenance access to the battery box and fuel tank fill neck.

Please take the time to read these messages when you seen them, and remember: WARNING Indicates a potentially hazardous situation which, i f not avoided, could result in death or serious injury. CAUTION Signals a potentially hazardous situation which, if not avoided, could result in minor or moderate injury or damage to the vehicle. NOTE Useful information that is related to the topic being discussed.

2-1

Section 2 Safety & Compliance FEDERAL MOTOR VEHICLE SAFETY STANDARDS COMPLIANCE As an Original Equipment Manufacturer (OEM), Kenworth Truck Co. ensures that our products comply with all applicable U.S. or Canadian Federal Motor Vehicle Safety Standards. However, the fact that this vehicle has no fifth wheel and that a Body Builder (Intermediate or Final Stage Manufacturer) will be doing additional modifications means that the vehicle was incomplete when it left the build plant. See next section and Appendix A for additional information.

Incomplete Vehicle Certification An Incomplete Vehicle Document is shipped with the vehicle, certifying that the vehicle is not complete. See Figure 2–1. In addition, affixed to the driver’s side door frame or edge is an Incomplete Vehicle Certification label. See Figure 2–2.. For further information on Vehicle Certification and Identification, see APPENDIX A “VEHICLE IDENTIFICATION.”

NOTE

These documents list the U.S. or Canadian Federal Motor Vehicle Safety Standard regulations that the vehicle complied with when it left the build plant. You should be aware that if you add, modify or alter any of the components or systems covered by these regulations, it is your responsibility as the Intermediate or Final Stage Manufacturer to ensure that the complete vehicle is in compliance with the particular regulations upon completion of the modifications. U.S. EPA Noise Label (U.S. registered vehicles only) Tire, Rim and Weight Rating Data label

Final Stage Manufacturer Label to be Installed by Final Stage Manufacturer

Chassis Serial Number

Safety Mark (Canadian Registry Only)

Figure 2-1. Incomplete Vehicle Certification Document

Incomplete Vehicle Certification Label

Major Components and Weights Label

Figure 2-2. Locations of Certification Labels - Driver’s Door and Frame

As the Intermediate or Final Stage Manufacturer, you should retain the Incomplete Vehicle Document for your records. In addition, you should record and retain the manufacturer and serial number of the tires on the vehicle. Upon completion of the vehicle (installation of the body and any other modifications), you should affix your certification label to the vehicle as required by Federal law. This tag identifies you as the “Intermediate or Final Stage Manufacturer” and certifies that the vehicle complies with Federal Motor Vehicle Safety Standards. (See Figure 2–2.) For Canadian final stage manufacturers see: http://candagazette.gc.ca/partII/2002/20020213/html/sor55-e.html and http://www.tc.gc.ca/acts-regulations/GENERAL/M/mvsa/regulations/mvsrg/toc_mvsrg.htm for the regulations. Or contact: Transport Canada Tower C, Place de Ville, 330 Sparks Street Ottawa, Ontario K1A 0N5 (613) 990-2309 TTY: 1-888-675-6863 02/06

2-2

Section 2 Safety & Compliance Noise and Emissions Requirements NOTE

NOTE

This truck may be equipped with a converter muffler or independent converter unit i n order to meet both noise and exhaust emissions requirements. Removal or tampering with the converter muffler or independent converter will not improve engine performance. Also tampering is against the rules that are established by the U.S. Code of Federal Regulations and Environment Canada Regulations. The converter muffler or independent converter may only be replaced with an approved part. Relocation of converter mufflers or independent converters will affect noise and emission performance. Contact the engine manufacturer for any requirements and restrictions prior to any modifications. In particular there are requirements and restrictions for exhaust pipe materials and for maximum exhaust system lengths from turbo outlet to muffler inlet.

2-3

02/06

Section 3 Dimensions ABBREVIATIONS Throughout this section and in other sections as well, abbreviations are used to describe cer tain characteristics on your vehicle. The chart below lists the abbreviated terms used.

Table 3-1. Abbreviations Used. A

OVERALL VEHICLE LENGTH

AF

FRAME RAIL OVERHANG LENGTH BEHIND REAR AXLES

B

FRONT BUMPER TO FRONT AXLE LENGTH

CA

BACK OF CAB TO REAR AXLE LENGTH

D

CAB HEIGHT

WB

WHEELBASE LENGTH

TURNING RADIUS Approximate turning radius specifications for the T300 are listed (by wheelbase) in the following tables. Tables 3-2 and 3-3 list turn radius information for chassis with standard components. Optional components may give different results. TABLE 3-2 Turning Radius Steering Gear

TAS 40

Rear Axles

Single

Tire, Bridgestone

R250F 245/70R19.5

Single R250F 295/75R22.5

TAS 65

Tandem

Single R294 275/70R22.5 Tandem

M110P

Single R250 295/80R22.5 Tandem

Single M843 12R22.5 Tandem

Wheelbase Range, Inch

Curb to Curb Est. Radius, ft

Wall to Wall Radius Est., ft (1)

140 152 176 188 206 218 236 245 254 260 272 145 150 160 200 215 230 245 260 280 175 190 205 220 235 250 260 140 150 160 170 180 190 165 175 190 140 150 160 170 180 190 165 175 190 140 150 160 170 180 190 165 175 190

24 26 30 32 34 36 39 40 41.5 42 44 20 21 22 27 29 31 32 34 36 26 27 29 31 33 35 36 22 23 24 25 27 28 26 28 30 31 33 34 36 38 40 38 40 43 34 36 38 40 42 44 42 44 47

27 29 33 35 37 39 42 43 44.5 45 47 23 24 25 30 32 34 35 37 39 29 30 32 34 36 38 39 25 26 27 28 30 31 29 31 33 34 36 37 39 41 43 41 43 46 37 39 41 43 45 47 45 47 50

(1) For stainless steel clad alum channel bumper, subtract 1.5 ft.

02/06

3-1

Section 3 Dimensions

OVERALL DIMENSIONS

This section includes drawings and charts of the base model T300 vehicle, which includes a 10,000 lb. front suspension, a 20,000 lb. rear suspension, and R250F 295/75R22.5 tires. Use these drawings to plan overall vehicle configurations. On the pages that follow, detail drawings show particular views of each vehicle component. They illustrate important measurements critical to designing bodies of all types. See the “Contents” at the beginning of the manual to locate the drawing you need.

T300 with Single Rear Axle 68 (1,727)

CA

D

WB

B

AF

A

Figure 3-1. Side View — T300 with Single Rear Axle Height and Length Measurement TABLE 3-4. T300 with Single Rear Axle: Overall Dimensions [inches (mm)] UNLADEN WB

A

AF

140 (3556)***

232.2 (5898)

55 (1397)

72 (1829)

145 (3810)

237.2 (6025)

55 (1397)

77 (1956)

150 (3810)

237.2 (6025)

50 (1270)

82 (2083)

152 (3861)***

244.2 (6203)

55 (1397)

84 (2134)

160 (4064)

261.2 (6634)

64 (1626)

92 (2337)

176 (4470)***

277.2 (7041)

64 (1626)

108 (2743)

188 (4775)***

301.2 (7651)

76 (1930)

120 (3048)

194 (4928)

301.2 (7651)

70 (1778)

126 (3200)

200 (5080)

309.2 (7854)

72 (1829)

132 (3353)

206 (5232)***

325.2 (8260)

82 (2083)

215 (5461)

333.2 (8463)

81 (2057)

147 (3734)

218 (5537)***

349.2 (8870)

94 (2388)

150 (3810)

230 (5842)

357.2 (9073)

90 (2286)

162 (4115)

236 (5994)***

373.2 (9479)

100 (2540)

168 (4267)

245 (6223) ***

381.2 (9683 )

99 (2515)

177 (4496)

254 (6452)***

421.2 (10699)

130 (3302)

186 (4724)

260 (6604)***

445.2 (11308)

148 (3759)

192 (4877)

150 (3810)

204 (5182)

140 (3556)

212 (5385)

272 (6909)*** 390 (7112)

459.2 (11664) 457.2 (11613)

* CA is measured from true back of cab to rear axle centerline. *** Hydraulic brake chassis only available in these wheelbases.

B

37.2 (945)

CA*

138 (3505)

D **

104.9 (2664)

** Determined with Bridgestone R250F 295/75R22.5 front tires.

3-2

02/06

Section 3 Dimensions Side View — T300 with Tandem Rear Axle 68 (1,727)

Rear Bogie C/L CA

D

WB

B

AF

A

Figure 3-2. Side View — T300 with Tandem Rear Axle Height and Length Measurement TABLE 3-5. T300 with tandem Rear Axle: Overall Dimensions [inches (mm)] UNLADEN WB

A

AF

B

175 (4445)

283.2 (7193)

71 (1803)

107 (2718)

190 (4826)

307.2 (7803)

80 (2032)

122 (3099)

205 (5207)

331.2 (8412)

89 (2261)

137 (3480)

220 (5588)

355.2 (9022)

98 (2489)

235 (5969)

379.2 (9632)

107 (2718)

250 (6350)

403.2 (10241)

116 (2946)

182 (4623)

260 (6604)

427.2 (10851)

130 (3302)

192 (4877)

280 (7112)

451.2 (11460)

134 (3403)

212 (5385)

37.2 (945)

* CA measured from true back of cab to rear bogie centerline ** Determined with Front Tire Bridgestone R250F 295/75R22.5

02/06

CA *

3-3

152 (3861) 167 (4242)

D **

104.9 (2664)

Section 3 Dimensions Front and Rear Views — T300 39.5 (1003) 107.7 (2735)

8.9 (226) 79.1 (2019) 95.3 (2421)

Figure 3-3. T300 Front View: Width and Ground Clearance Measurements [inches (mm)]. 71.8 (1824) 36 (914)

17 (432) 76.6 (1946) Highest Point on Roof 46.3 (1177)

34 (864)

76.4 (1941) Highest Point in Dip of Roof

Bottom of Frame Rail Flange 9.7 (248)

71.9 (1827) 96 (2440)

Figure 3-4. T300 Rear View: Width and Ground Clearance Measurements [inches (mm)]. 3-4

02/06

Section 3 Dimensions Detail Views Side View Detail

68 (1727)

29.8 (757) 76.7 (1948)

30 (762)

66.9 (1699)

FS

RS

AXLE C/L

37.2 (945)

BOTTOM FLANGE

61 (1550)

36 (914)

14 (355)

82.8 (2102)

Figure 3-5. T300 Detailed Side View: Specific Measurements [inches (mm)].

TABLE 3-6. T300 Front and Rear Suspension (FS/RS) Centerline (C/L) to Rail Measurements CENTERLINE OF AXLE TO BOTTOM FLANGE OF RAIL [IN. (MM)] LOAD    E    L    X    A    R    A    E    R    E    L    G    N    I    S

   E    L    X    A    R    A    E    R    M    E    D    N    A    T

02/06

REAR SUSPENSION

FS

RS

UNLADEN LADEN

REYCO 79KB

8.4 (213) 6.6 (168)

9.0 (229) 6.6 (168)

UNLADEN LADEN

REYCO 79KB WITH HELPER 26K

8.4 (214) 6.6 (168)

11.3 (287) 8.2 (208)

UNLADEN LADEN

HENDRICKSON HAS 210L/230L AIR

8.4 (213) 6.6 (168)

7.8 (198) 7.8 (198)

UNLADEN LADEN

REYCO 102 MULTILEAF

8.4 (213) 6.6 (168)

8.5 (216) 7.2 (183)

UNLADEN LADEN

HENDRICKSON HAS 402

8.4 (213) 6.6 (168)

7.8 (198) 7.8 (198)

UNLADEN LADEN

HENDRICKSON RT-403

8.4 (213) 6.6 (168)

8.6 (218) 7.6 (193)

UNLADEN LADEN

CHALMERS 854-40-XL

8.4 (213) 6.6 (168)

9.3 (236) 6.9 (175)

3-5

Section 3 Dimensions Detail Views Left side: Step and Cab Floor Height - T300

C B A Figure 3-6. T300 Battery Box Step and Cab Floor: Side View, Left Side [inches (mm)]. Table 3-7. T300 Battery Box Step and Cab Floor Measurements.

POSITION

UNLADEN

LADEN

IN. (MM)

IN. (MM)

A FIRST STEP

21.3 (540)

18.9 (481)

B SECOND STEP

37.0 (940)

34.7 (881)

C CAB FLOOR

44.6 (1133)

42 (1069)

3-6

02/06

Section 3 Dimensions Detail Views Right side: Step and Cab Floor Height - T300

C B A

Figure 3-7. T300 Fuel Tank Step and Cab Floor: Side View, Right Side [inches (mm)].

Table 3-8. T300 Fuel Tank Step and Cab Floor Measurements.

RECTANGULAR STEEL

ROUND 22” DIA ALUM

STEEL TOOLBOX

02/06

POSITION

UNLADEN IN. (MM)

LADEN IN. (MM)

C CAB FLOOR

44.6 (1,133)

42 (1,069)

A FIRST STEP

23.3 (592)

21.0 (533)

B SECOND STEP

38.1 (967)

35.8 (908)

A FIRST STEP

15.6 (396)

13.3 (338)

B SECOND STEP

32.2 (820)

29.9 (759)

A FIRST STEP

21.6 (549)

19.3 (490)

B SECOND STEP

37.6 (955)

35.3 (896)

3-7

Section 3 Dimensions Detail Views Top of Cab View - T300, Roof Mounted Options

14.6 (370)

14.6 (370)

17.2 (436)

45.7 (1161) Dual 22” Rectangular Horn Locations

20.9 (531)

Radio Antenna Location

Figure 3-8.1. Top of Cab View, T300, Roof Mounted Options.

3.9 (100)

5.0 (127)

Highest Roof Point

Figure 3-8.2. Top of Side Cab View, T300, Roof Mounted Options 3-8

02/06

Section 3 Dimensions Detail Views Back of Cab View - T300, Pedestal Mounted Flood Lamps 20.9 (530)

This Location Is Not Used With Vertical Tailpipe Back Of Cab

20.9 (530)

High Mount Flood Lamp Elevation

71.0 (1803)

Low Mount Flood Lamp Location

C/L

23.6 (599)

Figure 3-8.3. Pedestal Mounted Flood Lamp Locations, [inches (mm)].

Cab Roof

4.2 (107) Figure 3-8.4. Pedestal Mounted Flood Lamp Clearance, [inches (mm)]. 02/06

3-9

Bottom of Rail

Section 3 Dimensions Detail Views Back of Cab View - T300, Flush Mounted Flood Lamps

25 (635)

25 (635)

High Mount Flood Lamp Elevation Mid Mount Flood Lamp Elevations

62.4 (1585) Mid Mount Flood Lamp Location for Vertical Tailpipe Back of Cab

14.4 (365)

14.4 (365)

43.7 (1110) 37.2 (945)

C/L

Bottom of Rail Figure 3-8.5. Flush Mounted Flood Lamp Locations, [inches (mm)].

3-10

02/06

Section 3 Dimensions

Detail Views Crew Cab Conversion Dimensions - T300

Figure 3-8.6. T300 Crewcab Conversion, Overall Dimensions, [Inches (mm)].

NOTE

02/06

This Configuration is Not Available from the Factory.

3-11

Section 3 Dimensions Detail Views Extended Cab Dimensions - T300

B

Figure 3-8.7. T300 Extended Cab, Overall Dimensions, [Inches (mm)].

NOTE

This Configuration is Not Available from the Factory.

3-12

02/06

Section 3 Dimensions Detail Views Crossmember Locations - T300, Air Brake, Single Rear Axle AF

WB

118 (2997)

50 - 55 Deg.

A B C D E Figure 3 - 9.1. T300 Crossmember Location and Overall Width with Doors Open TABLE 3-9.1. T300 Air Brakes Single Rear Axle, Crossmember Locations: Measured From Front Axle Centerline [Inches (mm)]*** WB

A

CB

145 *

85.2 (2165)

(1)

146 - 150 *

90.7 (2305)

(1)

151 - 160 *

90.7 (2305)

Y

161 - 185 *

101.8 (2585)

Y

186 - 200 *

101.8 (2585)

Y

201 - 215 *

90.7 (2305)

216 - 230 *

101.8 (2585)

231 - 245 *

B

CB

C

CB

D

1.) For without a square end of frame crossmember with an AF range of 80 (2032) to 125 (3175) or for with a square end of frame crossmember for an AF range of 87 (2210) to 125 (3175), a crossmember is installed at:

140.4 (3565) 118.3 (3005)

Y

Y

162.4 (4125)

Y

101.8 (2585)

Y

162.4 (4125)

Y

246 - 260 *

101.8 (2585)

Y

162.4 (4125)

Y

261 - 280 *

101.8 (2585)

Y

140.4 (3565)

150 - 173 **

None

174 - 187 **

101.8 (2585)

Y

188 - 206 **

101.8 (2585)

Y

134.8 (3425)

207 - 229 **

101.8 (2585)

Y

145.9 (3705)

Y

230 - 245 **

101.8 (2585)

Y

156.9 (3985)

Y

246 - 260 **

112.8 (2865)

Y

162.4 (4125)

Y

E

156.9 (3985)

E = WB + 64.4” (1636 mm) 201.0 (5105) 178.9 (4545)

Y

217.5 (5525)

None

2.) For AF range of 126 (3200) to 173 (4394) a 2nd crossmember is installed at: E = WB + 112.4” (2855 mm)

201.0 (5105)

Y Driveline centerbearing (CB) is mounted on this crossmember. (1) Dimensions noted are based on the use of the standard T300 transmission, rear axle and driveline. * STD (1710) or SPL170 Driveline Series ** SPL100 Driveline Series *** Applies to FS5406, FSO6406/FSO8606, RT8608, RT8709, FR9210, FRO11210

To assist in preparing drawings for body and allied equipment, a frame layout in DXF format or a FAX frame layout can be ordered by specifying one of the following sales code on the trucks sales order: 6390096 FAX FRAME LAYOUT TO DEALER (WEEK 4) *INFORMATION ONLY, NO CHANGES* 6390097 DXF FRAME LAYOUT TO DEALER (WEEK 4) *INFORMATION ONLY, NO CHANGES* 02/06

3-13

Section 3 Dimensions Detail Views Crossmember Locations - T300, Air Brake, Tandem Rear Axles

AF

WB

A B C E Figure 3-9.2. T300 Crossmember Location TABLE 3-9.2. T300 Air Brakes Tandem Rear Axles, Crossmember Locations: Measured From Front Axle Centerline [inches (mm)]*** WB

A

CB

157 - 177

90.7 (2305)

178 - 193

90.7 (2305)

Y

194 - 217

101.7 (2585)

Y

218 - 231

101.7 (2585)

Y

232 - 247

90.7 (2305)

248 - 256

101.7 (2585)

257 - 262

101.7 (2585)

B

CB

C

CB

E

118.3 (3005)

Y

156.9 (3985)

Y

151.4 (3845)

Y

340.4 (8646)

Y

156.9 (3985)

Y

350.4 (8900)

140.3 (2565) 325.4 (8265)

Y Driveline centerbearing (CB) is mounted on this crossmember. *** Applies to FS5406, FSO6406/FSO8606, RT8608, RT8709, FR9210, FRO11210 To assist in preparing drawings for body and allied equipment, a frame layout in DXF format or a FAX frame layout can be ordered by specifying one of the following sales code on the trucks sales order: 6390096 FAX FRAME LAYOUT TO DEALER (WEEK 4) *INFORMATION ONLY, NO CHANGES* 6390097 DXF FRAME LAYOUT TO DEALER (WEEK 4) *INFORMATION ONLY, NO CHANGES*

3-14

02/06

Section 3 Dimensions Detail Views Crossmember Locations - T300, Hydraulic Brake, Single Rear Axle AF

WB

A B C D E Figure 3 - 9.3. T300 Crossmember Location TABLE 3-9.3. T300 Hydraulic Brakes Single Rear Axle, Crossmember Locations: Measured From Front Axle Centerline [inches (mm)]*** WB

A

CB

B

CB

C

140 (3556)

101.8 (2585)

152 (3861)

90.7 (2305)

Y

176 (4470)

101.8 (2585)

Y

188 (4775)

101.8 (2585)

Y

206 (5232) *

101.8 (2585)

Y

151.4 (3845)

206 (5232) **

112.8 (2865)

Y

151.4 (3845)

218 (5537)

101.8 (2585)

Y

145.9 (1705)

Y

236 (5994)

101.8 (2585)

Y

156.9 (3985)

Y

245 (6223)

101.8 (2585)

Y

156.9 (3985)

Y

254 (6452) *

101.8 (2585)

Y

162.4 (4125)

Y

201 (5105)

254 (6452) **

112.8 (2865)

Y

167.9 (4265)

Y

201 (5105)

260 (6604) *

101.8 (2585)

Y

162.4 (4125)

Y

201 (5105)

260 (6604) **

112.8 (2865)

Y

167.9 (4265)

Y

201 (5105)

272 (6909) *

112.8 (2865)

Y

167.9 (4265)

Y

217.5 (5525)

272 (6909) **

112.8 (2865)

Y

178.9 (4545)

Y

217.5 (5525)

CB

D

E 1.) For without a square end of frame crossmember with an AF range of 80 (2032) to 125 (3175) or for with a square end of frame crossmember for an AF range of 87 (2210) to 125 (3175), a crossmember is installed at: E = WB + 64.4” (1636 mm) 2.) For AF range of 126 (3200) to 173 (4394) a 2nd crossmember is installed at:

E = WB + 112.4” (2855 mm)

Y Driveline centerbearing (CB) is mounted on this crossmember. * SPL100 ONLY ** SPL140 ONLY *** Applies to FS6406, FSO6406, FSO8406, RT8608L, RT8709, FR9210, FRO11210

To assist in preparing drawings for body and allied equipment, a frame layout in DXF format or a FAX frame layout can be ordered by specifying one of the following sales code on the trucks sales order: 6390096 FAX FRAME LAYOUT TO DEALER (WEEK 4) *INFORMATION ONLY, NO CHANGES* “6390097 DXF FRAME LAYOUT TO DEALER (WEEK 4) *INFORMATION ONLY, NO CHANGES* 02/06 3-15

Section 3 Dimensions Detail Views Fuel Tank Locations - T300

A

B

Fuel Tank Shown

A

B

Standard Battery Box Shown

FIGURE 3-9.4. Fuel Tank Locations

TABLE 3 - 10. T300 Fuel Tank and Optional Battery Box Locations for Common Wheelbase Configurations [inches (mm)]. A*

Fuel Tank and Battery Box

B

RH Under Cab Rectangular Steel

50 Gal

33.5 (851)

40 Gal

25.7 (652)

56 Gal Round 22” Aluminum

75 Gal

32.8 (833)

35.6 (904) 47.3 (1201)

100 Gal

62.2 (1580)

120 Gal

74.3 (1887)

56 Gal

35.6 (904)

LH and RH Behind Cab Round 22” Aluminum

75 Gal

77.3 (1963)

100 Gal

47.3 (1201) 62.2 (1580)

LH Behind Cab Rectangular Steel

50 Gal

78.3 (1989)

30.5 (775)

70 Gal

77.7 (1974)

42.6 (1082)

LH Under Cab Round 22” Aluminum

56 Gal 75 Gal

32.8 (833)

35.6 (904) 47.3 (1201)

LH Behind Cab Cantilever Box

N/A

87.2 (2216)

17.8 (451)

* Measured from centerline of front axle.

3-16

02/06

Section 3 Dimensions COMPONENTS Frame Rail Configurations — T300 .5 (12.7)

3.74 (95)

10.5” Rail

3.46 (87.8)

.31 (7.94)

10.62” Rail Heat Treated

10.5 (266.7)

10.24 (260)

10 (25.4)

10 (254) Inverted L Reinforcement Shown

0.25 (6.35)

3.5 (88.9)

9.88 (251)

10.62 (269.9)

Optional Insert, Heat Treated Shown

0.25 (6.35)

0.25 (6.35)

FIGURE 3-10. T300, 10.5” and 10.62 “ Rail Measurements [Inches (mm)] RAIL STRENGTH

10.5” Rail W/O Inverted L Reinforcement

10.5” Rail with Inverted L Reinforcement

10.62” Rail, Heat Treated

10.62” Rail With Insert, Both Heat Treated

Yield Strength, PSI

80,000

80,000

120,000`

120,000

Section Modulus, Cu In

12.31

16.75

14.8

24.37

RBM, Lbs-Inch

985,000

1,340,000

1,776,000

2,925,000

TABLE 3 - 11. Frame Rail Strength Characteristics

Battery Box and Air Tanks — T300 Standard Battery Box With Air Tanks 33 (838)

8.7 (220)

7.2 (184) 12.6 (319)

13.6 (346) Laden 15.9 (404) Unladen

Rear View Ground

FIGURE 3-11. T300 Battery Box and Air Tank Measurements [Inches(mm)] 3-17 02/06

Section 3 Dimensions 22-inch Fuel Tanks — T300

14.3 (363)

Figure 3-12. T300 Optional 22” Fuel Tank Mounting Measurements [inches (mm)]

Fuel Tank and Exhaust — T300 Standard Rectangular Fuel Tank Mounting

Std Horizontal Exhaust/Muffler Mounting From outside of rail - 1.3 (32) 3.3 (84)

11.1 (282) 7.2 (184)

For muffler offset 2” to right for PTO clearance

Rear View

12.2 (309)

Rear View Figure 3-13. T300 Standard Rectangular Fuel Tank and Horizontal Exhaust Measurements [inches (mm)]

3-18

02/06

Section 3 Dimensions Horizontal Muffler-Vertical Tailpipe on Cab — T300, Cummins ISB

Bottom of Tailpipe

67 (1701)

11.1 (282) 13.8 (351)

12.2 (309)

From Outside Of Frame

FIGURE 3-14 T300 Vertical Tailpipe on Side of Cab [Inches(mm)]

Bottom of Tailpipe

68.2 (1732)

11.1 (282)

13.8 (351)

12.2 (309) From Outside Of Frame

FIGURE 3-15 T300 Vertical Tailpipe on Back of Cab [Inches(mm)] 02/06

3-19

Section 3 Dimensions Vertical Muffler- RH Side of Cab — T300, Cummins ISB 7.0 (177) Bottom of Tailpipe

62.6 (1589)

C/L

11.8 (300) 11.4 (290)

FIGURE 3-16. T300 with 56 Gallon Fuel Tank, RH Under Cab [Inches (mm)]

Bottom of Tailpipe

62.6 (1589)

C/L

11.8 (300) 11.4 (290)

FIGURE 3-17. T300 with 40 Gallon Fuel Tank RH Under Cab. [Inches (mm)] 02/06

3-20

Section 3 Dimensions Transverse Muffler — T300, Cummins ISB

C/L Chassis

4.5 (115)

15.1 (383)

17 (432)

FIGURE 3-18. T300 Transverse Muffler Under Cab [Inches (mm)]

02/06

3-21

Back Of Cab

Section 3 Dimensions Horizontal Muffler- Vertical Tailpipe on Cab — T300, Caterpillar C7 & Cummins ISC Bottom of Tailpipe

7.9 (201)

67.0 (1701)

13.1 (332)

36.3 (921)

15.6 (396)

14.3 (363)

FIGURE 3-19. T300 Vertical Tailpipe on Side of Cab [Inches (mm)]

C/L 10.75 (273) to shield (not shown)

Bottom of Tailpipe

24.8 (631)

4.9 (125) for shield (not shown)

62.8 (1596)

13.1 (332)

36.3 (921)

15.6 (396)

14.3 (363)

FIGURE 3-20. T300 Vertical Tailpipe on Back of Cab [Inches (mm)] 3-22

02/06

Section 3 Dimensions Vertical Muffler - RH Side of Cab — T300, Caterpillar C7 & Cummins ISC 0.4 (10) for Cat C7 210 HP or Less 1.5 (37) for Cummins ISC any HP or Cat C7 greater than 210 HP

Bottom of Tailpipe

7 (128) to Back Of Cab

63.2 (1606)

FIGURE 3-21. T300 Vertical Muffler for 56 Gallon Fuel Tank RH Under Cab [Inches (mm)]

02/06

3-23

Section 3 Dimensions Vertical Muffler - RH Side of Cab — T300, Caterpillar C7 & Cummins ISC 0.4 (10) for Cat C7 210 HP or Less 1.5 (37) for Cummins ISC any HP or Cat C7 greater than 210 HP

Bottom of Tailpipe

63.2 (1606)

FIGURE 3-22. T300 Vertical Muffler for 40 Gallon Fuel Tank RH Under Cab [Inches (mm)]

02/06

3-24

Section 3 Dimensions Transverse Muffler — T300, Caterpillar C7 & Cummins ISC Back Of Cab

4.7 (120)

3 (76) To Rear Cab Crossmember

C/L

16.3 (413)

7.8 (197)

9.2 (234)

FIGURE 3-23. T300 Transverse Muffler for Shorter Transmissions (1) [Inches (mm)] (1) Allison 2100/2200/2500, 3000HS. 6 Speed Eaton Autoshift, 6 Speed Eaton Manual Transmissions Back Of Cab

7.8 (195 )

3 (76) To Rear Cab Crossmember

C/L

16.3 (413)

7.8 (197)

9.2 (234)

FIGURE 3-24. T300 Transverse Muffler for Longer Transmissions (2) [Inches (mm)] (2) Allison 3000/3500 with RDS, 3000EVS, 9 &10 Speed Eaton Manual Transmissions 02/06

3-25

Section 4 Body Mounting CRITICAL CLEARANCES Rear Wheels and Cab CAUTION:

Insufficient clearance between rear tires and body structure could cause damage  to the body during suspension movement. Allow at least 8 inches clearance (See  Figure 4–1.) 

Normal suspension movement could cause contact between the tires and the body. body. To To prevent this, mount the body so that the minimum clearance between the top of the tire and the bottom of the body is 8 inches (203 mm). This should be measured with the body empty. empty. See Figure 4–1.

FIGURE 4-1. Minimum Clearance Between Top Top Of Rear Tires And Body Structure Overhang.

CAUTION:

Maintain adequate clearance between back of cab and the front (leading edge) of mounted body. See Figure 4–2.

Note:

Be sure to provide maintenance access to battery box and fuel tank fill neck.

The true distance from the centerline of the front axle to the back of the cab is 68 inches (1727 mm). It is recommended that the leading edge of the body be mounted a minimum of 4 inches (102 mm) behind the cab. The result is a minimum back–of–cab clearance of 72 inches (1829 mm) from the front axle to the leading edge of the body. body. See SECTION 3 “DIMENSIONS” for for further details on dimensions and clearances. Also, see APPENDIX B “WEIGHT DISTRIBUTION” for for explanation of back–of–cab (BOC) / CA calculations. 72 (1829) Minimum

4 (102)

FIGURE 4-2. Minimum Back of Cab Clearance 4-1

02/06

Section 4 Body Mounting Body

0.5 (12.7) Gap

Reinforcement

Frame Rail

Body

Reinforcement

FIGURE 4-3. Air Gap with Frame Frame Rail with Reinforcement

Chassis with Reinforcements Reinforcements A 10½-inch non-heat treated frame rail with a reinforcement inverted “L” “L” reinforcement will have an air gap of approximately 6.4 mm (¼ inch) between the bottom of the outsert reinforcement reinforcement flange and the top of the frame rail flange. This gap is for manufacturing manufacturing tolerance purposes and guarantees that the outsert reinforcement will fit over the frame rail.

WARNING: Note:

If the frame rail flanges are modified or damaged, the rail could fail prematurely and cause an accident. When mounting a body to the chassis, DO NOT drill holes in the upper or lower flange of the frame rail. Mount the body using body mounting brackets or U–bolts.

Install a 12.7 mm (½ inch) thick spacer on the frame rail aft of the reinforcement to support the body. The purpose of the spacer is i s to fill the “gap” See Figure 4–3. above.

Body Mounting Using Brackets CAUTION:

Always install a spacer between the body subframe subframe and the top flange of the frame rail. Failure to do so could result in corrosion due to dissimilar materials.

Installation of a spacer between the body subframe and the top flange of the frame rail will help prevent premature wear of the components due to chafing or corrosion.

Frame Sill If the body is mounted to the frame with brackets, brackets, we recommend that the frame sill spacer be made from a strip of rubber or plastic (delrin or nylon). These materials will not undergo large dimensional changes during periods of high or low humidity. The strip will be less likely to fall out during duri ng extreme relative motion between body and chassis. See Figure 4–4. 02/06

4-2

Section 4 Body Mounting

Body Subframe (Rail) Spacer Chassis Frame (Rail) Sill

FIGURE 4-4. Spacer Between Frame Sill and Body Rail - Rubber or Plastic

Brackets When mounting a body to the chassis with brackets, we recommend designs that offer limited amount of relative movement, bolted securely but not too rigid. Brackets should allow for slight movement between the body and the chassis. For instance, Figure 4–5 shows a high compression spring between the bolt and the bracket.

Spring

Rubber Spacer

FIGURE 4-6. Rubber Spacer Between Brackets

FIGURE 4-5. High Compression Spring Between the Mounting Bolt and Upper Bracket

Another possibility is mounting a rubber spacer between the brackets. See Figure 4–6. These designs will allow relative movement between the body and the chassis dur ing extreme frame racking situations. Extreme frame racking, and mountings that are too rigid, could cause damage to the body. This is particularly par ticularly true with tanker installations.

Mounting Holes When installing the lower bracket on frame rails the mounting holes in the chassis frame bracket and frame rail must comply with the general spacing and location guidelines illustrated in Figure 4–7. The hole diameter should not exceed the bolt diameter by more than .060 inches (1.5 mm).

Upper Frame Flange

A or B Equal to or Greater Than 2 Inches (50 mm)

Lower Frame Flange FIGURE 4-7. Hole Locations Guidelines for Frame Rail and Bracket 4-3

02/06

Section 4 Body Mounting 4 HOLES

6 HOLES

.5 IN. DIA.

.5 IN. DIA.

(12.7mm)

(12.7mm)

5.63

5.63

(143mm)

(143mm)

2.0

2.0

(50mm)

(50mm)

5.5

5.5

(140mm)

(140mm) 11.0 (279mm)

FIGURE 4-8. Crossmember-Gusset Hole Pattern Requirements. [inch(mm)]

Frame Drilling WARNING

When mounting a body to the chassis, DO NOT drill holes in the upper or lower flange of the frame rail. If the frame rail flanges are modified or damaged, the rail could fail prematurely and cause an accident. Mount the body using body mounting brackets or U–bolts.

CAUTION:

Use care when drilling the frame web so the wires and air lines routed inside the rail are not damaged, Failure to do so could cause an inoperable electrical or air system circuit.

WARNING

Do not drill new holes any closer than 2 inches (50 mm) to existing holes. Frame drilling affects the strength of the rails.

Hole Location Guidelines Holes must be located from the flange as indicated in Figure 4–7. They must be no closer than 2 inches (50 mm) to each other.

Note:

If your design permits placement of body mounting brackets at crossmember locations, you can use the crossmember gusset bolt holes for body mounting. See Figure 4-8

BODY MOUNTING USING U–BOLTS Spacers If the body is mounted to the frame with U–bolts, use a hardwood sill (minimum 1/2 inch (12 mm) thick) between the frame rail and body frame to protect the top surface of the rail flange. 02/06

4-4

Section 4 Body Mounting WARNING!

Do not allow the frame rails or flanges to deform when tightening the U–bolts. It will weaken the frame and could cause an accident. Use suitable spacers made of steel or hardwood on the inside of the frame rail to prevent collapse of the frame flanges.

Use a hardwood spacer between the bottom flange and the U–bolt to prevent the U–bolt from notching the frame flange. See Figure 4–9.

U-Bolt

Body Structure

Wood Sill 0.5 (12) Minimum

Truck Frame U-Bolt Spacer (Hardwood) Frame Rail Spacer (Fabricated Steel or Hardwood) FIGURE 4-9. Acceptable U-Bolt Mounting with Wood and Fabricated Spacers [inch(mm)]

WARNING!

Do not allow spacers and other body mounting parts to interfere with brake lines, fuel lines, or wiring harnesses routed inside the frame rail. Crimped or damaged brake lines, fuel lines, or wiring could result in loss of braking, fuel leaks, electrical overload or a fire. Carefully inspect the installation to ensure adequate clearances for air brake lines, fuel lines, and wiring. See Figure 4–10.

CAUTION:

Mount U–bolts so they do not chafe on frame rail. Failure to do so could result in premature wear of the U-bolt or frame rail.

Frame Rail

U-Bolt

Air Lines and Wiring Harness

Frame Rail Spacer (Hardwood or Steel

Check Clearance Space for Air Lines and Wiring

U-Bolt Spacer

FIGURE 4-10. Clearance Space for Air Lines and Cables

4-5

02/06

Section 4 Body Mounting

WARNING!

Do not notch frame rail flanges to force a U–bolt fit. Notched or damaged frame flanges could result in premature frame failure. Use a larger size U–bolt. Use a hardwood spacer as shown in Figure 4-9.

Rear Body Mount When U–bolts are used to mount a body we recommend that the last body attachment be made with a “fishplate” bracket. See Figure 4–11. This provides a firm attaching point and helps prevent any relative fore or aft movement between the body and frame.

Body Structure

Frame Rail

FIGURE 4-11 Example of Fishplate Bracket at Rear End of Body, used with U-Bolts 02/06

4-6

Section 5 Frame Modifications FRAME MODIFICATIONS Introduction The T300 offers customer specified wheelbases. So, in most cases frame modifications to produce a certain wheelbase should not be necessary. However, some installations may require slight modifications, while other installations will require extensive modifications. .Sometimes an existing dealer stock chassis may need to have the wheelbase changed to better fit a customer’s application. The modifications may be as simple as shortening or lengthening the frame cutoff, or they may be as complex as changing the wheelbase.

DRILLING RAILS Location and Hole Pattern If holes need to be drilled to attach anything to the rail, see SECTION 4 “BODY MOUNTING” for more information. Follow the general spacing and hole location guidelines on Page 4–3, Figure 4–7.

WARNING!

When mounting a body to the chassis, DO NOT drill holes in the upper or lower flange of the frame rail. If the frame rail flanges are modified or damaged, the rail could fail prematurely and cause an accident. Mount the body using body mounting brackets or U–bolts

WARNING!

Do not drill new holes any closer than 2 inches (50 mm) to existing holes. Frame drilling affects the strength of the rails.

CAUTION:

An appropriately sized bolt and nut must be installed and torqued properly in all unused frame holes. Failure to do so could result in frame crack initiation around the hole.

CAUTION:

Use care when drilling the frame web so the wires and air lines routed inside the rail are not damaged, Failure to do so could cause an inoperable electrical or air system circuit.

CAUTION:

Never use a torch to make holes in the rail. Use the appropriate diameter drill bit. Heat from a torch will affect the material properties of the frame rail and could result in frame rail cracks.

CAUTION:

Hole diameter should not exceed the bolt diameter by more than .060 inches (1.5 mm). Oversized holes could result in excessive frame wear around the hole.

Never use a torch to make a hole in the rail. Use the appropriate diameter drill bit. Hole pattern dimensions for crossmember designs are illustrated in Page 4–4, Figure 4–8. Hole diameter should not exceed the bolt diameter by more than .060 inches (1.5 mm).

5-1

02/06

Section 5 Frame Modifications

MODIFYING FRAME LENGTH The frame cutoff after the rear axle can be shortened to match a par ticular body length. Using a torch is acceptable; however, heat from a torch will affect the material characteristics of the frame rail. The affected material will normally be confined to within 1 to 2 inches (25 to 50 mm) of the flame cut and may not adversely affect the strength of the chassis or body installation. The frame cutoff can be lengthened by adding frame extenders. When extending 10.5” frame rails, the additional sections can be welded to the existing rails. The joint should be welded and reinforced as illustrated in Figure 5–1.

Note:

See page 5-4 for more information on welding frames.

WARNING!

Do not drill new holes any closer than 2 inches (50 mm) to existing holes. Frame drilling affects the strength of the rails.

Frame Insert A frame insert must be added after welding a frame rail extension to compensate for lost strength. The insert should be of the same material as the frame member, or of steel, and at least equal to the frame rail in thickness. Attachment of the insert to the frame should be made with Ream-Fit heat-treated bolts, 5/8 in. (16 mm) dia. or the next larger size. Both the reinforcement and frame holes should be reamed to provide a fit of from .001 in. to .003 in. (.025 to .076 mm) clearance. Do not weld reinforcing members. The insert should span a distance of at least 24 in. (610 mm) on either side of the crack to insure an even distribution of stresses. Cut the ends of the inser t at 45° as shown in Figure 5–2 unless the inser t extends to the end of the frame.

0

FIGURE 5-1 Detail of Frame Extension and Joint Welding

24 Inch Minimum (610 mm)

FIGURE 5-2 Frame Insert 02/06

5-2

Section 5 Frame Modifications Where possible, use existing bolt holes to attach the inser t to the frame. Bolt holes must not be located closer to the frame flanges than the present bolt pattern. If the insert is placed in a section of the main frame where few bolts are located, additional bolts are required. Use the following guideline for locating additional bolt holes.

Changing Wheelbase We do not recommend modifying the wheelbase. Occasionally, however, a chassis wheelbase will need to be reduced or lengthened. When this needs to be done there are a few guidelines that should to be considered.

WARNING!

When changing the wheelbase, be sure to follow the driveline manufacturer’s recommendations for driveline length or angle changes. Incorrectly modified drivelines can fail prematurely due to excessive vibration. This can cause an accident.

WARNING!

When changing the wheelbase, a continuous blank frame insert/outsert must be added in the area of the new rear suspension mounting bolts. All new mounting holes must pass through the original rail and the insert/outsert. Failure to do so could cause excessive stress in the original rail due to additional holes.

Before changing the wheelbase the driveline angles of the proposed wheelbase need to be examined to ensure that no harmful vibrations are created. Consult the driveline manufacturer for appropriate recommendations.

WARNING!

Do not drill new holes any closer than 2 inches (50 mm) to existing holes. Frame drilling affects the strength of the rails.

Before the rear suspension is relocated, check the new location of the spring hanger brackets. The new holes for the spring hanger brackets must not overlap existing holes and should not come any closer than 2 inches (50 mm) to existing holes in the frame.

WARNING!

When relocating a suspension bracket, do not mount it on the extended (added) section of a frame rail. The suspension loading could result in premature failure of the added section splice. This could cause an accident. Use care when planning the wheelbase so that the rear suspension bracket is always mounted on the original rail section. See Figure 5–3.

If you are extending the wheelbase, you may also have to extend the frame length to accommodate a body. When you reposition the rear suspension spring hangers, do not mount them on the added extended portion of the rail. The relocated rear suspension bracket should be located on the origi nal frame rails. See Figure 5–3. When reducing the wheelbase, we recommend that the suspension be moved forward and relocated on the original rail. The rail behind the suspension can then be cut to achieve the desired frame cutoff. See Figure 5–3.

5-3

02/06

Section 5 Frame Modifications WARNING!

Do not drill new holes any closer than 2 inches (50 mm) to existing holes. Frame drilling affects the strength of the rails.

Before the rear suspension is relocated, check the new location of the spring hanger brackets. The new holes for the spring hanger brackets must not overlap existing holes and should not come any closer than 2 inches (50 mm) to existing holes. Mount the suspension Brackets On the Original Rail (see frame insert section & fuguers 5-1 & 5-2)

Extended Wheelbase

Do Not Mount the Suspension Bracket On the Added Frame Rail

Original Wheelbase Relocated Rear Suspension

Shortened Wheelbase FIGURE 5-3 Comparison of Original, Shortened, and Extended Wheelbases.

Cut Frame at Rear to Obtain Desired Cutoff

Crossmembers After changing a wheelbase, an additional crossmember may be required to maintain the original frame strength. The maximum allowable distance between adjacent crossmembers is 60 inches (1524 mm). If the distance between adjacent crossmembers exceeds this dimension, add a crossmember between them. See Figure 5–4.

Less Than 60”

Before Wheelbase is Lengthened

Greater Than 60”

Additional Crossmember FIGURE 5 - 4 Crossmember Added When Distance Exceeds 60 Inches (1524 mm) 02/06

5-4

Section 5 Frame Modifications WELDING The 10.5 inch frame rail on the T300 is non–heat treated steel and can be welded using the following precautions. However, the 10.62 inch rail is heat treated; therefore, it is not weldable.

Precautions CAUTION: Before welding, disconnect the negative terminal battery cable.

CAUTION:

Before welding, disconnect the alternator terminals. Failure to do so could result in damage to the voltage regulator and/or alternator.

CAUTION:

The 10.62 (10-5/8) inch rail and the 9.88 (9-7/8) insert for the 10.62 inch rail are heat treated; therefore are not weldable. The inverted L reinforcement used with the 10.5 inch rail may be heat treated; and if so is not weldable. Welding can affect frame rail strength leading to a failure resulting in serious injury and /or an accident. Rail failures resulting from such modifications are not warrantable. To Determine if the inverted L reinforcement is heat treated: 1. Through Kenworth ECAT check for the following heat treated part numbers: A70-1041R/  RM, -1043R/RM, - 1044R/RM, -1045R/RM and A70-1056R/RM. Non heat treated part numbers are P078-239-XXXX, where XXXX is the length in mm. 2.

Or check for heat treat caution labels on the inverted L reinforcements. See figure 5-5.

FIGURE 5 - 5. Heat Treated Frame Rail Warning Label The 10.5 inch frame is non-heat treated 80 KSI High Strength Low Alloy (HSLA) steel. Use the following guidelines when welding this material. •

Due to low carbon and alloy contents, HSLA steels possess good characteristics for welding and are resistant to hot and cold cracking. Preheating and postheating is not required when welding HSLA steels. Even with high heat inputs, joint efficiencies (strength of weld compared to that of base metal) of 95 to 100 percent can be obtained.

•

For best results when arc welding, use a E 10018 (low hydrogen) electrode. Along with shielded arc welding, HSLA steels can be readily welded with gas metal arc (manual or semi-automatic) or submerged arc welding techniques. For details concerning specific welding techniques refer to welding wire manufacturers for recommendations.

5-5

02/06

Section 6 Electrical ELECTRICAL Introduction Electrical wiring can sometimes be very frustrating. This is especially true when adding circuits to an existing setup. Through the use of a optional body harness and additional spare circuits, we have tried to reduce the complexity associated with adding common circuits to a body installation.

Note:

The most common circuits that body builders may need are pre-connected to this optional wiring harness.

The new body related circuits can be added by connecting the added circuit wires to the appropriate wires in this harness.

ELECTRICAL CIRCUITS Capacity WARNING!

Do not install an electrical circuit that requires more amperage (electrical capacity) than what is available in the specific chassis circuit. An overloaded circuit could cause a fire. Compare the amperage requirements of the new circuit to the electrical current capacity of the existing chassis circuit before adding the body or other equipment.

When adding an electrical circuit, you must know the current capacity (amperes) of each circuit. The capacity of the existing system in the chassis must be enough to power the additional circuit. The new circuit will require a certain amount of power to operate; so, the existing (battery or alternator) power source must have the capacity to provide additional power or the new circuit will not function properly. Check the current (ampere) demand of the circuit to be added. Compare it to the current capacity of the circuit you are connecting into. The current carrying capacity of the wires, controls, switches, and circuit breakers that provide current to the circuit must be equal to or greater than the demand of the added circuit otherwise these components may not work properly. See Table 6–1.1 and Figure 6 - 2 for relevant circuit information.

Additional Spare Circuits for Wiring Depending on options ordered for the truck, there may be up to four spare circuits with label ed connectors available in the fuse panel (dash) harness. These are wired to labeled connectors on the engine or chassis harness. See Table 6-1.1 for circuit information, circuit CAPACITY, connector breakout locations and location to install fuses in fuse panel. For unused spare circuits, since these are separate circuits; you will not affect existing circuits in the chassis by connecting to them. An example of how these can be used: You can wire a device to be powered in the chassis to the chassis harness SPARE 3 connector. You can wire a switch to the SPARE 3 connector in the dash to control it. You should install an appropriate rated fuse in the fuse panel behind the dash. This circuit would only have power when the key is in the accessory position. Two wire connectors with 12” long pigtails and butt splices are available through PACCAR Parts. For connecting to the dash harness use K246-746. For connecting to the engine or chassis harness us K246-744. Fuses for the fuse panel are available through PACCAR Parts in different ratings: K371-39-5 for 5 ampere rating, K371-3910 for 10 ampere rating, and K371-39-15 for 15 ampere rating.

02/06

6-1

Section 6 Electrical    )   e   n   i   e   t    h   e   r   w    G   s    /    i    k   c   D   a   N    l    B   G    (

   )   e    t   w   i   o    l    h    l   e   w    Y   s    /    i    k   c   D   a   N    l    B   G    (

   )   e   n   i   e   t    h   e   r   w    G   s    /    i    k   c   D   a   N    l    B   G    (

   )   e   n   i   e   t    h   e   r   w    G   s    /    i    k   c   D   a   N    l    B   G    (

   1    P    S    C

   2    P    S    C

   3    P    S    C

   4    P    S    C

   1    P    S    C

   2    P    S    C

   3    P    S    C

   4    P    S    C

   B    A    D    N    G

   L    D    N    G

   C    A    D    N    G

   W    D    N    G

  :    t    l    l   r   e   r   s   n   n   e   f   o   a   i   a   s   e   o   e   g   r   w   d   e   n   r   s   F   n    i   g   r   a   e   s   :    l   e   g   a   d    f   s   s   e   n    h   e    h   n   a   s   h   a   i   o   a    h   e   w   r   e   h   r   e   n   a   e    t    C  n    i    t   e   r    f   e   g   f   r   t   e   n   r   a   l   e   s   n   a    L   o    h    E   c

  e    d    i   e   f   o   s    i   s   n   m   k   s   I   a   c   s   :   r   a   b   a   a   s    F    B   C    h   s    t    l    f   e    i    C  n   e   a   r   L   R   a    h

  :   s    f   s   o   e   d   r   n   e   e   r   n   n   a   a   n   r    i    h   h   o   g    f   c   n   e   t   n   e   r   e    i   g   L   a   n   e   r    E

   d   n   e    d   h   r    i   o   e   s   l   n   e   t   u   e   n   i    b   a   f    h   s   a   a   c   e   d   m  o   n   p   b   u   L   o    N

   5    2

   4    3

   7    3

 .   e   y   )   s   a   f    t    t   a   g    i   e    l   o   i   r   n   c   r   l    i   a   e   t   a   e   p    t   p   p   s   s   o   a   a   m  n   f   u   r   r   p    C   A   I   p    (   a

   5    1

   5    1

   0    1

   5    1

  r   e   o   r    l    i   o    W    C

  e    t    i    h    W    /    k   c   a    l    B

  w   o    l    l   e    Y    /    k   c   a    l    B

   d   e    R    /    k   c   a    l    B

  n   e   e   r    G    /    k   c   a    l    B

   t    i   u   c   r    i    C

   1    0    3

   2    0    3

   3    0    3

   4    0    3

   B   n    i    P

   X    A    1    0    3    C

   X    A    2    0    3    C

   X    A    3    0    3    C

   X    A    4    0    3    C

   A   n    i    P

   X    A    1    0    3    P

   X    A    2    0    3    P

   X    A    3    0    3    P

   X    A    4    0    3    P

   4    1

   4    1

   4    1

   4    1

  e   r   a   1   p    S

  e   r   a   2   p    S

  e   r   a   3   p    S

  e   r   a   4   p    S

  y   r   o   s   s   e   c   c    A

  n   o    i    t    i   n   g    I

  y   r   o   s   s   e   c   c    A

  y   r   e    t    t   a    B

  r   e   l   o   r    i   o    W    C   r   o    t   c   e   n   n   o    C   s   s   e   n   r   a    H   s    i   s   s   a    h    C   r   o   e   n    i   g   n    E

   h   s   a    D    d   n    i    h   e    B   r   o    t   c   e   n   n   o    C   s   s   e   n   r   a    H    h   s   a    D

   t    i   u   c   r    i    C

   B   n    i    P

   A   n    i    P    d   r   n   o   a   n   o    t    t    t   u   c   e   i   a   o   n    k   n   c   o   a   o   L   e   r    C    B

  m   e   u   e   g   r   u   m   i    i   n   W  a    i    G    M   r   o   n   t   o   c    l   e   e    b   n   a   n   o    L   C   :    h    t    d   e   e   r   g   r    i   u   u   a   c   r   e   p   i   w  o   r    S   C  o   h    P   T

   6    2

6-2

 .   s   r   o    t   c   e   n   n   o   c   e   r   a   p   s   s   s   e   n   r   a    h    h   s   a    d   o    t   g   n    i    t   c   e   n   n   o   c   e   s   u   r   o    f   s   e   c    i   p   s    t    t   u    b    h    t    i   w   s    l    i   a    t   g    i   p   g   n   o    l    ”    2    1    h    t    i   w   r   o    t   c   e   n   n   o    C   :    6    4    7      6    4    2    K

  s   r   o    t   c   e   n   n   o   c   e   r   a   p   s   s   s   e   n   r   a    h   s    i   s   s   a    h   c   r   o   e   n    i   g   n   e   o    t   g   n    i    t   c   e   n   n   o   c   e   s   u   r   o    f   s   e   c    i   p   s    t    t   u    b    h    t    i   w   s    l    i   a    t   g    i   p   g   n   o    l    ”    2    1    h    t    i   w   r   o    t   c   e   n   n   o    C   :    4    4    7      6    4    2    K

  g   n    i   r    i    W   r   o    f   s    t    i   u   c   r    i    C   e   r   a   p    S    l   a   n   o    i    t    i    d    d    A  .    1  .    1      6    E    L    B    A    T

02/06

Section 6 Electrical

Optional Body Harness The optional body harness can be connected to the chassis harness through a standard connector mounted on the left hand frame rail directly behind the battery box. See Figure 6–1.

Truck Body Connector to Chassis Harness

Left Rail

FIGURE 6 - 1. Location of Standard Body Harness Connection. For shipping purposes the body har ness is coiled and shipped loose in the cab. The body harness wire ends are tagged with circuit markers, identifying the connecting circuit. See Figure 6–2 on the next page.

02/06

6-3

Section 6 Electrical Fuse and Circuit Identification Fuses protect each wire (See CAPACITY in Figure 6-2 for capacity of each circuit). These are separate circuits; so by connecting to them, you will not affect the existing circuit in the chassis.

(For chassis built after First Quarter 1998)

WIRE DESCRIPTION

FUNCTION

PIN

CIRCUIT

WIRE COLOR

CAPACITY (AMPERES

FUSE NUMBER

WIRE GAUGE

BACKUP LAMP/ ALARM

X

L79BL

PINK / WHITE

10

29

12

RH TURN

RIGHT TURN SIGNAL LAMP

W

L34RT

GREEN / BLACK

20

1

14

LH TURN

LEFT TURN SIGNAL LAMP

Y

L33LT

YELLOW / BLACK

20

1

14

U

P4TRC

BLUE

15

37

10

BACKUP LP

AUX PWR

AUXILIARY POWER, BODY OR TRAILER

STD Config - IGN power

10

14

Optional config - BAT power

CLEARANCE LP STOP LP TAIL LP GND

MARKER/ CLEARANCE LAMPS

Z

L3MLB

BLACK

15

6

12

BRAKE LAMP

S

L2STC

RED

20

1

10

TAIL LAMP

V

L1TL

BROWN

15

5

12

GROUND

R

GND

WHITE

6

FIGURE 6 - 2. Optional Truck and Body Harness (after 3/98)

6-4

02/06

Section 6 Electrical Circuits Wired Through the Ignition The following circuits are powered on when the ignition key is turned to the ON position. Right and Left Turn Signal Backup Lamp After the connections are made by splicing into the optional body harness, the body components will have power when the similar chassis components receive power. For instance, when the right hand turn signal is activated and the right hand turn signal light flashes on the cab, the right hand turn signal light on the installed body will also flash.

Connecting Ignition Circuits Ignition circuits are tagged as follows: Right Turn Signal - The right turn signal wire is tagged RH TURN and is green/black. Left Turn Signal - The left turn signal wire is tagged LH TURN and is yellow/black. Backup Lamp - The backup lamp wire is tagged BACKUP LP and is pink/white. Ground - The ground wire is tagged GND and is white. Auxiliary Power - (Standard config for chassis built after first quarter, 1998) The auxiliary power circuit wire is tagged AUX PWR and is blue. Used for TRLR ABS if there is a trailer. This aux power circuit is a 15 ampere capacity circuit in the ignition circuit. Install a 15 ampere fuse in the fuse panel (locations 37) behind the dash panel. This aux power circuit can be used only when the ignition switch is ON.

Circuits Wired to Battery The following circuits are wired directly to the battery through a fuse and switch. Auxiliary Power - Optional if there are no trailer connections.) Brake Lamp Tail Lamp Clearance Lamps When the optional body harness is properly connected, the similar circuit in the body will also have power. If the chassis clearance lamps are activated, the body clearance lamps will also be activated. Auxiliary Power in Battery Circuit The auxiliary power circuit is a 10 ampere capacity circuit connected directly to the battery. Install a 10 ampere fuse in the fuse panel location 14 behind the dash. Use this circuit whenever you need power for auxiliary equipment. There is continuous power to this circuit (when the batteries are charged) even when the engine is off. For example, if the van body has interior lights or floodlights, these can be wired to the auxiliary power circuit and switched ON from inside the van. Connecting Battery Circuits Battery circuits are tagged as follows: Auxiliary Power (optional w/o TRLR connections) - The auxiliary power circuit wire is tagged AUX PWR and is blue. Brake Lamp - The brake lamp wire is tagged STOP LP and is red. Tail Lamp - The tail lamp wire is tagged TAIL LP and is brown. Clearance Lamps - The clearance lamp wire is tagged CLEARANCE LP and is black. 02/06

6-5

Section 6 Electrical INSTALLING A THIRD BATTERY A third battery is a published option and can be ordered with your vehicle. If this was not done, use Figure 6–3 as a guide for installing a third battery. You will need the following additional par ts to install the third battery: Qty.

Item

Part Number

1

BATTERY GRP 31 W/ THREADED POSTS

P27-6100-111

1

HOLDDOWN

K144–282

1

TRAY

K032–3424

1

JUMPER CABLE

K396–1010–008

1

JUMPER CABLE

K396–1020–008

2

NUTS

K169–111

TABLE 6 - 2. Third Battery Installation Parts

K396-1020-008 Battery Jumper

K396-1010-008 Battery Jumper

Third Battery (Optional)

Figure 6 -3. Adding a Third Battery

WIRING FOR A LIFTGATE

CAUTION:

Consult the liftgate manufacturer’s installation instructions for details concer ning wiring for their product and specific model.

A liftgate will usually require current much greater than 10 amperes. Typically, 100 to 150 amperes is required and some models require more than 150 amperes. For a liftgate installation a third battery is required for adequate power.

Note:

A liftgate installation must have a dedicated circuit to distribute power to the liftgate.

Liftgate Power Source Liftgate motors will typically use DC power. A convenient power source is the battery. Use Figure 6-4 as a guide. Install the circuit breaker inside the battery box on the rear panel.

WARNING!

DO NOT use a circuit breaker of lower capacity than the liftgate amperage requirements. If you do, it could result in an electrical overload or fire. Follow the liftgate installation instructions and use a circuit breaker with the recommended capacity.

A 200 ampere circuit breaker is available from PACCAR Parts. This should be adequate for most installations. However, the liftgate manufacturer’s recommendation should determine the actual circuit breaker used. 200 Ampere Circuit Breaker Part Number: 7855–7–200

6-6

02/06

Section 6 Electrical Connecting the Liftgate Power Follow these instructions to connect the liftgate to the third battery. See Figure 6-4. 1.

Connect the liftgate power cable to one terminal of the circuit breaker.

2.

Connect one end of the circuit breaker cable to the other terminal of the circuit breaker.

3.

Install the third battery.

4.

Connect the remaining end of the circuit breaker cable to the positive terminal of the third battery.

The cable used to connect the circuit breaker to the battery is available from PACCAR Parts. Circuit Breaker Cable Part Number: K396–1C91F014 The remainder of the wiring installation should be in accordance with the liftgate manufacturer’s installation instructions.

Liftgate Power Cable

Mount Circuit Breaker On this Panel

Connect K3961C91F014 Circuit Breaker Cable To Battery Positive Terminal

7855-7-200 Circuit Breaker

Figure 6 - 4. Liftgate Circuit Breaker Inside Battery Box

Engine Connections Electronic engines have the ability to send and receive control and warning signals from the components on the chassis and body. Consult the appropriate body builder manual before making connections to the engine electronic control unit (ECU) or to other electronic engine components.

02/06

6-7

Section 6 Electrical Remote PTO/Throttle Harness This option provides wiring from the engine to end of frame for remote control of engine throttle and a customer installed PTO. Controls are not provided with this option. Included is a 354.3 inch (9000 mm) wiring harness with a 7-pin connector that is routed to the end of frame. Any excess is coiled and secured there. See Table 6-3 for wiring harness connector pin outs and Figure 6-5 for end of frame connector configuration.

WARNING!

Follow the engine manufacturer’s guidelines for use of these circuits. See your engine manufacturer to verify that the engine is programed correctly for the intended applications. Failure to properly program the engine or wire these circuits could cause an accident.

Engine Harness, Cummins, ISC and ISB

Engine Harness, CAT C7

KW Wiring Harness Connector Pin Outs for CAT and Cummins

Engine Mfgr Circuit Function Name

Engine ECU Pin #

KW Circuit #

Wire Color

Wire Gauge

Pin Outs

69

Input Sensor Common #2

3

220

Brown

16

A

4

112

PTO On/Off Switch

56

112

Green

16

B

Not Used

None

None

Remote PTO Set

58

216

Pink

16

C

Remote Accelerator On/Off

3

59

Remote PTO Resume

60

217

Yellow

16

D

Remote Accelerator Supply

21

127

Remote Throttle

68

59

Purple

16

E

Remote Accelerator Position

26

60

Service Brake

64

32

Gray

16

F

Remote Accelerator Return

32

69

PTO Lamp

30

215

Blue

16

G

Engine Mfgr Circuit Function Name

Engine ECU Pin #

KW Circuit #

Switch Return

34

Remote PTO On/Off

Table 6 - 3. Remote PTO/Throttle Wiring Harness B

G

F

C

A E D

Figure 6 - 5. Remote PTO/Throttle Control Wiring Harness Connector Pinouts

6-8

02/06

Body Builders’ Manual Appendicies

APPENDIX A - VEHICLE IDENTIFICATION VEHICLE IDENTIFICATION NUMBER VIN Location Chassis Number Locations CERTIFICATION LABELS Components and Weights Label Tire/Rim and Weight Rating Data Label Incomplete Vehicle Certification Label Noise Emission Label Paint Identification Label COMPONENT IDENTIFICATION Engine Identification Transmission Identification Front Axle Identification Rear Axle Identification

A-1 A-1 A-1 A-2 A-2 A-2 A-2 A-3 A-3 A-3 A-3 A-4 A-4 A-4

APPENDIX B - WEIGHT DISTRIBUTION INTRODUCTION Abbreviations CALCULATIONS Weight Distribution without Body Weight Distribution with Body Chassis Weights Option Weights Rear Liftgate Example COMPLETE (LOADED) VEHICLE Water Level Load Weight Distribution Analysis Body Length

02/06

B-1 B-1 B-2 B-2 B-3 B-3 B-3 B-6 B-7 B-7 B-7 B-8

Appendix A Vehicle Identification VEHICLE IDENTIFICATION NUMBER A 17–character number (numeral and letter combination) forms the Vehicle Identification Number (VIN) which includes the Chassis Number. It contains among other information, the model year (4), assembly plant (5), and vehicle serial number (6). See Figure A–1

M

Serial Number

Chassis Number

Figure A - 1. Vehicle Identification Number (VIN). The model year (4) is designated by an alphanumeric code in the tenth character position in the VIN. See Table A-1 and Figure A–1.

Code 5 6 7 8 9

Year 2005 2006 2007 2008 2009

Table A - 1. Model Year (Code) Designations.

VIN Location The VIN is marked on the Incomplete Vehicle Certification Label (on trucks). It is located either on the driver’s door edge or door frame. See Figure A–2.

Chassis Number Locations The Chassis Number comprises the last six characters of the VIN. • • • • • • • •

The T300 chassis number is shown in multiple locations. Right frame rail, bottom flange (underside), about 4 to 4.5 ft. from the front end: stamped. Left frame rail, top of flange, about 4 to 4.5 feet from front end: stamped Left side of cab, lower right corner of door frame: stamped plate. Tire, Rim, and Weight Rating Data label. Major Components and Weights label. Noise Emission label. Paint Identification label.

A-1

02/06

Appendix A Vehicle Identification CERTIFICATION LABELS Components and Weights Label The Major Components and Weights Label is located on either the driver’s side door edge or on the door frame. See Figure A–2. It includes: chassis weight and gross weight; plus, model and serial numbers for the vehicle, engine, transmission, and axles. U.S. EPA Noise Label (U.S. Registrations Only) Final Stage Manufacturer Label to be Installed by Final Stage Manufacturer

Tire, Rim and Weight Rating Data label

Chassis Serial Number

Safety Mark (Canadian Registry Only)

Incomplete Vehicle Certification Label

Major Components and Weights Label

Figure 2-2. Locations of Certification Labels - Driver’s Door

Figure A - 2. Drivers Door and Door Frame Label

Tire/Rim and Weight Rating Data Label The Tire/Rim and Weight Rating Data Label is located on the driver’s side door edge, above the door latch. See Figure A–2. It contains the following information: • • • •

Note:

GVWR — Gross Vehicle Weight Rating GAWR FRONT and REAR — Gross Axle Weight Ratings for Front and Rear Axle TIRE/RIM SIZES AND INFLATION PRESSURES — Tire/Rim Sizes and Cold Pressure Minimums Chassis (Serial) Number GVWR is the TOTAL WEIGHT the vehicle is designed to carry. This includes the weight of the empty vehicle, loading platform, occupants, fuel, and any load. Axle weight ratings are listed on the edge of the driver’s door.

Incomplete Vehicle Certification Label The Incomplete Vehicle Certification Label is located on the driver’s side door edge below the latch. See Figure A–2. It contains the following information: • • • 02/06

DATE OF MANUFACTURE VIN — Vehicle Identification Number LISTING OF APPLICABLE FEDERAL MOTOR VEHICLE SAFETY STANDARDS

A-2

Appendix A Vehicle Identification Noise Emission Label The Noise Emission Label is located on the left upper front side of the door frame. It contains information regarding U.S. noise emission regulations, chassis number, and date of manufacture. Not provided on Canadian registered vehicles.

Paint Identification Label The Paint Identification Label contains the paint colors used by the factory to paint your truck. It lists frame, wheels, cab interior and exterior colors. This label is located underneath the dash to the left of the steering column support.

COMPONENT IDENTIFICATION Each of the following components has their own identification label.

Engine Identification The engine serial number is stamped on a plate located on the left front for Cummins and right rear of the engine for Caterpillar. For further information, please refer to the Engine Operation and Maintenance Manual (included in the glove compartment of each vehicle).

Engine Identification Location (Cummins ISC Shown)

Cummins Label Shown Figure A - 3. Engine Identification Location

A-3

02/06

Appendix A Vehicle Identification Transmission Identification The transmission identification number is stamped on a tag affixed to the right forward side of the transmission case. It includes among other specifications the transmission model, serial , and part number.

Front Axle Identification The front axle has a identification tag located on the front axle beam. It includes the axle model, part number and serial number.

Figure A - 4. Front Axle Identification

Rear Axle Identification The rear axle identification numbering system i ncludes two labels or stamps. 1.

Axle Housing Number Tag, located on the left forward side of the housing arm. This tag identifies the axle housing.

2.

Axle Differential Carrier Identification, located on the top side of the differential carrier. The following information is either stamped, or marked with a metal tag: Model No., Carrier Production Assembly No., Carrier Assembly Serial No., Gear Ratio, Axle Specifications Number and OEM par t number and country of origin.

2 1

Figure A - 5. Rear Axle Identification

Note:

Illustrated identification tag locations are typical. Actual locations may vary by axle manufacturer and with single versus tandem axles.

02/06

A-4

Appendix B Weight Distribution INTRODUCTION In the Medium Duty truck market, matching the wheelbase to the body specification is extremely important. Selection of the wrong wheelbase may lead to premature component failure, poor performance, and ultimately a dissatisfied customer. Before selecting the proper wheelbase, it is impor tant to have a basic understanding of weight distribution.

Abbreviations Throughout this section, abbreviations are used to describe cer tain features and requirements of the vehicle (see the list below). Review this list frequently so you know what the abbreviations mean. AF BL CA

Note:

= = =

The T300 CA figures are measured from the true back of cab to the centerline of the rear axle. To obtain a usable CA the body builder must subtract any required space behind the cab, which may be needed for other equipment.

CG

=

CGf

=

FA = GVWR = L = Lf Lr RA WB

Frame rail overhang length – behind the rear axle Body Length Back of cab to centerline of rear axle

= = = =

Center of gravity: the balance point or center of a load. It is usually identified by a circle with alternating black and white quarters. Distance from the centerline of the front axle to the center of gravity of the load (L). The load can be any load such as a fuel tank, a body, or the payload. Front Axle Gross Vehicle Weight Rating Load: the weight that is carried. This could be the body, the payload or any item that has its weight distributed between the two axles. Portion of load (L) carried by front axle Portion of load (L) carried by rear axle Rear Axle Wheelbase Length

02/06

B-1

Appendix B Weight Distribution CALCULATIONS Weight Distribution without Body There are two primary equations used in weight distribution calculations: •

The first equation determines the portion of the load carried by the rear axle (Lr). Lr =

•

CGf WB

XL

Portion of Load Carried by the Rear Axle

Equation 1

The second determines the portion of the load carried by the front axle (Lf). Lf =

Note:

Portion of Load Carried by the Front Axle Equation 2

L - Lr

For the purposes of calculation, the load (L) in these equations can be either actual revenue producing load or it can be other weight that is carried such as the van body or an optional fuel tank. 100 lbs

Front Axle 100 In. 200 In. Figure B - 1. Balanced Load: CGf 100 in. from front axle

Step 1. Figures B–1 and B–2 show a representation of a 200–inch (5080 mm) wheelbase (WB) truck designed to carry a 100–lb. (45.3–kg) load. Figure B–1 represents a truck with the load placed an equal distance between the two axles. a.

For our balanced load example we need to establish the center of gravity location (CGf, as shown in Figure B–1) by dividing the wheelbase by 2: CGf =

b.

= 100 in (2540mm)

Use equations 1 and 2 to determine the portions of the load carried by each axle. •

•

02/06

200 2

The weight distribution is calculated as illustrated below: Lr =

CGf WB

Lf =

L - Lr

XL

100 200

X 100 = 50 lbs (23 kg)

100 - 50 = 50 lbs (23 kg)

Since the load is centered between both axles, 50 percent of the load is carried by each axle: i.e., 50 lb. (22.6 kg) is distributed to each axle.

B-2

Appendix B Weight Distribution C.

In Figure B–2, the load (L) is located 133 in. (3378 mm) from the front axle. Moving the load towards the rear axle changes the weight distribution. Use equations 1 and 2 to determine the portion of the load carried by each axle. 100 lbs Front Axle 133 In. 200 In.

Figure B - 2. Unbalanced Load: CGf 133 In. From Front Axle CGf

=

Lr =

CGf WB

Lf =

L - Lr

•

133 in. (3378 mm) XL

133 200

X 100 = 66 lbs (30 kg)

100 - 66 = 34 lbs (15 kg)

The rear axle now carries a greater proportion of the load than the front axle.

Although it is usually not impor tant to know the CG of the chassis; it is important to know the CG location of truck bodies, accessories, or loads that may be placed on the chassis. This example shows that the location of the CG of an object relative to the front and rear axles (FA and RA) affects the load carried by each axle. For most relatively uniform objects such as van bodies and fuel tanks, the CG is located close to the midpoint of the object. For non–uniform objects such as liftgates and refrigeration units, obtain the CG from the equipment manufacturer.

B-3

02/06

Appendix B Weight Distribution Weight Distribution with Body Chassis Weights Step 2. In the following example, a truck is modified to include a van body mounted to the chassis. This example is a T300 chassis, 200 inches (5080 mm) in WB, with a standard drivetrain and fuel tank. It is a 33,000 lb. GVWR with a 12,000 lb. front axle and a 21,000 lb. rear axle. In addition, the chassis is equipped with an optional LH mount 50 gallon fuel tank. When calculating weight distributions, start by determining chassis ground weights for each axle. The actual chassis weight will vary with the wheelbase and the options installed. Listed in Tables B-1 and B-2 are the chassis tare weights for the standard single rear axle and tandem rear axle T300 vehicles and each wheelbase configuration. From Table B-1 we see that the 200-inch wheelbase, 2-axle T300 has the following tare weights: FA = 6618 RA = 3514 Table B-3 lists several available options on the T300 with nominal weights and CGs. See your Kenworth Dealer for more exact weights and CGs. It also lists their added weight when installed on the chassis and the location (from the front axle) of the CG of this added weight. Wheelbase Inches

140 145 150 152 160 176 188 194 200 206 215 218 230 236 245 254 260 272 280

Front

5,959 (2,702) 6,025 (2,732) 6,124 (2,777) 6,148 (2,788) 6,251 (2,835) 6,409 (2,907) 6,532 (2,962) 6,571 (2980) 6,618 (3,001) 6,678 (3,029) 6,738 (3,056) 6,826 (3,096) 6,894 (3,127) 6,945 (3,150) 6,995 (3,172) 7,093 (3,217) 7,153 (3,244) 7,214 (3,272) 7,236 (3,282)

Rear

3,848 3,798 3,792 3,775 3,726 3,620 3,575 3,536 3,514 3,506 3,472 3,529 3,487 3,487 3,463 3,494 3,512 3,496 3,468

Total

(1,745) (1,722) (1,720) (1,712) (1,690) (1,642) (1,621) (1,604) (1,594) (1,590) (1,575) (1,600) (1,581) (1,581) (1,571) (1,585) (1,593) (1,585) (1,573)

9,807 9,823 9,916 9,923 9,977 10,029 10,107 10,107 10,132 10,184 10,210 10,355 10,381 10,432 10,458 10,587 10,665 10,710 10,704

(4,448) (4,455) (4,497) (4,500) (4,525) (4,548) (4,584) (4,584) (4,595) (4,619) (4,630) (4,696) (4,708) (4,731) (4,743) (4,801) (4,837) (4,857) (4,854)

TABLE B-1. T300 Single Rear Axle “Bare” Chassis Tare Weights (no driver, no fuel), lb (kg).

Note: 02/06

The weights in Table B-1 represent a standard chassis (built to standard specifications). Weights do not include any options. For tandem rear axle chassis weights, see next page. B-4

Appendix B Weight Distribution

Wheelbase Inches

Front

190 205 235 260 280

6,463 (2,931) 6,622 (3,003) 6,836 (3,100) 7,047 (3,196) 7,146 (3,241)

Rear

6,102 (2,767) 6,082 (2,758) 6,008 (2,725) 6,030 (2,735) 6,001 (2,722)

Total

12,565 (5,698) 12,704 (5,761) 12,844 (5,825) 13,077 (5,931) 13,147 (5,962)

TABLE B-2. T300 Tandem Rear Axle “Bare” Chassis Tare Weights (no driver, no fuel), lb. (kg).

Note:

The weights in Table B-2 represent a standard chassis )built to standard specifications). Weights do not include any options.

Note:

The options listed in Table B-3 do not include all that are available. This list is included only to give a representational of options weights. For a complete current list or to obtain the weight of a particular option, consult a T300 Data Book at your nearest Kenworth Dealer.

Option Weights Step 3.

Some chassis are ordered with an optional transmission, suspension, cab items, etc. Each optional component will have a portion of its total weight distributed to both the front and rear axles. In all cases, you must calculate the load each option places on each axle. We need to determine how the weight of the optional 50 gallon fuel tank is distributed to each of the axles. From Table B-3 we find the option weight and its CG location relative to the front axle. The fuel tank adds 125 lbs (57 kg) and is located 93.5 inches (2375 mm) from the front axle. With CGf = 93.5, use equations 1 and 2 to calculate the distributed additional weight of the optional 50 gallon fuel tank. Add your results to the “bare” chassis axle weights from Table B-1 or Table B-2.

Lr =

CGf WB

Lf =

L - Lr

XL

93.5 200 X 125 = 58 lbs (26 kg) 125 - 58 = 67 lbs (30 kg)

B-5

02/06

Appendix B Weight Distribution TABLE B-3. T300 Typical Options Description ENGINES Cummins ISB CAT C7 ENGINE EQUIPMENT Borg Warner viscous hub Vertical muffler, side of cab Horizontal muffler, vertical tailpipe back of cab Horizontal muffler, vertical tailpipe side of cab 48” Vertical tail pipe Coolant filer for CAT or Cummins ISC engines Racor fuel/water separator for CAT C7 only Engine Immersion Block heater Pacbrake exhaust brake for Cummins ISB Pacbrake exhaust brake for Cummins ISC Jacobs extarder for CAT 270 amp alternator Third battery TRANSMISSIONS AND EQUIPMENT Fuller FS5406 Fuller FSO6406/FSO8606 Fuller RT8608 Fuller RT8709 Fuller RT8908LL Fuller FR9210 Fuller FRO11210 Allison 3000 HS series Allison 3000/3500 RDS/EVS series Allison 2100/2200 HS series Allison 2100/2200 RDS series Ceramic clutch (ISB/C7) Dual std duty D/L with one center bearing Four std duty D/L with two center bearing Three std duty D/L with three center bearing One HD center bearing cross member Two HD center bearing cross member Three HD center bearing cross member FRONT AXLE AND EQUIPMENT Dana Spicer 13.2K front axle Dana Spicer 8K front axle Dana Spicer 14.6K front axle MeritorX-30 lightweight drums Brakes with cast spider Front taperleaf springs for 13.2 and 14.6K frt axle Front taperleaf springs for 10K frt axle Sheppard M110 for 14.6K frt axle 02/06

Weight, lbs

Location (CGf, inch)

-389 -171

5.1 4.4

-15 50 50 50 5 10 15 2 9 15 15 10 55

-30 63 74 63 63 74 16 0 7.4 7.4 7.4 -30 48.7

-4 39 232 224 332 230 230 212 251 15 25 -30 77 169 273 10 20 20

41 39.3 41.9 42.6 44.8 42.5 42.9 37.3 40.3 34.8 37.8 21 0.75 x wb 0.75 x wb 0.75 x wb 0.75 x wb 0.75 x wb 0.75 x wb

0 31 57 -32 10 0 38 55

0 0 0 0 0 0 0 -25

B-6

Appendix B Weight Distribution Description

Weight, lbs

REAR AXLES-Single 21060D wheel diff lock 15 21060T two-speed 75 S21-170/S23-170 182 S21-170D/S23-170 210 23082T 351 23-190 255 23-190D 278 S26-190 325 S26-190D 335 REAR AXLES-Tandem DSP40 2140 DSP41 2178 DSP41P 2196 REAR AXLE AND EQUIPMENT (Single) Dust shields 8 Meritor X-30 lightweight drum -40 Iron hubs 30 REAR AXLE AND EQUIPMENT (Tandem) Dust shields 15 Meritor X-30 lightweight drum -80 Iron hubs 60 Wheel diff lock DSP40/41 (P) rear rear axle 15 Wheel diff lock DSP40/41 (P) fwd rr and rear rr axle 38 SUSPENSIONS AND EQUIPMENT (Single) HAS 210L -121 Reyco 79KB taperleaf spring 23K 56 HAS 230L -105 Reyco 79KB multileaf with helper spring 26K 120 Shocks for Reyco 79KB 36 Stabilizer bar for Reyco 79KB 68 HD cross member for 79KB 41 HD cross member for HAS 4 SUSPENSIONS AND EQUIPMENT (Tandem) Chalmers 854-40-XL 452 Reyco 102 254 HAS 402 468 TIRES (weight per pair) Bridgestone R294 255/70R22.5 -50 Bridgestone M726 255/70R22.5 -36 Bridgestone R250F 295/75R22.5 0 Bridgestone R250F 11R22.5 8 Bridgestone R250F 12R22.5 36 Bridgestone R260F 295/75R22.5 0 Bridgestone M711 11R22.5 18

B-7

Location (CGf, inch) wb wb wb wb wb wb wb wb wb wb wb wb wb wb wb wb wb wb wb wb wb wb wb wb wb wb wb wb wb wb wb

02/06

Appendix B Weight Distribution Description Bridgestone M720FE 295/75R22.5 Bridgestone M725 295/75R22.5 Bridgestone M726EL 11R22.5 Michelin XZE 11R22.5 Michelin XDN2 12R22.5 WHEELS & RIMS (weight per pair) Accuride 28408RPW 22.5X8.25 Accuride 28487RPW 22.5x8.25 Alcoa 88364 22.5X8.25 Kenworth/Alcoa 88761 22.5X8.25 FRAME AND EQUIPMENT Stainless Steel clad alum bumper Front tow hook, 2 removable Cantilever battery box back of cab Temporary battery box between rails 1’ deck plate 2’ deck plate 3’ deck plate One bolted alum cross member replacing std Two bolted alum cross member replacing std HD rear cab cross member Holland PH-T-60AOL-8 pintle hook Square end of frame with cross member (Single axle) Stainless Steel Quarter fenders Polypropylene Quarter fenders KW plastic rear mud flaps Betts B-25 mud flap arms FUEL TANKS AND EQUIPMENT (fuel) 40 gal 22” Al RH under 50 gal rectangular steel LH behind cab 70 gal rectangular steel LH behind 56 gal 22” Al RH under 70 gal 22” Al RH under 100 gal 22” All RH under 120 gal 22” All RH under 56 gal 22” Al LH behind 75 gal 22” Al LH behind 100 gal 22” All LH behind CAB AND EQUIPMENT Grab handle with short extension over door LH/RH NFPA compliant grab handles Single 22” air horn Dual 22” air horn Dual Moto mirrors 02/06

Weight, lbs

Location (CGf, inch)

4 18 36 4 62 0 -4 -62 -56 -19 16 -21 -100 6 10 15 -11 -22 18 200 41

-37 -37 83 83 92 98 104 0.75 x wb 0.75 x wb 68 wb + AF wb + AF

55 43 9 12

wb - 25 wb - 25 wb + 40 wb - 40

7 lb/gal 125 140 -19 -11 0 8 92 100 111

Fuel tank 46 93.5 99 51 57 64 70 95 101 108

5 4 5 10 4

58 58 39 39 25

B-8

Appendix B Weight Distribution Description

Weight, lbs

Dual KW Aeromirrors Hood mounted convex mirror Fender mounted convex mirror Sliding rear window Rear window delete Corner Windows Power window RH Power window LH/RH Peeper window Sunvisor with lights Sunvisor, Stainless Tilt steering column Driver’s KW Air cushion Plus Int. Back w/air comp. Driver’s KW Air cushion Plus High Back Driver’s KW Air cushion Plus High Back w/air comp. Drivers Seats Inc 911 Full Bench Rider’s KW Air cushion Plus Int. Back w/air comp. Rider’s high-back tool box seat, High Back Rider’s KW air cushion Plus High or Interm. Back Rider’s KW Air cushion Plus High Back Rider’s KW Air cushion Plus High Back w/air comp. Riders Seats Inc 911, air suspension Riders Seats Inc 911 SCBA, air suspension Riders Seats Inc 911 SCBA, fixed 2-man passenger seat Delete dual arm rests Workstation between seats Radio Dash mounted CB brackets and binding posts LIGHTS AND SIGNALS Fog lights Delete tail lamps Backup alarm Beacon lights AIR EQUIPMENT Full Truck Kit SPECIAL EQUIPMENT Fire extinguisher Triangle reflector kit

Location (CGf, inch)

26 3 4 13 -15 24 4 8 0 7 11 5 5 2 7 10 -3 5 2 33 2 7 35 58 26 62 -6 20 4 4

25 -30 -30 68 68 66 35 35 20 16 16 25 42 42 42 42 42 42 42 42 42 42 42 42 42 42 42 42 16 16

4 -6 4 6

-37 wb + AF wb + AF 35

15

wb

4 11

60 60

B-9

02/06

Appendix B Weight Distribution Now we will calculate the distributed weight of a 14 foot van body that weights 2400 pounds (1089 kg). Since an empty van is very close to a uniform object, you can assume that the CG of the van body is at a point equal to half of the BL. 168 in. BL 72 in.

84 in.

2,400 lbs

156 in. CGf 200 in. WB

Figure B-3. Balanced Body Unloaded: CGf 156 in. (3962 mm) from front axle. When the body is mounted on the chassis, assume that the forward edge is positioned 4 inches (102 mm) behind the back of the cab. This is equivalent to 72 inches (1829 mm) behind the front axle. Therefore, the CG of the body is located 72 inches plus half the body length from the front axle.

CGf =

1 (168) + 72 = 156 in. 2

1 BL + 72 2

Use Equations 1 and 2 to calculate the distributed additional weight of the body: Lr =

CGf WB

Lf =

L - Lr

156 200

XL

X 2400 = 1872 lbs (849 kg)

2400 - 1872 = 528 lbs (240 kg)

Adding a liftgate to the van body will present some interesting weight distribution results. We will add a 1000 pound (454 kg) liftgate to the end of the van body. The CG location of non-uniform objects, such as a liftgate, must be provided by the equipment manufacturer. For our example, the liftgate manufacturer has provided installation information that indicates the liftgate CGf is located 246 in (6248 mm) behind the front axle.

Rear Liftgate Example

1,000 lbs

200 in. WB 246 in. CGf

Figure B-4. Liftgate Example: CGf 246 in. (6248 mm) from front axle. 02/06

B-10

Appendix B Weight Distribution Use CGf = 246 in equations 1 and 2 to determine how the liftgate weight is distributed to the axles.

Lr =

CGf WB

Lf =

L - Lr

XL

246 200

X 1000 = 1230 lbs (558 kg)

1000 - 1230 = -230 lbs (-104 kg)

This negative weight on the front axle illustrates the difference between the distribution of weight (L) mounted behind the rear axle versus in front of the rear axle. •

The load carried by the rear axle is greater than the weight of the liftgate itself. Since the weight of the liftgate (added to the vehicle) cannot be greater than 1,000 lb, the front axle loading is reduced by a compensating amount (230 lb). The combined weight on the front and rear axles is equal to that of the liftgate.

•

Weight added behind the rear axle has the effect of unloading the front axle. The amount of this front axle load reduction is equal to the “extra” weight added to the rear axle.

•

By positioning equipment behind the rear axle, the effective load on the rear axle is more than the weight of the equipment.

•

The farther behind the rear axle the load is mounted, the greater the load on the rear axle. However, the combined weight, distributed to the front and rear axles (Lf plus Lr), does not exceed the weight of the liftgate.

In order to get a realistic curb weight, we add weight for a driver and fuel. For purposes of calculation, we use a standard of 200 lbs. (91 kg) for the driver. Of course, your driver weight will vary. Using CGf = 51 in equations 1 and 2: Lr =

CGf WB

Lf =

L - Lr

XL

51 200

X 200 = 51 lbs (23 kg)

200 - 51 = -149 lbs (68 kg)

We calculate the fuel load using 7 lbs per gallon as the weight for diesel fuel. 50 gal x (7 lbs/gal) = 350 lbs (159 kg) for each tank Using CGf=51 and equations 1 and 2 for the standard tank RH Under Cab: Lr =

CGf WB

Lf =

L - Lr

XL

51 200

X 350 = 89 lbs (40 kg)

350 - 89 = 261 lbs (118 kg)

B-11

02/06

Appendix B Weight Distribution Using CGf=93.5 and equations 1 and 2 for the optional tank LH Behind Cab:

Lr =

CGf WB

Lf =

L - Lr

XL

93.5 200

X 350 = 164 lbs (74 kg)

350 - 164 = 186 lbs (84 kg)

COMPLETE (LOADED) VEHICLE Water Level Load Step 4. The final step is to put a payload in the van. Assume that the payload is evenly distributed. Freight that is distributed evenly is referred to as a “water level” load. Our payload total is 16,000 lb. Since it is an evenly distributed “water level” load, its CG location will be the same as the CG location of the van body. See Figure B–5.

CGf =

1 (168) + 72 = 156 in. 2

1 BL + 72 2

Using CGf = 156 in equations 1 and 2:

Lr =

CGf WB

Lf =

L - Lr

XL

156 200

X 16,000 = 12,480 lbs (5,661 kg)

16,000 - 12,480 = 3,520 lbs (1,597 kg)

16,000 lbs

156 in. CGf 200 in. WB

Figure B-5. Loaded Vehicle Example: CGf 156 inches (3962 mm) from front axle.

02/06

B-12

Appendix B Weight Distribution

Item

Front Axle (FA) lb (kg)

Chassis

Rear Axle (RA) lb (kg)

Total lb (kg)

6618

3001

3514

1594

10132

4595

67

30

58

25

125

57

Tare Weight

6685

3031

3572

1620

10257

4613

Van Body

528

240

1872

849

2400

1089

Liftgate

-230

-104

1230

558

1000

454

Driver

149

68

51

23

200

91

Fuel 50 Gal Std, Tank RH Under

261

118

89

40

350

159

84

164

74

350

159

Option Fuel Tank

Fuel 50 Gal Opt. Tank, LH Behind 186 Curb Weight

7579

3437

6978

3164

14557

6604

Payload

3520

1597

12480

5661

16000

7257

Total Ground Weight

11099

5034

19458

8825

30557

13861

Chassis Axle Ratings

12000

5443

21000

9525

33000

14969

Table B-4. T300 Weight Distribution and Chassis Rating Calculation (sample)

Weight Distribution Analysis Step 5. The final step is to total all the front and rear axle weights to ensure that the axles are not overloaded. Table B-4 shows the assembled information in an easy to read format. •

Compare the calculated axle ground totals against the axle weight ratings to be sure that the truck is properly specified to haul this load.

•

From this, it is evident that the chassis is properly equipped for this job.

These calculations illustrate the importance of doing the weight distribution analysis. In some cases the addition of one component (for example, a liftgate) can produce a dramatic difference.

Body Length Step 6. Your analysis may produce results that indicate an overloaded axle with a total loaded chassis weight less than the GVW. This shows that you need to use a different body length for the truck. Each wheelbase can accommodate several different body lengths. However, for each wheelbase and GVW one particular body length will provide close to optimum weight distribution on both axles. a.

Tables B-5 and B-6 list Recommended Body Lengths for a particular wheelbase and GVW. These body lengths provide the best weight distribution for the listed wheelbase.

Note:

These charts were generated assuming a plain van body with “water level” loading. Any common additions such as lift gates or refrigeration units may indicate a different wheelbase for a given body length. Also, different body styles may require a different WB for a given size.

02/06

B-13

Appendix B Weight Distribution

Body Length (Ft) Wheelbase In. (MM)

30,000 GVW

33,000 GVW

145 (3683)

8

8

150 (3810)

10

10

160 (4064)

12

12

185 (4699)

14

14

200 (5080)

16

14

215 (5461)

18

16

230 (5842)

20

18

245 (6223)

22

20

260 (6604)

24

22

280 (7112)

26

24

Table B-5. Recommended T300 Body Lengths (Single Rear Axle). •

Remember that water level loading assumes that the load is arranged evenly in the body (as water would be in a tank). If uneven load distribution is part of the vehicle layout, your weight distribution analysis may indicate that a different body length, deviating from the recommended length, will provide the best weight distribution.

Note:

You should always perform a weight distribution analysis to help ensure the vehicle performs properly and meets your customer’s expectations.

Wheelbase In. (MM) Body Length (Ft) 175 (4445)

14

190 (4826)

16

205 (5207)

18

220 (5588)

20

235 (5969)

22

250 (6350)

24

260 (6604)

26

Table B-6. Recommended T300 Body Lengths (Tandem Rear Axles).

02/06

B-14

Index

Frame, welding Front axle serial number Front View Fuel tank locations

5-4 A-4 3-4 3-16

6-3 4-6 4-1 4-4 4-2

G Ground clearance

3-4

I Incomplete vehicle certification Incomplete Vehicle Certification Label

2-2 A-2

B-2 2-1 2-2 1-1 A-1 B-4 6-4 4-5 4-1 3-13 5-4

L Liftgate

6-6

M Mounting holes, frame

4-3

N Noise Emission Label Noise Requirements Notes

A-3 2-3 2-1

O Operating information Options weights

1-1 B-5

R Rear axle identification Rear suspension, changing Rear View Remote PTO/throttle harness Repair information

A-4 5-3 3-4 6-8 1-1

S Safety signals Scope Sill spacer Spare Circuits Step height

2-1 1-1 4-3 6-1 3-6, 3-7

T Third battery option Tire And Rim Data Label Transmission identification Turning radius

6-6 A-2 A-4 3-1

A Abbreviations, dimensions Auxiliary power

3-1 6-5

B Body harness Body mount, rear Body mounting Body mounting with U-bolts Brackets, body mounting C Calculations Cautions Certification label Chassis maintenance Chassis Number Chassis weight Circuits, description Clearance, air lines and wiring Critical clearances Crossmember location Crossmembers D Dimensions Dimensions, air tanks Dimensions, battery box Dimensions, crew cab, conversion Dimensions, exhaust, horizontal Dimensions, exhaust, vertical, ISB Dimensions, exhaust, vertical muffler, ISB Dimensions, exhaust, vertical muffler, ISC/C7 Dimensions, exhaust, transverse muffler, ISB Dimensions, exhaust, transverse muffler, ISC/C7 Dimensions, exhaust, vertical tailpipe ISB Dimensions, exhaust, vertical tailpipe ISC/C7 Dimensions, extended cab conversion Dimensions, flood lamps, flush Dimensions, flood lamps, pedestal Dimensions, frame rails Dimensions, fuel tank Dimensions, optional fuel tank Dimensions, overall Dimensions, roof mounted options

3-1 3-17 3-17 3-11 3-18 3-19 3-20 3-23, 3-24 3-21 3-25 3-19 3-22 3-12 3-10 3-9 3-17 3-18 3-18 3-2 3-8

E Electrical circuits Electrical circuits Emissions requirements Engine serial number

6-1 6-1 2-3 A-3

F Federal Motor Vehicle Safety Standards Final stage manufacturer Fishplate bracket FMVSS Frame, changing length Frame, drilling

2-2 2-2 4-6 2-1 5-1 4-4

V Vehicle Identification Number W Warnings Water level load Weight distribution Weight distribution analysis Wheelbase, changing Width with doors open

A-1 2-1 B-12 B-1 B-13 5-2 3-13

02/06