T300 Body Builder’s Manual

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

with Medium-Duty Truck Dealer Service”

Medium DutyBody Builder’s Manual

Model: T300For Trucks Produced After October 2005

SECTION 1 - INTRODUCTION SCOPE 1-1

SECTION 2 - SAFETY AND COMPLIANCE

SAFETY SIGNALS 2-1 Warnings, cautions, and notes 2-1 FEDERAL MOTOR VEHICLE SAFETY STANDARDS COMPLIANCE 2-1 Incomplete Vehicle Certification 2-2 Noise and Emissions Requirements 2-3

SECTION 3 - DIMENSIONS

ABBREVIATIONS 3-1 TURNING RADIUS 3-1 OVERALL DIMENSIONS 3-1 Side View — T300 with Single Rear Axle 3-2 Side View — T300 with Tandem Rear Axle 3-3 Front and Rear Views — T300 3-4 DETAIL VIEWS 3-5 Side View Detail — T300 3-5 Left Side: Step and Cab Floor Height — T300 3-6 Right Side: Step and Cab Floor Height — T300 3-7 Top of Cab: Roof Mounted Options 3-8 Back of Cab: Pedestal Mounted Flood Lights 3-9 Back of Cab: Flush Mounted Flood Lights 3-10 Crew Cab Conversion Dimensions 3-11 Extended Cab Dimensions 3-12 Crossmember Locations: Single Axle 3-13 Crossmember Locations: Tandem Axle 3-14 Crossmember Locations: Single Axle, Hydraulic Brakes 3-15 Fuel Tank Locations 3-16 COMPONENTS Frame Rail Configurations 3-17 Battery Box and Air Tank Locations 3-17 Fuel Tank Dimensions 3-18 Horizontal Muffler Vertical Tailpipe on Cab Locations, Cummins ISB 3-19 Vertical Muffler RH Side of Cab, Cummins ISB 3-20 Transverse Muffler, Cummins ISB 3-21 Horizontal Muffler Vertical Tailpipe on Cab, Cat C7 & Cummins ISC 3-22 Vertical Muffler RH Side of Cab, Cat C7 and Cummins ISC 3-23 Vertical Muffler RH Side of Cab, Cat C7 and Cummins ISC 3-24 Transverse Muffler, Cat C7 and Cummins ISC 3-25 SECTION 4 - BODY MOUNTING CRITICAL CLEARANCES 4-1 Rear Wheels and Cab 4-1 Chassis with Reinforcements 4-2 BODY MOUNTING USING BRACKETS 4-2 Frame Sill 4-2 Brackets 4-3 Mounting Holes 4-3 Frame Drilling 4-4 BODY MOUNTING USING U–BOLTS 4-4 Spacers 4-4 Rear Body Mount 4-5

Body Builder’s Manual Contents

02/06I

SECTION 5 - FRAME MODIFICATIONS

INTRODUCTION 5-1 DRILLING RAILS 5-1 Location and Hole Pattern 5-1 MODIFYING FRAME LENGTH 5-1 Frame Insert 5-2 Changing Wheelbase 5-2 Crossmembers 5-4 WELDING 5-4 Precautions 5-4

SECTION 6 - ELECTRICAL

INTRODUCTION 6-1 ELECTRICAL CIRCUITS 6-1 Capacity 6-1 Additional Spare Circuits for Wiring 6-1 Optional Body Harness 6-3 Fuse and Circuit Identification 6-4 Circuits Wired Through the Ignition 6-5 Connecting Ignition Circuits 6-5 Circuits Wired to Battery 6-5 INSTALLING A THIRD BATTERY 6-6 WIRING FOR A LIFTGATE 6-6 Liftgate Power Source 6-6 Connecting the Liftgate Power 6-7 ENGINE CONNECTIONS 6-7 REMOTE PTO/THROTTLE HARNESS 6-8 APPENDIX A - VEHICLE IDENTIFICATION

VEHICLE IDENTIFICATION NUMBER A-1 VIN Location A-1 Chassis Number Locations A-1 CERTIFICATION LABELS A-2 Components and Weights Label A-2 Tire/Rim and Weight Rating Data Label A-2 Incomplete Vehicle Certification Label A-2 Noise Emission Label A-3 Paint Identification Label A-3 COMPONENT IDENTIFICATION A-3 Engine Identification A-3 Transmission Identification A-4 Front Axle Identification A-4 Rear Axle Identification A-4

APPENDIX B - WEIGHT DISTRIBUTION INTRODUCTION B-1 Abbreviations B-1 CALCULATIONS B-2 Weight Distribution without Body B-2 Weight Distribution with Body B-4 Chassis Weights B-4 Option Weights B-5 COMPLETE (LOADED) VEHICLE B-12 Water Level Load B-12 Weight Distribution Analysis B-13 Body Length B-13INDEX

Body Builder’s Manual Contents

02/06II

Figure 2–1. Incomplete Vehicle Certification Document. 2-2Figure 2–2. Location of Certification Labels - Driver’s Door and Frame 2-2Figure 3–1. T300 W/ Single Rear Axle: Height and Length Measurements. 3-2Figure 3–2. T300 W/ Tandem Rear Axle: Height and Length Measurements. 3-3Figure 3–3. T300 Front View: Width and Ground Clearance Measurements [inches (mm)]. 3-4Figure 3–4. T300 Rear View: Width and Ground Clearance Measurements [inches (mm)]. 3-4Figure 3–5. T300 Detailed Side View: Specific Measurements [inches (mm)]. 3-5Figure 3–6. T300 Battery Box Step and Cab Floor: side view, left side. 3-6Figure 3–7. T300 Fuel Tank Step and Cab Floor: side view, right side. 3-7Figure 3-8.1 Top of Cab View, Roof Mounted Options 3-8Figure 3-8.2 Top of Side Cab View, Roof Mounted Options 3-8Figure 3-8.3 Pedestal Mounted Flood Lamp Locations 3-9Figure 3-8.4 Pedestal Mounted Flood Lamp Clearance 3-9Figure 3-8.5 Flush Mounted Flood Lamp Locations 3-10Figure 3-8.6 Crew Cab Conversion Overall Dimensions 3-11Figure 3-8.7 Extended Cab Overall Dimensions 3-12Figure 3–9.1 T300 Crossmember Location and Overall Width with Doors Open, Single Axle. 3-13Figure 3–9.2 T300 Crossmember Locations, Tandem Axle. 3-14Figure 3–9.3 T300 Crossmember Location, Single Axle, Hydraulic Brakes. 3-15Figure 3–9.4 T300 Fuel Tank Locations. 3-16Figure 3–10. T300 10.5 and 10.62–Inch Rail Measurements [Inches (mm)] 3-17Figure 3–11. T300 Battery Box and Air Tank Measurements [Inches (mm)]. 3-17Figure 3–12. T300 Optional 22-inch Fuel Tank Mounting Measurements [Inches (mm)]. 3-18Figure 3–13. T300 Standard Fuel Tank and Horizontal Exhaust Measurements [Inches (mm)]. 3-18Figure 3–14 T300 Vertical Tailpipe on Side of Cab [Inches (mm)]. 3-19Figure 3–15. T300 Vertical Tailpipe on Back of Cab [Inches (mm)]. 3-19Figure 3-16 T300 with 56 Gallon RH Under Cab 3-20Figure 3-17 T300 with 40 Gallon RH Under Cab 3-20Figure 3-18 T300 Transverse Muffler Under Cab 3-21Figure 3-19 T300 Vertical Tailpipe on Side of Cab 3-22Figure 3-20 T300 Vertical Tailpipe on Back of Cab 3-22Figure 3-21 T300 Vertical Muffler for 56 Gallon Fuel Tank RH Under Cab 3-23Figure 3-22 T300 Vertical Muffler for 40 Gallon Fuel Tank RH Under Cab 3-24Figure 3-23 T300 Transverse Muffler for Short Transmissions 3-25Figure 3-24 T300 Transverse Muffler for Long Transmissions 3.25Figure 4–1. Minimum Clearance Between Top of Rear Tires and Body Structure Overhang. 4-1Figure 4–2. Minimum Back–of–Cab Clearance. 4-1Figure 4–3. Air Gap with Frame Rail with Reinforcements 4-2Figure 4–4. Spacer Between Frame Sill and Body Rail — Rubber or Plastic. 4-3Figure 4–5. High Compression Spring Between the Mounting Bolt and Upper Bracket. 4-3Figure 4–6. Rubber Spacer Between Brackets. 4-3Figure 4–7. Hole Location Guidelines for Frame Rail and Bracket. 4-3Figure 4–8. Crossmember–Gusset Hole Pattern Requirements. 4-4Figure 4–9. Acceptable U–Bolt Mounting with Wood and Fabricated Spacers. 4-5Figure 4–10. Clearance Space for Air Lines and Cables. 4-5Figure 4–11. Example of Fishplate Bracket at Rear End of Body, used with U–Bolts. 4-6Figure 5–1. Detail of Frame Extensions and Joint Welding. 5-2Figure 5–2. Frame Insert 5-2Figure 5–3. Comparison of Original, Shortened, and Extended Wheelbases. 5-3Figure 5–4. Crossmember Added When Distance Exceeds 60 Inches (1524mm). 5-4Figure 5-5 Heat Treated Warning Label 5-5Figure 6–1. Location of Optional Body Harness Connection. 6-3Figure 6–2. Prewired Truck and Body Harness (after 3/98) 6-4Figure 6–3. Adding a Third Battery 6-6Figure 6–4. Liftgate Circuit Breaker Inside Battery Box. 6-7Figure 6-5 Remote PTO/Throttle Control Wiring Harness Connector Pin Outs 6-8Figure A–1. Vehicle Identification Number (VIN). A-1Figure A–2. Driver’s Door and Door Frame Labels A-2Figure A–3. Engine Identification Plate. A-3Figure A–4. Front Axle Identification. A-4Figure A–5. Rear Axle Identification Labels. A-4Figure B–1. Balanced Load: CGf 100 in. from front axle. B-2Figure B–2. Unbalanced Load: CGf 133 in. from front axle. B-3Figure B–3. Balanced Body Unloaded: CGf 156 in. (3962 mm) from front axle. B-10Figure B–4. Liftgate Example: CGf 246 in. (6248 mm) from front axle. B-10Figure B–5. Loaded Vehicle Example: CGf 156 in. (3962 mm) from front axle. B-12

Figures

02/06III

TABLE 3-1. Abbreviations Used. 3-1TABLE 3-2. Turning Radius-T300 w/single and tandem rear axles 3-1TABLE 3-4. T300 w/ Single Rear Axle: Overall Dimensions [inches (mm)]. 3-2TABLE 3-5. T300 w/ Tandem Rear Axle: Overall Dimensions [inches (mm)]. 3-3TABLE 3-6. T300 Front and Rear Suspension (FS/RS) Centerline (C/L) to Rail Measurements. 3-5TABLE 3-7. T300 Battery Box Step and Cab Floor Measurements. 3-6TABLE 3-8. T300 Fuel Tank Step and Cab Floor Measurements. 3-7TABLE 3-9.1. T300 Crossmember Locations: Single Axle, Air Brake 3-13TABLE 3-9.2 T300 Crossmember Locations: Tandem Axles, Air Brakes 3-14TABLE 3-9.3 T300 Crossmember Locations: Single Axle, Hydraulic Brakes 3-15TABLE 3-10 T300 Fuel Tank and Optional Battery Box Locations for Common WB Configurations 3-16TABLE 3-11 Frame Rail Strength Characteristics. 3-17TABLE 6-1.1 Additional Spare Circuits for Wiring 6-2TABLE 6-2 Third Battery Installation Parts 6-6TABLE 6-3 Remote PTO/Throttle Wiring Harness 6-8TABLE A-1. Model Year Letter (CODE) Designations. A-1TABLE B-1. T300 Single Rear Axle “Bare” Chassis Tare Weights (no driver, no fuel), lb (kg). B-4TABLE B-2. T300 Tandem Rear Axle “Bare” Chassis Tare Weights (no driver, no fuel), lb (kg). B-5TABLE B-3. T300 Typical Options B-6TABLE B-4. T300 Weight distribution and chassis rating calculation (sample) B-13TABLE B-5. Recommended T300 Body Lengths (Single Rear Axle). B-14TABLE B-6. Recommended T300 Body Lengths (Tandem Rear Axle). B-14

Tables

02/0602/06IV

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 as-sociated 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 infor-mation 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 Ser-vice 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.

•

•

Section 1 Introduction

1-1

SAFETY SIGNALSWe’ve put a number of alerting 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 indicate 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

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.

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.

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, if 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.

Section 2Safety & Compliance

WARNING

CAUTION

NOTE

2-1

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 CertificationAn 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.”

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.

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 andhttp://www.tc.gc.ca/acts-regulations/GENERAL/M/mvsa/regulations/mvsrg/toc_mvsrg.htm for the regulations.

Or contact:Transport CanadaTower C, Place de Ville, 330 Sparks StreetOttawa, Ontario K1A 0N5(613) 990-2309TTY: 1-888-675-6863

FEDERAL MOTOR VEHICLE SAFETYSTANDARDS COMPLIANCE

Figure 2-1. Incomplete Vehicle Certification Document

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

Section 2Safety & Compliance

NOTE

U.S. EPA Noise Label (U.S. registered vehicles only)

Final Stage Manufacturer Label to be Installed by Final Stage Manufacturer

Chassis Serial Number

Major Components and Weights Label

Incomplete Vehicle Certification Label

Safety Mark (Canadian Registry Only)

Tire, Rim and Weight Rating Data label

02/062-2

This truck may be equipped with a converter muffler or independent converter unit in 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.

Noise and Emissions Requirements

Section 2Safety & Compliance

NOTE

NOTE

02/062-3

ABBREVIATIONSThroughout this section and in other sections as well, abbreviations are used to describe certain 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 RADIUSApproximate 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 Rear Axles Tire, Bridgestone Wheelbase Range, Inch Curb to Curb Est. Radius, ft Wall to Wall Radius Est., ft (1)

140 24 27 152 26 29 176 30 33 188 32 35 206 34 37 Single R250F 245/70R19.5 218 36 39 236 39 42 245 40 43 254 41.5 44.5 260 42 45 272 44 47 145 20 23 150 21 24 160 22 25 200 27 30 Single 215 29 32 230 31 34 245 32 35 R250F 295/75R22.5 260 34 37 280 36 39 175 26 29 190 27 30 205 29 32 Tandem 220 31 34 235 33 36 250 35 38 260 36 39 140 22 25 150 23 26 Single 160 24 27 170 25 28 R294 275/70R22.5 180 27 30 190 28 31 165 26 29 Tandem 175 28 31 190 30 33 140 31 34 150 33 36 160 34 37 Single 170 36 39 R250 295/80R22.5 180 38 41 190 40 43 165 38 41 Tandem 175 40 43 190 43 46 140 34 37 150 36 39 160 38 41 Single 170 40 43 M843 12R22.5 180 42 45 190 44 47 165 42 45 Tandem 175 44 47 190 47 50 (1) For stainless steel clad alum channel bumper, subtract 1.5 ft.

Section 3Dimensions

TAS 65

M110P

TAS 40

02/06 3-1

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 mea-surements 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

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

UNLADEN

WB A AF B CA* D **

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) 37.2 (945) 138 (3505) 104.9 (2664)

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)

272 (6909)*** 459.2 (11664) 150 (3810) 204 (5182)

390 (7112) 457.2 (11613) 140 (3556) 212 (5385)

* CA is measured from true back of cab to rear axle centerline. ** Determined with Bridgestone R250F 295/75R22.5 front tires. *** Hydraulic brake chassis only available in these wheelbases.

D

68(1,727)

AF

A

WBB

CA

Section 3Dimensions

02/063-2

Figure 3-2. Side View — T300 with Tandem Rear Axle Height and Length Measurement

Side View — T300 with Tandem Rear Axle

D

68(1,727)

AF

A

WBB

CA

TABLE 3-5. T300 with tandem Rear Axle: Overall Dimensions [inches (mm)]

UNLADEN

WB A AF B CA * D **

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) 152 (3861)

235 (5969) 379.2 (9632) 107 (2718) 167 (4242)

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)

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

Section 3Dimensions

37.2 (945) 104.9 (2664)

02/063-3

Rear Bogie C/L

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

Front and Rear Views — T30039.5

(1003)

107.7 (2735)

95.3 (2421)

79.1 (2019)

8.9 (226)

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

36 (914)

71.8 (1824)

96 (2440)

71.9 (1827)

9.7 (248)

34 (864)

76.6 (1946)

Highest Point on Roof

76.4(1941)

Highest Point in Dip of Roof

Section 3Dimensions

17 (432)

46.3 (1177)

Bottom of Frame Rail Flange

02/063-4

76.7(1948)

68(1727)

82.8 (2102)

Detail ViewsSide View Detail

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

LOAD REAR SUSPENSION FS RS

UNLADEN REYCO 79KB 8.4 (213) 9.0 (229)LADEN 6.6 (168) 6.6 (168)

UNLADEN REYCO 79KB WITH HELPER 26K 8.4 (214) 11.3 (287)LADEN 6.6 (168) 8.2 (208)

UNLADEN HENDRICKSON HAS 210L/230L AIR 8.4 (213) 7.8 (198)LADEN 6.6 (168) 7.8 (198) UNLADEN REYCO 102 MULTILEAF 8.4 (213) 8.5 (216)LADEN 6.6 (168) 7.2 (183) UNLADEN HENDRICKSON HAS 402 8.4 (213) 7.8 (198)LADEN 6.6 (168) 7.8 (198) UNLADEN HENDRICKSON RT-403 8.4 (213) 8.6 (218)LADEN 6.6 (168) 7.6 (193)

UNLADEN CHALMERS 854-40-XL 8.4 (213) 9.3 (236)LADEN 6.6 (168) 6.9 (175)

CENTERLINE OF AXLE TO BOTTOM FLANGE OF

RAIL [IN. (MM)]

SIN

GL

E R

EA

R A

XL

ETA

ND

EM

RE

AR

AX

LE

66.9(1699)

37.2 (945)

29.8 (757)

30(762)

61 (1550)

36 (914)

14(355)

BOTTOM FLANGE

AXLE C/L

FS RS

TABLE 3-6. T300 Front and Rear Suspension (FS/RS) Centerline (C/L) to Rail Measurements

Section 3Dimensions

02/063-5

Detail ViewsLeft side: Step and Cab Floor Height - T300

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)

Table 3-7. T300 Battery Box Step and Cab Floor Measurements.

A

B

C

Section 3Dimensions

Figure 3-6. T300 Battery Box Step and Cab Floor: Side View, Left Side [inches (mm)].

02/063-6

Detail ViewsRight side: Step and Cab Floor Height - T300

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)

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

A

B

C

RECTANGULAR STEEL

ROUND 22” DIA ALUM

STEEL TOOLBOX

Section 3Dimensions

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

02/063-7

Detail ViewsTop of Cab View - T300, Roof Mounted Options

Figure 3-8.1. 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

Radio Antenna Location

20.9 (531)

5.0 (127) 3.9 (100)

Section 3Dimensions

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

Highest Roof Point

02/06

3-8

Detail ViewsBack of Cab View - T300, Pedestal Mounted Flood Lamps

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

23.6 (599)

4.2 (107)

Figure 3-8.4. Pedestal Mounted Flood Lamp Clearance, [inches (mm)].

Cab Roof

20.9 (530)

71.0 (1803)

C/L

20.9 (530)

Low Mount Flood Lamp Location

This Location Is Not Used With Vertical Tailpipe Back Of Cab

High Mount Flood Lamp Elevation

Bottom of Rail

Section 3Dimensions

02/063-9

Detail ViewsBack of Cab View - T300, Flush Mounted Flood Lamps

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

37.2(945)

25 (635)

62.4(1585)

C/L

25 (635)

High Mount Flood Lamp Elevation

Bottom of Rail

43.7(1110)

Mid Mount Flood Lamp Elevations

Mid Mount Flood Lamp Location for Vertical Tailpipe Back of Cab

Section 3Dimensions

14.4 (365) 14.4 (365)

02/063-10

Detail ViewsCrew Cab Conversion Dimensions - T300

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

Section 3Dimensions

02/063-11

NOTE This Configuration is Not Available from the Factory.

Detail ViewsExtended Cab Dimensions - T300

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

Section 3Dimensions

B

02/063-12

NOTE This Configuration is Not Available from the Factory.

WB A CB B CB C CB D E

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 140.4 (3565)

201 - 215 * 90.7 (2305) 118.3 (3005) Y 156.9 (3985)

216 - 230 * 101.8 (2585) Y 162.4 (4125) Y

231 - 245 * 101.8 (2585) Y 162.4 (4125) Y

246 - 260 * 101.8 (2585) Y 162.4 (4125) Y 201.0 (5105)

261 - 280 * 101.8 (2585) Y 140.4 (3565) 178.9 (4545) Y 217.5 (5525)

150 - 173 ** None 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 201.0 (5105)

Detail ViewsCrossmember Locations - T300, Air Brake, Single Rear Axle

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)] ***

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. (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*

WB AF

ABCDE

Section 3Dimensions

118(2997)

50 - 55 Deg.

02/06 3-13

Detail ViewsCrossmember Locations - T300, Air Brake, Tandem Rear Axles

WB A CB B CB C CB E

157 - 177 90.7 (2305)

178 - 193 90.7 (2305) Y

194 - 217 101.7 (2585) Y

218 - 231 101.7 (2585) Y 140.3 (2565)

232 - 247 90.7 (2305) 118.3 (3005) Y 156.9 (3985) 325.4 (8265)

248 - 256 101.7 (2585) Y 151.4 (3845) Y 340.4 (8646)

257 - 262 101.7 (2585) Y 156.9 (3985) Y 350.4 (8900)

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)]***

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*

WB AF

ABCE

Section 3Dimensions

02/063-14

Detail ViewsCrossmember Locations - T300, Hydraulic Brake, Single Rear Axle

WB A CB B CB C CB D E

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)

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)]***

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*

WB AF

ABCDE

Section 3Dimensions

02/06 3-15

Fuel Tank and Battery Box A * B

RH Under Cab

Rectangular Steel 50 Gal 33.5 (851)

40 Gal 25.7 (652)

56 Gal 35.6 (904)

Round 22” Aluminum 75 Gal 47.3 (1201)

100 Gal 62.2 (1580)

120 Gal 74.3 (1887)

LH and RH Behind Cab

56 Gal 35.6 (904)

Round 22” Aluminum 75 Gal 77.3 (1963) 47.3 (1201)

100 Gal 62.2 (1580)

LH Behind Cab

50 Gal 78.3 (1989) 30.5 (775)

70 Gal 77.7 (1974) 42.6 (1082)

LH Under Cab

56 Gal 35.6 (904)

75 Gal 47.3 (1201)

LH Behind Cab

Cantilever Box N/A 87.2 (2216) 17.8 (451)

Detail ViewsFuel Tank Locations - T300

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

A B

A B

FIGURE 3-9.4. Fuel Tank Locations

* Measured from centerline of front axle.

Section 3Dimensions

Fuel Tank Shown

Standard Battery Box Shown

02/063-16

Rectangular Steel

Round 22” Aluminum

32.8 (833)

32.8 (833)

Battery Box and Air Tanks — T300

COMPONENTS

Frame Rail Configurations — T300

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

RAIL STRENGTH 10.5” Rail W/O Inverted 10.5” Rail with Inverted 10.62” Rail, Heat 10.62” Rail With Insert, L Reinforcement L Reinforcement Treated 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

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

10.5(266.7)

.5(12.7)

3.74(95)

0.25(6.35)

10(254)

9.88(251)

10.62 (269.9)

0.25 (6.35)

10.24(260)

0.25(6.35)

10(25.4)

3.5 (88.9)

10.5” Rail

3.46 (87.8).31

(7.94)

10.62” Rail Heat Treated

Standard Battery Box With Air Tanks

8.7(220)

Ground

13.6 (346) Laden15.9 (404) Unladen

33(838)

12.6(319)

7.2(184)

Section 3Dimensions

Inverted L Reinforcement

ShownOptional

Insert, Heat Treated Shown

02/063-17

TABLE 3 - 11. Frame Rail Strength Characteristics

Rear View

Section 3Dimensions

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

22-inch Fuel Tanks — T300

Fuel Tank and Exhaust — T300

Std Horizontal Exhaust/Muffler MountingStandard Rectangular Fuel Tank Mounting

From outside of rail - 1.3 (32)

12.2(309)

11.1(282)

7.2(184)

For muffler offset 2” to

right for PTO clearance

3.3 (84)

14.3(363)

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

Rear View

Rear View

02/063-18

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

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

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

Section 3Dimensions

13.8(351)

67 (1701)

12.2(309)

Bottom of Tailpipe

From Outside Of Frame

11.1(282)

68.2 (1732)

12.2(309)

Bottom of Tailpipe

11.1(282)

From Outside Of Frame

02/063-19

13.8(351)

Vertical Muffler- RH Side of Cab — T300, Cummins ISB

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

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

Section 3Dimensions

11.8(300)

62.6(1589)

11.4(290)

7.0(177)

Bottom of Tailpipe

11.8(300)

62.6(1589)

11.4(290)

Bottom of Tailpipe

C/L

C/L

02/063-20

Transverse Muffler — T300, Cummins ISB

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

Section 3Dimensions

4.5(115)

17(432)

15.1 (383)

Back Of

CabC/LChassis

02/063-21

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

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

Section 3Dimensions

15.6(396)

67.0(1701)

Bottom of Tailpipe

C/L

36.3(921)

7.9(201)

13.1 (332)

15.6(396)

62.8(1596)

Bottom of Tailpipe

36.3(921)

13.1 (332)

14.3 (363)

4.9 (125) for shield

(not shown)24.8 (631)

10.75 (273) to shield

(not shown)

14.3 (363)

02/06

Horizontal Muffler- Vertical Tailpipe on Cab — T300, Caterpillar C7 & Cummins ISC

3-22

Vertical Muffler - RH Side of Cab — T300, Caterpillar C7 & Cummins ISC

Section 3Dimensions

63.2(1606)

Bottom of Tailpipe 7 (128) to

Back Of Cab

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

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

02/063-23

Vertical Muffler - RH Side of Cab — T300, Caterpillar C7 & Cummins ISC

Section 3Dimensions

63.2(1606)

Bottom of Tailpipe

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

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

02/063-24

Transverse Muffler — T300, Caterpillar C7 & Cummins ISC

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

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

Section 3Dimensions

C/L

16.3(413)

4.7 (120)

3 (76) To Rear Cab

Crossmember

7.8 (197)

9.2 (234)

Back Of Cab

C/L

16.3(413)

7.8 (195 )

3 (76) To Rear Cab

Crossmember

7.8 (197)

9.2 (234)

Back Of Cab

02/063-25

Section 4Body Mounting

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.

See SECTION 3 “DIMENSIONS” for further details on dimensions and clearances.Also, see APPENDIX B “WEIGHT DISTRIBUTION” for explanation of back–of–cab (BOC) / CA calculations.

CRITICAL CLEARANCESRear Wheels and Cab

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. 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. See Figure 4–1.

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

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

CAUTION:

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

CAUTION:

Note:

FIGURE 4-2. Minimum Back of Cab Clearance

72 (1829) Minimum

4 (102)

02/064-1

Always install a spacer between the body subframe and the top flange of the frame rail. Fail-ure 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 SillIf the body is mounted to the frame with 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 extreme relative motion between body and chassis. See Figure 4–4.

Section 4Body Mounting

Chassis with Reinforcements

WARNING:

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

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

If the frame rail flanges are modified or damaged, the rail could fail prematurely and cause an ac-cident. 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.

0.5 (12.7)Gap

Frame RailReinforcement

Reinforcement

Body

Body Mounting Using Brackets

CAUTION:

Body

02/06 4-2

Note: 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 to fill the “gap” See Figure 4–3. above.

When mounting a body to the chassis with brackets, we recommend designs that offer limited amount of relative move-ment, 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.

Section 4Body Mounting

Brackets

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

Body Subframe (Rail)

Chassis Frame (Rail) Sill

Spacer

These designs will allow relative movement between the body and the chassis during extreme frame racking situations. Extreme frame racking, and mountings that are too rigid, could cause damage to the body. This is particularly true with tanker installations.

FIGURE 4-6. Rubber Spacer Between Brackets

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

Rubber Spacer

Spring

Another possibility is mounting a rubber spacer between the brackets. See Figure 4–6.

When installing the lower bracket on frame rails the mounting holes in the chassis frame bracket and frame rail must com-ply 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).

Mounting Holes

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

Lower Frame Flange

Upper Frame Flange

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

02/064-3

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

Frame Drilling

Section 4Body Mounting

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

4 HOLES.5 IN. DIA.(12.7mm)

5.5(140mm)

2.0(50mm)

5.63(143mm)

5.5(140mm)

2.0(50mm)

5.63(143mm)

11.0(279mm)

6 HOLES.5 IN. DIA.(12.7mm)

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

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.

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

Note:

Hole Location Guidelines

SpacersBODY MOUNTING USING U–BOLTS

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.

02/064-4

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!

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.

Do not allow spacers and other body mounting parts to interfere with brake lines, fuel lines, or wir-ing 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 installa-tion to ensure adequate clearances for air brake lines, fuel lines, and wiring. See Figure 4–10.

Section 4Body Mounting

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.

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.

Body Structure

Wood Sill 0.5 (12) Minimum

Truck Frame

Frame Rail Spacer (Fabricated Steel or

Hardwood)

U-Bolt Spacer (Hardwood)

FIGURE 4-9. Acceptable U-Bolt Mounting with Wood and Fabricated Spacers [inch(mm)]

CAUTION:

Frame Rail

Air Lines and Wiring Harness

Check Clearance Space for Air

Lines and Wiring

U-Bolt

Frame Rail Spacer (Hardwood or Steel

U-Bolt Spacer

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

U-Bolt

02/064-5

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.

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.

Section 4Body Mounting

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

Body Structure

Frame Rail

02/064-6

Section 5Frame Modifications

FRAME MODIFICATIONSIntroductionThe T300 offers customer specified wheelbases. So, in most cases frame modifications to produce a certain wheelbase should not be necessary.

.

Location and Hole PatternDRILLING RAILS

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.

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).

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 ac-cident. Mount the body using body mounting brackets or U–bolts

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

WARNING!

WARNING!

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 applica-tion. The modifications may be as simple as shortening or lengthening the frame cutoff, or they may be as complex as changing the wheelbase.

5-1

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 dam-aged, 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.

CAUTION:

02/06

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) clear-ance. 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 insert at 45° as shown in Figure 5–2 unless the insert extends to the end of the frame.

Section 5Frame Modifications

FIGURE 5-1 Detail of Frame Extension and Joint Welding

FIGURE 5-2 Frame Insert

Frame Insert

24 Inch Minimum (610 mm)

0

02/06 5-2

MODIFYING FRAME LENGTHThe frame cutoff after the rear axle can be shortened to match a particular 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.

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

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

WARNING!

Where possible, use existing bolt holes to attach the insert 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

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 exces-sive vibration. This can cause an accident.

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.

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!

WARNING!

Section 5Frame Modifications

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 original 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.

02/065-3

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.

WARNING!

Section 5Frame Modifications

CrossmembersAfter 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.

FIGURE 5 - 4 Crossmember Added When Distance Exceeds 60 Inches (1524 mm)

Before Wheelbase is Lengthened

Less Than 60”

Greater Than 60”

Additional Crossmember

02/06 5-4

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.

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

Original Wheelbase

Extended Wheelbase

Shortened Wheelbase

Cut Frame at Rear to Obtain Desired Cutoff

Do Not Mount the Suspension Bracket On the Added Frame Rail

Mount the suspension Brackets On the Original Rail (see frame insert section & fuguers 5-1 & 5-2)

Relocated Rear Suspension

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

WELDINGThe 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.

Before welding, disconnect the negative terminal battery cable.

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: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.

1.

PrecautionsCAUTION:

CAUTION:

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 recom-mendations.

•

•

Section 5Frame Modifications

FIGURE 5 - 5. Heat Treated Frame Rail Warning Label

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

2.

02/065-5

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

CAUTION:

Section 6Electrical

ELECTRICALIntroductionElectrical 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.

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

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 re-quire 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 con-necting 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.

Note:

WARNING!

Additional Spare Circuits for Wiring

Depending on options ordered for the truck, there may be up to four spare circuits with labeled 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, K371-39-10 for 10 ampere rating, and K371-39-15 for 15 ampere rating.

02/066-1

Section 6Electrical

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02/06

6-2

Section 6Electrical

Optional Body HarnessThe 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.

For shipping purposes the body harness 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.

FIGURE 6 - 1. Location of Standard Body Harness Connection.

Truck Body Connector to Chassis Harness

Left Rail

02/066-3

Fuse and Circuit Identification

Section 6Electrical

Fuses protect each wire (See CAPACITY in Figure 6-2 for capacity of each circuit). These are separate circuits; so by con-necting to them, you will not affect the existing circuit in the chassis.

WIRE FUNCTION PIN CIRCUIT WIRE CAPACITY FUSE WIREDESCRIPTION COLOR (AMPERES NUMBER GAUGE

BACKUP LP 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 AUX PWR AUXILIARY POWER, BODY OR TRAILER U P4TRC BLUE 15 37 10

10 14 CLEARANCE LP MARKER/ CLEARANCE LAMPS Z L3MLB BLACK 15 6 12 STOP LP BRAKE LAMP S L2STC RED 20 1 10 TAIL LP TAIL LAMP V L1TL BROWN 15 5 12 GND GROUND R GND WHITE 6

Optional config - BAT power

STD Config - IGN power

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

(For chassis built after First Quarter 1998)

02/066-4

Section 6Electrical

Circuits Wired Through the IgnitionThe 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 BatteryThe 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 continu-ous 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 CircuitsBattery 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 6Electrical

INSTALLING A THIRD BATTERYA 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 parts to install the third battery:

Qty. Item Part Number

1 BATTERY GRP 31 P27-6100-111 W/ THREADED POSTS

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 Figure 6 -3. Adding a Third Battery

K396-1020-008 Battery Jumper

K396-1010-008 Battery Jumper

Third Battery (Optional)

WIRING FOR A 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.

CAUTION:

WARNING!

Consult the liftgate manufacturer’s installation instructions for details concerning 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.

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

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

Note:

02/066-6

Follow these instructions to connect the liftgate to the third battery. See Figure 6-4.

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

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

Install the third battery.

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.

1.

2.

3.

4.

Connecting the Liftgate Power

Section 6Electrical

Figure 6 - 4. Liftgate Circuit Breaker Inside Battery Box

7855-7-200 Circuit Breaker

Liftgate Power CableMount Circuit Breaker On this Panel

Connect K396-1C91F014 Circuit Breaker Cable To Battery Positive Terminal

Engine ConnectionsElectronic 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.

02/066-7

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 connec-tor that is routed to the end of frame. Any excess is coiled and secured there. See Table 6-3 for wiring harness connec-tor pin outs and Figure 6-5 for end of frame connector configuration.

Remote PTO/Throttle Harness

Section 6Electrical

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.

WARNING!

Engine Mfgr Circuit Function Name

Switch Return

Remote PTO On/Off

Not Used

Remote Accelerator On/Off

Remote Accelerator Supply

Remote Accelerator Position

Remote Accelerator Return

Engine ECU Pin #

34

4

None

3

21

26

32

KW Circuit #

69

112

None

59

127

60

69

Engine Mfgr Circuit Function

Name

Input Sensor Common #2

PTO On/Off Switch

Remote PTO Set

Remote PTO Resume

Remote Throttle

Service Brake

PTO Lamp

Engine ECU Pin #

3

56

58

60

68

64

30

KW Circuit #

220

112

216

217

59

32

215

Wire Color

Brown

Green

Pink

Yellow

Purple

Gray

Blue

Wire Gauge

16

16

16

16

16

16

16

Pin Outs

A

B

C

D

E

F

G

Engine Harness, Cummins, ISC and ISB

Engine Harness, CAT C7 KW Wiring Harness Connector Pin Outs for CAT and Cummins

Table 6 - 3. Remote PTO/Throttle Wiring Harness

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

G

F

A

ED

C

B

02/066-8

APPENDIX A - VEHICLE IDENTIFICATION

VEHICLE IDENTIFICATION NUMBER A-1 VIN Location A-1 Chassis Number Locations A-1 CERTIFICATION LABELS A-2 Components and Weights Label A-2 Tire/Rim and Weight Rating Data Label A-2 Incomplete Vehicle Certification Label A-2 Noise Emission Label A-3 Paint Identification Label A-3 COMPONENT IDENTIFICATION A-3 Engine Identification A-3 Transmission Identification A-4 Front Axle Identification A-4 Rear Axle Identification A-4

APPENDIX B - WEIGHT DISTRIBUTION

INTRODUCTION B-1 Abbreviations B-1 CALCULATIONS B-2 Weight Distribution without Body B-2 Weight Distribution with Body B-3 Chassis Weights B-3 Option Weights B-3 Rear Liftgate Example B-6 COMPLETE (LOADED) VEHICLE B-7 Water Level Load B-7 Weight Distribution Analysis B-7 Body Length B-8

Body Builders’ ManualAppendicies

02/06

Appendix A Vehicle Identification

VEHICLE IDENTIFICATION NUMBERA 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

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.

VIN LocationThe 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 LocationsThe 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: stampedLeft 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.

••••••••

Figure A - 1. Vehicle Identification Number (VIN).

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

Code Year5 20056 20067 20078 20089 2009

M

Serial Number

02/06A-1

Chassis Number

CERTIFICATION LABELSComponents and Weights LabelThe 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.

Appendix A Vehicle Identification

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

U.S. EPA Noise Label (U.S. Registrations Only)

Final Stage Manufacturer Label to be Installed by Final Stage Manufacturer

Chassis Serial Number

Major Components and Weights Label

Incomplete Vehicle Certification Label

Safety Mark (Canadian Registry Only)

Tire, Rim and Weight Rating Data label

Tire/Rim and Weight Rating Data LabelThe 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:

GVWR — Gross Vehicle Weight RatingGAWR FRONT and REAR — Gross Axle Weight Ratings for Front and Rear AxleTIRE/RIM SIZES AND INFLATION PRESSURES — Tire/Rim Sizes and Cold Pressure MinimumsChassis (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 LabelThe 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:

DATE OF MANUFACTUREVIN — Vehicle Identification NumberLISTING OF APPLICABLE FEDERAL MOTOR VEHICLE SAFETY STANDARDS

•••

Note:

Figure A - 2. Drivers Door and Door Frame Label

02/06A-2

Noise Emission LabelThe 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 LabelThe 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 IdentificationThe 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).

Appendix A Vehicle Identification

Engine Identification Location (Cummins ISC Shown)

Figure A - 3. Engine Identification Location

02/06A-3

Cummins Label Shown

Transmission IdentificationThe 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 IdentificationThe front axle has a identification tag located on the front axle beam. It includes the axle model, part number and serial number.

Appendix A Vehicle Identification

Figure A - 4. Front Axle Identification

Rear Axle Identification

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

The rear axle identification numbering system includes two labels or stamps.

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

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 part number and country of origin.

1.

2.

Note:

Figure A - 5. Rear Axle Identification

1

2

02/06A-4

Appendix BWeight Distribution

INTRODUCTION

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

AF = Frame rail overhang length – behind the rear axleBL = Body LengthCA = Back of cab to centerline of rear axle

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 = Center of gravity: the balance point or center of a load. It is usually identified by a circle with alternating black and white quarters. CGf = 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.FA = Front AxleGVWR = Gross Vehicle Weight RatingL = 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.Lf = Portion of load (L) carried by front axleLr = Portion of load (L) carried by rear axleRA = Rear AxleWB = Wheelbase Length

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 important to have a basic understanding of weight distribution.

Abbreviations

Note:

02/06B-1

Appendix BWeight Distribution

Step 1. Figures B–1 and B–2 show a representation of a 200–inch (5080 mm) wheelbase (WB) truck de-signed 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:

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

The weight distribution is calculated as illustrated below:

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.

•

•

CALCULATIONSWeight Distribution without BodyThere are two primary equations used in weight distribution calculations:

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

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

•

•

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.

Lr =CGf WB X L Portion of Load Carried by the Rear Axle Equation 1

Portion of Load Carried by the Front Axle Equation 2Lf = L - Lr

Note:

CGf =200 2 = 100 in (2540mm)

100 lbs

200 In.

100 In.

Figure B - 1. Balanced Load: CGf 100 in. from front axle

Lr =CGf WB X L

Lf = L - Lr

100200 X 100 = 50 lbs (23 kg)

100 - 50 = 50 lbs (23 kg)

Front Axle

02/06B-2

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.

Appendix BWeight Distribution

Although it is usually not important 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 equip-ment manufacturer.

100 lbs

200 In.

133 In.

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

Front Axle

CGf = 133 in. (3378 mm)

Lr =CGf WB X L

Lf = L - Lr

133200 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.

•

02/06B-3

Appendix BWeight 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 = 6618RA = 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.

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

140 5,959 (2,702) 3,848 (1,745) 9,807 (4,448)145 6,025 (2,732) 3,798 (1,722) 9,823 (4,455)150 6,124 (2,777) 3,792 (1,720) 9,916 (4,497)152 6,148 (2,788) 3,775 (1,712) 9,923 (4,500)160 6,251 (2,835) 3,726 (1,690) 9,977 (4,525)176 6,409 (2,907) 3,620 (1,642) 10,029 (4,548)188 6,532 (2,962) 3,575 (1,621) 10,107 (4,584)194 6,571 (2980) 3,536 (1,604) 10,107 (4,584)200 6,618 (3,001) 3,514 (1,594) 10,132 (4,595)206 6,678 (3,029) 3,506 (1,590) 10,184 (4,619)215 6,738 (3,056) 3,472 (1,575) 10,210 (4,630)218 6,826 (3,096) 3,529 (1,600) 10,355 (4,696)230 6,894 (3,127) 3,487 (1,581) 10,381 (4,708)236 6,945 (3,150) 3,487 (1,581) 10,432 (4,731)245 6,995 (3,172) 3,463 (1,571) 10,458 (4,743)254 7,093 (3,217) 3,494 (1,585) 10,587 (4,801)260 7,153 (3,244) 3,512 (1,593) 10,665 (4,837)272 7,214 (3,272) 3,496 (1,585) 10,710 (4,857)280 7,236 (3,282) 3,468 (1,573) 10,704 (4,854)

Wheelbase Front Rear TotalInches

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.

Note:

02/06 B-4

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 gal-lon fuel tank. Add your results to the “bare” chassis axle weights from Table B-1 or Table B-2.

Lr =CGf WB X L

Lf = L - Lr

93.5200 X 125 = 58 lbs (26 kg)

125 - 58 = 67 lbs (30 kg)

Appendix BWeight Distribution

190 6,463 (2,931) 6,102 (2,767) 12,565 (5,698)205 6,622 (3,003) 6,082 (2,758) 12,704 (5,761)235 6,836 (3,100) 6,008 (2,725) 12,844 (5,825)260 7,047 (3,196) 6,030 (2,735) 13,077 (5,931)280 7,146 (3,241) 6,001 (2,722) 13,147 (5,962)

Wheelbase Front Rear TotalInches

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 specifica-tions). Weights do not include any options.

The options listed in Table B-3 do not include all that are available. This list is includ-ed 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.

Note:

02/06B-5

Appendix BWeight Distribution

ENGINES Cummins ISB -389 5.1CAT C7 -171 4.4ENGINE EQUIPMENT Borg Warner viscous hub -15 -30Vertical muffler, side of cab 50 63Horizontal muffler, vertical tailpipe back of cab 50 74Horizontal muffler, vertical tailpipe side of cab 50 6348” Vertical tail pipe 5 63Coolant filer for CAT or Cummins ISC engines 10 74Racor fuel/water separator for CAT C7 only 15 16Engine Immersion Block heater 2 0Pacbrake exhaust brake for Cummins ISB 9 7.4Pacbrake exhaust brake for Cummins ISC 15 7.4Jacobs extarder for CAT 15 7.4270 amp alternator 10 -30Third battery 55 48.7TRANSMISSIONS AND EQUIPMENT Fuller FS5406 -4 41Fuller FSO6406/FSO8606 39 39.3Fuller RT8608 232 41.9Fuller RT8709 224 42.6Fuller RT8908LL 332 44.8Fuller FR9210 230 42.5Fuller FRO11210 230 42.9Allison 3000 HS series 212 37.3Allison 3000/3500 RDS/EVS series 251 40.3Allison 2100/2200 HS series 15 34.8Allison 2100/2200 RDS series 25 37.8Ceramic clutch (ISB/C7) -30 21Dual std duty D/L with one center bearing 77 0.75 x wbFour std duty D/L with two center bearing 169 0.75 x wbThree std duty D/L with three center bearing 273 0.75 x wbOne HD center bearing cross member 10 0.75 x wbTwo HD center bearing cross member 20 0.75 x wbThree HD center bearing cross member 20 0.75 x wbFRONT AXLE AND EQUIPMENT Dana Spicer 13.2K front axle 0 0Dana Spicer 8K front axle 31 0Dana Spicer 14.6K front axle 57 0MeritorX-30 lightweight drums -32 0Brakes with cast spider 10 0Front taperleaf springs for 13.2 and 14.6K frt axle 0 0Front taperleaf springs for 10K frt axle 38 0Sheppard M110 for 14.6K frt axle 55 -25

Description Weight, lbs Location (CGf, inch)

TABLE B-3. T300 Typical Options

02/06 B-6

Appendix BWeight Distribution

Description Weight, lbs Location (CGf, inch)

REAR AXLES-Single 21060D wheel diff lock 15 wb21060T two-speed 75 wbS21-170/S23-170 182 wbS21-170D/S23-170 210 wb23082T 351 wb23-190 255 wb23-190D 278 wbS26-190 325 wbS26-190D 335 wbREAR AXLES-Tandem DSP40 2140 wbDSP41 2178 wbDSP41P 2196 wbREAR AXLE AND EQUIPMENT (Single) Dust shields 8 wbMeritor X-30 lightweight drum -40 wbIron hubs 30 wbREAR AXLE AND EQUIPMENT (Tandem) Dust shields 15 wbMeritor X-30 lightweight drum -80 wbIron hubs 60 wbWheel diff lock DSP40/41 (P) rear rear axle 15 wbWheel diff lock DSP40/41 (P) fwd rr and rear rr axle 38 wbSUSPENSIONS AND EQUIPMENT (Single) HAS 210L -121 wbReyco 79KB taperleaf spring 23K 56 wbHAS 230L -105 wbReyco 79KB multileaf with helper spring 26K 120 wbShocks for Reyco 79KB 36 wbStabilizer bar for Reyco 79KB 68 wbHD cross member for 79KB 41 wbHD cross member for HAS 4 wbSUSPENSIONS AND EQUIPMENT (Tandem) Chalmers 854-40-XL 452 wbReyco 102 254 wbHAS 402 468 wbTIRES (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

02/06B-7

Bridgestone M720FE 295/75R22.5 4 Bridgestone M725 295/75R22.5 18 Bridgestone M726EL 11R22.5 36 Michelin XZE 11R22.5 4 Michelin XDN2 12R22.5 62WHEELS & RIMS (weight per pair) Accuride 28408RPW 22.5X8.25 0 Accuride 28487RPW 22.5x8.25 -4 Alcoa 88364 22.5X8.25 -62 Kenworth/Alcoa 88761 22.5X8.25 -56 FRAME AND EQUIPMENT Stainless Steel clad alum bumper -19 -37Front tow hook, 2 removable 16 -37Cantilever battery box back of cab -21 83Temporary battery box between rails -100 831’ deck plate 6 922’ deck plate 10 983’ deck plate 15 104One bolted alum cross member replacing std -11 0.75 x wbTwo bolted alum cross member replacing std -22 0.75 x wbHD rear cab cross member 18 68Holland PH-T-60AOL-8 pintle hook 200 wb + AFSquare end of frame with cross member 41 wb + AF(Single axle) Stainless Steel Quarter fenders 55 wb - 25Polypropylene Quarter fenders 43 wb - 25KW plastic rear mud flaps 9 wb + 40Betts B-25 mud flap arms 12 wb - 40FUEL TANKS AND EQUIPMENT (fuel) 7 lb/gal Fuel tank40 gal 22” Al RH under 4650 gal rectangular steel LH behind cab 125 93.570 gal rectangular steel LH behind 140 9956 gal 22” Al RH under -19 5170 gal 22” Al RH under -11 57100 gal 22” All RH under 0 64120 gal 22” All RH under 8 7056 gal 22” Al LH behind 92 9575 gal 22” Al LH behind 100 101100 gal 22” All LH behind 111 108CAB AND EQUIPMENT Grab handle with short extension over door 5 58LH/RH NFPA compliant grab handles 4 58Single 22” air horn 5 39Dual 22” air horn 10 39Dual Moto mirrors 4 25

Description Weight, lbs Location (CGf, inch)

Appendix BWeight Distribution

02/06 B-8

Appendix BWeight Distribution

Dual KW Aeromirrors 26 25Hood mounted convex mirror 3 -30Fender mounted convex mirror 4 -30Sliding rear window 13 68Rear window delete -15 68Corner Windows 24 66Power window RH 4 35Power window LH/RH 8 35Peeper window 0 20Sunvisor with lights 7 16Sunvisor, Stainless 11 16Tilt steering column 5 25Driver’s KW Air cushion Plus Int. Back w/air comp. 5 42Driver’s KW Air cushion Plus High Back 2 42Driver’s KW Air cushion Plus High Back w/air comp. 7 42Drivers Seats Inc 911 10 42Full Bench -3 42Rider’s KW Air cushion Plus Int. Back w/air comp. 5 42Rider’s high-back tool box seat, High Back 2 42Rider’s KW air cushion Plus High or Interm. Back 33 42Rider’s KW Air cushion Plus High Back 2 42Rider’s KW Air cushion Plus High Back w/air comp. 7 42Riders Seats Inc 911, air suspension 35 42Riders Seats Inc 911 SCBA, air suspension 58 42Riders Seats Inc 911 SCBA, fixed 26 422-man passenger seat 62 42Delete dual arm rests -6 42Workstation between seats 20 42Radio 4 16Dash mounted CB brackets and binding posts 4 16LIGHTS AND SIGNALS Fog lights 4 -37Delete tail lamps -6 wb + AFBackup alarm 4 wb + AFBeacon lights 6 35AIR EQUIPMENT Full Truck Kit 15 wbSPECIAL EQUIPMENT Fire extinguisher 4 60Triangle reflector kit 11 60

Description Weight, lbs Location (CGf, inch)

02/06B-9

Appendix BWeight 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.

When the body is mounted on the chassis, assume that the forward edge is positioned 4 inches (102 mm) be-hind 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.

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

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.

168 in. BL

200 in. WB

156 in. CGf

84 in.

72 in.

2,400 lbs

Figure B-3. Balanced Body Unloaded: CGf 156 in. (3962 mm) from front axle.

CGf = 12

BL + 72 (168) + 72 = 156 in.12

Lr =CGf WB X L

Lf = L - Lr

156200 X 2400 = 1872 lbs (849 kg)

2400 - 1872 = 528 lbs (240 kg)

Rear Liftgate Example

200 in. WB

246 in. CGf

1,000 lbs

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

02/06 B-10

Appendix BWeight Distribution

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

Lr =CGf WB X L

Lf = L - Lr

246200 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. How-ever, 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 equa-tions 1 and 2:

•

•

•

•

Lr =CGf WB X L

Lf = L - Lr

51200 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 X L

Lf = L - Lr

51200 X 350 = 89 lbs (40 kg)

350 - 89 = 261 lbs (118 kg)

02/06B-11

Lr =CGf WB X L

Lf = L - Lr

93.5200 X 350 = 164 lbs (74 kg)

350 - 164 = 186 lbs (84 kg)

Appendix BWeight Distribution

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

COMPLETE (LOADED) VEHICLE

Water Level LoadStep 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.

Using CGf = 156 in equations 1 and 2:

CGf = 12

BL + 72 (168) + 72 = 156 in.12

Lr =CGf WB X L

Lf = L - Lr

156200 X 16,000 = 12,480 lbs (5,661 kg)

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

200 in. WB

156 in. CGf

16,000 lbs

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

02/06

B-12

Appendix BWeight Distribution

Item Front Axle Rear Axle Total lb (kg) (FA) lb (kg) (RA) lb (kg) Chassis 6618 3001 3514 1594 10132 4595

Option Fuel Tank 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

Fuel 50 Gal Opt. Tank, LH Behind 186 84 164 74 350 159

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)

Step 5. The final step is to total all the front and rear axle weights to ensure that the axles are not overload-

ed. 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 addi-tion of one component (for example, a liftgate) can produce a dramatic difference.

•

•

Weight Distribution Analysis

Body LengthStep 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.

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.

Note:

02/06

B-13

Appendix BWeight Distribution

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

Body Length (Ft)

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 recom-mended length, will provide the best weight distribution.

•

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

Note:

02/06

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).

B-14

AAbbreviations, dimensions 3-1Auxiliary power 6-5

BBody harness 6-3Body mount, rear 4-6Body mounting 4-1Body mounting with U-bolts 4-4Brackets, body mounting 4-2

CCalculations B-2Cautions 2-1Certification label 2-2Chassis maintenance 1-1Chassis Number A-1Chassis weight B-4Circuits, description 6-4Clearance, air lines and wiring 4-5Critical clearances 4-1Crossmember location 3-13Crossmembers 5-4

DDimensions 3-1Dimensions, air tanks 3-17Dimensions, battery box 3-17Dimensions, crew cab, conversion 3-11Dimensions, exhaust, horizontal 3-18Dimensions, exhaust, vertical, ISB 3-19Dimensions, exhaust, vertical muffler, ISB 3-20Dimensions, exhaust, vertical muffler, ISC/C7 3-23, 3-24Dimensions, exhaust, transverse muffler, ISB 3-21Dimensions, exhaust, transverse muffler, ISC/C7 3-25Dimensions, exhaust, vertical tailpipe ISB 3-19Dimensions, exhaust, vertical tailpipe ISC/C7 3-22Dimensions, extended cab conversion 3-12Dimensions, flood lamps, flush 3-10Dimensions, flood lamps, pedestal 3-9Dimensions, frame rails 3-17Dimensions, fuel tank 3-18Dimensions, optional fuel tank 3-18Dimensions, overall 3-2Dimensions, roof mounted options 3-8

EElectrical circuits 6-1Electrical circuits 6-1Emissions requirements 2-3Engine serial number A-3

FFederal Motor Vehicle Safety Standards 2-2Final stage manufacturer 2-2Fishplate bracket 4-6FMVSS 2-1Frame, changing length 5-1Frame, drilling 4-4

Frame, welding 5-4Front axle serial number A-4Front View 3-4Fuel tank locations 3-16

GGround clearance 3-4

IIncomplete vehicle certification 2-2Incomplete Vehicle Certification Label A-2

LLiftgate 6-6

MMounting holes, frame 4-3

NNoise Emission Label A-3Noise Requirements 2-3Notes 2-1

OOperating information 1-1Options weights B-5

RRear axle identification A-4Rear suspension, changing 5-3Rear View 3-4Remote PTO/throttle harness 6-8Repair information 1-1

SSafety signals 2-1Scope 1-1Sill spacer 4-3Spare Circuits 6-1Step height 3-6, 3-7

TThird battery option 6-6Tire And Rim Data Label A-2Transmission identification A-4Turning radius 3-1

VVehicle Identification Number A-1WWarnings 2-1Water level load B-12Weight distribution B-1Weight distribution analysis B-13Wheelbase, changing 5-2Width with doors open 3-13

02/06

Index

A DIVISION OF PACR

Kenworth Truck CompanyP.O. Box 1000Kirkland, WA 98083(425) 828-5000

®