Ken Worth Heavy Duty Bodybuilder Manual 1

Kenworth Heavy Duty Body Builder Manual

Body Builder ManualContents

08/06 iv

SECTION 1: INTRODUCTION 1-1

SECTION 2: SAFETY AND COMPLIANCE 2-1SAFETY SIGNALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1FEDERAL MOTOR VEHICLE SAFETYSTANDARDS COMPLIANCE . . . . . . . . . . . . 2-2

SECTION 3: DIMENSIONS 3-1DIMENSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1ABBREVIATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1TURNING RADIUS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1OVERALL DIMENSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4T800 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4T800 WITH SPLIT FENDERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5T800 SHORT HOOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6T800 SHORT HOOD WITH FEPTO (FRONT ENGINE POWER TAKE OFF) . . . . . . . . . 3-7T800 WIDE HOOD. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8W900S . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9W900B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10EXTENDED DAY CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1138” AEROCAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12RIDE HEIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13REAR SUSPENSION LAYOUTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14REYCO 79KB SINGLE REAR AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14REYCO 102 TANDEM REAR AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15NEWAY AD 123 SINGLE REAR AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16NEWAY AD 246 TANDEM SUSPENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17NEWAY AD 369 TRIDEM SUSPENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18HENDRICKSON PRIMAAX TANDEM SUSPENSION. . . . . . . . . . . . . . . . . . . . . 3-19HENDRICKSON PRIMAAX TRIDEM SUSPENSION . . . . . . . . . . . . . . . . . . . . . 3-20HENDRICKSON HMX TANDEM SUSPENSION . . . . . . . . . . . . . . . . . . . . . . . 3-21HENDRICKSON RT TANDEM SUSPENSION. . . . . . . . . . . . . . . . . . . . . . . . . 3-22CHALMERS 856-46 TANDEM SUSPENSION. . . . . . . . . . . . . . . . . . . . . . . . . 3-23PUSHER AXLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25GROUND CLEARANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28EXHAUST INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30PTO CLEARANCES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31FRAME LAYOUTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-34FRAME LAYOUT INDEX. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-35CHARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-41

SECTION 4: BODY MOUNTING 4-1FRAME INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1CRITICAL CLEARANCES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2BODY MOUNTING USING BRACKETS. . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3MOUNTING HOLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5BODY MOUNTING USING U–BOLTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6

Body Builder ManualContents

08/06v

SECTION 5: FRAME MODIFICATIONS 5-1FRAME MODIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1DRILLING RAILS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1MODIFYING FRAME LENGTH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2CHANGING WHEELBASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3CROSSMEMBERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5WELDING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6TORQUE REQUIREMENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7

SECTION 6: ELECTRICAL 6-1ELECTRICAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1MULTIPLEX INSTRUMENTATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1INTERIOR IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2ACCESSING GAUGES AND SWITCHES . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9ACCESSING SWITCHES IN THE UPPER DASH . . . . . . . . . . . . . . . . . . . . . . . 6-15TELLTALE SYMBOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18ADDITIONAL SPARE CIRCUITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-21MULTIFUNCTION TURN SIGNAL STALK. . . . . . . . . . . . . . . . . . . . . . . . . . . 6-24REMOTE PTO/THROTTLE HARNESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-25

Figures

08/06 vi

FIGURE 2-1. INCOMPLETE VEHICLE CERTIFICATION DOCUMENT. . . . . . . . . . . . 2-2FIGURE 2-2. LOCATIONS OF CERTIFICATION LABELS - DRIVER’S DOOR

AND FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2FIGURE 3-1. PROSPECTER TURN CIRCLE ANALYSIS . . . . . . . . . . . . . . . . . . . 3-3FIGURE 4-1. MINIMUM CLEARANCE BETWEEN TOP OF REAR TIRES AND

BODY STRUCTURE OVERHANG. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2FIGURE 4-2. MINIMUM BACK OF CAB CLEARANCE . . . . . . . . . . . . . . . . . . . . 4-3FIGURE 4-3. SPACER BETWEEN FRAME SILL AND BODY RAIL -

RUBBER OR PLASTIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4FIGURE 4-4. HIGH COMPRESSION SPRING . . . . . . . . . . . . . . . . . . . . . . . . 4-4 FIGURE 4-5. RUBBER SPACER BETWEEN BRACKETSBETWEEN THE

MOUNTING BOLT AND UPPER BRACKET . . . . . . . . . . . . . . . . . . . . . . . 4-4FIGURE 4-6. CROSSMEMBER-GUSSET HOLE PATTERN

REQUIREMENTS. [INCH (MM)] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5FIGURE 4-7. ACCEPTABLE U-BOLT MOUNTING WITH WOOD AND

FABRICATED SPACERS [INCH (MM)] . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6FIGURE 4-8. CLEARANCE SPACE FOR AIR LINES AND CABLES . . . . . . . . . . . . . 4-7FIGURE 4-9. EXAMPLE OF FISHPLATE BRACKET AT REAR END OF BODY,

USED WITH U-BOLTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8FIGURE 5-1. DETAIL OF FRAME EXTENSION AND JOINT WELDING . . . . . . . . . . . 5-2FIGURE 5-2. FRAME INSERT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3FIGURE 5-3. COMPARISON OF ORIGINAL, SHORTENED, AND

EXTENDED WHEELBASES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4FIGURE 5-4. CROSSMEMBER ADDED WHEN DISTANCE

EXCEEDS 60 INCHES (1524 MM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5FIGURE 6-1. CECU LOCATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2FIGURE 6-2. INSTRUMENT CLUSTER COMPONENTRY. . . . . . . . . . . . . . . . . . . 6-3FIGURE 6-3. CVSG GAUGES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5FIGURE 6-5. INSTRUMENTATION HARNESS INTERFACE DIAGRAM . . . . . . . . . . . 6-7FIGURE 6-6. FIREWALL AIR JUNCTION BLOCK . . . . . . . . . . . . . . . . . . . . . . 6-8FIGURE 6-7. FUEL FILTER RESTRICTION PRESSURE GAUGE SENSOR

LOCATION (TYPICAL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8FIGURE 6-8. TELLTALE SYMBOL STANDARD CARDS . . . . . . . . . . . . . . . . . . . 6-18FIGURE 6-9. BLANK TELLTALE CARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18FIGURE 6-10. TELLTALE ICONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-19FIGURE 6-11. SPARE BULLET CONNECTORS . . . . . . . . . . . . . . . . . . . . . . . 6-22FIGURE 6-12. SPARE PIGTAIL CONNECTOR . . . . . . . . . . . . . . . . . . . . . . . . 6-22FIGURE 6-13. SPARE RELAY CONNECTORS . . . . . . . . . . . . . . . . . . . . . . . . 6-23

Tables

08/06vii

TABLE 3-1. ABBREVIATIONS USED . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1TABLE 3-2. TURNING RADIUS . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1TABLE 3-3. RIDE HEIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13TABLE 3-4. REAR SUSPENSION OPTIONS . . . . . . . . . . . . . . . . . . . . . . . . . 3-14TABLE 3-5. REAR SUSPENSION OPTIONS . . . . . . . . . . . . . . . . . . . . . . . . . 3-15TABLE 3-6. REAR SUSPENSION OPTIONS . . . . . . . . . . . . . . . . . . . . . . . . . 3-16TABLE 3-7. REAR SUSPENSION OPTIONS . . . . . . . . . . . . . . . . . . . . . . . . . 3-17TABLE 3-8. REAR SUSPENSION OPTIONS . . . . . . . . . . . . . . . . . . . . . . . . . 3-18TABLE 3-9. REAR SUSPENSION OPTIONS . . . . . . . . . . . . . . . . . . . . . . . . . 3-19TABLE 3-10. REAR SUSPENSION OPTIONS . . . . . . . . . . . . . . . . . . . . . . . . 3-20TABLE 3-11. REAR SUSPENSION OPTIONS . . . . . . . . . . . . . . . . . . . . . . . . 3-21TABLE 3-12. REAR SUSPENSION OPTIONS . . . . . . . . . . . . . . . . . . . . . . . . 3-22TABLE 3-13. REAR SUSPENSION OPTIONS . . . . . . . . . . . . . . . . . . . . . . . . 3-23TABLE 3-14. GROUND CLEARANCE FOR FUEL TANKS . . . . . . . . . . . . . . . . . . 3-28TABLE 3-15. GROUND CLEARANCE FOR BATTERY BOXES . . . . . . . . . . . . . . . 3-29TABLE 3-16. FRAME LAYOUT DIMENSIONS . . . . . . . . . . . . . . . . . . . . . . . . 3-34TABLE 4-1. SINGLE STEEL RAILS . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1TABLE 4-2. INSERTED STEEL RAILS . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1TABLE 5-1. CUSTOMARY GRADE 8 UNF OR UNC. . . . . . . . . . . . . . . . . . . . . . 5-7TABLE 5-2. U.S. CUSTOMARY – GRADE 8. METRIC CLASS 10.9 . . . . . . . . . . . . . 5-7TABLE 6-1. TELLTALES POSITION AND COLOR . . . . . . . . . . . . . . . . . . . . . . 6-20TABLE 6-2. TSM GUIDELINE . . . . . . . . . . . . . . . . . . . . . . . . . . 6-24TABLE 6-3. 2007 CUMMINS ISX AND ISM. . . . . . . . . . . . . . . . . . . . . . . . . . 6-25TABLE 6-4. 2007 CAT C15 AND C13. . . . . . . . . . . . . . . . . . . . . . . . . . . 6-25

Section 1Introduction

08/06 1-1

This manual was created to provide body builders with appropriate information and guidelines useful in the body planning and installation process. This information will be helpful when installing bodies or other associated equipment.

This manual contains appropriate dimensional information, guidelines for mounting bodies, guide-lines for modifying frames, electrical wiring information, and other information useful in the body installation process.

The Body Builder Manual can be very useful when specifying a vehicle, particularly when the body builder is involved in the vehicle defi nition and ordering process. Early in the process, professional body builders can often contribute valuable information that reduces the ultimate cost of the body installation.

In the interest of continuing product development, Kenworth reserves the right to change speci-fi cations or products at any time without prior notice. It is the responsibility of the user to ensure that he is working with the latest released information. Check Kenworth.com for the latest released version.

If you require additional information or reference materials, please contact your local Kenworth dealer.

Section 2Safety & Compliance

08/06 2-1

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 dam-age 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 incor-rectly specifi ed circuit breaker could result in a electrical overload or fi re 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 mod-erate 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 effi ciently.

Example:

Note: Be sure to provide maintenance access to the battery box and fuel tank fi ll neck.

Please take the time to read these messages when you see them, and remember:

WARNINGIndicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.

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

NOTEUseful information that is related to the topic being discussed.

WARNING

CAUTION

NOTE


08/06 2-2

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

Incomplete Vehicle Certifi cationAn Incomplete Vehicle Document is shipped with the vehicle, certifying that the vehicle is not complete. See Figure 2–1. In addition, affi xed to the driver’s side door frame or edge is an Incomplete Vehicle Certifi cation label. See Figure 2–2. For further information on Vehicle Certifi cation and Identifi cation, 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 regula-tions upon completion of the modifi cations.

FIGURE 2-1. Incomplete Ve-hicle Certifi cation Document

FIGURE 2-2. Locations of Certifi ca-tion Labels - Driver’s Door and Frame

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 Certifi cation Label

Safety Mark (Canadian Registry Only)

Tire, Rim and Weight Rating Data label

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 modifi cations), you should affi x your certifi cation label to the vehicle as required by Federal law. This tag identifi es you as the “Intermediate or Final Stage Manufacturer” and certifi es that the vehicle complies with Federal Motor Vehicle Safety Standards. (See Figure 2–2.) Be advised that effective September 1, 2006, a new regulation affects the intermediate and fi nal stage manufacturer certifi cation process and documentation.

In part, if the fi nal stage manufacturer can complete and certify the vehicle within the instruction in the incomplete vehicle document (IVD) the certifi cation label would need a statement that reads, “This vehicle has been completed in accordance with the prior manufacturers‚ IVD where applicable. This vehicle conforms to all applicable Federal Motor Vehicle Safety Standards [and Bumper and Theft Prevention Standards if applicable] in effect in (month, year).”

However, if the vehicle can not be completed and certifi ed with in the guidance provided in the IVD, the fi nal stage manu-facturer must ensure the vehicle conforms to all applicable Federal Motor Vehicle Safety Standards (FMVSS). The fi nal stage manufactures certifi cation label would need a statement that reads, “This vehicle conforms to all applicable Federal Motor Vehicle Safety Standards [and Bumper and Theft Prevention Standards if applicable] in effect in (month, year).”


08/06 2-3

These statements are just part of the changes to the new certifi cation regulation. Please refer to the Feb 15, 2005 fi nal rule for all of the details related to this regulation. You can contact NTEA Technical Services Depart-ment at 1-800-441-NTEA for a copy of the fi nal rule (DocID 101760).

For Canadian fi nal stage manufacturers see:

http://canadagazette.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

Noise and Emissions Requirements

This truck may be equipped with a Diesel Particulate Filter (DPF) muffl er unit in order to meet both noise and exhaust emissions requirements. Removal or tampering with the DPF muffl er will not improve engine performance. Also tampering with the exhaust system is against the rules that are established by the U.S. Code of Federal Regulations and Environment Canada Regulations. The DPF muffl er may only be replaced with an approved part.

Relocation of DPF muffl ers will affect noise and emission performance. Contact the engine manufacturer for any requirements and restrictions prior to any modifi cations. In particular there are requirements and restrictions for exhaust pipe materials and for exhaust temperature change from turbo outlet to DPF muffl er inlet.

NOTE

NOTE

Section 3Dimensions

08/06 3-1

DIMENSIONSThis section has been designed to provide enough information to successfully layout chassis in the body planning process. Optional equipment may not be depicted. Please contact your local Kenworth dealer if more dimensional information is desired.

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

CA BACK OF CAB TO CENTERLINE OF REAR AXLE OR CENTERLINE OF TANDEMS ON TANDEM SUSPENSION

EOF FRAME RAIL OVERHANG BEHIND REAR AXLE – MEASURED FROM THE CENTERLINE OF TANDEMS

FS FRONT SUSPENSION HEIGHT

RS REAR SUSPENSION HEIGHT

WB WHEELBASE

SOC SIDE OF CAB

BOC BACK OF CAB

TURNING RADIUSApproximate turning radius specifi cations are listed in the following tables as a general guide. It is important to note that optional components may alter the results.

TABLE 3-2. Turning Radius

Model Steering Gear Front Axle Front Wheel Front TireRear

SuspensionWheel Base

Est Curb to Curb Turning

Radius (ft)

T800T800WT800SH

Single TAS 65

Dana Spicer E-1202I 12K

Accuride 28487 22.5 X 8.25

Bridgestone R287

295/75R22.5

Tandem52” Axle Spacing

181 28

193 29.5

201 30.5

213 32

220 33

232 34.5

240 35.5

252 37

260 38

272 39.5

280 40.5

291 42

303 43.5

323 46

331 47

TABLE 3-2 CONTINUES ON NEXT PAGE…

Section 3Dimensions

08/06 3-2

Model Steering Gear Front Axle Front Wheel Front TireRear

SuspensionWheel Base

Est Curb to Curb Turning

Radius (ft)

T800T800WT800SH

DualTAS 65

Dana Spicer EFA-20F4 20KStandard Track

Alcoa 28487 22.5 X 8.25

Bridgestone M844

425/65R22.5


181 31.5

193 33.5

201 34.5

213 36.5

220 37.5

232 39

240 40

252 42

260 43

272 45

280 46

291 47.5

303 49.5

323 52.5

331 53.5

W900SDual

TAS 65


Alcoa 8236522.5 X 12.25

Bridgestone M844

425/65R22.5


181 33

193 35

201 36

213 38

220 39

232 41

240 42

252 44

260 45

272 47

280 48.5

291 50

303 52

323 55

331 56

W900BDual

TAS 65


Alcoa 8236522.5 X 12.25

Bridgestone M844

425/65R22.5


181 37

193 39

201 40.5

213 42.5

220 44

232 46

240 47.5

252 49.5

260 51

272 53

280 54.5

291 56.5

303 58.5

323 62

331 63

TABLE 3-2 CONTINUED

Section 3Dimensions

08/06 3-3

Prospector Turn Circle Analysis:

Please see Figure 3-2 as an example of Kenworth’s turn circle calculation made in Prospector for your specifi c chassis. Your local Kenworth dealer can provide this information to you.

FIGURE 3-1. Prospecter Turn Circle Analysis

Please consult your local Kenworth Dealer for this information, as it is chassis specifi c.

Section 3Dimensions

08/06 3-4

OVERALL DIMENSIONSThis section includes drawings and charts of the following Class 8 models: T800, T800 with Split Fenders, T800 Short Hood, T800 Short Hood with FEPTO, T800 Wide Hood, W900S, and W900B. The Extended Day Cab and 38” AeroCab are also included.

On the pages that follow, detail drawings show particular views of each vehicle, all dimensions are in inches (in). They illustrate important measurements critical to designing bodies of all types. See the “Contents” at the beginning of the manual to locate the drawing that you need.

Note: To determine overall height please locate the chart Table 3-3 on page 3-13 and add that value to the height. All heights are given from the bottom of the frame rail.

Kenworth also offers .dxf fi les and frame layouts of ordered chassis four weeks prior to build. Please speak with your salesman to request this feature when specifying your chassis.

T800 The following drawings are of a standard T800, shown with standard chassis components.

Section 3Dimensions

08/06 3-5

T800 WITH SPLIT FENDERSThe following drawings are of a standard T800 with the optional of the Split Fender hood, shown with standard chassis components.

Section 3Dimensions

08/06 3-6

T800 SHORT HOODThe following drawings are of a T800 Short Hood, shown with standard chassis components.

Section 3Dimensions

08/06 3-7

T800 SHORT HOOD WITH FEPTO (FRONT ENGINE POWER TAKE OFF)The following drawings are of a T800 Short Hood with the optional FEPTO package. Note the extended frame rails and raised cab.

Section 3Dimensions

08/06 3-8

T800 WIDE HOODThe following drawings are of a T800 Wide Hood, which allows for the 1780 square inch radiator.

Section 3Dimensions

08/06 3-9

W900SThe following drawings are of the W900 Sloped Hood chassis, shown with some optional components.

Section 3Dimensions

08/06 3-10

W900BThe following drawings are of the W900B Straight Hood chassis, shown with standard chassis components.

Section 3Dimensions

08/06 3-11

EXTENDED DAY CABThe Extended Day Cab is shown on a standard T800 chassis. It is important to note that the Extended Day will increase any of the models bumper to back of cab dimension and front axle to back of cab dimension by 5.7”. The height (from the bottom of the frame rail) will be 86.9” across the models with the exception of the T8 Short Hood with FEPTO which will have a dimension of 90.5” due to the raised cab.

Section 3Dimensions

08/06 3-12

38” AEROCABThe 38” Aerocab is shown on a standard T800 chassis. It is important to note that the 38” will increase any of the models bumper to back of cab dimension and front axle to back of cab dimension by 28”. The height (from the bottom of the frame rail) will be 93.2” across the models.

Section 3Dimensions

08/06 3-13

RIDE HEIGHTSThe front (FS) and rear (RS) suspension ride heights are provided as a basic tool to determine the overall height of the cab, height of exhaust components, and frame heights. The heights are all calculated from the centerlines of the axles, please be sure to include the tire radius dimension to determine overall height. Note: the frame rail height itself will not affect the overall height as all components are located from the bottom of the frame rail.

TABLE 3-3. Ride Heights

Front Suspension Rear SuspensionRide Height Front “FS” (in) Ride Height Rear “RS” (in)

Laden Unladen Laden Unladen

Taperleaf 12K Rating

Reyco 79KB 23K Rating 10.2 11.4 8.3 10.8

Reyco 102 38K Rating 10.2 11.4 9.2 10.8

Neway AD123 23K Rating 10.2 11.4 10 10

Chalmers 854-40-L-HS 40K Rating 10.2 11.4 9.6 11

Taperleaf 20K Rating

Chalmers 854-46-H 46K Rating 10.4 11.9 10.1 12.4

Chalmers 854-50-H-HS 50K Rating 10.4 11.9 10.8 12.5

Chalmers 865-65-XL 65K Rating 10.4 11.9 13 15.7

Hendrickson HMX460 46K Rating 17.5” Saddle Height

10.4 11.9 10.5 11.5

Hendrickson Primaax 46K Rating 10.4 11.9 10 10

Hendrickson RT463 46K Rating 10.4 11.9 10 11.1

Hendrickson RT523 52K Rating 6” Saddle Height

10.4 11.9 9.9 11

Neway AD246 46K Rating 6” Saddle Height

10.4 11.9 10 10

Neway AD369 69K Rating 10.4 11.9 10 10

Section 3Dimensions

08/06 3-14

REAR SUSPENSION LAYOUTSThe rear suspension layouts are provided as a tool to help layout bodies prior to arrival. The applicable dimensions are shown. Be sure to check the axle spacing that is shown, as alternate spacings may exist and could change some of the dimensions. The dimensions shown below are the most typical installations, in special cases some hole locations will move. If you are planning on using the holes shown for your body installation, please confi rm with your local KW dealer that the drawing below will be the installation used on your specifi c truck. Ensure that proper torque is used to reinstall any suspension components. See Tables 5-1 and 5-2 on page 5-7.

It would be a good idea in this case to order the frame layout of your chassis along with your truck order. This can be done on any Kenworth truck, and will be provided 4 weeks ahead of the build schedule.

If there are hole locations that are not detailed please work with your local Kenworth Dealer to request that information.

Additionally optional axle spacings are shown in the charts, if you would like details on the frame drilling with optional spacings, please contact your local Kenworth dealer.

REYCO 79KB SINGLE REAR AXLE

Optional Reyco 79KB Suspensions

TABLE 3-4. Rear Suspension Options

Suspension Type Rating Axle SpacingLaden Ride

HeightUnladen Ride

Height

Reyco 79KB single 20K - 8.3” 10.8”




Section 3Dimensions

08/06 3-15

REYCO 102 TANDEM REAR AXLEShown with a 52” Axle Spacing

Reyco 102 Suspension Data


Suspension Type Rating Axle Spacing Laden Ride HeightUnladen Ride

Height

Reyco 102 Tandem 38K 52” 9.2” 10.8”

Section 3Dimensions

08/06 3-16

NEWAY AD 123 SINGLE REAR AXLE

Optional Neway AD Single Suspensions



HeightUnladen Ride

Height

Neway AD123 single 23K - 10” 10”

Neway AD126 single 26K - 10” 10”

Section 3Dimensions

08/06 3-17

NEWAY AD 246 TANDEM SUSPENSIONShown with a 54” Axle Spacing

Optional Neway AD Tandem Suspensions



HeightUnladen Ride

Height

Neway AD246 tandem 46K 54” 10” 10”







Section 3Dimensions

08/06 3-18

NEWAY AD 369 TRIDEM SUSPENSIONShown with 54” Axle Spacings

Optional Neway AD Tridem Suspensions



HeightUnladen Ride

Height

Neway AD369 tridem 69K 54” 10” 10”



Section 3Dimensions

08/06 3-19

HENDRICKSON PRIMAAX TANDEM SUSPENSIONShown with 54” Axle Spacings

Optional Hendrickson Primaax Tandem Suspensions



HeightUnladen Ride

Height

Hendrickson Primaax Tandem 46K 54” 10” 10”



Section 3Dimensions

08/06 3-20

HENDRICKSON PRIMAAX TRIDEM SUSPENSIONShown with 54” Axle Spacings

Optional Hendrickson Primaax Tridem Suspensions



HeightUnladen Ride

Height

Hendrickson Primaax Tridem 69K 54” 10” 10”

Hendrickson Primaax Tridem 69K 60” 10” 10”

Section 3Dimensions

08/06 3-21

HENDRICKSON HMX TANDEM SUSPENSIONShown with 54” Axle Spacing

Optional Hendrickson HMX Tandem Suspensions



HeightUnladen Ride

Height

Hendrickson HMX400 16.5” saddle 40K 54” 9.5” 10.6”




Section 3Dimensions

08/06 3-22

HENDRICKSON RT TANDEM SUSPENSIONShown with a 54” Axle Spacing Without Track Rods

Optional Hendrickson RT Tandem Suspensions



HeightUnladen Ride

Height

Hendrickson RT463 6” saddle 46K 52” 10.0” 11.1”


Hendrickson RT463 7.19” saddle 46K 54” 11.2” 12.5”




Hendrickson RTE463 7.19” saddle 46K 52” 10.5” 11.6”







Section 3Dimensions

08/06 3-23

CHALMERS 856-46 TANDEM SUSPENSIONShown with a 54” Axle Spacing

Optional Chalmers Tandem Suspensions



HeightUnladen Ride

Height

Chalmers 854-40-L 40K 54” 8.9” 11.1”

Chalmers 854-40-L-HS 40K 54” 9.6” 11.1”

Chalmers 854-40-H 40K 54” 10.2” 12.4”

Chalmers 854-40-H-HS 40K 54” 10.9” 12.4”

Chalmers 854-46-L 46K 54” 8.9” 11.3”

Chalmers 854-46-L-HS 46K 54” 9.6” 11.3”

Chalmers 854-46-H 46K 54” 10.1” 12.5”

Chalmers 854-46-H-HS 46K 54” 10.9” 12.5”

Chalmers 854-46-XXH-HS 46K 54” 15.6” 17.3”

Chalmers 854-46-XXXH-HS 46K 54” 17.1” 18.8”

Chalmers 854-50-L 50K 54” 8.9” 11.3”

TABLE 3-13 CONTINUES ON NEXT PAGE…

Section 3Dimensions

08/06 3-24


HeightUnladen Ride

Height

Chalmers 854-50-L-HS 50K 54” 9.6” 11.3”

Chalmers 854-50-H 50K 54” 10.1” 12.5”

Chalmers 854-50-H-HS 50K 54” 10.9” 12.5”

Chalmers 854-50-XXH 50K 54” 15.5” 17.3”

Chalmers 854-52-L-HS 52K 54” 9.6” 11.3”

Chalmers 854-52-H-HS 52K 54” 10.9” 12.5”

Chalmers 860-40-L 40K 60” 8.9” 11.1”

Chalmers 860-40-H 40K 60” 10.2” 12.4”

Chalmers 860-46-L 46K 60” 8.9” 11.3”

Chalmers 860-46-L-HS 46K 60” 9.6” 11.3”

Chalmers 860-46-H 46K 60” 10.1” 12.5”

Chalmers 860-46-H-HS 46K 60” 10.9” 12.5”

Chalmers 860-46-XXH-HS 46K 60” 15.6” 17.3”

Chalmers 860-50-L 50K 60” 8.9” 11.3”

Chalmers 860-50-L-HS 50K 60” 9.6” 11.3”

Chalmers 860-50-H 50K 60” 10.1” 12.5”

Chalmers 860-50-H-HS 50K 60” 10.9” 12.5”

Chalmers 860-50-XH 50K 60” 12.1” 14.6”

Chalmers 860-52-H 52K 60” 10.9” 12.5”

Chalmers 860-52-XXH 52K 60” 15.6” 17.6”

Chalmers 872-46-H 46K 72” 10.1” 12.5”

Chalmers 872-46-H-HS 46K 72” 11.0” 12.5”

Chalmers 872-50-H-HS 50K 72” 11.0” 12.5”

TABLE 3-13 CONTINUED

Section 3Dimensions

08/06 3-25

PUSHER AXLESThe rear pusher axle layouts are provided as a tool to help layout bodies prior to arrival. The applicable dimensions are shown. When using the pusher layouts to determine available frame space please be aware that clearances required are not shown. For information that may not be detailed in these drawings work with your local Kenworth Dealer to request that information.

Watson & Chalin Super Lite 8K Steerable Pusher

Watson & Chalin Tru Track Alumilite 13.2K Steerable Pusher

Section 3Dimensions

08/06 3-26

Watson & Chalin Tru Track 20K Steerable Pusher

Watson & Chalin Atlas 22.5K Non-Steerable Pusher

Section 3Dimensions

08/06 3-27

Hendrickson Paralift Ultra II 13.2K Steerable Pusher

Section 3Dimensions

08/06 3-28

GROUND CLEARANCEThis information is provided as a reference, not all optional equipment is included. In order to calculate the height on your specifi c chassis, please use the ride height information provided on page 3-14. For comparison the FS value shown is 11.4” unladen and 10.4” laden.

TABLE 3-14. Ground Clearance for Fuel Tanks

Front Suspension

Front TiresRear

SuspensionRear Tires Component

Dimension “A”

Distance from

Bottom of Frame Rail

(in)

Dimension “B” Ground Clearance (in)

Unladen Laden

20K Taper-leaf Spring

M844F 425/65R22.5

Tires

Hendrickson HMX 460

17.5” Saddle Height

M711 11R24.5

22” Fuel Tank 16.3 17.2 14.9

24.5” Fuel Tank

18.2 15.3 13

28.5” Fuel Tank

21.4 12 9.7

Section 3Dimensions

08/06 3-29

TABLE 3-15. Ground Clearance for Battery Boxes

Front Suspension

Front TiresRear

SuspensionRear Tires Component

Dimension “A”

Distance from

Bottom of Frame Rail

(in)

Dimension “B” Ground Clearance (in)

Unladen Laden

20K Taper-leaf Spring

M844F 425/65R22.5

Tires

Hendrickson HMX 460

17.5” Saddle Height

M711 11R24.5

Battery Box with Air Tanks

17.3 16.2 13.9

Vocational Battery Box

with Air Tanks17.8 15.7 13.4

Single DPF Box

15.5 17.9 15.6

Dual DPF Box (Required for high HP Cat)

18.5 14 12.6

Section 3Dimensions

08/06 3-30

EXHAUST INFORMATIONThis section includes information on how to calculate tailpipe heights, and reference information for PTO clearance. Optional equipment is not shown.

Tailpipe Stack Height Calculation

Dimension A

Tailpipes side of Aerocab, RH under DPF

75.0”

Tailpipes independent back of sleeper, RH under DPF

66.0”

DPF mounted independent back of cab or sleeper

Tailpipes side of cab mount, DPF RH under

Tailpipes back of cab mount, DPF RH under

68.0”

DIMENSION “B” IS THE TAILPIPE LENGTH.

For approximate unladen stack height (12,000 pound springs) use the following frame heights:

Tire Size Top of Rail

11R24.5 43.5”

11R22.5 42.5”

285/75R24.5 42”

295/75R22.5 41.5”

*Use Prospector frame heights for more accurate results.

Sample: Tailpipe height 13’6” = Desired overall stack height = 162.0” (–) Prospector frame height (–) 43.5” (+) Frame rail depth (+) 10.6” (–) Dimension ‘A’ from chart (–) 68.6” = Tail pipe length = 60.5”

Cummins Cat

76.5” 73.5”

Section 3Dimensions

08/06 3-31

PTO CLEARANCESThe following visuals are provided to help aid in determining PTO locations and clearances. For specifi c dimensions please work through your local Kenworth dealer. Note: All drawings depict the Caterpillar CGI line (2” diameter exhaust line returning to the engine), Cummins engines will not have the CGI return line.

Manual Transmission:

Bottom view from right rear of chassis View from rear

Bottom view from forward right Bottom view from front left under

MANUAL TRANSMISSION CONTINUES ON NEXT PAGE…

Section 3Dimensions

08/06 3-32

MANUAL TRANSMISSION CONTINUED

Top view

Bottom view

Section 3Dimensions

08/06 3-33

Allison Transmission:

Bottom view Bottom right front

Top view Bottom right rear

Section 3Dimensions

08/06 3-34

FRAME LAYOUTSThe dimensions in the frame layout section are intended to aid in layout of the chassis, and to help determine the best possible combination of fuel tanks, battery boxes, and the diesel particulate fi lter (DPF). For your application, the layouts focus on the under cab area, with appropriate dimensional information included for pertinent back of cab components. Not all optional equipment is included in this section. Additional components may be placed on the rail behind components show. The Back of Cab components are shown primarily for reference. For more specifi c requirements please work with your local Kenworth Dealer. Please read the instructions carefully.

The following dimensions are consistent across the entire section to aid in the comparison of one layout option versus another.

TABLE 3-16. Frame Layout Dimensions

Dimension Location

A RH Side, Under Cab, Below Rail

B RH Side, Above Rail

C LH Side, Under Cab, Below Rail

D LH Side, Above Rail

E RH Side, Under Rail Back of Cab

F LH Side, Under Rail Back of Cab

BOC Back of Cab

The layouts are organized by type, specifi cally the arrangement of under cab components. The visual index that follows will give you a quick overview of the layouts that are included. Using the index locate the layout that you are interested in, then turn to the specifi ed pages. The charts that follow are then model specifi c. It is important that the correct chart is used for accurate dimensional information.

Visual Index

Symbol Description

Diesel Particulate Filter

Vertical Diesel Particulate Filter

Standard Battery Box

Vocational Battery Box

Fuel Tank

, Tailpipes (Horizontal, Vertical)

Section 3Dimensions

08/06 3-35

FRAME LAYOUT INDEX

Day Cab Chassis Layout Options

D1 is used for dual or single exhaust located side of cab (SOC) with battery box LH under, DPF RH under and fuel tanks back of cab (BOC). Note: This layout can be used with a modular sleeper, dimensions will not change. Charts located on pages 3-41 and 3-42.

D2 is used for dual or single exhaust located side of cab with the vocational style battery box LH BOC, fuel tank LH under, and DPF RH under. Note: This layout can be used with a modular sleeper, dimensions will not change. Charts located on pages 3-43 through 3-46.

D3 is used for dual or single exhaust located side of cab with fuel tank LH under, DPF RH under and battery box BOC. Note: This layout can be used with a modular sleeper, dimensions will not change. Charts located on pages 3-47 through 3-50.

D4 is used for single exhaust right hand (RH) back of cab with battery box LH under, DPF RH under and fuel tanks BOC. Charts located on pages 3-51 and 3-52.

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Section 3Dimensions

08/06 3-36

D5 is used for single exhaust RH back of cab with vocational style battery box LH BOC, fuel tank LH under and DPF RH under. Charts located on pages 3-53 through 3-56.

D6 is used for single exhaust RH back of cab with fuel tank LH under, DPF RH under and battery box LH BOC. Charts located on pages 3-57 through 3-60.

D7 is used for horizontal exhaust back of cab with battery box LH under, DPF RH under and fuel tanks BOC. Note: This layout can be used with a modular sleeper, dimensions will not change. Charts located on pages 3-61 and 3-62.

D8 is used for horizontal exhaust back of cab with vocational style battery box LH BOC, fuel tank LH under and DPF RH under. Note: This layout can be used with a modular sleeper, dimensions will not change. Charts located on pages 3-63 through 3-65.

D9 is used for horizontal exhaust back of cab with fuel tank LH under, DPF RH under and battery box LH BOC. Note: This layout can be used with a modular sleeper, dimensions will not change. Charts located on page 3-66 through 3-68.

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Section 3Dimensions

08/06 3-37

D10 is used for vertical independent exhaust RH back of cab, including DPF, battery box LH under, and fuel tank RH under. Charts located on pages 3-69 through 3-72.

D11 is used for vertical independent exhaust RH back of cab, including DPF, battery box LH under, tool box RH under and fuel tanks located BOC. Charts located on pages 3-73 and 3-74.

D12 is used for vertical independent exhaust RH back of cab, including DPF, vocational style battery box LH BOC, fuel tank LH under and tool box RH under. Charts located on pages 3-75 through 3-78.

D13 is used for vertical independent exhaust RH back of cab, including DPF, vocational style battery box LH BOC, fuel tank LH under and fuel tank RH under. Charts located on pages 3-79 through 3-86.

D14 is used for vertical independent exhaust RH back of cab, including DPF, fuel tanks LH and RH under, and battery box LH BOC. Charts located on pages 3-87 through 3-90.

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Section 3Dimensions

08/06 3-38

D15 is used for horizontal exhaust back of cab, including DPF, battery box LH under, and fuel tank RH. Charts located on pages 3-91 and 3-93.

D16 is used for horizontal exhaust back of cab, including DPF, vocational style battery box LH BOC, fuel tank LH under and tool box RH under. Charts located on page 3-94 through 3-96.

D17 is used for horizontal exhaust back of cab, including DPF, vocational style battery box LH BOC, fuel tank LH under and fuel tank RH under. Charts located on pages 3-97 through 3-102.

D18 is used for horizontal exhaust back of cab, including DPF, fuel tanks LH and RH under, and battery box LH BOC. Charts located on pages 3-103 and 3-105.

D19 is used for horizontal exhaust back of cab, including DPF, battery box LH under, tool box RH under, fuel tanks LH and RH BOC. Charts located on pages 3-106 and 3-107.

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Section 3Dimensions

08/06 3-39

D20 is used for vertical exhaust back of cab with fuel tank LH under, DPF RH under and vocational battery box RH BOC. Charts located on pages 3-108 through 3-111.

Sleeper Chassis Layout Options

S4 is used for dual AeroCab style exhaust with battery box LH under, DPF RH under and fuel tanks BOC. Chart located on page 3-112.

S5 is used for dual AeroCab style exhaust with fuel tank LH under, DPF RH under and battery box BOC. Chart located on page 3-113.

S9 is used for vertical independent exhaust RH back of sleeper, including integrated DPF, battery box LH under, fuel tank RH under. Note: This confi guration available on either the 38” AeroCab or 42” modular sleeper. Charts located on pages 3-114 through 3-116.

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Section 3Dimensions

08/06 3-40

S10 is used for vertical independent exhaust back of sleeper, including DPF, vocational style battery box LH BOC, fuel tank LH under, and toolbox RH under. Note: This confi guration available on either the 38” AeroCab or 42” modular sleeper. Charts located on pages 3-117 through 3-119.

S11 is used for vertical independent exhaust back of sleeper, including DPF, vocational style battery box LH BOC, fuel tank LH under, and fuel tank RH under. Note: This confi guration available on either the 38” AeroCab or 42” modular sleeper. Charts located on pages 3-120 through 3-122.

S12 is used for vertical independent exhaust back of sleeper, including DPF, fuel tanks under LH and RH and battery box LH BOC. Note: This confi guration available on either the 38” AeroCab or 42” modular sleeper. Charts located on pages 3-123 through 3-125.

S18 is used for vertical independent exhaust back of sleeper, including DPF, battery box LH under, tool box RH under and fuel tanks BOC. Note: This confi guration available on either the 38” AeroCab or 42” modular sleeper. Charts located on pages 3-126 and 3-127.

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Section 3Dimensions

08/06 3-41

D1 C

harts

CHARTSD1A—Use with the following models: T800, T800SH

DPF Location: RH Under CabBattery Box: LH Under CabFuel Tank: BOC

TABLE 3-17.

Model Cab Confi guration Tailpipe Confi gurationDimension A

DPF to BOC (in.)

T800

Day CabSingle RH SOC

5.4Dual SOC

Extended Day CabSingle RH SOC

-0.3Dual SOC

T800SHDay Cab Single RH SOC 7.2

Extended Day Cab Single RH SOC 1.5

22” Fuel Tank 24.5” Fuel Tank 28.5” Fuel Tank

GallonsTank

Length (in.)

Dim. F Day Cab BOC to End of

Fuel Tank (in.)

Dim. F Extended Day Cab BOC to End of

Fuel Tank (in.)

GallonsTank

Length (in.)


Fuel Tank (in.)


Fuel Tank (in.)

GallonsTank

Length (in.)


Fuel Tank (in.)


Fuel Tank (in.)

40 25.6 22.5 16.8 45 22.9 19.8 14.1 75 28.7 25.6 19.9

56 35.5 32.4 26.7 60 30.5 27.4 21.7 90 34.2 31.1 25.4

60 38.0 34.9 29.2 75 38.5 35.4 29.7 105 38.8 35.7 30.0

75 47.3 44.2 38.5 90 45.5 42.4 36.7 120 45.8 42.7 37.0

100 62.2 59.1 53.4 100 50.0 46.9 41.2 135 50.8 47.7 42.0

120 74.2 71.1 65.4 110 54.9 51.8 46.1 150 56.2 53.1 47.4

120 60.5 57.4 51.7 177 66.1 63.0 57.3

135 67.2 64.1 58.4

150 74.5 71.4 65.7

NOTE: DIMENSION “F” IS CALCULATED USING A STANDARD SIZED BATTERY BOX. OPTIONAL EXTENDED BOXES WILL CHANGE DIMENSION “F”.

Section 3Dimensions

08/06 3-42

D1

Ch

arts

D1B—Use with the following models: W900B / W900S


TABLE 3-18.


DPF to BOC (in.)

W900B / W900S

Day Cab Single RH SOC 5.4

Extended Day Cab Single RH SOC -0.3


GallonsTank

Length (in.)


Fuel Tank (in.)


Fuel Tank (in.)

GallonsTank

Length (in.)


Fuel Tank (in.)


Fuel Tank (in.)

GallonsTank

Length (in.)


Fuel Tank (in.)


Fuel Tank (in.)

40 25.6 16.4 10.7 45 22.9 13.7 8.0 75 28.7 19.5 13.8

56 35.5 26.3 20.6 60 30.5 21.3 15.6 90 34.2 25.0 19.3

60 38.0 28.8 23.1 75 38.5 29.3 23.6 105 38.8 29.6 23.9

75 47.3 38.1 32.4 90 45.5 36.3 30.6 120 45.8 36.6 30.9

100 62.2 53.0 47.3 100 50.0 40.8 35.1 135 50.8 41.6 35.9

120 74.2 65.0 59.3 110 54.9 45.7 40.0 150 56.2 47.0 41.3

120 60.5 51.3 45.6 177 66.1 56.9 51.2

135 67.2 58.0 52.3

150 74.5 65.3 59.6


Section 3Dimensions

08/06 3-43

D2 C

harts

D2A—Use with the following models: T800

DPF Location: RH Under CabBattery Box: Vocational LH BOCFuel Tank: LH Under Cab

TABLE 3-19.


DPF to BOC (in.)

T800


5.4Dual SOC


-0.3Dual SOC


GallonsTank

Length (in.)

Dim. C Day Cab BOC to

Batt. Box (in.)

Dim. C Extended Day Cab BOC to

Batt. Box (in.)

GallonsTank

Length (in.)


Batt. Box (in.)


Batt. Box (in.)

GallonsTank

Length (in.)


Batt. Box (in.)


Batt. Box (in.)

56 35.5 12.7 6.9 60 30.5 7.6 1.9 751, 2 28.7 5.8 0.1

60 38.0 15.2 9.4 75 38.5 15.7 9.9 90 34.2 11.4 5.6

75 47.3 24.5 18.8 90 45.5 22.7 17.0 105 38.8 16.0 10.3

100 62.2 39.4 33.7 100 50.0 27.2 21.5 120 45.8 23.0 17.3

120 74.2 51.4 45.7 110 54.9 32.1 26.4 135 50.8 28.0 22.3

120 60.5 37.7 32.0 150 56.2 33.4 27.7

135 67.2 44.4 38.7 177 66.1 43.3 37.6

150 74.5 51.7 46.0

1 MAXIMUM DAYCAB FUEL TANK TO MATCH DIMENSION “A”2 MAXIMUM EXTENDED DAYCAB FUEL TANK TO MATCH DIMENSION “A”

Section 3Dimensions

08/06 3-44

D2

Ch

arts

D2B—Use with the following models: T800SH


TABLE 3-20.


DPF to BOC (in.)

T800SH


7.2Dual SOC


1.5Dual SOC


GallonsTank

Length (in.)


Batt. Box (in.)


Batt. Box (in.)

GallonsTank

Length (in.)


Batt. Box (in.)


Batt. Box (in.)

GallonsTank

Length (in.)


Batt. Box (in.)


Batt. Box (in.)

56 35.5 12.6 6.9 602 30.5 7.6 1.9 751, 2 28.7 5.8 0.1

60 38.0 15.1 9.4 75 38.5 15.6 9.9 90 34.2 11.3 5.6

75 47.3 24.4 18.7 90 45.5 22.6 16.9 105 38.8 15.9 10.2

100 62.2 39.3 33.6 100 50.0 27.1 21.4 120 45.8 22.9 17.2

120 74.2 51.3 45.6 110 54.9 32.0 26.3 135 50.8 27.9 22.2

120 60.5 37.6 31.9 150 56.2 33.3 27.6

135 67.2 44.3 38.6 177 66.1 43.2 37.5

150 74.5 51.6 45.9

1 MAXIMUM DAY CAB FUEL TANK TO MATCH DIMENSION “A” 2 MAXIMUM EXTENDED DAY CAB FUEL TANK TO MATCH DIMENSION “A”

Section 3Dimensions

08/06 3-45

D2 C

harts

D2C—Use with the following models: W900B


TABLE 3-21.


DPF to BOC (in.)

W900B


5.4Dual SOC


-0.3Dual SOC


GallonsTank

Length (in.)


Batt. Box (in.)


Batt. Box (in.)

GallonsTank

Length (in.)


Batt. Box (in.)


Batt. Box (in.)

GallonsTank

Length (in.)


Batt. Box (in.)


Batt. Box (in.)

56 35.5 -4.0 -9.7 75 38.5 -1.0 -6.7 90 34.2 -5.3 -11.0

601, 2 38.0 -1.5 -7.2 901, 2 45.5 6.1 0.3 105 38.8 -0.7 -6.4

75 47.3 7.8 2.1 100 50.0 10.6 4.9 1201, 2 45.8 6.3 0.6

100 62.2 22.8 17.1 110 54.9 15.5 9.8 135 50.8 11.4 5.6

120 74.2 34.8 29.1 120 60.5 21.1 15.4 150 56.2 16.8 11.1

135 67.2 27.8 22.1 177 66.1 26.7 21.0

150 74.5 35.1 29.4

1 MAXIMUM DAY CAB FUEL TANK TO MATCH DIMENSION “A”2 MAXIMUM EXTENDED DAY CAB FUEL TANK TO MATCH DIMENSION “A”

Section 3Dimensions

08/06 3-46

D2

Ch

arts

D2D—Use with the following models: W900S


TABLE 3-22.


DPF to BOC (in.)

W900S


5.4Dual SOC


-0.3Dual SOC


GallonsTank

Length (in.)


Batt. Box (in.)


Batt. Box (in.)

GallonsTank

Length (in.)


Batt. Box (in.)


Batt. Box (in.)

GallonsTank

Length (in.)


Batt. Box (in.)


Batt. Box (in.)

56 35.5 1.5 -4.3 751, 2 38.5 4.5 -1.3 90 34.2 0.2 -5.5

601, 2 38.0 4.0 -1.8 90 45.5 11.5 5.8 1051, 2 38.8 4.8 -1.0

75 47.3 13.3 7.6 100 50.0 16.0 10.3 120 45.8 11.8 6.1

100 62.2 28.2 22.5 110 54.9 20.9 15.2 135 50.8 16.8 11.1

120 74.2 40.2 34.5 120 60.5 26.5 20.8 150 56.2 22.2 16.5

135 67.2 33.2 27.5 177 66.1 32.1 26.4

150 74.5 40.5 34.8


Section 3Dimensions

08/06 3-47

D3 C

harts


DPF Location: RH Under CabBattery Box: BOCFuel Tank: LH Under Cab

TABLE 3-23.


DPF to BOC (in.)

T800


5.4Dual SOC


-0.3Dual SOC


GallonsTank

Length (in.)

Dim. C Day Cab BOC to End of

Fuel Tank (in.)

Dim. C Extended Day Cab BOC to End of

Fuel Tank (in.)

GallonsTank

Length (in.)


Fuel Tank (in.)


Fuel Tank (in.)

GallonsTank

Length (in.)


Fuel Tank (in.)


Fuel Tank (in.)

56 35.5 -3.5 -9.2 60 30.5 -8.6 -14.3 75 28.7 -10.4 -16.1

601, 2 38.0 -1.1 -6.8 751, 2 38.5 -0.6 -6.3 90 34.2 -4.9 -10.6

75 47.3 8.2 2.5 90 45.5 6.4 0.7 1051 38.8 -0.3 -6.0

100 62.2 23.1 17.4 100 50.0 10.9 5.2 1202 45.8 6.7 1.0

120 74.2 35.1 29.4 110 54.9 15.8 10.1 135 50.8 11.7 6.0

120 60.5 21.4 15.7 150 56.2 17.1 11.4

135 67.2 28.1 22.4 177 66.1 27.0 21.3

150 74.5 35.4 29.7


Section 3Dimensions

08/06 3-48

D3

Ch

arts



TABLE 3-24.


DPF to BOC (in.)

T800SH

Day Cab Single RH SOC 7.2

Extended Day Cab Single RH SOC 1.5


GallonsTank

Length (in.)


Fuel Tank (in.)


Fuel Tank (in.)

GallonsTank

Length (in.)


Fuel Tank (in.)


Fuel Tank (in.)

GallonsTank

Length (in.)


Fuel Tank (in.)


Fuel Tank (in.)

56 35.5 -3.7 -9.4 60 30.5 -8.7 -14.4 75 28.7 -10.5 -16.2

60 38.0 -1.2 -6.9 75 38.5 -0.7 -6.4 90 34.2 -5.0 -10.7

751, 2 47.3 8.1 2.4 901, 2 45.5 6.3 0.6 105 38.8 -0.4 -6.1

100 62.2 23.0 17.3 100 50.0 10.8 5.1 1201, 2 45.8 6.6 0.9

120 74.2 35.0 29.3 110 54.9 15.7 10.0 135 50.8 11.6 5.9

120 60.5 21.3 15.6 150 56.2 17.0 11.3

135 67.2 28.0 22.3 177 66.1 26.9 21.2

150 74.5 35.3 29.6


Section 3Dimensions

08/06 3-49

D3 C

harts



TABLE 3-25.


DPF to BOC (in.)

W900B


5.4Dual SOC


-0.3Dual SOC


GallonsTank

Length (in.)


Fuel Tank (in.)


Fuel Tank (in.)

GallonsTank

Length (in.)


Fuel Tank (in.)


Fuel Tank (in.)

GallonsTank

Length (in.)


Fuel Tank (in.)


Fuel Tank (in.)

56 35.5 -20.2 -25.9 75 38.5 -17.2 -22.9 90 34.2 -21.5 -27.2

60 38.0 -17.7 -23.4 90 45.5 -10.2 -15.9 105 38.8 -16.9 -22.6

75 47.3 -8.4 -14.1 100 50.0 -5.7 -11.4 120 45.8 -9.9 -15.6

1001, 2 62.2 6.5 0.8 110 54.9 -0.8 -6.5 135 50.8 -4.9 -10.6

120 74.2 18.5 12.8 1201, 2 60.5 4.8 -0.9 1501, 2 56.2 0.5 -5.2

135 67.2 11.5 5.8 177 66.1 10.4 4.7

150 74.5 18.8 13.1


Section 3Dimensions

08/06 3-50

D3

Ch

arts



TABLE 3-26.


DPF to BOC (in.)

W900S


5.4Dual SOC


-0.3Dual SOC


GallonsTank

Length (in.)


Fuel Tank (in.)


Fuel Tank (in.)

GallonsTank

Length (in.)


Fuel Tank (in.)


Fuel Tank (in.)

GallonsTank

Length (in.)


Fuel Tank (in.)


Fuel Tank (in.)

56 35.5 -14.8 -20.5 75 38.5 -11.8 -17.5 90 34.2 -16.1 -21.8

60 38.0 -12.3 -18 90 45.5 -4.8 -10.5 105 38.8 -11.5 -17.2

751, 2 47.3 -3 -8.7 100 50.0 -0.3 -6 120 45.8 -4.5 -10.2

100 62.2 11.9 6.2 1101, 2 54.9 4.6 -1.1 135 50.8 0.5 -5.2

120 74.2 23.9 18.2 120 60.5 10.2 4.5 1501, 2 56.2 5.9 0.2

135 67.2 16.9 11.2 177 66.1 15.8 10.1

150 74.5 24.2 18.5


Section 3Dimensions

08/06 3-51

D4 C

harts

D4A—Use with the following models: T800 / T800SH


TABLE 3-27.

Model Cab Confi gurationTailpipe

Confi gurationDimension A

DPF to BOC (in.)Dimension B

Max from BOC (in.)

T800 Day Cab RH BOC

5.410.9

T800SH 7.2


GallonsTank Length

(in.)

Dim. F Day Cab BOC to End of Fuel Tank (in.)

GallonsTank Length

(in.)


GallonsTank Length

(in.)


40 25.6 22.5 45 22.9 19.8 75 28.7 25.6

56 35.5 32.4 60 30.5 27.4 90 34.2 31.1

60 38.0 34.9 75 38.5 35.4 105 38.8 35.7

75 47.3 44.2 90 45.5 42.4 120 45.8 42.7

100 62.2 59.1 100 50.0 46.9 135 50.8 47.7

120 74.2 71.1 110 54.9 51.8 150 56.2 53.1

120 60.5 57.4 177 66.1 63.0

135 67.2 64.1

150 74.5 71.4


Section 3Dimensions

08/06 3-52

D4B—Use with the following models: W900B / W900S


TABLE 3-28.




Max from BOC (in.)

W900B / W900S Day Cab RH BOC 5.4 10.9


GallonsTank Length

(in.)


GallonsTank Length

(in.)


GallonsTank Length

(in.)


40 25.6 16.4 45 22.9 13.7 75 28.7 19.5

56 35.5 26.3 60 30.5 21.3 90 34.2 25.0

60 38.0 28.8 75 38.5 29.3 105 38.8 29.6

75 47.3 38.1 90 45.5 36.3 120 45.8 36.6

100 62.2 53.0 100 50.0 40.8 135 50.8 41.6

120 74.2 65.0 110 54.9 45.7 150 56.2 47.0

120 60.5 51.3 177 66.1 56.9

135 67.2 58.0

150 74.5 65.3


D4

Ch

arts

Section 3Dimensions

08/06 3-53



TABLE 3-29.




Max from BOC (in.)

T800 Day Cab RH BOC 5.4 10.9


GallonsTank Length

(in.)


Batt. Box (in.)Gallons

Tank Length (in.)



Tank Length (in.)


Batt. Box (in.)

56 35.5 12.7 602 30.5 7.6 751 28.7 5.8

60 38.0 15.2 75 38.5 15.7 902 34.2 11.4

75 47.3 24.5 90 45.5 22.7 105 38.8 16.0

100 62.2 39.4 100 50.0 27.2 120 45.8 23.0

120 74.2 51.4 110 54.9 32.1 135 50.8 28.0

120 60.5 37.7 150 56.2 33.4

135 67.2 44.4 177 66.1 43.3

150 74.5 51.7

1 MAXIMUM DAY CAB FUEL TANK TO MATCH DIMENSION “A”2 MAXIMUM DAY CAB FUEL TANK TO MATCH DIMENSION “B”

D5 C

harts

Section 3Dimensions

08/06 3-54



TABLE 3-30.




Max from BOC (in.)

T800SH Day Cab RH BOC 7.2 10.9


GallonsTank Length

(in.)



Tank Length (in.)



Tank Length (in.)


Batt. Box (in.)

56 35.5 12.6 601, 2 30.5 7.6 751 28.7 5.8

60 38.0 15.1 75 38.5 15.6 902 34.2 11.3

75 47.3 24.4 90 45.5 22.6 105 38.8 15.9

100 62.2 39.3 100 50.0 27.1 120 45.8 22.9

120 74.2 51.3 110 54.9 32.0 135 50.8 27.9

120 60.5 37.6 150 56.2 33.3

135 67.2 44.3 177 66.1 43.2

150 74.5 51.6


D5

Ch

arts

Section 3Dimensions

08/06 3-55



TABLE 3-31.




Max from BOC (in.)

W900B Day Cab RH BOC 5.4 10.9


GallonsTank Length

(in.)



Tank Length (in.)



Tank Length (in.)


Batt. Box (in.)

56 35.5 -4.0 75 38.5 -1.0 90 34.2 -5.3

60 38.0 -1.5 901 45.5 6.1 105 38.8 -0.7

752 47.3 7.8 1002 50.0 10.6 1201 45.8 6.3

100 62.2 22.8 110 54.9 15.5 1352 50.8 11.4

120 74.2 34.8 120 60.5 21.1 150 56.2 16.8

135 67.2 27.8 177 66.1 26.7

150 74.5 35.1


D5 C

harts

Section 3Dimensions

08/06 3-56

D5

Ch

arts



TABLE 3-32.




Max from BOC (in.)

W900S Day Cab RH BOC 5.4 10.9


GallonsTank Length

(in.)



Tank Length (in.)



Tank Length (in.)


Batt. Box (in.)

56 35.5 1.5 75 38.5 4.5 90 34.2 0.2

601,2 38.0 4.0 902 45.5 11.5 1051 38.8 4.8

75 47.3 13.3 100 50.0 16.0 1202 45.8 11.8

100 62.2 28.2 110 54.9 20.9 135 50.8 16.8

120 74.2 40.2 120 60.5 26.5 150 56.2 22.2

135 67.2 33.2 177 66.1 32.1

150 74.5 40.5


Section 3Dimensions

08/06 3-57


DPF Location: RH Under CabBattery Box: LH BOCFuel Tank: LH Under Cab

TABLE 3-33.




Max from BOC (in.)

T800 Day Cab RH BOC 5.4 10.9


GallonsTank Length

(in.)


Fuel Tank (in.)

GallonsTank Length

(in.)


Fuel Tank (in.)

GallonsTank Length

(in.)


Fuel Tank (in.)

56 35.5 -3.5 60 30.5 -8.6 75 28.7 -10.4

601 38.0 -1.1 751 38.5 -0.6 90 34.2 -4.9

752 47.3 8.2 90 45.5 6.4 1051 38.8 -0.3

100 62.2 23.1 1002 50.0 10.9 1202 45.8 6.7

120 74.2 35.1 110 54.9 15.8 135 50.8 11.7

120 60.5 21.4 150 56.2 17.1

135 67.2 28.1 177 66.1 27.0

150 74.5 35.4


D6 C

harts

Section 3Dimensions

08/06 3-58



TABLE 3-34.




Max from BOC (in.)

T800SH Day Cab RH BOC 7.2 10.9


GallonsTank Length

(in.)Dim. C Day

Cab BOC (in.)Gallons

Tank Length (in.)

Dim. C Day Cab BOC (in.)

GallonsTank Length

(in.)Dim. C Day

Cab BOC (in.)

56 35.5 -3.7 60 30.5 -8.7 75 28.7 -10.5

60 38.0 -1.2 75 38.5 -0.7 90 34.2 -5.0

751, 2 47.3 8.1 901 45.5 6.3 105 38.8 -0.4

100 62.2 23.0 1002 50.0 10.8 1201 45.8 6.6

120 74.2 35.0 110 54.9 15.7 1352 50.8 11.6

120 60.5 21.3 150 56.2 17.0

135 67.2 28.0 177 66.1 26.9

150 74.5 35.3


D6

Ch

arts

Section 3Dimensions

08/06 3-59



TABLE 3-35.




Max from BOC (in.)

W900B Day Cab RH BOC 5.4 10.9


GallonsTank Length

(in.)


Fuel Tank (in.)

GallonsTank Length

(in.)


Fuel Tank (in.)

GallonsTank Length

(in.)


Fuel Tank (in.)

56 35.5 -20.2 75 38.5 -17.2 90 34.2 -21.5

60 38.0 -17.7 90 45.5 -10.2 105 38.8 -16.9

751 47.3 -8.4 100 50.0 -5.7 120 45.8 -9.9

1002 62.2 6.5 110 54.9 -0.8 135 50.8 -4.9

120 74.2 18.5 1201 60.5 4.8 1501 56.2 0.5

1352 67.2 11.5 1772 66.1 10.4

150 74.5 18.8


D6 C

harts

Section 3Dimensions

08/06 3-60



TABLE 3-36.




Max from BOC (in.)

W900S Day Cab RH BOC 5.4 10.9


GallonsTank Length

(in.)


Fuel Tank (in.)

GallonsTank Length

(in.)


Fuel Tank (in.)

GallonsTank Length

(in.)


Fuel Tank (in.)

56 35.5 -14.8 75 38.5 -11.8 90 34.2 -16.1

60 38.0 -12.3 90 45.5 -4.8 105 38.8 -11.5

751 47.3 -3 100 50.0 -0.3 120 45.8 -4.5

1002 62.2 11.9 110 54.9 4.6 135 50.8 0.5

120 74.2 23.9 1202 60.5 10.2 1501, 2 56.2 5.9

135 67.2 16.9 177 66.1 15.8

150 74.5 24.2


D6

Ch

arts

Section 3Dimensions

08/06 3-61



TABLE 3-37.


DPF to BOC (in.)

T800 Day Cab

Horizontal

5.4

Extended Day Cab -0.3

T800SHDay Cab 7.2

Extended Day Cab 1.5


GallonsTank

Length (in.)


Fuel Tank (in.)


Fuel Tank (in.)

GallonsTank

Length (in.)


Fuel Tank (in.)


Fuel Tank (in.)

GallonsTank

Length (in.)


Fuel Tank (in.)


Fuel Tank (in.)

40 25.6 22.5 16.8 45 22.9 19.8 14.1 75 28.7 25.6 19.9

56 35.5 32.4 26.7 60 30.5 27.4 21.7 90 34.2 31.1 25.4

60 38.0 34.9 29.2 75 38.5 35.4 29.7 105 38.8 35.7 30.0

75 47.3 44.2 38.5 90 45.5 42.4 36.7 120 45.8 42.7 37.0

100 62.2 59.1 53.4 100 50.0 46.9 41.2 135 50.8 47.7 42.0

120 74.2 71.1 65.4 110 54.9 51.8 46.1 150 56.2 53.1 47.4

120 60.5 57.4 51.7 177 66.1 63.0 57.3

135 67.2 64.1 58.4

150 74.5 71.4 65.7


D7 C

harts

Section 3Dimensions

08/06 3-62

D7B—Use with the following models: W900B


TABLE 3-38.


DPF to BOC (in.)

W900B Day Cab

Horizontal5.4



GallonsTank

Length (in.)


Fuel Tank (in.)


Fuel Tank (in.)

GallonsTank

Length (in.)


Fuel Tank (in.)


Fuel Tank (in.)

GallonsTank

Length (in.)


Fuel Tank (in.)


Fuel Tank (in.)

40 25.6 16.4 10.7 45 22.9 13.7 8.0 75 28.7 19.5 13.8

56 35.5 26.3 20.6 60 30.5 21.3 15.6 90 34.2 25.0 19.3

60 38.0 28.8 23.1 75 38.5 29.3 23.6 105 38.8 29.6 23.9

75 47.3 38.1 32.4 90 45.5 36.3 30.6 120 45.8 36.6 30.9

100 62.2 53.0 47.3 100 50.0 40.8 35.1 135 50.8 41.6 35.9

120 74.2 65.0 59.3 110 54.9 45.7 40.0 150 56.2 47.0 41.3

120 60.5 51.3 45.6 177 66.1 56.9 51.2

135 67.2 58.0 52.3

150 74.5 65.3 59.6


D7

Ch

arts

Section 3Dimensions

08/06 3-63



TABLE 3-39.



DPF to BOC (in.)

T800Day Cab

Horizontal5.4



GallonsTank

Length (in.)


Batt. Box (in.)


Batt. Box (in.)

GallonsTank

Length (in.)


Batt. Box (in.)


Batt. Box (in.)

GallonsTank

Length (in.)


Batt. Box (in.)


Batt. Box (in.)

56 35.5 12.7 6.9 601 30.5 7.6 1.9 751, 2 28.7 5.8 0.1

60 38.0 15.2 9.4 75 38.5 15.7 9.9 90 34.2 11.4 5.6

75 47.3 24.5 18.8 90 45.5 22.7 17.0 105 38.8 16.0 10.3

100 62.2 39.4 33.7 100 50.0 27.2 21.5 120 45.8 23.0 17.3

120 74.2 51.4 45.7 110 54.9 32.1 26.4 135 50.8 28.0 22.3

120 60.5 37.7 32.0 150 56.2 33.4 27.7

135 67.2 44.4 38.7 177 66.1 43.3 37.6

150 74.5 51.7 46.0

1 MAXIMUM DAYCAB FUEL TANK TO MATCH DIMENSION “A”2 MAXIMUM EXTENDED DAYCAB FUEL TANK TO MATCH DIMENSION “A”

D8 C

harts

Section 3Dimensions

08/06 3-64



TABLE 3-40.



DPF to BOC (in.)

T800SHDay Cab

Horizontal7.2



GallonsTank

Length (in.)


Batt. Box (in.)


Batt. Box (in.)

GallonsTank

Length (in.)


Batt. Box (in.)


Batt. Box (in.)

GallonsTank

Length (in.)


Batt. Box (in.)


Batt. Box (in.)

56 35.5 12.6 6.9 601, 2 30.5 7.6 1.9 751,2 28.7 5.8 0.1

60 38.0 15.1 9.4 75 38.5 15.6 9.9 90 34.2 11.3 5.6

75 47.3 24.4 18.7 90 45.5 22.6 16.9 105 38.8 15.9 10.2

100 62.2 39.3 33.6 100 50.0 27.1 21.4 120 45.8 22.9 17.2

120 74.2 51.3 45.6 110 54.9 32.0 26.3 135 50.8 27.9 22.2

120 60.5 37.6 31.9 150 56.2 33.3 27.6

135 67.2 44.3 38.6 177 66.1 43.2 37.5

150 74.5 51.6 45.9

1 MAXIMUM DAYCAB FUEL TANK TO MATCH DIMENSION “A”2 MAXIMUM EXTENDED DAY CAB FUEL TANK TO MATCH DIMENSION “A”

D8

Ch

arts

Section 3Dimensions

08/06 3-65



TABLE 3-41.



DPF to BOC (in.)

W900BDay Cab

Horizontal5.4



GallonsTank

Length (in.)


Batt. Box (in.)


Batt. Box (in.)

GallonsTank

Length (in.)


Batt. Box (in.)


Batt. Box (in.)

GallonsTank

Length (in.)


Batt. Box (in.)


Batt. Box (in.)

56 35.5 -4.0 -9.7 75 38.5 -1.0 -6.7 90 34.2 -5.3 -11.0

601,2 38.0 -1.5 -7.2 901, 2 45.5 6.1 0.3 105 38.8 -0.7 -6.4

75 47.3 7.8 2.1 100 50.0 10.6 4.9 1201, 2 45.8 6.3 0.6

100 62.2 22.8 17.1 110 54.9 15.5 9.8 135 50.8 11.4 5.6

120 74.2 34.8 29.1 120 60.5 21.1 15.4 150 56.2 16.8 11.1

135 67.2 27.8 22.1 177 66.1 26.7 21.0

150 74.5 35.1 29.4


D8 C

harts

Section 3Dimensions

08/06 3-66



TABLE 3-42.



DPF to BOC (in.)

T800Day Cab

Horizontal5.4



GallonsTank

Length (in.)


Fuel Tank (in.)


Fuel Tank (in.)

GallonsTank

Length (in.)


Fuel Tank (in.)


Fuel Tank (in.)

GallonsTank

Length (in.)


Fuel Tank (in.)


Fuel Tank (in.)

56 35.5 -3.5 -9.2 60 30.5 -8.6 -14.3 75 28.7 -10.4 -16.1

601,2 38.0 -1.1 -6.8 75 38.5 -0.6 -6.3 90 34.2 -4.9 -10.6

75 47.3 8.2 2.5 901, 2 45.5 6.4 0.7 105 38.8 -0.3 -6.0

100 62.2 23.1 17.4 100 50.0 10.9 5.2 1201, 2 45.8 6.7 1.0

120 74.2 35.1 29.4 110 54.9 15.8 10.1 135 50.8 11.7 6.0

120 60.5 21.4 15.7 150 56.2 17.1 11.4

135 67.2 28.1 22.4 177 66.1 27.0 21.3

150 74.5 35.4 29.7


D9

Ch

arts

Section 3Dimensions

08/06 3-67



TABLE 3-43.



DPF to BOC (in.)

T800SHDay Cab

Horizontal7.2



GallonsTank

Length (in.)


Fuel Tank (in.)


Fuel Tank (in.)

GallonsTank

Length (in.)


Fuel Tank (in.)


Fuel Tank (in.)

GallonsTank

Length (in.)


Fuel Tank (in.)


Fuel Tank (in.)

56 35.5 -3.7 -9.4 60 30.5 -8.7 -14.4 75 28.7 -10.5 -16.2

601, 2 38.0 -1.2 -6.9 75 38.5 -0.7 -6.4 90 34.2 -5.0 -10.7

75 47.3 8.1 2.4 901, 2 45.5 6.3 0.6 105 38.8 -0.4 -6.1

100 62.2 23.0 17.3 100 50.0 10.8 5.1 1201, 2 45.8 6.6 0.9

120 74.2 35.0 29.3 110 54.9 15.7 10.0 135 50.8 11.6 5.9

120 60.5 21.3 15.6 150 56.2 17.0 11.3

135 67.2 28.0 22.3 177 66.1 26.9 21.2

150 74.5 35.3 29.6


D9 C

harts

Section 3Dimensions

08/06 3-68



TABLE 3-44.



DPF to BOC (in.)

W900BDay Cab

Horizontal5.4



GallonsTank

Length (in.)


Fuel Tank (in.)


Fuel Tank (in.)

GallonsTank

Length (in.)


Fuel Tank (in.)


Fuel Tank (in.)

GallonsTank

Length (in.)


Fuel Tank (in.)


Fuel Tank (in.)

56 35.5 -20.2 -25.9 75 38.5 -17.2 -22.9 90 34.2 -21.5 -27.2

60 38.0 -17.7 -23.4 90 45.5 -10.2 -15.9 105 38.8 -16.9 -22.6

751, 2 47.3 -8.4 -14.1 100 50.0 -5.7 -11.4 120 45.8 -9.9 -15.6

100 62.2 6.5 0.8 110 54.9 -0.8 -6.5 135 50.8 -4.9 -10.6

120 74.2 18.5 12.8 1201, 2 60.5 4.8 -0.9 1501, 2 56.2 0.5 -5.2

135 67.2 11.5 5.8 177 66.1 10.4 4.7

150 74.5 18.8 13.1


D9

Ch

arts

Section 3Dimensions

08/06 3-69


DPF Location: RH Vertical BOCBattery Box: LH Under CabFuel Tank: RH Under Cab

TABLE 3-45.


Confi gurationDimension B

Max from BOC (in.)

T800 Day Cab

Vertical 19.8Extended Day Cab


GallonsTank

Length (in.)

Dim. A Day Cab BOC (in.)

Dim. A Extended Day Cab BOC (in.)

GallonsTank

Length (in.)



GallonsTank

Length (in.)



56 35.5 -3.5 -9.2 60 30.5 -8.6 -14.3 75 28.7 -10.4 -16.1

60 38.0 -1.1 -6.8 75 38.5 -0.6 -6.3 90 34.2 -4.9 -10.6

751 47.3 8.2 2.5 90 45.5 6.4 0.7 105 38.8 -0.3 -6.0

1002 62.2 23.1 17.4 100 50.0 10.9 5.2 120 45.8 6.7 1.0

120 74.2 35.1 29.4 1101 54.9 15.8 10.1 135 50.8 11.7 6.0

1202 60.5 21.4 15.7 1501,2 56.2 17.1 11.4

135 67.2 28.1 22.4 177 66.1 27.0 21.3

150 74.5 35.4 29.7

1 MAXIMUM DAY CAB FUEL TANK TO MATCH DIMENSION “B”2 MAXIMUM EXTENDED DAY CAB FUEL TANK TO MATCH DIMENSION “B”3 CGI LINE WILL BE PRESENT WITH CATERPILLAR ENGINES. CUMMINS ENGINES WILL NOT HAVE A CGI LINE.

CGI line3

CGI line3

D10 C

harts

Section 3Dimensions

08/06 3-70



TABLE 3-46.



Max from BOC (in.)

T800SHDay Cab



GallonsTank

Length (in.)



GallonsTank

Length (in.)



GallonsTank

Length (in.)



56 35.5 -3.7 -9.4 60 30.5 -8.7 -14.4 75 28.7 -10.5 -16.2

60 38.0 -1.2 -6.9 75 38.5 -0.7 -6.4 90 34.2 -5.0 -10.7

751 47.3 8.1 2.4 90 45.5 6.3 0.6 105 38.8 -0.4 -6.1

1002 62.2 23.0 17.3 100 50.0 10.8 5.1 120 45.8 6.6 0.9

120 74.2 35.0 29.3 1101 54.9 15.7 10.0 135 50.8 11.6 5.9

1202 60.5 21.3 15.6 1501,2 56.2 17.0 11.3

135 67.2 28.0 22.3 177 66.1 26.9 21.2

150 74.5 35.3 29.6


CGI line3

CGI line3

D10

Ch

arts

Section 3Dimensions

08/06 3-71



TABLE 3-47.



Max from BOC (in.)

W900BDay Cab



GallonsTank

Length (in.)



GallonsTank

Length (in.)



GallonsTank

Length (in.)



56 35.5 -20.2 -25.9 75 38.5 -17.2 -22.9 90 34.2 -21.5 -27.2

60 38.0 -17.7 -23.4 90 45.5 -10.2 -15.9 105 38.8 -16.9 -22.6

75 47.3 -8.4 -14.1 100 50.0 -5.7 -11.4 120 45.8 -9.9 -15.6

100 62.2 6.5 0.8 110 54.9 -0.8 -6.5 135 50.8 -4.9 -10.6

1201,2 74.2 18.5 12.8 120 60.5 4.8 -0.9 150 56.2 0.5 -5.2

135 67.2 11.5 5.8 1771,2 66.1 10.4 4.7

1501,2 74.5 18.8 13.1


CGI line3

CGI line3

D10 C

harts

Section 3Dimensions

08/06 3-72



TABLE 3-48.



Max from BOC (in.)

W900SDay Cab



GallonsTank

Length (in.)



GallonsTank

Length (in.)



GallonsTank

Length (in.)



56 35.5 -14.8 -20.5 75 38.5 -11.8 -17.5 90 34.2 -16.1 -21.8

60 38.0 -12.3 -18 90 45.5 -4.8 -10.5 105 38.8 -11.5 -17.2

75 47.3 -3 -8.7 100 50.0 -0.3 -6 120 45.8 -4.5 -10.2

1001 62.2 11.9 6.2 110 54.9 4.6 -1.1 135 50.8 0.5 -5.2

1202 74.2 23.9 18.2 120 60.5 10.2 4.5 150 56.2 5.9 0.2

1351 67.2 16.9 11.2 1771, 2 66.1 15.8 10.1

1502 74.5 24.2 18.5


CGI line3

CGI line3

D10

Ch

arts

Section 3Dimensions

08/06 3-73


DPF Location: RH Vertical BOCBattery Box: LH Under CabFuel Tank: BOC

TABLE 3-49.



Max from BOC (in.)

T800 / T800SHDay Cab



GallonsTank

Length (in.)


Fuel Tank


Fuel Tank

GallonsTank

Length (in.)


Fuel Tank


Fuel Tank

GallonsTank

Length (in.)


Fuel Tank


Fuel Tank

40 25.6 22.5 16.8 45 22.9 19.8 14.1 75 28.7 25.6 19.9

56 35.5 32.4 26.7 60 30.5 27.4 21.7 90 34.2 31.1 25.4

60 38.0 34.9 29.2 75 38.5 35.4 29.7 105 38.8 35.7 30.0

75 47.3 44.2 38.5 90 45.5 42.4 36.7 120 45.8 42.7 37.0

100 62.2 59.1 53.4 100 50.0 46.9 41.2 135 50.8 47.7 42.0

120 74.2 71.1 65.4 110 54.9 51.8 46.1 150 56.2 53.1 47.4

120 60.5 57.4 51.7 177 66.1 63.0 57.3

135 67.2 64.1 58.4

150 74.5 71.4 65.7

NOTE: DIMENSION “F” IS CALCULATED USING A STANDARD SIZED BATTERY BOX. OPTIONAL EXTENDED BOXES WILL CHANGE DIMENSION “F”.3 CGI LINE WILL BE PRESENT WITH CATERPILLAR ENGINES. CUMMINS ENGINES WILL NOT HAVE A CGI LINE.

CGI line3

CGI line3

D11 C

harts

Section 3Dimensions

08/06 3-74

D11B—Use with the following models: W900S / W900B

DPF Location: RH Vertical BOCBattery Box: LH Under CabFuel Tank: BOC

TABLE 3-50.



Max from BOC (in.)

W900S / W900BDay Cab



GallonsTank

Length (in.)


Fuel Tank


Fuel Tank

GallonsTank

Length (in.)


Fuel Tank


Fuel Tank

GallonsTank

Length (in.)


Fuel Tank


Fuel Tank

40 25.6 16.4 10.7 45 22.9 13.7 8.0 75 28.7 19.5 13.8

56 35.5 26.3 20.6 60 30.5 21.3 15.6 90 34.2 25.0 19.3

60 38.0 28.8 23.1 75 38.5 29.3 23.6 105 38.8 29.6 23.9

75 47.3 38.1 32.4 90 45.5 36.3 30.6 120 45.8 36.6 30.9

100 62.2 53.0 47.3 100 50.0 40.8 35.1 135 50.8 41.6 35.9

120 74.2 65.0 59.3 110 54.9 45.7 40.0 150 56.2 47.0 41.3

120 60.5 51.3 45.6 177 66.1 56.9 51.2

135 67.2 58.0 52.3

150 74.5 65.3 59.6

NOTE: DIMENSION “F” IS CALCULATED USING A STANDARD SIZED BATTERY BOX. OPTIONAL EXTENDED BOXES WILL CHANGE DIMENSION “F”.3 CGI LINE WILL BE PRESENT WITH CATERPILLAR ENGINES. CUMMINS ENGINES WILL NOT HAVE A CGI LINE.

CGI line3

CGI line3

D11

Ch

arts

Section 3Dimensions

08/06 3-75


DPF Location: RH Vertical BOCBattery Box: Vocational LH BOCFuel Tank: LH Under Cab

TABLE 3-51.



Max from BOC (in.)

T800Day Cab



GallonsTank

Length (in.)


Batt. Box (in.)


Batt. Box (in.)

GallonsTank

Length (in.)


Batt. Box (in.)


Batt. Box (in.)

GallonsTank

Length (in.)


Batt. Box (in.)


Batt. Box (in.)

56 35.5 12.7 6.9 60 30.5 7.6 1.9 75 28.7 5.8 0.1

601 38.0 15.2 9.4 751 38.5 15.7 9.9 90 34.2 11.4 5.6

752 47.3 24.5 18.8 902 45.5 22.7 17.0 1051 38.8 16.0 10.3

100 62.2 39.4 33.7 100 50.0 27.2 21.5 1202 45.8 23.0 17.3

120 74.2 51.4 45.7 110 54.9 32.1 26.4 135 50.8 28.0 22.3

120 60.5 37.7 32.0 150 56.2 33.4 27.7

135 67.2 44.4 38.7 177 66.1 43.3 37.6

150 74.5 51.7 46.0


CGI line3

CGI line3

D12 C

harts

Section 3Dimensions

08/06 3-76

D12

Ch

arts



TABLE 3-52.



Max from BOC (in.)

T800SHDay Cab



GallonsTank

Length (in.)


Batt. Box (in.)


Batt. Box (in.)

GallonsTank

Length (in.)


Batt. Box (in.)


Batt. Box (in.)

GallonsTank

Length (in.)


Batt. Box (in.)


Batt. Box (in.)

56 35.5 12.6 6.9 60 30.5 7.6 1.9 75 28.7 5.8 0.1

601 38.0 15.1 9.4 751 38.5 15.6 9.9 90 34.2 11.3 5.6

752 47.3 24.4 18.7 902 45.5 22.6 16.9 1051 38.8 15.9 10.2

100 62.2 39.3 33.6 100 50.0 27.1 21.4 1202 45.8 22.9 17.2

120 74.2 51.3 45.6 110 54.9 32.0 26.3 135 50.8 27.9 22.2

120 60.5 37.6 31.9 150 56.2 33.3 27.6

135 67.2 44.3 38.6 177 66.1 43.2 37.5

150 74.5 51.6 45.9


CGI line3

CGI line3

Section 3Dimensions

08/06 3-77



TABLE 3-53.



Max from BOC (in.)

W900BDay Cab



GallonsTank

Length (in.)


Batt. Box (in.)


Batt. Box (in.)

GallonsTank

Length (in.)


Batt. Box (in.)


Batt. Box (in.)

GallonsTank

Length (in.)


Batt. Box (in.)


Batt. Box (in.)

56 35.5 -4.0 -9.7 75 38.5 -1.0 -6.7 90 34.2 -5.3 -11.0

60 38.0 -1.5 -7.2 90 45.5 6.1 0.3 105 38.8 -0.7 -6.4

751 47.3 7.8 2.1 100 50.0 10.6 4.9 120 45.8 6.3 0.6

1002 62.2 22.8 17.1 1101 54.9 15.5 9.8 135 50.8 11.4 5.6

120 74.2 34.8 29.1 1202 60.5 21.1 15.4 1501, 2 56.2 16.8 11.1

135 67.2 27.8 22.1 177 66.1 26.7 21.0

150 74.5 35.1 29.4


CGI line3

CGI line3

D12 C

harts

Section 3Dimensions

08/06 3-78



TABLE 3-54.



Max from BOC (in.)

W900BDay Cab



GallonsTank

Length (in.)


Batt. Box (in.)


Batt. Box (in.)

GallonsTank

Length (in.)


Batt. Box (in.)


Batt. Box (in.)

GallonsTank

Length (in.)


Batt. Box (in.)


Batt. Box (in.)

56 35.5 1.5 -4.3 75 38.5 4.5 -1.3 90 34.2 0.2 -5.5

60 38.0 4.0 -1.8 90 45.5 11.5 5.8 105 38.8 4.8 -1.0

751,2 47.3 13.3 7.6 1001 50.0 16.0 10.3 120 45.8 11.8 6.1

100 62.2 28.2 22.5 110 54.9 20.9 15.2 1351 50.8 16.8 11.1

120 74.2 40.2 34.5 1202 60.5 26.5 20.8 1502 56.2 22.2 16.5

135 67.2 33.2 27.5 177 66.1 32.1 26.4

150 74.5 40.5 34.8


CGI line3

CGI line3

D12

Ch

arts

Section 3Dimensions

08/06 3-79


DPF Location: RH Vertical BOCBattery Box: Vocational LH BOCFuel Tank: LH Under Cab RH Under Cab

TABLE 3-55.



DPF to BOC (in.)

T800 Day Cab Vertical 19.8


GallonsTank

Length (in.)



Batt. Box (in.)

GallonsTank

Length (in.)



Batt. Box (in.)

GallonsTank

Length (in.)



Batt. Box (in.)

56 35.5 -3.5 12.7 60 30.5 -8.6 7.6 75 28.7 -10.4 5.8

602 38.0 -1.1 15.2 752 38.5 -0.6 15.7 90 34.2 -4.9 11.4

751 47.3 8.2 24.5 90 45.5 6.4 22.7 1052 38.8 -0.3 16.0

100 62.2 23.1 39.4 100 50.0 10.9 27.2 120 45.8 6.7 23.0

120 74.2 35.1 51.4 1101 54.9 15.8 32.1 135 50.8 11.7 28.0

120 60.5 21.4 37.7 1501 56.2 17.1 33.4

135 67.2 28.1 44.4 177 66.1 27.0 43.3

150 74.5 35.4 51.7

1 MAXIMUM RH DAY CAB FUEL TANK TO MATCH DIMENSION “B”2 MAXIMUM LH DAY CAB FUEL TANK TO MATCH DIMENSION “B”3 CGI LINE WILL BE PRESENT WITH CATERPILLAR ENGINES. CUMMINS ENGINES WILL NOT HAVE A CGI LINE.

CGI line3

CGI line3

D13 C

harts

Section 3Dimensions

08/06 3-80


DPF Location: RH Vertical BOCBattery Box: Vocational LH BOCFuel Tank: LH Under Cab RH Under Cab

TABLE 3-56.



DPF to BOC (in.)

T800SH Day Cab Vertical 19.8


GallonsTank

Length (in.)



Batt. Box (in.)

GallonsTank

Length (in.)



Batt. Box (in.)

GallonsTank

Length (in.)



Batt. Box (in.)

56 35.5 -3.7 12.6 60 30.5 -8.7 7.6 75 28.7 -10.5 5.8

602 38.0 -1.2 15.1 752 38.5 -0.7 15.6 90 34.2 -5.0 11.3

751 47.3 8.1 24.4 90 45.5 6.3 22.6 1052 38.8 -0.4 15.9

100 62.2 23.0 39.3 100 50.0 10.8 27.1 120 45.8 6.6 22.9

120 74.2 35.0 51.3 1101 54.9 15.7 32.0 135 50.8 11.6 27.9

120 60.5 21.3 37.6 1501 56.2 17.0 33.3

135 67.2 28.0 44.3 177 66.1 26.9 43.2

150 74.5 35.3 51.6


CGI line3

CGI line3

D13

Ch

arts

Section 3Dimensions

08/06 3-81

D13C—Use with the following models: T800

DPF Location: RH Vertical BOCBattery Box: Vocational LH BOCFuel Tank: RH Under Cab LH Under Cab

TABLE 3-57.



DPF to BOC (in.)

T800 Extended Day Cab Vertical 19.8


GallonsTank

Length (in.)



Batt. Box (in.)

GallonsTank

Length (in.)



Batt. Box (in.)

GallonsTank

Length (in.)



Batt. Box (in.)

56 35.5 -9.3 6.9 60 30.5 -14.3 1.9 75 28.7 -16.1 0.1

60 38.0 -6.8 9.4 75 38.5 -6.3 9.9 90 34.2 -10.6 5.6

752 47.3 2.5 18.8 902 45.5 0.7 17.0 105 38.8 -6.0 10.3

1001 62.2 17.4 33.7 100 50.0 5.2 21.5 1202 45.8 1.0 17.3

120 74.2 29.4 45.7 110 54.9 10.1 26.4 135 50.8 6.0 22.3

1201 60.5 15.7 32.0 1501 56.2 11.4 27.7

135 67.2 22.4 38.7 177 66.1 21.3 37.6

150 74.5 29.7 46.0

1 MAXIMUM RH EXTENDED DAY CAB FUEL TANK TO MATCH DIMENSION “B”2 MAXIMUM LH EXTENDED DAY CAB FUEL TANK TO MATCH DIMENSION “B”3 CGI LINE WILL BE PRESENT WITH CATERPILLAR ENGINES. CUMMINS ENGINES WILL NOT HAVE A CGI LINE.

CGI line3

CGI line3

D13 C

harts

Section 3Dimensions

08/06 3-82

D13D—Use with the following models: T800SH


TABLE 3-58.



DPF to BOC (in.)

T800SH Extended Day Cab Vertical 19.8


GallonsTank

Length (in.)



Batt. Box (in.)

GallonsTank

Length (in.)



Batt. Box (in.)

GallonsTank

Length (in.)



Batt. Box (in.)

56 35.5 -9.4 6.9 60 30.5 -14.4 1.9 75 28.7 -16.2 0.1

60 38.0 -6.9 9.4 75 38.5 -6.4 9.9 90 34.2 -10.7 5.6

752 47.3 2.4 18.7 902 45.5 0.6 16.9 105 38.8 -6.1 10.2

1001 62.2 17.3 33.6 100 50.0 5.1 21.4 1202 45.8 0.9 17.2

120 74.2 29.3 45.6 110 54.9 10.0 26.3 135 50.8 5.9 22.2

1201 60.5 15.6 31.9 1501 56.2 11.3 27.6

135 67.2 22.3 38.6 177 66.1 21.2 37.5

150 74.5 29.6 45.9


CGI line3

CGI line3

D13

Ch

arts

Section 3Dimensions

08/06 3-83

D13E—Use with the following models: W900B


TABLE 3-59.



DPF to BOC (in.)

W900B Day Cab Vertical 19.8


GallonsTank

Length (in.)



Batt. Box (in.)

GallonsTank

Length (in.)



Batt. Box (in.)

GallonsTank

Length (in.)



Batt. Box (in.)

56 35.5 -20.2 -4.0 75 38.5 -17.2 -1.0 90 34.2 -21.5 -5.3

60 38.0 -17.7 -1.5 90 45.5 -10.2 6.1 105 38.8 -16.9 -0.7

752 47.3 -8.4 7.8 100 50.0 -5.7 10.6 120 45.8 -9.9 6.3

100 62.2 6.5 22.8 1102 54.9 -0.8 15.5 135 50.8 -4.9 11.4

1201 74.2 18.5 34.8 120 60.5 4.8 21.1 1502 56.2 0.5 16.8

135 67.2 11.5 27.8 1771 66.1 10.4 26.7

1501 74.5 18.8 35.1


CGI line3

CGI line3

D13 C

harts

Section 3Dimensions

08/06 3-84

D13F—Use with the following models: W900S


TABLE 3-60.



DPF to BOC (in.)

W900S Day Cab Vertical 19.8


GallonsTank

Length (in.)



Batt. Box (in.)

GallonsTank

Length (in.)



Batt. Box (in.)

GallonsTank

Length (in.)



Batt. Box (in.)

56 35.5 -14.8 1.5 75 38.5 -11.8 4.5 90 34.2 -16.1 0.2

60 38.0 -12.3 4.0 90 45.5 -4.8 11.5 105 38.8 -11.5 4.8

752 47.3 -3.0 13.3 1002 50.0 -0.3 16.0 120 45.8 -4.5 11.8

1001 62.2 11.9 28.2 110 54.9 4.6 20.9 1352 50.8 0.5 16.8

120 74.2 23.9 40.2 120 60.5 10.2 26.5 150 56.2 5.9 22.2

1351 67.2 16.9 33.2 1771 66.1 15.8 32.1

150 74.5 24.2 40.5


CGI line3

CGI line3

D13

Ch

arts

Section 3Dimensions

08/06 3-85

D13G—Use with the following models: W900B


TABLE 3-61.



DPF to BOC (in.)

W900B Extended Day Cab Vertical 19.8


GallonsTank

Length (in.)



Batt. Box (in.)

GallonsTank

Length (in.)



Batt. Box (in.)

GallonsTank

Length (in.)



Batt. Box (in.)

56 35.5 -25.9 -9.7 75 38.5 -22.9 -6.7 90 34.2 -27.2 -11.0

60 38.0 -23.4 -7.2 90 45.5 -15.9 0.3 105 38.8 -22.6 -6.4

75 47.3 -14.1 2.1 100 50.0 -11.4 4.8 120 45.8 -15.6 0.6

1002 62.2 0.8 17.1 110 54.9 -6.5 9.7 135 50.8 -10.6 5.6

1201 74.2 12.8 29.1 1202 60.5 -0.9 15.4 1502 56.2 -5.2 11.1

135 67.2 5.8 22.1 1771 66.1 4.7 21.0

1501 74.5 13.1 29.4


CGI line3

CGI line3

D13 C

harts

Section 3Dimensions

08/06 3-86

D13H—Use with the following models: W900S


TABLE 3-62.



DPF to BOC (in.)

W900S Extended Day Cab Vertical 19.8


GallonsTank

Length (in.)



Batt. Box (in.)

GallonsTank

Length (in.)



Batt. Box (in.)

GallonsTank

Length (in.)



Batt. Box (in.)

56 35.5 -20.5 -4.3 75 38.5 -17.5 -1.3 90 34.2 -21.8 -5.6

60 38.0 -18.0 -1.8 90 45.5 -10.5 5.8 105 38.8 -17.2 -1.0

752 47.3 -8.7 7.6 100 50.0 -6.0 10.3 120 45.8 -10.2 6.1

100 62.2 6.2 22.5 110 54.9 -1.1 15.2 135 50.8 -5.2 11.1

1201 74.2 18.2 34.5 1202 60.5 4.5 20.8 1502 56.2 0.2 16.5

135 67.2 11.2 27.5 1771 66.1 10.1 26.4

150 1 74.5 18.5 34.8


CGI line3

CGI line3

D13

Ch

arts

Section 3Dimensions

08/06 3-87


DPF Location: RH Vertical BOCBattery Box: BOCFuel Tank: LH Under Cab RH Under Cab

TABLE 3-63.



DPF to BOC (in.)

T800 Day Cab



GallonsTank

Length (in.)

Dim. A & C Day

Cab BOC to Fuel

Tank (in.)

Dim. A & C

Extended Day Cab BOC to

Fuel Tank (in.)

GallonsTank

Length (in.)

Dim. A & C Day

Cab BOC to Fuel

Tank (in.)

Dim. A & C


Fuel Tank (in.)

GallonsTank

Length (in.)

Dim. A & C Day

Cab BOC to Fuel

Tank (in.)

Dim. A & C


Fuel Tank (in.)

56 35.5 -3.5 -9.2 60 30.5 -8.6 -14.3 75 28.7 -10.4 -16.1

60 38.0 -1.1 -6.8 75 38.5 -0.6 -6.3 90 34.2 -4.9 -10.6

751 47.3 8.2 2.5 90 45.5 6.4 0.7 105 38.8 -0.3 -6.0

1002 62.2 23.1 17.4 100 50.0 10.9 5.2 120 45.8 6.7 1.0

120 74.2 35.1 29.4 1101 54.9 15.8 10.1 135 50.8 11.7 6.0

1202 60.5 21.4 15.7 1501,2 56.2 17.1 11.4

135 67.2 28.1 22.4 177 66.1 27.0 21.3

150 74.5 35.4 29.7


CGI line3

CGI line3

D14 C

harts

Section 3Dimensions

08/06 3-88



TABLE 3-64.



DPF to BOC (in.)

T800SHDay Cab



GallonsTank

Length (in.)

Dim. A & C Day

Cab BOC to Fuel

Tank (in.)

Dim. A & C


Fuel Tank (in.)

GallonsTank

Length (in.)

Dim. A & C Day

Cab BOC to Fuel

Tank (in.)

Dim. A & C


Fuel Tank (in.)

GallonsTank

Length (in.)

Dim. A & C Day

Cab BOC to Fuel

Tank (in.)

Dim. A & C


Fuel Tank (in.)

56 35.5 -3.7 -9.4 60 30.5 -8.7 -14.4 75 28.7 -10.5 -16.2

60 38.0 -1.2 -6.9 75 38.5 -0.7 -6.4 90 34.2 -5.0 -10.7

751 47.3 8.1 2.4 90 45.5 6.3 0.6 105 38.8 -0.4 -6.1

1002 62.2 23.0 17.3 100 50.0 10.8 5.1 120 45.8 6.6 0.9

120 74.2 35.0 29.3 1101 54.9 15.7 10.0 135 50.8 11.6 5.9

1202 60.5 21.3 15.6 1501,2 56.2 17.0 11.3

135 67.2 28.0 22.3 177 66.1 26.9 21.2

150 74.5 35.3 29.6


CGI line3

CGI line3

D14

Ch

arts

Section 3Dimensions

08/06 3-89



TABLE 3-65.



DPF to BOC (in.)

W900BDay Cab



GallonsTank

Length (in.)

Dim. A & C Day

Cab BOC to Fuel

Tank (in.)

Dim. A & C


Fuel Tank (in.)

GallonsTank

Length (in.)

Dim. A & C Day

Cab BOC to Fuel

Tank (in.)

Dim. A & C


Fuel Tank (in.)

GallonsTank

Length (in.)

Dim. A & C Day

Cab BOC to Fuel

Tank (in.)

Dim. A & C


Fuel Tank (in.)

56 35.5 -20.2 -25.9 75 38.5 -17.2 -22.9 90 34.2 -21.5 -27.2

60 38.0 -17.7 -23.4 90 45.5 -10.2 -15.9 105 38.8 -16.9 -22.6

75 47.3 -8.4 -14.1 100 50.0 -5.7 -11.4 120 45.8 -9.9 -15.6

100 62.2 6.5 0.8 110 54.9 -0.8 -6.5 135 50.8 -4.9 -10.6

1201,2 74.2 18.5 12.8 120 60.5 4.8 -0.9 150 56.2 0.5 -5.2

135 67.2 11.5 5.8 1771,2 66.1 10.4 4.7

1501,2 74.5 18.8 13.1


CGI line3

CGI line3

D14 C

harts

Section 3Dimensions

08/06 3-90



TABLE 3-66.



DPF to BOC (in.)

W900SDay Cab



GallonsTank

Length (in.)

Dim. A & C Day

Cab BOC to Fuel

Tank (in.)

Dim. A & C


Fuel Tank (in.)

GallonsTank

Length (in.)

Dim. A & C Day

Cab BOC to Fuel

Tank (in.)

Dim. A & C


Fuel Tank (in.)

GallonsTank

Length (in.)

Dim. A & C Day

Cab BOC to Fuel

Tank (in.)

Dim. A & C


Fuel Tank (in.)

56 35.5 -14.8 -20.5 75 38.5 -11.8 -17.5 90 34.2 -16.1 -21.8

60 38.0 -12.3 -18 90 45.5 -4.8 -10.5 105 38.8 -11.5 -17.2

75 47.3 -3 -8.7 100 50.0 -0.3 -6 120 45.8 -4.5 -10.2

1001 62.2 11.9 6.2 110 54.9 4.6 -1.1 135 50.8 0.5 -5.2

1202 74.2 23.9 18.2 120 60.5 10.2 4.5 150 56.2 5.9 0.2

1351 67.2 16.9 11.2 1771, 2 66.1 15.8 10.1

1502 74.5 24.2 18.5


CGI line3

CGI line3

D14

Ch

arts

Section 3Dimensions

08/06 3-91


DPF Location: Horizontal BOCBattery Box: LH Under CabFuel Tank: RH Under Cab

TABLE 3-67.


Confi gurationDimension E

Rear of DPF to BOC (in.)

T800 Day Cab

Horizontal45.0



GallonsTank

Length (in.)



GallonsTank

Length (in.)



GallonsTank

Length (in.)



56 35.5 -3.5 -9.2 60 30.5 -8.6 -14.3 75 28.7 -10.4 -16.1

60 38.0 -1.1 -6.8 75 38.5 -0.6 -6.3 90 34.2 -4.9 -10.6

75 47.3 8.2 2.5 90 45.5 6.4 0.7 105 38.8 -0.3 -6.0

100 62.2 23.1 17.4 100 50.0 10.9 5.2 120 45.8 6.7 1.0

120 74.2 35.1 29.4 110 54.9 15.8 10.1 135 50.8 11.7 6.0

120 60.5 21.4 15.7 150 56.2 17.1 11.4

135 67.2 28.1 22.4 177 66.1 27.0 21.3

150 74.5 35.4 29.7

D15 C

harts

Section 3Dimensions

08/06 3-92



TABLE 3-68.




T800SHDay Cab

Horizontal45.0



GallonsTank

Length (in.)



GallonsTank

Length (in.)



GallonsTank

Length (in.)



56 35.5 -3.7 -9.4 60 30.5 -8.7 -14.4 75 28.7 -10.5 -16.2

60 38.0 -1.2 -6.9 75 38.5 -0.7 -6.4 90 34.2 -5.0 -10.7

75 47.3 8.1 2.4 90 45.5 6.3 0.6 105 38.8 -0.4 -6.1

100 62.2 23.0 17.3 100 50.0 10.8 5.1 120 45.8 6.6 0.9

120 74.2 35.0 29.3 110 54.9 15.7 10.0 135 50.8 11.6 5.9

120 60.5 21.3 15.6 150 56.2 17.0 11.3

135 67.2 28.0 22.3 177 66.1 26.9 21.2

150 74.5 35.3 29.6

D15

Ch

arts

Section 3Dimensions

08/06 3-93



TABLE 3-69.




W900BDay Cab

Horizontal45.0



GallonsTank

Length (in.)



GallonsTank

Length (in.)



GallonsTank

Length (in.)



56 35.5 -20.2 -25.9 75 38.5 -17.2 -22.9 90 34.2 -21.5 -27.2

60 38.0 -17.7 -23.4 90 45.5 -10.2 -15.9 105 38.8 -16.9 -22.6

75 47.3 -8.4 -14.1 100 50.0 -5.7 -11.4 120 45.8 -9.9 -15.6

100 62.2 6.5 0.8 110 54.9 -0.8 -6.5 135 50.8 -4.9 -10.6

120 74.2 18.5 12.8 120 60.5 4.8 -0.9 150 56.2 0.5 -5.2

135 67.2 11.5 5.8 177 66.1 10.4 4.7

150 74.5 18.8 13.1

D15 C

harts

Section 3Dimensions

08/06 3-94


DPF Location: Horizontal BOCBattery Box: Vocational LH BOCFuel Tank: LH Under Cab

TABLE 3-70.




T800Day Cab

Horizontal45.0



GallonsTank

Length (in.)


Batt. Box (in.)


Batt. Box (in.)

GallonsTank

Length (in.)


Batt. Box (in.)


Batt. Box (in.)

GallonsTank

Length (in.)


Batt. Box (in.)


Batt. Box (in.)

56 35.5 12.7 6.9 60 30.5 7.6 1.9 75 28.7 5.8 0.1

60 38.0 15.2 9.4 75 38.5 15.7 9.9 90 34.2 11.4 5.6

75 47.3 24.5 18.8 90 45.5 22.7 17.0 105 38.8 16.0 10.3

100 62.2 39.4 33.7 100 50.0 27.2 21.5 120 45.8 23.0 17.3

120 74.2 51.4 45.7 110 54.9 32.1 26.4 135 50.8 28.0 22.3

120 60.5 37.7 32.0 150 56.2 33.4 27.7

135 67.2 44.4 38.7 177 66.1 43.3 37.6

150 74.5 51.7 46.0

D16

Ch

arts

Section 3Dimensions

08/06 3-95



TABLE 3-71.




T800SHDay Cab

Horizontal45.0



GallonsTank

Length (in.)


Batt. Box (in.)


Batt. Box (in.)

GallonsTank

Length (in.)


Batt. Box (in.)


Batt. Box (in.)

GallonsTank

Length (in.)


Batt. Box (in.)


Batt. Box (in.)

56 35.5 12.6 6.9 60 30.5 7.6 1.9 75 28.7 5.8 0.1

60 38.0 15.1 9.4 75 38.5 15.7 9.9 90 34.2 11.3 5.6

75 47.3 24.4 18.7 90 45.5 22.7 17.0 105 38.8 15.9 10.2

100 62.2 39.3 33.6 100 50.0 27.2 21.5 120 45.8 22.9 17.2

120 74.2 51.3 45.6 110 54.9 32.1 26.4 135 50.8 27.9 22.2

120 60.5 37.7 32.0 150 56.2 33.3 27.6

135 67.2 44.4 38.7 177 66.1 43.2 37.5

150 74.5 51.7 46.0

D16 C

harts

Section 3Dimensions

08/06 3-96



TABLE 3-72.




W900BDay Cab

Horizontal45.0



GallonsTank

Length (in.)


Batt. Box (in.)


Batt. Box (in.)

GallonsTank

Length (in.)


Batt. Box (in.)


Batt. Box (in.)

GallonsTank

Length (in.)


Batt. Box (in.)


Batt. Box (in.)

56 35.5 -4.0 -9.7 60 30.5 -9.0 -14.7 75 28.7 -10.8 -16.5

60 38.0 -1.5 -7.2 75 38.5 -1.0 -6.7 90 34.2 -5.3 -11.0

75 47.3 7.8 2.1 90 45.5 6.1 0.3 105 38.8 -0.7 -6.4

100 62.2 22.8 17.1 100 50.0 10.6 4.9 120 45.8 6.3 0.6

120 74.2 34.8 29.1 110 54.9 15.5 9.8 135 50.8 11.4 5.6

120 60.5 21.1 15.4 150 56.2 16.8 11.1

135 67.2 27.8 22.1 177 66.1 26.7 21.0

150 74.5 35.1 29.4

D16

Ch

arts

Section 3Dimensions

08/06 3-97


DPF Location: Horizontal BOCBattery Box: Vocational LH BOCFuel Tank: LH Under Cab RH Under Cab

TABLE 3-73.




T800 Day Cab Horizontal 45.0


GallonsTank

Length (in.)

Dim. A Day Cab BOC to

Fuel Tank (in.)


Batt. Box (in.)

GallonsTank

Length (in.)


Fuel Tank (in.)


Batt. Box (in.)

GallonsTank

Length (in.)


Fuel Tank (in.)


Batt. Box (in.)

56 35.5 -3.5 12.7 60 30.5 -8.6 7.6 75 28.7 -10.4 5.8

60 38.0 -1.1 15.2 75 38.5 -0.6 15.7 90 34.2 -4.9 11.4

75 47.3 8.2 24.5 90 45.5 6.4 22.7 105 38.8 -0.3 16.0

100 62.2 23.1 39.4 100 50.0 10.9 27.2 120 45.8 6.7 23.0

120 74.2 35.1 51.4 110 54.9 15.8 32.1 135 50.8 11.7 28.0

120 60.5 21.4 37.7 150 56.2 17.1 33.4

135 67.2 28.1 44.4 177 66.1 27.0 43.3

150 74.5 35.4 51.7

D17 C

harts

Section 3Dimensions

08/06 3-98



TABLE 3-74.




T800SH Day Cab Horizontal 45.0


GallonsTank

Length (in.)


Fuel Tank (in.)


Batt. Box (in.)

GallonsTank

Length (in.)


Fuel Tank (in.)


Batt. Box (in.)

GallonsTank

Length (in.)


Fuel Tank (in.)


Batt. Box (in.)

56 35.5 -3.7 12.6 60 30.5 -8.7 7.6 75 28.7 -10.5 5.8

60 38.0 -1.2 15.1 75 38.5 -0.7 15.6 90 34.2 -5.0 11.3

75 47.3 8.1 24.4 90 45.5 6.3 22.6 105 38.8 -0.4 15.9

100 62.2 23.0 39.3 100 50.0 10.8 27.1 120 45.8 6.6 22.9

120 74.2 35.0 51.3 110 54.9 15.7 32.0 135 50.8 11.6 27.9

120 60.5 21.3 37.6 150 56.2 17.0 33.3

135 67.2 28.0 44.3 177 66.1 26.9 43.2

150 74.5 35.3 51.6

D17

Ch

arts

Section 3Dimensions

08/06 3-99

D17C—Use with the following models: T800


TABLE 3-75.




T800 Extended Day Cab Horizontal 39.3


GallonsTank

Length (in.)

Dim. A Extended Day Cab BOC to

Fuel Tank (in.)


Batt. Box (in.)

GallonsTank

Length (in.)


Fuel Tank (in.)


Batt. Box (in.)

GallonsTank

Length (in.)


Fuel Tank (in.)


Batt. Box (in.)

56 35.5 -9.4 6.9 60 30.5 -14.4 1.9 75 28.7 -16.2 0.1

60 38.0 -6.9 9.4 75 38.5 -6.5 9.9 90 34.2 -10.7 5.7

75 47.3 2.4 18.8 90 45.5 0.6 17.0 105 38.8 -6.1 10.3

100 62.2 17.2 33.7 100 50.0 5.0 21.5 120 45.8 0.9 17.3

120 74.2 29.3 45.7 110 54.9 10.0 26.4 135 50.8 5.9 22.3

120 60.5 15.6 32.0 150 56.2 11.3 27.7

135 67.2 22.3 38.7 177 66.1 21.2 37.6

150 74.5 29.6 46.0

D17 C

harts

Section 3Dimensions

08/06 3-100

D17D—Use with the following models: T800SH


TABLE 3-76.




T800SH Extended Day Cab Horizontal 39.3


GallonsTank

Length (in.)


Fuel Tank (in.)


Batt. Box (in.)

GallonsTank

Length (in.)


Fuel Tank (in.)


Batt. Box (in.)

GallonsTank

Length (in.)


Fuel Tank (in.)


Batt. Box (in.)

56 35.5 -9.4 6.9 60 30.5 -14.4 1.9 75 28.7 -16.2 0.1

60 38.0 -6.9 9.4 75 38.5 -6.4 9.9 90 34.2 -10.7 5.6

75 47.3 2.4 18.7 90 45.5 0.6 16.9 105 38.8 -6.1 10.2

100 62.2 17.3 33.6 100 50.0 5.1 21.4 120 45.8 0.9 17.2

120 74.2 29.3 45.6 110 54.9 10.0 26.3 135 50.8 5.9 22.2

120 60.5 15.6 31.9 150 56.2 11.3 27.6

135 67.2 22.3 38.6 177 66.1 21.2 37.5

150 74.5 29.6 45.9

D17

Ch

arts

Section 3Dimensions

08/06 3-101

D17E—Use with the following models: W900B


TABLE 3-77.




W900B Day Cab Horizontal 45.0


GallonsTank

Length (in.)


Fuel Tank (in.)


Batt. Box (in.)

GallonsTank

Length (in.)


Fuel Tank (in.)


Batt. Box (in.)

GallonsTank

Length (in.)


Fuel Tank (in.)


Batt. Box (in.)

56 35.5 -20.2 -4.0 75 38.5 -17.2 -1.0 90 34.2 -21.5 -5.3

60 38.0 -17.7 -1.5 90 45.5 -10.2 6.1 105 38.8 -16.9 -0.7

75 47.3 -8.4 7.8 100 50.0 -5.7 10.6 120 45.8 -9.9 6.3

100 62.2 6.5 22.8 110 54.9 -0.8 15.5 135 50.8 -4.9 11.4

120 74.2 18.5 34.8 120 60.5 4.8 21.1 150 56.2 0.5 16.8

135 67.2 11.5 27.8 177 66.1 10.4 26.7

150 74.5 18.8 35.1

D17 C

harts

Section 3Dimensions

08/06 3-102

D17F—Use with the following models: W900B


TABLE 3-78.




W900B Extended Day Cab Horizontal 39.3


GallonsTank

Length (in.)


Fuel Tank (in.)


Batt. Box (in.)

GallonsTank

Length (in.)


Fuel Tank (in.)


Batt. Box (in.)

GallonsTank

Length (in.)


Fuel Tank (in.)


Batt. Box (in.)

56 35.5 -25.9 -9.7 75 38.5 -22.9 -6.7 90 34.2 -27.2 -11.0

60 38.0 -23.4 -7.2 90 45.5 -15.9 0.3 105 38.8 -22.6 -6.4

75 47.3 -14.1 2.1 100 50.0 -11.4 4.8 120 45.8 -15.6 0.6

100 62.2 0.8 17.1 110 54.9 -6.5 9.7 135 50.8 -10.6 5.6

120 74.2 12.8 29.1 120 60.5 -0.9 15.4 150 56.2 -5.2 11.1

135 67.2 5.8 22.1 177 66.1 4.7 21.0

150 74.5 13.1 29.4

D17

Ch

arts

Section 3Dimensions

08/06 3-103


DPF Location: Horizontal BOCBattery Box: BOCFuel Tank: LH Under Cab RH Under Cab

TABLE 3-79.




T800Day Cab

Horizontal45.0



GallonsTank

Length (in.)

Dim. A & C Day

Cab BOC to Fuel

Tank (in.)

Dim. A & C


Fuel Tank (in.)

GallonsTank

Length (in.)

Dim. A & C Day

Cab BOC to Fuel

Tank (in.)

Dim. A & C


Fuel Tank (in.)

GallonsTank

Length (in.)

Dim. A & C Day

Cab BOC to Fuel

Tank (in.)

Dim. A & C


Fuel Tank (in.)

56 35.5 -3.5 -9.2 60 30.5 -8.6 -14.3 75 28.7 -10.4 -16.1

60 38.0 -1.1 -6.8 75 38.5 -0.6 -6.3 90 34.2 -4.9 -10.6

75 47.3 8.2 2.5 90 45.5 6.4 0.7 105 38.8 -0.3 -6.0

100 62.2 23.1 17.4 100 50.0 10.9 5.2 120 45.8 6.7 1.0

120 74.2 35.1 29.4 110 54.9 15.8 10.1 135 50.8 11.7 6.0

120 60.5 21.4 15.7 150 56.2 17.1 11.4

135 67.2 28.1 22.4 177 66.1 27.0 21.3

150 74.5 35.4 29.7

D18 C

harts

Section 3Dimensions

08/06 3-104



TABLE 3-80.




T800SHDay Cab

Horizontal45.0



GallonsTank

Length (in.)

Dim. A & C Day

Cab BOC to Fuel

Tank (in.)

Dim. A & C


Fuel Tank (in.)

GallonsTank

Length (in.)

Dim. A & C Day

Cab BOC to Fuel

Tank (in.)

Dim. A & C


Fuel Tank (in.)

GallonsTank

Length (in.)

Dim. A & C Day

Cab BOC to Fuel

Tank (in.)

Dim. A & C


Fuel Tank (in.)

56 35.5 -3.7 -9.4 60 30.5 -8.7 -14.4 75 28.7 -10.5 -16.2

60 38.0 -1.2 -6.9 75 38.5 -0.7 -6.4 90 34.2 -5.0 -10.7

75 47.3 8.1 2.4 90 45.5 6.3 0.6 105 38.8 -0.4 -6.1

100 62.2 23.0 17.3 100 50.0 10.8 5.1 120 45.8 6.6 0.9

120 74.2 35.0 29.3 110 54.9 15.7 10.0 135 50.8 11.6 5.9

120 60.5 21.3 15.6 150 56.2 17.0 11.3

135 67.2 28.0 22.3 177 66.1 26.9 21.2

150 74.5 35.3 29.6

D18

Ch

arts

Section 3Dimensions

08/06 3-105



TABLE 3-81.




W900BDay Cab

Horizontal45.0



GallonsTank

Length (in.)

Dim. A & C Day

Cab BOC to Fuel

Tank (in.)

Dim. A & C


Fuel Tank (in.)

GallonsTank

Length (in.)

Dim. A & C Day

Cab BOC to Fuel

Tank (in.)

Dim. A & C


Fuel Tank (in.)

GallonsTank

Length (in.)

Dim. A & C Day

Cab BOC to Fuel

Tank (in.)

Dim. A & C


Fuel Tank (in.)

56 35.5 -20.2 -25.9 75 38.5 -17.2 -22.9 90 34.2 -21.5 -27.2

60 38.0 -17.7 -23.4 90 45.5 -10.2 -15.9 105 38.8 -16.9 -22.6

75 47.3 -8.4 -14.1 100 50.0 -5.7 -11.4 120 45.8 -9.9 -15.6

100 62.2 6.5 0.8 110 54.9 -0.8 -6.5 135 50.8 -4.9 -10.6

120 74.2 18.5 12.8 120 60.5 4.8 -0.9 150 56.2 0.5 -5.2

135 67.2 11.5 5.8 177 66.1 10.4 4.7

150 74.5 18.8 13.1

D18 C

harts

Section 3Dimensions

08/06 3-106


DPF Location: Horizontal Under Sleeper / BOCBattery Box: LH Under CabFuel Tank: BOCToolbox: RH Under Cab

TABLE 3-82.




T800 / T800SHDay Cab

Horizontal45.0



GallonsTank

Length (in.)


Fuel Tank (in.)


Fuel Tank (in.)

GallonsTank

Length (in.)


Fuel Tank (in.)


Fuel Tank (in.)

GallonsTank

Length (in.)


Fuel Tank (in.)


Fuel Tank (in.)

40 25.6 22.5 16.8 45 22.9 19.8 14.1 75 28.7 25.6 19.9

56 35.5 32.4 26.7 60 30.5 27.4 21.7 90 34.2 31.1 25.4

60 38.0 34.9 29.2 75 38.5 35.4 29.7 105 38.8 35.7 30.0

75 47.3 44.2 38.5 90 45.5 42.4 36.7 120 45.8 42.7 37.0

100 62.2 59.1 53.4 100 50.0 46.9 41.2 135 50.8 47.7 42.0

120 74.2 71.1 65.4 110 54.9 51.8 46.1 150 56.2 53.1 47.4

120 60.5 57.4 51.7 177 66.1 63.0 57.3

135 67.2 64.1 58.4

150 74.5 71.4 65.7


D19

Ch

arts

Section 3Dimensions

08/06 3-107

D19B—Use with the following models: W900B

DPF Location: Horizontal BOCBattery Box: LH Under CabFuel Tank: BOCToolbox: RH Under Cab

TABLE 3-83.




W900BDay Cab

Horizontal45.0



GallonsTank

Length (in.)


Fuel Tank (in.)


Fuel Tank (in.)

GallonsTank

Length (in.)


Fuel Tank (in.)


Fuel Tank (in.)

GallonsTank

Length (in.)


Fuel Tank (in.)


Fuel Tank (in.)

40 25.6 16.4 10.7 45 22.9 13.7 8.0 75 28.7 19.5 13.8

56 35.5 26.3 20.6 60 30.5 21.3 15.6 90 34.2 25.0 19.3

60 38.0 28.8 23.1 75 38.5 29.3 23.6 105 38.8 29.6 23.9

75 47.3 38.1 32.4 90 45.5 36.3 30.6 120 45.8 36.6 30.9

100 62.2 53.0 47.3 100 50.0 40.8 35.1 135 50.8 41.6 35.9

120 74.2 65.0 59.3 110 54.9 45.7 40.0 150 56.2 47.0 41.3

120 60.5 51.3 45.6 177 66.1 56.9 51.2

135 67.2 58.0 52.3

150 74.5 65.3 59.6


D19 C

harts

Section 3Dimensions

08/06 3-108


DPF Location: RH Under CabBattery Box: Vocational RH Behind DPF Fuel Tank: LH Under Cab

TABLE 3-84.


Confi gurationDim. A

DPF to BOC (in.)Dim. B

Max from BOC (in.)Dim. E

BOC (in.)

T800Day Cab

RH BOC5.4

10.925.2

Extended Day Cab -0.3 19.1


GallonsTank

Length (in.)


Fuel Tank (in.)


Fuel Tank (in.)

GallonsTank

Length (in.)


Fuel Tank (in.)


Fuel Tank (in.)

GallonsTank

Length (in.)


Fuel Tank (in.)


Fuel Tank (in.)

56 35.5 -3.5 -9.2 60 30.5 -8.6 -14.3 75 28.7 -10.4 -16.1

60 38.0 -1.1 -6.8 75 38.5 -0.6 -6.3 90 34.2 -4.9 -10.6

75 47.3 8.2 2.5 90 45.5 6.4 0.7 105 38.8 -0.3 -6.0

1001, 2 62.2 23.1 17.4 100 50.0 10.9 5.2 120 45.8 6.7 1.0

120 74.2 35.1 29.4 110 54.9 15.8 10.1 135 50.8 11.7 6.0

1201, 2 60.5 21.4 15.7 150 56.2 17.1 11.4

135 67.2 28.1 22.4 1771, 2 66.1 27.0 21.3

150 74.5 35.4 29.7

1 MAXIMUM DAYCAB FUEL TANK TO MATCH DIMENSION “E”2 MAXIMUM EXTENDED DAYCAB FUEL TANK TO MATCH DIMENSION “E”

D20

Ch

arts

Section 3Dimensions

08/06 3-109



TABLE 3-85.





BOC (in.)

T800SHDay Cab

RH BOC7.2

10.926.4

Extended Day Cab 1.5 20.7


GallonsTank

Length (in.)


Fuel Tank (in.)


Fuel Tank (in.)

GallonsTank

Length (in.)


Fuel Tank (in.)


Fuel Tank (in.)

GallonsTank

Length (in.)


Fuel Tank (in.)


Fuel Tank (in.)

60 38.0 -1.2 -6.9 75 38.5 -0.7 -6.4 90 34.2 -5.0 -10.7

75 47.3 8.1 2.4 90 45.5 6.4 0.6 105 38.8 -0.4 -6.1

1001, 2 62.2 23.0 17.3 100 50.0 10.9 5.0 120 45.8 6.6 0.9

120 74.2 35.0 29.3 110 54.9 15.8 10.0 135 50.8 11.6 5.9

1201, 2 60.5 21.4 15.6 150 56.2 17.0 11.3

135 67.2 28.1 22.3 1771, 2 66.1 26.9 21.2

150 74.5 35.4 29.6


D20 C

harts

Section 3Dimensions

08/06 3-110



TABLE 3-86.





BOC (in.)

W900BDay Cab

RH BOC5.4

10.925.2



GallonsTank

Length (in.)


Fuel Tank (in.)


Fuel Tank (in.)

GallonsTank

Length (in.)


Fuel Tank (in.)


Fuel Tank (in.)

GallonsTank

Length (in.)


Fuel Tank (in.)


Fuel Tank (in.)

56 35.5 -20.2 -25.9 75 38.5 -17.2 -22.9 90 34.2 -21.5 -27.2

60 38.0 -17.7 -23.4 90 45.5 -10.2 -15.9 105 38.8 -16.9 -22.6

75 47.3 -8.4 -14.1 100 50.0 -5.7 -11.4 120 45.8 -9.9 -15.6

100 62.2 6.5 0.8 110 54.9 -0.8 -6.5 135 50.8 -4.9 -10.6

1201, 2 74.2 18.5 12.8 120 60.5 4.8 -0.9 150 56.2 0.5 -5.2

135 67.2 11.5 5.8 1771, 2 66.1 10.4 4.7

1501, 2 74.5 18.8 13.1


D20

Ch

arts

Section 3Dimensions

08/06 3-111



TABLE 3-87.





BOC (in.)

W900SDay Cab

RH BOC5.4

10.925.2



GallonsTank

Length (in.)


Fuel Tank (in.)


Fuel Tank (in.)

GallonsTank

Length (in.)


Fuel Tank (in.)


Fuel Tank (in.)

GallonsTank

Length (in.)


Fuel Tank (in.)


Fuel Tank (in.)

56 35.5 -14.8 -20.5 75 38.5 -11.8 -17.5 90 34.2 -16.1 -21.8

60 38.0 -12.3 -18 90 45.5 -4.8 -10.5 105 38.8 -11.5 -17.2

75 47.3 -3 -8.7 100 50.0 -0.3 -6 120 45.8 -4.5 -10.2

100 62.2 11.9 6.2 110 54.9 4.6 -1.1 135 50.8 0.5 -5.2

1201, 2 74.2 23.9 18.2 120 60.5 10.2 4.5 150 56.2 5.9 0.2

135 67.2 16.9 11.2 1771, 2 66.1 15.8 10.1

1501, 2 74.5 24.2 18.5


D20 C

harts

Section 3Dimensions

08/06 3-112

S4—Use with the following models: T800 / T800SH / W900B

DPF Location: RH Under CabBattery Box: LH Under CabFuel Tank: BOCToolbox: RH Under Cab

TABLE 3-88.

Model Sleeper Confi guration Tailpipe Confi guration

T800 / T800SH / W900B 38” Sleeper Dual Aero Cab


Gallons Tank Length (in.) Gallons Tank Length (in.) Gallons Tank Length (in.)

40 25.6 45 22.9 75 28.7

56 35.5 60 30.5 90 34.2

60 38.0 75 38.5 105 38.8

75 47.3 90 45.5 120 45.8

100 62.2 100 50.0 135 50.8

120 74.2 110 54.9 150 56.2

120 60.5 177 66.1

135 67.2

150 74.5

S4

Ch

arts

Section 3Dimensions

08/06 3-113

S5 C

harts

S5—Use with the following models: T800 / T800SH / W900B


TABLE 3-89.

Model Sleeper Confi guration Tailpipe Confi guration

T800 / T800SH / W900B 38” Sleeper Dual Aero Cab


Gallons Tank Length (in.) Gallons Tank Length (in.) Gallons Tank Length (in.)

56 35.5 60 30.5 75 28.7

601 38.0 751 38.5 90 34.2

752 47.3 90 45.5 1051 38.8

100 62.2 100 50.0 120 45.8

120 74.2 1102 54.9 1352 50.8

120 60.5 150 56.2

135 67.2 177 66.1

150 74.5

1 MAXIMUM FUEL TANK UNDER CAB W/ T800 / T800SH AEROCAB EXHAUST2 MAXIMUM FUEL TANK UNDER CAB W/ W900B AEROCAB EXHAUST

Section 3Dimensions

08/06 3-114

S9A—Use with the following models: T800

DPF Location: RH Vertical BOSBattery Box: LH Under CabFuel Tank: RH Under Cab

TABLE 3-90.

Model Sleeper Confi guration Tailpipe Confi gurationDimension B

Maximum from BOS

T800

38” Sleeper

Vertical 19.8

42” Sleeper


Gallon Tank (in.)

38” Slpr. Dim. A BOS to

Fuel Tank (in.)


Fuel Tank (in.)

Gallon Tank (in.)


Fuel Tank (in.)


Fuel Tank (in.)

Gallon Tank (in.)


Fuel Tank (in.)


Fuel Tank (in.)

56 35.5 -31.6 -47.6 60 30.5 -36.6 -52.6 75 28.7 -38.4 -54.4

60 38.0 -29.1 -45.1 75 38.5 -28.6 -44.6 90 34.2 -32.9 -48.9

75 47.3 -19.8 -35.8 90 45.5 -21.6 -37.6 105 38.8 -28.3 -44.3

100 62.2 -4.9 -20.9 100 50.0 -17.1 -33.1 120 45.8 -21.3 -37.3

120 74.2 7.1 -8.9 110 54.9 -12.2 -28.2 135 50.8 -16.3 -32.3

120 60.5 -6.6 -22.6 150 56.2 -10.9 -26.9

135 67.2 0.1 -15.9 177 66.1 -1.0 -17.0

150 74.5 7.4 -8.6

1 CGI LINE WILL BE PRESENT WITH CATERPILLAR ENGINES. CUMMINS ENGINES WILL NOT HAVE A CGI LINE.

CGI line1

CGI line1

S9

Ch

arts

Section 3Dimensions

08/06 3-115

S9B—Use with the following models: T800SH


TABLE 3-91.


Maximum from BOS

T800SH

38” Sleeper

Vertical 19.8

42” Sleeper


Gallon Tank (in.)


Fuel Tank (in.)


Fuel Tank (in.)

Gallon Tank (in.)


Fuel Tank (in.)


Fuel Tank (in.)

Gallon Tank (in.)


Fuel Tank (in.)


Fuel Tank (in.)

56 35.5 -31.7 -47.7 60 30.5 -36.7 -52.7 75 28.7 -38.5 -54.5

60 38.0 -29.2 -45.2 75 38.5 -28.7 -44.7 90 34.2 -33.0 -49.0

75 47.3 -19.9 -35.9 90 45.5 -21.7 -37.7 105 38.8 -28.4 -44.4

100 62.2 -5.0 -21.0 100 50.0 -17.2 -33.2 120 45.8 -21.4 -37.4

120 74.2 7.0 -9.0 110 54.9 -12.3 -28.3 135 50.8 -16.4 -32.4

120 60.5 -6.7 -22.7 150 56.2 -11.0 -27.0

135 67.2 0.0 -16.0 177 66.1 -1.1 -17.1

150 74.5 7.3 -8.7


CGI line1

CGI line1

S9 C

harts

Section 3Dimensions

08/06 3-116

S9C—Use with the following models: W900B


TABLE 3-92.


Maximum from BOS

W900B

38” Sleeper

Vertical 19.8

42” Sleeper


Gallon Tank (in.)


Fuel Tank (in.)


Fuel Tank (in.)

Gallon Tank (in.)


Fuel Tank (in.)


Fuel Tank (in.)

Gallon Tank (in.)


Fuel Tank (in.)


Fuel Tank (in.)

56 35.5 -48.2 -64.2 75 38.5 -45.2 -61.2 90 34.2 -49.5 -65.5

60 38.0 -45.7 -61.7 90 45.5 -38.2 -54.2 105 38.8 -44.9 -60.9

75 47.3 -36.4 -52.4 100 50.0 -33.7 -49.7 120 45.8 -37.9 -53.9

100 62.2 -21.5 -37.5 110 54.9 -28.8 -44.8 135 50.8 -32.9 -48.9

120 74.2 -9.5 -25.5 120 60.5 -23.2 -39.2 150 56.2 -27.5 -43.5

135 67.2 -16.5 -32.5 177 66.1 -17.6 -33.6

150 74.5 -9.2 -25.2


CGI line1

CGI line1

S9

Ch

arts

Section 3Dimensions

08/06 3-117


DPF Location: RH Vertical BOSBattery Box: Vocational LH BOCFuel Tank: LH Under CabToolbox: RH Under Cab

TABLE 3-93.


Maximum from BOS

T800

38” Sleeper

Vertical 19.8

42” Sleeper


Gallon Tank (in.)

38” Slpr. Dim. C BOS to

Fuel Tank (in.)


Fuel Tank (in.)

Gallon Tank (in.)


Fuel Tank (in.)


Fuel Tank (in.)

Gallon Tank (in.)


Fuel Tank (in.)


Fuel Tank (in.)

56 35.5 -15.4 -31.4 60 30.5 -20.4 -36.4 75 28.7 -22.2 -38.2

60 38.0 -12.9 -28.9 75 38.5 -12.4 -28.4 90 34.2 -16.7 -32.7

75 47.3 -3.6 -19.6 90 45.5 -5.4 -21.4 105 38.8 -12.1 -28.1

100 62.2 11.4 -4.7 100 50.0 -0.9 -16.9 120 45.8 -5.1 -21.1

120 74.2 23.4 7.3 110 54.9 4.0 -12.0 135 50.8 -0.1 -16.1

120 60.5 9.6 -6.4 150 56.2 5.3 -10.7

135 67.2 16.4 0.3 177 66.1 15.3 -0.8

150 74.5 23.7 7.6


CGI line1

CGI line1

S10 C

harts

Section 3Dimensions

08/06 3-118



TABLE 3-94.


Maximum from BOS

T800SH

38” Sleeper

Vertical 19.8

42” Sleeper


Gallon Tank (in.)


Fuel Tank (in.)


Fuel Tank (in.)

Gallon Tank (in.)


Fuel Tank (in.)


Fuel Tank (in.)

Gallon Tank (in.)


Fuel Tank (in.)


Fuel Tank (in.)

56 35.5 -15.5 -31.5 60 30.5 -20.5 -36.5 75 28.7 -22.3 -38.3

60 38.0 -13.0 -29.0 75 38.5 -12.5 -28.5 90 34.2 -16.8 -32.8

75 47.3 -3.7 -19.7 90 45.5 -5.5 -21.5 105 38.8 -12.2 -28.2

100 62.2 11.3 -4.7 100 50.0 -0.9 -17.0 120 45.8 -5.2 -21.2

120 74.2 23.3 7.3 110 54.9 4.0 -12.1 135 50.8 -0.1 -16.2

120 60.5 9.6 -6.5 150 56.2 5.3 -10.8

135 67.2 16.3 0.3 177 66.1 15.2 -0.9

150 74.5 23.6 7.6


CGI line1

CGI line1

S10

Ch

arts

Section 3Dimensions

08/06 3-119



TABLE 3-95.


Maximum from BOS

W900B

38” Sleeper

Vertical 19.8

42” Sleeper


Gallon Tank (in.)


Fuel Tank (in.)


Fuel Tank (in.)

Gallon Tank (in.)


Fuel Tank (in.)


Fuel Tank (in.)

Gallon Tank (in.)


Fuel Tank (in.)


Fuel Tank (in.)

56 35.5 -32.0 -48.0 75 38.5 -29.0 -45.0 90 34.2 -33.3 -49.3

60 38.0 -29.5 -45.5 90 45.5 -22.0 -38.0 105 38.8 -28.7 -44.7

75 47.3 -20.2 -36.2 100 50.0 -17.5 -33.5 120 45.8 -21.7 -37.7

100 62.2 -5.3 -21.3 110 54.9 -12.6 -28.6 135 50.8 -16.7 -32.7

120 74.2 6.8 -9.3 120 60.5 -7.0 -23.0 150 56.2 -11.3 -27.3

135 67.2 -0.3 -16.3 177 66.1 -1.4 -17.4

150 74.5 7.1 -9.0


CGI line1

CGI line1

S10 C

harts

Section 3Dimensions

08/06 3-120


DPF Location: RH Vertical BOSBattery Box: Vocational LH BOCFuel Tank: LH Under Cab RH Under Cab

TABLE 3-96.

Model Sleeper Confi guration Tailpipe Confi guration Dimension B

T800 38” Sleeper

Vertical 19.842” Sleeper


GallonTank (in.)

38” Slpr. Dim.

A BOS

to Fuel Tank (in.)

38” Slpr. Dim.

C BOS

to Fuel Tank (in.)

42” Slpr. Dim.

A BOS

to Fuel Tank (in.)

42” Slpr. Dim.

C BOS

to Fuel Tank (in.)

GallonTank (in.)

38” Slpr. Dim.

A BOS

to Fuel Tank (in.)

38” Slpr. Dim.

C BOS

to Fuel Tank (in.)

42” Slpr. Dim.

A BOS

to Fuel Tank (in.)

42” Slpr. Dim.

C BOS

to Fuel Tank (in.)

GallonTank (in.)

38” Slpr. Dim.

A BOS

to Fuel Tank (in.)

38” Slpr. Dim.

C BOS

to Fuel Tank (in.)

42” Slpr. Dim.

A BOS

to Fuel Tank (in.)

42” Slpr. Dim.

C BOS

to Fuel Tank (in.)

56 35.5 -31.6 -15.4 -47.6 -31.4 60 30.5 -36.6 -20.4 -52.6 -36.4 75 28.7 -38.4 -22.2 -54.4 -38.2

60 38.0 -29.1 -12.9 -45.1 -28.9 75 38.5 -28.6 -12.4 -44.6 -28.4 90 34.2 -32.9 -16.7 -48.9 -32.7

75 47.3 -19.8 -3.6 -35.8 -19.6 90 45.5 -21.6 -5.4 -37.6 -21.4 105 38.8 -28.3 -12.1 -44.3 -28.1

100 62.2 -4.9 11.4 -20.9 -4.7 100 50.0 -17.1 -0.9 -33.1 -16.9 120 45.8 -21.3 -5.1 -37.3 -21.1

120 74.2 7.1 23.4 -8.9 7.3 110 54.9 -12.2 4.0 -28.2 -12.0 135 50.8 -16.3 -0.1 -32.3 -16.1

120 60.5 -6.6 9.6 -22.6 -6.4 150 56.2 -10.9 5.3 -26.9 -10.7

135 67.2 0.1 16.4 -15.9 0.3 177 66.1 -1.0 15.3 -17.0 -0.8

150 74.5 7.4 23.7 -8.6 7.6


CGI line1

CGI line1

S11

Ch

arts

Section 3Dimensions

08/06 3-121



TABLE 3-97.


T800SH 38” Sleeper



GallonTank (in.)

38” Slpr. Dim.

A BOS

to Fuel Tank (in.)

38” Slpr. Dim.

C BOS

to Fuel Tank (in.)

42” Slpr. Dim.

A BOS

to Fuel Tank (in.)

42” Slpr. Dim.

C BOS

to Fuel Tank (in.)

GallonTank (in.)

38” Slpr. Dim.

A BOS

to Fuel Tank (in.)

38” Slpr. Dim.

C BOS

to Fuel Tank (in.)

42” Slpr. Dim.

A BOS

to Fuel Tank (in.)

42” Slpr. Dim.

C BOS

to Fuel Tank (in.)

GallonTank (in.)

38” Slpr. Dim.

A BOS

to Fuel Tank (in.)

38” Slpr. Dim.

C BOS

to Fuel Tank (in.)

42” Slpr. Dim.

A BOS

to Fuel Tank (in.)

42” Slpr. Dim.

C BOS

to Fuel Tank (in.)

56 35.5 -31.7 -15.5 -47.7 -31.5 60 30.5 -36.7 -20.5 -52.7 -36.5 75 28.7 -38.5 -22.3 -54.5 -38.3

60 38.0 -29.2 -13.0 -45.2 -29.0 75 38.5 -28.7 -12.5 -44.7 -28.5 90 34.2 -33.0 -16.8 -49.0 -32.8

75 47.3 -19.9 -3.7 -35.9 -19.7 90 45.5 -21.7 -5.5 -37.7 -21.5 105 38.8 -28.4 -12.2 -44.4 -28.2

100 62.2 -5.0 11.3 -21.0 -4.7 100 50.0 -17.2 -0.9 -33.2 -17.0 120 45.8 -21.4 -5.2 -37.4 -21.2

120 74.2 7.0 23.3 -9.0 7.3 110 54.9 -12.3 4.0 -28.3 -12.1 135 50.8 -16.4 -0.1 -32.4 -16.2

120 60.5 -6.7 9.6 -22.7 -6.5 150 56.2 -11.0 5.3 -27.0 -10.8

135 67.2 0.0 16.3 -16.0 0.3 177 66.1 -1.1 15.2 -17.1 -0.9

150 74.5 7.3 23.6 -8.7 7.6


CGI line1

CGI line1

S11 C

harts

Section 3Dimensions

08/06 3-122



TABLE 3-98.


W900B 38” Sleeper



GallonTank (in.)

38” Slpr. Dim.

A BOS

to Fuel Tank (in.)

38” Slpr. Dim.

C BOS

to Fuel Tank (in.)

42” Slpr. Dim.

A BOS

to Fuel Tank (in.)

42” Slpr. Dim.

C BOS

to Fuel Tank (in.)

GallonTank (in.)

38” Slpr. Dim.

A BOS

to Fuel Tank (in.)

38” Slpr. Dim.

C BOS

to Fuel Tank (in.)

42” Slpr. Dim.

A BOS

to Fuel Tank (in.)

42” Slpr. Dim.

C BOS

to Fuel Tank (in.)

GallonTank (in.)

38” Slpr. Dim.

A BOS

to Fuel Tank (in.)

38” Slpr. Dim.

C BOS

to Fuel Tank (in.)

42” Slpr. Dim.

A BOS

to Fuel Tank (in.)

42” Slpr. Dim.

C BOS

to Fuel Tank (in.)

56 35.5 -48.2 -32.0 -64.2 -48.0 75 38.5 -45.2 -29.0 -61.2 -45.0 90 34.2 -49.5 -33.3 -65.5 -49.3

60 38.0 -45.7 -29.5 -61.7 -45.5 90 45.5 -38.2 -22.0 -54.2 -38.0 105 38.8 -44.9 -28.7 -60.9 -44.7

75 47.3 -36.4 -20.2 -52.4 -36.2 100 50.0 -33.7 -17.5 -49.7 -33.5 120 45.8 -37.9 -21.7 -53.9 -37.7

100 62.2 -21.5 -5.3 -37.5 -21.3 110 54.9 -28.8 -12.6 -44.8 -28.6 135 50.8 -32.9 -16.7 -48.9 -32.7

120 74.2 -9.5 6.8 -25.5 -9.3 120 60.5 -23.2 -7.0 -39.2 -23.0 150 56.2 -27.5 -11.3 -43.5 -27.3

135 67.2 -16.5 -0.3 -32.5 -16.3 177 66.1 -17.6 -1.4 -33.6 -17.4

150 74.5 -9.2 7.1 -25.2 -9.0


CGI line1

CGI line1

S11

Ch

arts

Section 3Dimensions

08/06 3-123


DPF Location: RH Vertical BOSBattery Box: LH BOCFuel Tank: LH Under Cab RH Under Cab

TABLE 3-99.


T800 38” Sleeper



GallonTank (in.)

38” Slpr. Dim.

A BOS

to Fuel Tank (in.)

38” Slpr. Dim.

C BOS

to Fuel Tank (in.)

42” Slpr. Dim.

A BOS

to Fuel Tank (in.)

42” Slpr. Dim.

C BOS

to Fuel Tank (in.)

GallonTank (in.)

38” Slpr. Dim.

A BOS

to Fuel Tank (in.)

38” Slpr. Dim.

C BOS

to Fuel Tank (in.)

42” Slpr. Dim.

A BOS

to Fuel Tank (in.)

42” Slpr. Dim.

C BOS

to Fuel Tank (in.)

GallonTank (in.)

38” Slpr. Dim.

A BOS

to Fuel Tank (in.)

38” Slpr. Dim.

C BOS

to Fuel Tank (in.)

42” Slpr. Dim.

A BOS

to Fuel Tank (in.)

42” Slpr. Dim.

C BOS

to Fuel Tank (in.)

56 35.5 -31.6 -47.6 1.4 -14.6 60 30.5 -36.6 -52.6 -3.6 -19.6 75 28.7 -38.4 -54.4 -5.4 -21.4

60 38.0 -29.1 -45.1 3.9 -12.1 75 38.5 -28.6 -44.6 4.4 -11.6 90 34.2 -32.9 -48.9 0.1 -15.9

75 47.3 -19.8 -35.8 13.2 -2.8 90 45.5 -21.6 -37.6 11.4 -4.6 105 38.8 -28.3 -44.3 4.7 -11.3

100 62.2 -4.9 -20.9 28.1 12.1 100 50.0 -17.1 -33.1 15.9 -0.1 120 45.8 -21.3 -37.3 11.7 -4.3

120 74.2 7.1 -8.9 40.1 24.1 110 54.9 -12.2 -28.2 20.8 4.8 135 50.8 -16.3 -32.3 16.7 0.7

120 60.5 -6.6 -22.6 26.4 10.4 150 56.2 -10.9 -26.9 22.1 6.1

135 67.2 0.1 -15.9 33.1 17.1 177 66.1 -1.0 -17.0 32.0 16.0

150 74.5 7.4 -8.6 40.4 24.4


CGI line1

CGI line1

S12 C

harts

Section 3Dimensions

08/06 3-124



TABLE 3-100.


T800SH38” Sleeper



GallonTank (in.)

38” Slpr. Dim.

A BOS

to Fuel Tank (in.)

38” Slpr. Dim.

C BOS

to Fuel Tank (in.)

42” Slpr. Dim.

A BOS

to Fuel Tank (in.)

42” Slpr. Dim.

C BOS

to Fuel Tank (in.)

GallonTank (in.)

38” Slpr. Dim.

A BOS

to Fuel Tank (in.)

38” Slpr. Dim.

C BOS

to Fuel Tank (in.)

42” Slpr. Dim.

A BOS

to Fuel Tank (in.)

42” Slpr. Dim.

C BOS

to Fuel Tank (in.)

GallonTank (in.)

38” Slpr. Dim.

A BOS

to Fuel Tank (in.)

38” Slpr. Dim.

C BOS

to Fuel Tank (in.)

42” Slpr. Dim.

A BOS

to Fuel Tank (in.)

42” Slpr. Dim.

C BOS

to Fuel Tank (in.)

56 35.5 -31.7 -47.7 1.3 -14.7 60 30.5 -36.7 -52.7 -3.7 -19.7 75 28.7 -38.5 -54.5 -5.5 -21.5

60 38.0 -29.2 -45.2 3.8 -12.2 75 38.5 -28.7 -44.7 4.3 -11.7 90 34.2 -33.0 -49.0 0.0 -16.0

75 47.3 -19.9 -35.9 13.1 -2.9 90 45.5 -21.7 -37.7 11.3 -4.7 105 38.8 -28.4 -44.4 4.6 -11.4

100 62.2 -5.0 -21.0 28.0 12.0 100 50.0 -17.2 -33.2 15.8 -0.2 120 45.8 -21.4 -37.4 11.6 -4.4

120 74.2 7.0 -9.0 40.0 24.0 110 54.9 -12.3 -28.3 20.7 4.7 135 50.8 -16.4 -32.4 16.6 0.6

120 60.5 -6.7 -22.7 26.3 10.3 150 56.2 -11.0 -27.0 22.0 6.0

135 67.2 0.0 -16.0 33.0 17.0 177 66.1 -1.1 -17.1 31.9 15.9

150 74.5 7.3 -8.7 40.3 24.3


CGI line1

CGI line1

S12

Ch

arts

Section 3Dimensions

08/06 3-125



TABLE 3-101.


W900B38” Sleeper



GallonTank (in.)

38” Slpr. Dim.

A BOS

to Fuel Tank (in.)

38” Slpr. Dim.

C BOS

to Fuel Tank (in.)

42” Slpr. Dim.

A BOS

to Fuel Tank (in.)

42” Slpr. Dim.

C BOS

to Fuel Tank (in.)

GallonTank (in.)

38” Slpr. Dim.

A BOS

to Fuel Tank (in.)

38” Slpr. Dim.

C BOS

to Fuel Tank (in.)

42” Slpr. Dim.

A BOS

to Fuel Tank (in.)

42” Slpr. Dim.

C BOS

to Fuel Tank (in.)

GallonTank (in.)

38” Slpr. Dim.

A BOS

to Fuel Tank (in.)

38” Slpr. Dim.

C BOS

to Fuel Tank (in.)

42” Slpr. Dim.

A BOS

to Fuel Tank (in.)

42” Slpr. Dim.

C BOS

to Fuel Tank (in.)

56 35.5 -48.2 -64.2 -15.2 -31.2 60 30.5 -53.2 -69.2 -20.2 -36.2 75 28.7 -55.0 -71.0 -22.0 -38.0

60 38.0 -45.7 -61.7 -12.7 -28.7 75 38.5 -45.2 -61.2 -12.2 -28.2 90 34.2 -49.5 -65.5 -16.5 -32.5

75 47.3 -36.4 -52.4 -3.4 -19.4 90 45.5 -38.2 -54.2 -5.2 -21.2 105 38.8 -44.9 -60.9 -11.9 -27.9

100 62.2 -21.5 -37.5 11.5 -4.5 100 50.0 -33.7 -49.7 -0.7 -16.7 120 45.8 -37.9 -53.9 -4.9 -20.9

120 74.2 -9.5 -25.5 23.5 7.5 110 54.9 -28.8 -44.8 4.2 -11.8 135 50.8 -32.9 -48.9 0.1 -15.9

120 60.5 -23.2 -39.2 9.8 -6.2 150 56.2 -27.5 -43.5 5.5 -10.5

135 67.2 -16.5 -32.5 16.5 0.5 177 66.1 -17.6 -33.6 15.4 -0.6

150 74.5 -9.2 -25.2 23.8 7.8


CGI line1

CGI line1

S12 C

harts

Section 3Dimensions

08/06 3-126

S18A—Use with the following models: T800 / T800SH

DPF Location: RH Vertical BOSBattery Box: LH Under CabFuel Tank: LH Under Sleeper RH Under SleeperToolbox: RH Under Cab

TABLE 3-102.


T800 / T800SH38” Sleeper



Gallon Tank (in.)

38” Slpr. Dim. A & C BOS to Fuel Tank

(in.)


(in.)

Gallon Tank (in.)


(in.)


(in.)

Gallon Tank (in.)


(in.)


(in.)

40 25.6 -5.5 -21.5 45 22.9 -8.2 -24.2 75 28.7 -2.4 -18.4

56 35.5 4.4 -11.6 60 30.5 -0.6 -16.6 90 34.2 3.1 -12.9

60 38.0 6.9 -9.1 75 38.5 7.4 -8.6 105 38.8 7.7 -8.3

75 47.3 16.22 0.2 90 45.5 14.42 -1.6 120 45.8 14.72 -1.3

100 62.2 31.12 15.12 100 50.0 18.92 2.9 135 50.8 19.72 3.7

120 74.2 43.12 27.12 110 54.9 23.82 7.8 150 56.2 25.12 9.12

120 60.5 29.42 13.42 177 66.1 35.02 19.02

135 67.2 36.12 20.12

150 74.5 43.42 27.42

NOTE: DIMENSION “C” IS CALCULATED USING A STANDARD SIZED BATTERY BOX. OPTIONAL EXTENDED BOXES WILL CHANGE DIMENSION “C”.1 CGI LINE WILL BE PRESENT WITH CATERPILLAR ENGINES. CUMMINS ENGINES WILL NOT HAVE A CGI LINE.2 RH SIDE FUEL TANK LIMITED BY INDEPENDANT EXHAUST. THESE FUEL TANK SIZES ARE NOT AVAILABLE ON THE RH SIDE.

CGI line1

CGI line1

S18

Ch

arts

Section 3Dimensions

08/06 3-127

S18B—Use with the following models: W900B / W900S

DPF Location: RH Vertical BOSBattery Box: LH Under CabFuel Tank: LH Under Sleeper RH Under Sleeper

TABLE 3-103.


W900B / W900S38” Sleeper



Gallon Tank (in.)


(in.)


(in.)

Gallon Tank (in.)


(in.)


(in.)

Gallon Tank (in.)


(in.)


(in.)

40 25.6 -11.7 -27.7 45 22.9 -14.4 -30.4 75 28.7 -8.6 -24.6

56 35.5 -1.8 -17.8 60 30.5 -6.8 -22.8 90 34.2 -3.1 -19.1

60 38.0 0.8 -15.3 75 38.5 1.3 -14.8 105 38.8 1.6 -14.5

75 47.3 10.12 -6.0 90 45.5 8.3 -7.8 120 45.8 8.6 -7.5

100 62.2 25.02 9.02 100 50.0 12.82 -3.3 135 50.8 13.62 -2.5

120 74.2 37.02 21.02 110 54.9 17.72 1.7 150 56.2 19.02 3.0

120 60.5 23.32 7.3 177 66.1 28.92 12.92

135 67.2 30.02 14.02

150 74.5 37.32 21.32

NOTE: DIMENSION “C” IS CALCULATED USING A STANDARD SIZED BATTERY BOX. OPTIONAL EXTENDED BOXES WILL CHANGE DIMENSION “C”.1 CGI LINE WILL BE PRESENT WITH CATERPILLAR ENGINES. CUMMINS ENGINES WILL NOT HAVE A CGI LINE.2 RH SIDE FUEL TANK LIMITED BY INDEPENDANT EXHAUST. THESE FUEL TANK SIZES ARE NOT AVAILABLE ON THE RH SIDE.

CGI line1

CGI line1

S18 C

harts

08/06

Section 4Body Mounting

4-1

FRAME INFORMATIONFrame information provided is per rail, some specifi cations are written for RBM requirements per pair of rails. Make sure to know the requirement before deciding on the frame rail.

TABLE 4-1. Single Steel Rails

Rail Height Flange Width Web Thickness Section Modulus RBM (in lbs) Weight (lbs/in)

H W T S R W

10 - 5/8” x 3 -1/2” x 5/16” 14.80 1,776,000 2.90

10 - 3/4” x 3 -1/2” x 3/8” 17.80 2,132,000 3.46

10 -11/16” x 3 -1/2” x 1/2” 22.35 2,683,000 4.53

11- 5/8” x 3 -7/8” x 3/8” 21.43 2,572,000 3.80

TABLE 4-2. Inserted Steel Rails

Rail Height Insert Material Section Modulus RBM (in lbs) Weight (lbs/in)

10 - 5/8” Single 9-7/8”x 2-7/8” x 1/4” 24.37 2,925,000 4.96

10 - 3/4” Single 9-7/8”x 2-7/8” x 1/4” 27.33 3,280,000 5.53

11- 5/8” Single 10-3/4” x 3-1/2” x 1/4” 39.20 4,704,000 7.28

11- 5/8”Double (one 10-3/4” x 3-1/2” x 1/4”

and one 9-7/8”x 2-7/8” x 1/4” )48.77 5,853,000 9.33

08/06


4-2

CRITICAL CLEARANCES

Rear Wheels and Cab

Insuffi cient 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.

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

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 fi ll neck.

CAUTION:

CAUTION:

Note:

08/06


4-3

FIGURE 4-2. Minimum Back of Cab Clearance

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

BODY MOUNTING USING BRACKETS

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

Installation of a spacer between the body subframe and the top fl ange of the frame rail will help prevent premature wear of the components due to chafi ng or corrosion.

WARNING:

CAUTION:

4”

08/06


4-4

Frame SillIf the body is mounted to the frame with brackets, we recommend that the frame sill spacer be made from a strip of rub-ber 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 4–3.

FIGURE 4-3. Spacer Between Frame Sill and Body Rail - Rubber or Plastic

BracketsWhen 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 4–4 shows a high compression spring between the bolt and the bracket.

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

Another possibility is mounting a rubber spacer between the brackets. See Figure 4–5.

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.

Body Subframe (Rail)

Chassis Frame (Rail) Sill

Spacer

Spring

Rubber Spacer

08/06


4-5

MOUNTING HOLESWhen 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 4–6. The hole diameter should not exceed the bolt diameter by more than .060 inches (1.5 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)

FIGURE 4-6. Crossmember-Gusset Hole Pattern Requirements. [inch (mm)]

Frame Drilling

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

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.

Do not drill closely spaced holes in the frame rail. Hole centers of two adjacent holes should be spaced no less than twice the diameter of the largest hole. Closer spacing could induce a failure between the holes.

WARNING:

CAUTION:

WARNING:

08/06


4-6

BODY MOUNTING USING U–BOLTS

SpacersIf 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 fl ange.

Do not allow the frame rails or fl anges 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 fl anges.

Use a hardwood spacer between the bottom fl ange and the U–bolt to prevent the U–bolt from notching the frame fl ange. See Figure 4–7.

Body Structure

Wood Sill 0.5 (12) Minimum

Truck Frame

Frame Rail Spacer (Fabricated Steel or

Hardwood)

U-Bolt Spacer (Hardwood)

U-Bolt

FIGURE 4-7. Acceptable U-Bolt Mounting with Wood and Fabricated Spacers [inch (mm)]

Do not allow spacers and other body mounting parts to interfere with brake lines, fuel lines, or wiring harnesses routed inside the frame rail. Crimped or damaged brake lines, fuel lines, or wiring could result in loss of braking, fuel leaks, electrical overload or a fi re. Carefully inspect the installation to ensure adequate clearances for air brake lines, fuel lines, and wiring. See Figure 4–8.

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.

WARNING:

CAUTION:

WARNING:

08/06


4-7

FIGURE 4-8. Clearance Space for Air Lines and Cables

Do not notch frame rail fl anges to force a U–bolt fi t. Notched or damaged frame fl anges could result in premature frame failure. Use a larger size U–bolt. Use a hardwood spacer as shown in Figure 4-7.

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

WARNING:

08/06


4-8

Rear Body MountWhen U–bolts are used to mount a body we recommend that the last body attachment be made with a “fi shplate” bracket. See Figure 4–9. This provides a fi rm attaching point and helps prevent any relative fore or aft movement between the body and frame.

FIGURE 4-9. Example of Fishplate Bracket at Rear End of Body, used with U-Bolts

Body Structure

Frame Rail

08/06

Section 5Frame Modifi cations

5-1

FRAME MODIFICATIONS

IntroductionKenworth offers customer specifi ed wheelbases. So, in most cases frame modifi cations to produce a certain wheelbase should not be necessary.

However, some installations may require slight modifi cations, while other installations will require extensive modifi cations. Sometimes an existing dealer stock chassis may need to have the wheelbase changed to better fi t a customer’s applica-tion. The modifi cations may be as simple as shortening or lengthening the frame cutoff, or they may be as complex as changing the wheelbase.

DRILLING RAILS

Location and Hole PatternIf 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 4–5, Figure 4–6.

When mounting a body to the chassis, DO NOT drill holes in the upper or lower fl ange of the frame rail. If the frame rail fl anges are modifi ed or damaged, the rail could fail prema-turely and cause an accident. Mount the body using body mounting brackets or U–bolts.

Do not drill closely spare holes in the web of the frame. Hole centers of two adjacent holes should be spaced no less than twice the diameter of the largest hole. Closer spacing could induce a failure between the holes.

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.

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.

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.

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.

WARNING!

CAUTION:

WARNING!

CAUTION:

CAUTION:

CAUTION:

08/06


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 confi ned to within 1 to 2 inches (25 to 50 mm) of the fl ame 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 5-6 for more information on welding frames.

Frame InsertA 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 fi t 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 joint 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.

FIGURE 5-1. Detail of Frame Extension and Joint Welding

Note:

08/06


5-3

FIGURE 5-2. Frame Insert

Where possible, use existing bolt holes to attach the insert to the frame. Bolt holes must not be located closer to the frame fl anges 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 fol-lowing guideline for locating additional bolt holes.

CHANGING WHEELBASEWe 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.

When changing the wheelbase, be sure to follow the driveline manufacturer’s recom-mendations for driveline length or angle changes. Incorrectly modifi ed drivelines can fail prematurely due to excessive vibration.

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.

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

Before 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.

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.

24 Inch Minimum(610 mm)

WARNING!

WARNING!

WARNING!

WELDED JOINT

08/06


5-4

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.

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.

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

WARNING!

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 & Figures 5-1 and 5-2)

Relocated Rear Suspension

08/06


5-5

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 adja-cent crossmembers exceeds this dimension, add a crossmember between them. See Figure 5–4.

Before Wheelbase is Lengthened

Less Than 60”

Greater Than 60”

Additional Crossmember

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

08/06


5-6

WELDINGKenworth DOES NOT recommend frame welding. The high heat of welding nullifi es the special heat treatment of the rails, greatly reducing the tensile strength of the frame rail. If a frame member becomes cracked from overloading, fatigue, surface damage or a collision, the only permanent repair is to replace the damaged frame member with a new part.

The following information is provided (for temporary emergency repair). Prior to welding a cracked frame rail, the area should be beveled (V’d out) to allow for a better weld. To prevent spreading of the crack, a 7 to 9 mm (1/4 in. to 3/8 in.) dia. hole should be drilled at the end of the crack. Widen the crack along its full length by using two hack saw blades together. When welding steel frames use the shielded arc method. When welding aluminum frames use either the tungsten inert gas (TIG) or consumable electrode method. Be sure to obtain full weld penetration along the entire length of the crack.

Precautions

Before welding, disconnect the negative terminal battery cable.

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

To prevent damage to electrical equipment, disconnect battery cables before arc-welding on a truck, and be sure that the welding ground lead is connected to the frame. Bearings and other parts will be damaged if current must pass through them in order to complete the circuit.

Welding Precautions: All Electronic EnginesBefore welding on vehicles with electronic engines, the following precautions should be observed.

1. Disconnect all electrical connections to the vehicle batteries.

2. Disconnect all ECM connectors.

3. Do no use the ECM or engine ground stud for the ground of the welding probe.

4. Ensure that the ground connection for the welder is as close to the weld point as possible. This ensures maxi-mum weld current and minimum risk to damage electrical components on the vehicle.

5. Turn off key.

Bosch ABS and Wabco ABS: Disconnect ECU.

CAUTION:

CAUTION:

CAUTION:

Note:

08/06


5-7

TORQUE REQUIREMENTSTABLE 5-1. Customary Grade 8 UNF or UNC.

Fastener Torque

Size Nm Lb.-Ft

5/16 22–30 16–22

3/8 41–54 30–40

7/16 75–88 55–65

1/2 109–122 80–90

9/16 156–190 115-140

5/8 224–265 165–195

3/4 394–462 290–340

7/8 517–626 380–460

1 952–1129 800–830

1-1/8 1346–1591 990–1170

1-1/4 1877–2217 1380–1630

Torque values apply to fasteners with clean threads, lightly libricated, with hardened steel washers, and nylon-insert nuts.

TABLE 5-2. U.S. Customary – Grade 8. Metric Class 10.9

Torque

Fastener Nm Lb-Ft

M6 9–15 7–11

M8 23–31 17–23

M10 33–43 24–32

M12 75–101 55–75

M14 134–164 99–121

M16 163–217 120–160

M20 352–460 260–340

08/06

Section 6Electrical

6-1

ELECTRICALElectrical wiring can sometimes be very frustrating. This is especially true when adding circuits to an existing setup. Through the use of optional engine connectors and additional spare circuits, we have tried to reduce the complexity as-sociated with adding common circuits to a body installation.

Information in this section will cover the following topics:

• Overview of Kenworth’s multiplex instrumentation

• Access instructions for the dash, gauges, and switches.

• Wiring instructions for telltale (warning light) symbols

• Spare circuits (standard and adding)

• Multifunction turn signal stalk

• Remote PTO/Throttle harness

MULTIPLEX INSTRUMENTATIONKenworth utilizes Multiplex instrumentation and wiring to continuously improve our quality and the capability of our trucks. Multiplexing utilizes the industry standard J1939 data bus to send multiple signals over a single twisted pair of wires instead of individual wires for each function. The advantages are fewer wires, sensors, and connections that provide greater consistency and improved reliability. The following information is provided to increase your awareness about the Kenworth product, it may be useful in installing telltales (warning lights) and gauges.

Don’t cut or tap into green/yellow twisted pairs. Only use “T” connectors, and only add approved J1939 components with validated software.

WARNING!

08/06

Section 6Electrical

6-2

INTERIOR IDENTIFICATIONKenworth began production of this interior in 2005. Chassis with this new interior can be identifi ed by appearance. All dashes that resemble the following picture will utilize multiplex wiring.

The information contained in this manual is specifi c to chassis with 2007 engines. For pre-2007 engines please work with your local Kenworth dealer.

Functional DescriptionCab Electronic Control Unit (CECU)

The heart of the multiplexed instrumentation system is the Cab Electronic Control Unit (CECU). The CECU is located behind the center console. See Figure 6-1.

FIGURE 6-1. CECU Location.Vehicle component inputs are sent to the CECU through the J1939 data bus or conventional wiring. The CECU interprets the various inputs and monitors/controls the functions for each input through the CECU software. Output signals from the CECU provide data for the gauges, warning lamps, audible alarms, and displays inside the cluster.

Note:

CECU

08/06

Section 6Electrical

6-3

Central Instrument Cluster

The central instrument cluster includes the speedometer (including odometer and trip meter) and tachometer (including engine hour meter and outside temperature display), plus pre-installed standard and/or editable warning light symbols called “telltale” cards.

Each “telltale” card slides into the left and right sides of the cluster. The standard cards cover most warning light requirements; editable cards can be used for less common components that also require warning lights.

The central instrument cluster receives input data from the CECU via the “I-CAN” (see Figure 6-6) data bus. When the ig-nition key is fi rst turned ON, the cluster will perform a calibration “power on self-test”. Please see pages 6-18 through 6-20 for more detailed information.

Power On Self-Test

• Ignition key turned ON.

• The speedometer and tachometer gauge pointers move from pointing at zero, counter-clockwise to their me-chanical limit (approx. -8°), stay there for one second and go back to pointing at zero.

• At the same time, all LED indicators and telltales are switched on together, and then switched off together.

• A “Warning” sound sequence is also activated fi ve times without break.

The warning lamps in the cluster are all activated by the CECU, except for Telltale Position 5 (usually Refrigerator) and Position 11 (editable) which are wired directly to the cluster. The CECU receives direct wire inputs for all warning lamps with the exception of the Low Coolant Level warning and the Traction Control/Stability Control lamp. These lamp inputs are received via the J1939 (Vehicle CAN) data link. The CECU typically receives the Trailer ABS warnings via the J1939 (Vehicle CAN) data link, however it can also be direct wired to the CECU from the ABS unit on the trailer, if required. See Figure 6-2 below.

FIGURE 6-2. Instrument Cluster Componentry.

Card locks into place -Installation tab breaks off

Telltale cards pre-installed in slots on both sides of cluster.

Baseline Cluster

Card locks into place –installation tab breaks off

Telltale cards

The cluster is installed with four screws

Single electrical connection on back of cluster

Standard card

Editable card

08/06

Section 6Electrical

6-4

CVSG Gauges

The right and left instrument panel gauges used with the multiplexed instrumentation are commonly referred to as Commercial Vehicle Smart Gauges (CVSG). Like the central instrument cluster, the 2-inch gauges also receive input data directly from the CECU. CVSG’s are electronic and mechanical. The electronic CVSG’s receive digital data from the CECU via the CVSG data bus. The mechanical gauges (i.e. suspension air pressure, etc.) are driven directly from the air pressure. Both types of gauges receive backlighting signals from the CECU via a 4-wire “daisy chained” jumper harness that links one gauge to another.

When the ignition key is fi rst turned ON, all the electronic 2-inch gauges will perform a calibration “power on self-test”.

The mechanical CVSG do not perform a power on self-test.

Power On Self-Test

• Ignition key turned ON.

• The gauge pointers move from pointing at zero, counter-clockwise to their mechanical limit (approx. -5°), stay there for one second and go back to pointing at zero.

• At the same time, all LED indicators are switched on together, and then switched off together.

Additional CVSG gauge information body builders should be aware of:

• The CECU sends 2-inch electronic gauges information over a data link (blue wire) between the CECU and the gauge.

• 2-inch electronic gauges get their power from the CECU. • Yellow = Power wire (9-16 volts) • White = Ground (return) wire.

• 4-way jumper harnesses link each 2-inch gauge together.

Pin # Color Function

1 Blue Data, backlighting for Electronic Gauges

2 Brown Backlighting for Mechanical Gauges

3 White Return

4 Yellow Power

• Backlighting for 2-inch electronic gauges is sent from the CECU to the gauges via the data link (blue wire).

• Optional mechanical gauge (i.e. air suspension) needles are driven mechanically with air pressure. There is no red warning lamp and the backlighting is powered through the brown wire from the CECU (a pulse-width modulated signal). The 4-way jumper harness is still used to pass all 4 circuits through the gauge to the next gauge in the chain.

• Specialty CVSG gauges (i.e. clock, PTO hour meter) are stand alone gauges and are independent of the CECU.

• Gauges can be relocated to any position in the dash. To relocate a gauge unhook the connector at the back and move it to the desired position. Plug the jumper wire in. (See page 6-9 for instructions on physically moving the gauge). The connector will require a fi rm pull to remove it. When reinstalling the connector ensure that it is fully inserted. Both connector sockets on the rear of the gauge are the same, either one can be used.

Note:

08/06

Section 6Electrical

6-5

Panel is held to dashwith four screws

Gauge is heldto panel withthreaded lockcollar

Back of 2-inch gauges

Jumpers

GaugeCollar

TorqueTool

FIGURE 6-3. CVSG Gauges.

Data Bus Communication

The multiplexed instrumentation system uses several different data links to transmit input/output data from other systems to the Cab Electronic Control Unit (CECU), and ultimately to the Central Instrument Cluster and CVSG Gauges. See Figure 4, Multiplexed Instrumentation Block Diagram on page 6-6.

Panel is held to dash with four screws

Gauge is held to panel with threaded lock collar

Back of 2-inch gauges

Jumpers

08/06

Section 6Electrical

6-6

FIGURE 6-4. Multiplexed Instrumentation Block Diagram.

• V-CAN = Vehicle Controller Area Network

The V-CAN, also referred to as the J1939, is used to transmit data between the transmission, ABS system, engine, etc. to the Cab Electronic Control Unit (CECU).

• I-CAN = Instrumentation Controller Area Network

The I-CAN provides data link communication from the Cab Electronic Control Unit (CECU) to the Central Instrument Cluster.

• K-Line = Serial Data Bus Line for Diagnostics

The K-Line interface is used to provide data link communication to and from the Electronic Service Analyst (ESA) hardware/software diagnostic service tool and to and from the Cab Electronic Control Unit (CECU).

• CVSG Bus

The CVSG bus is a private data bus used to transmit data from the Cab Electronic Control Unit (CECU) to the individual 2-inch gauges. A series of “daisy chained” jumper harnesses link each gauge to another.

08/06

Section 6Electrical

6-7

The following diagram shows the locations of standard connectors in the wiring harnesses. This allows you to easily locate connectors to add gauges. To add an electronic gauge install the sensor (available from your local Kenworth dealer) in the noted location, plug in the wiring harness, and then install the gauge in the dash. The gauge will then need to be activated. Your local Kenworth dealer can easily activate the gauge using Kenworth’s Electronic Service Analyst (ESA).

FIGURE 6-5. Instrumentation Harness Interface Diagram

08/06

Section 6Electrical

6-8

The following diagrams show the location of sensors on the fi rewall junction block. This is to aid in locating these sensors.

FIGURE 6-6. Firewall Air Junction Block

FIGURE 6-7. Fuel Filter Restriction Pressure Gauge Sensor Location (typical)

08/06

Section 6Electrical

6-9

ACCESSING GAUGES AND SWITCHESIn order to access and install components described later on in the manual, you will need to know how to correctly remove

the dash panels without causing damage.

1. Remove trim bezel by prying upward at one of the four pry points. Carefully pry the remaining clips.

2. Remove (4) screws to remove Speedo - Tach panel.

08/06

Section 6Electrical

6-10

3. Unclip harness and remove Speedo - Tach panel.

4. Remove (7) screws to remove right gauge panel.

5. Unclip leads to gauges, effort is required to separate the friction lock.

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6. Pinch to unlock connector and remove right gauge panel.

7. Unscrew gauge collar to remove gauge.

8. To remove switches, push both tabs down...

...and then push switch out of plate on top side...

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...then fl ip over and do the same on the bottom side.

9. Push down to unhook connector from switch.

10. Remove (4) screws to remove left gauge panel.

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11. Pinch to unlock connectors from switches.

12. Unclip harness and remove left gauge panel.

13. Unscrew gauge collar to remove gauge.

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14. To remove switches, push both tabs down...



15. Push down to unhook connector from switch.

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ACCESSING SWITCHES IN THE UPPER DASH

1. Remove trim bezel by prying upward at one of the four pry points. Carefully unzip the remaining clips

2. Remove (4) screws to remove Upper Switch Cluster.

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3. Pinch to unlock connector and remove Upper Switch Cluster

4. To remove switches push both tabs down...



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5. Push down to unhook connector from switch

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TELLTALE SYMBOLSKenworth’s interior allows Body Builders to customize the dash telltale symbols (warning lights). The editable telltale symbols are located on removable cards inside the baseline cluster. This section will describe how to replace and insert editable cards, as well as how to activate the telltale lights.

To remove the editable cards follow steps 1-3 in the instructions for accessing gauges and switches (page 6-9). Remove the rubber access cover on the side of the cluster by pulling by hand. The access cards have a positive lock. To remove the card pry upwards on the lock with a small screwdriver and pull the card out with pliers. See Figure 6-8 below that details the cards. To reinstall a card slide it in either by hand or with pliers. New cards will come with the installation tab (as shown in the fi gure). After installing the card simply break off the tab by bending.

FIGURE 6-8. Telltale Symbol Standard CardsAll cards come with standard editable telltale lights, even if the chassis you have was not ordered with related compo-nents. The standard cards are shown above (in Figure 6-8). Editable cards are also available from your local Kenworth dealer. The left side editable card is shown in Figure 6-9 below.

FIGURE 6-9. Blank Telltale Card

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Your local Kenworth dealer will also sell a sheet of telltale light icons to install on the editable card. The symbols that are available are shown in Figure 6-10 below.

FIGURE 6-10. Telltale Icons

Courtesy Lamp Mounting Plate

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The telltales can then be peeled off of the sheet and applied directly to the card. The color of the telltale is controlled by the light, all of the icons are clear. Please see Table 6-1 below to determine the position and color of the telltales. (Posi-tions are shown on Figure 6-8)

Table 6-1. Telltales Position and Color

Position Standard Function Light Color Editable or Fixed?

1 Engine Retarder Green Fixed

2 Wait To Start Yellow Fixed

3 Fifth Wheel Slide Red Fixed

4 King Pin Lock Red Editable

5 Refrigerator Green Fixed

6 Park Brake Red Fixed

7 Check Transmission Red Editable

8 Transmission Temp Yellow Editable

9 Pump Mode Green Editable

10 Fasten Seatbelt Red Fixed

11 Blank Yellow Editable

12 PTO Yellow Editable

13 Emission Temp Warning Yellow Fixed

14 Message Waiting Green Editable

15 Trans Axle Lock Green Fixed

16 Trailer Body Up Red Fixed

Only the positions labeled as “editable” in the chart above can be changed. You must apply the standard icons on the editable card on all the positions that read “fi xed”.

In order to activate the editable lights (either on the standard card or the editable card) locate the wiring connections on pigtail connectors behind the right hand side gauge panel. The wires will be labeled and tagged with position numbers. The color of the tag corresponds to the color of the light. When these circuits are either grounded or powered the light in the dash will turn on.

Note:

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ADDITIONAL SPARE CIRCUITSKenworth provides the option of coding for spare switches, however you may want to wire into one of 26 spare circuits we provide. Kenworth also has provisions for fl at panel inserts that can be easily modifi ed or removed to add switches or gauges. The small panel is 5” x 5” and the large panel is 7.5” x 5”.

Do not install an electrical circuit that requires more amperage (electrical capacity) than what is available in the specifi c chassis circuit. An overloaded circuit could cause a fi re. 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.

The central electrical panel (CEP) has a total of 17 spare circuits (3 of which can be connected to spare relays on the CEP).

They include:

• 9 spare battery circuits

• 4 spare accessory circuits

• 4 spare ignition circuits

Some spare circuits may be used with factory installed options. For specifi c chassis questions please work with your Kenworth Dealer.

The CEP has two different options available for tapping into spare BATT, ACC, or IGN power. The two options are de-scribed in detail on the following pages.

WARNING!

Note:

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Adding Spare Switches Option #1: Spare Circuit Bullet Connectors1. Remove the LH gauge panel above ignition key switch.

2. From behind the gauge panel, locate one of the 20 spare BATT, ACC, or IGN bullet connectors not currently being used. See Figure 6-11.

FIGURE 6-11. Spare Bullet Connectors

3. Plug one end of a K333-127-2 pigtail harness into the appropriate spare circuit bullet connector. See Figure 6-12.

FIGURE 6-12. Spare Pigtail Connector

4. Connect the other end of the pigtail harness to the accessory. If the accessory is to be controlled by a dash switch, connect a ground wire to the switch, then to the accessory.

5. Install the correct rated fuse, or circuit breaker, into the fuse socket that corresponds to the spare circuit selected in step 2.

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Adding Spare Switches Option #2: Spare Circuit Relays (For loads exceeding 20 amps)

1. Remove the LH gauge panel above ignition key switch.

2. From behind the gauge panel, locate one of the spare relay connectors not currently used. See Figure 6-13.

FIGURE 6-13. Spare Relay Connectors

3. Plug one end of a spare relay harness (PN P92-1947-X) into the appropriate spare relay circuit connector.

Use a P92-1947-1 or -3 harness for a Normally Open (NO) spare relay circuit. Use a P92-1947-2 or -4 harness for a Normally Closed (NC) spare relay circuit.

Note:

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MULTIFUNCTION TURN SIGNAL STALKKenworth introduced the multifunction turn signal stalk along with the new interior. The information that follows covers the functions of the turn signal stalk, along with guidelines for installing additional lights on chassis.

Exterior Lighting Circuit LimitsThe Turn Signal Stalk (TSM) is designed to operate within specifi c current limits for

• headlamps

• vehicle stop/turn signal lamps

• trailer turn/vehicle forward side facing turn signal lamps

If the current limits for any of these circuits are exceeded, the TSM will default to a protection mode (see “TSM Failure Management” on page 4), causing the lamps to not function properly but still providing suffi cient lighting for safe operation of the vehicle.

The vehicle can exceed current ratings on a particular circuit in two ways

• Installing too many lamps on a circuit

• Using bulbs of excessive wattage

The following table is a recommended guideline to avoid exceeding the current limits of the TSM.

TABLE 6-2. TSM Guideline

Circuit TSM Current Limit General Lamp Limits

Low Beam Headlamp (LH or RH) 5.4A (6.1A for T660) (1) 65W bulb each side maximum*

High Beam Headlamp (LH or RH) 9.3A (6.7A for T660) (1) 65W bulb each side maximum*

Left Turn/Left Trailer Turn Lamps20A combined between left turn and left trailer turn

(9) #1156 or #1157 bulbs on left side of truck and trailer combined**

Right Turn/Right Trailer Turn Lamps20A combined between right turn and right trailer turn

(9) #1156 or #1157 bulbs on right side of truck and trailer combined**

Left Stop/Turn Combination Lamps 7.8A for left side (3) #1156 or #1157 bulbs per side**

Right Stop/Turn Combination Lamps 7.8A for right side (3) #1156 or #1157 bulbs per side**

*A maximum wattage of 65W should not be exceeded for either low or high beam headlamps.

**The maximum number of lamps can be exceeded if LED lamps are used in place of incandescent bulbs. LED type lamps draw far less current, but in any case, all lamps must not exceed the TSM current limits.

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REMOTE PTO/THROTTLE HARNESSThis option provides a connection from the engine ECU for remote control of engine throttle and PTOs. Options that extend the wiring to the end of frame also exist, however controls are not provided. A 12-pin Deutsch connector (Deutsch P/N DT06-12SA-P012) is included. See Table 6-3 and 6-4 below for wiring harness connector pin outs.

Adding Electrical Options

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.

Table 6-3. 2007 Cummins ISX and ISM.

Mating View Contact Function Circuit No.

1

2

3 COMMON RTN #1 (SWITCH) GRN3115

4 REMOTE THROTTLE SIGNAL BLU3144

5 PTO ON / OFF GRA3511

6 REMOTE THROTTLE ENABLE GRA3143

7 SWITCHED POWER (IGN) ORN1229

8 GROUND WHT1513

9 TORQUE LIMIT SWITCH GRA3149

10 V SUPPLY VIO3115

11 COMMON RTN #3 (SENSOR) GRN3117

12 REMOTE THROTTLE ON/OFF GRA3143

TABLE 6-4. 2007 CAT C15 and C13.

Mating View Contact FunctionPACCAR

Circuit No.CAT

Circuit No.CAT ECU

PIN #

1 PTO RESUME GRA3513 K982-YL 60

2 PTO SET GRA3512 K980-PK 58

3 COMMON RTN #1 (SWITCH) GRN3115 H795-PK 5

4 REMOTE PTO ACCEL POS BLU3144 G845-PU 68

5 PTO ON / OFF GRA3511 K999-GN 56

6 REMOTE THROTTLE ENABLE GRA3143

7 SWITCHED POWER (IGN) ORN1229 ORN1229

8 GROUND WHT1513 WHT1513

9 PTO ENGINE SHUTDOWN G841-GN 7

10 IGNORE BRAKE / CLUTCH SW GRA3195 G844-PK 46

11 COMMON RTN #3 (SENSOR) GRN3117 993-BR 3

12 PTO SWITCH ON LAMP E718-PK 10

WARNING!

A DIVISION OF PACR

Kenworth Truck Company

P.O. Box 1000

Kirkland, WA 98083

(425) 828-5000

®

Ken Worth Heavy Duty Bodybuilder Manual 1

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