Table of Contents P. 5-1
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1 Western Star odybuilder ook: Revision 3.1 Table of ontents P. -1 Section hassis omponents & DEF Locations hassis Frame Grid -2 WST hassis ir Tanks Overview -3 WST hassis ir Tanks /4900/ D hassis ir Tanks Fuel/Hydraulic Tanks /4800/4900/ /4900 SF/S DEF & Fuel Tank Locations /4900 DEF Tank Mounting SF/S 13 Gallon DEF Tanks SF/S 6 Gallon DEF Tank Locations DEF Tank Relocation Prep Rectangular Fuel Tanks EP - 48/49/69 att/tool ox onfigs EP /4900 attery/tool ox /4800/4900/6900 In ab attery ox Single and Double Person ox Mounting Person Passenger seat battery box vented to outside of cab -17 Pre-2010 EP - attery/tool ox -18 This guide is to be used as a reference document only. Please consult your Western Star E representative on specific spec ing needs as the information contained in this document can change without notice.
2 Western Star odybuilder ook: Revision 3.1 hassis Frame Grid P /4900/6900 Models Standard WST hassis Grid Models Standard D hassis Grid 0mm 0mm L Frame 0 ottom of Rail 0mm 2mm 0mm 7mm L 7mm Frame 0 WST Frame Rails Daimler ommon hassis (D) Frame Rails WST frame rails are designed to maintain a constant outside dimension of 34 with the exception of the 48 outer reinforcement. Frame 0.0 for these rails is located at the bottom of the rail with all dimension located up from this 0.0 point. This constant datum point provides body builders with a consistent working position regardless of the frame size. See Section 3 for more detailed Frame Information D frame rails are designed to maintain a constant main rail inside dimension of The frame 0.0 point of these rails is located at the center line of the rail web with all frame holes dimensioned up or down from the center of rail. For this reason frame size is a critical component that must be taken into account when locating components off existing hole patterns and calculating ride heights. See Section 3 for more detailed Frame Information
3 Western Star odybuilder ook: Revision 3.1 WST hassis ir Tanks Overview P. -3 ir System Overview Standard air system is broken down into 3 groups: Supply These tanks are used to hold the air from the compressor and capture most of the water which is passed on from the compressor and condensates in the tank as it cools. system or Primary Generally used for supplying the rear brakes. system or Secondary Generally used for supplying the front brakes. Note: systems will change based on individual customer requirements always check schematic to confirm line routing. ddition systems include: tank Used as lift axle supply tank. Receiver Tank Used with 24cfm or larger compressors to aid in the cooling of air before the air dryer. moisture ejector is mandatory in receiver tank applications. ir Tank Location Guide There are many factors that determine the size, quantity, and location of air tanks on any given vehicle. Some of the factors that determine the air tank size include: Ÿ Ÿ Ÿ rake size Number of xles Type of brakes (drum vs. disc) This information, along with government safety regulations, helps determine the volume of air required. The quantity and location of the air tanks is determined by the following: Ÿ Fuel Tank, type, size, and location Ÿ Exhaust type and location Ÿ Wheel-base Ÿ Engine/Transmission (including PTO's) Ÿ Other frame-mounted components (battery box, back-of-cab access steps, air dryer, etc.) Ÿ lear frame requests (module 607) Ÿ Location specific sales codes for air tanks (module 460) These last two points are often the customers most direct infuence on the location of air tanks. If you would like to keep air tanks out of a certain area then use a 607 code. ir drains are mounted in the lowest rear port of all air tanks; combination tanks will require an additional drain in the forward portion of the tank. ir tank quantities and sizes are calculated in engineering based on the total area requirements of the brake chambers on the truck and trailer. system air volume is generally larger than the system due to the rear axle supply requirements. See options chart on P /4900/6900 Perpendicular Mounting 4800/4900/6900 In rail and outside rail Mounting 4800/4900/6900 (Standard) below rail mounting 4700 In Rail/elow Rail combination 4700 elow rail mounting
4 Western Star odybuilder ook: Revision 3.1 WST hassis ir Tanks Overview P. -4 OPTION DESRIPTION STD EXT STEEL IR RKE RESERVOIRS X X LUMINUM IR RKE RESERVOIRS X X STEEL IR RKE RESERVOIRS MOUNTED INSIDE RIL X X STEEL IR TNKS MOUNTED ELOW FRME RILS X LUMINUM IR RKE RESERVOIRS MOUNTED INSIDE RILS X X LUMINUM IR RKE RESERVOIRS ND STEEL W D-IS (DRM) IR RESERVOIR X STEEL IR RKE RESERVOIRS MOUNTED T LEST 40 INHES FT OF INSIDE OR ELOW RILS X STEEL IR RKE RESERVOIRS MOUNTED PERPENDIULR TO OUTSIDE RIL X X STEEL IR TNKS MOUNTED FT INSIDE ND/OR ELOW FRME JUST FORWRD OF RER SUSPENSION X STEEL IR TNKS INSIDE RIL WITH HEVY DUTY RKETS PREFERRED; OTHERS ELOW RIL WITH HEVY DUTY RKETS X X STEEL IR TNKS MOUNTED UNDER TTERY OX WHEN POSSILE (NON-DRM TNKS ONLY) X LUMINUM IR TNKS MOUNTED UNDER TTERY OX WHEN POSSILE (NON-DRM TNKS ONLY) X STEEL IR RKE RESERVOIRS MOUNTED PERPENDIULR TO OUTSIDE RIL RHS JUST FORWRD OF RER SUSPENSION. X STEEL IR RKE RESERVOIRS MOUNTED PERPENDIULR TO OUTSIDE RIL LHS JUST FORWRD OF RER SUSPENSION. X STEEL IR RKE RESERVOIRS MOUNTED INSIDE RIL ND UNDER TTERY OX X LUMINUM IR RKE RESERVOIRS MOUNTED INSIDE RIL ND UNDER TTERY OX X LUMINUM IR TNKS MOUNTED FT INSIDE ND/OR ELOW FRME JUST FORWRD OF RER SUSPENSION X RN REGISTERED STEEL IR TNKS INSIDE RIL PREFERRED; OTHERS ELOW RIL WITH HEVY DUTY RKETS X X STEEL IR RKE RESERVOIRS, NO TRIPLE OR TORPEDO TNKS X LUMINUM IR RKE RESERVOIRS, NO TRIPLE OR TORPEDO TNKS X STEEL IR RKE RESERVOIRS; USTOMER EPTS TNKS MOUNTED PERPENDIULR TO RIL X LUMINUM IR RKE RESERVOIRS; USTOMER EPTS TNKS MOUNTED PERPENDIULR TO RIL X STEEL IR RKE RESERVOIRS MOUNTED PERPENDIULR RH UNDER X LUMINUM IR RKE RESERVOIRS MOUNTED PERPENDIULR RH UNDER X STEEL IR RKE RESERVOIRS MOUNTED PERPENDIULR RH UNDER ND FT S POSSILE FOR REMINING TNKS X LUMINUM IR RKE RESERVOIRS MOUNTED PERPENDIULR RH UNDER ND FT S POSSILE FOR REMINING TNKS X 460-1E STEEL IR TNKS MOUNTED FOR MX GROUND LERNE, (ELLY PLOW ) X 460-1F LUMINUM IR TNKS MOUNTED FOR MX GROUND LERNE, (ELLY PLOW ) X 460-1G LUMINUM IR RKE RESERVOIRS MOUNTED PERPENDIULR TO OUTSIDE RIL X X 460-1H STEEL IR RKE RESERVOIRS MOUNTED INSIDE RIL WITH NO OUTORD RKETS X 460-1J STEEL IR RKE RESERVOIRS MOUNTED PERPENDIULR RH UNDER ND INSIDE RIL FOR REMINING TNKS X 460-1K LUMINUM IR RKE RESERVOIRS MOUNTED PERPENDIULR RH UNDER ND INSIDE RIL FOR REMINING TNKS X 460-1M STEEL IR RKE RESERVOIRS MOUNTED INSIDE RIL; USTOMER EPTS TNKS MOUNTED IN RER OVERHNG/RER SUSPENSION X 460-1N LUMINUM IR RKE RESERVOIRS MOUNTED INSIDE RIL WITH NO OUTORD RKETS X
5 Western Star odybuilder ook: Revision 3.1 WST hassis ir Tanks /4900/6900 P u. In. Tank Volume Dim /900 comb ½ NPTF (6) 1/4 NPTF (2) 12 o 3/8 NPTF (1) ½ NPTF (6) 1/4 NPTF (2) 1.2 In Rail Tank o " 2.7" 2.2" R (Tank).87" 10.7" elow Rail Tank
6 Western Star odybuilder ook: Revision 3.1 D hassis ir Tanks P. -6 Option Description Steel air brake reservoirs luminum air brake reservoirs Steel air brake reservoirs mounted inside rail Steel air tanks mounted below frame rails luminum air brake reservoirs and steel bw ad-is (drm) air reservoir Steel air brake reservoirs mounted at least 40" aft of cab inside or below rails Steel air tanks mounted aft inside and/or below frame just forward of rear suspension luminum air brake reservoirs mounted perpendicular RH under cab Steel air brake reservoirs mounted perpendicular RH under cab Perpendicular tanks under cab RH mm 2mm 130, 1740 ir Tank, Mounted Inside Rail 47mm mm L Frame Rail L Frame Rail 100mm 2mm , 2030 ir Tank Mounting 900 ir Tank Triple, 12", elow Rail mm 8.6 2mm 100mm Secondary Primary 40mm 100mm 1740, 2030 ir Tank Mounting 1740 Tank shown 2mm L Frame Rail 16.3 Supply mm 11.9
7 Western Star odybuilder ook: Revision 3.1 Fuel/Hydraulic Tanks /4800/4900/6900 P ½ NPT D Hydraulic Tanks Data ode Dimension D 23" Diameter Gallon 30.0" 1.7" 1.7" 23" allon 3." 1.7" 1.7" 23" allon 46." 19.7" 1.7" 23" allon 8.0" 19.7" 1.7" 23" 2" Diameter allon 30." 16.2" 16.2" 2" allon 40.0" 16.2" 16.2" 2" allon 0.0" 20.2" 16.2" 2" This Flange and Plug Omitted on 0 and al Tanks D 23" Diameter " Diameter Fuel Tanks Data ode Dimension D 204/ Gallon 30.0" 1.7" 1.00" 23" 204/ allon 3." 1.7" 17.7" 23" 204/ allon 46." 1.7" 17.7" 23" 204/ allon 8.0" 19.7" 17.7" 23" 204/ Gallon 69.0" 19.7" 17.7" 23" 204/ Gallon 86.0" 1.7" 17.7" 23" 204/ allon 30." 1.2" 1.2" 2" 204/ allon 40.0" 17.2" 20.2" 2" 204/ allon 0.0" 17.2" 20.2" 2" 204/ Gallon 61." 17.2" 20.2" 2" 204/ Gallon 73.0" 19.2" 20.2" 2" Diesel Fuel affle Hydraulic ombination Tanks 2½ NPT D 23" Diameter " Diameter Fuel/Hydraulic Split-Tanks Data ode Gallons Fuel / Hydraulic D 204/ /0 7.20" 16.2" 16.2" 23.0" 204/ / " 16.2" 16.2" 23.0" 204/ / " 16.2" 16.2" 23.0" 204/ / " 16.2" 16.2" 23.0" 204/ / " 16.2" 2.0" 204/ /60 2.6" 17.2" 16.2" 2.0" 204/ / " 16.2" 2.0" 204/ /6 62.1" 17.2" 16.2" 2.0" 204/ / " 19.0" 16.2" 2.0"
8 Western Star odybuilder ook: Revision /4900 SF/S DEF & Fuel Tank Locations P /4900 Diesel Exhaust Fluid (DEF) / Fuel Tank onfigurations: WST hassis DEF Tanks are offered in 3 sizes to comply with EP guidelines. DEF tanks are to be filled no less than once every 2.3 fuel tank fills. Tanks 100 gallons and less can use the 6 gallon DEF tank configuration. Larger tanks require the 13 and 23 Gallon configurations. Larger DEF tanks can also be ordered for small tanks if customers want to incorporate DEF refills into monthly maintenance programs. 13 Gal/23Gal DEF Tanks 6 Gal DEF Tank D F axle to O Model 4800S 4800SF 4900S 4900SF 4900EX DEF Tank Fuel Tank Fuel Tank Size Dia Volume (Fuel) (O Protrusion) 23 Gallon DEF 23 Gallon DEF 23 Gallon DEF 23 Gallon DEF 23" 23" 23" 23" 0 G Gallon DEF 23" 120 G Gallon DEF 23" 10 G Gallon DEF 2" Gallon DEF 2" Gallon DEF 2" Gallon DEF 2" 12 G Gallon DEF 2" 10 G Gallon DEF 2" Gallon DEF 2" Gallon DEF 2" Gallon DEF 2" 12 G Gallon DEF 2" 10 G Gallon DEF 2" Gallon DEF 2" Gallon DEF 2" L Gal D Front xle to Frame 0 23 and 13 Gal DEF enter Fwd axle to O Fuel Tank and D Dimensions O Fuel 2 O Offset (6 Gal) 4900SF 4900S 4900SF 4900S 4900SF Dim " 3.0" 3.1" 36." 42.6" D
9 Western Star odybuilder ook: Revision /4900 DEF Tank Mounting Tank ack Model pplication 4900S 6900XD 4900EX 4900SF 4900EX 4900S 4900SF 4900S 4900SF 123" 141" 132" 123" 132" 123" 123" 109" 109" Tandem Steer XD "EX" LowMax SF" LowMax EX S SF S SF P and 23 Gal DEF Tank Location (Forward Mount only) Set ack Fwd Face Loc'n From DEF Tank DEF Tank Dimension from ft Face ft Face enter Line Front xle 13 Gallon 23 Gallon Station 0" Gal DEF tanks mount rear of Fuel tanks 23 Gal 13 Gal DEF Tank Size Maximum Fuel ap 6 gal 100 gal 13 gal 200 gal 23 gal 300 gal 6 Gal WESTERN STR 13 and 23 Gal DEF tanks mount forward of fuel tanks in all configurations Model 4900S 4900S 4900S 4800SF 4800SF 4800SF 4800S 4800S 4800S 123" 123" 123" 109" 109" 109" 109" 109" 109" 6 Gal DEF Tank ft Location (Rear Mount Only) Fuel Set ack Rear Face Loc'n From Tank Dim'n from Station enter Line Front xle Dia "0" (inches) (inches) Fuel Tank Gallons 60G 80G
10 Western Star odybuilder ook: Revision SF/S 13 Gallon DEF Tanks P DEF Tank onfigurations 4700 DEF Tanks are also offered in 3 sizes to comply with EP guidelines. DEF tanks are to be filled no less than once every 2.3 fuel tank fills. Tanks 100 gallons and less can use the 6 gallon DEF tank configuration. Larger fuel volumes require the 13 Gallon configuration. Larger DEF tanks can also be ordered for small tanks if customers want to incorporate DEF refills into monthly maintenance programs. Please contact your E representative for more information on the 23 gallon DEF tank. DEF Tank Size Maximum Fuel ap 6 gal 100 gal 13 gal 200 gal 23 gal 300 gal 4700 SF 13 Gal DEF Forward to 4. depending on tank size Fuel Tank ack of ab (O) Model 4700 SF 4700 S DEF Tank Size 13 Gal Def Forward of Fuel 13 Gal Def Forward of Fuel Fuel Tank Dia 2" Diameter 23" Diameter 2" Diameter 23" Diameter Fuel Tank Volume 0 G 0 G (Fuel) (O Protrusion) S 13 Gal DEF Forward 43.4 L 4700S xle Fuel Tank ack of ab (O) L 4700SF xle
11 4700 DEF Tank onfigurations Western Star odybuilder ook: Revision SF/S 6 Gallon DEF Tank Locations 4700 DEF Tanks are also offered in 3 sizes to comply with EP guidelines. DEF tanks are to be filled no less than once every 2.3 fuel tank fills. Tanks 100 gallons and less can use the 6 gallon DEF tank configuration. Larger fuel volumes require the 13 Gallon configuration. Larger DEF tanks can also be ordered for small tanks if customers want to incorporate DEF refills into monthly maintenance programs. Please contact your E representative for more information on the 23 gallon DEF tank. DEF Tank Size Maximum Fuel ap 6 gal 100 gal P gal 200 gal 4700 SF 6 Gal DEF Fwd Fuel Tank ack of ab (O) Model 4700 SF 4700 S DEF Tank Size 6 Gal Def Forward of Fuel 6 Gal Def Rear of Fuel Fuel Tank Dia 2" Diameter 23" Diameter 2" Diameter 23" Diameter Fuel Tank Volume 0 G 0 G (Fuel) (O Protrusion) to 34 depending on tank size 4700 S 6 Gal DEF Rear Fuel Tank ack of ab (O) 8.4 L 4700SF xle L 4700S xle
12 Western Star odybuilder ook: Revision DEF Tank Relocation Prep 43X LH temporarily mounted diesel exhaust fluid tank aft back of cab with maximum approved length def lines coiled at def tank. This option provides the maximum length coolant lines and electrical Harness coiled in the frame with the DEF tank mounted rear of the fuel tank. Lis location provides the maximum forward position for fuel and maximum frame space rear of the cab. For more frame space the coiled DEF lines allow easy relocation of DEF tank into body or rear on frame to clear components. onsult the Exhaust modifications for DEF placement height and distance requirements. Max Length DEF Tank Harness ref Installation drawings in Mod 43V Detroit: PN# ummins: PN# DD13 HRN-TS-JMPR,13+23G,HTR - ISL HRN-TS,DEF TNK,STD Max Length DEF Tank Hose Lines ref Installation drawings in Mod 43W PN# PN# LUE,/8"NM,.94"OD EXESS DEF TNK - RED,/8"NM,.94"OD EXESS DEF TNK 4700S with 23 Dia Tanks 4700SF with 23 Dia Tanks L L L Fuel tank position moves rear with smaller tanks to accommodate Perp air tanks 0 GL 4700S With 2 Dia Tanks L L L 0 GL 4700SF With 2 Dia Tanks L L L L DEF tank mounted rear of tank regardless of tank volume L DEF tank mounted rear of tank regardless of tank volume L The truck comes equipped with max length DEF lines and harness to accommodate easy repositioning of DEF Tank P. -12
13 Western Star odybuilder ook: Revision Rectangular Fuel Tanks P Rectangular Fuel Tanks (Snow Plow Only) RETNGULR LUMINUM FUEL TNK - LH Tank al/227 Liter 90 Gal/340 Liter Depth 18." 18." Height 14.8" 14.8" Length 63.6" 8.1" 6 Gallon FWD Mounted DEF with a 90 Gallon fuel tank on a 4700SF. lso available with a 13 Gallon DEF tank. Note: Rectangular fuel tanks are not available on 4700S with a DD 13 engine for Snow Plow configurations.
14 Western Star odybuilder ook: Revision EP - 48/49/69 att/tool ox onfigs im Lid D 36.9 ox Dim 3.6 im Lid D 3.8 ox Dim TT/TOOL OX OMO OX im id D Dim L x.0 17 o.7 1 im Lid D im D ox STK TOOL OX DEF TNK STK LONG TOOL OX DEF TNK TT/TOOL OX at/tool/def Tank ox Lid Mounting OMO OX P. -14
15 Western Star odybuilder ook: Revision EP /4900 attery/tool ox P. -1 Stacked attery/tool ox DEFTank ombo ox 3.6 att/tool ox ox over Top View Side View Long Stacked attery ox Side View attery ox Frame racket
16 Western Star odybuilder ook: Revision /4800/4900/6900 In ab attery ox Single and Double Person ox Mounting D / Two Person attery ox Seat Description Dimension etween Seat ase 21" etween Seat ushions - ostrom 1" etween Seat ushions - National 14" / One Person attery ox Seat Description Dimension etween Seat ase 34.7" etween Seat ushions - ostrom 27." etween Seat ushions - National 28." Person Seat (4) atteries D 1 Person Seat (3) atteries P. -16
17 Western Star odybuilder ook: Revision /4800/4900/6900 In ab attery ox P Person Passenger seat battery box vented to outside of cab Storage Tray Two man Seating 14.0 mple room for ontrols see next page for exact details Front Storage can also be used to mount hardware storage tray WST s two man seating option with in cab batteries provides extra storage and seating for 3 people comfortably while at the same time offering clear frame space and ample room for in cab controls L ab L Seat ack ngle ack View Side View Typical seat belt installation for 2-man, box base seat Side Wall
18 Western Star odybuilder ook: Revision 3.1 Pre-2010 EP - attery/tool ox P (4) bottom of rail rackets Mounted Outward Out Figure #1 Description Drilling "" "" "" 4/4 ox rkts - Out FD " 17/32" 31.7" 4/4 ox rkts - Out FD " 21/32" 31.7" 4/4 ox rkts - Out FD " 17/32" 31.7" 4/4 ox rkts - Out FD " 17/32" 31.7" 4/4 ox rkts - Out FD " 17/32" 31.7" 4/4 ox rkts - I/O FD " 17/32" 31.7" 4/4 ox rkts - I/O FD " 17/32" 31.7" 4/4 ox rkts - Out FD " 17/32" 31.7" 4/4 ox rkts - In FD " 17/32" 31.7" rackets Mounted Inward IN 3/4 ox rkts - Out FD " 17/32" 23.94" 3/4 ox rkts - Out FD " 17/32" 23.94" 3/4 ox rkts - I/O FD " 17/32" 23.94" 3/4 ox rkts - I/O FD " 17/32" 23.94" 3/4 ox rkts - Out FD " 17/32" 23.94" 3/4 ox rkts - In FD " 17/32" 23.94" Figure #2 Figure #3 1 racket Mounted Inward Position and 1 racket Mounted Outward Position NOTE: rackets mounted Outboard is the standard mounting configuration (Figure #1). rackets mounted in the inward position requires less frame rail real-estate (Figure #2). combination of one bracket mounted inward position and one bracket mounted outward position Figure #3 allows for addition allows for less frame rail forward or aft of box. Mounting configuration 2 or 3 allows other components either inside of rail or out side of rail to be located closer to the battery box.. 1/2 ox rkts - I/O FD " 21/32" 17.12" 1/2 ox rkts - O/I FD " 21/32" 17.12" 1/2 ox rkts - Out FD " 17/32" 17.12" ½ ox rkts - Out FD " 17/32" 17.12" 1/2 ox rkts - Out FD " 17/32" 17.12" 1/2 ox rkts - I/O FD " 17/32" 17.12" 1/2 ox rkts - I/O FD " 17/32" 17.12" 1/2 ox rkts - Out FD " 17/32" 17.12" 1/2 ox rkts - In FD " 17/32" 17.12"
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