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UC Commercial Bus Body Builder

1. 5 Crossmembers Crossmember Location 169 Wheelbase WB CENTERLINE CENTERLINE gt FRONT AXLE REAR AXLE 169 WB 4300 dii 190 0554 g 7 102 5 79 O 2603 TM c CET 1 Je n LLL d 7 I 5 5 9 ds c o gt l 9 o Z Le ds ym UY y wee u Y H v wu 6 p W AF FUEL TANK o A B 777 i o o 512 T 52 Sy i B 64 7 e 1645 ur A 11 JA 1 L m Z mtt B V ur N AF FUEL TANK 22 2 S Ae SINGLE STAMPED CROSSMEMBER WITH FLAT FLANGE UP DOUBLE STAMPED CROSSMEMBER WITH FLAT FLANGE UP FUEL TANK CROSSMEMBERS D SINGLE STAMPED CROSSMEMBERS WITH FLAT FLANGE DOWN UC COMMERCIAL BUS 63 UC crossmembers 169wb IC BUS U C COMMERCIAL BUS
2. I 99 Engine Location m 100 L c 101 Rear Axles amp Rear Suspensions Rear Axle 103 Rear Suspension Bracket Location sese 104 Fuel Tanks Fuel Tank nnns 109 c C C 3 3 D D o C lt lt o o o o lt UJ IC BUS UG COMMERCIAL BUS ii Cab Door Swing Clearance Air Conditioning System Modifications 113 Instrument Panel I T COD DIMENSIONS tuu 114 lt C o 3 E D 4 3 D o C gui lt c o O F e o lt lt PREFACE FOREWORD The Commercial Bus Cutaway Bus Chassis Body Builder contains information related to the features and specifications for the UC Commercial Bus product line Disclaimer The Body Builder Book provides product information to assist those who wish to modify these products for individual applications Navistar Inc does not recommend or approve any firm or party nor make any judgements on the quality of the work performed by a particular firm or party Individuals who use the services of a Body Builder must satisfy themselves as to the quality o
3. C 3 3 D D o O lt o o o lt 4 ee eee LE AXLE e 4 5 E Manufactured in Canada we ENE KG yx www WW MMY eee ee WX XXX LBL wy Xa XE KEK Yw xww WIM z34556758BSDlz2345567 DATE Mi VN Figure 1 3 Incomplete Vehicle Information Labels 0008 0009 U C COMMERCIAL BUS 11 IC BUS U C COMMERCIAL BUS dd IC BUS Canada All IC Bus Incomplete Vehicles manufactured and sold in Canada must also have a Canada National Safety Mark and National Emissions Mark affixed to the vehicle reference Figure 1 4 O 0010 Figure 1 4 Canada National Safety Mark and National Emissions Mark c 3 D 29 c D lt c D o lt UJ Intermediate Manufacturer Definition Section 567 3 of Title 49 of the CFR defines an INTERMEDIATE MANUFACTURER as a person other than the Incomplete Vehicle Manufacturer or Final Stage Manufacturer who performs manufacturing operations on a vehicle manufactured in two or more stages Compliance Responsibility In accordance with section 568 4 of Title 49 of the CFR Navistar Inc furnishes an Incomplete Vehicle Document with each incomplet
4. 3 D c e lt c D o lt UJ Special Service Tools Hydraulic Unit Model No 940 Used for removal and installation of the Huck Bolt O O o 7 gt o C gui lt o C o o o lt Figure 2 21 Hydraulic Unit 01 0031 U C COMMERCIAL BUS 55 IC BUS UC COMMERCIAL BUS 56 Nose Assembly Tool ym NOSE ASSEMBLY TOOL Figure 2 22 Nose Assembly Tool 01 0032 Table 1 12 Nose Assembly Tool Description Tool Number For 1 2 Dia Fastener 99 1484 For 5 8 Dia Fastener 99 1481 IC BUS C C E E D D o C lt o C D o o lt Hydraulic Installation Tool Figure 2 23 Hydraulic Installation Tool 01_0033 Table 1 13 Hydraulic Installation Tool Description For 1 2 Dia Fasteners For 5 8 Dia Fasteners Collar Removal Tool Tool Number 557 585 Table 1 14 Collar Removal Tool Description For 1 2 Dia Fasteners For 5 8 Dia Fasteners Order tools from Huck International Inc P O Box 2270 One Corporate Drive Kingston NY 12401 U C COMMERCIAL BUS cB Tool Number 516 520 Phone 914 331 7300 Fax 914 334
5. 55 SPAN XXX SOR x ORR 4 S Harness Connectors Viewed from Mating End Mating Connector x AX 555 SS Connector Connector Lock 352874C1 352875C1 Terminals 1667742C1 Wire Gauge Cable Seal 16 18 20 1661872C1 2 55 7205 gt UOU 08 0021 08 0220 U C COMMERCIAL BUS IC BUS U C COMMERCIAL BUS 98 It BUS THIS PAGE INTENTIONALLY LEFT BLANK D c o O F lt lt o O O o lt lt ENGINE MopEL 4x2 Cooling Obstruction Guidelines 57 8 1468 TOMIRROR 87 0 2210 FENDER WIDTH om XS pA M 61 8 1570 TO HEADLAMPS 85 0 2158 BUMPER WIDTH NOTE DO NOT OBSTRUCT AIR FLOW IN FRONT OF GRILLE OR BELOW BUMPER UG COMMERCIAL BUS 99 UC front view c 3 3 D 5 gt D 00 lt o lt o gt o 00 o lt 00 c D IC BUS U C COMMERCIAL BUS 100 It BUS MODEL 4x2 C Engine Location o 5 m mnt E w FRONT VIEW 154 cary 5 s gt AD 3 CENTER LINE 5 X OFFSET TO OF CRANKSHAFT RIGHT SIDE N D Sea m
6. serene 30 CORO IUE 32 l HOA i Tm 32 Repair and Reinforcement Recommended Procedures 34 Bolt and Torque Information 0 I n T 46 Special Service Tools 55 After Market Modifications nasa 58 Wheelbase 60 Frame Rail Specifications Cross Section 61 sostenida DU Rerum und uenit DUE du 62 U C COMMERCIAL BUS Frame Drilling Guidelines enne 67 Frame Drilling Restrictions Tapered Rails 68 Frame Height 69 Front Axles gings 77 Front Suspensions Front Suspension Brackets sse 79 Brakes Brake 81 Hydraulic Control Unit Plumbing nenne 02 Hydraulic Brake System With 3 Channel ABSc 83 G Ill i u uu u uuu 84 Steering Steering Gear Location Dimensions l a 85 Electrical Battery Box Location 95 Engine Cooling Obstruction Guidelines
7. lt The frame must be properly aligned as this affects body axle and suspension mounting If the vehicle has been involved in accident or has been overloaded it is recommended that the frame be checked for proper alignment Pre Alignment Inspection Before checking alignment park vehicle on level ground and set parking brake Inspect frame assembly for loose parts welds cracks and bends Be sure to make all necessary repairs before attempting to check frame alignment Method of Checking Frame Alignment A satisfactory method of checking the frame and axle alignment particularly when a body and cab is on a chassis is to 1 Place a plumb bob against the point of measurement All measurements must be taken with the plumb bob positioned against bare metal 2 Tack or tape pieces of paper to the floor directly under each point of measurement on the chassis as indicated by the letter in Figure 2 2 Figure 2 2 Centerline of Chassis 01_0012 Method of Checking After each measurement point has been carefully marked on the floor proceed as follows c O 3 e c e D lt c D lt UJ L 1 1 Locate centerline of chassis by measuring front and rear end widths using marks on floor If frame widths are within specification draw centerline on floor the full length of t
8. D lt c o D o lt SN TL lt 9 5 156 2 241 6 Bus 79 BUS U C COMMERCIAL BUS 80 It BUS THIS PAGE INTENTIONALLY LEFT BLANK D c o O F lt lt o O O o lt lt BRAKES MopEL 4x2 Brake Restrictions Safety Measures Should it be necessary to modify the braking system for example in connection with a wheelbase alteration the following must always be observed Make sure that the brake circuits are not altered Before any part of the braking system is dismantled mark the brake pipes and connections concerned or make a sketch showing the original routing Avoid joints preferably change the entire brake pipe Preferably use bent brake pipes instead of elbow unions so as not to affect the brake application release times Install the brake pipes in positions where they are protected against damage and heat Install the air tanks so that the drain valves still function well and are easy to reach CAUTION When a brake pipe is replaced or jointed use only genuine IC Bus parts of the correct type NOTE On vehicles with ABS brakes the sensor cable must not be jointed If necessary it must be completely replaced C 3 3 D
9. D UJ o m lt UJ o o UJ lt UJ L 1 U C COMMERCIAL BUS Bes IC BUS IC BUS 82 U C COMMERCIAL BUS MODEL 4x2 UC Commercial Bus Cutaway Bus Chassis Body Builder October 2011 04 0108 Hydraulic Control Unit Plumbing x v CROSSMEMBER REAR CAB 1 4 TUBE TO SECONDARY MASTER CYLINDER 1 4 TUBE TO 2 84 LL MASTER CYLINDER 1 4 TUBE TO 1 4 TUBE TO PRIMARY LEFT FRONT 1 4 TUBE TO REAR CIRCUIT Hydraulic Control Unit Plumbing Hydraulic Brake System With 3 Channel ABSc with Brake System Code 04087 ABS Wheel c C C 3 3 D 1 D UJ m lt UJ o o UJ lt UJ secondary Brake Hosmz Primary Brake Hosmz Includes Fhid Level Switch 04 0079 U C COMMERCIAL BUS 83 IC BUS U C COMMERCIAL BUS 84 IC BUS ALL MODELS Routing Guidelines If modifications are made to International vehicles with the addition or re routing of tubing the following guidelines found in the Federal Motor Carrier Safety Regulations Pocketbook section 393 45 should be followed Be designed and constructed in a manner that insures proper adequate and continued functioning of the tubing or hose Be installed i
10. 3 3 D 2 c e D lt c D o 72 lt U C COMMERCIAL BUS 37 IC BUS U C COMMERCIAL BUS 38 IC BUS 1 V GROOVE INTO SOUND METAL 2 COPPER CHILL STRIP 3 FRAME RAIL 4 V GROOVE 5 CRACK 6 WELD GROUND FLUSH WITH FRAME GRIND IN c O o 3 T c o lt LONGITUDINAL DIRECTION OF SIDEMEMBER o lt Figure 2 4 Use of Chill Strip 01_0014 High Strength Low Alloy Steel Frames 50 000 60 000 and 80 000 PSI Yield Strength Any of the electric arc methods previously described may be used The choice of a suitable electrode or wire depends somewhat upon the equipment available for welding and the method selected The SMAW and the GMAW methods are preferred for welding the HSLA frames The use of low hydrogen electrodes is recommended Refer to Table 1 8 for selection of recommended electrodes and wires or refer to A W S A 5 standard available from www aws org for equivalent strength electrodes wires or rods and power leads to be used in the welding methods The double V notch weld preparation using the weld procedure shown in Figure 2 4 is the preferred welding method Table 1 8 Recommended Electrodes and Wires Recommended Electrode and Wire Material Strength PSI Amperage and voltage recommendations for welding are shown
11. 1 D UJ m lt UJ o o UJ lt UJ L 1 IC BUS U C COMMERCIAL BUS 110 It BUS MODEL 4 2 Fuel Tank Location Continued Code 15STD Single Mounted Between Rails Behind Rear Axle 55 Gallon with Fuel Fill Tube 3 5 Per EPA Title 40 Part 86 86 007 35 c the decal shown 13 9 90 below must be installed on the vehicle 352 Decal is included with Owner s Guide Kit located in the cab glove box CET 252 6 4 SULFUR 15 0005 INSTRUCTIONS FOR DECAL PLACEMENT 56 2 1426 1 The decal must be placed as close as possible to the fuel inlet and be clearly visible c o 3 4 D c o r 5 lt c o D N o o o lt 6 1 155 with 169 4300 WB 21 7 551 with 195 4950 WB 2 The decal should be placed above or to the side of the fuel cap to avoid corrosion by possible contact with fuel 23 0 8 0 3 3 The decal may be placed on aerodynamic fairings 6 3 57 20 7 bodies etc as long as the decal is clearly visible and 159 in close proximity to the fuel inlet 8 5 4 For installed bodies that have a fuel door e g 217 buses the decal should be placed above or to the side of the fuel door Thoroughly clean the area of all grease dirt etc before application of the decal
12. 7 0 LIST t BELL V JEN LEE 202 9902 No Y L o IN mn I r p LX m 3 CHASSIS C ENGINE FRONT SPRING EYE REAR FACE OF B FLYWHEEL HOUSING 12 0213 MODEL 4x2 Engine Port Location International MaxxForce 7 Type NPTF PTF Usage Water W1 Air Compressor Water Supply W2 Air Compressor Water Return W3 Deaeration Supply W4 Heater Supply w Block Heater we Engine Water Inlet w Engine Water Outlet W8 Heater Return Air A1 Turbo Outlet Exhaust A2 ___ Turbo Air Outlet to Inter Cooler A3 om Engine Air Inlet from Inter Cooler A4 Engine Air Inlet from Air Cleaner Oil L1 Supply Air Compressor L2 Return Air Compressor 3 Engine Oil Fill L4 OilLevel Gauge 5 OilFilter 3 3 gt UJ O lt o C o lt D Fuel AH a DES T F1 Fuel Supply 2 a s e F2 Fuel Return Xr ARES m Hydraulic H1 7 8 14 Power Steering Hydraulic Line H2 Power Steering Pump Supply Line 12_0214 U C COMMERCIAL BUS 101 IC BUS U C COMMERCIAL BUS 102 IC BUS THIS PAGE INTENTIONALLY LEFT BLANK D
13. Amperage and voltage recommendations for welding are shown in Table 1 11 Table 111 SMAW Method Heat treated Frames Position Amperes Voltage Downhand 130 140 21 23 Overhead 130 140 21 23 Vertical Up 110 120 22 24 c 3 D c mp D lt c D o lt A heavy copper chill strip should be clamped to the rail side away from the groove to help control the temperature and cooling rate during welding Figure 2 4 Short lengths of discarded heavy copper electrical bus bars make suitable chill strips Preheat the frame rail along the crack area to 500 600 F 260 316 C Either alternating current or direct current reversed polarity combined with a short arc and a beading or narrow weave technique may be used Direct current reversed polarity is recommended Slag should be removed after each pass and an interpass temperature of 200 F 93 C should be maintained Grind smooth and flush with surrounding sidemember material in a direction that is parallel to the longitudinal axis of the sidemember Figure 2 4 A V groove is ground from the side opposite the repair and the procedure outlined above repeated Chill strips should be used whenever possible The V groove ground on the opposite side of the repair should be deep enough to enter the sound metal of the first weld repair as shown in Figure 2 4 Reinfor
14. NOTE INSTALLATION OF THE REINFORCEMENT 11 TYPIGAL ON THE INSIDE 15 PREFERRED FOR STRENGTH D RAIL HEIGHT LOCAL FLAT PLATE REINFORCEMENT LOCATION BOLTS ADDED TO SECURE REIN FORCEMENT IN SPECIFIC MODEL BOOKS FOR MINIMAL VALUE FORAAND B ZONE OF APPLICATION FOR FLAT PLATE APPLICATION 75 3 D c mp lt c D o lt E RUN OFF BLOCK FOR WELDING SIDEMEMBER EDGE ZONE Y 77 WELD REFAIR MUST NOT EXTEND BEYOND THIS ZONE 1 EN HOLE DRILLEC P AT CRACK ZONES Y amp Z ARE DRILL RESTRICTED GROOVE BLOCK ZONES TO MATCH FLANGE SEE FRAME DRILLING DIAGRAMS GROGVE IN SPECIFIC MODEL BOOKS FOR RUN OFF BLOCK CLAMP TO SIDEMEMBER MINIMAL VALUE FOR AAND B NOT TACK WELD TO Figure 2 5 Reinforcement Application 01_0015 Cracks which occur in the critical zones have a greater probability of growing vertically through the section and the reduced strength after weld repair necessitates a more substantial reinforcement These guidelines potentially affect the structural integrity of the frame assembly and are intended for those who have the equipment and experience required to qualify as frame repair specialists General Weld Repair Reinforcement Procedures 1 The thickness and material strength of the local plate L and channel reinforcements should match the sec
15. U C COMMERCIAL BUS Wheel axis to bottom of frame in unladen position Refer to tabulated data Wheel axis to bottom of frame in loaded position Refer to tabulated data Frame rail height Refer to tabulated data otatic Loaded Radius The distance from the wheel axis to the ground for a properly inflated fully loaded loaded to its maximum capacity tire To obtain tire dimensions contact the tire manufacturer Tire Radius one half of tire outside diameter not mounted on the vehicle To obtain tire dimensions contact the tire manufacturer Calculated Tire Radius on an unloaded chassis The value of is calculated using the following method R R 2 R SLR Front Frame Height at the front axle centerline in unloaded condition Front Frame Height at the front axle centerline in loaded condition Y D R for unloaded condition Y SLR for loaded condition Values calculated for Y and Y are strictly for the frame height at the front axle centerline For frame heights at the front of the frame rail refer to Model 4x2 on page 74 in this book 69 c C C 3 3 D D o C 95 lt lt o o o o lt D L 1 IC BUS U C COMMERCIAL BUS 70 It BUS MODEL 4X2 Frame Height Data Front Front Suspension Spindle to Bottom of Frame Type Capacity Unloaded D Loaded 6 000
16. c o O F lt lt o O O o lt lt REAR AXLES amp REAR SUSPENSIONS MODEL 4 2 Rear Axle Tread TREAD Distance width between vertical centerlines of single tires at opposite ends of axle TREAD D S TIRE SECT or between vertical centerlines of dual spacing D S at opposite ends of axle DS TREAD DS TIRE SECT TIRE SECT Overall width of new tire at top of tire under maximum load including 24 hour inflation pe TREAD 0 5 Tire Secti growth and including protective side ribs bars and decorations recommended by tire TIRE SECT manufacturer D S Dimension width between vertical centerlines of two tires duals assembled at one Dual Spacing end of an axle TREAD D S TIRE SECT Tread plus Dual Spacing Overall width of axle dual rims and tire assembly at top of tires under load plus Tire Section TREAD D S TIRE SECT Tread min s Dual Spacing Distance width between near sides of inner tires of dual assembly at top of tires nder load minus Tire Section SLR Distance from ground to centerline of hub when tires are correctly inflated and under Static Loaded Radius maximum load recommended by tire manufacturer Dual Tires 14 0005 The table shown here list tread information for various wheel axle combinations Tread dimensions are not dependent on tire size Other dimensions expl
17. 64 IC BUS MopEL 4x2 Crossmembers Crossmember Location 195 Wheelbase WB lt C 3 3 CENTERLINE CENTERLINE OF D FRONT AXLE REAR AXLE 194 9 lt 195 WB 4950 n 128 9 984 3275 98 AT 2501 104 3 2648 M 2006 E n 93 7 2379 nA A la Je o i O i i gt A 2 1 o Y Y J vi Y ii B D W AF FUEL TANK 5 fx Br lt 64 7 B 1645 EX H P A JH LLL B Lo A I N w y f Y d TU 1 V 7 E N AF FUEL TANK v ono A SINGLE STAMPED CROSSMEMBER WITH FLAT FLANGE UP CENTER BEARING CROSSMEMBER C DOUBLE STAMPED CROSSMEMBER WITH FLAT FLANGE UP D AF FUEL TANK CROSSMEMBERS E SINGLE STAMP
18. Apply the decal at room temperature 65 to 75 F UC fuel tank rsm 4300 4950 Fuel Tank Location Continued Code 15STY Single Mounted Between Rails Behind Rear Axle 55 Gallon with Fuel Fill Tube HR Per EPA Title 40 Part 86 86 007 35 c the decal 47 8 shown below must be installed on the vehicle 1 21 5 Decal is included with Owner s Guide Kit located in the N cab glove box AA ULTRA LOW SULFUR C 3 3 D D UJ O lt lt UJ o o UJ o lt UJ L 1 26 4 670 DIESEL FUEL ONLY PER 15 0005 v u u i 254 INSTRUCTIONS FOR DECAL PLACEMENT 29 7 4 9 756 1 The decal must be placed as close as possible to 123 fuel inlet and clearly visible FRONT 26 5 PN 2 The decal should be placed above or to the side of 674 448 4 63 the fuel cap to avoid corrosion by possible contact 80 159 T with fuel 1524 214 9 3 The decal may be pl
19. It is essential that a new one piece outer channel reinforcement be obtained rather than cutting and re using the original reinforcement The original frame should also be reinforced with an inner channel reinforcement extending at least two feet beyond the cut s on either side of the cut s The reinforcement must be of the same material as the original frame Blank and pre punched chassis channel reinforcements are available through your dealer parts department On both medium and high strength aluminum frames re welding to lengthen the frame is not recommended Refer to Reinforcement and Reinforcement Attachment for additional information c 3 D 4 29 c r D lt c D o lt MODEL 4x2 Frame Rail Specifications Cross Section 2 A B C FRONT 12 F BACK OF FRAME 30 mu B 30 OF FRAME 3 08 T m m 11 30 10 306 9 125 312 3124 3124 3124 3 33 SECTION A A SECTION B B SECTION C C 01 0240 Side Rail Descriptions amp Reinforcement Description i Section Modulus Resisting Bending Moment Section Dimensions inches Yield Strength inches g In Lbs Nominal psi Drop Center Side Rail Kick Up at Rear Suspension Rearward B B 26 05 24 17 2 084 000 1 933 000 C C 9 125 0 312 80 000 B 11 70 10 93 935 800 87
20. Location Code 14TCP International Ride Optimized Air Suspension 8 0 Ride Height 887 7 641 8 2 94 33 4 38 174 6 861 111 3 34 95 11 13 4 58 517 7 282 7 116 4 mai E 2 14 58 16 86 17 9 Vie 370 4 4253 EI lm i AXLE UC iros 14tcp bracket location IC BUS C 3 D c o O F lt UJ o e o lt lt D MODEL 4x2 Rear Suspension Drilling Code 14TCP International Ride Optimized Air Suspension 8 0 Ride Height 36 55 928 3 31 88 31 18 809 7 791 9 2 4 8 82 0 44 61 224 583 eor ar 1043 c 3 1 lt c 72 D o 72 UJ lt 2 4 im 216 238 140 3 01 2 2 129 2 2 61 22 54 9 60 5 765 759 56 56 t REAR AXLE UC iros 14tcp suspension drilling U C COMMERCIAL BUS IC BUS U C COMMERCIAL BUS 108 It BUS THIS PAGE INTENTIONALLY LEFT BLANK D c o O F lt lt o O O o lt lt FUEL TANKS MopEL 4x2 Fuel Tank Location Code 15SSW Single Mounted Between Rails Behind Rear Axle 40 Gallon with Fuel Fill
21. from side to side They will differ fore and aft due to typical frame rake Axle Alignment With Frame After determining that the frame is properly aligned the axle alignment with the frame should be checked by comparing diagonals If necessary adjust axle to frame alignment Frame Straightening NOTE Frame straightening should only be performed by a qualified frame alignment facility Under no circumstance should frame alignment be performed by inexperienced or unqualified service personnel Do not use heat to straighten Use of heat is not recommended when straightening heat treated frame sidemembers Heat will weaken these frame members consequently all straightening should be done at room temperature Add reinforcement per section if heat straightening is done c 3 D 4 29 72 r D lt c D o lt Frame members which bent buckled sufficiently to show cracks weakness after straightening should replaced reinforced Heat treated frame members must not be intermixed with non heat treated members If one sidemember is to be replaced the new member must match the former frame member in both cross section and material strength Repair and Reinforcement Recommended Procedures In some cases of frame damage the sidemembers must be replaced rather than repaired Examples of this are 1 When
22. it tends to bend about an axis different from that of the main sidemember section Because of this its length and or attachment specifications are typically greater than for the channel type Recommended Applications This type of reinforcement is recommended for cases in which the weld repair is confined to the web of the section but extends beyond the application zone of the flat plate reinforcements shown in Figure 2 5 Application Procedures 1 Figure 2 5 shows a typical installation for an L reinforcement on the inside of a sidemember section along with minimum recommended dimensions 2 The flange of the reinforcement should be oriented up or down so that flange is on the same side as the damaged area 3 Formaximum strength the reinforcement should be installed on the outside of the sidemember section Flat Plate Weld Repair Reinforcements This reinforcement is intended for the less critical web portion of the sidemember section where typical cracking is due to local stresses which tend to diaphragm or dish the web without creating appreciable stresses for overall bending of the section Typical crack patterns radiate out from the edge of a mounting bracket or crossmember or from a hole in the web Cracks which radiate from a web hole occupied by a fastener are frequently an indication of a defective joint whether by the loosening of the fastener or poor joint design Figure 2 5 Recommended Applications The flat plate
23. lt 9 Electrodes Only low hydrogen electrodes should be used These should be purchased in hermetically sealed containers or dried for two hours at a temperature between 450 F 232 C and 500 F 260 After drying the electrodes should be stored in an oven at a temperature of at least 250 F 121 C If exposed to the atmosphere for more than four 4 hours the electrodes should be dried before use Any moisture introduced into the weld could develop porosity or embrittlement leading to further cracking Welding procedures will vary among different frame materials Outlined below are recommendations for welding of the various types of frames 1 Preheat the frame member along the prepared weld joint to 500 to 600 F 260 to 316 C Insure the area is clean and any moisture present is eliminated 2 Permit heated area to cool to 200 F 93 C or below before welding is started The weld repair area must be clean before welding 3 Either alternating current or direct current reversed polarity combined with a short arc and beading or narrow weave technique may be used Direct current reversed polarity is recommended 4 should be removed after each pass and an interpass temperature of 200 F 93 C should be maintained 5 Grind smooth and flush with surrounding sidemember material Grind the weld in a direction that is 90 to crack direction Figure 2 4 6 Add reinforcement c O
24. unloaded condition Z Rear Frame Height at the rear axle centerline in loaded condition 250 for unloaded condition Z 0 SLR F for loaded condition NOTE Values calculated for Z and Z are strictly for the frame height at the rear axle centerline For frame heights at the rear of the frame rail refer to Model 4x2 on page 74 in this book U C COMMERCIAL BUS 71 IC BUS U C COMMERCIAL BUS MODEL 4X2 Bump Heights Rear 72 Bump Height refers to the maximum distance of the tires above the side rails as the rear axle of the bus travels over object Bump Heights are important in the selection of bus bodies since it may be necessary to incorporate wheelwells into the body floor to allow adequate clearance for tire travel Straight Bump Height is used when both sets of wheels travel over an object at the same time such as a parking lot speed bump S IDEMEMBER REAR AXLE horizontal SIDEMEMBER Cocked Bump Height refers to the condition that exists when only one set of rear wheels travels over an object an example of this would be climbing over a curb when turning a corner The Cocked Bump Height Charts presented here assume a 7 deflection from Tu LLL LC C SLA gl uM a ul an uf I f uf ur ul ul auf uU uf uf uh uf yf LSS v a orar ur ura uu ue FN Wl C WU FU un f uu UU uf ug ur uf S ALAS f Au VW uf Z W
25. 8 inches 200mm of the exhaust pipe outlet to avoid damage from hot exhaust gases When modifying other chassis systems maintain clearances shown in Table 3 2 c o 3 4 D o r 5 lt c o D N o o o lt TABLE 3 1 TAILPIPE EXTENSION MATERIAL AND PIPE SIZING TABLE 3 2 MINIMUM CLEARANCES BETWEEN EXHAUST SYSTEM 5 AND OTHER 5515 5 MaxxForce 7 2 Minimum Clearance o Component i D Pipe Material 409 Stainless Steel in mm Pipe Diameter 4 Electric Harness 6 0 150 1 Wall Thickness 0 065 Electric Harness w heat guard 4 0 100 e 2 0 50 2 Fuel Tube metal 6 0 150 T Fuel Tube rubber plastic 6 0 150 D metal 4 0 100 Brake Tube rubber plastic 4 0 100 4 0 100 2 Fuel Tank 4 0 100 U C COMMERCIAL BUS 91 IC BUS UC COMMERCIAL BUS 92 Allowable backpressure tailpipe modification worksheet Engine MaxxForce 7 Exhaust Configuration Horizontal Horizontal Qty of 90x elbows added Qty of 60x elbows added Qty of 45x elbows added Qty of 30x elbows added Feet of straight pipe added Temperature Control Device Pressure Pipe Exit Pressure Total Modification Backpressure Add a g Allowable Backpressure Limit 3 3 Is
26. 946 1946 000 3016 27050 gs us 2186 3256 Chart data based on vehicle with standard equipment Artwork may show some optional equipment Dimension data and optional add on weights for this model are based on the 158 wheelbase with 100 after frame unless otherwise noted Weight includes standard chassis standard tires oil and water but less fuel c O o 3 D c o mp lt 5 lt o gt D N o o o lt U C COMMERCIAL BUS 19 IC BUS U C COMMERCIAL BUS 20 MODEL 4 2 Standard Features All ground dimensions on this chassis diagram are based on a bus with the following equipment and a loaded chassis Item Specification FRAME RAILS High Strength Low Alloy Steel 80 000 PSI Yield 7 375 x 3 079 x 312 187 45mm x 78 2 8 0mm With Transition to 9 125 x 3 079 x 312 231 8mm x 78 2mm x 8 0mm Includes 1 2 30mm Drop Under Cab 335 2 8512 2mm Maximum OAL Code 01CDN Front Axle AXLE FRONT NON DRIVING Dana Spicer D600 N I Beam Type 6 000 Ib Capacity Code 02AGN Front Suspension SUSPENSION FRONT SPRING Taper Leaf Shackle Type 6 000 Ib Capacity With Shock Absorbers Code OSAGP Rear Axle AXLE REAR SINGLE Dana Spicer 5110 Single B10 Reduction With Offset Housing 13 500 Ib Capacity 160 Wheel En
27. Certified Vehicles Protective cover 435654C2 should be installed over this label c O 3 e c e D lt c D o lt 4 U C COMMERCIAL BUS 15 IC BUS U C COMMERCIAL BUS 16 IC BUS CONFORMS TO ALL APPLICABLE FEDERAL MOTOR VEHICLE SAFETY STANDARDS AF EFFECT JN 449893C5 for U S Certified Vehicles 4 88305 COLO QUAL THUS WAS AI TERED A MODIFI E DATE EE FR REAH RR KG Ko LE LH A SUITABLE TIRES AND RIM CHUILE RWS P3 COLO SIMGLE PSI COLO DUAL 1676840C3 for Canada Certified Vehicles B 758400 3 c O o D c o r 5 lt c o D N o o o lt Figure 1 6 Vehicle Alterer Certification Label Alterers of Canadian certified vehicles must apply the Canada National Safety Mark and National Emissions Mark with their identification number adjacent to the Vehicle Alterer Certification label Such authorization and identification number must be obtained from the Minister of Transport at Transport Canada Reference Figure 1 4 Canada National Safety Mark and National Emissions Mark Exterior Noise Certification Label Incomplete vehicles identified as a chassis cab by Navistar Inc have the vehicle exterior noise
28. EPA and the California Air Resources Board ARB The aftertreatment devices may include a combination of particulate filters catalysts catalytic converter and temperature and pressure sensors along with other components Proper long term operation of these components requires controlling exhaust stream temperatures and the exhaust flow pattern throughout the system This controls the required location of the components as well as the insulation of the various parts of the system For this reason application guidelines for aftertreatment and tailpipe installations are much more complex and restrictive than in the past Navistar Inc will ensure correct factory installation of aftertreatment devices to assure compliance with the certification requirements Modified systems could damage the engine aftertreatment system and other truck systems and void the warranty coverage In that regard Navistar Inc will make it a policy to procure and correctly install the appropriate aftertreatment devices pursuant to applicable specifications and application guidelines That brings with it the benefit of certified systems that will be fully covered under warranty provided the vehicle is properly maintained and not modified beyond the extent allowed by the Body Builder book The following guidelines are meant to clarify the allowable modifications for aftertreatment systems Please consult applicable federal state and local laws and requirements in conjuncti
29. Tube s 29 6 1 751 N E TH 13 8 208 351 FRONT 36 5 927 61 7 1567 18 5 470 UC 40 gallon btr fuel tank UC COMMERCIAL BUS 109 Per EPA Title 40 Part 86 86 007 35 the decal shown below must be installed on the vehicle Decal is included with Owner s Guide Kit located in the cab glove box ULTRA LOW SULFUR 15 0005 INSTRUCTIONS FOR DECAL PLACEMENT 1 The decal must be placed as close as possible to the fuel inlet and be clearly visible 2 The decal should be placed above or to the side of the fuel cap to avoid corrosion by possible contact with fuel 3 The decal may be placed on aerodynamic fairings bodies etc as long as the decal is clearly visible and in close proximity to the fuel inlet 4 For installed bodies that have a fuel door e g buses the decal should be placed above or to the side of the fuel door Thoroughly clean the area of all grease dirt etc before application of the decal Apply the decal at room temperature 65 to 75 F C 3 3 D
30. allowable Backpressure Limit GREATER than Total Modification Backpressure If YES Modifications MEET Engine Manufacturer s Guidelines and CAN be performed If NO Modifications will NOT MEET Engine Manufacturer s Guidelines and CANNOT be performed IC BUS c 3 D c mp D lt c D o lt UJ MODEL 4X2 Horizontal Aftertreatment Code 07BDV Right Side Mounted 81 5 _ 266 __ 239 2069 675 4 608 3 97 1 m r 255 9 12 6 246 9 P 3 204 sa a IS I THO pe Ply i 19 7 349 an is T Ji O O O 3 5 oD o O lt c o O Q o lt D 4 EE O FRONT ai SPRING EYE e 00 35 7 906 9 1 19 4 493 6 E d 2 x P GERE zi sli Cm x FRONT 6 1 B ME SPRING EYE 153 228 8 2 79 4 2016 5 UC 07 right side mount U C COMMERCIAL BUS 93 IC BUS U C COMMERCIAL BUS 94 IC BUS THIS PAGE INTENTIONALLY LEFT BLANK D c o O F lt lt o O O
31. and framework U C COMMERCIAL BUS ues IC BUS U C COMMERCIAL BUS 118 It BUS THIS PAGE INTENTIONALLY LEFT BLANK D c o O F lt lt o O O o lt lt 2011 BUILDER UC Commercial Bus Cutaway Bus Chassis Body Builder PBB 39100 Navistar Inc October 2011 Edition 2701 Navistar Drive Order Number PBB 39100 Lisle Illinois 60532
32. apart as practicable One as close as practicable to vertical centerline One on each side One lamp on each side of vertical centerline as far apart as practicable HEIGHT ABOVE ROAD SURFACE In inches measured from the center of the lamp on vehicle at curb height No requirements Not less than 15 Not less than 15 Both on the same level between 15 and 83 All three on the same level as close as practicable to the top of the vehicles with lamp centers spaced not less than 6 or more than 12 apart Both on the same level between 15 and 83 c O e c e D lt c D o lt 4 IC BUS U C COMMERCIAL BUS a IC BUS LEGEND 1 Headlamps 2 White 4 optional 2 Side marker lamps Front 2 Amber 3 Side reflectors Front 2 Amber 4 Turn signal lamps Front 2 Amber 4a Turn signal lamps Front 2 Amber Optional location 5 Identification lamps Front 3 Amber 5a Identification lamps Front 3 Amber Optional location Clearance lamps Front 2 Amber 6 7 Side marker lamps Rear 2 Red 8 Side reflectors Rear 2 Red c 3 D 29 c mp lt c D o
33. are used avoid drilling holes closer than 2 0 inches 51 mm from the ends of the reinforcement Bolts must be periodically checked to insure that the proper torque and clamping force is maintained Never drill any holes in the flanges of the frame rail UC COMMERCIAL BUS 67 c O 3 7 2 e lt c 72 D o 72 lt IC BUS U C COMMERCIAL BUS 68 MODEL 4 2 Frame Drilling Restrictions Tapered Rails 25 3 643 1 5 S A 38 x 38 NO DRILL ZONE DENTES 1 5 254 2 CENTERLINE Pn REAR SUSPENSION AS SHOWN SECTION A A 01_0245 DO NOT leave less than 0 75 19mm of material between holes DO NOT drill holes in the following areas Distance from top of top flange to centerline of hole Distance from bottom of bottom flange to centerline of hole IC BUS c 3 D 29 c mp lt c D o lt MODEL 4x2 Frame Height Calculations At Centerline of Front Axle The front frame height at the centerline of the front axle may be calculated using the following equations Refer to the illustration for a visual explanation of the symbols used in these calculations r T Y Y R SLR FRONT AXLE CENTER LINE 010045 Y Y z NOTE
34. be oriented up or down so that the flange is on the same side as the damaged area 2 Formaximum strength the flange should be on the outside of the section 3 Follow the general recommendations above for attachment of the reinforcement Local Channel Weld Repair Reinforcements This type of reinforcement must be custom fabricated either by cutting lengths from full length reinforcements or by forming from flat stock Figure 2 5 Recommended Applications 1 Casesin which the weld repair extends into the sidemember flange after substantial service life c 3 D 4 29 72 r D lt c D o lt 2 Cases accompanied by extensive abrasive wear of the sidemember section In these cases the length of the wear area should be added to the length recommendations below Application Procedures 1 The channel should be installed on the outside of the section for greater strength 2 Figure 2 5 gives recommended dimensional data and attachment specifications for a typical installation Holes drilled for the attachment must be within the frame drilling guidelines in the specific model body builder book Local L or Inverted L Weld Repair Reinforcements This type of reinforcement is also generally custom fabricated It has a greater tendency to loosen than a channel reinforcement because for vertical deflections of the frame assembly
35. force Operation of the joint with loose or improperly tightened bolts can lead to failure of the joint The bolts and nuts should be inspected periodically to insure that proper torque is maintained Bolts of high strength material conforming to SAE Grade 8 bolts should be used on all frames For installation of reinforcements 0 5 inch 13 mm diameter flange head bolts are recommended The SAE Grade 8 bolt is identified by six radial line markings on the head of the bolt Figure 2 6 Nuts must be Grade 8 flange type 1 SAE GRADE 5 BOLTS ARE IDENTIFIED BY 3 RADIAL LINES 2 5 GRADE 8 BOLTS ARE IDENTIFIED BY 6 RADIAL LINES Figure 2 6 Bolt Identification 01 0016 These bolts 0 5 inch 13 mm diameter flange head type should be tightened to 110 to 120 ft lbs 149 to 163 Nm based on new bolts and nuts lubricated with engine oil Whenever possible hold the bolt and tighten the nut c 1 72 r D lt c D o lt If frame components aluminum flange head bolts and nuts or bolts with hardened flat washers must be used If modification or repair requires replacement of existing bolts with new bolts or bolts of a greater length the old flange head nuts should not be used with new standard bolts Careful consideration is given to the number location and sizes of frame bolt holes in the design of a
36. not permitted The factory installed HVAC system is optimized for the evaporator condenser and compressor combination on the vehicle To introduce an additional evaporator or other components into the system will create an imbalance and unsatisfactory performance The Refrigerant Control and Diagnostics RCD software that resides in the vehicle s body computer is designed to monitor the factory installed AC system only Adding any additional equipment or components to the original air conditioning system will introduce conditions that the RCD software will interpret as out of specification conditions and cause faults to be logged The factory compressor clutch is cycled by the RCD software residing in the ESC of the vehicle Modification of this control system to add an auxiliary system could result in damage to other vehicle components Since the HVAC system has been optimized for the factory components there is no extra condenser capacity available for an auxiliary evaporator c O 3 e c e D lt c D O D o lt COMMERCIAL BUS IC BUS IC BUS 114 U C COMMERCIAL BUS MODEL 4x2 UC Commercial Bus Cutaway Bus Chassis Body Builder 77 0 i n s IH in es es Cab Dimensions Side View Front View Octob
37. o lt lt ELECTRICAL MopEL 4x2 Battery Box Location Left Side Mounted Under Cab 2 Batteries BACK OF STD CAB I sad 6 6 7 2g 167 178 E 72 5 452 3 284 SLIDER 713 7 2 BATTERY BOX SYSTEM O O O 3 3 7 ny UJ o O si lt o O Q o O lt J 78 198 4 es 8 OF RAIL TO BOTTOM OF REINFORCEMENT UC slider 2 battery box U C COMMERCIAL BUS 95 IC BUS U C COMMERCIAL BUS 96 It BUS MODEL 4X2 Battery Box Location Continued Left Side Mounted Under Cab 3 Batteries mil Emm H pL i i lt LL m i O lt O lt FRONT REAR CAB XMBR lt x 26 0 17 9 4 660 455 B D 423 3 BATTERY BOX 312 20 3 287 SYSTEM E 517 728 pss C C E E D D o C lt UJ o C D o o lt Jmm m 1 26 2 7 0 666 2 7 178 35 3 68 896 08 0134 MODEL 4x2 Electrical System Allison Automatic Transmission 1000 2000 Series
38. operations before the first purchase of the vehicle other than for resale in such a manner as may affect the conformity of the vehicle with one or more FMVSS or the validity of the vehicle s stated weight ratings or vehicle type classification Compliance Responsibility In accordance with section 567 7 of Title 49 of the CFH if a person alters a certified vehicle before the first purchase of the vehicle other than for resale the responsibility for compliance of the modified vehicle rests with the Alterer The vehicle manufacturer s Certification Label and any Information Labels shall remain affixed to the vehicle and the alterer shall affix an additional certification label that will supplement the certification label originally furnished with the vehicle by Navistar Inc or the Final Stage Manufacturer This certification label must state the following This vehicle was altered by name of Alterer in month and year in which alterations were completed and as altered it conforms to all applicable Federal Motor Vehicle Safety Bumper and Theft Prevention Standards affected by the alteration and in effect on the date of no earlier than the date of manufacture of the certified vehicle as specified on the certification label and no later than the date alterations were completed This label Reference Figure 1 6 is available from International service parts under Part No 449893C5 for U S Certified Vehicles and Part No 1676840C3 for Canada
39. side reflectors if over 30 in length One on each side of vertical centerline as far apart as practicable One on each side rear As far to the rear as practicable As far to the front as practicable HEIGHT ABOVE ROAD SURFACE In inches measured from the center of the lamp on vehicle at curb height Both on the same level between 15 and 72 Both on the same level as high as practicable Both on the same level as high as practicable Not less than 15 Between 15 and 60 Both on the same level between 15 and 60 Between 15 and 60 Between 15 and 60 IC BUS c 3 D 4 29 72 r D lt c D o lt REQUIRED LIGHTING EQUIPMENT License Plate Lamp Rear Side Marker Lamp Front Side Marker Lamp Rear Turn Signal Rear Identification Lamp Rear Vehicular Hazard Warning Flashing Lamps Backup Lamp Required Vehicle Lighting Equipment for Buses with an Overall Width of 80 inches or more QUANTITY U C COMMERCIAL BUS Table 1 2 COLOR White Amber Amber Amber or Red White LOCATION At rear license plate POSITION To illuminate the license plate from the top or sides As far to the front as One on each side practicable As far to the rear as practicable One lamp on each side of the vertical centerline as far
40. the frame height at both the front and rear axle centerlines we can determine the frame height values at both rail ends FRONT AXLE REAR AXLE 22 FRAME RAIL BUMPER NZ FG gt N NS Z GROUND LINE BA WB AF 01_0049 First we must determine the rake of the frame i e the slope of the frame from front end to For situations where the rake is positive i e Y lt Z or Y lt Z the equations for determining rear end If the front end of the frame is higher than the rear end i e Y gt Z or gt 277 then the frame height at the rail ends are truck is said to have a negative rake In this situation the equations for determining the frame height at the rail ends are C C E E D 4 D o C lt UJ o D o o lt UJ Frame Height Front End of Rail Frame Height Front End of Rail 4 for unloaded condition for unloaded condition FG Y T x FG FG Y Z X BA for loaded condition FG z X BA for loaded condition WB WB Frame Height Rear End of Rail Frame Height Rear End of Rail RG Z e X for unloaded condition RG Z X for unloaded condition 2 T 4 X AF for loaded condition RG Z Y X AF for loaded condition WB WB MODEL 4x2 Bumpers Standard Frame Rails
41. 10 3 92 Parabolic 5 42 7 000 10 3 42 O o 1 gt o O lt o O o lt D MODEL 4x2 At Centerline of Rear Axle The rear frame height at the centerline of the rear axle may be calculated using the following equations Refer to the illustration for a visual explanation of the symbols used in these calculations Wheel axis to bottom of frame in unladen position Refer to tabulated data b Wheel axis to bottom of frame in loaded position Refer to tabulated data lt D D Frame rail height Refer to tabulated data 2 2 SLR Static Loaded Radius The distance from the wheel axis to the ground for a properly inflated fully loaded R SLR loaded to its maximum capacity tire To obtain tire dimensions contact the tire manufacturer MEN Tire Radius half of tire outside diameter not CENTER LINE mounted on the vehicle To obtain tire dimensions contact the tire manufacturer 01 0046 Calculated Tire Radius on an unloaded chassis The value of R gt is calculated using the following method R R 2 R SLR c C C 3 3 D D o C lt o o o o lt D L 1 Z Rear Frame Height at the rear axle centerline in
42. 2011 BUILDER COMPANY 39100 October 2011 Edition 57 8 1468 TO MIRROR 87 0 2210 FENDER WIDTH NEM Nm SN N 2 723 ES Y tici i 1570 To HEADLAMPS 85 0 2158 BUMPER WIDTH E Commercial Bus Cutaway Bus Chassis Body Builder TABLE OF CONTENTS PIP Government Requirements Your Obligations Under The LaW J I I I H 1 Federal Motor Vehicle Standards FMVSS and Canadian Motor Vehicle Safety Standards CMVSS 3 Additional Lighting Information l J nenne 5 Additional Requirements EPA Certification of Incomplete Vehicles Manufactured by IC Bus 10 Alterations To Completed Vehicles eese 15 Exterior Noise Certification Label l l I 17 Additional Certification Label Information and Instructions 17 4x2 Specifications Chassis Diagrams Weight Distribution Dimensions Turning Radius Chart 19 Standard TOS GS u A T 20 Frames General Frame Information l I I nrnna 27 General Frame Recommendalions 27 Identification of Frame Rail Material a a 28 Famo OG spa uu uuu uu 29 Welding and Reinforcement
43. 4 000 High Strength Low Alloy Steel Section Modulus Maximum Tolerance All frame dimensions are at maximum tolerance used by some competitors as advertised values Nominal Calculated using design dimensions indicates the design load capacity of the frame Reinforcement dimensions and specifications are shown in italics UC COMMERCIAL BUS 61 c C 3 3 D 1 D UJ o O lt UJ o o o UJ lt UJ L 3 IC BUS U C COMMERCIAL BUS 62 IC BUS MODEL 4x2 Crossmembers H Crossmember Location 158 Wheelbase WB CENTERLINE OF CENTERLINE OF D FRONT AXLE REAR AXLE 4000 O 2603 94 3 Q 79 2394 2006 o O uH a Moa Je 5 n 2 Ed lt mt i W 6 o ojo g hi A CENTER BEARING CROSSMEMBER B SINGLE STAMPED CROSSMEMBER WITH FLAT FLANGE UP DOUBLE STAMPED CROSSMEMBER WITH FLAT FLANGE UP D AF FUEL TANK CROSSMEMBERS UC crossmembers 158wb MODEL 4x2
44. 7333 c 3 7 2 72 e D lt c 72 D o 72 lt IC BUS U C COMMERCIAL BUS 58 IC BUS After Market Modifications Cutting the frame behind the rear axle to shorten the frame is acceptable Mechanical cutting or sawing is preferred to torch cutting Whenever it is necessary to cut the frame the sidemember should be cut at an angle of 90 to the longitudinal axis For information on cutting of the frames to lengthen the frames or modify the wheelbase refer to Wheelbase Alterations The addition or installation of this special equipment on the vehicle can significantly affect the loading of the chassis frame In some cases it may be necessary to reinforce the frame Care must be exercised to insure that the gross vehicle weight rating GVWR and or the gross axle weight ratings GAWR are not exceeded Installation of this special equipment may involve State and Federal requirements which affect vehicle certification for noise emissions exhaust emissions brake requirements lighting system requirements etc The specialized equipment installer is responsible for the safety and durability of their product and in addition is responsible to insure that the equipment and its installation comply with all applicable State and Federal Department of Transportation requirements and OSHA regulations Addition of specialized equip
45. 90 to the crack direction to remove all of the coarse grind marks 6 Inspect the weld repaired area carefully after grinding Grind out any remaining cracks notches or undercuts and repeat the finishing and inspections 7 For welding cracks to the edge of the sidemember flange locate a run off block at the edge as in to obtain a continuous weld without undercuts After welding the run off block should be cut off and the weld should be ground and inspected as in steps 5 and 6 above 8 Weld to the edges of the holes The weld should continue into the hole to form a plug weld with a copper chill block on the opposite side to help form the plug The weld should then be finished as in steps 5 and 6 above and redrilled Chamfer the hole edges If the hole was open and unused install a Grade 8 bolt to help attach the weld repair reinforcement Invisible ultraviolet and infrared rays emitted in welding can injure unprotected eyes and skin Protection such as welder s helmet with dark colored filter lenses of the proper density must be used GTAW or TIG welding will produce intense radiation therefore filter plate lenses of the deepest shade providing adequate visibility are recommended It is strongly recommended that persons working in the weld area wear flash safety goggles Also wear protective clothing IC BUS c 3 D 29 c r D lt c D o
46. Body builder Input Output connection for Allison 1000 2000 transmissions is located on the front dash panel in the engine compartment on the drivers side The table below gives the circuit and connector cavity information For a complete circuit diagram of the transmission wiring and for connector amp terminal part numbers see vehicle circuit diagram book Circuit Maximum Cavity Number 0 Current Connector Number 7205 92C103 Signal Ground 928143 PTO Enable A B C 92 150 Output 500 mAmp PTO Enable 2 D 47C125 Output E 92 101 Auxiliary Function Range Inhibit F 92 123 Auto Neutral for PTO G 92 145 Output 500 mAmp Range Indicator H 92 105 Output Output Speed Indicator NOTE 1 See Allison technical manual for suggested circuit design Description Non Zero Crossing Speedo 16 Pulses Rev c O gt c e D lt c D lt UJ L 1 NOTE 2 See special features table on next page for package content NOTE 3 MUST COMPLY WITH FMVSS STANDARD 102 2 9 0 4 S 5525 525250505 x 2 gt 2 lt KK SKS SKS 95590 XX X Connector 7205 has its mating connector attached and filled with cavity plugs To use connector remove cavity plugs and use the following 250 x gt Pe J A XXX 5
47. E DATE MANLFACTURE SHOWER ABO 2422 GAYR ARE BASED ON ORIGIONAL AFFECT CAPACITIES SEE DWMER S FOR OTHER TIRE TY JAF DN O 0011 Bu MFD BY Bp KI KG 575 LE E LB LB SUITABLE TIRE TIRES TIRES AND CHOICE RIMS RIKS PSI COLD SINGLE PSI COLD w TYPE 169690002 _0012 Figure 1 5 Final Stage Manufacturer Certification Label Canada Certified Final Stage Manufacturers of Canadian vehicles must affix the Canada National Safety Mark and National Emissions Mark with their identification number installed on it next to the final certification label shown above Such authorization and identification number must be obtained from the Minister of Transport at Transport Canada Reference Figure 1 4 436076C4 U S gt 1698980C2 Canada gt Canada National Safety Mark and National Emissions Mark IC BUS c O o 3 D c o r 5 55 lt CU c o D N o o o lt Alterations To Completed Vehicles Definition Section 567 3 of Title 49 of the CFR defines an Altered Vehicle as a completed vehicle previously certified in accordance with section 567 4 or 567 5 that has been altered other than by the addition substitution or removal of readily attachable components or by minor finishing
48. ED CROSSMEMBERS WITH FLAT FLANGE DOWN UC crossmembers 195wb MODEL 4x2 Crossmember Diagrams ENGINE CROSSMEMBER SINGLE CROSSMEMBER 01_0246 c 3 7 2 72 e lt c D o 72 lt 01_0247 U C COMMERCIAL BUS 65 IC BUS U C COMMERCIAL BUS 66 IC BUS MODEL 4 2 Crossmember Diagrams continued 3 8 97 C CHANNEL AF AND BTR FUEL TANK CROSSMEMBER c o 3 D c o r 5 lt c o D N o o o lt DOUBLE STAMPED CROSSMEMBER 01 249 UC btr crossmember MODEL 4x2 Frame Drilling Guidelines The drilling of the frame sidemember presents no unusual difficulty Standard high speed steel drills of good quality will serve provided they are sharpened properly and not overheated during sharpening or use Hole Location Guidelines 1 2 Never drill holes into the restricted areas of the frame rails Refer to diagrams on the following pages Use existing holes whenever possible Maintain a minimum of 0 75 inch 19 of material between holes There should not be more than three holes located on a vertical line Bolt holes should be no larger than is required for the size of bolts being used in no instance larger than 11 16 688 inch If reinforcements
49. F uf uu yh ur yf f ue ALPS ut uh uf ur uh uh ul ur ur ur uh y OF Z VL yl al ur ur uf ur Z ALS 4 af ul uw C UP ul ul ul uh ul KH Z eg uf oom ah uf f uh ul uf P ruf ar uf ur LO AT Fr Cot ut ar P ur ay IL COCKED BUMP HEIGHT G 7 DEFLECTION 01 0047 01 0048 D Wheel Axis to bottom of frame in straight bump position Refer to tabulated data lireradius one half of tire outside diameter not mounted on the vehicle To obtain tire dimensions contact the tire manufacturer Frame Rail Height Refer to tabulated data Straight Bump Height 07 F Cocked Bump Height Straight Bump Height 3 5 In IC BUS lt O O 3 3 4 D UJ o O lt UJ o O o UJ lt UJ D MODEL 4x2 Frame and Bump Height Data Rear Rear Suspension Spindle to Bottom of Sidemember Capacity Unloaded D Loaded D Bump 0 01CDN 9 125 O 3 D co UJ o r lt o o e o CU o lt UJ D U C COMMERCIAL BUS 73 IC BUS U C COMMERCIAL BUS 74 IC BUS MODEL 4x2 At Front and Rear Rail Ends Now that we have learned to calculate
50. G COMMERCIAL BUS 36 Shielded metal arc welding SMAW gas metal arc welding GMAW also known as metal inert gas MIG welding gas tungsten arc welding GTAW also known as tungsten inert gas TIG welding or flux cored arc welding FCAW are recommended methods for repair of steel frame members To avoid serious personal injury death or possible engine damage when welding or using an acetylene torch always wear welding goggles and gloves Insure that acetylene and oxygen tanks are separated by a metal shield and are chained to a cart Do not weld or heat areas near fuel tanks or fuel lines Utilize proper shielding around hydraulic lines General Hecommendations IMPORTANT To properly perform the repair procedure the following rules must be observed All Steel Sidemembers 1 Welding should not be performed when surfaces are wet or exposed to rain snow high wind or when repair personnel are exposed to inclement conditions Frames exposed to inclement weather must be thoroughly cleaned and dried before the repair is made 2 Surface areas and edges to be joined must be clean and free of oil grease loose scale rust moisture paint or other material that could contribute to poor quality welds 3 Always avoid craters notching and undercutting 4 Peennew welds prior to grinding to relieve stresses caused by shrinkage 5 Grind all welds flush with the surrounding surfaces Use a coarse grinder followed by smooth grind at
51. Gross Vehicle Weight Rating of the intended Complete Vehicle Vehicle Type into which the Incomplete Vehicle may appropriately be manufactured Suitable tire and rim choice with inflation pressure List of all Federal U S or Canadian safety standards applicable to the type of vehicle Those standards to which the vehicle complies as produced by Navistar Inc will be identified For all Incomplete Vehicles except those without a cab the IVD is placed in the left hand door dispatch compartment For Incomplete Vehicles without a cab the IVD is placed in a clear plastic envelope and strap locked to the radiator stay rod In accordance with section 567 5 of Title 49 of the CFR IC will also affix an Incomplete Vehicle Information Label to the hinge pillar door latch post or door edge that meets the door latch post next to the driver s seating position reference Figure 1 3 VEHILLE MANUFACTURED HICLILE MCOMPLET FABRIGUE 1 ENGINE CORPORAT OF En I LEI FRDHT AXLE e 3 5 B we ON KG IXGXXX ree EX RXR LBI XX w KE WE EREM RR a MMM RX LHX LEI Manufactured in the U S or Mexico YIN z345567H3D z34557 DATE MANUFACTURED OY HICLILE INCOMPLET FABFRJIDLU AND ENG CORPORAT
52. IC chassis are presently manufactured with frame rails of High strength low alloy HSLA steel 50 000 60 000 and 80 000 PSI yield strength Heat treated steel 110 000 and 120 000 psi yield strength Each type has different repair procedures The frame rail material can be determined by inspecting the frame and consulting the dealer vehicle lineset ticket and the sales data book Heat treated rails are marked on the inside of the section with a decal which cautions against welding flame cutting or the addition of holes in critical zones These practices are restricted for all frame rails however heat treated rails are much more sensitive to these alterations Frame Damage The major sources of frame damage are accidents overloading the vehicle and local overstressing due to a variety of causes In accident cases the reasons for the damage are readily apparent Such damage may often be repaired by e Straightening and reinforcing the frame e Repairing the damaged area and reinforcing the frame sidemember e Replacing the frame sidemembers and crossmembers Damage to the chassis frame such as a crack in the frame sidemember or crossmember which is not associated with impact damage may be an indication of overloading the vehicle Damage to the chassis frame may also be an indication of the creation of locally high stresses due to operating conditions or equipment mounting practices Examples of overloading are 1 Exc
53. THEREOF Es AY PERSON ARE For Vehicles Built in Canada ACT LAI THE J TEH MTROL OEVICE aoe te 1 SE ACTS THE FE SUCH DEwICE OF ELEMENT OF DESIGN HAS BEEN REMOVED OR RENDERED 3JMOFERATIWE c C C O 3 3 D 1 D o C lt o o o o lt D 4 00016 Figure 1 7 Vehicle Exterior Noise Label Additional Certification Label Information and Instructions 1 All labels must be fully filled out 2 All labels must be affixed to the vehicle in accordance with Sections 567 of Title 49 of the CFR or Canadian Motor Vehicle Safety Regulations Sections 6 and 7 3 No label shall be installed over another label 4 It is unlawful to affix an incorrect certification label to a vehicle U C COMMERCIAL BUS 17 IC BUS U C COMMERCIAL BUS 18 BUS THIS PAGE INTENTIONALLY LEFT BLANK O O D c o O F lt o O O o lt 4X2 SPECIFICATIONS CHASSIS DIAGRAMS Weight Distribution Dimensions Turning Radius Chart Wheelbase EE Chassis Weight Ibs Turning Radius in Total OAL To Curb MUT Clearance 158 16035 4 659 3 308 7 967 183 6 100 0 290 6 251 10 26 ft 9 in gs tors
54. UMPER WIDTH UC COMMERCIAL BUS 25 UC front rear view C O O o O lt UJ o o o o UJ o lt D IC BUS IC BUS 26 COMMERCIAL BUS UC Commercial Bus Cutaway Bus Chassis Body Builder 2012 FRAMES ALL MODELS General Frame Information Introduction The frame is the structure that carries and supports the rated load under anticipated driving conditions and secures the major components of a vehicle in their relative positions The frame assembly consists of two sidemembers and depending upon the length of the frame five or more crossmembers General Frame Recommendations It is very important that the frame be inspected periodically for cracks buckling crossmember loosening or other damage that may cause eventual failure of the frame Additional inspections should be made whenever the chassis has been overloaded or involved in an accident An alignment check IS NOT SUFFICIENT since local cracks crossmember loosening or sidemember buckling will not necessarily cause misalignment On reinforced sidemember sections when cracks exist in either of the sidemember sections the members must be separated for repair After separation follow the procedures for non reinforced sections The two sidemember sections MUST NOT be welded together After the weld repairs the sections shoul
55. aced on aerodynamic fairings bodies etc as long as the decal is clearly visible and in close proximity to the fuel inlet 4 For installed bodies that have a fuel door e g buses the decal should be placed above or to the side of the fuel door Thoroughly clean the area of all grease dirt etc before application of the decal Apply the decal at room temperature 65 to 75 F 55 gallon tank UC COMMERCIAL BUS IC BUS U C COMMERCIAL BUS IC BUS THIS PAGE INTENTIONALLY LEFT BLANK D c o O F lt lt o O O o lt lt CAB Air Conditioning System Modifications The HVAC system provided with IC Series should not be modified NO additional components should be added to the factory installed HVAC system as it is delivered from the manufacturer If additional air conditioning capacity is needed a completely independent system should be added to handle the additional load requirements of the Body Builder There are additional costs for a second system it would however provide for optimal performance from both HVAC systems The factory installed system cannot be modified in any manner Modification of the HVAC system will void the IC Warranty on that system There are several reasons why HVAC system modifications are
56. ained here are related to tread and require tire dimensions Please contact your tire supplier or consult the International Sales Data Component Book PDB 70000 for tire dimensions Wheel Rim Axle Code 14ACN Disc 19 5 x 6 00 10 70 74 0 UC COMMERCIAL BUS 103 c O e c e D lt c D o lt UJ L 1 IC BUS U C COMMERCIAL BUS 104 IC BUS MopEL 4x2 Rear Suspension Bracket Location Code 14SAC Vari Rate Steel Suspension O o D D lt P c F D D lt c O z D o o D lt u Tu 1 4 62 5 0 5 58 T 117 4 127 1417 48 7 38095 a 1 39 69 10 4 29 8 270 49 1008 1 264 2 AXLE UC vari rate 14sac bracket location MODEL 4x2 Rear Suspension Drilling Code 14SAC Vari Rate Steel Suspension 2 94 74 7 51 6 8 8 6 25 5 1 7 44 1310 9 223 5 158 9 140 188 9 c C 3 3 D gt c 7 O 5 1 86 i UJ 7 gt o T lt UJ AXLE UC vari rate 14sac suspension drilling U C COMMERCIAL BUS 105 IC BUS U C COMMERCIAL BUS 106 MODEL 4 2 Rear Suspension
57. and Standard Steel Bumper 01LRR 23 5 597 gy 69 21 4 89 552 75 144 26 8 4 BUMPER 681 MOUNTING 34 6 HOLE LOCATIONS 880 42 5 1079 MEGA BRACKETS 85 2158 For license plate mounting use a tapping self drilling hex head 1 4 14 x 5 8 screw UC COMMERCIAL BUS 75 01 0241 c C 3 3 D 1 D UJ o O lt UJ o o o UJ lt UJ gt IC BUS U C COMMERCIAL BUS 76 IC BUS THIS PAGE INTENTIONALLY LEFT BLANK D c o O F lt lt o O O o lt lt FRONT AXLES MODEL 4x2 Front Axle Tread TIRE SECT TREAD Distance width between vertical centerlines of single tires at opposite ends of axle or between vertical centerlines of dual spacing D S at opposite ends of axle Overall width of new tire at top of tire under maximum load including 24 hour inflation TIRE SECT i Tr growth and including protective side ribs bars and decorations recommended by tire Tire Section manufacturer TREAD TIRE SECT Overall Width of axle rim and tire assembly at top of tires under maximum load SLR Tread plus Tire Section recommended by tire manufacturer m TREAD TIRE SECT Distance width between near sides of tires at opposite ends of axle at top of tire Tread mi
58. antly reduce the performance of the Aftertreatment Module and VOID any applicable warranty 3 D 4 29 c r D lt c D o lt All Modifications to Aftertreatment Module Location Geometry Materials Wiring Sensors or Tubing MUST be approved by Navistar Inc If so equipped heat shields and protective wraps must be maintained on the vehicle to ensure the proper performance of the Aftertreatment Module and for the protection of the installed truck systems Never mount any additional harnesses or other equipment to the Aftertreatment Module TEMPERATURE CONTROL DEVICE The function of the Temperature Control Device if so equipped is to reduce the exit exhaust gas temperature emitted from the Aftertreatment Device This device has been specifically designed to draw in cooler air to mix with the hotter exhaust gases It is critical that the openings in the device that draw in cooler air remain unblocked of debris or other equipment This device is critical to ensure that the emitted temperatures of the exhaust are minimized Any modifications to the Temperature Control Device without the written approval of Navistar Inc may significantly reduce the efficiency of the Temperature Control Device and significantly increase the emitted gas temperatures and VOID any applicable warranty If so equipped any installed Temperature C
59. ately 7 rear suspension tandem liner reinforcements are available for some tractor models Inverted L and C channel reinforcements are available for most models For models which do not have reinforcements necessary to contact Sales Engineering to obtain reinforcement recommendations c O 3 e c e D lt c D lt o STANDARD HEAVY DUTY L REINFORCEMENT C REINFORCEMENT SIDEMEMBER SECTION SIDEMEMBER SECTION SIDEMEMBER SECTION SIDEMEMBER SECTION Figure 21 Frame Rails and Reinforcements Typical 01_0011 These reinforcements are generally installed on the outside of the sidemember although certain models require C channel reinforcements installed to the inside of the sidemember Contact your IC Bus dealer regarding the required type of reinforcement Depending on model application there will be other parts affected such as spring brackets for example which are bolted to the flange as well as the web of the sidemember To maintain proper alignment of the springs these brackets may require replacement with new brackets designed to accept the reinforcements These brackets are available through your IC Bus parts department NOTE When an inside reinforcement is added the lengths of the crossmembers will be affected U C COMMERCIAL BUS IC BUS U C COMMERCIAL BUS IC BUS Reinforcem
60. cational Engineers Paul Nieuwlandt Vocational Brent Bot Vocational Paul Schunke Vocational Truck Body Integration gt c 72 c mp D lt c D o lt IC BUS UC COMMERCIAL BUS iv PUBLICATION ORDERING INFORMATION You can easily order UC Commercial Bus Cutaway Bus Chassis Body Builder or Diamond Logic Control Systems books by accessing the Marketing Resource Center and clicking the Order Literature link using your regular User ID and password Revisions to the following product publications are available automatically by subscribing to the Product Information Revision Service Also additional copies of product publications can be ordered individually on a one time basis When ordering include the publication number description and quantity required UC Commercial Bus Cutaway Bus Chassis Body Builder Diagrams u REEE waren PBB 39100 Diamond Logic Control Systems PBB 71000 IC BUS c 3 c e D lt c O D o lt GOVERNMENT REQUIREMENTS Your Obligations Under The Law The important information in this section will acquaint you with U S and Canadian safety and emission standards that appl
61. cement The strength of the sidemember in the weld joint repair region has been reduced by welding and this region must be reinforced sufficiently to insure that the service life of the frame is not shortened Reinforcement of the frame after welding is intended to reduce the stresses in the weld repair region to a lower level than was previously permitted Improper drilling will also reduce the strength of the sidemembers Refer to Drilling or Notching The type length material and attachment techniques for reinforcements vary with the type and location of the crack and with the loading conditions associated with the crack It is not practical to give specific recommendations for all cases of frame cracking therefore the various types of reinforcements are identified with general descriptions of their applications and installation procedures To aid in making the distinctions between the more critical flange area and the less critical web area critical zones are defined as shown 2 4 c 3 3 D c e lt c D o 72 lt o U C COMMERCIAL BUS 41 IC BUS U C COMMERCIAL BUS 42 IC BUS LOCAL L REINFORCEMENT LOCATION 3D MINIMUM INSIDE STAAT NOTE NOT TO BE USED FOR CRACKS BELOW START OF BEND BEND OUTSIDE B LOCAL C REINFORCEMENT LOCATION t 1 2D MINIMUM REINFORCEMENT
62. ct compliance performed on a new vehicle prior to delivery to the customer meets the requirements specified by all mandated standards It is the responsibility of the Final Stage Manufacturer who typically installs a body or other equipment or makes any modifications to an Incomplete Vehicle supplied by International to certify compliance with the applicable standards for the vehicle when completed Further it is the responsibility of the Final Stage Manufacturer to determine and fully comply with any additional requirements of the several States and Provinces In addition the Final Stage Manufacturer must certify compliance with any other standards set forth in U S and Canadian regulations statutes and ordinances c O 3 C3 c e D lt c D lt Penalties For Violations Violation of the provisions contained within the U S Federal Motor Vehicle Safety Standards is subject to fines of up to 5 000 per vehicle or up to a maximum of 15 000 000 The following violations are subject to these penalties 1 Any manufacturer who knowingly or unknowingly produces for sale a motor vehicle subject to the law but which does not meet all the applicable provisions of the law LLOZ 1940120 U C COMMERCIAL BUS 1 IC BUS U C COMMERCIAL BUS 2 IC BUS 2 Any party who sells or offers for sale a motor vehicle built af
63. d be reinforced with the appropriate section and re assembled with mounting bolts tightened to SAE Grade 8 torque levels c O 3 gt c mp D lt c D lt UJ Drilling or Notching Sidemembers should not be drilled or notched without approval from IC Engineering Do not exceed the maximum allowable sidemember hole size in the unrestricted zones See model specific books for illustrations Welding or Flame Cutting Welding or flame cutting of the frame components is unacceptable because of the associated loss of fatigue strength This restriction applies not only to the heat treated components but also the high strength low alloy HSLA and low carbon steel components Exceptions to this are cases with IC Engineering approval for repair operations as described in this service manual section U C COMMERCIAL BUS 27 IC BUS U C COMMERCIAL BUS 068 IC BUS To avoid serious personal injury death or possible engine damage when welding or using an acetylene torch always wear welding goggles and gloves Insure that acetylene and oxygen tanks are separated by a metal shield and are chained to a cart Do not weld or heat areas near fuel tanks or fuel lines Utilize proper shielding around hydraulic lines Reinforcement to Increase Capacity Reinforcement of the chassis frame to support either additi
64. dards Modifications to the vehicle and or engine which will cause noncompliance are prohibited by the regulations For further information see the vehicle owner s manual and the engine manual Replacement or Service Parts The Motor Vehicle Safety Standards primarily specify the requirements and or performance standards that a Complete Vehicle must comply with However certain specific components of the vehicle when sold by a dealer or distributor as replacement or service parts are required to comply with the requirements and or performance standards specified by the standards Certification of compliance must also be provided for these components and those items that are subject to these procedures are as follows Windshield and window glass FMVSS CMVSS 205 Seat belts FMVSS CMVSS 209 Hydraulic brake hose FMVSS CMVSS 106 Hydraulic brake fluids FMVSS CMVSS 116 Lamps and reflective devices FMVSS CMVSS 108 Warning devices FMVSS 125 Reflective Triangle Tires and Wheels FMVSS CMVSS 119 120 Platform Lift System FMVSS 403 The standards require that all of the above items manufactured for sale whether for use in the manufacture of a vehicle or for sale as parts must comply with applicable provisions of the safety standards Such items when sold by dealers or distributors must be labeled to certify compliance Such labeling may be placed on the part itself or on the container in which the part
65. ds Code 14 Rear Suspension SUSPENSION RR SPRING SINGLE Vari Rate 13 500 Ib Capacity Code 145 Tires Front amp Rear Goodyear 225 70R 19 5 LR F Code 7709440101 IC BUS 3 3 D c D lt c O gt D o 72 lt e MODEL 4x2 Chassis Diagram Plan View Standard Cab Maintain a 3 mininum clearance fore and aft of tire in area over the truck axle between the rails body crossmembers cannot extend beyond the outside L 1 J dimension of the frame EXHAUST j Hui Il Es 850 9 HII t 1 N EHCU HYD To inside of frame rail BRAKE UNIT BTR 2 BATTERY BOX FUEL TANK SYSTEM FRONT REAR AXLE AXLE UC std cab plan view NOTE This drawing should not be used to determine crossmember locations that information can be found beginning on page 62 in this book UC COMMERCIAL BUS eB c O 3 72 c e D lt c O gt D o lt IC BUS U C COMMERCIAL BUS 22 IC BUS MODEL 4x2 Chassis Diagram Plan View Standard Cab with Optional Right Side Mount
66. e vehicle Navistar Inc will also affix an information label to the hinge pillar door latch post or door edge that meets the door latch post next to the drivers seating position as specified in part 567 5 of Title 49 of the CFR In accordance with section 568 5 of Title 49 of the CFR each intermediate manufacturer is required to provide an addendum to the IVD for any modification made by them to the incomplete vehicle that affects the validity of the compliance statements that appear in the IVD The addendum must provide the name and mailing address of the intermediate manufacturer and specify the changes that must be made to the IVD to reflect the modifications that they made to the vehicle Final Stage Manufacturer Definition As defined by section 567 3 of Title 49 of the CFR a FINAL STAGE MANUFACTURER is a person who performs such manufacturing operations on an incomplete vehicle that it becomes a complete vehicle Compliance Responsibility Section 568 6 of Title 49 of the CFR requires that the final stage manufacturer shall complete the vehicle in such manner that it meets all applicable safety standards in effect on the date of manufacture of the incomplete vehicle the date of final completion or a date between these dates When completed the tractor must comply with all applicable Federal Motor Vehicle Safety Standards Section 567 5 of Title 49 of the CFR stipulates that the Final Stage Manufacturer is responsible for installi
67. ed 55 Gallon Fuel Tank Maintain a 3 mininum clearance fore and aft of tire in area over the truck axle between the rails Body crossmember cannot extend beyond the outside dimension of the frame rail O7WBE TAIL PIPE LONG RIGHTSIDEMTD SS _ HORIZ EXIT RIGHT FUELTANK 8 1 T3 UNDER BUMPER PENES GENERO Hl Hn C moa Li a 3 3 D c e lt c O gt D o 72 lt ja 33 6 sp 852 8 me NEZ Ivo EHCU HYD UNIT on r9a A 07WBG TAIL PIPE LONG HORIZ EXIT LEFT 2 UNDER BUMPER BOX SYSTEM n _ REAR To inside of frame rail AXLE AXLE UC std cab plan view opt rsm NOTE This drawing should not be used to determine crossmember locations that information can be found beginning on page 62 in this book MODEL 4x2 Chassis Diagram Side View Standard Cab CF BBC 107 CA AF 2717 9 Tess ser De lt B 744 GROUND LINE 1889 5 O 72 c e D lt UJ c D o lt 2 LH 669 kh BA 32 6 828 4 WB OAL UC side view Frame height values represent standard equi
68. eeding either the gross vehicle weight rating GVWR or the gross axle weight rating GAWR loading the frame beyond its design capacity 2 Uneven load distribution 3 Using the vehicle in operating conditions or with equipment it was not designed for Examples of creation of locally high stresses are 1 Mounting bodies or equipment in a manner that causes stress concentrations and or abrasive wear in either the flange or web portion of the sidemember c O O 3 e c e D lt c D lt UJ L 1 2 Improper modification or repair of frame components 3 Equipment which is susceptible to resonant vibration due to excess flexibility of its mounting Frame damage may also be caused by corrosion resulting from the contact between dissimilar metals Damage to the chassis frame which is not associated with impact damage should not be repaired until the cause of the damage has been determined and corrective actions taken to prevent re occurrence of the non impact damage U C COMMERCIAL BUS 29 IC BUS U C COMMERCIAL BUS 30 IC BUS Welding and Reinforcement The guidelines below deal with the general procedures for weld repair and reinforcement Because of the many variables associated with these repairs it is recommended that your field service representative be consulted prior to undertaking the repair This wi
69. emoved in order to retain the same joint integrity it is strongly recommended that new Huck fasteners be used for attachment reattachment of components Installation NOTE Huckbolt HP 8 fasteners cannot be installed without Huck installation equipment 1 Install the HP 8 fastener into the component and frame hole 2 Place the collar over the fastener pintail See Figure 2 9 c o 3 D c o r 5 lt c o D N o o o lt Figure 2 9 Place Collar Over Fastener Pintail 01 0019 3 Place the Huck installation tool over the HP 8 fastener pintail See Figure 2 10 Figure 2 10 Place Installation Tool Over Fastener Pintail 01_0020 4 Activate the Huck installation tool NOTE The Huck installation tool creates a pulling force on the fastener seating the bolt head and closing the gap between the mating surfaces The collar is swaged into the pintail locking grooves developing clamping force See Figure 2 11 As pulling forces further increase the body of the fastener separates at the breakneck See Figure 2 12 completing installation c 3 7 2 72 e D lt UJ D o lt Bie m Figure 2 11 Clamping Force is Developed 01 0021 F
70. ent Attachment The reinforcements must never be welded to the original chassis sidemembers High strength SAE Grade 8 bolts are to be used to fasten the reinforcement to the sidemember Existing bolt holes in the sidemembers should be used whenever possible NOTE The reinforcements should be bolted to the chassis frame using high strength SAE Grade 8 bolts not less than 0 5 inch 13 mm In diameter refer to Bolt and Torque Information Corrosion If aluminum and steel are allowed to come into direct contact with each other a galvanic cell can be formed In order for the cell to form the dissimilar metals must be in direct contact and an electrolyte such as moisture must be present Aluminum is anodic with respect to steel and will corrode when in the presence steel Corrosion of aluminum frame crossmembers will reduce the load carrying capacity of the frame member and may eventually lead to the failure of the frame To prevent the formation of a galvanic cell isolation techniques such as non conductive or barrier type spacers or sealers must be used so that the steel and aluminum are not in direct contact It is recommended that a sealer such as Tectyl 400C or equivalent be painted onto the surface of both the aluminum and steel as well as on the washers under the head of the bolts and nuts Frame Alignment c 1 72 r D lt c D o
71. er 2011 16_0266 MODEL 4x2 Cab Dimensions Continued Key Description A Shoulder Room C Inside Height D Steering Wheel Diameter E Steering Wheel to Seat Back Maximum F Bottom of Instrument Panel to Dash G Engine Cover Width H Lateral Foot Room Driver J Lateral Foot Room Passenger Outside Cab Width M Top of Front Seat Cushion to Floor Driver Seat Track Travel KA Inside Length U C COMMERCIAL BUS A Dimension Inches 70 6 56 8 18 0 18 2 13 9 7 11 2 20 2 18 8 82 2 19 6 Fixed Seat 7 9 fore aft Air Suspension Seat 7 4 mm fore aft 52 4 C C 3 3 D D UJ o lt UJ o o o UJ lt UJ 4 IC BUS IC BUS 116 U C COMMERCIAL BUS MODEL 4x2 UC Commercial Bus Cutaway Bus Chassis Body Builder October 2011 Door Swing Clearance 16 0010 MODEL 4x2 Instrument Panel Do not drill into surface of instrument panel HVAC ducts lie under the surfa and will be damaged D o O gui lt o O o o o O lt 4 Cross cab tie bar and flat panel mounting Wing Panel Mounting 16 0011 NOTE It is not recommended to add any accessory to the instrument panel If an accessory must be added it must be attached to the tie bar
72. erson who manufactures an incomplete vehicle by assembling components none of which taken separately constitute an incomplete vehicle Compliance Responsibility As manufactured by Navistar Inc an Incomplete Vehicle is built with all appropriate safety items that comply with the applicable regulatory requirements to the extent that the vehicle s state of completion will permit To obtain a Complete Vehicle status under section 567 3 of Title 49 of the CFR an Intermediate or Final Stage Manufacturer must mount a body or other similar load carrying equipment on the chassis prior to delivery to the end user c 3 D 4 29 c mp D lt c D o lt Navistar Inc identifies an Incomplete Vehicle with one of the following designations depending on the vehicle s state of completion Chassis Cab Flat Back Cowl FBC Chassis Bus or School Bus Partial Cab Bus or School Bus Partial Cab Truck Stripped Chassis In accordance with section 568 4 of Title 49 of the CFR Navistar Inc furnishes an Incomplete Vehicle Document IVD with each Incomplete Vehicle This document provides the following information Name and mailing address of the Incomplete Vehicle manufacturer Date of manufacture Vehicle Identification Number GAWR Gross Axle Weight Rating for each axle of the intended Complete Vehicle GVWR
73. f the work The party installing a body any other equipment or making any modifications to complete the vehicle for delivery and make it road ready is responsible to see that the completed vehicle complies with all applicable certification procedures and safety standards as may be set forth in Federal State and local statues rules and regulations Specifications descriptions and illustrative material in this literature are as accurate as known at time of publication but are subject to change without notice Navistar Inc cannot accept responsibility for typographical errors which may have occurred Illustrations are not always to scale and may include optional equipment and accessories but may not include all standard equipment IC a trademark of International Truck and Engine Corporation U C COMMERCIAL BUS Engineering Contacts Application Engineers 331 332 2718 curt studebaker navistar com URS Manager TerraStar 331 332 3010 melissa gauger navistar com Manager PayStar abhilash pamulaparthy 331 332 3463 navistar com Abhi Pamulaparthy Mark Netzly 331 332 6415 331 332 3695 331 332 3997 mark netzly navistar com DuraStar WorkStar TerraStar PayStar Steve Hartman steven hartman Q navistar com Scott Laman scott laman Q navistar com 3313326415 marknetziy navistarcom 3313329095 _stevenharman navistarcom 3313329997 scot amanGnaistarcom Vo
74. fuel tanks or fuel lines Utilize proper shielding around hydraulic lines c 3 D 4 29 c r D lt c D o lt With an electronic engine controller such as Celect do not connect the ground cable to the control module s or the cooling plate To protect the control module s it is mandatory to remove all connectors going to the control modules The following is a general guideline for the steel frames Welding of the HSLA 50 000 60 000 and 80 000 PSI yield strength steel side member and the heat treated 110 000 and 120 000 PSI yield strength steel sidemember involves a significant reduction in the strength of the frame in the heat affected zones of the weldment This means that the frame in the welded region is no longer capable of carrying the same load or stress as the original section To restore the strength of the frame rails after welding the welded area must be reinforced using reinforcements as indicated in Repair and Reinforcement Recommended Procedures Welding must be done properly to make an effective repair Therefore only those who are properly trained and qualified should perform the welding repairs in this section Reinforcement Reinforcements Figure 2 1 to increase load capacity are generally full length The actual length of the reinforcement varies with the model Shorter approxim
75. he chassis and continue with step 2 If frame widths are out of specification lay out centerline as follows Centerline can be drawn through the intersection of any one pair of equal diagonals A A B B C C D D and center point of one end of frame or through points of intersection of any two pairs of equal diagonals 2 Measure distance from centerline to opposite points marked over entire length of frame Measurements should not vary more than 0 12 inch 3 0 mm at any point 3 Measuring diagonals A A B B C C D D will indicate point where misalignment occurs If diagonals in each pair are within 0 12 inch 3 0 mm that part of the frame included between points of measurement may be considered in satisfactory alignment These diagonals should intersect within 0 12 inch 3 0 of the centerline U C COMMERCIAL BUS 33 IC BUS U C COMMERCIAL BUS 34 IC BUS If the diagonals are not within specification try loosening and re tightening all cross members Then re check alignment Refer to the Bolt Torque Chart Phosphate and Oil Coated If frame is still out of alignment the vehicle must be taken to a suitable frame alignment establishment to confirm frame misalignment If misalignment is confirmed suitable measures must be taken to repair the damage Side Elevation Dimensions Dimensions for side elevation of the frame should be checked at the points indicated and should not vary more than 0 12 inch 3 0 mm
76. igure 2 12 Body of Fastener Separates at Breakneck 01_0022 U C COMMERCIAL BUS 49 IC BUS U C COMMERCIAL BUS 50 IC BUS Huck Spin Fasteners Description Huck Spin fasteners are used in various positions in frame rail construction The installed fastener has a collar that is cold worked or swaged over the grooved pin Figure 2 13 Advantages to this style fastener are consistent clamp load and a high resistance to loosening due to vibration The need to recheck fastener torque is eliminated SWAQED SECTION Figure 2 13 Huck Spin Collar 01 0023 o gt o O lt o O D o o lt Remove The collar cannot be removed by twisting or hammering The collar must be cut longitudinally to the extent of the swaged section This can be accomplished with a small wheel grinder Figure 2 14 Figure 2 14 Cutting Collar with Wheel Grinder 01_0024 Drilling on opposite sides of the collar may also be used Figure 2 15 c 3 3 D 1 2 72 e lt c D o 72 UJ lt Figure 2 15 Drilling the Collar 01 0025 U C COMMERCIAL BUS 51 IC BUS U C COMMERCIAL BUS 52 IC BUS Another method o splitting the colla
77. in Table 1 10 and 1 11 Table 1 9 SMAW Method HSLA Frames Welding Current posten secre See inch Current Horizontal and Vertical 110 140 20 14 24 Table 1 10 GMAW Method HSLA Frames Welding Current E Horizontal Vertical 190 220 20 30 350 400 7 Preheat frame rail along the weld joint to 500 to 600 F 260 to 316 C to insure any moisture present is eliminated and to prevent too rapid cooling of weld metal 8 Direct current reversed polarity is preferred Weld using a short arc and a beading or narrow weave technique 9 Slag should be removed after each pass and an interpass temperature of 200 F 93 C should be maintained 10 Grind smooth and flush with surrounding sidemember material Grind the weld in a direction that is at 90 to crack direction Figure 2 4 11 Add reinforcement UC COMMERCIAL BUS 39 O 7 a c e D lt c D lt o IC BUS U C COMMERCIAL BUS 40 IC BUS Heat Treated Frames if equipped 110 000 and 120 000 PSI Yield Strength When welding Heat Treated Frames 110 000 PSI and 120 000 Yield Strength use low hydrogen electrodes which have superior crack resistance and notch toughness similar to AWS E 11018 This type electrode should be stored in a moisture free container to avoid porosity during welding
78. ion of that vehicle become the responsibility of the Intermediate Manufacturer or Final Stage Manufacture or both Table 1 1 TYPE OF CONFORMANCE FMVSS CMVSS SUBJECT NUMBER TYPE 1 TYPE2 TYPE 102 Transmission Shift Lever Sequence Starter Interlock and Transmission Braking Effect 103 Windshield Defrosting and Defogging Systems X 104 Windshield Wiping and Washing Systems 105 Hydraulic and Electric Brake Systems 106 Brake Hoses c O 3 C3 e c e D lt c D lt 4 __ _ __ _ __ j x _ __ _ 108 Lamps Reflective Devices and Associated Equipment x 111 Rearview Mirrors ae 113 Hood Latch System 115 Vehicle Identification Number 116 Motor Vehicle Brake Fluids X 8 119 New Pneumatic Tires for Vehicles Other Than Passenger Cars 120 Tire Selection and Rims for Motor Vehicles with GVWR of more than 4 536 10 000 Ibs 2 x x U C COMMERCIAL BUS 2 IC BUS U C COMMERCIAL BUS Hes IC BUS Table 1 1 OF CONFORMANCE FMVSS CMVSS SUBJECT NUMBER TYPE 1 TYPE2 3 208 Occupant Crash Protection X X c O o 3 D c o r 5 lt c o D N o o o lt of C
79. is shipped c C C 3 3 D C3 D UJ o C lt UJ c o o o o lt D 4 1102 1940120 The items listed above that are manufactured by or for Navistar Inc as service parts will comply with all applicable standards as required U C COMMERCIAL BUS x IC BUS U C COMMERCIAL BUS 10 IC BUS Certification of Incomplete Vehicles Manufactured by IC Bus In accordance with the laws of the United States and Canada all vehicles manufactured for sale and sold for use in these countries must comply with the applicable federal safety standards and certification of compliance must be provided with the vehicle oection 567 3 of Title 49 of the CFR defines an Incomplete Vehicle as an assemblage consisting at a minimum of chassis including the frame structure power train steering system suspension system and braking system in the state that those systems are to be part of the completed vehicle but requires further manufacturing operations to become a completed vehicle For an Incomplete Vehicle manufactured by Navistar Inc to be classified as a Complete Vehicle subsequent manufactures must mount a body or other load carrying equipment on the chassis prior to delivery to the end user so that it can perform its intended function Incomplete Vehicle Manufacturer Definition Section 567 3 of Title 49 of the CFR defines an Incomplete Vehicle Manufacturer as a p
80. ission control noise level and applicable safety standards U C COMMERCIAL BUS 87 IC BUS U C COMMERCIAL BUS 88 IC BUS TURBO PIPE The function of the Turbo Pipe is to deliver exhaust gases from the engine to the Aftertreatment Module so that temperature losses are minimized and so that the flow pattern of the exhaust gases maximizes the efficiency of the Aftertreatment Module Any modifications to this piping without written approval of Navistar Inc may significantly reduce the performance of the Aftertreatment Module and VOID any applicable warranty Modifications to Turbo Pipe Location Geometry and Materials MUST be approved by Navistar Inc If so equipped heat shields and protective wraps must be maintained on the vehicle to ensure the proper performance of the Aftertreatment Module and for the protection of the installed truck systems Never mount any additional harnesses or other equipment to the Aftertreatment Module AFTERTREATMENT MODULE The function of the Aftertreatment Module is to catch soot exhausted from the engine and convert it to ash It is critical that the temperature and pressure sensors wiring remain intact for the Aftertreatment Module to perform as designed It is critical to maintain the location of the Aftertreatment Module as installed from the factory to ensure its proper operation Any modifications to the Aftertreatment Module without the written approval of Navistar Inc may signific
81. label Reference Figure 1 7 permanently attached in a readily visible position in the operators compartment For incomplete vehicles other than a chassis cab the final stage manufacturer must assume responsibility and comply with EPA PART 205 SUBPART B CMVSS 1106 NOISE EMISSION FOR MEDIUM AND HEAVY TRUCKS WEHICLE SE EM 5510W CONTROL PIE ORM T Cr THIS WEHICLE BUILT BY INTERAMAT TONAL TROC MSS depen HE CORPORAT OM HIS VEHICLE COMP U S EPA Siege Ee Sb ET EM SS APPLICABLE TO MEDILE AD HE THE FOLLOWING ACTS OF THE CAUSING THEREOF BY ARE For Vehicles Built In the U S PROHIBITED AY THE HOISE CONTROL ACT OF TLE PREHDV AL J JANOPERATIVYE OTHER FOR PLBPOSES CF REPAIR OF REPLACEMENT OF ANY MOISE CONTROL DEVICE EL E ME JT DES Gr ILISTED OFFERS ITO THES E PERLE 1H THE FJ MI SE CONTROL THE 15 VEHICLE AFTE DEVICE OF ELEMENT OF DESIGN HAS BEEN CRE MOWED RENDERED IHOPERAT IVES F 00015 WEHICLE MOISE EMISSION CONTROL JEJE DERIT THIS VEHICLE BUILT BY I ONAL ELE ON HIS WEHICLE CONFORMS TUI REGULATIONS FOR NOISE EMISSOR APPLIC EBLE TO MED Av TRIN SS ACTS THE EE TM
82. ll also help to determine whether a specific set of recommendations has already been developed for the case in question The essential elements of repairing the sidemembers are the restoring of BOTH the shape and local strength so that the load capacity is at least as good as before the damage occurred The sidemembers may look like new but may have local strength reduction due to small cracks or material strength reduction Even if the frame has acceptable alignment and there is no gross deformation local deformations may reduce the strength in the area to be weld repaired Examples of this are local bulges in the web vertical portion of the section and buckling of the flanges These local deformations must be repaired by straightening before proceeding with the weld repair Welding Precautions When welding on any vehicle care must be taken to prevent damage to the electronic components Vehicles with ELECTRONIC ENGINE CONTROL SYSTEMS require additional precautions CAUTION vehicle disconnect both the positive and negative battery cables from the battery before welding on the vehicle Attach the welder ground cable as close as possible to the part being welded To avoid serious personal injury death or possible engine damage when welding or using an acetylene torch always wear welding goggles and gloves Insure that acetylene and oxygen tanks are separated by a metal shield and are chained to a cart Do not weld or heat areas near
83. lt UJ 2 3 4 9 10 10 9 Identification lamps Rear 3 Red 10 Clearance lamps Rear 2 Red 11 Reflectors Rear 2 Red 12 Stop lamps Rear 2 Red 13 License plate lamp Rear 1 White 14 Backup lamp Rear 1 White location 14 optional provided optional requirements are ka 14 met 17 5 5 17 15 Side marker lamps Intermediate 2 Amber LO if vehicle is 30 or more overall length 12818 12 amp 18 16 Side reflectors Intermediate 2 Amber if PAS vehicle is 30 overall length 2 y ehicle is or more overall length 5 17 Turn signal lamps Rear 2 Amber or Red N 18 Taillamps Rear 2 Red Figure 1 1 0 0005 ADDITIONAL REQUIREMENTS EPA EPA Part 205 Subpart B CMVSS 1106 Noise Emission For Medium And Heavy Trucks Incomplete Vehicles identified as a Chassis Cab by Navistar Inc and all Complete Vehicles will comply with the requirements specified by PART 205 SUBPART and CMVSS 1106 provided that no changes are made to the noise generating and or suppression equipment installed by IC EPA Part 86 CMVSS 1100 Emission Control Engines provided with IC Bus vehicles will comply with all applicable exhaust emission stan
84. ment may have a significant effect on other vehicle components such as the brake system steering system suspension system etc Simple reinforcement of the chassis frame may not be adequate to provide safe operation of the vehicle In any modification of the chassis frame the addition of holes reinforcements welds clamps splices etc may cause an increase in the local stress in the frame at the point of the modification These local stress concentrations can significantly affect the life of the chassis frame The specific effect which the stress concentrator will have on the life of the chassis frame is influenced by the location of the stress concentration the frequency and severity of the loading and the type of stress concentration Any modification of the frame may void the manufacturer s warranty c 3 D 4 29 72 r D lt c D o lt Refer to Welding and Reinforcement information page 30 AS Cut at 45 Angle Weld as Shown Figure 2 24 Frames Preparation of Joint for Welding Extension 01_0034 UC Commercial Bus Cutaway Bus Chassis Body Builder 01_0035 Correct Grind Direction Incorrect Grind Depth Incorrect Grind Direction Incorrect Grind Depth Correct Grind Direction Correct Grind Depth Incorrect Grind Direction Correct Grind Depth Figure 2 25 Cross sectional Views Sho
85. n a manner that insures proper continued functioning of the tubing or hose Be long and flexible enough to accommodate without damage all normal motions of the part to which it is attached Be suitably secured against chafing kinking or other mechanical damage Be installed in a manner that prevents it from contacting the vehicle s exnaust system or any other source of high temperatures 3 3 D 1 c o mp D lt o D o lt o STEERING MopEL 4x2 Steering Gear Location Dimensions Code 05PSN TL m y b 6 NOU HE SE s x 9 05_0039 UG COMMERCIAL BUS 85 3 7 72 r lt UJ D o 72 UJ lt IC BUS U C COMMERCIAL BUS 86 It BUS THIS PAGE INTENTIONALLY LEFT BLANK D c o O F lt lt o O O o lt lt EXHAUST SYSTEM GUIDELINES FOR AFTERTREATMENT MODIFICATIONS Navistar Inc has a responsibility to supply install and ensure that the engines and aftertreatment emission control devices comply with the certification requirements of the U S Environmental Protection Agency
86. ng an appropriate certification label that must be securely and permanently affixed to the completed vehicle For those situations when an entity other than an International facility certifies a completed vehicle that entity becomes the Final Stage Manufacturer and has the option to create its own label or purchase a label from IC service parts Labels purchased from service parts do not have the name of the Final Stage Manufacturer and information about the vehicle This information has been left blank Final Stage Manufacturers that utilize the appropriate label and protective cover 435654C2 and provide the required information comply with the requirements specified by part 567 of Title 49 of the CFR The label see Figure 1 4 is referred to as a Final Stage Manufacturer Certification Label and is identified with International part number 436076C4 for a vehicle sold in the U S or 1698980C2 for a vehicle sold in Canada c C C 3 3 D D UJ o C lt o o o o lt D 4 U C COMMERCIAL BUS 13 IC BUS UG COMMERCIAL BUS _ 14 SET PECES eee TE F ROHT FR REAR RR LB SUITABLE TIRES CHOICE Ry WS PS COLD SINGLE AT PSI COLD CUAL THIS VEHICLE CONFORMS ALL APPLICABLE FEDERAL MOTOR SAFETY STANDARDS EFFECT TH
87. nus Tire Section under maximum load recommended by the tire manufacturer TREAD TIRE SLR Distance from ground to centerline of hub when tires are correctly inflated and under lt TREAD Static Loaded Radius maximum load recommended by tire manufacturer lt TIRE 02_0003 The table shown here lists tread information for various wheel axle combinations Tread dimensions are not dependent on tire size Other dimensions explained here are related to tread and require tire dimensions Please contact your tire supplier or consult the International Sales Data Component Book PDB 70000 for tire dimensions Wheel Rim Axle Code Type Hydraulic Brake Disc 19 5 x 6 00 UC COMMERCIAL BUS B77 c C C 3 3 D D o C lt o o o o lt D 4 IC BUS U C COMMERCIAL BUS 78 IC BUS THIS PAGE INTENTIONALLY LEFT BLANK D c o O F lt lt o O O o lt lt FRONT SUSPENSIONS MopEL 4x2 Front Suspension Brackets with 6 000 Ib 7 000 Ib Front Suspension 5 1 129 TRANSITION OF FRAME A h E HL L XH FH 7 1 179 5 c 3 7 2 72
88. on with this document to ensure compliance to those requirements Also refer to applicable vehicle warranty information before performing any modifications to the vehicle Non compliance to the requirements of the warranty may nullify it in its entirety Where possible buses first and foremost should be ordered directly from the factory that meets the body installation requirements so that the minimum or no modification of the exhaust system will be required Where this is not possible if another exhaust configuration is available from the factory that closer meets the need of the body installation it is permissible to completely replace one exhaust configuration with the better choice exhaust system provided that would have been available with the same engine and the clearance guidelines in this reference are followed Exhaust Gas Temperatures may be as high as 800x C during vehicle operation Precautions should be taken to ensure that materials used in the vicinity of the exhaust system and exhaust gas stream can withstand these temperatures or are safely shielded lt o 3 3 D C3 D UJ o la lt lt UJ o C o o o lt D LLOZ 1940120 Meeting Legal Requirements It is the responsibility of the person performing modifications to the vehicle to ensure that the vehicle in its final configuration conforms to any applicable law regarding em
89. onal loading or concentrated loading does not increase vehicle load carrying capacity unless it has been fully verified that all other vehicle components such as the brake system steering system suspension system etc can properly and safely support the increased loading Increase in Local Stress In any modification of the chassis frame the addition of holes reinforcements welds clamps splices etc may cause an increase in the local stress in the frame at the point of the modification therefore causing a stress concentration in the frame sidemember s These local stress concentrations can significantly affect the life of the chassis frame The specific effect which the stress concentrator will have on the life of the chassis frame is influenced by the location of the stress concentration the frequency and severity of the loading and the magnitude of stress concentration Deviation from the repair procedures in this section may void manufacturer s warranty Identification of Frame Rail Material c 3 1 72 r D lt c D o lt IC chassis are manufactured with frame rails of different alloy steels and some heat treated Each material must be handled in a specific manner to assure maximum service life therefore the frame material must be determined before attempting repair or modification
90. onformance Type 1 The vehicle when completed will conform to the standard if no alterations are made to the identified components Type 2 The vehicle when completed will conform to the standard if the specific conditions of final manufacture are met Type 3 Conformance with the standard cannot be determined based upon the components supplied on the vehicle therefore Navistar Inc makes no representation as the conformity of the vehicle to the standard Additional Lighting Information Lighting Devices and Reflectors Required by FMVSS 108 and CMVSS 108 Table 1 2 Required Vehicle Lighting Equipment for Buses with an Overall Width of 80 inches or more REQUIRED LIGHTING QUANTITY EQUIPMENT Headlamps 2 at least Turn signal Front Identification Lamp Front Tail Lamp mm U C COMMERCIAL BUS COLOR White Amber Amber LOCATION At or near front POSITION On the front at the same height an equal number at each side of the vertical centerline as far apart as practicable One on each side of the vertical centerline at the same height and as far apart as practicable As close as practicable to the vertical centerline of the vehicle or the vertical centerline of the cab where different from the centerline of the vehicle One lamp each side of the vertical centerline at the same height and as far apart as practicable HEIGHT ABOVE ROAD SURFACE In inches measured from the cen
91. ontrol Device MUST remain as part of the exhaust piping Changes to the location of the Temperature Control Device relative to the Aftertreatment Module must meet federal emissions noise and safety requirements The responsibility for demonstrating that legal requirements are met when modifications have been made belongs to the modifier of the system If changing the location special attention must be given to maintaining clearances around the exhaust piping as well as maintaining the structural integrity and exhaust backpressure of the system Tables included in this document provide recommended clearances and back pressure estimation procedures EXHAUST PIPING MODIFICATIONS Never modify the internal structure of the Turbo Pipe the Aftertreatment Module or the Temperature Control Device When lengthening or shortening tailpipes beyond the Aftertreatment Module observe the following precautions 1 Use the same size and material to extend or shorten the original pipe Refer to Table 3 1 for proper material and sizing of pipes when extending or shortening tailpipe sections 2 Adding additional extensions and bends will change internal exhaust gas pressure which could result in damage to the Aftertreatment Module or other engine components as well as a reduction in fuel economy Use the worksheets provided to compute the change in backpressure of the modified exhaust piping Ensure that the limits within the worksheet are met to avoid pe
92. pment and are intended for reference only To compute actual frame height refer to the frame height calculation section beginning on page 69 2 Frame Height at centerline of front axle unloaded 26 23 loaded 25 79 3 Frame Height at centerline of rear axle unloaded 32 14 loaded 29 30 NOTE Due to internal spring friction and manufacturing tolerances these values may vary up to 0 5 inches To achieve these nominal values directly after loading or unloading a vehicle it may be necessary to drive the vehicle for a short period U C COMMERCIAL BUS 23 IC BUS U C COMMERCIAL BUS 24 It BUS MODEL 4 2 Chassis Diagram Side View Hood Tilt Dimensions HOOD TILT ANGLE 70 70 63 6 fi 1616 d SWING HEIGHT SHON 1 4 N fei FN wb O D o O lt o O o lt GROUND LINE UC side hood tilt MODEL 4x2 Chassis Diagram Front and Rear View 57 8 1468 TO MIRROR 87 0 2210 FENDER WIDTH A ee 2 s ZZ Z me i CI 4 61 8 1570 HEADLAMPS 85 0 2158 B
93. r is to chisel the walls of the collar Figure 2 16 Figure 2 16 Using a Chisel to Split the Collar 01 0026 When the collar has been opened over the length of the swaged portion on two opposite sides Figure 2 17 the fastener can be removed The fastener may need to be hammered to remove the collar c O o 4 D c P F lt 77 o lt o Figure 2 17 Collar with Reliefs for Removal 01 0027 In the event the collar doesn t come loose use a chisel or suitable tool to peel the collar sections back Figure 2 18 Figure 2 18 Collar Peeled Back to Assist Removal 01_0028 The fastener will come free when sufficient collar material has been pulled away Figure 2 19 t o 7 gt o C lt o C o o o lt Figure 2 19 Fastener Removed 01 0029 U C COMMERCIAL BUS 53 IC BUS U C COMMERCIAL BUS 54 IC BUS Install The Huck Spin is installed by spinning the collar onto the fastener The pulling action of the Huck Spin installation tool swages the collar into the grooves of the fastener and then automatically disengages from the fastener Figure 2 20 Figure 2 20 Huck Spin Installation 01_0030
94. reinforcements are recommended for weld repairs in which the weld does not extend beyond the zone defined in Figure 2 5 Application Procedures 1 Atypical installation is shown in Figure 2 5 The length and height of the plate will vary with the size of the weld repair area In general it should be such that it will accommodate an array of reinforcement attachment bolts at a typical 3 to 5 inch 76 to 127 mm spacing all around the weld repair area 2 plate should generally be installed on the side opposite the component which transferred the local bending load into the web 3 The edges of the plate should be staggered with respect to the edges of other relatively stiff web mounted components to avoid the creation of stress concentrations UC COMMERCIAL BUS 45 O 7 a c mp D lt c D lt L 1 IC BUS U C COMMERCIAL BUS 46 IC BUS Bolt and Torque Information Most frames are assembled with bolts and nuts Others are riveted Bolts must always be used when attaching a reinforcement Rivets should be replaced by bolts as required when the frame is repaired and reinforced In bolted joints the majority of the load is transferred by frictional force or clamping force between the members of the joint The bolts must be properly tightened to develop and maintain the desired clamping
95. rformance issues and to maintain warranty of the engine and aftertreatment system 3 Support additional piping using rubber mounts approved by International Truck and Engine Corporation P N 3533072C1 Isolator and P N 3561980C1 Metal Sleeve Add one additional support for every 4 linear feet of exhaust piping added evenly spaced along the length of the chassis c O 3 e c e D lt c D lt The exhaust piping should be routed so that the Temperature Control Device if so equipped is at end of the exhaust pipe and oriented in the same manner as received from the factory Route all piping with minimum clearances to other chassis components as shown in Table 3 2 LLOZ 1940120 U C COMMERCIAL BUS 89 IC BUS U C COMMERCIAL BUS 90 IC BUS MOUNTING OF BODY EQUIPMENT In comparison to vehicles produced prior to 2007 exhaust components surface temperatures and exhaust gas temperatures will typically be higher As a result of the increased temperatures clearances to exhaust components will need to be increased compared to pre 2007 model year clearances Typical installation clearances used for pre 2007 model year engines and exhaust systems should be increased by 4096 to ensure that body equipment is not damaged by the increased heat of these systems Do not mount any Body Equipment within
96. sidemember cracks caused complete separation or a visible deformation of the section 2 When the sidemembers are extensively deformed Consult with your field service representative and frame repair specialists if in doubt Preparation of Frame for Repair Bevel Crack to Weld To assure complete weld penetration bevel the crack from one side when welding from one side Bevel the crack from both sides when welding from both sides The existing crack in the sidemember must be entirely removed Flgure 2 3 Widen the crack its full length to 1 8 inch 3 mm If required a rubber backed disc grinder or high speed steel burr may be used Clean Surface to Weld Surfaces to be welded and surfaces adjacent to the weld must be free of loose scale slag rust grease moisture paint or other material that could contribute to poor quality welds 1 FRAME RAIL 2 WIDEN CRACK D 5 UJ lt o lt UJ o F o o UJ o lt lt UJ 3 3 BEVEL EDGES R Figure 2 3 Preparing For Weld Repair 01_0013 Welding Electric arc welding is recommended for repair of steel frames The shielded arc method should be used because the heat generated during welding is localized and burning of material is minimized using this method Additional advantages are that the finished weld can be ground flush and drilled as necessary U C COMMERCIAL BUS 35 IC BUS U
97. ter of the lamp on vehicle at curb height Not less than 22 or more than 54 Not less than 15 or more than 83 All three on same level as close as practicable to the top of the vehicle with lamp centers spaced not less than 6 inches or more than 12 inches apart Both on the same level between 15 and 72 c O e c e D lt c D o lt IC BUS UC COMMERCIAL BUS 6 Table 1 2 Required Vehicle Lighting Equipment for Buses with an Overall Width of 80 inches or more REQUIRED LIGHTING QUANTITY COLOR LOCATION EQUIPMENT Stop Lamp One on each side of Amber front Front Clearance Lamps One on each side of Rear Clearance Lamps rear Side Marker Lamp Intermediate Amber One on each side Reflex Reflector Intermediate Side Amber One on each side Reflex Reflector Rear Reflex Reflector Rear Side Reflex Reflector Front Side One on each side front POSITION One lamp each side of the vertical centerline at the same height and as far apart as practicable One on each side of the vertical centerline to indicate width One on each side of the vertical centerline to indicate overall width At or near midpoint between front and rear side marker lamps if vehicle over 30 in length At or near midpoint between front and rear
98. ter the effective date of a standard which in the knowledge of the selling party does not comply with the standard 3 Any party manufacturer dealer body builder or other who completes a vehicle for sale in compliance with the law but fails to certify the completed vehicle in the prescribed manner 4 Any party who knowingly certifies a vehicle as complying which does not in fact meet the requirements of the law Situations where the government was intentionally misled in regards to safety related defects are criminal violations and are punishable by a maximum of 15 years in prison The U S Department of Transportation has declared its intent to institute procedures periodically to inspect vehicles subject to the law and to implement enforcement procedures that will permit detection of violations The requirements of the law are stringent and the penalties for violation are severe It is therefore mandatory that all personnel involved in any of the following aspects of motor vehicles become familiar with the provisions of the law as they relate to their responsibilities Installation of equipment sub assemblies and or bodies Intermediate and Final Stage Manufacturer Sales Preparation for delivery Modification or conversion Alterer Maintenance and repair 3 D 4 29 c r D lt c D o lt UJ Violation of
99. the Canada Motor Vehicle Safety Standards law carries similar penalties NOTE The Canadian Mexican and U S vehicle standards which regulate the manufacture of vehicles for sale in their respective countries may at any time exceed all or a portion of the mandated requirements of one or both of the other two countries This situation exists due to established standards or regulatory revisions in one country which have not yet been incorporated by the other s Each of these countries require that any vehicle crossing its border s in commerce must comply with all applicable standards of their country and comply with the standards that were in effect as of the date of manufacture of that vehicle Federal Motor Vehicle Standards FMVSS and Canadian Motor Vehicle Safety Standards CMVSS The following standards of Title 49 of the CFR apply to all liquid fueled vehicles having a GVWR greater than 10 000 pounds Presently all IC Bus trucks and buses are powered with diesel engines and have been designed to have a GVWR of greater than 10 000 pounds For any vehicle manufactured by and purchased from International and defined by section 567 3 of Title 49 of the CFR as an Incomplete Vehicle consult the Incomplete Vehicle Document IVD provided with each Incomplete Vehicle to determine those particular safety standards with which the vehicle complies Any standards with which International cannot certify compliance because of the level of complet
100. tion being reinforced 2 corners of the reinforcements which will be in contact with the sidemember along the reinforcement edges must be chamfered to prevent damage to the sidemember 3 All sidemember reinforcements must be bolted to the web section within the zone shown in the frame drilling guidelines in the specific model body builder book The bolts must be of SAE Grade 8 or better with integral flanges or with hardened flat washers and must be tightened to Grade 8 levels 4 Crossmember modification or replacement may be required if the reinforcement is on the same side as the crossmember 5 Consider the potential effects of the reinforcements on the various components mounted to the frame Check clearances for suspension wiring plumbing and other controls 6 For attachment of reinforcements use existing bolts wherever this is practical The weld repaired area of the sidemember and all of the reinforcement should be primed and painted before reinforcement installation For corrosive environments additional treatment of the interface may be needed c O 3 C3 gt c mp D lt c D lt UJ Full Length Channel Weld Repair Reinforcements Full length channel reinforcements are available through IC dealers for most models The actual length starting location and ending location vary from model
101. to model Different length reinforcements may also be available When applied as a repair reinforcement these reinforcements DO NOT increase the load capacity of the vehicle Their advantage in this case is their availability A disadvantage of this type is that it is likely to affect more of the components which mount to the frame In some cases this disadvantage may be offset by cutting the full length reinforcement to create a local reinforcement Recommended Applications 1 Cases of repair of vertical cracks in either the top or bottom flanges at very low mileage 2 Cases in which the weld repair is accompanied by extensive straightening of heat treated sidemembers U C COMMERCIAL BUS 43 IC BUS U C COMMERCIAL BUS 44 IC BUS Full Length L Weld Repair Reinforcements Steps 1 and 2 above also apply to the full length L reinforcements available from IC All of these are the inverted type and are designed for installation on the outside of the sidemember section except 9000 Series Figure 2 5 Recommended Applications This type of reinforcement is recommended for cases of cracking at very low mileage where a web crack has extended beyond the range for a flat plate reinforcement but ends short of the bend radius It is also applicable to cases in which the cracking is accompanied by flange buckling Application Procedures 1 Forcustom fabricated full length L reinforcements the section should
102. vehicle The number location and sizes of additional bolt holes put in the frame subsequent to manufacture of the vehicle can adversely affect frame strength The adverse effect of additional bolt holes can be minimized by following the guidelines Huckbolt Fasteners HP 8 Huckbolt HP 8 fasteners are used in various positions in frame rail construction Advantages to this style fastener are consistent clamp load and a high resistance to loosening due to vibration The need to recheck fastener torque is eliminated PINTAIL COLLAR Mb eye un DEM LOCK GROOVES PULL GROOVES Figure 2 7 Huckbolt Fasteners 01_0017 Removal The swaged collar cannot be unscrewed due to the locking grooves on the HP 8 fastener Removal requires a Huck Collar Cutter or the collar can be split with an air chisel while supporting the opposite side of the collar When the collar is split the fastener can be driven out with a punch c C 3 3 D 1 D UJ o O lt UJ o o o UJ lt UJ L 1 CHISEL Figure 2 8 Collar Can Be Split With an 01_0018 Air Chisel U C COMMERCIAL BUS 47 IC BUS U C COMMERCIAL BUS 48 IC BUS CAUTION The HP 8 fastener is not intended for re use To do so can result in damage to the vehicle frame or components attached to the frame CAUTION In the event that Huck fasteners are r
103. wing Correct and Incorrect Methods of Finishing the Joint October 2011 IC BUS NE oem U C COMMERCIAL BUS U C COMMERCIAL BUS 60 IC BUS Wheelbase Alterations Shortening or lengthening a wheelbase is an added expense for the customer Therefore it is often to the customer s benefit to order a chassis from the factory with the desired wheelbase rather than to alter the wheelbase of the chassis on site The preferred method for altering the wheelbase is to slide the rear axle forward or rearward as required Invariably this requires the lengthening or shortening of air lines brake lines electrical lines and driveline Extreme care should be taken in the modification of the air lines brake lines electrical lines and driveline to insure that they operate as reliably as those with which the vehicle was manufactured If the wheelbase is lengthened a reinforcement may be required Consult your IC Bus dealer before lengthening the wheelbase In those instances when it is necessary to cut and weld the frame to alter the wheelbase the frame must be reinforced with a channel type reinforcement of the same strength as the original frame material in the area where the frame has been cut extending at least two feet on either side of the cut and bolted as specified in Figure 2 5 shown earlier in this section If the frame was built with both a main frame and a reinforcement the reinforcement should be removed before cutting the main frame
104. y to Navistar Inc vehicles sold in the two countries of those laws that established these standards and the identity of the parties responsible for certification of compliance for both Complete Vehicles and Incomplete Vehicles To the best of International s knowledge it is correct as of the date of this printing International however cannot accept responsibility for it s completeness and currency User must ascertain this on his own The National Traffic and Motor Vehicle Safety Act of 1966 in the U S gave rise to the Federal Motor Vehicle Safety Standards FMVSS In addition The Environmental Protection Agency through the Environmental Policy Act of 1969 set forth environmental protection standards In Canada the Motor Vehicle Safety Act of 1970 established the Canadian Motor Vehicle Safety Standards CMVSS Act These standards place the responsibility for compliance of a Complete Vehicle on the vehicle and engine manufacturers Any vehicle purchased from International as a Complete Vehicle as defined by section 568 3 of Title 49 of the Code of Federal Regulations CFR is certified by International to comply with all applicable safety standards provided modifications or additions to the vehicle do not result in non compliance with applicable U S and Canadian standards to which Navistar Inc has certified compliance Also it is the responsibility of every International dealer to assure that the service work or modifications that can affe

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