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Western Star Bodybuilder Book: Revision

3.1

This guide is to be used as a reference document only.

Please consult your Western Star CAE representative on

specific spec’ing needs as the information contained in

this document can change without notice.

Section

Frame, Bumper

& Crossmember

Components

Table of Contents

P. 3-1

4700 Main Frame Rail 3-2

4800/4900/6900 Main Frame Rail 3-3

4800/4900/6900 Frame Inner & Outer Liners 3-4

All Models Frame Height Calculation 3-5

All Models Frame Slope Calculation 3-6

Basic 4700 Design Parameters 3-7

Basic 4800 Design Parameters 3-8

Basic 4900 Design Parameters 3-9

Basic 4900XD Design Parameters 3-10

Basic 6900XD Design Parameters 3-11

4700 Front Frame Options

4700 SF Cast Drop Frame 3-12

4700 SB Stamped Front Frame 3-13

4700 SB Bolt-on Front Frame 3-14

4700 SF/SB Front Frame Extensions 3-15

4800/4900/6900 Front Frame Options

SF/SB Drop Frame Non Logger 3-16

4800/4900 SF/SB - Drop Cast Logger Bumper & Flush Mount Tow Pin 3-17

4800/4900 Non Logger Front Frame Extensions

Frame Extensions 12” and Under 3-18

Frame Extensions Over 12” 3-19

48/4900 SB Snow Plow Reinforcement 605-043 3-20

All Models Basic Crossmember Layout 3-21

Midship Crossmembers

4700 SF/SB 3-22

4800/4900/6900 SF/SB 3-23

End of Frame Crossmembers

4700 SF/SB Standard Rear Crossmembers 3-24

4700 SF/SB Clevis Tow Crossmembers 3-25

4700 SF/SB Drop Centre Towing Crossmembers 3-26

4800/4900/6900 SF/SB Standard Rear Crossmembers 3-27

4800/4900/6900 SF/SB Drop Centre Towing Crossmembers 3-28

4800/4900/6900 SF/SB C-Channel Crossmembers 3-29

Summary of content (29 pages)

PAGE 1
Western Star Bodybuilder Book: Revision 3.1 Table of Contents Section 3 Frame, Bumper & Crossmember Components This guide is to be used as a reference document only. Please consult your Western Star CAE representative on specific spec’ing needs as the information contained in this document can change without notice.
PAGE 2
Western Star Bodybuilder Book: Revision 3.1 3 4700 Main Frame Rail P. 3-2 4700 Frame Rails 4700 frame rails are designed to maintain a constant main rail inside dimension of 33.6”. Mod 546 4700 Chassis Grid Ÿ Main frame rails for the 4700 chassis are offered in only single channel configurations Ÿ Single Channel rail is made up of a single main frame rail component which can be 50mm 50mm combined with a 547 partial liner to add strength only where needed and reduce overall weight.
PAGE 3
Western Star Bodybuilder Book: Revision 3.1 3 4800/4900/6900 Main Frame Rail P. 3-3 Frame Design Data 4800/4900/6900 Frame Rails WST frame rails are designed to maintain a constant outside dimension of 34” with the exception of the 548 outer reinforcement. Mod 546 RBM Data Code 1.75” 1.75” 546-089 5/16"X3-1/2"X10-5/8" 120KSI 14.8 1,776,400 546-087 3/8"X3-1/2"X10-3/4" 120KSI 17.8 2,135,700 546-090 3/8"X3-7/8"X11-5/8" 120KSI 21.47 2,576,000 5/16"X3-1/2"X10-5/8" Double channel 120KSI 23.
PAGE 4
Western Star Bodybuilder Book: Revision 3.1 4800/4900/6900 Frame Inner & Outer Liners Mod 547 Partial Frame Rails Option Description 4xxx 69xx 3 P. 3-4 Liner Location Ÿ Partial Inner frame reinforcements are used in conjunction with module 546 SC and DC main frame rails. Ÿ Where weight is an issue WST’s partial liner options can help reduce overall 547-019 1/4” (6MM) C-channel insert at rear suspension only 547-026 1/4” (6.
PAGE 5
Western Star Bodybuilder Book: Revision 3.1 3 All Models Frame Height Calculation P. 3-5 Ride height information Tire, suspension and frame data will be calculated by your dealer sales person for a specific serial number once the order has been entered into SpecPro The ride height calculation information will be located under the Performance “tab” / Unladen FrameHeight / View - Graph.
PAGE 6
Western Star Bodybuilder Book: Revision 3.1 3 All Models Frame Slope Calculation P. 3-6 Frame Slope Calculations “Calculated Frame Slope @ Front/Rear Suspension Ratings” so chassis suitability is easier to determine for all parties. Negative (-) slope The frame slope percentage expresses the rake, or slope, of the frame rails as seen from the side of the vehicle when the axles are loaded to their Gross Axle Weight Ratings (GAWR’s).
PAGE 7
Western Star Bodybuilder Book: Revision 3.1 3 Basic 4700 Design Parameters P. 3-7 121.7” Bumper to C/L Back of Cab Crossmember 4700SF/SB 112.3” Bumper to Back of Cab Front Axle Position, see section 6 page 6-1, 6-2 Bumper to STN_0 5.6 C/L STN_0 zero point for locating most frame drilling holes For suspension Ride height information see section 8 page 8-3 for your TSO Option Rear cab supports are located outboard on the 4700 to improve access to Rear PTO locations.
PAGE 8
Western Star Bodybuilder Book: Revision 3.1 3 Basic 4800 Design Parameters P. 3-8 121.0 Bumper to C/L back of cab cross member 109.0 Bumper to back of cab Front axle position see section 6A, page 6-1, 6-2 Bottom of frame rails & STN_0 point for locating most frame drilling holes 2.
PAGE 9
Western Star Bodybuilder Book: Revision 3.1 3 Basic 4900 Design Parameters P. 3-9 128.50 Bumper to C/L of back of cab crossmember 127.10 Bumper to back of cab Front axle position see section 6A, page 6-1, 6-2 Bumper to STN_0 6.
PAGE 10
Western Star Bodybuilder Book: Revision 3.1 Basic 4900XD Design Parameters 148.93 Bumper to C/L of back of cab crossmember 147.46 Bumper to back of cab Front axle position see section 6A, pages 6-1, 6-2 Bumper to STN_0 26.
PAGE 11
Western Star Bodybuilder Book: Revision 3.1 3 Basic 6900XD Design Parameters P. 3-11 140.09 Bumper to back of cab Front axle position see section 6A, pages 6-1, 6-2 Bumper to STN_0 10.
PAGE 12
Western Star Bodybuilder Book: Revision 3.1 3 4700 Front Frame Options P. 3-12 4700 SF Cast Drop Frame 558-063 Heavy duty center mounted tow pin 5.6” 2” Tow Pin Detail 2.5” 17.1” 52.3 mm DIA C L 2.5” ½” UNC (4) 2.0” 11.0” 5.0” 44.
PAGE 13
Western Star Bodybuilder Book: Revision 3.1 3 4700 Front Frame Options P. 3-13 4700 SB Stamped Front Frame 558-033 Removable front tow hooks stored on the chassis frame Chassis C L Tow Hook Storage 3.2” Front Face of Bumper Mounting 33.6” Inside of Rail C L 3.42” Front Face of Bumper 0.6” 4.5”Center of Rail ½” NC (4) 1.3” Center of Rail C L Frame 6.4” 6.8” 13.5” 13.8” 46.25” 1.
PAGE 14
Western Star Bodybuilder Book: Revision 3.1 3 4700 Front Frame Options P. 3-14 4700 SB Bolt-on Front Frame 558-033 Heavy duty center mounted tow pin 5.6” 2.0`” Tow Pin Detail 49.57” C L Chassis 79.2m Front face of Bumper 88.7mm Front face of Brackets 44.75” 32.2” 2.3” 1.6” 1.1” 1.8” Frame C L Rail 4.6” 2.75” 14.0” 14.0” 10.0” 4.
PAGE 15
Western Star Bodybuilder Book: Revision 3.1 3 4700 Front Frame Options P. 3-15 4700 SF/SB Front Frame Extensions 549-002 - 24" Integral front frame extension 549-016 - 24" Integral front frame extension with 14” reinforcement 549-036 - 12" Integral front frame extension 549-018 - 12" Integral front frame extension with 14” reinforcement 46.7” Inside Rail C L Chassis Frame 4700SF With Brackets & Tow Hooks 4 X 0.68” Dia 1.2” 1.7” 1.2” (24” ext) (12” ext) 0.79” 2.
PAGE 16
Western Star Bodybuilder Book: Revision 3.1 4800/4900/6900 Front Frame Options SF/SB Drop Frame Non Logger 44.0” C L Frame 11.0" Bottom of Rail 3.61" 6.96" 17.0" Swept Back Brace 8.5" 22.0" 10.0" 3.0” Drop Cast Front Frame with or without Tow Hooks 558-998 No Front Tow Hooks 558-031 Front Tow Hooks - Flange Mounted 2.34” C L Station “0” Top View 22.0" C L Frame Vocational Bumper bracket Mounts Bottom of Rail 11.0" 6.96" 1.
PAGE 17
Western Star Bodybuilder Book: Revision 3.1 4800/4900/6900 Front Frame Options Front Face Crossmember Front Face Bumper 4800/4900 SF/SB - Drop Cast Logger Bumper & Flush Mount Tow Pin 2.5” 4.0” 3.45" 5.6” C L Frame 2.0” 6.0” 3.2" TopView 2” Dia 1.75” Std Tow Pin 44.0” C L Frame 17.0" 11.0" 3.61" Bottom of Rail 6.96" (1) 1/2”-13 UNC 22.0" (6) 1/2”-13 UNC 3 P.
PAGE 18
Western Star Bodybuilder Book: Revision 3.1 3 4800/4900 Non Logger Front Frame Extensions P. 3-18 Frame Extensions 12” and Under C L Frame 1.8” “A” 24.25” 2.25” 17.62” C L Frame 0.75” 5.0” 4.37” 8.33” 2.34” 5.51” (4) 11/16” Dia 2.0” 2.25” bottom of rail (6) 1/2”-13 UNC Mod 549 Extension Std 2” Ext 8” Ext 12” Ext “A” 13.25” 9.25” 1.
PAGE 19
Western Star Bodybuilder Book: Revision 3.1 4800/4900 Non Logger Front Frame Extensions Frame Extensions Over 12” 1.8” 34.0” Extention Length + 1.25” 24.25” 13.25” 2.25” 17.62” C L Frame 0.75” 2.25” 2.0” 5.0” 4.37” 8.33” 2.34” 2.25” bottom of rail (4) 11/16” Dia (6) 1/2”-13 UNC 3 P.
PAGE 20
Western Star Bodybuilder Book: Revision 3.1 48/4900 SB Snow Plow Reinforcement 605-043 2” 5.8” D 6.0” 1.25” 23/32” D (2) 1.25” 25/32” D (7) 1” 2.25” 3.25” 9.25” 8.25” 4.41” 8.0” 0.5” 16.0” 1.81” 24.0” 28.0” 3.87” Ref dwg no.15-25467 2.5” 34.0” Extention Length + 1.25” 0.75” 24.25” 0.75” 17.62” C L Frame Snow Plow Reinforcement 2.0” 6.0” 2.25” (4) 11/16” Dia 7.0” (6) 1/2”-13 UNC 35.5” 13.25” 3 P.
PAGE 21
Western Star Bodybuilder Book: Revision 3.1 All Models Basic Crossmember Layout * Same crossmembers will be used for all additional Midship positions - wheelbase dependent ** See suspension section 8 for individual configuration Example of a Front Towing Crossmember DC 558 3 P.
PAGE 22
Western Star Bodybuilder Book: Revision 3.1 Midship Crossmembers 4700 SF/SB Crossmember ordered using 562-*** sales code will be used for all chassis midship crossmembers (562, 563, 568, 573). See page 3-12 for reference. 3 P. 3-22 “A” Dimension dependant on frame rail conﬁguration. See “Frame Rail Combination Chart” on page 3-10 for crossmember width.
PAGE 23
Western Star Bodybuilder Book: Revision 3.1 Midship Crossmembers 4800/4900/6900 SF/SB Crossmember ordered using 562-*** sales code will be used for all chassis midship crossmembers (562, 563, 568, 573). See page 3-12 for reference. “A” Dimension dependant on frame rail conﬁguration. See “Frame Rail Combination Chart” on page 3-10 for crossmember width.
PAGE 24
Western Star Bodybuilder Book: Revision 3.1 End of Frame Crossmembers 4700 SF/SB Standard Rear Crossmembers “A” Dimension dependant on frame rail conﬁguration. See “Frame Rail Combination Chart” on page 3-10 for crossmember width.
PAGE 25
Western Star Bodybuilder Book: Revision 3.1 End of Frame Crossmembers 4700 SF/SB Clevis Tow Crossmembers “A” Dimension dependant on frame rail conﬁguration. See “Frame Rail Combination Chart” on page 3-10 for crossmember width. 572-009 5/16 INCH STEEL TOWING CROSSMEMBER AND A-FRAME WITH CLEVIS AND PIN ATTACHMENT - 40,000# CAPACITY 30.7” 12.25” 15.35” 11.33” 10.39” 33.6” 27.97” 6.13” 7.87” C L 13.97” 4.7” = = 5.7” 2.62” 16.85” 3 P.
PAGE 26
Western Star Bodybuilder Book: Revision 3.1 3 End of Frame Crossmembers 20.37” 4700 SF/SB Drop Centre Towing Crossmembers “A” Dimension dependant on frame rail conﬁguration. See “Frame Rail Combination Chart” on page 3-10 for crossmember width. Crossmember “A” Dimention 572-002 DROP CENTER TOWING CROSSMEMBER WITH U-BOLT ATTACHMENT - 40,000# CAPACITY P. 3-26 Frame Stack up 3/8x3/8 1/4 TC 3/8x1/4x1/4 TC 3/8x3/8 DC 3/8x1/4 DC 5/16x1/4 DC 1/4x1/4DC 3/8 SC 5/16 SC 1/4 SC 6.5” 4.0” “A” Dim 32.00 32.
PAGE 27
Western Star Bodybuilder Book: Revision 3.1 End of Frame Crossmembers 4800/4900/6900 SF/SB Standard Rear Crossmembers “A” Dimension dependant on frame rail conﬁguration. See “Frame Rail Combination Chart” on page 3-10 for crossmember width. “A” DIMENSION 572-057 INVERTED MOUNTED REAR CLOSING CROSSMEMBER 572-065 INVERTED MOUNTED REAR CLOSING CROSSMEMBER AFT 82 INCHES FROM REAR SUSPENSION CENTERLINE 572-034 TUBULAR STEEL REARMOST CROSSMEMBER 572-041 HEAVY DUTY TUBULAR STEEL REARMOST CROSSMEMBER 9.85” 7.
PAGE 28
Western Star Bodybuilder Book: Revision 3.1 3 End of Frame Crossmembers P. 3-28 20.37” 4800/4900/6900 SF/SB Drop Centre Towing Crossmembers “A” Dimension dependant on frame rail conﬁguration. See “Frame Rail Combination Chart” on page 3-10 for crossmember width. 572-002 DROP CENTER TOWING CROSSMEMBER WITH U-BOLT ATTACHMENT - 40,000# CAPACITY 19.5” 11.5” bottom 10.75” Top 6.
PAGE 29
Western Star Bodybuilder Book: Revision 3.1 3 End of Frame Crossmembers P. 3-29 4800/4900/6900 SF/SB C-Channel Crossmembers “A” Dimension dependant on frame rail conﬁguration. See “Frame Rail Combination Chart” on page 3-10 for crossmember width. 572-045 - 3/8 inch steel c-channel rear towing crossmember with a-frame, 40,000# capacity 572-043 - 1/4 inch steel c-channel crossmember without a-frame, non-towing 572-046 - 3/8 inch steel c-channel crossmember without a-frame, non-towing 1.44” 2.