31 mag 2023 — SCR / DPF 4HK1-TC ... Vehicle Owner's Manual. Low Speed Applications for LCF Series Chassis. Any ...
May 24, 2023 · ISUZU. NPR / NPR-HD / NPR-XD. 5. ISUZU. NQR/NRR. 6. ISUZU. FTR. Page 25. 2024 Chevrolet LCF. Revision: 05/31/23. 2024 Chevrolet Low Cab Forward.
2024 Chevrolet Low Cab Forward Important The digital version of this manual (.pdf) is fully linked from the table of contents directly to the contents of the manual. Click on any BOLD table of contents entry and that page will be selected automatically. 2024 Chevrolet LCF Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE i Table of Contents 2024 CHEVROLET LOW CAB FORWARD ..................................................................................................................................................................0.01 INTRODUCTION ........................................................................................................................................................................................................1.1 LCF MEDIUM DUYT V.I.N IDENTIFICATION .............................................................................................................................................................1.11 CAUTIONARY NOTES ................................................................................................................................................................................................1.2 Electrical Sensitivity and Battery Relocation Warning All Fluids and Lubricants Caution Low Speed Applications for LCF Series Chassis Auxiliary Transmission Cooler Warning Transmission Temperature Warning Lamp Fuel Tank Caution Tapping into Engine Cooling System Brake Override Logic NO-START CONDITION CLICKING OR BANGING FROM STARTER LCF Trucks Equipped with 5.2L (4HK1) Diesel Engines ...................................................................................................................................... 1.3 INSTALLATION OF BODY AND SPECIAL EQUIPMENT 4500, 5500 SERIES Clearances ................................................................................................2.01 Engine Transmission Front and Center Propeller Shafts Rear Propeller Shaft Exhaust System Diesel Particulate Filter and Selective Catalytic Reduction (SCR) Restrictions Exhaust Clearances Exhaust system surface temperatures During Manual Regeneration 2024 Chevrolet LCF Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE ii Rear Wheel Axle Other Clearances Body Installation ...........................................................................................................................................................................................2.10 Mirrors Sidestep Door Installation recommendations DPF/SCR Heat Shield Removal LCF 4500HD, 4500XD, 5500HD, 5500XD.........................................................................................................................................................2.13 Subframe Contour Prohibited Attachment Areas........................................................................................................................................................................2.15 Front U-bolt and Mounting Bracket, Mounting Locations Ahead of Transmission U-Bolt Placement 150" W/B Crew Cab Subframe Mounting ......................................................................................................................................................................................2.18 Bracket Installation Modular Frame Hole Pattern U-bolt Installation Crew Cab Body / Frame Requirements..........................................................................................................................................................2.20 Modification of the Frame.............................................................................................................................................................................2.21 Working on Chassis frame Drilling and Welding Reinforcement of Chassis Frame Welding Fluid Lines......................................................................................................................................................................................................2.23 Preparation of Additional Lines Installation of Additional Lines Electrical Wiring and Harnessing ...................................................................................................................................................................2.24 Wiring Wire Color Code 2024 Chevrolet LCF Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE iii Maximum Allowable Current ........................................................................................................................................................................2.27 Electrical System Modifications.....................................................................................................................................................................2.28 Exhaust System .............................................................................................................................................................................................2.29 Fuel System Rear Lighting Serviceability Wheelbase Alteration....................................................................................................................................................................................2.30 Shortening/Lengthening the Wheelbase Without Altering the Frame Altering the Wheelbase by Altering the Frame Glossary of Terms Chassis Wheelbase Alteration Wheelbase Alteration....................................................................................................................................................................................2.31 6500 XD Installation of Body and Special Equipment ................................................................................................................................... 3.02 Clearances Engine Compartment Transmission Front and Center Propeller Shfts Exhaust System Diesel Particulate Filter and Selective Reduction Restrictions (SCR) Exhaust Clearances Exhaust System Surface Temperatures During Manual Regeneration Rear Axle and Other Clearances 6500XD Body Installation Considerations..................................................................................................................................................... 3.09 Frame and Special Equipment ...................................................................................................................................................................... 3.11 Frame Prohibited Attachment Areas ............................................................................................................................................................ 3.13 Frame Bracket Specifications and U Bolts .................................................................................................................................................... 3.15 Frame Modification ...................................................................................................................................................................................... 3.18 Electrical ....................................................................................................................................................................................................... 3.21 2024 Chevrolet LCF Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE iv Exhaust System ............................................................................................................................................................................................ 3.25 Fuel System .................................................................................................................................................................................................. 3.26 Frame, Wheelbase Alteration....................................................................................................................................................................... 3.27 BODY APPLICATION SUMMARY CHART ............................................................................................................................................................... 3.11A 4500HD Diesel ...............................................................................................................................................................................................3.35 Body & Payload Weight Distribution (% Front/% Rear) 4500XD Diesel, 5500HD Diesel, 5500XD Diesel..............................................................................................................................................3.36 Automatic Transmission 4500HD, 4500XD, 5500HD Crew Cab Diesel...................................................................................................................................................3.38 Diesel Crew Cab Body & Payload Weight Distribution (% Front/% Rear) MECHANICAL AND CAB SPECIFICATIONS .................................................................................................................................................................4.1 Engine Horsepower and Torque Chart GVW/GCW Ratings Rear Frame Height Chart .................................................................................................................................................................................4.2 Body Application Summary Chart 6500 XD....................................................................................................................................................4.21 Paint Code Chart..............................................................................................................................................................................................4.3 Low Cab Forward Towing Procedure 4500, 5500 Series...................................................................................................................................4.4 When towing a vehicle Front End Towing (Front Wheels Off Ground) CAUTION: When towing After Towing Front End Towing (All Wheels On the Ground) Towing with all wheels on the ground CAUTION After Towing Rear End Towing Special Towing Instructions WEIGHT DISTRIBUTION CONCEPTS Mechanical and Cab Specifications................................................................................................................................................................5.01 2024 Chevrolet LCF Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE v 6500XD Towing Procedures ...........................................................................................................................................................................5.02 Weight Restrictions .........................................................................................................................................................................................5.1 Gross Axle Weight Rating Weighing the Vehicle Tire Inflation Center of Gravity Weight Distribution .........................................................................................................................................................................................5.3 Glossary of Dimensions ...................................................................................................................................................................................5.5 Weight Distribution Formulas .........................................................................................................................................................................5.6 Recommended Weight Distribution % of Gross Vehicle Weight by Axle .......................................................................................................5.12 Trailer Weight ................................................................................................................................................................................................5.14 Payload at Kingpin Payload at Rear Tandem Performance Calculations..............................................................................................................................................................................5.16 Speed Formula Grade Horsepower Formula Air Resistance Horsepower Formula Engine Horsepower Formula Gradeability Formula Startability Formula Vertical Center of Gravity Formula Horizontal Center of Gravity Formula Bridge Formula Weights .................................................................................................................................................................................5.26 COMMODITY AND MATERIAL WEIGHTS Approximate Weights of Commodities and Material........................................................................................................................................ 6.1 3500/4500/5500 12.0/14.5 GVW Gas-STD Cab 3500/4500 Gas Specifications ......................................................................................................................................................................... 8.1 2024 Chevrolet LCF Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE vi 5500 Gas Specifications ................................................................................................................................................................................... 8.2 Vehicle Weights, Dimensions and Ratings ....................................................................................................................................................... 8.3 Vehicle Weight Limits ...................................................................................................................................................................................... 8.4 Frame and Crossmember Specifications .......................................................................................................................................................... 8.5 Frame Chart..................................................................................................................................................................................................... 8.6 Top View.......................................................................................................................................................................................................... 8.7 Left Side View.................................................................................................................................................................................................. 8.8 Right Side View................................................................................................................................................................................................ 8.9 SCR / DPF 4HK1-TC..........................................................................................................................................................................................8.10 Cab Tilt ...........................................................................................................................................................................................................8.11 Turning Diameter ...........................................................................................................................................................................................8.12 Center of Gravity ............................................................................................................................................................................................8.13 Front Axle Chart ........................................................................................................................................................................................8.14 Rear Axle Chart...............................................................................................................................................................................................8.15 Suspension Deflection Chart...........................................................................................................................................................................8.17 Tire and Disc Wheel Chart ..............................................................................................................................................................................8.18 Propeller Shaft................................................................................................................................................................................................8.19 Brake System Diagram 14,500 GVW....................................................................................................................................................8.21 PTO Location Drive Gear and Opening Information .........................................................................................................................................8.22 Opening Diagram............................................................................................................................................................................................8.23 In-Frame Fuel Fill ........................................................................................................................................................................................... 8.24 Rear View Fuel Fill ......................................................................................................................................................................................... 8.25 2024 Chevrolet LCF Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE vii Top View Fuel Fill ............................................................................................................................................................................................8.26 Hose Modifications Various Bodies and Fuel Fill Vent Protection ...................................................................................................................8.27 Through the Rail Fuel Fill Frame Hole..............................................................................................................................................................8.28 3500/4500/5500 12.0/14.5 GVWR Gas Fuel filler Assembly......................................................................................................................................... 8.29 Installation Instructions and Considerations...................................................................................................................................................8.30 Roll-Over Valve Tubing .................................................................................................................................................................................................. 8.31 3500/4500/5500 12.0/14.5 GVW Gas-Crew Cab 3500/4500 Gas Specifications .......................................................................................................................................................................... 9.1 5500 Gas Specifications ................................................................................................................................................................................... 9.2 Vehicle Weights, Dimensions and Ratings ....................................................................................................................................................... 9.3 Vehicle Weight Limits ...................................................................................................................................................................................... 9.4 Frame and Crossmember Specifications .......................................................................................................................................................... 9.5 Frame Chart..................................................................................................................................................................................................... 9.6 Top View.......................................................................................................................................................................................................... 9.7 Left Side View .................................................................................................................................................................................................. 9.8 Right Side View................................................................................................................................................................................................ 9.9 SCR / DPF 4HK1-TC..........................................................................................................................................................................................9.10 Cab Tilt ...........................................................................................................................................................................................................9.11 Turning Diameter ............................................................................................................................................................................................9.12 Center of Gravity ............................................................................................................................................................................................9.13 2024 Chevrolet LCF Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE viii Front Axle Chart ............................................................................................................................................................................................9.14 Rear Axle Chart..............................................................................................................................................................................................9.15 Definitions .....................................................................................................................................................................................................9.16 Tire and Disc Wheel Chart .............................................................................................................................................................................9.17 Suspension Deflection Chart .........................................................................................................................................................................9.18 Propeller Shaft...............................................................................................................................................................................................9.19 Brake System Diagram 16,000 GVW .................................................................................................................................................. 9.21 PTO Location Drive Gear and Opening Information ......................................................................................................................................9.22 Opening Diagram...........................................................................................................................................................................................9.23 In-Frame Fuel Fill ...........................................................................................................................................................................................9.24 Rear View Fuel Fill .........................................................................................................................................................................................9.25 Top View Fuel Fill...........................................................................................................................................................................................9.26 Hose Modifications Various Bodies and Fuel Fill Vent Protection .................................................................................................................9.27 Through the Rail Fuel Fill Frame Hole............................................................................................................................................................9.28 3500/4500/5500 12.0/14.5 GVWR Gas Fuelfiller Assembly.......................................................................................................................9.29 Installation Instructions and Considerations .................................................................................................................................................9.30 Roll-Over Valve Tubing................................................................................................................................................................................................. 9.31 4500HG DIESEL SPECIFICATIONS ............................................................................................................................................................................10.1 Vehicle Weights, Dimensions Ratings............................................................................................................................................................10.2 Vehicle Weight Limits Technical Notes Chassis Curb Weight Maximum Payload Weight Frame and Crossmember Specifications........................................................................................................................................................10.4 2024 Chevrolet LCF Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE ix Frame Chart...................................................................................................................................................................................................10.5 4500HG Diesel Standard Cab - Top View........................................................................................................................................................10.6 4500HG Diesel Standard Cab - Left Side View................................................................................................................................................10.7 4500HG Diesel Standard Cab - Right Side View .............................................................................................................................................10.8 SCR / DPF 4HK1-TC ........................................................................................................................................................................................10.9 Option Side Fuel Tank ................................................................................................................................................................................................ 10.10 Addition to the Standard In Rail Fuel Tank RPO NLX Side View 150 Wheelbase Addition to the Standard In Rail Fuel Tank RPO NLX Side View 176 Wheelbase In place of the Standard In Rail Fuel Tank on T34003 ONLY Side View 176 Wheelbase Addition to the Standard In Rail Fuel Tank RPO NLX (150 and 176 WB, LH rail only) Replacing standard In Rail Fuel Tank (176 WB only, RH rail only) Cab Tilt ......................................................................................................................................................................................................................... 10.14 Turning Diameters .......................................................................................................................................................................................10.15 Center of Gravity .........................................................................................................................................................................................10.16 Front Axle Chart ..........................................................................................................................................................................................10.17 Rear Axle Chart............................................................................................................................................................................................10.18 Definitions Formulas for Calculating Rear Width and Height Dimensions 4500HG Suspension Deflection Charts ........................................................................................................................................................10.20 Tire and Disc Wheel Chart 4500HG ...........................................................................................................................................................10.21 Tire Disc Wheel Propeller Shaft.............................................................................................................................................................................................10.22 Brake System Diagram 14,500 GVW............................................................................................................................................................10.24 Vacuum Over Hydraulic PTO Location, Drive Gear and Opening Information ...................................................................................................................................10.25 Opening Diagram.........................................................................................................................................................................................10.26 2024 Chevrolet LCF Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE x In-Frame Diesel Fuel Fill ..............................................................................................................................................................................10.27 Rear View Fuel Fill Top View Fuel Fill Hose Modification .......................................................................................................................................................................................10.30 Various Width Bodies and Fuel Fill Vent Protection Ultra Low Sulfur Diesel Label.......................................................................................................................................................................10.31 Through the Rail Fuel Fill Frame Hole..........................................................................................................................................................10.32 4500HG Diesel Fuel Filler Kit Instructions ....................................................................................................................................................10.33 Installation Instructions and Considerations Roll-Over Valve Tubing Filler Neck Installation 4500XG DIESEL SPECIFICATIONS ............................................................................................................................................................................11.1 Vehicle Weights, Dimensions and Ratings.....................................................................................................................................................11.2 Vehicle Weight Limits Technical Notes Chassis Curb Weight Maximum Payload Weight Frame and Crossmember Specifications........................................................................................................................................................11.4 Frame Chart...................................................................................................................................................................................................11.5 4500XG Diesel Standard Cab - Top View........................................................................................................................................................11.6 4500XG Diesel Standard Cab - Left Side View................................................................................................................................................11.7 4500XG Diesel Standard Cab - Right Side View..............................................................................................................................................11.8 SCR / DPF 4HK1-TC ........................................................................................................................................................................................11.9 Option Side Fuel Tank ................................................................................................................................................................................................ 11.10 Addition to the Standard In Rail Fuel Tank RPO NLX Side View 150 Wheelbase Addition to the Standard In Rail Fuel Tank RPO NLX Side View 176 Wheelbase 2024 Chevrolet LCF Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE xi In place of the Standard In Rail Fuel Tank T44003 ONLY Side View 176 Wheelbase Addition to the Standard In Rail Fuel Tank RPO NLX (150 and 176 WB, LH rail only) Replacing standard In Rail Fuel Tank (176 WB only, RH rail only) Cab Tilt ......................................................................................................................................................................................................................... 11.14 Turning Diameters .......................................................................................................................................................................................11.15 Center of Gravity .........................................................................................................................................................................................11.16 Front Axle Chart ..........................................................................................................................................................................................11.17 Rear Axle Chart............................................................................................................................................................................................11.18 Definitions Formulas for Calculating Rear Width and Height Dimensions Tire and Disc Wheel Chart 4500XG............................................................................................................................................................11.20 Tire Disc Wheel 4500XG Suspension Deflection Charts.........................................................................................................................................................11.21 Propeller Shaft.............................................................................................................................................................................................11.22 Brake System Diagram 16,000 GVW............................................................................................................................................................11.24 Vacuum Over Hydraulic PTO Location, Drive Gear and Opening Information ...................................................................................................................................11.25 Opening Diagram.........................................................................................................................................................................................11.26 In-Frame Diesel Fuel Fill ..............................................................................................................................................................................11.27 Rear View Fuel Fill Top View Fuel Fill Hose Modification .......................................................................................................................................................................................11.30 Various Width Bodies and Fuel Fill Vent Protection Ultra Low Sulfur Diesel Label.......................................................................................................................................................................11.31 Through the Rail Fuel Fill Frame Hole..........................................................................................................................................................11.32 4500XG Diesel Fuel Filler Kit Instructions ....................................................................................................................................................11.33 2024 Chevrolet LCF Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE xii Installation Instructions and Considerations Roll-Over Valve Tubing Filler Neck Installation 5500HG DIESEL SPECIFICATIONS ............................................................................................................................................................................ 12.1 Vehicle Weights, Dimensions and Ratings .................................................................................................................................................... 12.2 Vehicle Weight Limits Technical Notes Chassis Curb Weight Maximum Payload Weight Frame and Crossmember Specifications ....................................................................................................................................................... 12.4 Frame Chart .................................................................................................................................................................................................. 12.5 5500HG Diesel Standard Cab Top View ......................................................................................................................................................... 12.6 5500HG Diesel Standard Cab -Left Side View ................................................................................................................................................ 12.7 5500HG Diesel Standard Cab Right Side View ............................................................................................................................................... 12.8 SCR / DPF 4HK1-TC ........................................................................................................................................................................................ 12.9 Option Side Fuel Tank ................................................................................................................................................................................................ 12.10 Addition to the Standard In Rail Fuel Tank RPO NLX Side View 150 Wheelbase Addition to the Standard In Rail Fuel Tank RPO NLX Side View 176 Wheelbase In place of the Standard In Rail Fuel Tank Addition to the Standard In Rail Fuel Tank RPO NLX (150 and 176 WB, LH rail only) Replacing standard In Rail Fuel Tank (176 WB only, RH rail only) Cab Tilt......................................................................................................................................................................................................................... 12.14 Turning Diameters ....................................................................................................................................................................................... 12.15 Center of Gravity.........................................................................................................................................................................................12.16 Front Axle Chart .......................................................................................................................................................................................... 12.17 Rear Axle Chart ........................................................................................................................................................................................... 12.18 Definitions 2024 Chevrolet LCF Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE xiii Formulas for Calculating Rear Width and Height Dimensions 5500HG Suspension Deflection Charts ........................................................................................................................................................12.20 Tire and Disc Wheel Chart ...........................................................................................................................................................................12.21 Tire Disc Wheel Propeller Shaft 5500HG ...............................................................................................................................................................................12.22 Automatic Transmission..............................................................................................................................................................................12.23 Brake System Diagram, Hydraulic Brake Booster ........................................................................................................................................12.24 PTO Location, Drive Gear and Opening Information ...................................................................................................................................12.25 Opening Diagram.........................................................................................................................................................................................12.26 Diesel Fuel Fill..............................................................................................................................................................................................12.27 Rear View Fuel Fill Top View Fuel Fill Hose Modification .......................................................................................................................................................................................12.30 Various Width Bodies and Fuel Fill Vent Protection Ultra Low Sulfur Diesel Label.......................................................................................................................................................................12.31 Through the Rail Fuel Fill Frame Hole..........................................................................................................................................................12.32 5500HG-Diesel Fuel Filler Kit Instructions....................................................................................................................................................12.33 Installation Instructions and Considerations Roll-Over Valve Tubing Filler Neck Installation 4500XG DIESEL SPECIFICATIONS.............................................................................................................................................................................13.1 Vehicle Weights, Dimensions and Ratings.....................................................................................................................................................13.2 Vehicle Weight Limits Technical Notes Chassis Curb Weight Maximum Payload Weight 2024 Chevrolet LCF Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE xiv Frame and Crossmember Specifications........................................................................................................................................................13.4 Frame Chart...................................................................................................................................................................................................13.5 4500XG Diesel Standard Cab Top View..........................................................................................................................................................13.6 4500XG Diesel Standard Crew Cab Left Side View.........................................................................................................................................13.7 4500XG Diesel Standard Crew Cab Right Side View.......................................................................................................................................13.8 SCR / DPF 4HK1-TC ........................................................................................................................................................................................13.9 Option Side Fuel Tank ................................................................................................................................................................................................ 13.10 Addition to the Standard In Rail Fuel Tank RPO NLX Side View 176 Wheelbase Center Of Gravity.........................................................................................................................................................................................13.11 Turning Diameters .......................................................................................................................................................................................13.12 Front Axle Chart 4500XG .............................................................................................................................................................................13.13 Rear Axle Chart 4500XG ..............................................................................................................................................................................13.14 Definitions Formulas for Calculating Rear Width and Height Dimensions 4500XG Suspension Deflection Charts.........................................................................................................................................................13.16 Tire and Disc Wheel Chart 4500XG............................................................................................................................................................13.17 Tire Disc Wheel Propeller Shaft 4500XG ...............................................................................................................................................................................13.18 Automatic Transmission..............................................................................................................................................................................13.19 Brake System Diagram, 16,000 GVW...........................................................................................................................................................13.20 Vacuum Over Hydraulic PTO Location, Drive Gear and Opening Information ...................................................................................................................................13.21 Opening Diagram.........................................................................................................................................................................................13.22 Diesel Fuel Fill..............................................................................................................................................................................................13.23 Rear View Fuel Fill Top View Fuel Fill Hose Modification .......................................................................................................................................................................................13.26 2024 Chevrolet LCF Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE xv Various Width Bodies and Fuel Fill Vent Protection Ultra Low Sulfur Diesel Label.......................................................................................................................................................................13.27 Through the Rail Fuel Fill Frame Hole..........................................................................................................................................................13.28 4500XG-Diesel Fuel Filler Kit Instructions ....................................................................................................................................................13.29 Installation Instructions and Considerations Roll-Over Valve Tubing Filler Neck Installation 4500HG, 5500HG CREW CAB DIESEL SPECIFICATIONS ............................................................................................................................................14.1 Vehicle Weights, Dimensions and Ratings.....................................................................................................................................................14.2 Vehicle Weight Limits Technical Notes Chassis Curb Weight Maximum Payload Weight Frame and Crossmember Specifications........................................................................................................................................................14.5 Frame Chart...................................................................................................................................................................................................14.6 4500HG, 5500HG Diesel Standard Crew Cab - Top View ................................................................................................................................14.7 4500HG, 5500HG Diesel Standard Crew Cab - Left Side View ........................................................................................................................14.8 4500HG, 5500HG Diesel Standard Crew Cab - Right Side View......................................................................................................................14.9 SCR / DPF 4HK1-TC ......................................................................................................................................................................................14.10 Option Side Fuel Tank ................................................................................................................................................................................................ 14.11 Addition to the Standard In Rail Fuel Tank RPO NLX Side View 176 Wheelbase Center of Gravity .........................................................................................................................................................................................14.12 Turning Diameters .......................................................................................................................................................................................14.13 Front Axle Chart 4500HG .............................................................................................................................................................................14.14 Front Axle Chart 5500HG .............................................................................................................................................................................14.15 Rear Axle Chart 4500HG ..............................................................................................................................................................................14.16 2024 Chevrolet LCF Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE xvi Definitions Formulas for Calculating Rear Width and Height Dimensions Rear Axle Chart 5500HG ..............................................................................................................................................................................14.18 Definitions Formulas for Calculating Rear Width and Height Dimensions 4500HG Suspension Deflection Charts ........................................................................................................................................................14.20 5500HG Suspension Deflection Charts ........................................................................................................................................................14.21 Tire and Disc Wheel Chart 4500HG .............................................................................................................................................................14.22 Tire Disc Wheel Tire and Disc Wheel Chart 5500HG .............................................................................................................................................................14.23 Tire Disc Wheel Propeller Shaft 4500HG, 5500HG.................................................................................................................................................................14.24 Automatic Transmission 4500HG, 5500 HG .................................................................................................................................................14.25 Brake System Diagram 14,500 GVW............................................................................................................................................................14.26 Vacuum Over Hydraulic Brake System Diagram 17,950 GVW............................................................................................................................................................14.27 Full Hydraulic PTO Location, Drive Gear and Opening Information ...................................................................................................................................14.28 Opening Diagram.........................................................................................................................................................................................14.29 Diesel Fuel Fill..............................................................................................................................................................................................14.30 Installation Instructions Rear View Fuel Fill Top View Fuel Fill Hose Modification .......................................................................................................................................................................................14.33 Various Width Bodies and Fuel Fill Vent Protection Ultra Low Sulfur Diesel Label.......................................................................................................................................................................14.34 2024 Chevrolet LCF Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE xvii Through the Rail Fuel Fill Frame Hole..........................................................................................................................................................14.35 LCF Diesel Fuel Filler Kit Instructions ...........................................................................................................................................................14.36 Installation Instructions and Considerations Roll-Over Valve Tubing Filler Neck Installation 5500XG DIESEL SPECIFICATION ..............................................................................................................................................................................15.1 Vehicle Weights, Dimensions and Ratings.....................................................................................................................................................15.2 Truck Weight Limits Technical Notes Chassis Curb Weight Maximum Payload Weight Frame and Crossmember Specifications........................................................................................................................................................15.4 Frame Chart...................................................................................................................................................................................................15.5 5500XG Diesel Standard Cab - Top View........................................................................................................................................................15.6 5500XG Diesel Standard Cab - Left Side View................................................................................................................................................15.7 5500XG Diesel Standard Cab - Right Side View..............................................................................................................................................15.8 SCR / DPF 4HK1-TC ........................................................................................................................................................................................15.9 Option Side Fuel Tank ................................................................................................................................................................................................ 15.10 Addition to the Standard In Rail Fuel Tank RPO NLX Side View 150 Wheelbase Addition to the Standard In Rail Fuel Tank RPO NLX Side View 176 Wheelbase In place of the Standard In Rail Fuel Tank on RPO NL7 Side View 176 Wheelbase In addition to the Standard In Rail Fuel tank RPO NLX (150 and 176 wb LH rail only) Replacing standard In Rail Fuel tank RPO NL7 (176 wb only RH rail only) Cab Tilt ......................................................................................................................................................................................................................... 15.14 Turning Diameters .......................................................................................................................................................................................15.15 Center of Gravity .........................................................................................................................................................................................15.16 2024 Chevrolet LCF Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE xviii Front Axle Chart ..........................................................................................................................................................................................15.17 Rear Axle Chart............................................................................................................................................................................................15.18 Definitions Formulas for Calculating Rear Width and Height Dimensions 5500XG Suspension Deflection Charts.........................................................................................................................................................15.20 Tire and Disc Wheel Chart ...........................................................................................................................................................................15.21 Tire Disc Wheel Propeller Shaft 5500XG ...............................................................................................................................................................................15.22 Automatic Transmission..............................................................................................................................................................................15.23 Brake System Diagram Hydraulic Brake Booster .........................................................................................................................................15.24 PTO Location, Drive Gear and Opening Information ...................................................................................................................................15.25 Opening Diagram.........................................................................................................................................................................................15.26 Diesel Fuel Fill..............................................................................................................................................................................................15.27 Installation Instructions Rear View Fuel Fill Top View Fuel Fill Hose Modification .......................................................................................................................................................................................15.30 Various Width Bodies and Fuel Fill Vent Protection Ultra Low Sulfur Diesel Label.......................................................................................................................................................................15.31 Through the Rail Fuel Fill Frame Hole..........................................................................................................................................................15.32 LCF Diesel Fuel Filler Kit Instructions ...........................................................................................................................................................15.33 Installation Instructions and Considerations Roll-Over Valve Tubing FillerNeck Installation VERTICAL EXHAUST LCF DIESEL ONLY .................................................................................................................................................................................. 16.1 VERTICAL EXHAUST LCF DIESEL ONLY DRAWING TO COME ................................................................................................................................16.2 2024 Chevrolet LCF Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE xix SINGLE CAB ............................................................................................................................................................................................................17.1 Side View Front View Rear View Crew Cab Cab Side View .............................................................................................................................................................................17.4 Front View Rear View Single Cab - Front and Side View (Air Shield on Single Cab only)...................................................................................................................17.7 LCF DIESEL SERIES 6500XD Diesel Specifications......................................................................................................................................................................................18.1 Vehicle Weights, Dimensions and Ratings Multi-Leaf Suspension................................................................................................................18.2 Vehicle Weights, Dimensions and Ratings Air Spring Suspension.................................................................................................................18.3 Vehicle Weights, Dimensions and Ratings Multi-leaf Suspension ................................................................................................................18.4 Vehicle Weights, Dimensions and Ratings Air-spring Suspension.................................................................................................................18.5 Optional Equipment Weights ........................................................................................................................................................................18.6 Frame and Crossmember Specifications........................................................................................................................................................18.7 Frame Chart...................................................................................................................................................................................................18.8 Diesel Multi-Leaf Spring Suspension - Top View ...........................................................................................................................................18.9 Diesel Multi-Leaf Spring Suspension - Left Side View .................................................................................................................................18.10 Diesel Multi-Leaf Spring Suspension - Right Side View...............................................................................................................................18.11 Diesel Multi-Leaf Spring Suspension - Top View .........................................................................................................................................18.12 Diesel Air Spring Suspension - Driver Side View .........................................................................................................................................18.13 Diesel Air Spring Suspension - Passenger Side View...................................................................................................................................18.14 Exhaust System Dimensions SCR / DPF 4HK1-TC .........................................................................................................................................18.15 Fuel Tank Dimensions - 100 Gallon Tank.................................................................................................................................................................18.16 Cab Tilt ......................................................................................................................................................................................................................... 18.17 2024 Chevrolet LCF Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE xx Turning Diameter.........................................................................................................................................................................................18.18 Center of Gravity .........................................................................................................................................................................................18.19 Front Axle Chart ..........................................................................................................................................................................................18.20 Rear Axle Chart............................................................................................................................................................................................18.21 Multi-leaf Spring Suspension Deflection Charts ..........................................................................................................................................18.22 Tire and Disc Wheel Chart ...........................................................................................................................................................................18.23 Propeller Shaft Angles .................................................................................................................................................................................18.24 Propeller Shaft Lengths ...............................................................................................................................................................................18.25 Brake System Diagram ................................................................................................................................................................................18.26 PAINT CODE CHART ................................................................................................................................................................................................19.1 2024 Chevrolet LCF Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 0.1 4500HD Crew Cab Diesel, 4500XD Crew Cab Diesel, 5500HD Crew Cab Diesel 6500XD Diesel Chassis Cab Attention Body Builders! Chevrolet LCF Medium Duty Body Body Builder guides are now available for FREE!- go to: www.gmupfitter.com Download the Body Builder Guide or sections for important information about up fitting your Chevrolet LCF Medium Duty Commercial truck. All printed material, specifications, and drawings contained in the Chevrolet LCF Medium Duty Body Builder Guide are based on the latest information available at the time of publication/posting. The manufacturer reserves the right to discontinue or change, at any time, without notice specifications, options, materials, equipment, design and models. Information contained in the guide includes: · FMVSS safety standard · EPA requirements · OE recommendations · Cautions for successful application up fitting and Frame modification procedures 2024 Chevrolet LCF Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 1.1 INTRODUCTION This guide has been provided as an aid to final stage manufacturers in determining conformity to the applicable Emission Control and Federal Motor Vehicle Safety Standards. Final stage manufacturers should maintain current knowledge of all Emission Regulations and Federal Motor Vehicle Safety Standards and be aware of their specific responsibility in regards to each standard. Any manufacturer making material alterations to this incomplete vehicle during the process of manufacturing the complete vehicle should be constantly alert to all effects, direct or indirect, on other components, assemblies or systems caused by such alterations. No alterations should be made to the incomplete vehicle that directly or indirectly results in any either component, assembly or system being in nonconformance with applicable Emission Regulations or Federal Motor Vehicle Safety Standards. General Motors will honor its warranty commitment (for the cab-chassis only), to the ultimate consumer, provided: (1) the final stage manufacturer has not made any alterations or modifications which do not conform to any applicable laws, regulations or standards, or adversely affect the operation of the cab-chassis; and (2) the final stage manufacturer complied with the instructions contained in this guide with respect to the completion of the vehicle. Otherwise, the warranty becomes the responsibility of the final stage manufacturer. The final stage manufacturer is solely responsible for the final certification of the vehicle and for compliance with Emission Control and Federal Motor Vehicle Safety Standards. The information contained in this guide has been provided for the final stage manufacturer's information and guidance. This guide contains information pertaining to the: Diesel Models: 4500HD Regular Cab Diesel, 4500XD Regular Cab Diesel, 5500HD Regular Cab Diesel 5500XD Regular Cab Diesel 4500HD Crew Cab Diesel, 4500XD Crew Cab Diesel, 5500HD Crew Cab Diesel, 6500XD Diesel Chassis Cab 2024 Chevrolet LCF Revision: 05/31/23 2024 Chevrolet Low Cab Forward LCF MEDIUM DUTY V.I.N. IDENTIFICATION CALLOUTS 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 JALE5J120H790075 0 CODE 1-3 JAL 54D MANUFACTURER / ASSEMBLER ISUZU MOTORS LTD, JAPAN SPARTAN MOTORS INC, USA CODE GVWR RANGE B 10001-14000 4 C 14001-16000 E 16001-19500 K 23501-26000 BRAKE SYSTEM HYDRAULIC BRAKE HYDRAULIC BRAKE HYDRAULIC BRAKE AIR BRAKE CODE 5 4 5 6 CODE W 6 J T S MAKE ISUZU ISUZU ISUZU DESCRIPTION NPR / NPR-HD / NPR-XD NQR/NRR FTR CAB TYPE Tilt Cab, BBC = 71 Inches Non-Tilt Cab, BBC = 110 Inches Stripped Chassis Tilt Cab, BBC = 81 Inches 7 CODE 1 AXLE DESCRIPTION 4X2, 2 AXLES, 1 DRIVING CODE ENGINE DESCRIPTION 6 8 7 5.2L, L4 Diesel, Turbo Intercooler 3.0L, L4 Diesel, Turbo Intercooler B 6.0L, V8 Gasoline C 6.0L, V8 Gasoline (convertible to CNG / LPG) 9 CHECK DIGIT CODE 10 F G H J MODEL YEAR 2015 2016 2017 2018 11 CODE 7 S PLANT FUJISAWA, JAPAN CHARLOTTE, MICHIGAN 12 13-17 CODE W M K 0 3 F 8 9 G DESCRIPTION Stripped Chassis (DSL) 12,000 GVWR Stripped Chassis (DSL) 13,000 GVWR 4500XD (DSL) 16,000GVWR 4500HD (DSL) 14,500GVWR 5500XD (DSL) 19,500 GVWR 3500HD (DSL) 13,000 GVWR 3500/4500 (GAS) 12,000 / 14,500 GVWR 5500HD (DSL) 17,950GVWR 6500XD (DSL) 25,950 GVWR PLANT SEQUENTIAL NUMBER PAGE 1.11 2024 Chevrolet LCF Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 1.2 CAUTIONARY NOTES: Electrical Sensitivity and Battery Relocation Warning The Low Cab Forward Trucks are sensitive to poor electrical integrity of the starting circuit when compared to previous year models. This is due to the ever increasing electrical demands from the base vehicle that includes the new emissions componentry as well as more sophisticated engines and transmissions. The control modules for these devices require healthy electrical circuits without significant voltage drops through the supply and return circuits. A relocation or modification of batteries coupled with insufficient wire gauge, poor terminal crimps, weak conductivity to frame rails, terminal corrosion, or loose bolts, could contributed to a possible no start condition. All Fluids and Lubricants Caution Any fluids or lubricants added to the chassis during the final manufacturing process must meet GM's fluids and lubricants specifications. These fluids and lubricant specifications vary based on model year and chassis model code. A recommended fluids list based on model and model year can be found in the Vehicle Owner's Manual. Low Speed Applications for LCF Series Chassis Any low speed vehicle applications using the Aisin Transmission such as sweeper, highway striping and road side mowing airport service must adhere to the following guidelines in order to prevent the over heating of the automatic transmission fluid. FACTORY RECOMMENDATION: Select Range 1 for low speed operations under 11 mph, (18km/h). Select Range 2 for low speed operation under 22 mph, (36km/h). Auxiliary Transmission Cooler Warning Installation of Auxiliary automatic transmission fluid cooler will void warranty on transmission/engine. Transmission Temperature Warning Lamp Automatic transmission fluid temperature warning lamp illuminates over 140 Centigrade/284°Fahrenheit. Fuel Tank Caution Fuel fill kit must be installed on cab chassis if it will be driven for an extended distance. (Note: fuel tank kit provides venting for the fuel tank) Tapping into Engine Cooling System Do not connect any auxiliary heating devices to the chassis cooling system. The chassis cooling system is part of the vehicle emission system and is used to thaw DEF fluid and meet mandatory emission thaw times. Brake Override Logic The ECM logic has adopted Brake Override Logic that will reduce engine RPM to idle RPM when the brake and accelerator pedals are applied simultaneously. This ECM logic has been adopted to enhance the safe operation of the vehicle. The brake override logic disables the accelerator pedal input and protects against vehicle malfunction in cases where the accelerator pedal and brake pedal are operated simultaneously, or if unintended driver acceleration pedal operations are detected. 2024 Chevrolet LCF Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 1.3 NO-START CONDITION CLICKING OR BANGING FROM STARTER LCF Trucks Equipped with 5.2L (4HK1) Diesel Engines It is possible to experience a no-start condition accompanied by a clicking or banging-type noise from the starter. This condition presents itself when vehicle battery voltage is low. The insufficient voltage/current will cause an improper ground for the X-17 starter relay. As a result, the starter will not remain engaged to start the engine. This is not an indication of a defective starter, alternator or ECM. The following is a list of common causes for low battery voltage. Inspect these items as possible causes for the described condition before further diagnosis. 1. Extreme low ambient temperatures (below 10°C / 50°F). The chemical reactions inside of batteries take place more slowly when the battery is cold. The vehicle systems therefore have less energy to work with when it tries to start the engine. 2. Vehicles stored for long periods without proper battery charging and maintenance. 3. Batteries that have been relocated further away from the starter than the original designed location. 4. Batteries or battery cables that have been replaced with improper gauge. 5. Corroded battery terminals and cables. 6. Vehicles that are started and stopped multiple times without allowing the charging system to replenish the batteries' charge. 7. Excessive use of electrical equipment such as electric lift gates. 8. Interior and exterior lighting left "On" without the engine running. NOTE: Do not diagnose starters, alternators, ECMs or other no-start conditions prior to ensuring the battery is fully charged and none of the above common causes exist 2024 Chevrolet LCF Revision: 05/31/23 2024 Chevrolet Low Cab Forward INSTALLATION OF BODY AND SPECIAL EQUIPMENT Clearances Engine At least 1.6 inches of clearance should be maintained around the engine. No obstacles should be added in front of the radiator or intercooler. PAGE 2.01 Front and Back Clearance 1 inch Figure 2.1.1 Transmission The transmission is removed from the rear. Enough clearance must be provided to allow rearward movement of the transmission assembly. Clearance should be sufficient to allow 5 to 6 inches of unrestricted movement of the transmission assembly. In addition, provide at least 2 inches of clearance around the control lever on the side of the transmission to allow free movement without any binding. 2024 Chevrolet LCF Figure 2.1.2 Front and Back Clearance 1 inch Revision: 05/31/23 2024 Chevrolet Low Cab Forward INSTALLATION OF BODY AND SPECIAL EQUIPMENT Clearances At least 2 inches of clearance should be maintained above the automatic transmission to allow for transmission removal. PAGE 2.02 Figure 2.2.1 Front and Center Propeller Shafts At least 1.25 inches of clearance should be maintained around front and center propeller shafts. 2024 Chevrolet LCF Figure 2.2.2 Revision: 05/31/23 2024 Chevrolet Low Cab Forward INSTALLATION OF BODY AND SPECIAL EQUIPMENT Clearances Rear Propeller Shaft With the rear springs at maximum deflection, at least 1.25 inches of clearance should be provided over the rear propeller shaft. PAGE 2.03 Rear Propeller Shaft Figure 2.3.1 2024 Chevrolet LCF Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 2.04 INSTALLATION OF BODY AND SPECIAL EQUIPMENT Clearances Exhaust System The exhaust system has a crucial role in meeting 2010 EPA regulations. In order to maintain compliance with the 2010 EPA emissions levels the Diesel Particulate Filter (DPF) and SCR package must not be moved. The distance between the engine exhaust manifold down pipe and Diesel Particulate Filter (DPF) / Selective Catalytic Reduction Package (SCR) must be maintained and the pressure in the system must be sustained at a constant level. Due to increased temperatures in the exhaust system during the regeneration cycle and the heat stress caused by these temperatures, body builders should closely evaluate the placement of equipment and provide protection to these added components as needed. Diesel Particulate Filter and Selective Catalytic Reduction (SCR) Restrictions The DPF/SCR has exhaust pressure pipes and temperature sensors. Care must be taken when a body is installed so as to not damage pipe sensors. The DPF/SCR should be free from impact or vibration during body installation. The DPF/SCR must have enough room for disassembly of the unit for service and cleaning. The DPF/SCR switch in the cab should not be removed or disabled. No modification or relocation of the DPF/SCR unit, pressure pipes, and sensor is permitted. No Modification Zones The DPF/SCR unit CAN NOT be modified or moved . The DEF tank and pump CANNOT be modified or removed. DEF lines and coolant lines CANNOT be modified or rerouted. 2024 Chevrolet LCF Figure 2.4.1 Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 2.05 INSTALLATION OF BODY AND SPECIAL EQUIPMENT Clearances Exhaust Clearances If flammable materials such as wood are used in the body, provide at least 3.9 inches of clearance between the body and any parts of the exhaust pipe, DPF/SCR Package. If it is impossible to maintain the minimum clearance, use a heat shield. Also use a heat shield if an oil pump or line is located above the exhaust pipe, muffler or catalytic converter. Figure 2.5.1 1) Clearances around SCR system components must be greater than 1.0 inch at all times to avoid potential contact between the body and the exhaust components. The 1.0 inch allows for thermal expansion and assembly tolerance of the exhaust system. It does not account for dynamic movement in the body due to road conditions and other loads. Body companies are instructed to adjust this 1.0 inch clearance as required to account for body displacement while driving. This guidance does not supercede guidance or exhaust clearances for temperature sensitive or flameable components. 2) Exhaust temperatures have not changed since the introduction of DPF in 2007. 2024 Chevrolet LCF Revision: 05/31/23 2024 Chevrolet Low Cab Forward INSTALLATION OF BODY AND SPECIAL EQUIPMENT Clearances Exhaust system surface temperatures During Manual Regeneration LCF Diesel Modification Guideline (heat issue) (EXHAUST PIPE HEAT) PAGE 2.06 4 inches from vehicle end or side 2024 Chevrolet LCF More than 8 inches More than 18 inches Less than 45 degree Figure 2.6.1 Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 2.07 INSTALLATION OF BODY AND SPECIAL EQUIPMENT Clearances Rear Wheel Axle The design and installation of the body should allow sufficient clearance for full vertical movement of the rear wheels and axle when the vehicle travels over rough or unlevel surfaces. See Note Figure 2.7.1 Note: For recommended clearances, please refer to the Rear Axle Chart in each model's respective section. Other Clearances The transmission control cable may be broken if it is bent by or interferes with the body and its fixtures. To prevent this, 1 inch of minimum clearance should be provided. When cable is detached from body mounting, be sure not to bend the cable. Accessibility to the grease nipple on the rear spring bracket/shackle should be provided so that serviceability with a grease gun is not hampered. Parts Brake Hose Parking Brake Cable Fuel Hose Shock Absorber Minimum Clearance 6.7 in. 1.6 in. 1.2 in. 1.6 in. 2.4 in. 1.2 in. Location Axle Side Frame Side -- -- Axle Side Frame Side 2024 Chevrolet LCF Figure 2.7.2 Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 2.10 Body Installation Mirrors The Chevrolet LCF series chassis will accommodate up to 96 inch wide bodies without modification to the mirror brackets. The Chevrolet 4500HD, 4500XD, 5500HD and 5500XD chassis will accommodate up to 96 inch wide bodies without modification to the mirror brackets. Bodies from 97 to 102 inches wide will require that the mirror brackets be modified. This Modification can be made at the port and the vehicle order/label will indicate a Regular Product Option of TBD indicating "Mirror Bracket for 102 wide body". The brackets can also be modified by the GM Chevrolet Dealer or the Body Company by installing mirror brackets ordered from General Motors Service. Side Step Door Installation recommendations Floor of body should be at least 10" above frame rail (2.5" wood + 4" long sill + 3" cross sill + 1.125" floor) Forward end plate of step well area can interfere with SCR system All body components should maintain a minimum 1.0" of clearance to exhaust components UNDER ALL (DYNAMIC) CONDITIONS. (Body company will need to add to this 1.0" clearance to account for flex or movement in the body) Outer heat shield on SCR system can be removed prior to mounting body if required for clearance Care should be taken to adequately shield exhaust Driver's side steps can also be accommodated, if door is located behind DEF tank Battery may have to be relocated, depending on door location Access hatch for DEF tank fill may have to be added, depending on door location DPF/SCR Heat shield Removal The exhaust external heat shield does not impact vehicle emissions or emissions system durability. This shield can be removed or modified in order to facilitate body or equipment mounting, but the completed vehicle manufacturer should ensure that, when completed, the exhaust will be adequately shielded to prevent unintentional contact with hot exhaust components, and that heat transfer to body components is not so high as to present safety or durability risks. www.gmupfitter.com 2024 Chevrolet LCF Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 2.11 Heat Shield DPF/SCR Heat Shield Removal this bracket can be Cut Off 19.6" 2024 Chevrolet LCF Figure 2.11.1 Revision: 05/31/23 2024 Chevrolet Low Cab Forward LCF 4500HD, 4500XD, 5500HD, 5500XD FRONT AXLE C/L TL=0 REAR AXLE C/L Figure 2.13.1 PAGE 2.13 2024 Chevrolet LCF Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 2.14 Subframe Contour Contouring of the front end of the subframe members as shown in the three illustrations below will prevent stresses from being concentrated on certain areas of the chassis frame 2024 Chevrolet LCF Drawing 1 2 3 Figure 2.14.1 A B H or more H or more Revision: 05/31/23 2024 Chevrolet Low Cab Forward When using a steel subframe, do not close the end of the subframe. PAGE 2.15 Figure 2.15.1 Prohibited Attachment Areas Do not attach the subframe with a bolt or bracket to the chassis frame at the points indicated in the following illustrations. 1. At the front end of the subframe. The attaching bolt or bracket must be at least 2 inches behind the kick up point of the subframe. 2024 Chevrolet LCF Figure 2.15.2 Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 2.16 Prohibited Attachment Areas 2. Front U-bolt and Mounting Bracket, Mounting Locations Ahead of Transmission Mandatory location due to after treatment device location and interior frame components. The chassis will be supplied with one steel crush block in cab for left hand forward body attaching location as illustrated in the drawings below and one body mounting bracket (painted yellow) attached to the right hand frame rail in the location shown in the drawings below. Body Builder will be required to design a mating bracket for attaching the body to the yellow painted chassis body mounting bracket (Ref page 2.16 for illustration of bolt clamping 2 brackets ). No U bolt type attaching allowed. 4500HD, 4500XD, 5500HD, 5500XD & 6500XD Forward 2024 Chevrolet LCF Ref Body mount kit Crush Block and U-Bolt (Left Hand -Rail) Body Mounting Bracket (Right Hand -Rail) Figure 2.16.2 Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 2.17 U-Bolt Placement 150" W/B Crew Cab Front, RHS U-bolt on 150" Wheelbase Crew Cab interferes with after treatment system. General Motors will supply body mounting bracket on chassis to facilitate body mounting on the passenger side of the vehicle as Illustrated. CREW CAB 150" WB Body Mounting Bracket (A) Dimensions CREW CAB 150" WB Body Mounting Bracket (A) Location · Material: ASTM A-36 or equivalent 6.35mm (0.25 inch) thick · Coating: OSHA Yellow powder coating · Hardware: GM supplied, two each · 10mm x 30mm hex head bolds · 10mm hex nuts · Packaging (two part numbers): · PIO - Poly-Bag; 1 bracket, 2 10mm x 30mm hex head bolts, 2 10mm hex nuts · PDC - Box; 1 bracket, 2 10mm x 30mm hex head bolts, 2 10mm hex nuts, installation instructions Body Mounting Bracket will be painted "YELLOW" for easy identification Figure 2.17.1 2024 Chevrolet LCF ( A) 1.38 in. (35 mm) Ref. Body Mount Kit crew cab 150 wheelbase. See GM Dealer. Figure 2.17.2 Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 2.18 Subframe Mounting Figure 2.18.1 Within 8 inches of bends in the chassis frame or the attachment points of any crossmembers. Bracket Installation Mounting brackets should be clamped to the chassis frame using bolts. For proper positions in which to install the bolts, refer to the preceding section and the section "Modifications to the Chassis Frame." In addition to the illustrated bracket and U -bolts a shear plate may be required for adequatley body mounting. The body company will be responsible for engineering their own mounting system. The frame material is a heat treated, carbon manganese, low alloy steel with good weldability. The frame has a 80/40 mm modular hole spacing standard. This standard pattern will assist in body mounting. 2024 Chevrolet LCF Figure 2.18.2 Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 2.19 MODULAR FRAME HOLE PATTERN The frame material is a heat treated carbon manganese, and low alloy steel with good welding characteristics. The frame has an 80/40mm modular hole spacing standard. This standard pattern will assist with body mounting. DepenDdeinpgenodninmgoodnelm, wohdeel,lbwahseeealbnadse and chassicshsapsescisifiscpaeticoinficsaotmione shomlees ahroeleisn aurseein use and soamnde shomlees ahroeleisntaernetioinnteanllytiomniaslslyinmg.issing. (Subje(cStutobjechctatnogcehwainthgoeuwt inthooticuet )n.otice). 2024 Chevrolet LCF Figure 2.19.1 WB (inches) 4500HD N (inches) 4500XD, 5500HD 5500XD 109 34.6 132.5 58.3 150 75.6 176 92.9 Note: Re-tighten all attaching parts that are loosened during body installation. Note: Dimensions in inches Figure 2.19.2 Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 2.20 U-bolt Installation When U-bolts are used to retain the subframe, reinforcement blocks must be installed in the frame members. This will prevent distortion of the frame flange as they are tightened. The drawing indicates the correct placement of reinforcement blocks. If you use wood blocks, be sure that there is sufficient clearance between them and any parts of the exhaust system. The use of J-bolts to retain the subframe is strictly prohibited. If any fluid lines or electric cables are located near the reinforcement blocks, you must provide at least 0.4 inches of clearance between rigid or stationary portions, and at least 1.6 inches between moveable or flexible portions of the lines. CAUTION: U-Bolt placement is critical with new emission systems and controls. Extra care must be taken when placing bodies on chassis so as not to damage these components Figure 2.20.1 For the installation positions of the U-bolts, refer to "Prohibited Attachment Areas." Crew Cab Body / Frame Requirements The Crew Cab 4500, 4500HD, 4500XD,and 5500HD will be available in two wheelbases, 150 and 176 inches. CA will be 88.5 and 114.5 inches. On this model chassis, General Motors will require that the body installed on the chassis have an understructure manufactured with any of the following structural steel "C" channels: 4" x 1-5/8", 7.5 lb./ft. 5" x 1-3/4", 6, 7 or 9.0 lb./ft. 6" x 2", 8.2, 10.5 or 13 lb./ft. 2024 Chevrolet LCF Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 2.21 Modification of the Frame Modifications of the chassis frame should be held to an absolute minimum. Modification work should be performed according to the instructions in the following paragraphs. When modification is complete, chassis frame members should be carefully inspected to eliminate the possibility of any safety-related defects. NOTE: PLEASE REFER TO NOTES ON CHASSIS FRAME MODIFICATION WITH ANTILOCK BRAKES. Working on Chassis frame The chassis frame is designed and built with consideration for proper load distribution. Sufficient physical strength is provided when the load is evenly distributed. Installation of special equipment on the chassis frame can cause variations in load distribution. If even distribution of load is not kept in mind when the equipment is installed, localization of stresses on specific areas of the frame could cause cracking of the chassis frame members or other problems, even if the total weight of the equipment is within the design limit. The chassis frame is designed as an integral unit. Therefore, we do not recommend cutting the chassis frame under any circumstances. Drilling and Welding IMPORTANT NOTE: For vehicles equipped with electronic engines and or electronic or hydra-matic transmissions, electric arc welding must be done with the negative battery cable disconnected. 1. Do not drill or weld in the shaded portions of the chassis frame members. Do not weld within 0.8 inches from the edges of any existing holes. ( Ref. page 2.20 ) 2. Hold the length of any welding beads within 1.2-2.0 inches. Allow at least 1.6 inches between adjacent welding beads. 3. All holes must be drilled. Do not use a torch to make any holes. 4. All riveting must be done with cold rivets. Do not use hot rivets. 5. The flange of the chassis frame must not be cut under any circumstances. 6. The subframe must be attached to the chassis frame with bolts. Do not weld. 7. Repaint exposed metal after drilling. 2024 Chevrolet LCF Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 2.22 H Dimensions: A - no more than 0.59 inches in diameter B - must be more than H/5 for welding and H/7 for holes C - must be more than 1.57 inches H = Frame Height Figure 2.22.1 Reinforcement of Chassis Frame Reinforcements must be installed to prevent the considerable variation in the section modulus. They must be welded so as to avoid localized stresses. The frame of the LCF is made of SAPH440 mild steel. The drawing on the following page illustrates correct and incorrect methods of frame reinforcement. Welding 1. Keep reinforcement plates and chassis frame free from moisture and water. 2. Avoid cooling with water after welding. 3. Use a suitable means to protect pipes, wires, rubber parts, leaf springs, etc. against heat and effect of sputtering. 4. Remove fuel tank assembly when welding portions near the fuel tank. 5. Remove coat of paint completely when welding painted areas. Repaint exposed metal after welding. 2024 Chevrolet LCF Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 2.23 SATISFACTORY Frame rail Plug weld or rivet Reinforcement UNSATISFACTORY Figure 2.23.1 Frame rail Reinforcement Welding is prohibited Fluid Lines Do not disturb the layout of any brake lines or fuel lines unless absolutely necessary. When modification is needed, follow the instructions below carefully to ensure safety. Brake fluid lines must not be cut and spliced under any circumstances. We do not recommend the cutting or splicing of any fuel lines, but if it is absolutely necessary, be sure that the correct fitting and tools are used to form the joint, and then pressure test the joint. Steel lines are metric sizes. Preparation of Additional Lines 1. Where possible, use only genuine GM lines as supplied by authorized GM Chevrolet dealers. 2. Use the correct metric flaring and bending tools to form the lines. 3. Avoid repeated bending. Do not use heat for flaring and bending the lines. Before and after forming the new lines, examine them carefully for scratches, distortion, dents and the presence of any foreign matter. 2024 Chevrolet LCF Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 2.24 Installation of Additional Lines Install new lines away from adjacent parts and away from any sources of heat. 1. A minimum clearance of 0.4 inches must be maintained between lines. Where necessary, clip the lines into position in order to maintain this minimum clearance. 2. Minimize any crossing between lines. If a crossing is unavoidable, use the following procedure: a. At least 0.4 inches of clearance should be maintained between lines at the crossing point. b. If the 0.4 inches of clearance cannot be maintained, or if the lines are subject to vibration, clip them securely. 3. Plan the bends and clipping points of the lines to minimize vibration and the resulting fatigue. 4. Use rust-proofed clips and apply vinyl coating to the portions of the lines to be clipped. 5. Install new lines in positions where they are protected against water, dirt, grit, sand, rocks and other foreign matter that can come from above or below, or can be flung up by the wheels. Lines Clip 0.4 in. or more Figure 2.24.1 Vinyl Clip Electrical Wiring and Harnessing To increase the reliability of the wiring, all frame harnesses are covered with corrugated vinyl tubing. The following instructions apply to extending or modifying these harnesses. See the Electrical Section for information on commonly used circuits in the 3500, 3500HD and 4500, 4500HD, 4500XD, 5500HD, amd 5500XD. 2024 Chevrolet LCF Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 2.25 Electrical Wiring and Harnessing Wiring 1. Most wiring connections on Chevrolet LCF vehicles are made with terminals. We recommend the use of terminals when splicing cables and wires. 2. When splicing, use new wire of the same gauge, and do not make splices inside the corrugated tubing. 3. When making connections to the end of the harness, make sure the connections are electrically perfect. Use insulating tape as needed to prevent the entry of water, which results in short circuits and/or corrosion. 4. When making new circuits, or modifying circuits already installed, make the cables only just taut enough to remove any slack. Use clips or grommets where required to protect cables from heat or sharp edges. When cables must run near the exhaust system, see the instructions in the "Exhaust System" section. 5. Always use rustproof clips, and apply vinyl coating to that portion of the clips in direct contact with the harnesses. No scotch clips or connectors. 6. To minimize the vibration of the harness, clipping points should be set up according to the table. Harness Diameter less than 0.2 in. 0.2 in. ~ 0.4 in. 0.4 in. ~ 0.8 in. Clip Distance less than 11.8 in. approx. 15.7 in. approx. 19.7 in. Figure 2.25.1 7. When changing the length of the battery cable, do not cut or splice the existing cable. Make up a new cable of the correct length and wire gauge for the load and distance, without splices. 8. When using connectors, use a socket (female) connector on the electrical source side and a plug (male) connector on the electrical load side to lower the possibility of a short circuit when disconnected. 9. When connecting cables to moving or vibrating parts such as the engine or transmission, be sure to maintain sufficient slack in the wiring to absorb the vibration. Follow the example of existing cables connected by General Motors. Keep flexible cables clear of other parts. 10. Do not use vinyl tape in the engine compartment. The heat will tend to make it peel off. Use plated steel clips coated with rubber or vinyl. 11. When locating auxiliary equipment or lines near the ECM caution should be used in order to protect the ECM from excessive vibration, heat or chemical reactions. 2024 Chevrolet LCF Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 2.26 Electrical Wiring and Harnessing · I -· .. '--.L' Figure 2.26.1 ·- ''*' 2024 Chevrolet LCF Figure 2.26.2 Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 2.27 Electrical Wiring and Harnessing Wire Color Code The electrical circuits of the Chevrolet LCF Chassis Cab are connected with low-voltage stranded wire for automotive applications. The color coding standards are as follows for the Chevrolet LCF Chassis Cab: (1) Black (2) White (3) Red (4) Green B Starter circuits and grounds W Generator (alternator) circuit R Lighting circuit G Signal circuit (5) Yellow (6) Brown (7) Light Green (8) Blue Y Instrument circuit Br Accessory circuit Lg Other circuit L Windshield wiper motor circuit Maximum Allowable Current Harness Design Diameter (mm) AWG Equivalent 100 00 85 0 60 1 50 1 40 1 30 2 20 4 15 6 8 8 5 8 3 12 2 14 1.25 16 0.85 18 0.5 20 No. of Wires/Wire Diameter (mm) Cross Sectional Area (mm2) Maximum Allowable Current (Amps) 217/0.80 109.1 363 169/0.80 84.96 305 127/0.80 63.84 248 108/0.80 54.29 223 85/0.80 42.73 191 70/0.80 35.19 171 41/0.80 20.61 123 84/0.45 13.36 93 50/0.45 7.952 68 65/0.32 5.228 51 41/0.32 3.297 39 26/0.32 2.091 29 16/0.32 1.287 21 11/0.32 0.8846 17 7/0.32 0.5629 13 Reference: The values given in the "maximum allowable current" column are based on the ambient temperature condition of 104°F with temperature increase of 104°F. 2024 Chevrolet LCF Figure 2.27.1 Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 2.28 Electrical System Modifications Electrical Wiring and Harnessing Modifications/add-on wiring must be carefully reviewed to ensure compatibility with the base vehicle wiring by reviewing system schematics, wire routing paths, harness connections, etc. Due to the wide range of modifications that may be required for vocational needs, it is not feasible for the O.E.M. to take into account all potential revisions. For this reason, any person modifying existing vehicle wiring must assume responsibility that the revisions have not degraded the electrical system performance. Any add-on wiring needs to be properly fused and routed to prevent cut, pinch, and chafe problems, as well as avoid exposure to excessive heat. Care must be exercised that existing vehicle interfaces do not have their current load capabilities exceeded, and that the respective control devices are not overloaded. Added wire size should be at least as large as the wire to which it is attaching in order for fuse protection to be maintained A Packard electric wiring repair kit is available through Kent-Moore (P/N J38125-B) (Phone # 1-800-345-2233). This kit contains instructions, tools and components for making repairs to wiring harness components. This kit would also greatly assist in accomplishing necessary add-on wiring such as body marker lamps, so that system reliability/durability is maintained. Electrical wiring components can be obtained through your authorized Chevrolet dealers. Packard Electric components are also available through Power and Signal (www.powerandsignal.com). Power and Signal may also be able to assist in making necessary wiring additions by providing custom wiring stubs or jumpers to your specifications. Caution: Before servicing any electrical component, the ignition key must be in the LOCK position and all electrical loads must be OFF, unless instructed otherwise in GM service procedures. If a tool or equipment could easily come in contact with a live exposed electrical terminal, also disconnect the negative battery cable. Do not disconnect cable within 3 minutes after turning the ignition key to the Lock position. Failure to follow these precautions may cause personal injury and/or damage to the vehicle or its components. Electrical Caution: Please see note in Section 1 Introduction on page 1.9 of on the subject of "NO-START CONDITION CLICKING OR BANGING FROM STARTER 2012-2015MY Chevrolet LCF Equipped with 5.2L (4HK1) Diesel Engines". Exhaust System Modification of the exhaust system should be avoided. If modifications are absolutely necessary, the following points should be maintained. 1. Maintain the clearance specified in the "Exhaust System" table between all parts of the exhaust system and any fuel lines, brake lines, brake hoses, electrical cables, etc. The exhaust outlet should not point toward any of these parts. Brake lines Flexible brake hoses Wiring harnesses and cables Steel fuel lines Rubber or vinyl fuel hoses Clearance 2.4 in. or more. (If the combined section of a group of parallel brake lines is more than 7.8 in., a clearance of 7 in. or mo re should be provided.) 7.8 in. or more. (The temperature of flexible brake hoses should not exceed 158oF. If the highest temperature is not measurable, a clearance of more than 15.7 in. should be maintained between the hoses and the exhaust system.) 7.8 in. or more. (The temperature of flexible brake hoses should not exceed 158oF. If the highest temperature is not measurable , a clearance of more than 15.7 in. should be maintained between the hoses and the exhaust system.) 3.1 in. or more. 5.9 in. or more. 2024 Chevrolet LCF Figure 2.28.1 Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 2.29 Exhaust System 2. If a tool box is installed, it should preferably be made from steel. If a wooden tool box is installed, at least 7.8 inches of clearance should be maintained between the tool box and any parts of the exhaust system. 3. If the exhaust system is modified, it is the responsibility of those making the modification to ensure that the noise level meets appropriate standards. 4. If the exhaust system is modified it is the responsibility of those making the modification to ensure that the emission levels meet appropriate standards. Fuel System Relocation of the fuel tank, or installation of additional fuel tanks, is not recommended. If modifications to the fuel system are unavoidable, follow these recommendations: 1. Maintain adequate clearance between the fuel tank and any other device or structure. 2. Do not connect any additional fuel hose. Rear Lighting Brackets installed are temporary. Please do not use these brackets for body installation. Serviceability No matter what other modifications or changes are made, access to components requiring daily preventive maintenance or other routine service must not be obstructed. This includes: 1. Inspection, filling and draining of engine oil and cooling water. 2. Inspection, filling and draining of transmission fluid. 3. Adjustment, removal and installation of the fan belts. 4. Inspection, filling and removal of the battery and battery cover. 5. Inspection and filling of brake fluid. 6. Inspection and bleeding of the brake system and servo unit. 7. Maintenance of clearance for tightening of check bolt on brake safety cylinder. 8. Operation of the spare tire carrier, including mounting and dismounting of the spare tire. 9. Adjustment, removal and installation of distributor and/or cover. 2024 Chevrolet LCF Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 2.30 Wheelbase Alteration With certain applications, it may become necessary to alter the wheelbase of the chassis. The next two sections provide the suggested guidelines for accomplishing either shortening or lengthening of the wheelbase. Shortening/Lengthening the Wheelbase Without Altering the Frame Since the frame is an integral part of the chassis, it is recommended that the frame not be cut if it is possible to avoid it. When shortening/lengthening the wheelbase on some models, it is possible to do so without cutting the frame. This is possible on models which have a straight frame rail. If the chassis does not have a straight frame rail, it may still be necessary to cut the frame. For instructions on shortening/lengthening these chassis, refer to the "Altering the Wheelbase by Altering the Frame" section of this book. Otherwise, the wheelbase may be shortened/lengthened by removing the rear suspension, drilling new suspension mounting holes at the appropriate spot in the frame, and sliding the rear suspension, suspension liner, and suspension crossmembers forward or aft. The suspension and suspension crossmembers' rivet holes left in the frame rail flange must be filled with GRADE 8 bolts and hardened steel washers at both the bolt head and nut, HUC bolts or GRADE 8 flanged bolts and hardened steel washers at the nut. When shortening/lengthening the wheelbase in this manner, the following guidelines must be adhered to: 1. All frame drilling must comply with the DRILLING AND WELDING section of this book. 2. All rivet holes left in the frame rail flange from the suspension and suspension crossmembers must be either filled with GRADE 8 bolts and hardened steel washers at both the bolt head and nut, HUC bolts or GRADE 8 flanged bolts and hardened steel washers at the nut. 3. The components required to be slid forward or aft are the suspension and suspension hangers, suspension crossmembers and suspension frame liner. Altering the Wheelbase by Altering the Frame Even on a straight frame rail, it may be desirable to cut the frame and lengthen or shorten the wheelbase rather than simply sliding the rear suspension back or forward. The following section offers some guidelines and suggestions for cutting and lengthening or shortening the frame. Glossary of Terms Chassis Wheelbase Alteration CA Length from back-of-cab to rear axle centerline in inches. AL Added length (in case of a lengthened wheelbase). Difference between WB (new) and WB (old). SL Shortened length (in case of shortened wheelbase). Difference between WB (old) and WB (new). 2024 Chevrolet LCF Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 2.31 Wheelbase Alteration 1. Determine the added length (AL) or shortened length (SL) required to lengthen or shorten chassis. (For added wheelbase: New CA = CA + AL; For shortened wheelbase: New CA = CA SL.) 2. Obtain the material to be used as the insert for the lengthened wheelbase in the correct length (AL). The insert must have the same cross sectional dimensions and yield strength as the original frame rail. 3. Divide the new CA by two (2). Measure (new CA)/2 from the center of the rear axle forward and mark this point on the chassis frame (see figure below). Figure 2.31.1 4. Cut the chassis frame at this point. If the wheelbase is to be lengthened, addition of the previously obtained insert (of length AL determined in step 1) will be made at this time. If the wheelbase is to be shortened, measure the distance (SL) forward of this cut and remove a length (SL) section from the chassis frame (see figure below). Ensure that an adequate area on the frame remains for the required addition of the necessary reinforcements. These are the only suggested places for cutting the frame and reinforcements but may be changed upon the advice of GM Upfitters Engineering. 2024 Chevrolet LCF Figure 2.31.2 Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 2.32 Wheelbase Alteration 5. When welding the insert (length AL for wheelbase lengthening) to the original frame rail, a continuous butt weld must be used at the splices. When shortening the wheelbase, weld the ends of the chassis frame together with a continuous butt weld over the junction of the frame ends. Weld can be both the inside and outside of the frame rails using welding techniques prescribed by established welding standards (ref. SAE J1147) and in accordance with this guide. An example of this weld is shown below. Figure 2.32.1 6. Determine the appropriate additional internal reinforcements which are required using this equation: Reinforcement Length = AL + 6 x (original frame rail web depth). The figure below shows how this reinforcement is to be placed over the extended or shortened section of the frame rail. D = Original frame rail web depth Figure 2.32.2 The suggested cross section of this reinforcement is a snug fit inner channel. If the new wheelbase exceeds the upper limit of the optional wheelbases of this model, i.e.; a "long bridge", it may be necessary to use an "inverted L" reinforcement in addition to the snug fit channel reinforcement (see figures on next page). Application Engineering should be consulted for approval of such cases. It should be noted that these methods of reinforcements, and any other methods which may be used, require a 45° angled cut at both ends to avoid stress concentrations in the frame (note the figures under item 7). 2024 Chevrolet LCF Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 2.33 Wheelbase Alteration OR Figure 2.33.1 Snug fit inner channel Snug fit inner channel with "Inverted L" for "Long Bridge" wheelbases 7. The reinforcements must be fastened securely to only the web of the original chassis frame rail. The reinforcement must be held rigidly in place using either HUC bolts, GRADE 8 bolts and hardened steel washers at both the bolt head and nut, or GRADE 8 flanged bolts and hardened steel washers at the nut. Below are some suggested bolt patterns. It should be noted that these bolt patterns must not align the bolts vertically, i.e.: the bolt pattern must be staggered. Figure 2.33.2 8. Lengthening the frame will also require extending the brake lines, basic chassis electrical harness. It is recommended that the original brake lines be removed and replaced with brake lines of the same diameter as the original lines and of the appropriate length. The extended ABS brake lines must be supported back to the frame to prevent vibration. The electrical harness must be extended in accordance with the ELECTRICAL WIRING AND HARNESSING section of this book. GM offers an electrical extension harnesses for the LCF chassis when a wheelbase is lengthened. One wheelbase longer is the recommended maximum wheelbase extension (please refer to the drive line section and particular models for number of drivelines and their maximum lengths). The extension of a wheelbase will require electrical extension harnesses. Diesel 2016-2019 CHAS WRG HARNESS ASM; QTY 1 (See your GM dealer for parts.) 2016-2019 CHAS RR WRG HARNCLIP; QTY 5 (See your GM dealer for parts.) 9. The propeller shaft's overall length will also need to be lengthened or shortened. If the extension is within the limits of the optional wheelbases of the respective model, the exact propeller shaft lengths and angles are given on or about Page 12 of the respective sections of this book. If the modified wheelbase exceeds the optional wheelbases of the respective model, the following guidelines must be adhered to: 2024 Chevrolet LCF Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 2.34 Wheelbase Alteration a. Propeller Shaft Length The maximum propeller shaft lengths (pin to pin) for the respective models are shown in the table below. ENGINE MODEL Propeller Shaft Diameter (in.) Maximum Propeller Shaft Length (in.) 4500HD 3.25 50.7 DIESEL 4500XD/5500HD 3.54 52.9 5500XD 3.54 52.9 Figure 2.34.1 b. Propeller Shaft Angles The maximum propeller shaft angles, with respect to the previous shaft, are shown in the table below. ENGINE MODEL Maximum Propeller Shaft Angle 4500HD 6.1o DIESEL 4500XD/5500HD 6.1o Figure 2.34.2 5500XD 6.1o c. The propeller shaft angles must be designed such that the angles will cancel to avoid propeller shaft whip. d. The propeller shaft yokes must be assembled such that the propeller shaft yokes are "in phase." 10. Extending the frame will also require relocation and/or addition of crossmembers. If the extension is within the limits of the optional wheelbases of the respective model, the exact crossmember locations and dimensions are given in the respective model sections of this book. If the modified wheelbase exceeds the optional wheelbases of the respective model, the following guidelines must be adhered to: a. The crossmember location will largely be determined by the propeller shaft lengths and where the center carrier bearing locations are for the propeller shaft assembly. b. A crossmember must be located at the front and rear spring hangers of the rear suspension (refer to the appropriate section of this book to see where these suspension crossmembers are to be located). c. The crossmember must be constructed such that it supports both the upper and lower flange on each frame rail (see drawing on next page). A crossmember such as the one on the next page may be constructed, or Chevrolet crossmembers may be obtained from your Chevrolet parts dealer. 2024 Chevrolet LCF Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 2.35 Wheelbase Alteration Figure 2.35.1 d. The maximum distance between crossmembers for the respective models is given in the table below. ENGINE MODEL Maximum Distance Between Crossmembers (in.) 4500HD 35.7 DIESEL 4500XD/5500HD 35.7 Figure 2.35.2 5500XD 35.7 e. The drilling for any additional holes in the frame rails must comply with the DRILLING AND WELDING section of this book. 11. All other aspects of lengthening or shortening the wheelbase must comply with the applicable section of this Body Builder's Guide. For special applications and longer than recommended body lengths, GM Upfitter Engineering must be consulted for approval. 12. Please contact GM Upfitter Engineering for guidelines on LCF CHASSIS frame modifications when the vehicle is equipped with an Antilock Brake System. 2024 Chevrolet LCF Revision: 05/31/23 2024 Chevrolet Low Cab Forward 2.36 Gas (6.6L Engine) No Modification Zones The vehicle exhaust, evaporative system, and fuel tank are integral parts of the evaporative/engine and emission/diagnostic control system and CANNOT be modified or rerouted. 2024 Chevrolet LCF Figure 2.35.3 Revision: 05/31/23 2024 Chevrolet Low Cab Forward INSTALLATION OF BODY AND SPECIAL EQUIPMENT 6500XD CLEARANCES Engine At least 1.6 inches of clearance should be maintained around the engine. No obstacles should be added in front of the radiator or intercooler. PAGE 3.02 Front and Back Clearance 1 inch Transmission Figure 3.2.1 The transmission is removed from the rear. Enough clearance must be provided to allow rearward movement of the transmission assembly. Clearance should be sufficient to allow 5 to 6 inches of unrestricted movement of the transmission assembly. In addition, provide at least 2 inches of clearance around the control lever on the side of the transmission to allow free movement without any binding. 2024 Chevrolet LCF Figure 3.2.2 Front and Back Clearance 1 inch Revision: 05/31/23 2024 Chevrolet Low Cab Forward At least 2 inches of clearance should be maintained above the automatic transmission to allow for transmission removal. PAGE 3.03 Front and Center Propeller Shafts Figure 3.3.1 At least 1.25 inches of clearance should be maintained around front and center propeller shafts. 2024 Chevrolet LCF Figure 3.3.2 Revision: 05/31/23 2024 Chevrolet Low Cab Forward Rear Propeller Shaft With the rear springs at maximum deflection, at least 1.25 inches of clearance should be provided over the rear propeller shaft. PAGE 3.04 Rear Propeller Shaft Figure 3.4.1 2024 Chevrolet LCF Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 3.05 Exhaust System The exhaust system has a crucial role in meeting 2010 EPA regulations. In order to maintain compliance with the 2010 EPA emissions levels the Diesel Particulate Filter (DPF) and SCR package must not be moved. The distance between the engine exhaust manifold down pipe and Diesel Particulate Filter (DPF) / Selective Catalytic Reduction Package (SCR) must be maintained and the pressure in the system must be sustained at a constant level. Due to increased temperatures n the exhaust system during the regeneration cycle and the heat stress caused by these temperatures, body builders should closely evaluate the placement of equipment and provide protection to these added components as needed. Diesel Particulate Filter and Selective Catalytic Reduction (SCR) Restrictions The DPF/SCR has exhaust pressure pipes and temperature sensors. Care must be taken when a body is installed so as to not dama ge pipe sensors. The DPF/SCR should be free from impact or vibration during body installation. The DPF/SCR must have enough room for disassembly of the unit for service and cleaning. The DPF/SCR switch in the cab should not be removed or disabled. No modification or relocation of the DPF/SCR unit, pressure pipes, and sensor is permitted. 6500XD No Modification Zones The DPF/SCR unit CANNOT be modified or moved . The DEF tank and pump CANNOT be modified or removed. DEF lines and coolant lines CANNOT be modified or rerouted. 2024 Chevrolet LCF Figure 3.5.1 Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 3.06 EXHAUST CLEARANCES If flammable materials such as wood are used in the body, provide at least 3.9 inches of clearance between the body and any parts of the exhaust pipe, DPF/SCR Package. If it is impossible to maintain the minimum clearance, use a heat shield. Also use a heat shield if an oil pump or line is located above the exhaust pipe, muffler or catalytic converter. Figure 3.6.1 1) Clearances around SCR system components must be greater than 1.0 inch at all times to avoid potential contact between the body and the exhaust components. The 1.0 inch allows for thermal expansion and assembly tolerance of the exhaust system. It does not account for dynamic movement in the body due to road conditions and other loads. Body companies are instructed to adjust this 1.0 inch clearance as required to account for body displacement while driving. This guidance does not supersede guidance or exhaust clearances for temperature sensitive or flammable components. 2) Exhaust temperatures have not changed since the introduction of DPF in 2007. 2024 Chevrolet LCF Revision: 05/31/23 2024 Chevrolet Low Cab Forward Exhaust system surface temperatures During Manual Regeneration 6500XD Modification Guideline (heat issue) (EXHAUST PIPE HEAT) 4 inches from vehicle endor side PAGE 3.07 2024 Chevrolet LCF More than 8 inches More than 18 inches Less than 45 deg Figure 3.7.1 Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 3.08 Rear Wheel Axle The design and installation of the body should allow sufficient clearance for full vertical movement of the rear wheels and axle when the vehicle travels over rough or unleveled surfaces. See Note Figure 3.7.1 Note: For recommended clearances, please refer to the Rear Axle Chart in each model's respective section. Other Clearances The transmission control cable may be broken if it is bent by or interferes with the body and its fixtures. To prevent this, 1 inch of minimum clearance should be provided. When cable is detached from body mounting, be sure not to bend the cable. Accessibility to the grease nipple on the rear spring bracket/shackle should be provided so that serviceability with a grease gun is not hampered. Parts Brake Hose Parking Brake Cable Fuel Hose Shock Absorber 2024 Chevrolet LCF Minimum Clearance 6.7 in. 1.6 in. 1.2 in. 1.6 in. 2.4 in. 1.2 in. Figure 3.7.2 Location Axle Side Frame Side -- -- Axle Side Frame Side Revision: 05/31/23 PAGE 2024 Chevrolet Low Cab Forward Body Installation Mirrors The LCF 6500XD chassis will accommodate up to 96 inch wide bodies without modification to the mirror brackets. 3.09 The LCF 6500XD chassis will accommodate up to 96 inch wide bodies without modification to the mirror brackets. Bodies from 97 to 102 inches wide will require that the mirror brackets be modified. This Modification can be made at the port and the vehicle order/label will indicate a Regular Product Option of XWL indicating "Mirror Bracket for 102 wide body". The brackets can also be modified by the Chevrolet Dealer or the Body Company by installing mirror brackets ordered from GM Service Parts. Side Step Door Installation recommendations Floor of body should be at least 10" above frame rail (2.5" wood + 4" long sill + 3" cross sill + 1.125" floor) Forward end plate of step well area can interfere with SCR system All body components should maintain a minimum 1.0" of clearance to exhaust components UNDER ALL (DYNAMIC) CONDITIONS. (Body company will need to add to this 1.0" clearance to account for flex or movement in the body) Outer heat shield on SCR system can be removed prior to mounting body if required for clearance Care should be taken to adequately shield exhaust Driver's side steps can also be accommodated, if door is located behind DEF tank Battery may have to be relocated, depending on door location Access hatch for DEF tank fill may have to be added, depending on door location DPF/SCR Heat shield Removal The exhaust external heat shield does not impact vehicle emissions or emissions system durability. This shield can be removed or modified in order to facilitate body or equipment mounting, but the completed vehicle manufacturer should ensure that, when completed, the exhaust will be adequately shielded to prevent unintentional contact with hot exhaust components, and that heat transfer to body components is not so high as to present safety or durability risks. Detailed information on removal of the heat shield can be found in the GM service manual. 2024 Chevrolet LCF Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 3.10 Body Installation Heat Shield DPF/SCR Heat Shield Removal this bracket can be Cut Off 19.6" 2024 Chevrolet LCF Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 3.11 6500XD Special Equipment on the Chassis When installing special equipment on the chassis, extra consideration must be given to the weight and construction of the equipment to assure proper distribution of the load. Localization of the load should be prevented. All special equipment should be properly secured into position. We recommend the use of sub frame members when installing special equipment. Sub frame Design and Mounting The sub frame assembly should be mounted as close to the cab as possible. It should be contoured to match the shape and dimensions of the chassis frame as closely as possible. 2024 Chevrolet LCF Figure 3.11.1 Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 3.12 Subframe Contour Contouring of the front end of the subframe members as shown in the three illustrations below will prevent stresses from being concentrated on certain areas of the chassis frame. 2024 Chevrolet LCF Figure 3.12.1 Revision: 05/31/23 2024 Chevrolet Low Cab Forward When using a steel subframe, do not close the end of the subframe. PAGE 3.13 Figure 3.13.1 Prohibited Attachment Areas Do not attach the sub frame with a bolt or bracket to the chassis frame at the points indicated in the following illustrations. 1. At the front end of the subframe. The attaching bolt or bracket must be at least 2 inches behind the kick up point of the subframe. 2024 Chevrolet LCF Figure 3.13.2 Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 3.14 2. Front U-bolt and Mounting Bracket, Mounting Locations Ahead of Transmission Mandatory location due to after treatment device location and interior frame components. The chassis will be supplied with one steel crush block in cab for left hand forward body attaching location as illustrated in the drawings below and one body mounting bracket (painted yellow) attached to the right hand frame rail in the location shown in the drawings below. Body Builder will be required to design a mating bracket for attaching the body to the yellow painted chassis body mounting bracket (Ref page 2.16 for illustration of bolt clamping 2 brackets ). No U bolt type attaching allowed. WHEELBASE (in) A 152.0 32.8 170.0 32.8 188.0 32.8 200.0 32.8 212.0 32.8 224.0 32.8 236.0 32.8 248.0 32.8 2024 Chevrolet LCF Figure 3.14.1 U---Bolt Crush Block Locations (in) B C D 79.0 39.6 N/A N/A 39.6 64.6 68.9 39.6 59.6 74.0 39.6 66.5 82.7 39.6 73.0 82.7 39.6 85.0 82.7 39.6 82.3 82.7 39.6 94.3 E N/A N/A 82.5 94.5 106.5 118.5 130.5 142.5 Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 3.15 Body Mounting Bracket Specifications 2024 Chevrolet LCF ·Hardware: Chevrolet supplied, two each Figure 3.15.1 Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 3.16 Subframe Mounting Figure 3.16.1 Within 8 inches of bends in the chassis frame or the attachment points of any crossmembers. Bracket Installation Mounting brackets should be clamped to the chassis frame using bolts. For proper positions in which to install the bolts, refer to the preceding section and the section "Modifications to the Chassis Frame." In addition to the illustrated bracket and U -bolts a shear plate may be required for adequately body mounting. The body company will be responsible for engineering their own mounting system. The frame material is a heat treated, carbon manganese, low alloy steel with good weldability. The frame has a 80/40 mm modular hole spacing standard. This standard pattern will assist in body mounting. 2024 Chevrolet LCF Figure 3.16.2 Revision: 05/31/23 2024 Chevrolet Low Cab Forward U-bolt Installation When U-bolts are used to retain the subframe, reinforcement blocks must be installed in the frame members. This will prevent distortion of the frame flange as they are tightened. The drawing indicates the correct placement of reinforcement blocks. If you use wood blocks, be sure that there is sufficient clearance between them and any parts of the exhaust system. The use of J-bolts to retain the subframe is strictly prohibited. If any fluid lines or electric cables are located near the reinforcement blocks, you must provide at least 0.4 inches of clearance between rigid or stationary portions, and at least 1.6 inches between moveable or flexible portions of the lines. PAGE 3.17 CAUTION: U-Bolt placement is critical with new emission systems and controls. Extra care must be taken when placing bodies on chassis so as not to damage these components. Figure 3.17.1 For the installation positions of the U-bolts, refer to "Prohibited Attachment Areas." 2024 Chevrolet LCF Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 3.18 Modification of the Frame Modifications of the chassis frame should be held to an absolute minimum. Modification work should be performed according to the instructions in the following paragraphs. When modification is complete, chassis frame members should be carefully inspected to eliminate the possibility of any safety-related defects. NOTE: PLEASE REFER TO NOTES ON CHASSIS FRAME MODIFICATION WITH ANTILOCK BRAKES. Working on Chassis frame The chassis frame is designed and built with consideration for proper load distribution. Sufficient physical strength is provided when the load is evenly distributed. Installation of special equipment on the chassis frame can cause variations in load distribution. If even distribution of load is not kept in mind when the equipment is installed, localization of stresses on specific areas of the frame could cause cracking of the chassis frame members or other problems, even if the total weight of the equipment is within the design limit. The chassis frame is designed as an integral unit. Therefore, we do not recommend cutting the chassis frame under any circumstances. Drilling and Welding IMPORTANT NOTE: For vehicles equipped with electronic engines and or electronic or hydra-matic transmissions, electric arc welding must be done with the negative battery cable disconnected. 1. Do not drill or weld in the shaded portions of the chassis frame members. Do not weld within 0.8 inches from the edges of any existing holes. ( Ref. page 2.20 ) 2. Hold the length of any welding beads within 1.2-2.0 inches. Allow at least 1.6 inches between adjacent welding beads. 3. All holes must be drilled. Do not use a torch to make any holes. 4. All riveting must be done with cold rivets. Do not use hot ri ve t s . 5. The flange of the chassis frame must not be cut under any circumstances. 6. The subframe must be attached to the chassis frame with bolts. Do not weld. 7. Repaint exposed metal after drilling. 2024 Chevrolet LCF Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 3.19 A - no more than 0.59 inches in diameter H B - must be more than H/5 for welding and H/7 for holes C - must be more than 1.57 inches H = Frame Height Reinforcement of Chassis Frame Figure 3.19.1 Reinforcements must be installed to prevent the considerable variation in the section modulus. They must be welded so as to avoid localized stresses. The frame of the 6500XD is made of SAPH440 mild steel. The drawing on the following page illustrates correct and incorrect methods of frame reinforcement. Welding 1. Keep reinforcement plates and chassis frame free from moisture and water. 2. Avoid cooling with water after welding. 3. Use a suitable means to protect pipes, wires, rubber parts, leaf springs, etc. against heat and effect of sputtering. 4. Remove fuel tank assembly when welding portions near the fuel tank. 5. Remove coat of paint completely when welding painted areas. Repaint exposed metal after welding. 2024 Chevrolet LCF Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 3.20 Figure 3.20.1 Fluid Lines Do not disturb the layout of any brake lines or fuel lines unless absolutely necessary. When modification is needed, follow the instructions below carefully to ensure safety. Brake fluid lines must not be cut and spliced under any circumstances. We do not recommend the cutting or splicing of any fuel lines, but if it is absolutely necessary, be sure that the correct fitting and tools are used to form the joint, and then pressure test the joint. Steel lines are metric sizes. Preparation of Additional Lines 1. Where possible, use only genuine Chevrolet lines as supplied by authorized Chevrolet dealers. 2. Use the correct metric flaring and bending tools to form the lines. 3. Avoid repeated bending. Do not use heat for flaring and bending the lines. Before and after forming the new lines, examine them carefully for scratches, distortion, dents and the presence of any foreign matter. 2024 Chevrolet LCF Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 3.21 Installation of Additional Lines Install new lines away from adjacent parts and away from any sources of heat. 1. A minimum clearance of 0.4 inches must be maintained between lines. Where necessary, clip the lines into position in order to maintain this minimum clearance. 2. Minimize any crossing between lines. If a crossing is unavoidable, use the following procedure: a. At least 0.4 inches of clearance should be maintained between lines at the crossing point. b. If the 0.4 inches of clearance cannot be maintained, or if the lines are subject to vibration, clip them securely. 3. Plan the bends and clipping points of the lines to minimize vibration and the resulting fatigue. 4. Use rust-proofed clips and apply vinyl coating to the portions of the lines to be clipped. 5. Install new lines in positions where they are protected against water, dirt, grit, sand, rocks and other foreign matter that can come from above or below, or can be flung up by the wheels. Figure 3.21.1 Electrical Wiring and Harnessing To increase the reliability of the wiring, all frame harnesses are covered with corrugated vinyl tubing. The following instructions apply to extending or modifying these harnesses. See the Electrical Section for information on commonly used circuits in the Chevrolet LCF trucks. 2024 Chevrolet LCF Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 3.22 Wiring 1. Most wiring connections on LCF vehicles are made with terminals. We recommend the use of terminals when splicing cables and wires. 2. When splicing, use new wire of the same gauge, and do not make splices inside the corrugated tubing. 3. When making connections to the end of the harness, make sure the connections are electrically perfect. Use insulating tape as needed to prevent the entry of water, which results in short circuits and/or corrosion. 4. When making new circuits, or modifying circuits already installed, make the cables only just taut enough to remove any slack. Use clips or grommets where required to protect cables from heat or sharp edges. When cables must run near the exhaust system, see the instructions in the "Exhaust System" section. 5. Always use rustproof clips, and apply vinyl coating to that portion of the clips in direct contact with the harnesses. No scotch clips or connectors. 6. To minimize the vibration of the harness, clipping points should be set up according to the table. Harness Diameter less than 0.2 in. 0.2 in. ~ 0.4 in. 0.4 in. ~ 0.8 in. Clip Distance less than 11.8 in. approx. 15.7 in. approx. 19.7 in. Figure 3.22.1 7. When changing the length of the battery cable, do not cut or splice the existing cable. Make up a new cable of the correct length and wire gauge for the load and distance, without splices. 8. When using connectors, use a socket (female) connector on the electrical source side and a plug (male) connector on the electrical load side to lower the possibility of a short circuit when disconnected. 9. When connecting cables to moving or vibrating parts such as the engine or transmission, be sure to maintain sufficient slack in the wiring to absorb the vibration. Follow the example of existing cables connected by Chevrolet LCF. Keep flexible cables clear of other parts. 10. Do not use vinyl tape in the engine compartment. The heat will tend to make it peel off. Use plated steel clips coated with rubber or vinyl. 11. When locating auxiliary equipment or lines near the ECM caution should be used in order to protect the ECM from excessive vibration, heat or chemical reactions. 2024 Chevrolet LCF Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 3.23 2024 Chevrolet LCF Figure 3.23.1 Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 3.24 Wire Color Code The electrical circuits of the 6500XD Chassis Cab are connected with low-voltage stranded wire for automotive applications. The color coding standards are as follows for the 6500XD Chassis Cab: (1) Black (2) White (3) Red (4) Green B Starter circuits and grounds W Generator (alternator) circuit R Lighting circuit G Signal circuit (5) Yellow (6) Brown (7) Light Green (8) Blue Y Instrument circuit Br Accessory circuit Lg Other circuit L Windshield wiper motor circuit Maximum Allowable Current Harness Design Diameter (mm) AWG Equivalent 100 00 85 0 60 1 50 1 40 1 30 2 20 4 15 6 8 8 5 8 3 12 2 14 1.25 16 0.85 18 0.5 20 No. of Wires/Wire Diameter (mm) Cross Sectional Area (mm2) Maximum Allowable Current(Amps) 217/0.80 109.1 363 169/0.80 84.96 305 127/0.80 63.84 248 108/0.80 54.29 223 85/0.80 42.73 191 70/0.80 35.19 171 41/0.80 20.61 123 84/0.45 13.36 93 50/0.45 7.952 68 65/0.32 5.228 51 41/0.32 3.297 39 26/0.32 2.091 29 16/0.32 1.287 21 11/0.32 0.8846 17 7/0.32 0.5629 13 Reference: The values given in the "maximum allowable current" column are based on the ambient temperature condition of 104oF with temperature increase of 1040F. Figure 3.24.1 2024 Chevrolet LCF Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 3.25 Electrical System Modifications Modifications/add-on wiring must be carefully reviewed to ensure compatibility with the base vehicle wiring by reviewing system schematics, wire routing paths, harness connections, etc. Due to the wide range of modifications that may be required for vocational needs, it is not feasible for the O.E.M. to take into account all potential revisions. For this reason, any person modifying existing vehicle wiring must assume responsibility that the revisions have not degraded the electrical system performance. Any add-on wiring needs to be properly fused and routed to prevent cut, pinch, and chafe problems, as well as avoid exposure to excessive heat. Care must be exercised that existing vehicle interfaces do not have their current load capabilities exceeded, and that the respective control devices are not overloaded. Added wire size should be at least as large as the wire to which it is attaching in order for fuse protection to be maintained A Packard electric wiring repair kit is available through Kent-Moore (P/N J38125-B) (Phone # 1-800-345-2233). This kit contains instructions, tools and components for making repairs to wiring harness components. This kit would also greatly assist in accomplishing necessary add-on wiring such as body marker lamps, so that system reliability/durability is maintained. Electrical wiring components can be obtained through your authorized Chevrolet dealers. Packard Electric components are also available through Power and Signal (www.powerandsignal.com). Power and Signal may also be able to assist in making necessary wiring additions by providing custom wiring stubs or jumpers to your specifications. Caution: Before servicing any electrical component, the ignition key must be in the LOCK position and all electrical loads must be OFF, unless instructed otherwise in Chevrolet service procedures. If a tool or equipment could easily come in contact with a live exposed electrical terminal, also disconnect the negative battery cable. Do not disconnect cable within 3 minutes after turning the ignition key to the Lock position. Failure to follow these precautions may cause personal injury and/or damage to the vehicle or its components. Exhaust System Modification of the exhaust system should be avoided. If modifications are absolutely necessary, the following points should be maintained. 1. Maintain the clearance specified in the "Exhaust System" table between all parts of the exhaust system and any fuel lines, brake lines, brake hoses, electrical cables, etc. The exhaust outlet should not point toward any of these parts. Brake lines Flexible brake hoses Wiring harnesses and cables Steel fuel lines Rubber or vinyl fuel hoses Clearance 2.4 in. or more. (If the combined section of a group of parallel brake lines is more than 7.8 in., a clearance of 7 in. or more should be provided.) 7.8 in. or more. (The temperature of flexible brake hoses should not exceed 158oF. If the highest temperature is not measurable, a clearance of more than 15.7 in. should be maintained between the hoses and the exhaust system.) 7.8 in. or more. (The temperature of flexible brake hoses should not exceed 158oF. If the highest temperature is not measurable , a clearance of more than 15.7 in. should be maintained between the hoses and the exhaust system.) 3.1 in. or more. 5.9 in. or more. Figure 3.25.1 2024 Chevrolet LCF Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 3.26 2. If a tool box is installed, it should preferably be made from steel. If a wooden tool box is installed, at least 7.8 inches of clearance should be maintained between the tool box and any parts of the exhaust system. 3. If the exhaust system is modified, it is the responsibility of those making the modification to ensure that the noise level meets appropriate standards. 4. If the exhaust system is modified it is the responsibility of those making the modification to ensure that the emission levels meet appropriate standards. Fuel System Relocation of the fuel tank, or installation of additional fuel tanks, is not recommended. If modifications to the fuel system are unavoidable, follow these recommendations: 1. Maintain adequate clearance between the fuel tank and any other device or structure. 2. Do not connect any additional fuel hose. Rear Lighting Brackets installed are temporary. Please do not use these brackets for body installation. Serviceability No matter what other modifications or changes are made, access to components requiring daily preventive maintenance or other routine service must not be obstructed. This includes: 1. Inspection, filling and draining of engine oil and cooling water. 2. Inspection, filling and draining of transmission fluid. 3. Adjustment, removal and installation of the fan belts. 4. Inspection, filling and removal of the battery and battery cover. 5. Maintenance of clearance for tightening of check bolt on brake safety cylinder. 6. Operation of the spare tire carrier, including mounting and dismounting of the spare tire. 2024 Chevrolet LCF Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 3.27 Wheelbase Alteration With certain applications, it may become necessary to alter the wheelbase of the chassis. The next two sections provide the suggested guidelines for accomplishing either shortening or lengthening of the wheelbase. Shortening/Lengthening the Wheelbase Without Altering the Frame Since the frame is an integral part of the chassis, it is recommended that the frame not be cut if it is possible to avoid it. W hen shortening/lengthening the wheelbase on some models, it is possible to do so without cutting the frame. This is possible on models which have a straight frame rail. If the chassis does not have a straight frame rail, it may still be necessary to cut the frame. For instructions on shortening/lengthening these chassis, refer to the "Altering the Wheelbase by Altering the Frame" section of this book. Otherwise, the wheelbase may be shortened/lengthened by removing the rear suspension, drilling new suspension mounting holes at the appropriate spot in the frame, and sliding the rear suspension, suspension liner, and suspension crossmembers forward or aft. The suspension and suspension crossmembers' rivet holes left in the frame rail flange must be filled with GRADE 8 bolts and hardened steel washers at both the bolt head and nut, HUC bolts or GRADE 8 flanged bolts and hardened steel washers at the nut. When shortening/lengthening the wheelbase in this manner, the following guidelines must be adhered to: 1. All frame drilling must comply with the DRILLING AND WELDING section of this book. 2. All rivet holes left in the frame rail flange from the suspension and suspension crossmembers must be either filled with GRADE 8 bolts and hardened steel washers at both the bolt head and nut, HUC bolts or GRADE 8 flanged bolts and hardened steel washers at the nut. 3. The components required to be slid forward or aft are the suspension and suspension hangers, suspension crossmembers and suspension frame liner. Altering the Wheelbase by Altering the Frame Even on a straight frame rail, it may be desirable to cut the frame and lengthen or shorten the wheelbase rather than simply sliding the rear suspension back or forward. The following section offers some guidelines and suggestions for cutting and lengthening or shortening the frame. Glossary of Terms Chassis Wheelbase Alteration CA Length from back-of-cab to rear axle centerline in inches. AL Added length (in case of a lengthened wheelbase). Difference between WB (new) and WB (old). SL Shortened length (in case of shortened wheelbase). Difference between WB (old) and WB (new). 2024 Chevrolet LCF Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 3.28 1. Determine the added length (AL) or shortened length (SL) required to lengthen or shorten chassis. (For added wheelbase: New CA = CA + AL; For shortened wheelbase: New CA = CA SL.) 2. Obtain the material to be used as the insert for the lengthened wheelbase in the correct length (AL). The insert must have the same cross sectional dimensions and yield strength as the original frame rail. 3. Divide the new CA by two (2). Measure (new CA)/2 from the center of the rear axle forward and mark this point on the chassis frame (see figure below). Figure 3.28.1 4. Cut the chassis frame at this point. If the wheelbase is to be lengthened, addition of the previously obtained insert (of length AL determined in step 1) will be made at this time. If the wheelbase is to be shortened, measure the distance (SL) forward of this cut and remove a length (SL) section from the chassis frame (see figure below). Insure that an adequate area on the frame remains for the required addition of the necessary reinforcements. These are the only suggested places for cutting the frame and reinforcements. 2024 Chevrolet LCF Figure 3.28.2 Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 3.29 5. When welding the insert (length AL for wheelbase lengthening) to the original frame rail, a continuous butt weld must be used at the splices. When shortening the wheelbase, weld the ends of the chassis frame together with a continuous butt weld over the junction of the frame ends. Weld can be both the inside and outside of the frame rails using welding techniques prescribed by established welding standards (ref. SAE J1147) and in accordance with this guide. An example of this weld is shown below. Figure 3.29.1 6. Determine the appropriate additional internal reinforcements which are required using this equation: Reinforcement Length = AL + 6 x (original frame rail web depth). The figure below shows how this reinforcement is to be placed over the extended or shortened section of the frame rail. D = Original frame rail web depth Figure 3.29.2 The suggested cross section of this reinforcement is a snug fit inner channel. If the new wheelbase exceeds the upper limit of the optional wheelbases of this model, i.e.; a "long bridge", it may be necessary to use an "inverted L" reinforcement in addition to the snug fit channel reinforcement (see figures on next page). Application Engineering should be consulted for approval of such cases. It should be noted that these methods of reinforcements, and any other methods which may be used, require a 45o angled cut at both ends to avoid stress concentrations in the frame (note the figures under item 7). 2024 Chevrolet LCF Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 3.30 Figure 3.30.1 7. The reinforcements must be fastened securely to only the web of the original chassis frame rail. The reinforcement must be held rigidly in place using either HUC bolts, GRADE 8 bolts and hardened steel washers at both the bolt head and nut, or GRADE 8 flanged bolts and hardened steel washers at the nut. Below are some suggested bolt patterns. It should be noted that these bolt patterns must not align the bolts vertically, i.e.: the bolt pattern must be staggered. Figure 3.30.2 8. Lengthening the frame will also require extending the brake lines, basic chassis electrical harness. It is recommended that the original brake lines be removed and replaced with brake lines of the same diameter as the original lines and of the appropriate length. The extended ABS brake lines must be supported back to the frame to prevent vibration. The electrical harness must be extended in accordance with the ELECTRICAL WIRING AND HARNESSING section of this book. 9. The propeller shafts' overall length will also need to be lengthened or shortened. If the extension is within the limits of the optional wheelbases of the respective model, the exact propeller shaft lengths and angles are given on or about Page 12 of the respective sections of this book. If the modified wheelbase exceeds the optional wheelbases of the respective model, the following guidelines must be adhered to: 2024 Chevrolet LCF Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 3.31 a. Propeller Shaft Length The maximum propeller shaft lengths (pin to pin) for the respective models are shown in the table below. ENGINE Model Propeller Shaft Diameter (in.) Maximum Propeller Shaft Length (in.) DIESEL 6500XD 4.0 67.9 b. Propeller Shaft Angles Figure 3.31.1 The maximum propeller shaft angles, with respect to the previous shaft, are shown in the table below. ENGINE Model Maximum Propeller Shaft Angle DIESEL 6500XD 3.4o Figure3.31.2 c. The propeller shaft angles must be designed such that the angles will cancel to avoid propeller shaft whip. d. The propeller shaft yokes must be assembled such that the propeller shaft yokes are "in phase." 10. Extending the frame will also require relocation and/or addition of crossmembers. If the extension is within the limits of the optional wheelbases of the respective model, the exact crossmember locations and dimensions are given in the respective model sections of this book. If the modified wheelbase exceeds the optional wheelbases of the respective model, the following guidelines must be adhered to: a. The crossmember location will largely be determined by the propeller shaft lengths and where the center carrier bearing locations are for the propeller shaft assembly. b. A crossmember must be located at the front and rear spring hangers of the rear suspension (refer to the appropriate section of this book to see where these suspension crossmembers are to be located). c. The crossmember must be constructed such that it supports both the upper and lower flange on each frame rail (see drawing on next page). A crossmember such as the one on the next page may be constructed, or LCF crossmembers may be obtained from your Chevrolet parts dealer. 2024 Chevrolet LCF Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 3.32 Figure 3.32.1 d. The maximum distance between crossmembers for the respective models is given in the table below. ENGINE Model Maximum Distance Between Crossmemebers (in.) DIESEL 6500XD 35.7 Figure 3.32.2 e. The drilling for any additional holes in the frame rails must comply with the DRILLING AND WELDING section of this book. 11. All other aspects of lengthening or shortening the wheelbase must comply with the applicable section of this Body Builder's Guide. 12. Please contact applications engineering for guidelines on 6500XD CHASSIS frame modifications when the vehicle is equipped with an Antilock Brake System. 2024 Chevrolet LCF Revision: 05/31/23 2024 Chevrolet Low Cab Forward LCF Gas and LCF Diesel Body Application Summary MODEL GVWR 3500 GAS 12,000 lbs 3500 CREW CAB GAS 12,000 lbs 4500 GAS 14,500 lbs 4500 CREW CAB GAS 14,500 lbs 4500 HD DIESEL 14,500 lbs 4500 HD CREW CAB DIESEL 14,500 lbs 4500 XD DIESEL 16,000 lbs 4500 XD CREW CAB DIESEL 16,000 lbs 5500 HD DIESEL 17,950 lbs 5500 HD CREW CAB DIESEL 17,950 lbs 5500 XD DIESEL 19,500 lbs 5500 XD CREW CAB DIESEL 19,500 lbs WB (in) 109 132.5 150 176 150 176 109 132.5 150 176 150 176 109 132.5 150 176 150 176 109 132.5 150 176 150 176 109 132.5 150 176 200 150 176 109 132.5 150 176 200 212 150 176 BOC (in) 7.7 7.7 7.7 7.7 5 5 7.7 7.7 7.7 7.7 5 5 7.7 7.7 7.7 7.7 5.3 5.3 7.7 7.7 7.7 7.7 5.3 5.3 7.7 7.7 7.7 7.7 7.7 5.3 5.3 7.7 7.7 7.7 7.7 7.7 7.7 5.3 5.3 10 ft. X X X X X 12 ft. X X X X X X[1] X X X[1] X X[1] X 14 ft. X X X X X BODY LENGTHS 16 ft. 18 ft. X X X X X X X[1] X X[1] X X X X X X 20 ft. X X X[1] X X X X X X X X 22 ft. X X 2024 Chevrolet LCF Notes: [1] Indicated body size and chassis wheelbase combination requires the installation of a liftgate for an acceptable weight distribution. [2] WARNING - Body selection recommendations are based on water level weight distribution and no accessories (i.e.liftgates or refrigeration units). This table is intended for reference and does not preclude the necessity for an accurate weight distribution calculation. [3] The BOC (back of cab) values shown are the minimum requirements for the chassis. A weight distribution analysis should be performed for the completed vehicle to determine the necessary BOC value. 24 ft. X PAGE 3.11A Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 3.35 4500HD - Body & Payload Weight Distribution (% Front/% Rear) AUTOMATIC TRANSMISSION MODEL GVWR WB CA CE OAL BOC 10 4500 4500 4500 4500 14,500 109 86.5 129.6 200.5 7.7 14,500 132.5 110 153.1 224.0 7.7 14,500 150 127.5 170.6 241.5 10.2 14,500 176 153.5 196.6 267.5 10.2 12 14 16 18 6/94 14/86 14/86 6/94 13/87 IMPORTANT: Weight distribution percentages listed do not include added accessories, liftgate or refrigeration units. Percentages based on water-level distribution of body and payload weight which is determined by subtracting chassis wet weight (including 200 lb. driver) from GVWR. These tables are intended for reference and do not preclude the necessity for an accurate weight distribution calculation. 2024 Chevrolet LCF Revision: 05/31/23 2024 Chevrolet Low Cab Forward 4500XD Diesel MODEL 4500XD DIESEL 4500XD DIESEL 4500XD DIESEL 4500XD DIESEL GVWR 16,000 16,000 16,000 16,000 WB 109 132.5 150 176 CA 86.5 110.0 127.5 153.5 CE 129.6 153.1 170.6 196.6 OAL 200.5 224.0 241.5 267.5 BOC 7.7 7.7 7.7 7.7 10 17/83 12 14 16 18 20 22 6/94 14/86 16/84 8/92 22/78 15/85 PAGE 3.36 AUTOMATIC TRANSMISSION MODEL 5500HD DIESEL 5500HD DIESEL 5500HD DIESEL 5500HD DIESEL 5500HD DIESEL GVWR 17,950 17,950 17,950 17,950 17,950 WB 109 132.5 150 176 200 CA 86.5 110.0 127.5 153.5 177.5 5500HD Diesel CE OAL BOC 10 12 129.6 200.5 7.7 17/83 6/94 153.1 224.0 7.7 170.6 241.5 7.7 196.6 267.5 7.7 220.6 291.5 7.7 14 14/86 16 16/84 18 20 8/92 22/78 15/85 22 19/81 AUTOMATIC TRANSMISSION MODEL 5500XD DIESEL 5500XD DIESEL 5500XD DIESEL 5500XD DIESEL 5500XD DIESEL 5500XD DIESEL GVWR 19,500 19,500 19,500 19,500 19,500 19,500 WB 109 132.5 150 176 200 212 CA 86.5 110.0 127.5 153.5 177.5 189.5 CE 129.6 153.1 170.6 196.6 220.6 232.6 5500XD Diesel OAL 200.5 224.0 241.5 267.5 291.5 303.5 BOC 7.7 7.7 7.7 7.7 7.7 7.7 10 17/83 12 6/94 23/77 14 14/86 16 18 16/84 8/92 22/78 20 22 15/85 19/81 24 18/82 IMPORTANT: Weight distribution percentages listed do not include added accessories, liftgate or refrigeration units. Percentages based o n water-level distribution of body and payload weight which is determined by subtracting chassis wet weight (including 200 lb. driver) from GVWR. These tables are intended for reference and do not preclude the necessity for an accurate weight distribution calculation. 2024 Chevrolet LCF Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 3.38 4500HD, 4500XD, 5500HD Crew Cab Diesel - Diesel Crew Cab Body & Payload Weight Distribution (% Front/% Rear) Crew Cab Diesel Engine MODEL 4500HD CREW CAB DSL 4500HD CREW CAB DSL GVWR WB CA CE OAL BOC 10 14,500 150 88.5 131.6 241.5 5.3 14,500 176 114.5 157.6 267.5 5.3 12 14 16 14/86 7/93 MODEL 4500XD CREW CAB DSL 4500XD CREW CAB DSL GVWR 16,000 16,000 WB CA CE OAL 150 88.5 131.6 241.5 176 114.5 157.6 267.5 BOC 5.3 5.3 10 12 14 16 7/93 14/86 7/93 MODEL 5500HD CREW CAB DSL 5500HD CREW CAB DSL GVWR 17,950 17,950 WB CA CE OAL 150 88.5 131.6 241.5 176 114.5 157.6 267.5 BOC 10 12 14 16 5.3 15/85 7/93 5.3 14/86 7/93 IMPORTANT: Weight distribution percentages listed do not include added accessories, liftgate or refrigeration units. Percentages based on water-level distribution of body and payload weight which is determined by subtracting chassis wet weight (including 200 lb. driver) from GVWR. These tables are intended for reference and do not preclude the necessity for an accurate weight distribution calculation. 2024 Chevrolet LCF Revision: 05/31/23 2024 Chevrolet Low Cab Forward MECHANICAL AND CAB SPECIFICATIONS Engine Horsepower and Torque Chart ENGINE MODEL ISUZU 4HK1-TC VEHICLE MODEL Net HP HP/RPM 1 Net Torque LBS-FT/RPM 1 AUTOMATIC TRANSMISSION 4500HD, 4500XD, 5500HD, 5500XD 210/2500 441/1850 Gross HP HP/RPM 1 215/2500 Gross Torque LBS FT/RPM 452/1850 Figure 4.1.1 NOTE:1 Horsepower and Torque Ratings are measured under SAE J1349 standards. The following table presents GVW ratings and corresponding GCW ratings for each model truck GVW/GCW Ratings Truck Model 4500HD DIESEL 4500XD DIESEL 5500HD DIESEL 5500XD DIESEL Transmission AUTOMATIC AUTOMATIC AUTOMATIC AUTOMATIC GVWR(lbs.) 14,500 16,000 17,950 19,500 Figure 4.1.2 GCWR (lbs.)1 20,500 22,000 23,950 25,500 PAGE 4.1 1 The Chevrolet Gas/Diesel engines are not approved for Hot Shot applications. 2024 Chevrolet LCF Revision: 05/31/23 2024 Chevrolet Low Cab Forward Rear Frame Height Chart The following table provides the rear frame height for each model/GVWR with standard tires: Model 4500HD Diesel 4500XD Diesel 5500HD Diesel 5500XD Diesel GVWR (lbs.) 14,500 16,000 17,950 19,500 Standard Tire 215/85R-16E 225/70R-19.5F 225/70R-19.5F 225/70R-19.5F Figure 4.2.1 4.2 Frame HT (in.) FH Std. Tires 31.1 33.0 33.0 33.0 PAGE 2024 Chevrolet LCF Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 4.21 BODY APPLICATION SUMMARY CHART 6500XD MODELS RPO CODE EG9 EH8 EK3 EM2 EL5 EK6 EG7 ES5 GVWR 25,950 WB 152 170 188 200 212 224 236 248 BOC 14 ft. 16 ft. 18 ft. 20 ft. 22 ft. 24 ft. 26 ft. 28 ft. 30 ft. x x x x x 3.0 x x x x Figure 4.21.1 2024 Chevrolet LCF Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 4.3 Paint Code Chart GM Ordering Color Name Exterior EXTERIOR PAINT CODE INFORMATION ISU695 ISU508 508 N/A 508 508 OEM Figure 4.3.1 2024 Chevrolet LCF Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 4.4 Low Cab Forward Towing Procedure WHEN TOWING A VEHICLE: Proper equipment must be used to prevent damage to vehicles during any towing. State and local laws which apply to vehicles in tow must be followed.Vehicles should not be towed at speeds in excess of 55 MPH (88 km/h). Connect to the main structural parts of the vehicle. Do not attach to bumpers, tow hooks or brackets. Use only equipment designed for this purpose. Follow the instructions of the wrecker manufacturer. A safety chain system must be used. The procedures below must be followed when towing to prevent possible damage. FRONT END TOWING (FRONT WHEELS OFF GROUND) To prepare a disabled vehicle for front end towing with front wheels raised off the ground, the following steps are necessary: · Block the rear wheels of the disabled vehicle. · Disconnect the propeller shaft at the rear axle. Secure the propeller shaft to the frame or cross member. CAUTION: WHEN TOWING, DISCONNECT THE DRIVESHAFT AT THE REAR AXLE TO ENSURE THE TRANSMISSION IS NOT DAMAGED. If there is damage or suspected damage to the rear axle, remove the axle shafts. Cover the hub openings to prevent the loss of lubricant or entry of dirt or foreign objects. Place a 10 cm (4 in) wood beam against the towing guide behind the bumper. (If no 10 cm (4 in) is available, then remove the bumper.) Ensure towing chains do not come into contact with the horns or the bumper. 2024 Chevrolet LCF Figure 4.4.1 Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 4.5 AFTER TOWING After towing the vehicle, block the rear wheels and install axle shafts or driveshaft. Apply the parking brake before disconnecting from the towing vehicle. FRONT END TOWING (ALL WHEELS ON THE GROUND) Your vehicle may be towed on all wheels provided the steering is operable. Remember that power steering and brakes will not have power assist. There must be a tow bar installed between the tow vehicle and the disabled vehicle. TOWING WITH ALL WHEELS ON THE GROUND To prepare a disabled vehicle for front end towing with all wheels on the ground, the following steps are necessary: · Block the wheels of the disabled vehicle. · Disconnect the propeller shaft at the rear axle. Secure the propeller shaft to the frame or crossmember. CAUTION: When towing, disconnect the driveshaft at the rear axle to ensure the transmission is not damaged. Provide wood blocking to prevent towing chains and bar from coming into contact with the bumper. If there is damage or suspected damage to the rear axle, remove the axle shafts. Cover the hub openings to prevent the loss of lubricant or entry of dirt or foreign objects. Figure 4.5.1 2024 Chevrolet LCF Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 4.6 CAUTION: When towing, disconnect the driveshaft at the rear axle to ensure the transmission is not damaged. Provide wood blocking to prevent towing chains and bar from coming into contact with the bumper. If there is damage or suspected damage to the rear axle, remove the axle shafts. Cover the hub openings to prevent the loss of lubricant or entry of dirt or foreign objects. AFTER TOWING After towing the vehicle, block the rear wheels and install axle shafts or propeller shaft. Apply the parking brake before disconnecting from the towing vehicle. Check and fill rear axle with oil, if required. REAR END TOWING When towing a vehicle with rear wheels raised, secure the steering wheel to maintain straight-ahead position. Make certain that the front axle is not loaded beyond the front axle gross axle weight rating (GAWR) as indicated on the vehicle's VIN and weight rating plate. SPECIAL TOWING INSTRUCTIONS 1. All state and local laws regarding such items as warning signals, night illumination, speed, etc., must be followed. 2. Safety chains must be used. 3. No vehicle should ever be towed over 55 MPH (88 km/h). 4. Loose or protruding parts of damaged vehicles should be secured prior to moving. 5. A safety chain system completely independent of the primary lifting and towing attachment must be used. 6. Operators should refrain from going under a vehicle which is being lifted by the towing equipment unless the vehicle is adequately supported by safety stands. 7. No towing operation which for any reason jeopardizes the safety of the wrecker operator or any bystanders or other motorists should be attempted. 2024 Chevrolet LCF Revision: 05/31/23 2024 Chevrolet Low Cab Forward MECHANICAL AND CAB SPECIFICATIONS Engine Horsepower and Torque Chart The following table presents Net versus Gross Horsepower and Torque ratings for Isuzu Product Engines: ENGINE MODEL ISUZU 4HK1-TC ISUZU 4HK1-TC VEHICLE MODEL Net HP HP/RPM1 Net Torque LBS-FT/RPM1 AUTOMATIC TRANSMISSION 4500HD, 4500XD, 5500HD, 5500XD 210/2500 441/1850 6500XD 210/2500 520/1600 Gross HP HP/RPM1 215/2500 215/2500 Gross Torque LBS FT/RPM 452/1850 520/1600 Figure 5.0.1 PAGE 5.01 GVW/GCW Ratings The following table presents GVW ratings and corresponding GCW ratings for each model truck: Truck Model 4500HD DIESEL 4500XD DIESEL 5500HD DIESEL 5500XD DIESEL 6500XD Transmission AUTOMATIC AUTOMATIC AUTOMATIC AUTOMATIC AUTOMATIC GVWR (lbs.) 14,500 16,000 17,950 19,500 25,950 GCWR (lbs.)3 20,500 22,000 23,950 25,500 30,000 Figure 5.0.2 NOTE: 1. Horsepower and Torque Ratings are measured under SAE J1349 standards. 2. Governed RPM 4HK1-TC 2760 rpm 3. Diesel engines are not approved for Hot Spot applications 2024 Chevrolet LCF Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 5.02 6500XD Towing Procedure When towing a vehicle: To move a disabled vehicle, it is best to rely on someone in the wrecker or tow truck business. If that is not possible, follow these procedures. When towing, use appropriate equipment and comply with state and local legal requirements. Do not try to start the engine by towing or pushing the vehicle. CAUTION: · Be sure to chock the wheels when disconnecting the axle shaft. The vehicle could start to move and cause a serious accident. The vehicle will start moving upon disconnecting the axle shaft. · Place the gearshift lever in the "N" position, and tow for a maximum distance of 6.2 miles (10 km) at speeds less than 25 MPH (40 km/h). Other than the above, disconnect the axle shaft when towing to avoid damage to the transmission. · Whenever possible, tow a vehicle with the engine started. If the engine is not started: · The brakes will not be as effective · The steering wheel will be hard to turn · The steering wheel could lock, making it impossible to move. This is extremely dangerous. (When the ignition key is removed.) · If you apply any one of the air brake parking controls while the vehicle is moving, your rig will stop suddenly. If you are not ready for this, you or others could be injured. Do not apply any one of these controls while you are driving, unless you have to make an emergency stop. Front End Towing (All wheels on the ground, or the front wheels are off the ground): When it is possible to operate the steering wheel, the vehicle can be towed with all wheels on the ground. If the engine cannot be started, the power steering system does not work, making steering difficult. In addition, when air pressure is low, the brakes will not work. Either install a tow bar between the towing vehicle and the disabled vehicle, or use a tow truck to move the disabled vehicle. To prevent damage to the differential and pinion seal, the axle shafts need to be removed whenever the vehicle is towed with the rear tires on the ground. Remove the axle shaft and plug up the opening of the hub to prevent differential gear oil from leaking, or to prevent dirt or foreign objects from entering the axle. When towing, disconnect the axle shaft at the rear axle to ensure the transmission is not damaged. 2024 Chevrolet LCF Figure 5.02.1 Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 5.03 1. If the vehicle is towing or is towed, firmly attach a rope to the front towing hook on the same side. 2. During towing, carefully watch the stop lights of the towing vehicle in order to prevent slack in the rope. Ensure that there are no strong shocks or lateral force applied to the vehicle. Excessive towing load can damage the towing hook. CAUTION: · Do not tow a vehicle at an angle of greater than 15°. This could exert too much stress on the vehicle and damage it. · Attach a rope to the towing hook only. Attaching a rope to any other part of the vehicle could damage it. · Make sure there are no people near the towing rope and hook before towing a vehicle. If the rope snaps, people nearby could be injured. · The towing hook is for use to tow a vehicle with about the same weight as the towing vehicle on good roads. · When coming to channels or muddy areas, unload the vehicle. Do not use the towing hook to tow, but tow with a rope attached to the axle. 2024 Chevrolet LCF Figure 5.03.1 Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 5.1 EIGHT DISTRIBUTION CONCEPTS Weight Restrictions The Gross Vehicle Weight Rating (GVWR) and the Gross Axle Weight Rating (GAWR) of each Incomplete Vehicle are specified on the cover of its Incomplete Vehicle Document in conformance to the requirements of Part 568.4 of the Federal Motor Vehicle Safety Regulations. The final stage manufacturer is responsible under Part 567.5 to place the GVWR and the GAWR of each axle on the Final Vehicle Certification Label. The regulation states that the appropriate rating "shall not be less than the sum of the unloaded vehicle weight, rated cargo load, and 150 pounds times the vehicle's designated seating capacity." Unloaded vehicle weight means the weight of a vehicle with maximum capacity of all fluids necessary for operation of the vehicle, but without cargo or occupants. During completion of this vehicle, GVWR and GAWR may be affected in various ways, including but not limited to the following: 1. The installation of a body or equipment that exceeds the rated capacities of this Incomplete Vehicle. 2. The addition of designated seating positions which exceeds the rated capacities of this Incomplete Vehicle. 3. Alterations or substitution of any components such as axles, springs, tires, wheels, frame, steering and brake systems that may affect the rated capacities of this Incomplete Vehicle. Use the following chart to assure compliance with the regulations. Chassis curb weight and GVW rating is located on Page 2 in each vehicle section. Always verify the results by weighing the completed vehicle on a certified scale. Curb Weight of Chassis (lbs.) PLUS weight of added body components, accessories or other permanently attached components. PLUS total weight of passengers, air conditioning and all load or cargo. EQUALS Gross Vehicle Weight (lbs.) (GVW) of completed vehicle. (From required vehicle section) + (Body, liftgate, reefer, etc.) + (Driver, passengers, accessories and load) = (Should equal GVWR from required vehicle section) 2024 Chevrolet LCF Figure 5.1.1 Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 5.2 Gross Axle Weight Rating The Gross Vehicle Weight is further restricted by the Gross AxIe Weight Rating (GAWR). The maximum GAWR for both front and rear axles is listed in each Vehicle Section. Weight distribution calculations must be performed to ensure GAWR is not exceeded. Always verify the results by weighing the completed vehicle on a certified scale. NOTE: Although the Front Gross Axle Weight Rating (FGAWR) plus the Rear Gross Axle Weight Rating (RGAWR) may exceed the Gross Vehicle Weight Rating (GVWR), the total GVW may not exceed the respective maximum GVWR. The variation in the GAWRs allow the second stage manufacturer some flexibility in the design of the weight distribution of the attached unit. Weighing the Vehicle Front and rear GAWRs and total GVWR should be verified by weighing a completed loaded vehicle. Weigh the front and rear of the vehicle separately and combine the weights for the total GVWR. All three weights must be less than the respective maximum shown in the vehicle sections. Tire Inflation Tire inflation must be compatible with GAWR and GVWR as specified on the cover of the Incomplete Vehicle Document for each vehicle. Center of Gravity The design of the truck body should be such that the center of gravity of the added load does not exceed the guidelines as listed in each Vehicle Section. If the body is mounted in such a way that the center of gravity height exceeds the maximum height of the center of gravity designated for each model, the directional stability at braking and roll stability at cornering will be adversely affected. A vertical and/or horizontal center of gravity calculation must be performed if a question in stability arises to ensure the designed maximum height of the center of gravity is not violated. 2024 Chevrolet LCF Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 5.3 Weight Distribution A truck as a commercial vehicle has but one purpose. That purpose is to haul some commodity from one place to another. A short distance or a long distance, the weight to be hauled, more than any other factor, determines the size of the truck. A small weight requires only a small truck; a large weight requires a large truck. A simple principle, but it can easily be misapplied. In any case, selecting the right size truck for the load to be hauled will ensure that the job will be done and that it will be able to be done with some degree of reliability and within the legal limitations of total gross weight and axle gross weights. Not only must a truck be selected that will handle the total load, but the weight must also be properly distributed between the axles. This is of extreme importance from both a functional and economic aspect. If a truck consistently hauls less than its capacity, the owner is not realizing full return on his investment and his operating costs will be higher than they should be. If the truck is improperly loaded or overloaded, profits will be reduced due to increased maintenance costs and potential fines resulting from overloading beyond legal limitations. Careful consideration must be given to distribution of the load weight in order to determine how much of the total, including chassis, cab, body and payload, will be carried on the front axle and how much will be carried on the rear axle, on the trailer axles and the total. Moving a load a few inches forward or backward on the chassis can mean the difference between acceptable weight distribution for the truck or an application that will not do the job satisfactorily. Every truck has a specific capacity and should be loaded so that the load distribution is kept within Gross Axle Weight Ratings (GAWR) and the truck's Gross Vehicle Weight Rating (GVWR) or Gross Combination Weight Rating (GCWR) for a tractor/trailer and the weight laws and regulations under which the truck will operate. Improper weight distribution will cause problems in many areas: 1. Excessive front end wear and failure a. Tie-rod and kingpin wear b. Front axle failure c. Overloading of front suspension d. Wheel bearing failure 2. Rapid tire wear a. When the weight on a tire exceeds its rating capacity, accelerated wear will result and could result in tire failure. 2024 Chevrolet LCF Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 5.4 Weight Distribution 3. Rough, erratic ride a. If the center of the payload is directly over or slightly behind the rear axle, the lack of sufficient weight on the front axle will create a bobbing effect, very rough ride, and erratic steering. This condition will be magnified when the truck is going uphill. 4. Hard steering a. When loads beyond the capacity of the front axle are imposed upon it, the steering mechanism is also overloaded and hard steering will result. b. Excessive overloading could result in steering component damage or failure. 5. Unsafe operating and conditions a.Poor traction on the steering axle effects the safety of the driver and equipment, particularly on wet, icy and slippery surfaces. Experience indicates that approximately 30% of the total weight at the ground on a truck or tractor should be on the front axle with a low cab forward vehicle. b.When a truck is overloaded, a dangerous situation may exist because minimum speeds cannot always be maintained, directional control may not be precise and insufficient braking capacity can cause longer than normal braking distances. 6. High maintenance costs a. Improper weight distribution and overloading cause excessive wear and premature failure of parts. Additional stresses imposed on the frame by the misapplication of wheelbases may be instrumental in causing the frame to crack or break. 7. Noncompliance with weight laws and regulations a.When there is the possibility that axle loads will exceed existing weight laws and regulations, careful weight distribution is necessary to provide a correct balance between front and rear axle loads and total load within legal limitations. In this way, maximum payloads may be carried without exceeding legal limits. If the body is too long for a wheelbase, the center of the body and payload is placed directly over the rear axle. This places all the payload on the rear axles, resulting in overloading the rear tires, rear axle springs and wheel bearings and potentially exceeding the rear axle legal weight limit. The front axle is then carrying no part of the payload and is easily lifted off the ground when going over rough terrain, creating a very rough ride and temporary loss of steering control. If the body is too short for the wheelbase used, frame stress may be increased and may result in excessive loads on the front axle. Excessive front axle loads increase wear on the kingpins and bushings, wheel bearings and steering gear. Excessive front axle loads also overstress the front axle, springs, tires and wheels. All of these contribute directly to higher maintenance costs and hard steering, both of which are undesirable. 2024 Chevrolet LCF Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 5.5 Weight Distribution Weight distribution analysis involves the application of basic mathematical principles to determine the proper positioning of the payload and body weight in relation to the wheelbase of the truck chassis. It is much less expensive to work all of this out on paper, make mistakes on paper and correct them there than to set up the truck incorrectly and either have it fail to do the job or, much worse, fail completely. It is important to become familiar with the dimensions of the truck, as these will be needed to perform the necessary calculations. BBC BA CA AB BOC CE Bumper to back of cab Bumper to axle Cab to axle Axle to back of cab Back of cab clearance Cab to end of frame 2024 Chevrolet LCF Figure 5.5.1 Glossary of Dimensions CG Center of gravity of body and payload WB Wheelbase OAL Overall length AF Axle to end of frame FH Frame height Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 5.6 Weight Distribution Formulas Figure 5.6.1 AB Front axle to back of cab BOC Distance between cab and body or trailer C Front of body to C.G. or front of trailer to kingpin D Distance C.G. of body or fifth wheel is ahead of rear axle F (AB + BOC +C) or distance C.G. of weight of fifth wheel is behind front axle WB Wheelbase W Weight of body plus payload, or kingpin load WF Portion of W transferred to front axle WR Portion of W transferred to rear axle C Length of body divided by 2 L/2 Load location at half of body length L Distance over which the payload is spread within the Body 2024 Chevrolet LCF Revision: 05/31/23 2024 Chevrolet Low Cab Forward Weight Distribution Formulas Basic Formulas (a) W x D = Wf x WB or (b) W x F = Wr x WB (c) WB = (AB + BOC + C + D) = (F + D) (d) W = Wf + Wr To find: 1. 2. 3. 4. 1. W f = WxD W WB 2. D = W x WB f W 3. WB = W x D f 4. W = W x WB f D 5. = WxF r WB 6. F = W x WB r W 7. WB = W x F r 8. W = W x WB r F Weight Distribution Formulas in Words Weight transferred to front axle = (Total weight) x (Distance C.G. is ahead of the rear axle) (Wheelbase) Distance C.G. must be placed ahead of rear axle = (Weight transferred to the front axle) x (Wheelbase) (Total weight) Wheelbase = (Total weight) x (Distance C.G. is ahead of the rear axle) (Weight to be transferred to the front axle) Total Weight = (Weight to be transferred to the front axle) x (Wheelbase) (Distance C.G. is ahead of the rear axle) PAGE 5.7 2024 Chevrolet LCF Revision: 05/31/23 2024 Chevrolet Low Cab Forward Weight Distribution Formulas 1. Weight transferred to rear axle = (Total weight) x (Distance C.G. is behind the front axle) (Wheelbase) 2. Distance C.G. must be placed behind the front axle = (Weight transferred to the rear axle) x (Wheelbase) (Total weight) 3. Wheelbase = (Total weight) x (Distance C.G. is behind the front axle) (Weight to be transferred to the rear axle) 4. Total Weight = (Weight to be transferred to the rear axle) x (Wheelbase) (Distance C.G. is behind the front axle) 9. Remember = Total weight must always equal weight transferred to the rear axle plus the weight transferred to the front axle PAGE 5.8 To find the value of "P", the leverages must be equal for balance. Figure 5.8.1 Example: 100 lbs. x 8 in. = "P" x 20 in. or "P" = 100 lbs. x 8 in. 20 in. Therefore: "P" = 40 lbs. This same approach is used to determine axle loadings on a tractor or truck chassis. Assuming the rear axle serves as a pivot point, the front axle l oad can be determined by applying the lever principle. 2024 Chevrolet LCF Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 5.9 Weight Distribution Formulas Front Axle Load: = Kingpin Load x 5th Wheel Location Wheelbase Figure 5.9.1 Rear Axle Load: = Kingpin Load Front Axle Load Example: (4) A tractor has a wheelbase of 150 inches. If the kingpin load is 20,000 lbs. and the fifth wheel location is 15 inches, fi nd the total weight on the front and rear axles. The tare weight of the tractor is 7,000 lbs. on the front axle and 4,400 lbs. on the rear axle. Front Axle Load 20,000 x 15 150 WB = 2,000 lbs. Rear Axle Load Therefore: Total Front Axle Weight Total Rear Axle Weight 2024 Chevrolet LCF = 2,000 + 7,000 lbs. = 9,000 lbs. = 2,000 + 9,000 lbs. = 11,000 lbs. = 4,400 + 18,000 lbs. = 22,400 lbs. Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 5.10 Weight Distribution Formulas In calculating the weight distribution for a truck, the same lever principle is applied; however, there is one change in the initial consideration of the method of loading the truck body. Instead of the trailer kingpin location ahead of the rear axle centerline, we must determine the posi tion of the center of gravity of the payload and body weight in relation to the rear axle centerline. For our calculations, we assume that the payload is distributed in the truck body so that the load is supported evenly over t he truck body floor (water-level distribution). The weight of the body itself is also considered to be evenly distributed along the truck frame. In this manner, we can add the payload and body weights together and calculate the distribution on the vehicle chassis as an evenly distributed load on the truck frame rails . So that we can make the necessary calculation in a simple manner, the total body and payload weight is considered to act at the center of gravity which will be at the center of the body length. Example: 2024 Chevrolet LCF Figure 5.10.1 Front Axle Load = (Body Weight + Payload) x C of G location Wheelbase Rear Axle Load = (Body Weight + Payload) Front Axle Load Therefore, Front Axle Load = 15,000 x 24 = 2,400 lbs. 150 Rear Axle Load = 15,000 2,400 = 12,600 lbs. Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 5.11 Weight Distribution Formulas If the truck tare weight without the body is 5,000 lbs. on the front axle and 2,400 lbs. on the rear axle, then Total Front Axle Weight = 5,000 + 2,400 = 7,400 lbs. and Total Rear Axle Weight = 2,400 + 12,600 = 15,000 lbs. This same lever principle is applied in all calculations of weight distribution, whether we are dealing with concentrated loads as with a kingpin load acting on a fifth wheel or if it be with an evenly distributed load as with a truck body. The same approach is made in calculating an eve nly distributed load on a trailer. In the case of a tractor/trailer or a tractor with a set of double or triple trailers, each unit is handled as a separated unit and then combined to determine the total. This simple example illustrates how the principles are applied. Using the formulas, find the weight distributed to each axle. Figure 5.11.1 Front Weight A. Wf = W x D WB Rear Weight A. W Wf B. 300 x 24 96 B. 300 75 C. = 75 lbs. C. = 225 lbs. The body manufacturer can provide the body length and weight, or actual measurements of the body may be taken with a tape. Generally, (D) is unknown. This you must find logically, or with a tape measure. 2024 Chevrolet LCF Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 5.12 Find (D) and then solve for Wf and Wr. Weight Distribution Formulas D = 60348 = 9 in. = 205 Figure 5.12.1 = 2,795 Recommended Weight Distribution % of Gross Vehicle Weight by Axle Conventional (2 Axle) COE (2 Axle) 2024 Chevrolet LCF Figure 5.12.2 Figure 5.12.3 Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 5.13 Recommended Weight Distribution % of Gross Vehicle Weight by Axle Conventional (3 Axle) COE (3 Axle) Figure 5.13.1 Calculating tractor/trailer weight distribution can be thought of in the same terms as calculating full trucks. Figure 5.13.2 The weight at the center of the body and the load when applied is the same as the single point load of the kingpin on the fifth wheel. 2024 Chevrolet LCF Figure 5.13.3 Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 5.14 Trailer Weight Figure 5.14.1 Figure 5.14.2 2024 Chevrolet LCF Figure 5.14.3 Revision: 05/31/23 In the following example, a 50,000-pound payload at water-level loading. Calculate the payload (PL) weight transfer to kingpin and the rear axle. NOTE: Apply the same principles used with truck chassis. 2024 Chevrolet LCF Revision: 05/31/23 2024 Chevrolet Low Cab Forward Trailer Weight Payload at Kingpin = W x D WB Calculate the "D" dimension. OAL/2 AF = D 45 feet/2 48 inches 36 inches = 186 inches = 50,000 lbs. x 186 in. = 20,394 lbs. 456 in. =20,394 lbs. Payload at Rear Tandem = W PL = 50,000 lbs. 20,394 lbs. = 29,606 lbs. = 29,606 lbs. PAGE 5.15 Once the weight on the kingpin is determined, it can then be treated on the tractor the same as a weight on a straight truck. Due to the variations in hauling and wheelbase requirements from one truck application to another, there is no one specific fifth wheel setting that will apply in all cases. A "rule of thumb" which has proven satisfactory in many cases sets the fifth wheel one inch ahead of the rear axle for every 10 inches of wheelbase. In the case of tandem axles, the wheelbase is measured from the center line of the front axle to the midpoint between the tandem rear axles. The location of the fifth wheel fixes the load distribution between the front and rear axles. Too far forward and the front axle is overloaded. If too far back, the front axle may be too lightly loaded and cause an unsafe steering and braking control situation at the front axle. 2024 Chevrolet LCF Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 5.16 Trailer Weight A tractor on a hill with the fifth wheel set at the axle center line or too close to it will result in an unsafe handling situation by transferring too much weight to the rear axle and actually unloading the front axle Figure 5.16.1 Performance Calculations The following calculations have been included to help you determine the performance characteristics required by your customers and to select the appropriate model vehicle: 1. Speed Formula This formula can be used to determine: 1. Top speed of the vehicle. 2. Speed in a given gear. 3. Final ratio required for a given speed. MPH @ Governed Speed = ( 60) x (RPM) (Rev/Mile) x (Gear Ratio) 2024 Chevrolet LCF Revision: 05/31/23 2024 Chevrolet Low Cab Forward Performance Calculations Definitions in formula: RPM Rev/Mile Gear Ratio 60 = Revolutions per minute of the engine at Governed Speed = Tire revolutions per mile = The product of the axle ratio times the transmission ratio = Time Constant Example: 3500 12,000 GVWR automatic transmission. RPM Rev/Mile Gear Ratio = 3,000 = 674 = .703 x 5.375 MPH @ Governed Speed = (60) x (3,000) (674) x (.703 x 5.375) MPH @ Governed Speed = 70 MPH 2. Grade Horsepower Formula This formula can be used to determine horsepower required for a given grade and speed. Horsepower Req'd. for a given grade = GVWR x Grade x Speed 37,500 x Efficiency Factor + AHP Definitions in formula: GVWR = Grade = Speed = 37,500 = Efficiency Factor = AHP Resistance = Gross Vehicle Weight Rating Grade anticipated in percent Speed in miles per hour Constant Factor for losses in drivetrain due to friction (use 0.9 for a 90% efficient driveline) Horsepower required to overcome wind force 2024 Chevrolet LCF PAGE 5.17 Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 5.18 Performance Calculations Example: 3500 11,050 GVWR automatic transmission with a van body. GVWR Grade Speed 37,500 Efficiency Factor AHP Resistance = 12,000 lbs. = 1 percent = 55 MPH = Constant = 0.9 = 53.6 HP (see the following formula for calculation) HP Required for Grade = 12,000 x 1 x 55 37,500 x 0.9 + 53.67 HP Required for Grade = 73.22 3. Air Resistance Horsepower Formula This formula is used to determine the horsepower required to overcome air resistance at a given speed. Air Resistance Horsepower = FA x Cd x (MPH)3 156,000 Definitions in formula: FA = Frontal area of vehicle in square feet Cd = Aerodynamic Drag Coefficient MPH = Speed of vehicle in miles per hour 156,000 = Constant Frontal area is calculated by multiplying the height of the vehicle by the width of the vehicle and subtracting the open area under the vehicle from the to tal. Aerodynamic Drag Coefficients (Source Material: Motor Truck Engineering Handbook): 0.70 for most trucks, semitrailer combinations with tanks or van bodies 0.77 for double and triple trailers and flatbeds with loads 2024 Chevrolet LCF Revision: 05/31/23 2024 Chevrolet Low Cab Forward Performance Calculations Example: 3500 12,000 GVWR van body with 96" wide, 115" high (84" body height + 31" frame height). FA = (96) x (115) 3.2 (12) x (12) FA Cd Speed = 73.47 ft.2 = 0.70 = 55 mph Air Resistance HP = 73.47 x 0.70 x (55)3 156,000 Air Resistance HP = 54.85 4. Engine Horsepower Formula This formula can be used to derive the output at a given RPM and torque. Horsepower = Torque x RPM 5,252 Definitions in formula: Torque RPM 5,252 = Twisting output of engine given in lbs.-ft. = Revolutions per minute of engine = Constant Example: 3500 12,000 GVWR automatic transmission. Torque RPM 132 HP = = 2,000 = (347) x (2,000) 5,252 2024 Chevrolet LCF PAGE 5.19 Revision: 05/31/23 2024 Chevrolet Low Cab Forward Performance Calculations 5. Gradeability Formula This formula can be used to determine how large of a grade a vehicle can climb. Percent Grade = 1,200 x (T) x (E) x (C) x (R) GVWR x r RR Definitions in formula: 1,200 = T = E = C = R = RR = GVWR = r = Constant Maximum Torque of Engine Engine Efficiency (0.9) Driveline Efficiency (0.9) Transmission Ration x Axle Ratio Rolling Resistance (see following chart) Gross Vehicle Weight Rating Loaded radius of tire Example: 350012,000 GVWR automatic transmission on concrete highway. T = E = C = R = RR = GVWR = r = 347 lbs.-ft. 0.9 0.9 .703 x 5.375 (in overdrive) 1.0 12,000 14.1 in. Percent Grade = 1,200 x (347) x (0.9) x (0.9) x (.703) x (5.375) 12,000 x 14.1 1.0 Percent Grade = 7.53 - 1 Gradeability = 6.53% 2024 Chevrolet LCF PAGE 5.20 Revision: 05/31/23 2024 Chevrolet Low Cab Forward Performance Calculations Road Surface Concrete, excellent Concrete, good Concrete, poor Asphalt, good Asphalt, fair Asphalt, poor Macadam, good Macadam, fair Macadam, poor Road Rolling Resistance Road Rolling Resistance Expressed in Percent Grade Grade Road 1.0 Surface Cobbles, ordinary 1.5 Cobbles, poor 2.0 Snow, 2 inches 1.25 Snow, 4 inches 1.75 Dirt, smooth 2.25 1.5 2.25 Dirt, sandy Mud Sand, level soft 3.75 Sand, dune Figure 5.21.1 6. Startability Formula This formula is used to determine what type of a grade a vehicle can be started on. Startability = Definitions in formula: (1,200) x (CET) x (E) x (C) x (R) (GVWR x r) 10% 1,200 CET E C R 10% GVWR r = Constant = Clutch Engagement Torque = 0.9 = 0.9 = Transmission x Axle Ratio = Average break away resistance and static inertia constant = Gross Vehicle Weight Rating = Loaded radius of tire 2024 Chevrolet LCF 5.21 Grade 5.5 8.5 2.5 3.75 2.5 3.75 3.75 to 15.0 6.0 to 15.0 16.0 to 30.0 Revision: 05/31/23 PAGE 2024 Chevrolet Low Cab Forward PAGE 5.22 Performance Calculations Example: 3500 LCF 12,000 GVWR manual transmission. CET R GVWR r = 260 lbs.-ft. = 6.02 x 4.10 = 12,000 lbs. = 14.1 in. Startability = (1,200) x (260) x (0.9) x (0.9) x (6.02 x 4.10) 10% (12,000 x 14.1) Startability = 26.86% 7. Vertical Center of Gravity Formula These formulas are used to estimate the vertical center of gravity of a completed vehicle in order to determine whether maximum allowable limits have been exceeded. This formula should be used when encountering high center of gravity loads. 7.1 Wv x (Vv) = Mv 7.2 Wb x (Vb) = Mb 7.3 Wp x (Vp) = Mp 7.4 We x (Ve) = Me 7.5 VCg = (Mv+ Mb+Mp+Me) (Wv + Wb + Wp + We) Definitions in formula: VCg = Wv = Wb = Wp = We = The total average vertical center of gravity of the completed vehicle (vehicle, body, payload and equipment) Weight of vehicle Weight of body Weight of payload Weight of equipment 2024 Chevrolet LCF Figure 5.22.1 Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 5.23 Performance Calculations Definitions in formula (continued): Vv = Vb = Vp = Ve = Mv = Mb = Mp = Me = Distance from ground to center of gravity of the vehicle Distance from ground to center of gravity of the body Distance from ground to center of gravity of the payload Distance from ground to center of gravity of the equipment Moment of vehicle Moment of body Moment of payload Moment of equipment Example: 3500 12,000 GVWR automatic transmission, 132" WB, 14' body length, 84" high body, full payload of boxes stacked to a maximum height of 48" above the flooring. Wv = Wb = Wp = Vv = Vb = Vp = Mv = Mb = Mp = 5,291 lbs. (from vehicle specifications) 2,100 lbs. (from body manufacturer) 4,609 lbs. (GVWR (Wv + Wb + We) 24.9 in. (from Body Builder's Guide, 3500 Section) 80 in. (from body manufacturer) 62 in. (1/2 of payload height + frame height + height from frame to flooring) 5,291 x 24.9 = 131,746 lbs.-in. (from 7.1) 2,100 x 80 = 168,000 lbs.-in. (from 7.2) 4,609 x 62 = 285,758 lbs.-in. (from 7.3) We, Ve, Me = None in this example (131,746+168,000+285,758) VCg = (5,291 + 2,100 + 4,609) VCg = (528,504) (12,000) = 48.8 inches 48.8 < 54.0 inches (54 inches is maximum allowable VCg per mfg. specifications from Body Builder's Guide, 3500 section) Since maximum VCg for this truck is not exceeded, 48" stack height above flooring is acceptable. 2024 Chevrolet LCF Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 5.24 Performance Calculations 8. Horizontal Center of Gravity Formula These formulas are used to estimate the horizontal center of gravity of a completed vehicle in order to determine whether it exists between the centerlines of the front and rear axles. This formula should be used when a load and/or permanent equipment (liftgate, reefer unit, snowplow, etc.) is installed on either extreme along the completed vehicle's overall length. 8.1 Wv x (Hv) = Mv 8.2 Wb x (Hb) = Mb 8.3 Wp x (Hp) = Mp 8.4 We x (He) = Me 8.5 HCg (Mv+Mb+Mp+Me) = (Wv + Wb + Wp + We) Definitions in formula: HCg = Wv = Wb = Wp = We = Hv = Hb = Hp = He = = = = Me = The total average horizontal center of gravity of the completed vehicle (vehicle, body, payload and equipment) Weight of vehicle Weight of body Weight of payload Weight of equipment Distance from front axle to center of gravity of the vehicle Distance from front axle to center of gravity of the body Distance from front axle to center of gravity of the payload Distance from front axle to center of gravity of the equipment Moment of vehicle He CG Equipment Overall Outside Body Length CG Payload Hp CG Body Hb HGg CG Complaete Vehicle Hv Wheelbase GROUND REFERENCE 2024 Chevrolet LCF Figure 5.24.1 Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 5.25 Performance Calculations Example: 3500 Gas 12,000 GVWR automatic transmission, 132" WB, 14' body length, full payload of boxes stacked and distributed evenly throughout the flooring, 1,000 lb. reefer unit attached in front of body. Wv = Wb = Wp = We = Hv = Hb = Hp* = He = Mv = Mb = Mp = Me = 5,291 lbs. (from vehicle specifications) 2,100 lbs. 3,609 lbs. (from body manufacturer) (GVWR (Wv + Wb + We)) 1,000 lbs. (from equipment manufacturer) 42.4 in. (from Body Builder's Guide, 3500 Section) 107.5 in. (from body manufacturer) 107.5 in. (1/2 of payload length + distance from front axle to front of body) 17.5 in. (from equipment manufacturer) 5,291 x 42.4 = 224,338 lbs.-in. (from 8.1) 2,100 x 107.5 = 225,750 lbs.-in. (from 8.2) 3,609 x 107.5 = 387,967 lbs.-in. (from 8.3) 1,000 x 17.5 = 17,500 lbs.-in. (from 8.4) HCg = (224,338+ 225,750 + 387,967+17,500) (5,291 + 2,100 + 3,609 + 1,000) HCg = (855,555) = 71.3 inches (12,000) 71.3 < 132 inches (132 inches is the wheelbase dimension) Since HCg for this truck is not greater than the WB or negative () (denotes HCg forward of front axle centerline), it exists between the centerlines of the front and rear axles. NOTE: Hp and Hb dimensions are the same in this example because CG of body and payload happen to be at the same point. 2024 Chevrolet LCF Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 5.26 Bridge Formula Weights To calculate maximum acceptable axle weights for use on the Interstate Highway System, use the Department of Transportation link shown below. http://ops.fhwa.dot.gov/freight/sw/brdgcalc/calc_page.htm 2024 Chevrolet LCF Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 6.1 COMMODITY AND MATERIAL WEIGHTS Approximate Weights of Commodities and Materials Product Acetone Alcohol, Alfalfa seed Aluminum, Apples, Apricots, Artichokes, Asbestos Asparagus, Avocados, Bananas, Barley Barytes, Basalt, Beans, dry, Beans, fresh, Commercial Proof spirits Pure (cast) Fresh Western, box New England, box Standard barrel Dried Fresh Western, box Box crate, Loose Bunches Box Single stem Mineral Rock Lima White Castor Lima String Size of Container -- -- -- -- -- -- -- -- -- bushel -- -- -- basket-bushel 11.5" x 12" x 20" 11.25" x 14.5" x 17.5" 17" head, 28.5" stave bushel bushel 5.5" x 12" x 20" 10" x 11.5" x 22" -- -- -- 11.5" high x 9.75" top 11" bottom x 19.38" long 5.75" x 11.25" x 17.5" bunch bushel -- -- -- -- -- -- bushel bushel bushel bushel bushel hamper, 5 peck Lbs. Per Cu. Ft. 50 51 57 -- -- 165 -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- 153 -- -- -- -- -- -- -- -- -- -- 280 185 -- -- -- -- -- -- -- -- -- -- -- -- No. of Lbs. / Per 6.6 / gallon 6.8 / gallon 7.6 / gallon 60 / bushel 4,450 / cu. yard 48 / bushel 50 / box 56 / box 160 / barrel 24 / bushel 48 / bushel 23 / box 44 / box 4,130 / cu. yard 38 / crate 31 / crate 16 / box 45-65 / bunch 48 / bushel 7,560 / cu. yard 5,000 / cu. yard 56 / bushel 60 / bushel 46 / bushel 39 / bushel 36 / bushel 45 / hamper Figure 6.1.1 Product Size of Container Lbs. Per Cu. Ft. Beef, Slack barrel 21"x 30"stave (200 lbs.net) -- -- Beer, Wood barrel .5 barrel (16 gal.) -- -- Wood barrel .25 barrel (8 gal.) -- -- Steel barrel .5 barrel (16 gal.) -- -- Steel barrel .25 barrel (8 gal.) -- -- Dutchman .13 barrel (4 gal.) -- -- Case carton,* Regular bottles 17.25" x 11.5" x 9.88" -- -- 24, 12 oz. Steinie bottles 18.38" x 12.13" x 7.38" -- -- Tin cans 16.13" x 11" x 5.13" -- -- Wooden case,* Regular bottles 21" x 13.5" x 10" -- -- 24, 12 oz. Steinie bottles 22" x 13.75" x 7.5" -- -- Beets bushel -- -- Small crate 9.75" x 13.75" x 24" -- -- Western crate 14" x 19" x 24.5" -- -- Berries, crate, 24 pint 9.75" x 9.97" x 20" -- -- 24 quart 11.75" x 11.75" x 24" -- -- 32 quart 15.5" x 11.75" x 24" -- -- Bluegrass seed bushel -- -- Bluestone -- -- -- 120 Bone -- -- -- 115 Borax -- -- -- 110 Bran bushel -- -- Brick, Soft 2.25" x 4" x 8.25" -- -- Common 2.25" x 4" x 8.25" -- -- Hard 2.25" x 4.25" x 8.5" -- -- Pressed 2.38" x 4" x 8.38" -- -- Paving 2.25" x 4" x 8.5" -- -- Paving block 3.5" x 4" x 8.5" -- -- Fire 2.5" x 4.5" x 9" -- -- * Note: Beer cases vary as to size and shape. Suggest checking with local source. No. of Lbs. / Per 254 / barrel 205 / barrel 105 / barrel 190 / barrel 95 / barrel 51 / barrel 45 / case 40 / case 28 / case 35 / case 46 / case 50-60 / bushel 50 / crate 95 / crate 25 / crate 48 / crate 63 / crate 44 / bushel 3,240 / cu. yard 3,110 / cu. yard 2,970 / cu. yard 20 / bushel 4,320 / thousand 5,400 / thousand 6,480 / thousand 7,500 / thousand 6,750 / thousand 8,750 / thousand 7,000 / thousand 2024 Chevrolet LCF Figure 6.1.2 Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 6.2 Product Size of Container Lbs. Per Cu. Ft. No. of Lbs. / Per Broccoli, Bushel crate 12.75" x 12.75" x 17" -- -- 30 / bushel Brussels sprouts, Crate 7.75" x 10.5" x 21.38" -- -- 26 / crate Buckwheat bushel -- -- 49 / bushel Butter, tub, Small 15" dia. x 5.75" -- -- 25 / tub Standard 15" dia. x 15" -- -- 70 / tub Butter,case, 30 1-lb.bricks 10.75" x 8.75" x 10.5" -- -- 32 / case 9-lb. pail pail -- -- 10 / pail Cabbage bushel -- -- 38 / bushel Hamper 1.5 bushel -- -- 58 / hamper Crate 12.75" x 18.5" x 19" -- -- 60 / crate Western crate 14" x 19" x 24.5" -- -- 85 / crate Barrel crate 12.75" x 18.75" x 37.38" -- -- 110 / crate Calf, Live (average) per head -- -- 140-160 / head Cantaloupe, crate, Pony 11.75" x 11.75" x 23.5" -- -- 58 / crate Standard 12.75" x 12.75" x 23.5" -- -- 68 / crate Jumbo 13.75" x 13.75" x 23.5" -- -- 78 / crate Pony flat 4.75" x 12.75" x 23.5" -- -- 26 / crate Standard flat 5.25" x 14.25" x 23.5" -- -- 28 / crate Jumbo flat 5.75" x 15.25" x 23.5" -- -- 32 / crate Honeydew (Casaba) 6.38" x 15.13" x 23.5" -- -- 35 / crate Carbolic acid -- -- -- 60 8.0 / gallon Carrots, Topped bushel -- -- 55 / bushel With tops bushel -- -- 40 / bushel Crate 11.75" x 14.13" x 24" -- -- 60 / crate Castor oil -- -- -- 61 8.1 / gallon Cauliflower bushel -- -- 30 / bushel Crate 9.38" x 19" x 24" -- -- 50 / crate Cedar* (lumber) -- -- -- 30 2,500 / M. Bd. ft. Celery, Standard crate 11.63" x 22" x 22.63" -- -- 70 / crate Half crate 10.75" x 13" x 20.38" -- -- 35 / crate Northern crate 16.5" x 21.25" x 22" -- -- 85 / crate *Kiln dried lumber averages 10% to 15% lighter, and green lumber 40% to 50% heavier, than air dried. Figure 6.2.1 2024 Chevrolet LCF Product Cement, Block Block Portland Portland Chalk Charcoal, Oak Pine Cheese, Small box Medium box Large box Cherries, Unstemmed Stemmed Lug box Chestnut* (lumber) Chestnuts Chickens, Live,broilers (20avg.) Fowl (12 avg.) Standard crate, Cinder blocks Cinders Clay, Cork Corn, Corn meal Dry lumps Wet lumps Wet packed Fire Ear Shelled Sweet corn (green) Crate Size of Container 8" x 8" x 16" 8" x 12" x 16" sack barrel (4 sacks per) -- -- -- -- -- -- -- -- -- 15" dia. x 5.25" 15" dia. x 7.5" 15" dia. x 15" bushel bushel 5.63" x 11.88" x 19.75" -- -- -- bushel standard crate standard crate empty 24" x 35" x 13" 8" x 8" x 16" 8" x 12" x 16" -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- bushel bushel bushel 12.88" x 12.88" x 24" bushel Lbs. Per Cu. Ft. No. of Lbs. / Per -- -- 42 / each -- -- 58 / each -- -- 94 / sack -- -- 376 / barrel 137 3,700 / cu. yard 33 890 / cu. yard 23 620 / cu. yard -- -- 25 / box -- -- 35 / box -- -- 70 / box -- -- 56 / bushel -- -- 64 / bushel -- -- 17 / box 37 3,080 / M. Bd. ft. -- -- 50 / bushel -- -- 58 / crate -- -- 78 / crate -- -- 18 / crate -- -- 35 / each -- -- 45 / each 50 1,350 / cu. yard 85 2,300 / cu. yard 110 2,970 / cu. yard 135 3,650 / cu. yard 125 3,375 / cu. yard 15 405 / cu. yard -- -- 35 / bushel -- -- 56 / bushel -- -- 43 / bushel -- -- 60 / crate -- -- 44 / bushel Figure 6.2.2 Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 6.3 Product Size of Container Lbs. Per Cu. Ft. No. of Lbs. / Per Corn oil -- -- -- 58 7.8 / gallon Corn syrup -- -- -- 86 11.5 / gallon Cotton, Gin bale Standard bale 30" x 48" x 54" 24" x 28" x 56" -- -- -- -- 515 / bale 515 / bale Comp. bale 20" x 24" x 56" -- -- 515 / bale Cotton seed bushel -- -- 32 / bushel Cottonseed oil -- -- -- 58 7.8 / gallon Cottonwood* (lumber) -- -- -- 37 3,080 / M. Bd. ft. Cow, Live-Feeder (average) per head -- -- 600 / head Butcher (average) per head -- -- 800 / head Butchersteer (average) per head -- -- 1100 / head Cranberries, 1/4 barrel box 9.5" x 11" x 14" -- -- 28 / box 1/2 barrel box 12.25" x 14.75" x 22" -- -- 60 / box Cream -- -- -- 64 8.5 / gallon Creosote -- -- -- 68 9.2 / gallon Crude oil -- -- -- 56 7.5 / gallon Cucumbers Crate bushel 9.75" x 13.75" x 24" -- -- -- -- 55 / bushel 75 / crate Case 5" x 13.25" x 19" -- -- 26 / case Earth, Loose, dry loam Packed -- -- -- -- -- -- 76 2,050 / cu. yard 95 2,565 / cu. yard Wet -- -- -- 125 3,375 / cu. yard Eggplant, Hamper bushel -- -- 40 / bushel Crate 14" x 11.75" x 24" -- -- 54 / crate Eggs, 30 dozencrate 12" x 12" x 26" -- -- 55 / crate Elm,* Soft -- -- -- 38 3,170 / M. Bd. ft. Rock -- -- -- 45 3,750 / M. Bd. ft. Fertilizer, Commercial burlap bag -- -- 100-200 / bag Fir,* Douglas -- -- -- 32 2,670 / M. Bd. ft. Eastern -- -- -- 25 2,080 / M. Bd. ft. *Kiln dried lumber averages 10% to 15% lighter, and green lumber 40% to 50% heavier, than air dried. Figure 6.3.1 Product Fish, fresh, Flour, Fuel oil, Furniture, Garbage, Gasoline Glass, Glue Glycerine Grapefruit, Grapes, Gravel, Greens Groceries, Hay, Hog, Honey Horse, Barrel 1/2 Barrel Barrel Furnace grade Diesel engine Household Dry, paperwrapped Wet Common window Plate or crown 1/4" plate Western box Southern box Basket Lug box Western keg Basket Dry Wet Misc. assorted Bale Bale Bale Live (average) Live (average) Size of Container 19" head, 29" stave 18.5" head, 23.5" stave 19.13" head, 30" stave -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- 11.5" x 11.5" x 24" 12.75" x 12.75" x 27" bushel 5.63" x 16.38" x 17.5" 15.5" dia. x 14" 12 quart -- -- -- -- -- -- bushel -- -- -- 26" x 30" x 46" 17" x 22" x 43" 14" x 16" x 43" per head -- -- -- per head Lbs. Per Cu. Ft. No. of Lbs. / Per -- -- 300 / barrel -- -- 160 / 1/2 barrel -- -- 215 / barrel 56 7.5 / gallon 52 7.0 / gallon 7 1,915 / cu. yard 15-30 405-810 / cu. yard 50 1,240 / cu. yard 45 6.0 / gallon -- -- 162 / cu. foot -- -- 161 / cu. foot -- -- 3.3 / sq. foot 80 2,160 / cu. yard 79 10.5 / gallon -- -- 68 / box -- -- 90 / box -- -- 48 / box -- -- 30 / box -- -- 45 / keg -- -- 18 / basket 95 2,565 / cu. yard 125 3,375 / cu. yard -- -- 25 / bushel 30 810 / cu. yard -- -- 210 / bale -- -- 115 / bale -- -- 85 / bale -- -- 225-250 / head 90 12.0 / gallon -- -- 1,200-1,500 / head Figure 6.3.2 2024 Chevrolet LCF Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 6.4 Product Size of Container Lbs. Per Cu. Ft. No. of Lbs. / Per Horseradish roots bushel -- -- 35 / bushel Ice -- -- -- 57 1,540 / cu. yard Ice (mfg.), Block 11"x 22"x 32" -- -- 250 /block Block 14"x 14"x 40" -- -- 255 /block Block 11"x 22"x 56" -- -- 440 /block Ice Cream, 2.5 gallon can, Full 9" dia. x 11" -- -- 18 / can Empty -- -- -- -- -- 6/ can 5 gallon can, Full 9" dia. x 21" -- -- 35 / can Empty -- -- -- -- -- 11 / can Kale bushel -- -- 25 / bushel Kerosene -- -- -- 50 6.6 / gallon Lamb, Live (average) per head -- -- 75-85 / head Lard, Barrel 18" head, 30" stave -- -- 425 / barrel Lath, Standard length 29" Packed in bundles of 50 -- -- 25 / bundle Average bundle, dia. 9" Leather, Dry -- ---- 55 1,485 / cu. yard Wet -- ---- 65 1,755 / cu. yard Lemons, Western box 10" x 13" x 25" -- -- 80 / box Southern box 12.75" x 12.75" x 27" -- -- 90 / box Lentils bushel -- -- 60 / bushel Lettuce, Hamper bushel -- -- 25 / bushel Hamper 1.5 bushel -- -- 38 / hamper Basket 8.5"x 11.75"x 21.38" -- -- 17 / basket Crate 18.75"x 17.5" x 24.5" -- -- 75 / crate 1/2 crate 9.5" x 13.5" x 24.5" -- -- 40 / 1/2 crate Lime, Hydrated bushel -- -- 30 / bushel Barrel (small) 16.5" head, 27.5" stave 62 210 / barrel Barrel (large) 62 320 / barrel Limes, Western box 10" x 13" x 25" -- -- 80 / box Southern box 12.75" x 12.75" x 27" -- -- 90 / box *Kiln dried lumber averages 10% to 15% lighter, and green lumber 40% to 50% heavier, than air dried. Product Linseed oil Lubricating oil Malt, Barley Rye Brewer's grain Maple syrup Maple,* Hard (lumber) Soft Meal-corn Milk, Bulk 5 gallon can 10 gallon can Crate, 20.5 pt. bottles 20 pt. bottles Millet Molasses Barrel Mortar, Lime Mud, Flowing Packed Muriatic acid, 40% Naptha, Petroleum Nitric acid, 91% Oak-red,* Black White Oats Okra, Hamper Hamper Oleomargarine, (mfg.-tub) Cases Size of Container -- -- -- -- -- -- bushel bushel bushel gallon -- -- -- -- -- -- bushel -- -- -- 10.25" dia. x 19" 13" dia. x 23" 8.5" x 12.75" x 16.75" 8.5" x 12.75" x 16.75" bushel -- -- -- 20.25" head, 34" stave -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- bushel 1/2 bushel bushel 21" head, 34" stave -- -- -- Lbs. Per Cu. Ft. 59 52 -- -- -- -- -- -- 82 44 34 -- -- 64 -- -- -- -- -- -- -- -- -- -- 90 -- -- 110 106 125 40 42 94 42 48 -- -- -- -- -- -- -- -- -- -- No. of Lbs. / Per 7.9 / gallon 7.0 / gallon 28 / bushel 32 / bushel 40 / bushel 11.0 / gallon 3,670 / M. Bd. ft. 2,830 / M. Bd. ft. 44 / bushel 8.6 / gallon 62 / can 115 / can 33 / crate 54 / crate 50 / bushel 12.0 / gallon 675 / barrel 2,970 / cu. yard 2,860 / cu. yard 3,375 / cu. yard 10.0 / gallon 5.6 / gallon 12.5 / gallon 3,500 / M. Bd. ft. 4,080 / M. Bd. ft. 32 / bushel 18 / hamper 34 / bushel 70 / tub 15-65 / case Figure 6.4.2 2024 Chevrolet LCF Figure 6.4.1 Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 6.5 Product Size of Container Lbs. Per Cu. Ft. No. of Lbs. / Per Olive oil -- -- -- 58 7.7 / gallon Onions,dry, Basket bushel -- -- 55 / bushel Bag 17" x 32" -- -- 50 / bag Crate 20.5" x 11.5" x 10.5" -- -- 58 /crate Green (with tops) bushel -- -- 32 / bushel Oranges, Western box 11.5" x 11.5" x 24" -- -- 80 / box Southern box 12.75" x 12.75" x 27" -- -- 90 / box Bushel box 10.75" x 10.75" x 23.5" -- -- 65 / box Oysters (shucked or meats) Crate with 5.1 gal. cans 18" x 12" x 24" (11.5 lbs. per gal.) 67 /crate With shells (bags) bushel -- -- 75 / bushel Paint, Lead and oil -- -- -- 127 17 / gallon Paper, Average solid -- -- -- 58 1,565 / cu. yard Newspaper rolls 34.25"x 35"dia. -- -- 500 / roll 51.5"x 35"dia. -- -- 1,000 /roll 64.25"x 35"dia. -- -- 1,300 /roll Paraffin -- -- -- 56 1,510 / cu. yard Parsley, Bushel crate 12.75" x 12.75" x 17" -- -- 30 / crate Parsnips bushel -- -- 50 / bushel Peaches, Basket bushel -- -- 48 / bushel 1/2 bushel -- -- -- -- -- 25 / basket Crate 10.5"x 11.25"x 24" -- -- 50 /crate Western box 5.5"x 12.25"x 19.75" -- -- 22 / box Peanuts, Unshelled bushel -- -- 22 / bushel Bag -- -- -- -- -- 100 /bag Peanut oil -- -- -- 57 7.6 / gallon Pears, Basket bushel -- -- 50 / bushel Western box 9.63" x 12.13" x 19.75" -- -- 51 / box Peas, Dry bushel -- -- 60 / bushel Fresh hamper bushel -- -- 35 / hamper Hamper 40 quarts -- -- 45 / hamper *Kiln dried lumber averages 10% to 15% lighter, and green lumber 40% to 50% heavier, than air dried. 2024 Chevrolet LCF Figure 6.5.1 Product Size of Container Pecans, Large bag -- -- -- Small bag -- -- -- Peppers, Basket bushel Crate 14.13" x 11.75" x 24" Petroleum -- -- -- Phosphate rock -- -- -- Pine,* Long leaf -- -- -- North Carolina -- -- -- Oregon -- -- -- Red -- -- -- White -- -- -- Yellow, long leaf -- -- -- Short leaf -- -- -- Pineapples, Crate 11" x 12.5" x 36" Pitch -- -- -- Plums, Basket bushel Western box 5.63" x 16.38" x 17.5" Pomegranates, Box 6.5" x 12" x 24.63" Popcorn, Ear bushel Shelled bushel Poplar* -- -- -- Porcelain -- -- -- Pork (dressed), Barrel (200 lbs. net) 18" head, 29" stave Potatoes, Sweet bushel White or Irish bushel Bag 1.67 bushel Barrel 17.13" head, 28.5" stave Prunes, Box 5.63" x 16.38" x 19.75" Box 5.63" x 11.88" x 19.75" Quinces bushel Lbs. Per Cu. Ft. No. of Lbs. / Per -- -- 100 / bag -- -- 50 / bag -- -- 25 / basket -- -- 45 / crate 56 7.5 / gallon 200 5,400 / cu. yard 44 3,670 / M. Bd. ft. 36 3,000 / M. Bd. ft. 32 2,670 / M. Bd. ft. 30 2,500 / M. Bd. ft. 26 2,170 / M. Bd. ft. 44 3,670 / M. Bd. ft. 38 3,170 / M. Bd. ft. -- -- 85 / crate 70 1,900 / cu. yard -- -- 56 / bushel -- -- 25 / box -- -- 30 / box -- -- 70 / bushel -- -- 56 / bushel 27 2,250 / M. Bd. ft. 150 4,050 / cu. yard -- -- 240 / barrel -- -- 55 / bushel -- -- 60 / bushel -- -- 102 / bag -- -- 185 / barrel -- -- 25 / box -- -- 22 / box -- -- 50 / bushel Figure 6.5.2 Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 6.6 Product Size of Container Lbs. Per Cu. Ft. No. of Lbs. / Per Radishes, Basket bushel -- -- 34 / bushel Crate 9.75" x 13.75" x 24" -- -- 40 / crate Redwood* -- -- -- 30 2,500 / M. Bd. ft. Resin -- -- -- 68 1,835 / cu. yard Rhubarb (pie plant) bushel -- -- 50 / bushel Box 5.25" x 11.5" x 22" -- -- 24 / box Rice, Unhulled bushel -- -- 43 / bushel Rock, Crushed (average) -- -- -- 100 2,700 / cu. yard Romaine, Crate 13.88" x 18.88" x 24.5" -- -- 64 / crate Crate 12.25" x 13" x 15.25" -- -- 27 / crate Rubber goods -- -- -- 94 2,540 / cu. yard Rutabagas bushel -- -- 56 / bushel Rye bushel -- -- 56 / bushel Salt, rock, Solid -- -- -- 136 3,670 / cu. yard Coarse -- -- -- 45 1,215 / cu. yard Fine -- -- -- 50 1,350 / cu. yard Barrel (average) -- -- -- -- -- 280 / barrel Sand, fine, Dry -- -- -- 110 2,970 / cu. yard Wet -- -- -- 125 3,375 / cu. yard Sand, coarse, Dry -- -- -- 95 2,565 / cu. yard Wet -- -- -- 120 3,240 / cu. yard Sand, Mixed -- -- -- 115 3,100 / cu. yard Sandstone, Solid -- -- -- 147 3,970 / cu. yard Crushed -- -- -- 86 2,325 / cu. yard Shale, Solid -- -- -- 172 4,645 / cu. yard Crushed -- -- -- 92 2,485 / cu. yard Sheep, Live (average) per head -- -- 125-150 / head Shingles, Bundle Pkg. in bndls. of 200-250 -- -- 50 / bundle Size(avg.)24"x 20"x 10" Snow, Moist-packed -- -- -- 50 1,350 / cu. yard *Kiln dried lumber averages 10% to 15% lighter, and green lumber 40% to 50% heavier, than air dried. Figure 6.6.1 Product Softdrinks, Half depthbottlebox 24-6 to 8 oz. bottles Full depth bottle box 12-24 to 32 oz. bottles Sorghum syrup Soybeans Soybean oil Spinach, Hamper Basket Spruce* Squash Starch Stone, Crushed, (average) Rip-rap Straw, Bale Bale Street sweepings Sugar Sugar, Bag Barrel (22 lbs. empty) Case Case Sugar cane syrup Sulphur Sulfuric acid, 87% Sweetcorn, Basket Crate Sycamore* Tallow Size of Container 12.25"x 18.75"x 8.5" 13.38"x 18.5"x 12.25" -- -- -- bushel -- -- -- bushel bushel -- -- -- bushel -- -- -- -- -- -- -- -- -- 17" x 22" x 42" 26" x 30" x 46" -- -- -- -- -- -- (100 lbs. net) 19.13" head, 30" stave 24 5-lb. cartons 60 2-lb. cartons -- -- -- -- -- -- -- -- -- bushel 13" x 13" x 24" -- -- -- -- -- -- Lbs. Per Cu. Ft. No. of Lbs. / Per -- -- 39 / box -- -- 86 -- -- 58 -- -- -- -- 28 -- -- 96 100 65 -- -- -- -- 32 100 -- -- -- -- -- -- -- -- 85 125 112 -- -- -- -- 37 60 60 / box 11.5 / gallon 60 / bushel 7.7 / gallon 20 / bushel 27 / bushel 2,330 / M. Bd. ft. 46 / bushel 2,590 / cu. yard 2,700 / cu. yard 1,755 / cu. yard 110 / bale 180 / bale 865 / cu. yard 2,700 / cu. yard 101 / bag 345 / barrel 135 / case 135 / case 11.3 / gallon 3,375 / cu. yard 15 / gallon 45 / bushel 60 / crate 3,080 / M. Bd. ft. 1,620 / cu. yard Figure 6.6.2 2024 Chevrolet LCF Revision: 05/31/23 2024 Chevrolet Low Cab Forward Product Size of Container Lbs. Per Cu. Ft. No. of Lbs. / Per Tanks, Acetylene, 102 cu. foot empty -- -- 70 / tank filled -- -- 75 / tank 310 cu. foot empty -- -- 200 / tank filled -- -- 220 / tank Tanks, Oxygen, 150 cu. foot empty -- -- 80 / tank filled -- -- 92 / tank 300 cu. foot empty -- -- 133 / tank filled -- -- 153 / tank Tar -- -- -- 65 1755 / cu. yard Tile, Solid -- -- -- 115 3,100 / cu. yard Partition (construction) -- -- -- 40 1,080 / cu. yard Tomatoes, Basket bushel -- -- 55 / bushel Lug box 7.25" x 14" x 17.5" -- -- 35 / box Crate 10.5" x 11.25" x 24" -- -- 48 / crate Basket 8.5" x 8.75" x 20" -- -- 18 / basket Basket (paper) 4.25" x 8.5" x 16.25" -- -- 9 / basket Basket (wood) 5.5" x 7.25" x 16.5" -- -- 10 / basket Turpentine -- -- -- 54 7.2 / gallon Turnips, Basket bushel -- -- 54 / bushel Vetch seed bushel -- -- 60 / bushel Vinegar -- -- -- 64 8.5 / gallon Walnuts, Bulk bushel -- -- 50 / bushel Bag 2 bushel -- -- 100 / bag Water, Fresh -- -- -- 63 8.4 / gallon Wheat, Bulk bushel -- -- 60 / bushel Bag 1.5 bushel -- -- 90 / bag Wool, Pressed -- -- -- 82 2,215 / cu. yard *Kiln dried lumber averages 10% to 15% lighter, and green lumber 40% to 50% heavier, than air dried. Figure 6.7.1 2024 Chevrolet LCF PAGE 6.7 Revision: 05/31/23 2024 Chevrolet Low Cab Forward 3500/4500 12.0/14.5 GVW Gas-STD Cab 3500 Gas Specifications MODEL GVWR / GCWR WB ENGINE 3500/4500 12,000 lbs. / 18,000 lbs., 14,500 lbs. / 20,500 lbs. (4500) 109 in., 132.5 in., 150 in., 176 in. GMPT L8T (Gen V), 8-cylinder, V Block 4-cycl, OHV, Direct Fuel Injection, Oil Jet Piston Cooling PAGE 8.1 MODEL/DISPLACEMENT HP (GROSS) TORQUE (GROSS) EQUIPMENT GMPT- 8/400 CID (6.6 liters) 350 HP @ 4500 RPM 425 lb.-ft. @ 3800 RPM Direct injection technology, mass air flow meter, powertrain interface module (PIM), onboard diagnostics, oxygen sensors, catalytic convertor, map sensor, with external oil cooler, engine cruise control, and rear engine cover. TRANSMISSION 6L90 Hydra-Matic 6-speed automatic with lock-up converter and double overdrive. No PT opening. STEERING Integral power steering 18.8-20.9:1 ratio. Tilt and telescoping steering column. FRONT AXLE FRONT SUSPENSION FRONT GAWR Reverse Elliot "I" -beam rated at 6,830 lbs. Semi-elliptical steel alloy tapered leaf springs with stabilizer bar and shock absorbers. 4,860 lbs. / 6,630 lbs. (4500) REAR AXLE REAR SUSPENSION REAR GAWR Full floating single speed with hypoid gearing rated at 14,550 lbs. Semi-elliptical steel alloy multi-leaf springs and shock absorbers. 8,840 lbs. / 11,020 lbs. (4500) WHEELS TIRES BRAKES 16 x 6.0 - 6-hole disc wheels, painted white. 19.5 x 6.0 (4500) 215/85R-16E (10 ply), 225/70R-19.5 (14 Ply) (4500) LRR (Low Rolling Resistance) tubeless steel belted radials, all season front and rear Dual circuit vacuum assisted hydraulic service brakes with EBD (Electronic Brake Distribution) system for load proportioning of the brake system front disc and self -adjust outboard mounted drum rear. The parking brake is a mechanical, cable actuated, internal expanding drum type, transmission mounted. 4 channel anti-lock brake system. FUEL TANK FRAME 38.6 gal. rectangular stainless-steel fuel tank. Mounted between the frame rails with electric type fuel pump (mounted in tank) and fuel tank zone module (mounted on rearward crossmember). Through the rail fuel fill. Ladder type channel section straight frame rail 33.5 inches wide through the total length of the frame. Yield strength 44,000 psi, section modulus 7.20 in3., RBM 316,800 lb-in 2024 Chevrolet LCF CAB CAB EQUIPMENT ELECTRICAL OPTIONS All steel, low cab forward, BBC 70.9 in, 45° mechanical tilt with torsion assist. TRICOT breathable cloth covered high back driver's seat with two occupant passenger seat. Dual cab mounted exterior mirrors with integral convex mirror. Tilt and telescoping steering column. Power windows and door locks, floor mats, tinted glass. AM/FM/CD Radio with Aux input/USB port and Bluetooth. Rear body dome lamp switch. Cab latch switch and indicator with buzzer. 12-volt, negative ground, 750 CCA maintenance free battery located on frame, 170 Amp alternator with integral regulator. See last page for options. Note: These selected specifications are subject to change without notice. Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 8.2 5500 17,950/19,500 GVW Gas-STD Cab 5500 HG,XG Gas Specifications MODEL GVWR / GCWR WB ENGINE 5500 HG, XG STD Gas 17,850 / 23,950 lbs. HG, 19,500 / 25,500 lbs. XG 109 in., 132.5 in., 150 in., 176 in. GMPT L8T (Gen V), 8-cylinder, V Block 4-cycl, OHV, Direct Fuel Injection, Oil Jet Piston Cooling MODEL/DISPLACEMENT HP (GROSS) TORQUE (GROSS) EQUIPMENT GMPT- 8/400 CID (6.6 liters) 350 HP @ 4500 RPM 425 lb.-ft. @ 3800 RPM Direct injection technology, mass air flow meter, powertrain interface module (PIM), onboard diagnostics, oxygen sensors, catalytic convertor, map sensor, with external oil cooler, engine cruise control, and rear engine cover. TRANSMISSION Allison 1000 RDS 6-speed automatic with lock-up converter and double overdrive. No PTO opening. STEERING Integral power steering 18.8-20.9:1 ratio. Tilt and telescoping steering column. FRONT AXLE FRONT SUSPENSION FRONT GAWR Reverse Elliot "I" -beam rated at 8,440 lbs. Semi-elliptical steel alloy tapered leaf springs with stabilizer bar and shock absorbers. 6830 HG / 8440 XG lbs. REAR AXLE REAR SUSPENSION REAR GAWR Full floating single speed with hypoid gearing rated at 14,550 lbs. Semi-elliptical steel alloy multi-leaf springs and shock absorbers. 13,660 HG / 14,460 XG lbs. WHEELS TIRES BRAKES 19.5 x 6.0 - 6-hole disc wheels, painted white. 225/70R-19.5 (14 ply) LRR (Low Rolling Resistance) tubeless steel belted radials, all season front and rear Dual circuit vacuum assisted hydraulic service brakes with EBD (Electronic Brake Distribution) system for load proportioning of the brake system front disc and self -adjust outboard mounted drum rear. The parking brake is a mechanical, cable actuated, internal expanding drum type, transmission mounted. 4 channel anti-lock brake system. FUEL TANK FRAME 38.6 gal. rectangular stainless-steel fuel tank. Mounted between the frame rails with electric type fuel pump (mounted in tank) and fuel tank zone module (mounted on rearward crossmember). Through the rail fuel fill. Ladder type channel section straight frame rail 33.5 inches wide through the total length of the frame. Yield strength 44,000 psi, section modulus 7.20 in3., RBM 316,800 lb-in 2024 Chevrolet LCF CAB CAB EQUIPMENT ELECTRICAL OPTIONS All steel, low cab forward, BBC 70.9 in, 45° mechanical tilt with torsion assist. TRICOT breathable cloth covered high back driver's seat with two occupant passenger seat. Dual cab mounted exterior mirrors with integral convex mirror. Tilt and telescoping steering column. Power windows and door locks, floor mats, tinted glass. AM/FM/CD Radio with Aux input/USB port and Bluetooth. Rear body dome lamp switch. Cab latch switch and indicator with buzzer. 12-volt, negative ground, 750 CCA maintenance free battery located on frame, 170 Amp alternator with integral regulator. See last page for options. Note: These selected specifications are subject to change without notice. Revision: 05/31/23 O H O W A H A W F W F H C W B W PAGE 2024 Chevrolet Low Cab Forward 8.3 3500/4500/5500 12.0/14.5 17,950/19,500 GVW Gas-STD Cab-Vehicle Weights, Dimensions and Ratings Dimension Constants: Code Inches Code Inches Variable Chassis Dimensions: AH 7.5 BW 83.3 Unit WB CA* CE* OAL AF AW 65.6 CW 65.0 Inch 109.0 86.5 129.6 200.5 43.1 BA 48.3 FW 33.5 Inch 132.5 110.0 153.1 224.0 43.1 BBC 70.7 OH 90.8 Inch 150.0 127.5 170.6 241.5 43.1 BOC 7.7/10.2 OW 81.3 Inch 176.0 153.5 196.6 267.5 43.1 FH 31.1 * Effective CA & CE are CA or CE less BOC * BOC 7.7 in. w/ 109.0 and 132.5 wb BOC 10.2 in. w/ 150.0 and 176.0 wb Vertical Exhaust Option Dimensions: Variable Chassis Dimensions: Unit WB EFF CA* EFF CE* Inch 109.0 62.5 105.6 Inch 132.5 86.0 153.1 Inch 150.0 103.5 146.6 Inch 176.0 129.5 172.6 OAL 200.5 224.0 241.5 267.5 * Effective CA & CE listed are standard CA or CE AF less vertical exhaust BOC of 24 inches. 43.1 Vertical Exhaust BOC = 24 inches 43.1 43.1 43.1 Figure 8.3.1 BBC CE CA BOC In-Frame Tank 14,500 lb GVWR Automatic Transmission Model Chassis Curb and Maximum Payload Weights Model WB RPO Unit T31003 109.0 in. EB4 lb. T32003 132.5 in. FNJ lb. T33003 150.0 in. FWH lb. T34003 176.0 in. FNW lb. Front 3907 3999 4061 4123 Rear 2057 2054 2034 2027 Total 5964 6053 6095 6150 Payload 8536 8447 8405 8350 Side Mounted Tank (Aux. Tank) 14,500 lb. GVWR Automatic Transmission Model Chassis Curb and Maximum Payload Weights Model WB RPO Unit Front Rear Total Payload T34003 176.0 in. FNW lb. 4258 1903 6161 8339 Figure 10.2.2 BA WB AF OAL 2024 Chevrolet LCF Figure 8.3.2 17,950 HG GVWR STD CAB Model WB RPO Unit Front Rear Total Payload CP52003 132.5 in. C7X lb. - - 5886 12,064 CP53003 150.0 in. C7X lb. - - 5929 12,021 CP54003 176.0 in. C7X lb. - - 5983 11,967 19,500 XG GVWR STD CAB Model WB RPO Unit Front Rear Total Payload CP62003 132.5 in. GZG lb. - - 5889 13,611 CP63003 150.0 in. GZG lb. - - 5932 13,568 CP64003 176.0 in. GZG lb. - - 5986 13,514 Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 8.4 3500/4500/5500 12.0/14.5 17,950/19,500 GVW Gas-STD Cab Vehicle Weight Limits Vehicle Weight Limits: GVWR Designed Maximum 14,500 lbs. GAWR, Front 5,360 lbs. GAWR, Rear 9,880 lbs. Technical Notes: Chassis Curb Weight reflects standard equipment and fuel but no driver or payload. Maximum Payload Weight is the allowed maximum for equipment, body, payload and driver and is calculated by subtracting chassis curb weight from the GVWR. 2024 Chevrolet LCF NPV 9D2 9C2 9E2 ATG 9B9 AJG KO5 KPG UIZ KQJ DB6 G7M MTE KPK KPJ NLX PTO DB8 TBD 9W8 IX2 UL5 KQN UZF V22 Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 8.5 3500/4500/5500 12.0/14.5 17,950/19,500 GVW Gas-STD Cab Frame and Crossmember Specifications Wheelbase 109 132.5 150 176 Frame Thickness 0.24 0.24 0.24 0.24 2024 Chevrolet LCF B C 28.3 8.2 28.3 8.2 28.3 8.2 28.3 8.2 Figure 8.5.1 Crossmember Type/Location D AA AA AA AA 46.5 46.5 46.5 46.5 E BB 57.5 BB 57.9 BB 74.4 Figure 8.5.2 F CC 24.2 CC 24.2 CC 24.2 CC 24.2 G DD DD DD DD 33.8 33.8 33.8 33.8 Dimensions in inches Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 8.6 3500/4500/5500 12.0/14.5 17,950/19,500 GVW Gas-STD Cab Frame Chart A B C A B C SECTION A-A Wheelbase 109.0 132.5 150.0 176.0 2024 Chevrolet LCF SECTION B-B Figure 8.6.1 Frame FL 182.5 206.1 223.8 249.8 Figure 8.6.2 SECTION C-C Frame Thickness 0.24 0.24 0.24 0.24 Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 8.7 3500/4500/5500 12.0/14.5 17,950/19,500 GVW Gas-STD Cab Top View WB 109 132.5 150 176 A 86.5 110 127.5 153.5 B 129.6 153.1 170.6 196.6 C 200.5 224 241.5 267.5 38.2 32.0 25.1 A 16.9 B 24.5 10.3 22.3 2024 Chevrolet LCF 14.0 12.8 22.4 WB 141.2 C Figure 8.7.1 Dimensions in inches Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 8.8 WB 109 132.5 150 176 A 86.5 110 127.5 153.5 3500/4500/5500 12.0/14.5 17,950/19,500 GVW Gas-STD Cab Left Side View 70.9 (BBC) 129.6 (CE) (A) 8.3 (BOC) 90.5 (OH) 48.5 (BA) 2024 Chevrolet LCF (WB) 200.5 (OAL) Figure 8.8.1 28.6 (FH 43.1 (AF) Dimensions in inches Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 8.9 3500/4500/5500 12.0/14.5 17,950/19,500 GVW Gas-STD Cab Right Side View WB 109 132.5 150 176 A 86.5 110 127.5 153.5 2024 Chevrolet LCF 18.9 A (WB) 30.7 Figure 8.9.1 Dimensions in inches Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 8.10 3500/4500/5500 12.0/14.5 17,950/19,500 GVW Gas-STD Cab SCR / DPF 4HK1-TC Front of Chassis Outside edge of frame rail Outside edge of frame rail Figure 8.10.1 2024 Chevrolet LCF Figure 8.10.2 Dimensions in inches Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 8.11 3500/4500/5500 12.0/14.5 17,950/19,500 GVW Gas-STD Cab Cab Tilt 2024 Chevrolet LCF Figure 8.11.1 Dimensions in inches Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 8.12 3500/4500/5500 12.0/14.5 17,950/19,500 GVW Gas-STD Cab Turning Diameter TURNING DIAMETERS The LCF steering also features a 49.5 inside wheel cut angle. This, coupled with the integral power steering, makes the LCF an extremely maneuverable truck. B=Minimum turning diameter curb to curb C=Minimum turning diameter wall to wall VN60 C A B WB 109.0 132.0 150.0 176.0 B curb to curb 31.5 38.7 42.7 51.2 C (ft. wall to wall (ft.) 37.1 44.0 48.9 56.4 LCF Diesel Turning Circle Diagram Figure 8.12.1 2024 Chevrolet LCF Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 8.13 3500/4500/5500 12.0/14.5 17,950/19,500 GVW Gas-STD Cab Center of Gravity 110 127.5 153.5 70.9 (BBC) 8.3 (BOC) 90.5 (OH) 129.6 (CE) (A) Horizontal and Vertical CG of Chassis WB 110 132.5 150 176 H H V in frame side tank tank 22.2 36.2 N/A 22.1 42.7 N/A 22.0 47.7 N/A 22.0 55.0 50.3 Figure 8.13.1 28.6 (FH The maximum vertical center of gravity specified below must not be exceeded at maximum GVWR and rated front and rear GAWR. The Center of Gravity (CG) maximum is 63" (1600 mm) above the ground. (LCF Cab Chassis and LCF Stripped Chassis) 48.5 (BA) (WB) 200.5 (OAL) 43.1 (AF) Figure 8.13.2 NOTE: The Final Manufacturer must ensure that the combined vertical center of gravity of the chassis, body, and available payload at full GVW does not exceed the maximum vertical center of gravity outlined in the Chevrolet LCF Incomplete Vehicle Document and the GM Body Builders Guide. The maximum dimensions for a body installed on the LCF chassis are 102 inches wide (outside*) by 91 inches high (inside). Any larger body applications must be approved by GM Upfitter Engineering. Contact us on GMUpfitter.com. * With 102 inches wide mirror brackets installed in place of standard mirror brackets Dimensions in inches 2024 Chevrolet LCF Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 8.14 3500/4500/5500 12.0/14.5 17,950/19,500 GVW Gas-STD Cab Front Axle Chart Formulas for calculating height dimensions: A = C = D = CH = DH = Tire Loaded Radius B Centerline of Axle to Top of Frame Rail at Curb Position Centerline of Axle to Top of Frame Rail at Design Load C + Tire Unloaded Radius D + Tire Loaded Radius Figure 8.14.1 Tire GVWR GAWR A B C D CH DH Track Tire Radius Unload Load 215/85R 16-E 14,500 lbs. 5,360 lbs. 7.5 6.6 12.8 11.7 27.4 25.8 65.5 14.6 14.1 Figure 8.14.2 Dimensions in inches 2024 Chevrolet LCF Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 8.15 3500/4500/5500 12.0/14.5 17,950/19,500 GVW Gas-STD Cab Rear Axle Chart 2024 Chevrolet LCF Figure 8.15.1 Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 8.16 3500/4500/5500 12.0/14.5 17,950/19,500 GVW Gas-STD Cab Rear Axle Chart Definitions A Centerline of axle to bottom of axle bowl. DW Minimum distance between the inner surfaces of the rear tires. B Centerline of axle to top of frame rail at metal-to-metal position. EW Maximum Rear Width: C Centerline of axle to top of frame rail at curb position. Overall width of the vehicle measured at the outermost surface of the rear tires. D Centerline of axle to top of frame rail at design load. HH Rear Tire Clearance: Minimum clearance between the rear axle and the ground-line. Rear Tire Clearance: Dual Tire Spacing: E Minimum clearance required for tires and chain measured from the HW Distance between the centerlines of the minimum distance required for tire top of the frame at the vertical centerline of the rear axle, when bounce as measured from the centerline of the rear axle and the top of the rear wheels on one side ride over a high spot. rear tire when one wheel rides over a high spot. Rear Frame Height: CH Vertical distance between the normal top of frame rail and CW Track Dual Rear Wheel Vehicles: the ground-line through the centerline of the rear axle Distance between the centerlines of the dual wheels measured at the ground-line. at curb position. Rear Frame Height: DH Vertical distance between the normal top of frame rail and the ground-line through the centerline of the rear axle at design load. Tire Section, Tire Radius, Tire Loaded Radius, Tire Clearance See Tire Chart for Values Figure 8.16.1 CW = Track CH = Tire loaded radius + C DH = Tire loaded radius + D DW = Track + 2 tire sections tire clearance EW = Track + 2 tire sections + tire clearance Formulas for Calculating Rear Width and Height Dimensions HH = Tire loaded radius A JH = KH B KH = Tire radius + 3.00 inches KW = DW 5.00 inches LW = 1.00-inch minimum clearance between tires and springs NOTE: Track and overall width may vary with optional equipment. Figure 8.16.2 Tire GAWR Track CW A 215/85R 16-E 9,880 lbs. 65.0 6.5 B C 9.3 15.4 D E 13.0 7.8 2024 Chevrolet LCF Figure 8.16.3 Dimensions in inches Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 8.17 3500/4500/5500 12.0/14.5 17,950/19,500 GVW Gas-STD Cab Suspension Deflection Chart 14,500 lb GVWR 14,500 lb GVWR Figure 8.17.1 2024 Chevrolet LCF Figure 8.17.2 Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 8.18 3500/4500/5500 12.0/14.5 17,950/19,500 GVW Gas-STD Cab Tire and Disc Wheel Chart Tire Tire Size 215/85R-16E Tire Load Limit and Cold Inflation Pressures Single Dual Lbs. PSI Lbs. PSI 3,315 85 3,115 85 Maximum Tire Load Limits (lbs.) Front Rear 2 Single 4 Dual 6,630 12,460 GVWR (Lbs.) 14,500 Figure 8.18.1 Tire Size 215/85R 16-E GVWR (Lbs.) 14,500 Tire Radius Loaded Unloaded Front Rear Front Rear 14.1 14.1 14.6 14.6 Tire Section Width 8.2 Tire Clearance 1.8 Design Rim Width 6.0 Disc Wheel Wheel Size Bolt Holes 16 x 6 K 6 JIS *O.D. Wrench Sizes Bolt Circle Dia. 8.75 Ft./Rr. Nut Size* 1.6142 (41 mm) BUD HEX Figure 8.18.2 Rear Stud Size* 0.8268 (21 mm) SQUARE Nut/Stud Torque Specs. 325 ft-lb. (440 N·m) Figure 8.18.3 Inner Circle Outside Disc Rim Type Material Mfg. Offset Thickeness 6.46 5.0 0.37 50 DC Steel TOPY 2024 Chevrolet LCF Figure 8.18.4 Dimensions in inches Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 8.19 3500/4500/5500 12.0/14.5 17,950/19,500 GVW Gas-STD Cab Propeller Shaft Figure 8.19.1 Figure 8.19.2 WheelBase (in.) Top View Side View 109 2.5º - 10.6º - 2.5º 2.5º 132.5 0º 2.7º 5.3º 7.4º 2.5º 2.5º 150.0 0º 2.7º 2.6º 8.0º 2.5º 2.5º 176 0º 1.8º 2.1º 5.4º 2.5º 2.5º Notes: 1. Angles provided in table are relative to the frame angle. Please take this into consideration for service measurements. 2. Driveline angles are based on the chassis curb weight which includes standard equipment, fuel but no driver, body, or payl oad. 2024 Chevrolet LCF Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 8.20 3500/4500/5500 12.0/14.5 17,950/19,500 GVW Gas-STD Cab Propeller Shaft Wheelbase No. of Shafts Trans. Type 109 1 6A/T 132.5 2 6A/T 150 2 6A/T 176 2 6A/T Shaft #1 O.D. Thickness Length Type 3.25'' 0.0906'' 36.69'' A 3.25'' 0.0906'' 16.97'' B 3.25'' 0.0906'' 34.29'' B 3.25'' 0.0906'' 43.47'' B Shaft #2 O.D. N/A Thickness N/A Length N/A Type N/A 3.25'' 0.0906'' 33.78'' C Figure 8.20.1 3.25'' 0.0906'' 34.17'' C 3.25'' 0.0906'' 50.71'' C Type Description Illustration Type A 1st shaft in 1-piece driveline L Type B 1st shaft in 2-piece driveline L Type C 2024 Chevrolet LCF 2nd shaft in 2-piece driveline Figure 8.20.2 L Dimensions in inches Revision: 05/31/23 2024 Chevrolet Low Cab Forward 3500/4500/5500 12.0/14.5 17,950/19,500 GVW Gas-STD Cab Brake System Diagram 14,500 GVW Vacuum Over Hydraulic Please refer to Introduction Section of book for antilock system cautions and wheelbase modification requirements. PAGE 8.21 Legend for 3500, 3500HD, 4500, 4500HD, 4500XD Brake System (1) Electronic Hydraulic Control Unit (EHCU) (2) Rear Wheel Cylinder (3) Vacuum Pump (4) Check Valve (5) Exhaust Brake Valve (6) Magnetic Valve (7) Check Valve (One-way Valve) (8) Vacuum Tank (9) 4-Way Connector (10) With Metering Valve (11) W/O Metering Valve (12) Brake Fluid Reservoir (13) Electric Vacuum Pump (14) Master Cylinder (15) Vacuum Booster (Servo Unit) (16) Front Wheel Cylinder Figure 8.21.1 2024 Chevrolet LCF Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 8.22 3500/4500/5500 12.0/14.5 17,950/19,500 GVW Gas-STD Cab PTO Location Drive Gear and Opening Information Figure 8.22.1 Trans. Opening Bolt A BCD E F Location Pattern Aisin 465 Left (Dr 2) 12.35 36.89 0 7.85 7.31 2.50 H 5.16 PTO Drive Gear Location PTO Gear Ratio of PTO Drv. Gear Spd. to Eng. Spd. 1:1 with turbine No. of Teeth 69 Pitch N/A Helix Angle 0 Max. Output Torque 134 lbs.-ft. @ 1,700 RPM Figure 8.22.2 2024 Chevrolet LCF Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 8.23 3500/4500/5500 12.0/14.5 17,950/19,500 GVW Gas-STD Cab Opening Diagram Aisin A460 Automatic Torque Converter Lock Up Function In either the Stationary Preset PTO Mode or Stationary Variable PTO Mode, when engine rpm exceeds 1200 RPM, the torque converter will lock up. The engine rpm can not be modified and the lockup function cannot be turned off. Please not that with PTO applications that operate around 1200 RPM, the transmission software holds the torque converter in lockup until engine speed falls below 1100 RPM. The lock up function will cancel if the transmission shift lever is moved from the park or neutral positions which will remove the transmission from the stationary mode. Additional PTO Functions For certain applications the Automatic regeneration function can be inhibited (Example Airport Ground Support vehicles). For certain applications the Automatic regeneration function can be enabled in the PTO stationary mode (Example Lawn care and carpet cleaning). For certain applications the Automatic regeneration function can be enabled in the PTO mobile mode (Example Line painting). Please refer to the PTO section of the BBG (section 17) for further details. 2024 Chevrolet LCF Figure 8.23.1 Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 8.24 3500/4500/5500 12.0/14.5 17,950/19,500 GVW Gas-STD Cab In-Frame Fuel Fill Installation Instructions 1. Disconnect battery. 2. Remove the short filler hose and the short breather hose from the breather and fuel filler pipes and the filler neck bracket assembly. 3. Filler kit hoses are designed for the 102 inch wide body width. Modify the hoses as required to fit the desired body width (Figure 15 - Dimension D). 4. Install flexible filler hose (Item 1) to fuel filler pipe and filler neck bracket assembly using existing screw clamps. 5. Install flexible breather hose (Item 2) to fuel breather pipe and filler neck bracket assembly using new clamps (item 3) 6. The filler neck must be mounted to allow the filler neck bracket to be parallel to the frame horizontal. 7. Filler neck (Figure 14 - Dimension A) must be between 6.85 inches and 8.5 inches above frame. 8. Secure the filler plate and ground strap to the bottom of the body and check for leaks. Ground straps should be connected to brackets or flanges, not the fuel filler hose or breather hose. Ground straps should have a minimum of 10mm clearance, in all deflected positions, from any metallic portions of the fuel filler hose or breather hose assembly. 9. Ensure that fill hose does not sag, creating an area where the fuel could pool in the fill hose. 10. Reconnect battery. Fuel Type Use regular unleaded gasoline rated at 87 octane or higher that meets specification ASTMD4814 in the U.S. Blended gasoline is suitable for use in the LCF Gas Chassis. Ethanol is ethyl or grain alcohol. Properly-blended fuel that is no more than 10% ethanol is fine for your vehicle. NOTICE: Fuel that is 15% Ethanol is not suitable for your vehicle. Fuel that is than 85% Ethanol is not suitable for your vehicle. Methanol is methyl or wood alcohol. NOTICE: - 6.6L Engine: Fuel that is more than 5% methanol is bad for your vehicle. And even at 5% or less, there must be "co-solvents" and corrosion preventives in this fuel to help avoid damage to the fuel system from methanol. - 6.0L Engine: Methanol-Gasoline mixtures are not suitable for your vehicle. 2024 Chevrolet LCF Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 8.25 3500/4500/5500 12.0/14.5 17,950/19,500 GVW Gas-STD Cab 38.6 Gal. RPO NH3 Rear View Fuel Fill 2024 Chevrolet LCF Figure 8.25.1 Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 8.26 3500/4500/5500 12.0/14.5 17,950/19,500GVW Gas-STD Cab 38.6 Gal. RPO NH3 Top View Fuel Fill 2024 Chevrolet LCF Figure 8.26.1 Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 8.27 3500/4500/5500 12.0/14.5 17,950/19,500 GVW Gas-STD Cab Hose Modifications Various Bodies and Fuel Fill Vent Protection Notes: 1. Modification of the filler neck outside the frame rail must comply with FMVSS regulations for avoiding fuel dripping on hot surfaces. 2. Do not install the connection point of Filler neck, pipe and hoses in unacceptable areas shown in the side and rear view above. 2024 Chevrolet LCF Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 8.28 3500/4500/5500 12.0/14.5 17,950/19,500 GVW Gas-STD Cab Through the Rail Fuel Fill Frame Hole 2024 Chevrolet LCF Figure 8.28.1 Dimensions in inches Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 8.29 3500/4500/5500 12.0/14.5 17,950/19,500 GVWR Gas 38.6 Gal. RPO NH3 Fuel filler Assembly FRONT FRONT Figure 8.29.1 Figure 8.29.2 Parts Kit: For LCF 3500/4500 GAS Fuel Filler chassis installation as shown. See authorized GM Dealer for Parts list and availability. 2024 Chevrolet LCF Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 8.30 3500/4500/5500 12.0/14.5 17,950/19,500 GVW Gas-STD Cab Installation Instructions and Considerations The fuel tank shutter valve (13) is meant to improve fuel splash-back performance of the fuel system. This valve (13) is located on the inlet (outboard side) of the fuel filler neck bulkhead assemble that is bolted to the left hand frame rail as shown in Figure 8.30.1. This plastic valve snaps into place in the inlet of the frame mounted fuel pipe. The valve should be installed so that the plastic clip is at the top of the valve, so that the flap door opens up, as shown in Figure 8.30.2. Figure 8.30.1 The fuel filler hose should be installed flush against the tank. The clamp should be installed between 1/16"and 3/8" from the tank. This is shown in Figure 8.30.3 to the right. 2024 Chevrolet LCF Figure 8.30.2 Figure 8.30.3 Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 8.31 3500/4500 12.0/14.5 GVW Gas-STD Cab Roll-Over Valve Tubing The roll-over valve has a hose attachment that will make this valve less sensitive to water intrusion. In order for the valve to work properly, it is critical that the hose be installed to the rollover valve. The proper assembly of the outer hose is shown in Figure 8.31.1. (1) Fuel Filler Hose Vent Hose (7) Protective Sleeve Figure 8.31.1 (4) Rollover Valve Hose Rollover Valve Filler Neck Installation The fuel filler neck (5) must be installed with the proper orientation on the body. The neck should be installed with the rol l-over valve pointing upward, with the bottom edge of the neck oriented parallel to the ground, plus 33 to minus 7 degrees. See Figure 8.31.2 for the proper orientation. 2024 Chevrolet LCF Rollover Valve pointing upward Filler Neck Base Angle Installed to Horizontal +33o -7o Figure 8.31.2 Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 8.32 3500/4500HD 12.0/14.5 GVW Gas-STD Cab Roll-Over Valve Tubing The roll-over valve has a hose attachment that will make this valve less sensitive to water intrusion. In order for the valve to work properly, it is critical that the hose be installed to the rollover valve. The proper assembly of the outer hose is shown in Figure 8.32.1. (1) Fuel Filler Hose Vent Hose (7) Protective Sleeve Figure 8.32.1 (4) Rollover Valve Hose Rollover Valve Filler Neck Installation The fuel filler neck (5) must be installed with the proper orientation on the body. The neck should be installed with the rol l-over valve pointing upward, with the bottom edge of the neck oriented parallel to the ground, plus 33 to minus 7 degrees. See Figure 8.32.2 for the proper orientation. 2024 Chevrolet LCF Rollover Valve pointing upward Filler Neck Base Angle Installed to Horizontal +33o -7o Figure 8.32.2 Revision: 05/31/23 2024 Chevrolet Low Cab Forward 3500/4500 12.0/14.5 GVW Gas-Crew Cab Gas Specifications MODEL GVWR / GCWR WB ENGINE 3500/4500 Crew Cab Gas 12,000 lbs. / 18,000 lbs., 14,500 lbs. / 20,500 lbs. (4500) 109 in., 132.5 in., 150 in., 176 in. GMPT L8T (Gen V), 8-cylinder, V Block 4-cycl, OHV, Direct Fuel Injection, Oil Jet Piston Cooling MODEL/DISPLACEMENT HP (GROSS) TORQUE (GROSS) EQUIPMENT GMPT- 8/400 CID (6.6 liters) 350 HP @ 4500 RPM 425 lb.-ft. @ 3800 RPM Direct injection technology, mass air flow meter, powertrain interface module (PIM), onboard diagnostics, oxygen sensors, catalytic convertor, map sensor, with external oil cooler, engine cruise control, and rear engine cover. TRANSMISSION 6L90 Hydra-Matic 6-speed automatic with lock-up converter and double overdrive. No PT opening. STEERING Integral power steering 18.8-20.9:1 ratio. Tilt and telescoping steering column. FRONT AXLE FRONT SUSPENSION FRONT GAWR Reverse Elliot "I" -beam rated at 6,830 lbs. Semi-elliptical steel alloy tapered leaf springs with stabilizer bar and shock absorbers. 4,860 lbs. / 6,630 lbs. (4500) REAR AXLE REAR SUSPENSION REAR GAWR Full floating single speed with hypoid gearing rated at 14,550 lbs. Semi-elliptical steel alloy multi-leaf springs and shock absorbers. 8,840 lbs. / 11,020 lbs. (4500) WHEELS TIRES BRAKES 16 x 6.0 - 6-hole disc wheels, painted white. 19.5 x 6.0 (4500) 215/85R-16E (10 ply), 225/70R-19.5 (14 Ply) (4500) LRR (Low Rolling Resistance) tubeless steel belted radials, all season front and rear Dual circuit vacuum assisted hydraulic service brakes with EBD (Electronic Brake Distribution) system for load proportioning of the brake system front disc and self -adjust outboard mounted drum rear. The parking brake is a mechanical, cable actuated, internal expanding drum type, transmission mounted. 4 channel anti-lock brake system. FUEL TANK FRAME 38.6 gal. rectangular stainless-steel fuel tank. Mounted between the frame rails with electric type fuel pump (mounted in tank) and fuel tank zone module (mounted on rearward crossmember). Through the rail fuel fill. Ladder type channel section straight frame rail 33.5 inches wide through the total length of the frame. Yield strength 44,000 psi, section modulus 7.20 in3., RBM 316,800 lb-in 2024 Chevrolet LCF CAB CAB EQUIPMENT ELECTRICAL OPTIONS All steel, low cab forward, BBC 70.9 in, 45° mechanical tilt with torsion assist. TRICOT breathable cloth covered high back driver's seat with two occupant passenger seat. Dual cab mounted exterior mirrors with integral convex mirror. Tilt and telescoping steering column. Power windows and door locks, floor mats, tinted glass. AM/FM/CD Radio with Aux input/USB port and Bluetooth. Rear body dome lamp switch. Cab latch switch and indicator with buzzer. 12-volt, negative ground, 750 CCA maintenance free battery located on frame, 170 Amp alternator with integral regulator. See last page for options. Note: These selected specifications are subject to change without notice. PAGE 9.1 Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 9.2 5500 17,950/19,500 GVW Gas-Crew Cab 5500 HG, XG Gas Specifications MODEL GVWR / GCWR WB ENGINE 5500 HG, XG Crew Cab Gas 17,850 / 23,950 lbs. HG, 19,500 / 25,500 lbs. XG 150 in., 176 in. GMPT L8T (Gen V), 8-cylinder, V Block 4-cycl, OHV, Direct Fuel Injection, Oil Jet Piston Cooling MODEL/DISPLACEMENT HP (GROSS) TORQUE (GROSS) EQUIPMENT GMPT- 8/400 CID (6.6 liters) 350 HP @ 4500 RPM 425 lb.-ft. @ 3800 RPM Direct injection technology, mass air flow meter, powertrain interface module (PIM), onboard diagnostics, oxygen sensors, catalytic convertor, map sensor, with external oil cooler, engine cruise control, and rear engine cover. TRANSMISSION Allison 1000 RDS 6-speed automatic with lock-up converter and double overdrive. No PTO opening. STEERING Integral power steering 18.8-20.9:1 ratio. Tilt and telescoping steering column. FRONT AXLE FRONT SUSPENSION FRONT GAWR Reverse Elliot "I" -beam rated at 8,440 lbs. Semi-elliptical steel alloy tapered leaf springs with stabilizer bar and shock absorbers. 6,830 lbs. HG / 8,440 lbs. XG REAR AXLE REAR SUSPENSION REAR GAWR Full floating single speed with hypoid gearing rated at 14,550 lbs. Semi-elliptical steel alloy multi-leaf springs and shock absorbers. 13,660 lbs. HG / 14,460 lbs. XG WHEELS TIRES BRAKES 19.5 x 6.0 - 6-hole disc wheels, painted white. 225/70R-19.5 (14 ply) LRR (Low Rolling Resistance) tubeless steel belted radials, all season front and rear Dual circuit vacuum assisted hydraulic service brakes with EBD (Electronic Brake Distribution) system for load proportioning of the brake system front disc and self -adjust outboard mounted drum rear. The parking brake is a mechanical, cable actuated, internal expanding drum type, transmission mounted. 4 channel anti-lock brake system. FUEL TANK FRAME 38.6 gal. rectangular stainless-steel fuel tank. Mounted between the frame rails with electric type fuel pump (mounted in tank) and fuel tank zone module (mounted on rearward crossmember). Through the rail fuel fill. Ladder type channel section straight frame rail 33.5 inches wide through the total length of the frame. Yield strength 44,000 psi, section modulus 7.20 in3., RBM 316,800 lb-in 2024 Chevrolet LCF CAB CAB EQUIPMENT ELECTRICAL OPTIONS All steel, low cab forward, BBC 70.9 in, 45° mechanical tilt with torsion assist. TRICOT breathable cloth covered high back driver's seat with two occupant passenger seat. Dual cab mounted exterior mirrors with integral convex mirror. Tilt and telescoping steering column. Power windows and door locks, floor mats, tinted glass. AM/FM/CD Radio with Aux input/USB port and Bluetooth. Rear body dome lamp switch. Cab latch switch and indicator with buzzer. 12-volt, negative ground, 750 CCA maintenance free battery located on frame, 170 Amp alternator with integral regulator. See last page for options. Note: These selected specifications are subject to change without notice. Revision: 05/31/23 O H O W A H A W F W F H C W B W PAGE 2024 Chevrolet Low Cab Forward 9.3 3500/4500/5500 12.0/14.5 17,950/19,500 GVW Gas-Crew Cab Vehicle Weights, Dimensions and Ratings In-Frame Tank 16000 lb. GVWR Automatic Transmission Model Chassis Curb and Maximum Payload Weights Model WB RPO Unit Front Rear Total Payload T41003 109.0 in EB4 lb. 4103 2290 6393 9607 T42003 132.5 in FNJ lb. 4194 2288 6482 9518 T43003 150.0 in FWH lb. T44003 176.0 in FNW lb. 4256 2267 6523 4296 2283 6579 9477 9421 Figure 9.3.1 Figure 11.2.1 BBC CE CA BOC Side Mounted Tank 16,000 lb. GVWR Automatic Transmission Model Chassis Curb and Maximum Payload Weights Model WB RPO Unit Front Rear Total Payload T44003 176.0 in FNW lb. 4430 2160 6590 9410 Vertical Exhaust Option Dimensions: Variable Chassis Dimensions: Unit WB EFF CA* EFF CE* OAL Inch 109.0 62.5 105.6 200.5 Inch 132.5 86.0 153.1 224.0 Inch 150.0 103.5 146.6 241.5 Inch 176.0 129.5 172.6 267.5 * Effective CA & CE listed are standard CA or CE AF less vertical exhaust BOC of 24 inches. 43.1 Vertical Exhaust BOC = 24 inches 43.1 43.1 43.1 Variable Chassis Dimensions: Unit WB CA* CE* OAL AF Inch 109.0 86.5 129.6 200.5 43.1 Inch 132.5 110.0 153.1 224.0 43.1 Inch 150.0 127.5 170.6 241.5 43.1 Inch 176.0 153.5 196.6 267.5 43.1 * Effective CA & CE are CA & CE less BOC Dimension Constants: Code Inches Code Inches AH 7.5 BW 833. AW 65.6 CW 65 BA 48.4 FW 33.5 BBC 70.7 OH 92.4 BOC 7.7 OW 81.3 FH 33.0 17,950 HG GVWR CREW CAB Model WB RPO Unit Front Rear Total Payload CP53043 150.0 in C7X lb. - - 6,479 11,471 CP54043 176.0 in C7X lb. - - 8,543 11,407 BA WB AF 2024 Chevrolet LCF FiguOArLe 11.2.2 Figure 9.3.2 19,500 XG GVWR CREW CAB Model WB RPO Unit CP63043 150.0 in GZG lb. CP64043 176.0 in GZG lb. Front - Rear Total Payload - 6,482 13,018 - 6,546 12,954 Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 9.4 3500/4500/5500 12.0/14.5 17,950/19,500 GVW Gas-Crew Cab Vehicle Weight Limits Vehicle Weight Limits: GVWR Designed Maximum 16,000 lbs. GAWR, Front 6,660 lbs. GAWR, Rear 11,020 lbs. NPV Technical Notes: 9D2 Chassis Curb Weight reflects standard equipment and fuel but no driver 9C2 or payload. 9E2 ATG Maximum Payload Weight is the allowed maximum for equipment, body, 9B9 payload and driver and is calculated by subtracting chassis curb weight AJG from the GVWR. KO5 KPG UIZ KQJ DB6 G7M MTE KPK KPJ NLX PTO DB8 TBD 9W8 IX2 UL5 KQN UZF V22 2024 Chevrolet LCF Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 9.5 3500/4500/5500 12.0/14.5 17,950/19,500 GVW Gas-Crew Cab Cab Frame and Crossmember Specifications A B C A B C SECTION A-A Wheelbase 109 132.5 150 176 Frame Thickness 0.24 0.24 0.24 0.24 B C 28.3 8.2 28.3 8.2 28.3 8.2 28.3 8.2 2024 Chevrolet LCF SECTION B-B SECTION C-C Figure 9.5.1 Crossmember Type/Location D AA 46.5 AA 46.5 AA 46.5 AA 46.5 E BB 57.5 BB 57.9 BB 74.4 FFigiguurere119.45.22 F CC 24.2 CC 24.2 CC 24.2 CC 24.2 G DD DD DD DD 33.8 33.8 33.8 33.8 Dimensions in inches Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 9.6 3500/4500/5500 12.0/14.5 17,950/19,500 GVW Gas-Crew Cab Frame Chart Wheelbase 109.0 132.5 150.0 176.0 2024 Chevrolet LCF Figguurree191..65..11 Frame FL 182.5 206.1 223.8 249.8 FFiigguurree191..65..22 Frame Thickness 0.24 0.24 0.24 0.24 Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 9.7 3500/4500/5500 12.0/14.5 17,950/19,500 GVW Gas-Crew Cab Top View WB A B C 150 88.5 131.6 241.5 176 114.5 156.6 267.5 66.5 64.5 B A 10.4 16.9 24.4 22.3 2024 Chevrolet LCF 12.8 14.0 61.5 150.3 182.5 Figure 9.7.1 Dimensions in inches Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 9.8 3500/4500/5500 12.0/14.5 17,950/19,500 GVW Gas-Crew Cab Left Side View WB A 150 88.5 176 114.5 113.0 (BBC) 4.9 (BOC) 128.9 (CE) 124.0 .7 (OH) 8.9 (AH) 48.5 (BA) 2024 Chevrolet LCF A (WB) Figure 9.8.1 30.3 (FH) 43.1 (AF) Dimensions in inches Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 9.9 3500/4500/5500 12.0/14.5 17,950/19,500 GVW Gas-Crew Cab Right Side View WB A 150 88.5 176 114.5 128.9 (CE) 113.0 (BBC) 124.0 (CA) 4.9 (BOC) 30.3 (FH) 43.1 (AF) 2024 Chevrolet LCF A WB 241.5 (C) Figure 9.9.1 89.7 (OH) 48.5 (BA) 8.9 (AH) Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 9.10 3500/4500/5500 12.0/14.5 17,950/19,500 GVW Gas-Crew Cab SCR / DPF 4HK1-TC Front of Chassis Outside edge of frame rail FFigiguurree 91.11.09.1 Outside edge of frame rail 2024 Chevrolet LCF FFiiggure 191.1.90..22 Dimensions in inches Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 9.11 3500/4500/5500 12.0/14.5 17,950/19,500 GVW Gas-Crew Cab Cab Tilt 2024 Chevrolet LCF Figure 9.11.1 Dimensions in inches Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 9.12 3500/4500/5500 12.0/14.5 17,950/19,500 GVW Gas-Crew Cab Turning Diameter TURNING DIAMETERS The LCF steering also features a 49.5 inside wheel cut angle. This, coupled with the integral power steering, makes the LCF an extremely maneuverable truck. B=Minimum turning diameter curb to curb C=Minimum turning diameter wall to wall VN60 C A B WB 109.0 132.0 150.0 176.0 B curb to curb 32.8 40.0 45.3 52.5 C (ft. wall to wall (ft.) 38.7 44.9 50.2 58.1 2024 Chevrolet LCF LCF Diesel Turning Circle Diagram Figure 9.12.1 Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 9.13 3500/4500/5500 12.0/14.5 17,950/19,500 GVW Gas-Crew Cab Center of Gravity Horizontal and Vertical CG of Chassis WB 110 132.5 150 176 H H V in frame side tank tank 23.5 38.4 N/A 23.3 44.9 N/A 23.3 49.9 N/A 23.3 57.2 52.5 113.0 (BBC) 4.9 (BOC) 128.9 (CE) 124.0 89.7 (OH) 8.9 (AH) 48.5 (BA) A (WB) Figure 9.13.2 FFiigguurree 191.1.136.1.1 The maximum vertical center of gravity specified below must not be exceeded at maximum GVWR and rated front and rear GAWR. The Center of Gravity (CG) maximum is 63" (1600 mm) above the ground. (LCF Cab Chassis and LCF Stripped Chassis) 30.3 (FH) Figure 11.16.2 43.1 (AF) NOTE: The Final Manufacturer must ensure that the combined vertical center of gravity of the chassis, body, and available payload at full GVW does not exceed the maximum vertical center of gravity outlined in the Chevrolet LCF Incomplete Vehicle Document and the GM Body Builders Guide. The maximum dimensions for a body installed on the LCF chassis are 102 inches wide (outside*) by 91 inches high (inside). Any larger body applications must be approved by GM Upfitter Engineering. Contact us at GMUpfitter.com. * With 102 inches wide mirror brackets installed in place of standard mirror brackets Dimensions in inches 2024 Chevrolet LCF Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 9.14 3500/4500/5500 12.0/14.5 17,950/19,500 GVW Gas-Crew Cab Front Axle Chart Formulas for calculating height dimensions: A = C = D = CH = DH = Tire Loaded Radius B Centerline of Axle to Top of Frame Rail at Curb Position Centerline of Axle to Top of Frame Rail at Design Load C + Tire Unloaded Radius D + Tire Loaded Radius Figure 9.14.1 Tire GVWR GAWR A B C D CH DH Track Tire Radius Unload Load 225/70R 19.5F 16,000 lbs. 6,630 lbs. 8.3 6.6 13 11.5 29 26.4 65.5 16 14.93 Figure 9.14.2 Dimensions in inches 2024 Chevrolet LCF Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 9.15 3500/4500/5500 12.0/14.5 17,950/19,500 GVW Gas-Crew Cab Rear Axle Chart 2024 Chevrolet LCF Figure 9.15.1 Dimensions in inches Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 9.16 3500/4500/5500 12.0/14.5 17,950/19,500 GVW Gas-Crew Cab Definitions Definitions Rear Frame Height: A Centerline of axle to bottom of axle bowl. DH Vertical distance between the normal top of frame rail and the ground-line through the centerline of the rear axle at design load. B Centerline of axle to top of frame rail at metal-to-metal position. DW Minimum distance between the inner surfaces of the rear tires. C Centerline of axle to top of frame rail at curb position. EW Maximum Rear Width: Overall width of the vehicle measured at the outermost surface of the rear tires. D Centerline of axle to top of frame rail at design load. Rear Tire Clearance: HH Minimum clearance between the rear axle and the ground-line. Rear Tire Clearance: Dual Tire Spacing: Minimum clearance required for tires and chain measured from the Distance between the centerlines of the minimum distance required for tire bounce E top of the frame at the vehicle centerline of the rear axle, when rear HW as measured from the centerline of the rear axle and the top of the rear tire when wheels on one side ride over a high spot. one wheel rides over a high spot. Rear Frame Height: Track Dual Rear Wheel Vehicle: CH Vertical distance between the normal top of frame rail and the CW Distance between the centerlines of the dual wheels measured at the ground-line. ground-line through the centerline of the rear axle at curb position. Tire Section, Tire Radius, Tire Loaded Radius, Tire Clearance See Chart for values. Figure 9.16.1 CW = Track CH = Tire loaded radius + C DH = Tire loaded radius + D DW = Track + 2 tire sections tire clearance EW = Track + 2 tire sections + tire clearance Formulas for Calculating Rear Width and Height Dimensions HH = Tire loaded radius A JH = KH B KH = Tire radius + 3.00 inches KW = DW 5.00 inches LW = 1.00-inch minimum clearance between tires and springs NOTE: Track and overall width may vary with optional equipment. Figure 9.16.2 Tire GAWR Track CW A 225/70R 19.5F 11,020 lbs. 65.0 7.7 B C 9.3 15.3 Figure 9.16.3 2024 Chevrolet LCF D E 13.4 8.4 Dimensions in inches Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 9.17 3500/4500/5500 12.0/14.5 17,950/19,500 GVW Gas-Crew Cab Tire and Disc Wheel Chart Tire Tire Size 225/70R 19.5F Tire Load Limit and Cold Inflation Pressures Single Dual Lbs. PSI Lbs. PSI 3,315 85 3,115 90 Maximum Tire Load Limits (lbs.) Front Rear 2 Single 4 Dual 6,900 12,980 GVWR (Lbs.) 16,000 Figure 9.17.1 Tire Size 225/70R 19.5F GVWR (Lbs.) 16,000 Tire Radius Loaded Unloaded Front Rear Front Rear 14.93 14.98 16 16 Tire Section Width 8.7 Tire Clearance 1.3 Design Rim Width 6.0 Disc Wheel Wheel Size Bolt Holes 19.5 x 6.00 6 JIS *O.D. Wrench Sizes Bolt Circle Dia. 8.75 Ft./Rr. Nut Size* 1.6142 (41 mm) BUD HEX Figure 9.17.2 Rear Stud Size* 0.8268 (21 mm) SQUARE Nut/Stud Torque Specs. 325 ft.-lb. (440 N·m) Inner Circle 6.46 Outside Disc Rim Type Material Mfg. Offset Thickeness 5.0 0.35 150 DC Steel TOPY Figure 9.17.3 2024 Chevrolet LCF Figure 9.17.4 Dimensions in inches Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 9.18 3500/4500/5500 12.0/14.5 17,950/19,500 GVW Gas-Crew Cab Suspension Deflection Chart 16,000 Ibs. 16,000 Ibs. Figure 9.18.1 2024 Chevrolet LCF Figure 9.18.2 Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 9.19 3500/4500/5500 12.0/14.5 17,950/19,500 GVW Gas-Crew Cab Propeller Shaft Figure 9.19.1 Figure 9.19.2 WheelBase (in.) 109 132.5 150 176 Top View A B 3.4º - 0º 3.3º 0º 3.2º 0º 2.2º D 11.3º 5.3º 2.6º 2.1º Side View E Trans - 2.5º 7.7º 2.5º 8.0º 2.5º 5.6º 2.5º Rear Axle 2.7º 2.7º 2.7º 2.7º Figure 9.19.3 Notes: 1. Angles provided in table are relative to the frame angle. Please take this into consideration for service measurements. 2. Driveline angles are based on the chassis curb weight which includes standard equipment, fuel but no driver, body, or payload. 2024 Chevrolet LCF Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 9.20 3500/4500/5500 12.0/14.5 17,950/19,500 GVW Gas-Crew Cab Propeller Shaft Trans. Type Wheelbase No. of Shafts Shaft #1 O.D. Thickness Length Type Shaft #2 O.D. Thickness Length Type Shaft #3 O.D. Thickness Length Type 109 1 3.54 0.126 35.7 A N/A N/A N/A N/A N/A N/A N/A N/A 6 Automatic. Transmission 132.5 150 2 2 3.54 3.54 0.126 0.126 22.91 40.24 B B 3.54 3.54 0.126 0.126 36.16 36.53 C C N/A N/A N/A N/A N/A N/A N/A N/A 176 2 3.54 0.126 49.69 B 3.54 0.126 52.93 C N/A N/A N/A N/A Type Description Figure 9.20.1 Illustration Type A 1st shaft in 1-piece driveline L Type B 1st shaft in 2-piece driveline L Type C 2024 Chevrolet LCF 2nd shaft in 2-piece driveline Figure 9.20.2 L Dimensions in inches Revision: 05/31/23 2024 Chevrolet Low Cab Forward 3500/4500/5500 12.0/14.5 17,950/19,500 GVW Gas - Crew Cab Brake System Diagram 16,000 GVW Vacuum Over Hydraulic Please refer to Introduction Section of book for antilock system cautions and wheelbase modification requirements. PAGE 9.21 Legend for 3500, 3500HD, 4500, 4500HD, 4500XD Brake System (1) Electronic Hydraulic Control Unit (EHCU) (2) Rear Wheel Cylinder (3) Vacuum Pump (4) Check Valve (5) Exhaust Brake Valve (6) Magnetic Valve (7) Check Valve (One-way Valve) (8) Vacuum Tank (9) 4-Way Connector (10) With Metering Valve (11) W/O Metering Valve (12) Brake Fluid Reservoir (13) Electric Vacuum Pump (14) Master Cylinder (15) Vacuum Booster (Servo Unit) (16) Front Wheel Cylinder Figure 9.21.1 LNWC5AMF000201 Revision: 02/28/2018 2024 Chevrolet LCF Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 9.22 3500/4500/5500 12.0/14.5 17,950/19,500 GVW Gas - Crew Cab PTO Location Drive Gear and Opening Information Figure 9.22.1 Trans. Opening Bolt A B CD E F Location Pattern Aisin 465 Left (Dr 2) 12.35 36.89 0 7.85 7.31 2.50 H 5.16 PTO Drive Gear Location PTO Gear Ratio of PTO Drv. Gear Spd. to Eng. Spd. 1:1 with turbine No. of Teeth 69 Pitch N/A Helix Angle 0 Max. Output Torque 134 lbs.-ft. @ 1,700 RPM 2024 Chevrolet LCF Figure 9.22.2 Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 9.23 3500/4500/5500 12.0/14.5 17,950/19,500 GVW Gas-Crew Cab Opening Diagram Aisin A460 Automatic Torque Converter Lock Up Function In either the Stationary Preset PTO Mode or Stationary Variable PTO Mode, when engine rpm exceeds 1200 RPM, the torque converter will lock up. The engine rpm can not be modified and the lockup function cannot be turned off. Please not that with PTO applications that operate around 1200 RPM, the transmission software holds the torque converter in lockup until engine speed falls below 1100 RPM. The lock up function will cancel if the transmission shift lever is moved from the park or neutral positions which will remove the transmission from the stationary mode. Additional PTO Functions For certain applications the Automatic regeneration function can be inhibited (Example Airport Ground Support vehicles). For certain applications the Automatic regeneration function can be enabled in the PTO stationary mode (Example Lawn care and carpet cleaning). For certain applications the Automatic regeneration function can be enabled in the PTO mobile mode (Example Line painting). Please refer to the PTO section of the BBG (section 17) for further details. 2024 Chevrolet LCF Figure 9.23.1 Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 9.24 3500/4500/5500 12.0/14.5 17,950/19,500 GVW Gas-Crew Cab In-Frame Fuel Fill Installation Instructions 1. Disconnect battery. 2. Loosen hose from the tie downs. Remove caps from plate on rail. 3. Install hoses onto the plate. 4. Extend hose out from the driver side of the rail to body rail. 5. The filler neck must be mounted to allow the fill plate bracket to be parallel to the frame horizontal. 6. Cover with protector wrap and secure with tie wraps. 7. Filler hose is set for 102 inches outside width body. 8. Filler neck (dimension A) must be between 6.85 inches and 8.5 inches above frame. 9. Secure the filler plate to the bottom of the body and check for leaks. 10. Ensure that fill hose does not sag, creating an area where the fuel could pool in the fill hose. 11. Reconnect battery. 2024 Chevrolet LCF Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 9.25 3500/4500/5500 12.0/14.5 17,950/19,500 GVW Gas-Crew Cab 38.6 Gal. RPO NH3 Rear View Fuel Fill Dimension: 6.75 - 8.5 inches (174-216mm) FUEL FILLER RUNS THROUGH THE FRAME RAIL 2024 Chevrolet LCF Figure 9.25.1 Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 9.26 3500/4500/5500 12.0/14.5 17,950/19,500 GVW Gas-Crew Cab 38.6 Gal. RPO NH3 Top View Fuel Fill Dimensions: B = 29.75 inches (756 mm) C = 34.00 inches (863 mm) D = 39.29 inches (998 mm) E = 33.86 inches (860 mm) F = 59.60 inches (1,514 mm) 2024 Chevrolet LCF 29.2 (F) 11.9 (E) 33.2 (B) 36.3 (C) 38.9 (D) Figure 11.29.1 Figure 9.26.1 Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 9.27 3500/4500/5500 12.0/14.5 17,950/19,500 GVW Gas-Crew Cab Hose Modifications Various Bodies and Fuel Fill Vent Protection Figure 11.30.1 "A" Dimensions: 102 inch wide body remove 0 inches 96 inch wide body remove 3 inches 90 inch wide body remove 5 inches 86 inch wide body remove 8 inches 80 inch wide body remove 8 inches 2024 Chevrolet LCF "A" NOTE: Shorten hose by "A Dimension" based on chart at left. Figure 9.27.1 Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 9.28 3500/4500/5500 12.0/14.5 17,950/19,500 GVW Gas-Crew Cab Through the Rail Fuel Fill Frame Hole 19.7 14.0 6.7 15.6 14.6 13.2 End of Frame 2024 Chevrolet LCF Figure 11.32.1 29.7 Figure 9.28.1 9.6 Dimensions in inches Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 9.29 3500/4500/5500 12.0/14.5 17,950/19,500 GVWR Gas 38.6 Gal. RPO NH3 Fuel filler Assembly FRONT FRONT Figure 9.29.1 Figure 9.29.2 Parts Kit: For LCF 3500/4500 GAS Fuel Filler chassis installation as shown. See authorized GM Dealer for Parts list and availability. 2024 Chevrolet LCF Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 9.30 3500/4500/5500 12.0/14.5 17,950/19,500GVW Gas-Crew Cab Installation Instructions and Considerations The fuel tank shutter valve (13) is meant to improve fuel splash-back performance of the fuel system. This valve (13) is located on the inlet (outboard side) of the fuel filler neck bulkhead assemble that is bolted to the left hand frame rail as shown in Figure 9.30.1. This plastic valve snaps into place in the inlet of the frame mounted fuel pipe. The valve should be installed so that the plastic clip is at the top of the valve, so that the flap door opens up, as shown in Figure 9.30.2. Figure 9.30.1 The fuel filler hose should be installed flush against the tank. The clamp should be installed between 1/16"and 3/8" from the tank. This is shown in Figure 9.30.3 to the right. 2024 Chevrolet LCF Figure 9.30.2 Figure 9.30.3 Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 9.31 3500/4500/5500 12.0/14.5 17,950/19,500 GVW Gas-Crew Cab Roll-Over Valve Tubing The roll-over valve has a hose attachment that will make this valve less sensitive to water intrusion. In order for the valve to work properly, it is critical that the hose be installed to the rollover valve. The proper assembly of the outer hose is shown in Figure 9.31.1. (1) Fuel Filler Hose Vent Hose (7) Protective Sleeve Figure 9.31.1 (4) Rollover Valve Hose Rollover Valve Filler Neck Installation The fuel filler neck (5) must be installed with the proper orientation on the body. The neck should be installed with the roll-over valve pointing upward, with the bottom edge of the neck oriented parallel to the ground, plus 33 to minus 7 degrees. See Figure 9.31.2 for the proper orientation. 2024 Chevrolet LCF Rollover Valve pointing upward Filler Neck Base Angle Installed to Horizontal +33o -7o Figure 9.31.2 Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 9.32 3500/4500HD 12.0/14.5 GVW Gas-Crew Cab Roll-Over Valve Tubing The roll-over valve has a hose attachment that will make this valve less sensitive to water intrusion. In order for the valve to work properly, it is critical that the hose be installed to the rollover valve. The proper assembly of the outer hose is shown in Figure 9.32.1. (1) Fuel Filler Hose Vent Hose (7) Protective Sleeve Figure 9.32.1 (4) Rollover Valve Hose Rollover Valve Filler Neck Installation The fuel filler neck (5) must be installed with the proper orientation on the body. The neck should be installed with the roll-over valve pointing upward, with the bottom edge of the neck oriented parallel to the ground, plus 33 to minus 7 degrees. See Figure 9.32.2 for the proper orientation. 2024 Chevrolet LCF Rollover Valve pointing upward Filler Neck Base Angle Installed to Horizontal +33o -7o Figure 9.32.2 Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 10.1 4500HG Diesel STD Cab Specifications MODEL GVWR WB ENGINE Model/Displacement HP (Gross) Torque (Gross) Equipment TRANSMISSION STEERING FRONT AXLE Suspension GAWR REAR AXLE Suspension GAWR WHEELS TIRES BRAKES FUEL TANK FRAME CAB Equipment ELECTRICAL OPTIONS 4500HG Diesel - STD Cab 14,500 lbs. 109 in, 132.5 in, 150 in. 176 in. Isuzu 4-cylinder, in-line 4-cycle, turbocharged, intercooled, direct injection diesel. 4HK1-TC/317 CID (5.19 liters) 14,500 GVWR 215 HP @ 2500 RPM w Automatic Transmission 14,500 GVWR 452 lb/ft torque @ 1850 RPM w/ Automatic Trans Dry element air cleaner with vertical intake; 2 rows 564 in2. radiator; 7 blade 20.1in diameter fan with viscous drive. Cold weather starting device and an oil cooler. Engine oil level check. Engine warning system with audible warning for low oil pressure, high coolant temperature, and low coolant level. Engine cruise control function. Rear engine cover. Aisin A465 6 speed automatic transmission with fifth and sixth gear overdrive with lock up in 2nd, 3rd, 4th, 5th and 6th. PTO capability with automatic torque converter lockup in stationary PTO mode. Integral power steering 18.8-20.9:1 ratio. Tilt and telescoping steering column. Reverse Elliot I" -Beam rated at 6,830 lbs. Semi-elliptical steel alloy tapered leaf springs with stabilizer bar and shock absorbers. 5,360 lbs. Full floating single speed with hypoid gearing rated at 11,020 lbs. Semi-elliptical steel alloy multi-leaf springs and shock absorbers. 9,880 lbs. 16x6.0-K 6 hole disc wheels, painted white. 215/85R-16E (10 pr) LRR ( Low Rolling Resistance ) tubeless steel belted radials, all season front and rear. Dual circuit vacuum assisted hydraulic service brakes with EBD (Electronic Brake Distribution) system for load proportioning of the brake system front disc and self-ad just outboard mounted drum rear. The parking brake is a mechanical, cable actuated, internal expanding drum type, transmission mounted. The exhaust brake is standard and is vacuum operated. 4 channel anti-lock brake system. 30 gal. (Opt. 35 or 55 gal.) rectangular steel fuel tank mounted in frame rail behind rear axle. Fuel water separator with indicator light on inst rument cluster. Ladder type channel section straight frame rail 33.5 in wide through the total length of the frame. Yield strength 44,000 psi, section modulus 7.20 in3. RBM 316,800. All steel low cab forward, BBC 70.7 in, 45o mechanical tilt with torsion assist. TRICOT breathable cloth covered high back driver's seat with two occupant passenger seat. Dual cab mounted exterior mirrors with integral convex mirror, AM/FM CD stereo radio. Tilt and telescoping steering column. Power windows and door locks, floor mats, tinted glass. 12 Volt, negative ground, dual maintenance free batteries, 750 CCA each, 140 Amp alternator with integral regulator. See last page for options NOTE: These selected specifications are subject to change without notice. 2024 Chevrolet LCF Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 10.2 Vehicle Weights, Dimensions and Ratings Figure 10.2.1 2024 Chevrolet LCF Figure 10.2.2 Dimension Constants: Code Inches Code Inches AH 7.5 BW 83.3 AW 65.6 CW 65.0 BA 48.3 FW BBC 70.7 OH 33.5 90.8 BOC 7.7/10.2 OW 81.3 FH 31.1 * BOC 7.7 in. w/ 109.0 and 132.5 wb BOC 10.2 in. w/ 150.0 and 176.0 wb Variable Chassis Dimensions: Unit WB CA* CE* OAL AF Inch 109.0 86.5 129.6 200.5 43.1 Inch 132.5 110.0 153.1 224.0 43.1 Inch 150.0 127.5 170.6 241.5 43.1 Inch 176.0 153.5 196.6 267.5 43.1 * Effective CA & CE are CA or CE less BOC Vertical Exhaust Option Dimensions: Variable Chassis Dimensions: Unit WB EFF CA* EFF CE* Inch 109.0 62.5 105.6 Inch 132.5 86.0 153.1 Inch 150.0 103.5 146.6 Inch 176.0 129.5 172.6 OAL 200.5 224.0 241.5 267.5 AF 43.1 43.1 43.1 43.1 * Effective CA & CE listed are standard CA or CE less vertical exhaust BOC of 24 inches. Vertical Exhaust BOC = 24 inches In-Frame Tank 14,500 lb. GVWR Automatic Transmission Model Chassis Curb and Maximum Payload Weights Model WB RPO Unit Front T31003 109.0 in. EB4 lb. 3907 T32003 132.5 in. FNJ lb. 3999 T33003 150.0 in. FWH lb. 4061 T34003 176.0 in. FNW lb. 4123 Side Mounted Tank (Aux. Tank) 14,500 lb. GVWR Automatic Transmission Model Chassis Curb and Maximum Payload Weights Model WB RPO Unit Front T34003 176.0 in. FNW lb. 4258 Rear 2057 2054 2034 2027 Rear 1903 Total 5964 6053 6095 6150 Payload 8536 8447 8405 8350 Total Payload 6161 8339 Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 10.3 Vehicle Weight Limits: GVWR Designed Maximum 14,500 lbs. GAWR, Front 5,360 lbs. GAWR, Rear 9,880 lbs. Technical Notes: Chassis Curb Weight reflects standard equipment and fuel but no driver or payload. Maximum Payload Weight is the allowed maximum for equipment, body, payload and driver and is calculated by subtracting chassis curb weight from the GVWR. 2024 Chevrolet LCF NPV 9D2 9C2 9E2 ATG 9B9 AJG KO5 KPG UIZ KQJ DB6 G7M MTE KPK KPJ NLX PTO DB8 TBD 9W8 IX2 UL5 KQN UZF V22 Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 10.4 Frame and Crossmember Specifications Wheelbase 109 132.5 150 176 Frame Thickness 0.24 0.24 0.24 0.24 2024 Chevrolet LCF B C 28.3 8.2 28.3 8.2 28.3 8.2 28.3 8.2 Figure 10.4.1 Crossmember Type/Location D AA AA AA AA 46.5 46.5 46.5 46.5 E BB 57.5 BB 57.9 BB 74.4 Figure 10.4.2 F CC 24.2 CC 24.2 CC 24.2 CC 24.2 G DD DD DD DD 33.8 33.8 33.8 33.8 Dimensions in inches Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 10.5 Frame Chart Wheelbase 109.0 132.5 150.0 176.0 2024 Chevrolet LCF Figure 10.5.1 Frame FL 182.5 206.1 223.8 249.8 Figure 10.5.2 Frame Thickness 0.24 0.24 0.24 0.24 Revision: 05/31/23 2024 Chevrolet Low Cab Forward 4500HG Diesel Standard Cab - Top View WB 109 132.5 150 176 A 43.4 49.7 43.4 43.4 B 78.0 84.3 78.0 78.0 PAGE 10.6 2024 Chevrolet LCF Figure 10.6.1 Dimensions in inches Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 10.7 4500HG Diesel Standard Cab - Left Side View WB 109 132.5 150 176 A 80.7 87.0 80.7 80.7 2024 Chevrolet LCF Figure 10.7.1 Dimensions in inches Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 10.8 4500HG Diesel Standard Cab - Right Side View WB 109 132.5 150 176 A 44.0 50.3 44.0 44.0 2024 Chevrolet LCF Figure 10.8.1 Dimensions in inches Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 10.9 SCR / DPF 4HK1-TC Front of Chassis Outside edge of frame rail Figure 10.9.1 Outside edge of frame rail 2024 Chevrolet LCF Figure 10.9.2 Dimensions in inches Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 10.10 RPO NL1 35 Gal. & ND5 55 Gal. Optional Side Fuel Tanks in addition to the Standard In Rail Fuel Tank RPO NH4 Side View 150 Wheelbase Figure 10.10.1 2024 Chevrolet LCF Figure 10.10.2 Dimensions in inches Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 10.11 RPO NL1 35 Gal. & ND5 55 Gal. Optional Side Fuel Tanks in addition to the Standard In Rail Fuel Tank RPO NH4 Side View 176 Wheelbase Figure 10.11.1 2024 Chevrolet LCF Figure 10.11.2 Dimensions in inches Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 10.12 RPO NL1 35 Gal. & ND5 55 Gal. Optional Side Fuel Tanks in place of the Standard In Rail Fuel Tank on T34003 ONLY Side View 176 Wheelbase 2024 Chevrolet LCF Figure 10.12.1 Dimensions in inches Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 10.13 Optional Side Fuel Tanks in addition to the Standard In Rail Fuel Tank RPO NH4 (150 and 176 WB, LH rail only) Optional Side Fuel Tanks replacing standard In Rail Fuel Tank (176 WB only, RH rail only) 2024 Chevrolet LCF Figure 10.13.1 Dimensions in inches Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 10.14 Cab Tilt 2024 Chevrolet LCF Figure 10.14.1 Dimensions in inches Revision: 05/31/23 2024 Chevrolet Low Cab Forward TURNING DIAMETERS The LCF Diesel steering also features a 49.5 inside wheel cut angle. This, coupled with the integral power steering, makes the LCF Diesel an extremely maneuverable truck. B=Minimum turning diameter curb to curb C=Minimum turning diameter wall to wall VN60 C A B WB 109.0 132.0 150.0 176.0 B curb to curb 31.5 38.7 42.7 51.2 C (ft. wall to wall (ft.) 37.1 44.0 48.9 56.4 LCF Diesel Turning Circle Diagram Figure 10.15.1 PAGE 10.15 2024 Chevrolet LCF Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 10.16 Center of Gravity Horizontal and Vertical CG of Chassis WB 110 132.5 150 176 V 22.2 22.1 22.0 22.0 H in frame tank 36.2 42.7 47.7 55.0 H side tank N/A N/A N/A 50.3 Figure 10.16.1 The maximum vertical center of gravity specified below must not be exceeded at maximum GVWR and rated front and rear GAWR. The Center of Gravity (CG) maximum is 63" (1600 mm) above the ground. (LCF Cab Chassis and LCF Stripped Chassis) Figure 10.16.2 NOTE: The Final Manufacturer must ensure that the combined vertical center of gravity of the chassis, body, and available payload at full GVW does not exceed the maximum vertical center of gravity outlined in the Chevrolet LCF Incomplete Vehicle Document and the GM Body Builders Guide. The maximum dimensions for a body installed on the LCF chassis are 102 inches wide (outside*) by 91 inches high (inside). Any larger body applications must be approved by GM Upfitter Engineering. Contact us on GMUpfitter.com. * With 102 inches wide mirror brackets installed in place of standard mirror brackets Dimensions in inches 2024 Chevrolet LCF Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 10.17 Front Axle Chart Formulas for calculating height dimensions: A = Tire Loaded Radius B C = Centerline of Axle to Top of Frame Rail at Curb Position D = Centerline of Axle to Top of Frame Rail at Design Load CH = C + Tire Unloaded Radius DH = D + Tire Loaded Radius Figure 10.17.1 Tire GVWR GAWR A B 215/85R 16-E 14,500 lbs. 5,360 lbs. 7.5 6.6 C 12.8 D 11.7 CH 27.4 DH 25.8 Track 65.5 Tire Radius Unload Load 14.6 14.1 Figure 10.17.2 Dimensions in inches 2024 Chevrolet LCF Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 10.18 Rear Axle Chart 2024 Chevrolet LCF Figure 10.18.1 Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 10.19 A Centerline of axle to bottom of axle bowl. B Centerline of axle to top of frame rail at metal-to-metal position. C Centerline of axle to top of frame rail at curb position. D Centerline of axle to top of frame rail at design load. Rear Tire Clearance: E Minimum clearance required for tires and chain measured from the top of the frame at the vertical centerline of the rear axle, when rear wheels on one side ride over a high spot. Rear Frame Height: CH Vertical distance between the normal top of frame rail and the ground-line through the centerline of the rear axle at curb position. Rear Frame Height: DH Vertical distance between the normal top of frame rail and the ground-line through the centerline of the rear axle at design load. Tire Section, Tire Radius, Tire Loaded Radius, Tire Clearance Definitions DW Minimum distance between the inner surfaces of the rear tires. EW Maximum Rear Width: Overall width of the vehicle measured at the outermost surface of the rear tires. HH Rear Tire Clearance: Minimum clearance between the rear axle and the ground-line. Dual Tire Spacing: HW Distance between the centerlines of the minimum distance required for tire bounce as measured from the centerline of the rear axle and the top of the rear tire when one wheel rides over a high spot. CW Track Dual Rear Wheel Vehicles: Distance between the centerlines of the dual wheels measured at the ground-line. See Tire Chart for Values Figure 10.19.1 CW = Track CH = Tire loaded radius + C DH = Tire loaded radius + D DW = Track + 2 tire sections tire clearance EW = Track + 2 tire sections + tire clearance Formulas for Calculating Rear Width and Height Dimensions HH = Tire loaded radius A JH = KH B KH = Tire radius + 3.00 inches KW = DW 5.00 inches LW = 1.00-inch minimum clearance between tires and springs NOTE: Track and overall width may vary with optional equipment. Figure 10.19.2 Tire GAWR Track CW A 215/85R 16-E 9,880 lbs. 65.0 6.5 B C 9.3 15.4 Figure 10.19.3 D E 13.0 7.8 Dimensions in inches 2024 Chevrolet LCF Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 10.20 4500HG Suspension Deflection Charts 14,500 lb GVWR 14,500 lb GVWR Figure 10.20.1 2024 Chevrolet LCF Figure 10.20.2 Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 10.21 Tire and Disc Wheel Chart 4500HG Tire Tire Size 215/85R-16E Tire Load Limit and Cold Inflation Pressures Single Dual Lbs. PSI Lbs. PSI 3,315 85 3,115 85 Figure 10.21.1 Maximum Tire Load Limits (lbs.) Front Rear 2 Single 4 Dual 6,630 12,460 GVWR (Lbs.) 14,500 Tire Size 215/85R 16-E GVWR (Lbs.) 14,500 Tire Radius Loaded Unloaded Front Rear Front Rear 14.1 14.1 14.6 14.6 Tire Section Width 8.2 Tire Clearance 1.8 Design Rim Width 6.0 Disc Wheel Wheel Size Bolt Holes 16 x 6 K 6 JIS *O.D. Wrench Sizes Bolt Circle Dia. 8.75 Ft./Rr. Nut Size* 1.6142 (41 mm) BUD HEX Figure 10.21.2 Rear Stud Size* 0.8268 (21 mm) SQUARE Nut/Stud Torque Specs. 325 ft-lb. (440 N·m) Inner Circle 6.46 Outside Disc Rim Type Material Mfg. Offset Thickeness 5.0 0.37 50 DC Steel TOPY Figure 10.21.3 2024 Chevrolet LCF Figure 10.21.4 Dimensions in inches Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 10.22 Propeller Shaft Figure 10.22.1 Figure 10.22.2 WheelBase (in.) Top View Side View 109 2.5º - 10.6º - 2.5º 2.5º 132.5 0º 2.7º 5.3º 7.4º 2.5º 2.5º 150.0 0º 2.7º 2.6º 8.0º 2.5º 2.5º 176 0º 1.8º 2.1º 5.4º 2.5º 2.5º Notes: 1. Angles provided in table are relative to the frame angle. Please take this into consideration for service measurements. 2. Driveline angles are based on the chassis curb weight which includes standard equipment, fuel but no driver, body, or payload. 2024 Chevrolet LCF Revision: 05/31/23 2024 Chevrolet Low Cab Forward Propeller Shaft Wheelbase No. of Shafts Trans. Type Shaft #1 O.D. Thickness Length Type Shaft #2 O.D. Thickness Length Type 109 1 6A/T 3.25'' 0.0906'' 36.69'' A N/A N/A N/A N/A 132.5 2 6A/T 3.25'' 0.0906'' 16.97'' B 3.25'' 0.0906'' 33.78'' C Figure 10.23.1 150 2 6A/T 3.25'' 0.0906'' 34.29'' B 3.25'' 0.0906'' 34.17'' C Type Description Illustration Type A 1st shaft in 1-piece driveline L Type B 1st shaft in 2-piece driveline L Type C 2nd shaft in 2-piece driveline L 2024 Chevrolet LCF Figure 10.23.2 10.23 176 2 6A/T 3.25'' 0.0906'' 43.47'' B 3.25'' 0.0906'' 50.71'' C Dimensions in inches Revision: 05/31/23 PAGE 2024 Chevrolet Low Cab Forward Brake System Diagram 14,500 GVW Vacuum Over Hydraulic Please refer to Introduction Section of book for antilock system cautions and wheelbase modification requirements. Legend for 3500, 3500HD, 4500, 4500HG, 4500XG Brake System (1) Electronic Hydraulic Control Unit (EHCU) (2) Rear Wheel Cylinder (3) Vacuum Pump (4) Check Valve (5) Exhaust Brake Valve (6) Magnetic Valve (7) Check Valve (One-way Valve) (8) Vacuum Tank (9) 4-Way Connector (10) With Metering Valve (11) W/O Metering Valve (12) Brake Fluid Reservoir (13) Electric Vacuum Pump (14) Master Cylinder (15) Vacuum Booster (Servo Unit) (16) Front Wheel Cylinder Figure 10.24.1 2024 Chevrolet LCF PAGE 10.24 Revision: 05/31/23 2024 Chevrolet Low Cab Forward PTO Location, Drive Gear and Opening Information PAGE 10.25 Figure 10.25.1 Trans. Opening Bolt A BCD E F Location Pattern Aisin 465 Left (Dr 2) 12.35 36.89 0 7.85 7.31 2.50 H 5.16 PTO Drive Gear Location PTO Gear Ratio of PTO Drv. Gear Spd. to Eng. Spd. 1:1 with turbine No. of Teeth 69 Pitch N/A Helix Angle 0 Max. Output Torque 134 lbs.-ft. @ 1,700 RPM Figure 10.25.2 2024 Chevrolet LCF Revision: 05/31/23 2024 Chevrolet Low Cab Forward Opening Diagram Aisin A460 Automatic Torque Converter Lock Up Function In either the Stationary Preset PTO Mode or Stationary Variable PTO Mode, when engine rpm exceeds 1200 RPM, the torque converter will lock up. The engine rpm can not be modified and the lockup function cannot be turned off. Please not that with PTO applications that operate around 1200 RPM, the transmission software holds the torque converter in lockup until engine speed falls below 1100 RPM. The lock up function will cancel if the transmission shift lever is moved from the park or neutral positions which will remove the transmission from the stationary mode. 10.26 Additional PTO Functions For certain applications the Automatic regeneration function can be inhibited (Example Airport Ground Support vehicles). For certain applications the Automatic regeneration function can be enabled in the PTO stationary mode (Example Lawn care and carpet cleaning). For certain applications the Automatic regeneration function can be enabled in the PTO mobile mode (Example Line painting). Please refer to the PTO section of the BBG (section 17) for further details. PAGE 2024 Chevrolet LCF Figure 10.26.1 Revision: 05/31/23 2024 Chevrolet Low Cab Forward In-Frame Diesel Fuel Fill Installation Instructions 1. Disconnect battery. 2. Loosen hose from the tie downs. Remove caps from plate on rail. 3. Install hoses onto the plate. 4. Extend hose out from the driver side of the rail to body rail. 5. The filler neck must be mounted to allow the fill plate bracket to be parallel to the frame horizontal. 6. Cover with protector wrap and secure with tie wraps. 7. Filler hose is set for 102 inches outside width body. 8. Filler neck (dimension A) must be between 6.85 inches and 8.5 inches above frame. 9. Secure the filler plate to the bottom of the body and check for leaks. 10. Ensure that fill hose does not sag, creating an area where the fuel could pool in the fill hose. 11. Reconnect battery. PAGE 10.27 2024 Chevrolet LCF Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 10.28 Rear View Fuel Fill Dimension: 6.75 - 8.5 inches (174-216mm) 2024 Chevrolet LCF Figure 10.28.1 Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 10.29 Top View Fuel Fill Dimensions: B = 29.75 inches (756 mm) C = 34.00 inches (863 mm) D = 39.29 inches (998 mm) E = 33.86 inches (860 mm) F = 59.60 inches (1,514 mm) 2024 Chevrolet LCF Figure 10.29.1 Revision: 05/31/23 2024 Chevrolet Low Cab Forward Hose Modification for Various Width Bodies and Fuel Fill Vent Protection PAGE 10.30 Figure 10.30.1 "A" Dimensions: 102 inch wide body remove 0 inches 96 inch wide body remove 3 inches 90 inch wide body remove 5 inches 86 inch wide body remove 8 inches 80 inch wide body remove 8 inches 2024 Chevrolet LCF "A" NOTE: Shorten hose by "A Dimension" based on chart at left. Figure 10.30.2 Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 10.31 Ultra Low Sulfur Diesel Label 2024 Chevrolet LCF Figure 10.31.1 Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 10.32 Through the Rail Fuel Fill Frame Hole 2024 Chevrolet LCF Figure 10.32.1 End of Frame Dimensions in inches Revision: 05/31/23 2024 Chevrolet Low Cab Forward 4500HG Diesel Fuel Filler Kit Instructions PAGE 10.33 Please review these instructions prior to installation of the fuel filler kit. Parts Kit: There is a parts kit for the Chevrolet LCF diesel product. Fuel filler kit shown below is used for 14,500 lb and higher GVWR chassis (3500HD, 4500HG, 4500XG, 5500HG, 5500XG). Parts list is shown in Figure 10.33.2. Parts photos are shown in Figure 10.33.1. ITEM # 1 2 3 4 5 6 7 8 9 10 11 12 13 FUEL FILLER KIT PART NAME HOSE: FUEL FILLER NECK HOSE: FUELFILLER CAP: FILLER HOSE: ROLL-OVER VALVE NECK ASM: FUEL FILLER CLIP: JOINT PROTECTOR: FILLER HOSE CLIP: BAND, HOSE FIXING CLIP: RUBBER, HOSE BRACKET: FILLER NECK SCREW: FILLER NECK CAUTION PLATE SHUTTER: FUEL TANK ** See Dealer for all part numbers. Figure 10.33.2 PART # ** ** ** ** ** ** ** ** ** ** ** ** ** QTY 1 1 1 1 1 4 1 2 1 1 3 1 1 Figure 10.33.1 2024 Chevrolet LCF Revision: 05/31/23 2024 Chevrolet Low Cab Forward Installation Instructions and Considerations PAGE 10.34 The fuel tank shutter valve (13) is meant to improve fuel splash-back performance of the fuel system. This valve (13) is located on the inlet (outboard side) of the fuel filler neck bulkhead assemble that is bolted to the left hand frame rail as shown in Figure 10.34.1. This plastic valve snaps into place in the inlet of the frame mounted fuel pipe. The valve should be installed so that the plastic clip is at the top of the valve, so that the flap door opens up, as shown in Figure 10.34.2. Figure 10.34.1 The fuel filler hose should be installed flush against the tank. The clamp should be installed between 1/16"and 3/8" from the tank. This is shown in Figure 10.34.3 to the right. 2024 Chevrolet LCF Figure 10.34.2 Figure 10.34.3 Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 10.35 Roll-Over Valve Tubing The roll-over valve has a hose attachment that will make this valve less sensitive to water intrusion. In order for the valve to work properly, it is critical that the hose be installed to the rollover valve. The proper assembly of the outer hose is shown in Figure 10.35.1. (1) Fuel Filler Hose Vent Hose (7) Protective Sleeve Figure 10.35.1 (4) Rollover Valve Hose Rollover Valve Filler Neck Installation The fuel filler neck (5) must be installed with the proper orientation on the body. The neck should be installed with the roll-over valve pointing upward, with the bottom edge of the neck oriented parallel to the ground, plus 33 to minus 7 degrees. See Figure 10.35.2 for the proper orientation. 2024 Chevrolet LCF Rollover Valve pointing upward Filler Neck Base Angle Installed to Horizontal +33o -7o Figure 10.35.2 Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 11. 1 4500XG Diesel - STD Cab Specifications MODEL GVWR WB ENGINE Model/Displacement HP (Gross) Torque (Gross) Equipment TRANSMISSION STEERING FRONT AXLE Suspension GAWR REAR AXLE Suspension GAWR WHEELS TIRES BRAKES FUEL TANK FRAME CAB Equipment ELECTRICAL OPTIONS 4500XG Diesel - STD Cab 16,000 lbs. 109 in, 132.5 in, 150 in. 176 in. Isuzu 4-cylinder, in-line 4-cycle, turbocharged, intercooled, direct injection diesel. 4HK1-TC/317 CID (5.19 liters) 215 HP @ 2500 RPM w/ Automatic Transmission 452 lb/ft torque @ 1850 RPM w/ Automatic Transmission Dry element air cleaner with vertical intake; 2 rows 564 in2. radiator; 7 blade 20.1in diameter fan with viscous drive. Cold weather starting device and an oil cooler. Engine oil level check. Engine warning system with audible warning for low oil pressure, high coolant temperature, and low coolant level. Engine cruise control function. Rear engine cover. Aisin A465 6 speed automatic transmission with fifth and sixth gear overdrive with lock up in 2nd, 3rd, 4th, 5th and 6th. PTO capability with automatic torque converter lockup in stationary PTO mode. Integral power steering 18.8-20.9:1 ratio. Tilt and telescoping steering column. Reverse Elliot I" -Beam rated at 6,830 lbs. Semi-elliptical steel alloy tapered leaf springs with stabilizer bar and shock absorbers. 6,630 lbs. Full floating single speed with hypoid gearing rated at 11,020 lbs. Semi-elliptical steel alloy multi-leaf springs and shock absorbers. 11,020 lbs. 19.5x6.0-K 6 hole disc wheels, painted white 225/70R-19.5 F (12 pr) LRR ( Low Rolling Resistance) tubeless steel belted radials, all season, front and rear. Dual circuit vacuum assisted hydraulic service brakes with EBD (Electronic Brake Distribution) system for load proportioning of the brake system front disc and self-ad just outboard mounted drum rear. The parking brake is a mechanical, cable actuated, internal expanding drum type, transmission mounted. The exhaust brake is standard and is vacuum operated. 4 channel anti-lock brake system. 30 gal. (Opt. 35 & 55 gal.) rectangular steel fuel tank mounted in frame rail behind rear axle. Fuel water separator with indicator light on instrum ent cluster. Ladder type channel section straight frame rail 33.5 in wide through the total length of the frame. Yield strength 44,000 psi, section modulus 7.20 in3. RBM 316,800. All steel low cab forward, BBC 70.7 in, 45o mechanical tilt with torsion assist. TRICOT breathable cloth covered high back driver's seat with two occupant passenger seat. Dual cab mounted exterior mirrors with integral convex mirror. Tilt and telescoping steering column. Power windows and door locks, floor mats, tinted glass. 12 Volt, negative ground, dual maintenance free batteries, 750 CCA each, 140 Amp alternator with integral regulator. See last page for options NOTE: These selected specifications are subject to change without notice. 2024 Chevrolet LCF Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 11. 2 Vehicle Weights, Dimensions and Ratings Figure 11.2.1 2024 Chevrolet LCF Figure 11.2.2 In-Frame Tank 16000 lb. GVWR Automatic Transmission Model Chassis Curb and Maximum Payload Weights Model WB RPO Unit Front T41003 109.0 in EB4 lb. 4103 T42003 132.5 in FNJ lb. 4194 T43003 150.0 in FWH lb. 4256 T44003 176.0 in FNW lb. 4296 Rear 2290 2288 2267 2283 Total 6393 6482 6523 6579 Payload 9607 9518 9477 9421 Side Mounted Tank 16,000 lb. GVWR Automatic Transmission Model Chassis Curb and Maximum Payload Weights Model WB RPO Unit Front T44003 176.0 in FNW lb. 4430 Rear 2160 Total 6590 Payload 9410 Vertical Exhaust Option Dimensions: Variable Chassis Dimensions: Unit WB EFF CA* EFF CE* OAL AF Inch 109.0 62.5 105.6 200.5 43.1 Inch 132.5 86.0 153.1 224.0 43.1 Inch 150.0 103.5 146.6 241.5 43.1 Inch 176.0 129.5 172.6 267.5 43.1 * Effective CA & CE listed are standard CA or CE less vertical exhaust BOC of 24 inches. Vertical Exhaust BOC = 24 inches Variable Chassis Dimensions: Unit WB CA* CE* OAL AF Inch 109.0 86.5 129.6 200.5 43.1 Inch 132.5 110.0 153.1 224.0 43.1 Inch 150.0 127.5 170.6 241.5 43.1 Inch 176.0 153.5 196.6 267.5 43.1 * Effective CA & CE are CA & CE less BOC Dimen sion Constants: Code Inches Code Inches AH 7.5 BW 833. AW 65.6 CW 65 BA 48.4 FW 33.5 BBC 70.7 OH 92.4 BOC 7.7 OW 81.3 FH 33.0 Revision: 05/31/23 2024 Chevrolet Low Cab Forward Vehicle Weight Limits: GVWR Designed Maximum 16,000 lbs. GAWR, Front 6,660 lbs. GAWR, Rear 11,020 lbs. NPV Technical Notes: 9D2 Chassis Curb Weight reflects standard equipment and fuel but no driver 9C2 or payload. 9E2 ATG Maximum Payload Weight is the allowed maximum for equipment, body, 9B9 payload and driver and is calculated by subtracting chassis curb weight AJG from the GVWR. KO5 KPG UIZ KQJ DB6 G7M MTE KPK KPJ NLX PTO DB8 TBD 9W8 IX2 UL5 KQN UZF V22 2024 Chevrolet LCF PAGE 11. 3 Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 11. 4 Frame and Crossmember Specifications Wheelbase 109 132.5 150 176 Frame Thickness 0.24 0.24 0.24 0.24 2024 Chevrolet LCF B C 28.3 8.2 28.3 8.2 28.3 8.2 28.3 8.2 Figure 11.4.1 Crossmember Type/Location D AA AA AA AA 46.5 46.5 46.5 46.5 E BB 57.5 BB 57.9 BB 74.4 Figure 11.4.2 F CC 24.2 CC 24.2 CC 24.2 CC 24.2 G DD DD DD DD 33.8 33.8 33.8 33.8 Dimensions in inches Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 11. 5 Frame Chart Wheelbase 109.0 132.5 150.0 176.0 2024 Chevrolet LCF Figure 11.5.1 Frame FL 182.5 206.1 223.8 249.8 Figure 11.5.2 Frame Thickness 0.24 0.24 0.24 0.24 Revision: 05/31/23 2024 Chevrolet Low Cab Forward 4500XG Diesel Standard Cab - Top View WB 109 132.5 150 176 A 43.4 49.7 43.4 43.4 B 78.0 84.3 78.0 78.0 PAGE 11. 6 2024 Chevrolet LCF Figure 11.6.1 Dimensions in inches Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 11. 7 4500XG Diesel Standard Cab - Left Side View WB 109 132.5 150 176 A 80.7 87.0 80.7 80.7 2024 Chevrolet LCF Figure 11.7.1 Dimensions in inches Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 11. 8 4500XG Diesel Standard Cab - Right Side View WB 109 132.5 150 176 A 44.0 50.3 44.0 44.0 2024 Chevrolet LCF Figure 11.8.1 Dimensions in inches Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 11. 9 SCR / DPF 4HK1-TC Front of Chassis Outside edge of frame rail Figure 11.9.1 Outside edge of frame rail 2024 Chevrolet LCF Figure 11.9.2 Dimensions in inches Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 11. 10 RPO NL1 35 Gal. & ND5 55 Gal. Optional Side Fuel Tanks in addition to the Standard In Rail Fuel Tank RPO NH4 Side View 150 Wheelbase Figure 11.10.1 2024 Chevrolet LCF Figure 11.10.2 Dimensions in inches Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 11. 11 RPO NL1 35 Gal. & ND5 55 Gal. Optional Side Fuel Tanks in addition to the Standard In Rail Fuel Tank RPO NH4 Side View 176 Wheelbase Figure 11.11.1 2024 Chevrolet LCF Figure 11.11.2 Dimensions in inches Revision: 05/31/23 2024 Chevrolet Low Cab Forward RPO NL1 35 Gal. & ND5 55 Gal. Optional Side Fuel Tanks in place of the Standard In Rail Fuel Tank - T44003 ONLY Side View 176 Wheelbase PAGE 11. 12 2024 Chevrolet LCF Figure 11.12.1 Dimensions in inches Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 11. 13 Optional Side Fuel Tanks in addition to the Standard In Rail Fuel Tank RPO NH4 (150 and 176 WB, LH rail only) Optional Side Fuel Tanks replacing standard In Rail Fuel Tank (176 WB only, RH rail only) 2024 Chevrolet LCF Figure 11.13.1 Dimensions in inches Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 11. 14 Cab Tilt 2024 Chevrolet LCF Figure 11.14.1 Dimensions in inches Revision: 05/31/23 2024 Chevrolet Low Cab Forward TURNING DIAMETERS The LCF Diesel steering also features a 49.5 inside wheel cut angle. This, coupled with the integral power steering, makes the LCF Diesel an extremely maneuverable truck. B=Minimum turning diameter curb to curb C=Minimum turning diameter wall to wall VN60 C A B WB 109.0 132.0 150.0 176.0 B curb to curb 32.8 40.0 45.3 52.5 C (ft. wall to wall (ft.) 38.7 44.9 50.2 58.1 LCF Diesel Turning Circle Diagram Figure 11.15.1 PAGE 11. 15 2024 Chevrolet LCF Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 11. 16 Center of Gravity Horizontal and Vertical CG of Chassis WB 110 132.5 150 176 V 23.5 23.3 23.3 23.3 H in frame tank 38.4 44.9 49.9 57.2 H side tank N/A N/A N/A 52.5 Figure 11.16.1 The maximum vertical center of gravity specified below must not be exceeded at maximum GVWR and rated front and rear GAWR. The Center of Gravity (CG) maximum is 63" (1600 mm) above the ground. (LCF Cab Chassis and LCF Stripped Chassis) Figure 11.16.2 NOTE: The Final Manufacturer must ensure that the combined vertical center of gravity of the chassis, body, and available payload at full GVW does not exceed the maximum vertical center of gravity outlined in the Chevrolet LCF Incomplete Vehicle Document and the GM Body Builders Guide. The maximum dimensions for a body installed on the LCF chassis are 102 inches wide (outside*) by 91 inches high (inside). Any larger body applications must be approved by GM Upfitter Engineering. Contact us at GMUpfitter.com. * With 102 inches wide mirror brackets installed in place of standard mirror brackets Dimensions in inches 2024 Chevrolet LCF Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 11. 17 Front Axle Chart Formulas for calculating height dimensions: A = Tire Loaded Radius B C = Centerline of Axle to Top of Frame Rail at Curb Position D = Centerline of Axle to Top of Frame Rail at Design Load CH = C + Tire Unloaded Radius DH = D + Tire Loaded Radius Figure 11.17.1 Tire GVWR GAWR A B C D CH DH Track Tire Radius Unload Load 225/70R 19.5F 16,000 lbs. 6,630 lbs. 8.3 6.6 13 11.5 29 26.4 65.5 16 14.93 Figure 11.17.2 Dimensions in inches 2024 Chevrolet LCF Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 11. 18 Rear Axle Chart 2024 Chevrolet LCF Figure 11.18.1 Dimensions in inches Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 11. 19 Definitions Rear Frame Height: A Centerline of axle to bottom of axle bowl. DH Vertical distance between the normal top of frame rail and the ground-line through the centerline of the rear axle at design load. B Centerline of axle to top of frame rail at metal-to-metal position. DW Minimum distance between the inner surfaces of the rear tires. C Centerline of axle to top of frame rail at curb position. EW Maximum Rear Width: Overall width of the vehicle measured at the outermost surface of the rear tires. D Centerline of axle to top of frame rail at design load. Rear Tire Clearance: HH Minimum clearance between the rear axle and the ground-line. Rear Tire Clearance: Dual Tire Spacing: Minimum clearance required for tires and chain measured from the Distance between the centerlines of the minimum distance required for tire bounce E top of the frame at the vehicle centerline of the rear axle, when rear HW as measured from the centerline of the rear axle and the top of the rear tire when wheels on one side ride over a high spot. one wheel rides over a high spot. Rear Frame Height: Track Dual Rear Wheel Vehicle: CH Vertical distance between the normal top of frame rail and the CW Distance between the centerlines of the dual wheels measured at the ground-line. ground-line through the centerline of the rear axle at curb position. Tire Section, Tire Radius, Tire Loaded Radius, Tire Clearance See Chart for values. Figure 11.19.1 CW = Track CH = Tire loaded radius + C DH = Tire loaded radius + D DW = Track + 2 tire sections tire clearance EW = Track + 2 tire sections + tire clearance Formulas for Calculating Rear Width and Height Dimensions HH = Tire loaded radius A JH = KH B KH = Tire radius + 3.00 inches KW = DW 5.00 inches LW = 1.00-inch minimum clearance between tires and springs NOTE: Track and overall width may vary with optional equipment. Figure 11.19.2 Tire GAWR Track CW A 225/70R 19.5F 11,020 lbs. 65.0 7.7 B C 9.3 15.3 Figure 11.19.3 D E 13.4 8.4 Dimensions in inches 2024 Chevrolet LCF Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 11. 20 Tire and Disc Wheel Chart 4500XG Tire Tire Size 225/70R 19.5F Tire Load Limit and Cold Inflation Pressures Single Dual Lbs. PSI Lbs. PSI 3,315 85 3,115 90 Figure 11.20.1 Maximum Tire Load Limits (lbs.) Front Rear 2 Single 4 Dual 6,900 12,980 GVWR (Lbs.) 16,000 Tire Size 225/70R 19.5F GVWR (Lbs.) 16,000 Tire Radius Loaded Unloaded Front Rear Front Rear 14.93 14.98 16 16 Tire Section Width 8.7 Tire Clearance 1.3 Design Rim Width 6.0 Disc Wheel Wheel Size Bolt Holes 19.5 x 6.00 6 JIS *O.D. Wrench Sizes Bolt Circle Dia. 8.75 Ft./Rr. Nut Size* 1.6142 (41 mm) BUD HEX Figure 11.20.2 Rear Stud Size* 0.8268 (21 mm) SQUARE Nut/Stud Torque Specs. 325 ft.-lb. (440 N·m) Inner Circle Outside Disc Rim Type Material Mfg. Offset Thickeness 6.46 5.0 0.35 150 DC Steel TOPY Figure 11.20.3 2024 Chevrolet LCF Figure 11.20.4 Dimensions in inches Revision: 05/31/23 2024 Chevrolet Low Cab Forward 4500XG Suspension Deflection Charts 16,000 Ibs. 16,000 Ibs. PAGE 11. 21 Figure 11.21.1 2024 Chevrolet LCF Figure 11.21.2 Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 11. 22 Propeller Shaft Figure 11.22.1 Figure 11.22.2 WheelBase (in.) 109 132.5 150 176 Top View A B 3.4º - 0º 3.3º 0º 3.2º 0º 2.2º D 11.3º 5.3º 2.6º 2.1º Side View E Trans - 2.5º 7.7º 2.5º 8.0º 2.5º 5.6º 2.5º Rear Axle 2.7º 2.7º 2.7º 2.7º Figure 11.22.3 Notes: 1. Angles provided in table are relative to the frame angle. Please take this into consideration for service measurements. 2. Driveline angles are based on the chassis curb weight which includes standard equipment, fuel but no driver, body, or payload. 2024 Chevrolet LCF Revision: 05/31/23 2024 Chevrolet Low Cab Forward Propeller Shaft Trans. Type Wheelbase No. of Shafts Shaft #1 O.D. Thickness Length Type Shaft #2 O.D. Thickness Length Type Shaft #3 O.D. Thickness Length Type 109 1 3.54 0.126 35.7 A N/A N/A N/A N/A N/A N/A N/A N/A 6 Automatic. Transmission 132.5 150 2 2 3.54 3.54 0.126 0.126 22.91 40.24 B B 3.54 3.54 0.126 0.126 36.16 36.53 C C N/A N/A N/A N/A N/A N/A N/A N/A Type Description Figure 11.23.1 Illustration Type A 1st shaft in 1-piece driveline L Type B 1st shaft in 2-piece driveline L Type C 2nd shaft in 2-piece driveline L 2024 Chevrolet LCF Figure 11.23.2 11. 23 176 2 3.54 0.126 49.69 B 3.54 0.126 52.93 C N/A N/A N/A N/A Dimensions in inches Revision: 05/31/23 PAGE 2024 Chevrolet Low Cab Forward Brake System Diagram 16,000 GVW Vacuum Over Hydraulic Please refer to Introduction Section of book for antilock system cautions and wheelbase modification requirements. Legend for 3500, 3500HD, 4500, 4500HG, 4500XG Brake System (1) Electronic Hydraulic Control Unit (EHCU) (2) Rear Wheel Cylinder (3) Vacuum Pump (4) Check Valve (5) Exhaust Brake Valve (6) Magnetic Valve (7) Check Valve (One-way Valve) (8) Vacuum Tank (9) 4-Way Connector (10) With Metering Valve (11) W/O Metering Valve (12) Brake Fluid Reservoir (13) Electric Vacuum Pump (14) Master Cylinder (15) Vacuum Booster (Servo Unit) (16) Front Wheel Cylinder Figure 11.24.1 2024 Chevrolet LCF PAGE 11. 24 LNWC5AMF000201 Revision: 05/31/23 2024 Chevrolet Low Cab Forward PTO Location, Drive Gear and Opening Information PAGE 11. 25 Figure 11.25.1 Trans. Opening Bolt A BCD E F Location Pattern Aisin 465 Left (Dr 2) 12.35 36.89 0 7.85 7.31 2.50 H 5.16 PTO Drive Gear Location PTO Gear Ratio of PTO Drv. Gear Spd. to Eng. Spd. 1:1 with turbine No. of Teeth 69 Pitch N/A Helix Angle 0 Max. Output Torque 134 lbs.-ft. @ 1,700 RPM Figure 11.25.2 2024 Chevrolet LCF Revision: 05/31/23 2024 Chevrolet Low Cab Forward Opening Diagram Aisin A460 Automatic Torque Converter Lock Up Function In either the Stationary Preset PTO Mode or Stationary Variable PTO Mode, when engine rpm exceeds 1200 RPM, the torque converter will lock up. The engine rpm can not be modified and the lockup function cannot be turned off. Please not that with PTO applications that operate around 1200 RPM, the transmission software holds the torque converter in lockup until engine speed falls below 1100 RPM. The lock up function will cancel if the transmission shift lever is moved from the park or neutral positions which will remove the transmission from the stationary mode. 11. 26 Additional PTO Functions For certain applications the Automatic regeneration function can be inhibited (Example Airport Ground Support vehicles). For certain applications the Automatic regeneration function can be enabled in the PTO stationary mode (Example Lawn care and carpet cleaning). For certain applications the Automatic regeneration function can be enabled in the PTO mobile mode (Example Line painting). Please refer to the PTO section of the BBG (section 17) for further details. PAGE 2024 Chevrolet LCF Figure 11.26.1 Revision: 05/31/23 2024 Chevrolet Low Cab Forward In-Frame Diesel Fuel Fill Installation Instructions 1. Disconnect battery. 2. Loosen hose from the tie downs. Remove caps from plate on rail. 3. Install hoses onto the plate. 4. Extend hose out from the driver side of the rail to body rail. 5. The filler neck must be mounted to allow the fill plate bracket to be parallel to the frame horizontal. 6. Cover with protector wrap and secure with tie wraps. 7. Filler hose is set for 102 inches outside width body. 8. Filler neck (dimension A) must be between 6.85 inches and 8.5 inches above frame. 9. Secure the filler plate to the bottom of the body and check for leaks. 10. Ensure that fill hose does not sag, creating an area where the fuel could pool in the fill hose. 11. Reconnect battery. PAGE 11. 27 2024 Chevrolet LCF Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 11. 28 Rear View Fuel Fill Dimension: 6.75 - 8.5 inches (174-216mm) 2024 Chevrolet LCF Figure 11.28.1 Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 11. 29 Top View Fuel Fill Dimensions: B = 29.75 inches (756 mm) C = 34.00 inches (863 mm) D = 39.29 inches (998 mm) E = 33.86 inches (860 mm) F = 59.60 inches (1,514 mm) 2024 Chevrolet LCF Figure 11.29.1 Revision: 05/31/23 2024 Chevrolet Low Cab Forward Hose Modification for Various Width Bodies and Fuel Fill Vent Protection PAGE 11. 30 Figure 11.30.1 "A" Dimensions: 102 inch wide body remove 0 inches 96 inch wide body remove 3 inches 90 inch wide body remove 5 inches 86 inch wide body remove 8 inches 80 inch wide body remove 8 inches 2024 Chevrolet LCF "A" NOTE: Shorten hose by "A Dimension" based on chart at left. Figure 11.30.2 Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 11. 31 Ultra Low Sulfur Diesel Label 2024 Chevrolet LCF Figure 11.31.1 Revision: 05/31/23 2024 Chevrolet Low Cab Forward Through the Rail Fuel Fill Frame Hole PAGE 11. 32 2024 Chevrolet LCF Figure 11.32.1 End of Frame Dimensions in inches Revision: 05/31/23 2024 Chevrolet Low Cab Forward 4500XG Diesel Fuel Filler Kit Instructions PAGE 11. 33 Please review these instructions prior to installation of the fuel filler kit. Parts Kit: There is a parts kit for the Chevrolet LCF diesel products. Fuel filler kit shown below is used for 14,500 lb and higher GVWR chassis (3500HD, 4500HG, 4500XG, 5500HG, 5500XG). Parts list is shown in Figure 33.33.2. Parts photos are shown in Figure 11.33.1. ITEM # 1 2 3 4 5 6 7 8 9 10 11 12 13 FUEL FILLER KIT PART NAME HOSE: FUEL FILLER NECK HOSE: FUELFILLER CAP: FILLER HOSE: ROLL-OVER VALVE NECK ASM: FUEL FILLER CLIP: JOINT PROTECTOR: FILLER HOSE CLIP: BAND, HOSE FIXING CLIP: RUBBER, HOSE BRACKET: FILLER NECK SCREW: FILLER NECK CAUTION PLATE SHUTTER: FUEL TANK ** See Dealer for all part numbers. Figure 11.33.2 PART # ** ** ** ** ** ** ** ** ** ** ** ** ** QTY 1 1 1 1 1 4 1 2 1 1 3 1 1 Figure 11.33.1 2024 Chevrolet LCF Revision: 05/31/23 2024 Chevrolet Low Cab Forward Installation Instructions and Considerations PAGE 11. 34 The fuel tank shutter valve (13) is meant to improve fuel splash-back performance of the fuel system. This valve (13) is located on the inlet (outboard side) of the fuel filler neck bulkhead assemble that is bolted to the left hand frame rail as shown in Figure 11.34.1. This plastic valve snaps into place in the inlet of the frame mounted fuel pipe. The valve should be installed so that the plastic clip is at the top of the valve, so that the flap door opens up, as shown in Figure 11.34.2. Figure 11.34.1 The fuel filler hose should be installed flush against the tank. The clamp should be installed between 1/16"and 3/8" from the tank. This is shown in Figure 11.34.3 to the right. 2024 Chevrolet LCF Figure 11.34.2 Figure 11.34.3 Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 11. 35 Roll-Over Valve Tubing The roll-over valve has a hose attachment that will make this valve less sensitive to water intrusion. In order for the valve to work properly, it is critical that the hose be installed to the rollover valve. The proper assembly of the outer hose is shown in Figure 11.35.1. (1) Fuel Filler Hose Vent Hose (7) Protective Sleeve Figure 11.35.1 (4) Rollover Valve Hose Rollover Valve Filler Neck Installation The fuel filler neck (5) must be installed with the proper orientation on the body. The neck should be installed with the roll-over valve pointing upward, with the bottom edge of the neck oriented parallel to the ground, plus 33 to minus 7 degrees. See Figure 11.35.2 for the proper orientation. 2024 Chevrolet LCF Rollover Valve pointing upward Filler Neck Base Angle Installed to Horizontal +33o -7o Figure 11.35.2 Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 12. 1 5500HG Diesel - STD Cab Specifications Model GVWR WB Engine Model/Displacement HP (Gross) Torque (Gross) Equipment Transmission Steering Front Axle Suspension GAWR Rear Axle Suspension GAWR Wheels Tires Brakes Fuel Tank Frame Cab Equipment Electrical Options 5500HG - STD Cab 17,950 lbs. 109 in., 132.5 in., 150 in., 176 in., 200 in.* Isuzu 4-cylinder, in-line 4-cycle, turbocharged, intercooled, direct injection diesel. 4HK1-TC/317 CID (5.19 liters) 215HP/2500 RPM w/Automatic Transmission 452 lb ft torque/1850 RPM w/ Automatic Transmission Dry element air cleaner with vertical intake; 2 rows 564 square in2. radiator; 7 blade 20.1 in diameter fan with viscous drive. Cold weather starting device and an oil cooler. Engine oil level check. Engine warning system with audible warning for low oil pressure, high coolant temperature, and low coolant level. Engine cruise control function. Rear engine cover. Aisin A465 6 speed automatic transmission with fifth and sixth gear overdrive with lock up in 2nd, 3rd, 4th, 5th and 6th, PTO capability with automatic torque converter lockup in stationary PTO mode. Integral power steering 18.8-20.9:1 ratio. Tilt and telescoping steering column. Reverse Elliot I" -Beam rated at 6,830 lbs. Semi-elliptical steel alloy tapered leaf springs with stabilizer bar and shock absorbers. 6,830 lbs. Full floating single speed with hypoid gearing rated at 14,550 lbs. Semi-elliptical steel alloy multi-leaf springs and shock absorbers. 14,550 lbs. 19.5x6.0-K 6 hole disc wheels, painted white. 225/70R-19.5E (12 pr) LRR (Low Rolling Resistance) tubeless steel belted radials, all season tread front and rear. Dual circuit power assisted hydraulic service brakes with EBD (Electronic Brake Distribution) system for load proportioning of the brake system front disc and self-adjust outboard mounted drum rear. The parking brake is mechanical, cable actuated, internal expanding drum type, transmission mounted. The exhaust brake is standard and is vacuum operated. 4 channel antilock brake system. 30 gal. (Opt. 35 & 55 gal.) rectangular steel fuel tank mounted in frame rail behind rear axle. Fuel water separator with indicator light. Ladder type channel section straight frame rail 33.5 in wide through the total length of the frame. Yield strength 44,000 psi, section modulus 7.20 in3. RBM 316,800. All steel low cab forward, BBC 70.9 in, 45o mechanical tilt with torsion assist. TRICOT breathabke cloth covered high back driver's seat with two occupant passenger seat. Dual cab mounted exterior mirrors with integral convex mirror. Tilt and telescoping steering column. Power windows and door locks, floor mats, tinted glass. 12 Volt, negative ground, dual maintenance free batteries, 750 CCA each, 140 Amp alternator with integral regulator. See last page for options NOTE: These selected specifications are subject to change without notice. 2024 Chevrolet LCF Revision: 03/15/24 2024 Chevrolet Low Cab Forward PAGE 12. 2 Vehicle Weights, Dimensions and Ratings Figure 12.2.1 2024 Chevrolet LCF Figure 12.2.2 In-Frame Tank 17,950 lb. GVWR Automatic Transmission Model Chassis Curb and Maximum Payload Weights Model RPO WB Unit Front Rear Total Payload T51003 EB4 109.0 in lb. 4132 2357 6489 11461 T52003 FNJ 132.5 in lb. 4221 2361 6582 11368 T53003 FWH 150.0 in lb. 4286 2342 6628 11322 T54003 FNW 176.0 in lb. 4324 2362 6686 11264 T55003 EM2 200.0 in lb. 4487 2524 7011 10939 Side Mounted Tank 17,950 lb. GVWR Automatic Transmission Model Chassis Curb and Maximum Payload Weights Model RPO WB Unit Front Rear Total Payload T54003 FNW 176.0 in lb. 4458 2238 6696 11254 Vertical Exhaust Option Dimensions: Variable Chassis Dimensions: Unit WB EFF CA* EFF CE* OAL AF Inch 109.0 62.5 105.6 200.5 43.1 Inch 132.5 86.0 153.1 224.0 43.1 Inch 150.0 103.5 146.6 241.5 43.1 Inch 176.0 129.5 172.6 267.5 43.1 * Effective CA & CE listed are standard CA or CE less vertical exhaust BOC of 24 inches. Vertical Exhaust BOC = 24 inches Variable Chassis Dimensions: Unit WB CA* CE* OAL AF Inch 109.0 86.5 129.6 200.5 43.1 Inch 132.5 110.0 153.1 224.0 43.1 Inch 150.0 127.5 170.6 241.5 43.1 Inch 176.0 153.5 196.6 267.5 43.1 Inch 200.0 177.5 220.6 291.5 43.1 * Effective CA &CE are CA & CE less BOC Dimension Constants: Code Inches Code Inches AH 7.5 BW 83.3 AW 65.6 CW 65 BA 48.4 FW 33.5 BBC 70.7 OH 92.4 BOC 7.7 OW 81.3 FH 33.0 Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 12. 3 Vehicle Weight Limits: Vehicle Weight Limits GVWR Designed Maximum 17,950 lbs. GAWR, Front 6,830 lbs. GAWR, Rear 12,980 lbs. Technical Notes: Chassis Curb Weight reflects standard equipment and fuel but no driver or payload. Maximum Payload Weight is the allowed maximum for equipment, body, payload and driver and is calculated by subtracting chassis curb weight from the GVWR. NPV 9D2 9C2 9E2 ATG 9B9 AJG K05 KPG UIZ KQN DB6 G7M MTE KPK KPJ NLX PTO DB8 TBD 9W8 IX2 UL5 KQN UZF V22 2024 Chevrolet LCF Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 12. 4 Frame and Crossmember Specifications Wheelbase 109 132.5 150 176 200 Frame Thickness 0.24 0.24 0.24 0.24 0.24 B 28.3 28.3 28.3 28.3 28.3 2024 Chevrolet LCF Figure 12.4.1 Crossmember Type/Location C D E E2 F G 7.9 AA 46.5 - - CC 24.2 DD 33.8 7.9 AA 46.5 BB 57.5 - CC 24.2 DD 33.8 7.9 AA 46.5 BB 57.9 - CC 24.2 DD 33.8 7.9 AA 46.5 BB 74.4 - CC 24.2 DD 33.8 7.9 AA 46.5 BB 98.4 BB 74.4 CC 24.2 DD 33.8 Figure 12.4.2 Note: Dimensions in inches Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 12. 5 Frame Chart Wheelbase 109.0 132.5 150.0 176.0 200.0 2024 Chevrolet LCF Figure 12.5.1 Frame FL 182.5 206.1 223.8 249.8 273.8 Figure 12.5.2 Frame Thickness 0.24 0.24 0.24 0.24 0.24 Note: Dimensions in inches Revision: 05/31/23 2024 Chevrolet Low Cab Forward 5500HG Diesel Standard Cab Top View WB A B 109 43.4 78.0 132.5 49.7 84.3 150 43.4 78.0 176 43.4 78.0 200 43.4 78.0 PAGE 12. 6 2024 Chevrolet LCF Figure 12.6.1 Note: Dimensions in inches Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 12. 7 5500HG Diesel Standard Cab -Left Side View WB A 109 80.7 132.5 87.0 150 80.7 176 80.7 200 80.7 2024 Chevrolet LCF Figure 12.7.1 Note: Dimensions in inches Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 12. 8 5500HG Diesel Standard Cab Right Side View WB A 109 44.0 132.5 50.3 150 44.0 176 44.0 200 44.0 2024 Chevrolet LCF Figure 12.8.1 Note: Dimensions in inches Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 12. 9 SCR / DPF 4HK1-TC Front of Chassis Outside edge of frame rail Figure 12.9.1 Outside edge of frame rail 2024 Chevrolet LCF Figure 12.9.2 Note: Dimensions in inches Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 12. 10 RPO NL1 35 Gal. & ND5 55 Gal. Optional Side Fuel Tanks in addition to the Standard In Rail Fuel Tank RPO NH4 Side View 150 Wheelbase 2024 Chevrolet LCF Figure 12.10.1 Figure 12.10.2 Note: Dimensions in inches Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 12. 11 RPO NL1 35 Gal. & ND5 55 Gal. Optional Side Fuel Tanks in addition to the Standard In Rail Fuel Tank RPO NH4 Side View 176 Wheelbase 2024 Chevrolet LCF Figure 12.11.1 Figure 12.11.2 Note: Dimensions in inches Revision: 05/31/23 2024 Chevrolet Low Cab Forward Option Side Fuel Tank in place of the Standard In Rail Fuel Tank PAGE 12. 12 2024 Chevrolet LCF Figure 12.12.1 Note: Dimensions in inches Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 12. 13 Optional Side Fuel Tank in addition to the Standard In Rail Fuel tank RPO NH4 (150 and 176 wb LH rail only) Optional Side Fuel Tank replacing standard In Rail Fuel tank (176 wb only RH rail only) 2024 Chevrolet LCF Figure 12.13.1 Note: Dimensions in inches Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 12. 14 Cab Tilt 2024 Chevrolet LCF Figure 12.14.1 Note: Dimensions in inches Revision: 05/31/23 2024 Chevrolet Low Cab Forward Turning Diameters TURNING DIAMETERS The LCF Series Diesel steering also features a 46.50 inside wheel cut angle. This, coupled with the integral power steering, makes the LCF Series Diesel an extremely maneuverable truck. B=MINIMUM TURNING DIAMETER CURB TO CURB C=MINIMUM TURNING DIAMETER WALL TO WALL Turning Diameters (design value) WB 109.0 132.0 150.0 176.0 200.0 212.0 B curb to curb 32.8 40.0 45.3 52.5 61.0 66.0 C (ft. wall to wall (ft.) 38.7 44.9 50.2 58.1 67.2 73.0 12. 15 B C PAGE 2024 Chevrolet LCF Revision: 05/31/23 2024 Chevrolet Low Cab Forward Center of Gravity Center of Gravity The center of gravity of the chassis cab. Horizontal and Vertical CG of Chassis WB 109 132.5 150 176 200 V 23.5 23.3 23.3 23.3 23.3 H in frame tank 38.4 44.9 49.9 57.2 64.5 H side tank N/A N/A N/A 52.5 N/A Figure 12.16.1 PAGE 12. 16 The maximum vertical center of gravity specified be- low must not be exceeded at maximum GVWR and rated front and rear GAWR. The Center of Gravity (CG) maximum is 63" (1600 mm) above the ground. (LCF Cab Chassis and LCF Stripped Chassis). Figure 12.16.2 NOTE: The Final Manufacturer must ensure that the combined vertical center of gravity of the chassis, body, and available payload at full GVW does not exceed the maximum vertical center of gravity outlined in the Chevrolet LCF Incomplete Vehicle Document and the GM Body Builders Guide. The maximum dimensions for a body installed on the N Series chassis are 102 inches wide (outside*) by 91 inches high (inside). Any larger body applications must be approved by GM Upfitter Engineering. Contact us on gmupfitters.com. * With 102 inches wide mirror brackets installed in place of standard mirror brackets Note: Dimensions in inches 2024 Chevrolet LCF Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 12. 17 Front Axle Chart Figure 12.17.1 Formulas for calculating height dimensions: A = C = D = CH = DH = Tire Loaded Radius B Centerline of Axle to Top of Frame Rail at Curb Position Centerline of Axle to Top of Frame Rail at Design Load C + Tire Unloaded Radius D + Tire Loaded Radius Tire GVWR GAWR A B C 225/70R 19.5F 17,950 lbs. 6,830 lbs. 8.3 6.6 13 D CH 11.5 29 DH 26.4 Track 65.5 Tire Radius Unload Load 16 14.93 2024 Chevrolet LCF Figure 12.17.2 Note: Dimensions in inches Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 12. 18 Rear Axle Chart 2024 Chevrolet LCF Figure 12.18.1 Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 12. 19 Definitions Rear Frame Height: A Centerline of axle to bottom of axle bowl. DH Vertical distance between the normal top of frame rail and the ground-line through the centerline of the rear axle at design load. B Centerline of axle to top of frame rail at metal-to-metal position. DW Minimum distance between the inner surfaces of the rear tires. C Centerline of axle to top of frame rail at curb position. EW Maximum Rear Width: Overall width of the vehicle measured at the outermost surface of the rear tires. D Centerline of axle to top of frame rail at design load. Rear Tire Clearance: HH Minimum clearance between the rear axle and the ground-line. Rear Tire Clearance: Dual Tire Spacing: Minimum clearance required for tires and chain measured from the Distance between the centerlines of the minimum distance required for tire bounce E top of the frame at the vehicle centerline of the rear axle, when rear HW as measured from the centerline of the rear axle and the top of the rear tire when wheels on one side ride over a high spot. one wheel rides over a high spot. Rear Frame Height: Track Dual Rear Wheel Vehicle: CH Vertical distance between the normal top of frame rail and the CW Distance between the centerlines of the dual wheels measured at the ground-line. ground-line through the centerline of the rear axle at curb position. Tire Section, Tire Radius, Tire Loaded Radius, Tire Clearance See Chart for values. Figure 12.19.1 CW = Track CH = Tire loaded radius + C DH = Tire loaded radius + D DW = Track + 2 tire sections tire clearance EW = Track + 2 tire sections + tire clearance Formulas for Calculating Rear Width and Height Dimensions HH = Tire loaded radius A JH = KH B KH = Tire radius + 3.00 inches KW = DW 5.00 inches LW = 1.00-inch minimum clearance between tires and springs NOTE: Track and overall width may vary with optional equipment. Figure 12.19.2 Tire GAWR Track CW A 225/70R 19.5F 12,980 lbs. 65.0 7.7 B C 9.3 15.3 Figure 12.19.3 D E 13.4 8.4 Note: Dimensions in inches 2024 Chevrolet LCF Revision: 05/31/23 2024 Chevrolet Low Cab Forward 5500HG Suspension Deflection Charts PAGE 12. 20 2024 Chevrolet LCF Figure 12.20.1 Figure 12.20.2 Revision: 05/31/23 2024 Chevrolet Low Cab Forward Tire Tire Size 225/70R 19.5F Tire and Disc Wheel Chart Tire Load Limit and Cold Inflation Pressures Single Dual Lbs. PSI Lbs. PSI 3,450 90 3,245 90 Maximum Tire Load Limits (lbs.) Front Rear 2 Single 4 Dual 7,280 13,660 Figure 12.21.1 PAGE 12. 21 GVWR (Lbs.) 17,950 Tire Size 225/70R 19.5F GVWR (Lbs.) 17,950 Tire Radius Loaded Unloaded Front Rear Front Rear 14.91 14.96 16.00 16.00 Tire Section Width 8.7 Tire Clearance 1.3 Design Rim Width 6.0 Figure 12.21.2 Disc Wheel Wheel Size Bolt Holes 19.5 x 6.00 K 6 JIS *O.D. Wrench Sizes Bolt Circle Dia. 8.75 Ft./Rr. Nut Size* 1.6142 (41 mm) BUD HEX Rear Stud Size* 0.8268 (21 mm) SQUARE Nut/Stud Torque Specs. 325 ft.-lb. (440 N·m) Inner Circle 6.46 Outside Disc Rim Type Material Mfg. Offset Thickeness 5.0 0.35 50 DC Steel TOPY Figure 12.21.3 2024 Chevrolet LCF Figure 12.21.4 Note: Dimensions in inches Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 12. 22 Propeller Shaft 5500HG Figure 12.22.1 Figure 12.22.2 Figure 12.22.3 Wheelbase Top View (in.) A B C D Side View E F Trans Rear Axle 109 3.4º 132.5 0º 150 0º 176 0º 200 0º - - 11.3º - - 3.3º - 5.3º 7.7º - 3.2º - 2.6º 8.0º - 2.2º - 2.1º 5.6º - 0º 2.2º 2.1º 0.0º 5.6º 2.5º 2.7º 2.5º 2.7º 2.5º 2.7º 2.5º 2.7º 2.5º 2.7º Notes: 1. Angles privuded in table are relative to the frame angle. Please take this into consideration for service measurements. 2. Driveline angles are based on the chassis curb weight which includes standard equipment, fuel but no driver, body, or payl oad. 2024 Chevrolet LCF Revision: 05/31/23 2024 Chevrolet Low Cab Forward Automatic Transmission Trans. Type Wheelbase No. of Shafts Shaft #1 O.D. Thickness Length Type Shaft #2 O.D. Thickness Length Type Shaft #3 O.D. Thickness Length Type 109 1 3.54 0.126 35.7 A N/A N/A N/A N/A N/A N/A N/A N/A 6 Automatic. Transmission 132.5 150 2 2 3.54 3.54 0.126 0.126 22.91 40.24 B B 3.54 3.54 0.126 0.126 36.16 36.53 C C N/A N/A N/A N/A N/A N/A N/A N/A Figure 12.23.1 176 2 3.54 0.126 49.69 B 3.54 0.126 52.93 C N/A N/A N/A N/A Type Type A Type B Type C 2024 Chevrolet LCF Description 1st shaft in 1-piece driveline 1st shaft in 2-piece driveline 2nd shaft in 2-piece driveline Figure 12.23.2 Illustration L L L PAGE 12. 23 200 3 3.54 0.126 49.69 B 3.54 0.126 24.00 B 3.54 0.126 52.93 C Note: Dimensions in inches Revision: 05/31/23 2024 Chevrolet Low Cab Forward Brake System Diagram, Hydraulic Brake Booster Please refer to Introduction Section of book for antilock system cautions and wheelbase modification requirements. Legend for 5000HG, 5500XG Brake System (1) Electronic Hydraulic Control Unit (EHCU) (2) Rear Wheel Cylinder (3) Hydraulic Booster OilPump (4) Hydraulic BoosterReservoir (5) Cooler Pipe (6) Pipe Connector (7) Brake Fluid Reservoir (8) Master Cylinder (9) Hydraulic Booster Unit (10) Front Wheel Cylinder PAGE 12. 24 2024 Chevrolet LCF Figure 12.24.1 Revision: 05/31/23 2024 Chevrolet Low Cab Forward PTO Location, Drive Gear and Opening Information AUTOMATIC TRANSMISSION PAGE 12. 25 Figure 12.25.1 Trans. Aisin (1) Opening Bolt A B CD E F Location Pattern Left (Dr 2) 12.35 36.89 0 7.85 7.31 2.50 H 5.16 PTO Drive Gear Location PTO Gear Ratio of PTO Drv. Gear Spd. to Eng. Spd. 1:1 with turbine No. of Teeth 69 Pitch N/A Helix Angle 00 Max. Output Torque 134 lbs.-ft. @ 1,700 RPM Figure 12.25.2 2024 Chevrolet LCF Note: Dimensions in inches Revision: 05/31/23 2024 Chevrolet Low Cab Forward Opening Diagram Aisin A460 Automatic Torque Converter Lock Up Function. In either the Stationary Preset PTO Mode or Stationary Variable PTO Mode, when engine rpm exceeds 1200 RPM, the torque converter will lock up. The engine rpm can not be modified and the lockup function cannot be turned off. Please not that with PTO applications that operate around 1200 RPM, the transmission software holds the torque converter in lockup until engine speed falls below 1100 RPM The lock up function will cancel if the transmission shift lever is moved from the park or neutral positions which will remove the trasmission from the stationary mode. 12. 26 Additional PTO Functions For certain applications the Automatic regeneration function can be inhibited (Example Airport Ground Support vehicles ). For certain applications the Automatic regeneration function can be enabled in the PTO stationary mode (Example Lawn care and carpet cleaning). For certain applications the Automatic regeneration function can be enabled in the PTO mobile mode (Example Line painting). Please refer to the PTO section of the BBG (section 17) for further details. PAGE 2024 Chevrolet LCF Figure 12.26.1 Revision: 05/31/23 2024 Chevrolet Low Cab Forward Diesel Fuel Fill Installation Instructions 1. Disconnect battery. 2. Loosen hose from the tie downs. Remove caps from plate on rail. 3. Install hoses onto the plate. 4. Extend hose out from the driver side of the rail to body rail. 5. The filler neck must be mounted to allow the fill plate bracket to be parallel to the frame horizontal. 6. Cover with protector wrap and secure with tie wraps. 7. Filler hose is set for 102 inches outside width body. 8. Filler neck (dimension A) must be between 6.85 inches and 8.5 inches above frame. 9. Secure the filler plate to the bottom of the body and check for leaks. 10. Ensure that fill hose does not sag, creating an area where the fuel could pool in the fill hose. 11. Reconnect battery. PAGE 12. 27 2024 Chevrolet LCF Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 12. 28 Rear View Fuel Fill Dimension: 6.75 - 8.5 inches (174-216mm) 2024 Chevrolet LCF Figure 12.28.1 Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 12. 29 Top View Fuel Fill Dimensions: B = 29.75 inches (756 mm) C = 34.00 inches (863 mm) D = 39.29 inches (998 mm) E = 33.86 inches (860 mm) F = 59.60 inches (1,514mm) 2024 Chevrolet LCF Figure 12.29.1 Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 12. 30 Hose Modification for Various Width Bodies and Fuel Fill Vent Protection Figure 12.30.1 "A" Dimensions: 102 inch wide body remove 0 inches 96 inch wide body remove 3 inches 90 inch wide body remove 5 inches 86 inch wide body remove 8 inches 80 inch wide body remove 8 inches "A" NOTE: Shorten hose by "A Dimension" based on chart at left. Figure 12.30.2 2024 Chevrolet LCF Revision: 05/31/23 2024 Chevrolet Low Cab Forward Ultra Low Sulfur Diesel Label PAGE 12. 31 2024 Chevrolet LCF Figure 12.31.1 Revision: 05/31/23 2024 Chevrolet Low Cab Forward Through the Rail Fuel Fill Frame Hole PAGE 12. 32 2024 Chevrolet LCF Figure 12.32.1 Note: Dimensions in inches Revision: 05/31/23 2024 Chevrolet Low Cab Forward 5500HG-Diesel Fuel Filler Kit Instructions Please review these instructions prior to installation of the fuel filler kit. PARTS KIT: This a kit for the Chevrolet LCF diesel products. Fuel filler kit shown below is used for 14,500 lb and higher GVWR chassis 3500HD, 4500HG, 4500XG, 5500HG, 5500XG. Parts list is shown in FIGURE 12.31.2. Parts photos are shown in FIGURE 12.31.1. PAGE 12. 33 FUEL FILLER KIT ITEM # PART NAME PART # QTY 1 HOSE: FUEL FILLER NECK See Dealer 1 2 HOSE: FUEL FILLER 3 CAP: FILLER See Dealer 1 See Dealer 1 4 HOSE: ROLL-OVER VALVE See Dealer 1 5 NECK ASM: FUEL FILLER 6 CLIP: JOINT See Dealer 1 See Dealer 4 7 PROTECTOR: FILLER HOSE See Dealer 1 8 CLIP: BAND, HOSE FIXING See Dealer 2 9 CLIP: RUBBER, HOSE See Dealer 1 10 BRACKET: FILLER NECK See Dealer 1 11 SCREW: FILLER NECK 12 CAUTION PLATE See Dealer 3 See Dealer 1 13 SHUTTER: FUEL TANK See Dealer 1 Figure 12.33.2 Figure 12.33.1 2024 Chevrolet LCF Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 12. 34 Installation Instructions and Considerations: The fuel tank shutter valve (13) was a new component for 2011 model year. This component is meant to improve fuel splash-back performance of the fuel system. This valve (13) is on the inlet (outboard side) of the fuel filler neck bulkhead assemble that is bolted to the left hand frame rail as shown in FIGURE 12.34.1. This plastic valve snaps into place in the inlet of the frame mounted fuel pipe. The valve should be installed so that the plastic clip is at the top of the valve, so that the flap door opens up, as shown in FIGURES 12.34.2. UP Figure 12.34.1 Figure 12.34.2 The fuel filler hose should be installed flush against the tank. The clamp should be installed between 1/16"and 3/8" from the tank. This is shown in FIGURE 12.34.3 below. 2024 Chevrolet LCF Figure 12.34.3 Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 12. 35 Roll-Over Valve Tubing The roll-over valve has a hose attachment that will make this valve less sensitive to water intrusion. In order for the valve to work properly, it is critical that the hose be installed to the rollover valve. The proper assembly of the outer hose is shown in Figure 12.35.1. (1) Fuel Filler Hose Vent Hose (7) Protective Sleeve Figure 12.35.1 (4) Rollover Valve Hose Rollover Valve Filler Neck Installation: The fuel filler neck (5) must be installed with the proper orientation on the body. The neck should be installed with the roll-over valve pointing upward, with the bottom edge of the neck oriented parallel to the ground, plus 33 to minus 7 degrees. See Figure 12.35.2. for the proper orientation. 2024 Chevrolet LCF Rollover Valve pointing upward Filler Neck Base Angle Installed to Horizontal +33o -7o Figure 15.35.2 Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 13. 1 4500XG Diesel Specifications Model GVWR WB Engine Model/Displacement HP(Gross) Torque(Gross) Equipment Transmission Steering Front Axle Suspension GAWR Rear Axle Suspension GAWR Wheels Tires Brakes Fuel Tank Frame Cab Equipment Electrical Options 4500XG Diesel Crew Cab 16,000 lbs. 150 in, 176 in. Isuzu 4-cylinder, in-line 4-cycle, turbocharged, intercooled, direct injection diesel. 4HK1-TC/317 CID (5.19 liters) 215 HP @ 2,500 rpm 452 lb-ft torque @ 1,850 rpm Dry element air cleaner with vertical intake; 2 rows 564 square in2. radiator; 7 blade 20.1 in diameter fan with viscous drive. Cold weather starting device and an oil cooler. Engine oil level check. Engine warning system with audible warning for low oi l pressure, high coolant temperature, and low coolant level. Engine cruise control function. Aisin A465 6 speed automatic transmission with fifth and sixth gear overdrive with lock up in 2nd, 3rd, 4th, 5th and 6th, PTO capability automatic torque converter lockup in stationary PTO mode. Integral power steering 18.8-20.9:1 ratio. Tilt and telescoping steering column. Reverse Elliot "I"-Beam rated at 6,830 lbs. Semi-elliptical steel alloy tapered leaf springs with stabilizer bar and shock absorbers. 6,630 lbs. Full-floating single speed with hypoid gearing rated at 11,020 lb. Semi-elliptical steel alloy multi-leaf springs and shock absorbers. 11,020 lbs. 19.5 x 6.0-K 6-hole disc wheels, painted white. 225/70R-19.5F (12 ply) LRR (Low Rolling Resistance) tubeless steel-belted radials, all-season front and rear Dual circuit vacuum assisted hydraulic service brakes with EBD (Electronic Brake Distribution) system for load proportioning of the brake system front disc and self-adjust outboard mounted drum rear. The parking brake is a mechanical, cable actuated, internal expanding drum type, transmission mounted. The exhaust brake is standard and is vacuum operated. 4 channel anti-lock brake system. 30 gal. (Opt. 35 & 55 gal.) rectangular steel fuel tank mounted in frame rail behind rear axle. Fuel water separator with indicator light. Ladder type channel section straight frame rail 33.5 inches wide through the total length of the frame. Yield strength 44,000 psi, section modulus 11.89 in., RBM 523,160. All-steel 7 passenger low cab forward BBC 109.9 in. Tricot breathable cloth covered high back driver's seat with two occupant passenger seat. Four passenger rear bench seat. Dual cab mounted exterior mirrors with integral convex mirror. Tilt and telescoping steering column. Power windows and door locks, front floor mats, tinted glass. 12 Volt, negative ground, dual maintenance free batteries, 750 CCA each, 140 Amp alternator with integral regulator. See last page for options. NOTE: These selected specifications are subject to change without notice. 2024 Chevrolet LCF Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 13. 2 Vehicle Weights, Dimensions and Ratings Figure 13.2.2 4500XG Variable Chassis Dimensions: Unit WB CA* CE* OAL AF Inch 150 88.5 131.6 241.5 43.1 Inch 176 114.5 157.6 267.5 43.1 * Effective CA & CE are CA or CE less BOC. 4500XG Dimension Constants: Code Inches Code Inches AH 7.5 BW 83.3 AW 65.6 CW 65 BA 48.3 FW 33.5 BBC 109.9 OH 92.4 BOC 5.3 OW 81.3 FH 33.0 4500XG In-Frame Tank 16,000 lb. GVWR Automatic Transmission Model Chassis Cab and Maximum Payload Weights Model RPO WB Unit Front Rear Total T43043 EE3 150 in lb. 4610 2485 7095 T44043 FNR 176 in lb. 4683 2477 7160 Payload 8905 8840 2024 Chevrolet LCF Figure 13.2.2 Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 13. 3 Vehicle Weight Limits: 4500XG Vehicle Weight Limits GVWR Designed Maximum 16,000 lbs. GAWR, Front 6,630 lbs. GAWR, Rear 11,020 lbs. Technical Notes: Chassis Curb Weight includes standard equipment and fuel. Does not include driver, passenger, payload, body or special equipment. Maximum Payload Weight is the allowed maximum for equipment, body, payload, driver and passengers and is calculated by subtracting chassis curb weight from the GVWR. 9D2 9C2 9E2 ATG 9B9 K05 KPG UIZ KQ3 BD6 MTE KPK KPJ PTO DB8 TBD 9W8 IX2 UL5 KGN UZF V22 2024 Chevrolet LCF Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 13. 4 Frame and Crossmember Specifications Wheelbase Frame Thick B 150.0 0.24 28.3 176.0 0.24 28.3 2024 Chevrolet LCF Figure 13.4.1 Crossmember Type/Location C D E 7.9 AA 46..5 BB 57.9 7.9 AA 46.5 BB 74.4 Figure 13.4.2 F CC 24.2 CC 24.2 G DD 33.8 DD 33.8 Note: Dimensions in inches Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 13. 5 Frame Chart Wheelbase 150.0 176.0 2024 Chevrolet LCF Figure 13.5.1 Frame FL 223.8 249.8 Figure 13.5.2 Frame Thickness 0.24 + 0.18 0.24 + 0.18 Note: Dimensions in inches Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 13. 6 4500XG Diesel Standard Cab Top View Wb A B 150 67.0 101.6 176 76.5 111.1 2024 Chevrolet LCF Figure 13.6.1 Note: Dimensions in inches Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 13. 7 4500XG Diesel Standard Cab Left Side View WB A 150 104.3 176 113.8 2024 Chevrolet LCF Figure 13.7.1 Note: Dimensions in inches Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 13. 8 4500XG Diesel Standard Cab Right Side View WB A 150 67.6 176 77.1 2024 Chevrolet LCF Figure 13.8.1 Note: Dimensions in inches Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 13. 9 SCR / DPF 4HK1-TC Front of Chassis Outside edge of frame rail Figure 13.9.1 Outside edge of frame rail 2024 Chevrolet LCF Figure 13.9.2 Note: Dimensions in inches Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 13. 10 RPO NL1 35 Gal. & ND5 55 Gal. Optional Side Fuel Tanks in addition to the Standard In Rail Fuel Tank RPO NH4 Side View 176 Wheelbase 2024 Chevrolet LCF Figure 13.10.1 Figure 13.10.2 Note: Dimensions in inches Revision: 05/31/23 2024 Chevrolet Low Cab Forward CENTER OF GRAVITY 4500XG WB V H 150 25.3 50.9 176 25.3 58.8 PAGE 13. 11 Figure 13.11.1 The center of gravity of the completed vehicle with a full load should not exceed 63 inches above ground level for the 16,000 lbs. GVWR, and must be located horizontally between the centerlines of the front and rear axles. NOTE: The Final Manufacturer must ensure that the combined vertical center of gravity of the chassis, body, and available payload at full GVW does not exceed the maximum vertical center of gravity outlined in the Chevrolet LCF Incomplete Vehicle Document and the GM Body Builders Guide. The maximum dimensions for a body installed on the LCF chassis are 102 inches wide (outside*) by 91 inches high (inside). Any larger body applications must be approved by GM Upfitter Engineering. Contact us on gmupfitter.com. *With 102 inches wide mirror brackets installed in place of standard mirror brackets Note: Dimensions in inches 2024 Chevrolet LCF Revision: 05/31/23 2024 Chevrolet Low Cab Forward Turning Diameters TURNING DIAMETERS The LCF Series Diesel steering also features a 46.50 inside wheel cut angle. This, coupled with the integral power steering, makes the LCF Series Diesel an extremely maneuverable truck. B=MINIMUM TURNING DIAMETER CURB TO CURB C=MINIMUM TURNING DIAMETER WALL TO WALL 4500XG WB B CURB TO CURB 150.0 45.3 176.0 52.5 ß C (FT. WALL TO WALL (FT.) 50.2 58.1 13. 12 B C PAGE 2024 Chevrolet LCF Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 13. 13 Front Axle Chart 4500XG Figure 13.13.1 Formulas for calculating height dimensions: A = C = D = CH = DH = Tire Loaded Radius B Centerline of Axle to Top of Frame Rail at Curb Position Centerline of Axle to Top of Frame Rail at Design Load C + Tire Unloaded Radius D + Tire Loaded Radius Tire GVWR GAWR A B 225/70R 19.5F 16,000 lbs. 6,630 lbs. 8.6 6.6 C 12.3 D 11.5 Figure 13.13.2 CH 28.4 DH 26.7 Track 65.5 Tire Radius Unload Load 16.1 15.24 Note: Dimensions in inches 2024 Chevrolet LCF Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 13. 14 Rear Axle Chart 4500XG 2024 Chevrolet LCF Figure 13.14.1 Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 13. 15 Definitions Rear Frame Height: A Centerline of axle to bottom of axle bowl. DH Vertical distance between the normal top of frame rail and the ground-line through the centerline of the rear axle at design load. B Centerline of axle to top of frame rail at metal-to-metal position. DW Minimum distance between the inner surfaces of the rear tires. C Centerline of axle to top of frame rail at curb position. EW Maximum Rear Width: Overall width of the vehicle measured at the outermost surface of the rear tires. D Centerline of axle to top of frame rail at design load. Rear Tire Clearance: HH Minimum clearance between the rear axle and the ground-line. Rear Tire Clearance: Dual Tire Spacing: Minimum clearance required for tires and chain measured from the Distance between the centerlines of the minimum distance required for tire bounce E top of the frame at the vehicle centerline of the rear axle, when rear HW as measured from the centerline of the rear axle and the top of the rear tire when wheels on one side ride over a high spot. one wheel rides over a high spot. Rear Frame Height: Track Dual Rear Wheel Vehicle: CH Vertical distance between the normal top of frame rail and the CW Distance between the centerlines of the dual wheels measured at the ground-line. ground-line through the centerline of the rear axle at curb position. Tire Section, Tire Radius, Tire Loaded Radius, Tire Clearance See Chart for values. Figure 13.15.1 CW = Track CH = Tire loaded radius + C DH = Tire loaded radius + D DW = Track + 2 tire sections tire clearance EW = Track + 2 tire sections + tire clearance Formulas for Calculating Rear Width and Height Dimensions HH = Tire loaded radius A JH = KH B KH = Tire radius + 3.00 inches KW = DW 5.00 inches LW = 1.00-inch minimum clearance between tires and springs NOTE: Track and overall width may vary with optional equipment. Figure 13.15.2 Tire GAWR Track CW A 225/70R-19.5F 11,020 lbs. 65.0 7.7 B C 9.3 15.5 Figure 13.15.3 D E 13.4 8.4 Note: Dimensions in inches 2024 Chevrolet LCF Revision: 05/31/23 2024 Chevrolet Low Cab Forward 4500XG Suspension Deflection Charts PAGE 13. 16 2024 Chevrolet LCF Figure 13.16.1 Figure 13.16.2 Revision: 05/31/23 2024 Chevrolet Low Cab Forward Tire Tire Size 225/70R 19.5F Tire and Disc Wheel Chart 4500XG Tire Load Limit and Cold Inflation Pressures Single Dual Lbs. PSI Lbs. PSI 3,315 85 3,115 85 Maximum Tire Load Limits (lbs.) Front Rear 2 Single 4 Dual 6,630 12,460 PAGE 13. 17 GVWR (Lbs.) 16,000 Figure 13.17.1 Tire Size 225/70R 19.5F GVWR (Lbs.) 16,000 Tire Radius Loaded Unloaded Front Rear Front Rear 14.93 14.98 16 16 Figure 13.17.2 Tire Section Width 8.7 Tire Clearance 1.3 Design Rim Width 6.0 Disc Wheel Wheel Size Bolt Holes 19.5 x 6.00 6 JIS *O.D. Wrench Sizes Bolt Circle Dia. 8.75 Ft./Rr. Nut Size* 1.6142 (41 mm) BUD HEX Rear Stud Size* 0.8268 (21 mm) SQUARE Nut/Stud Torque Specs. Inner Circle 325 ft.-lb. (440 N·m) 6.46 Figure 13.17.3 Outside Disc Rim Type Material Mfg. Offset Thickeness 5.0 0.35 150 DC Steel TOPY 2024 Chevrolet LCF Figure 13.17.4 Note: Dimensions in inches Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 13. 18 Propeller Shaft 4500XG Figure 13.18.1 WheelBase (in.) 150 176 Top View A B 0º 2.7º 0º 1.8º Side View D E Trans Rear Axle 2.6º 8.0º 2.5º 2.5º 2.1º 5.4º 2.5º 2.5º Figure 13.18.2 NOTES 1. Angles privuded in table are relative to the frame angle. Please take this into consideration for service measurements. 2. Driveline angles are based on the chassis curb weight which includes standard equipment, fuel but no driver, body, or payload. 2024 Chevrolet LCF Revision: 05/31/23 2024 Chevrolet Low Cab Forward Automatic Transmission 4500XG PAGE 13. 19 Type Type B Type C 2024 Chevrolet LCF Description 1st shaft in 2-piece driveline 36.53 C Figure 13.19.1 2nd shaft in 2-piece driveline Figure 13.19.2 52.93 C Illustration L L Note: Dimensions in inches Revision: 05/31/23 2024 Chevrolet Low Cab Forward Brake System Diagram, 16,000 GVW Vacuum Over Hydraulic Please refer to introduction section of book for antilock system cautions and wheelbase modification requirements. Legend for 3500, 3500HD, 4500, 4500HG, 4500XG Brake System (1) Electronic Hydraulic Control Unit (EHCU) (2) Rear Wheel Cylinder (3) Vacuum Pump (4) Check Valve (5) Exhaust Brake Valve (6) Magnetic Valve (7) Check Valve (One-way Valve) (8) Vacuum Tank (9) 4-Way Connector (10) With Metering Valve (11) W/O Metering Valve (12) Brake Fluid Reservoir (13) Electric Vacuum Pump (14) Master Cylinder (15) Vacuum Booster (Servo Unit) (16) Front Wheel Cylinder 2024 Chevrolet LCF Figure 13.20.1 PAGE 13. 20 Revision: 05/31/23 2024 Chevrolet Low Cab Forward PTO Location, Drive Gear and Opening Information AUTOMATIC TRANSMISSION PAGE 13. 21 Figure 13.21.1 Trans. Aisin (1) Opening Bolt A B CD E F Location Pattern Left (Dr 2) 12.35 36.89 0 7.85 7.31 2.50 H 5.16 PTO Drive Gear Location PTO Gear Ratio of PTO Drv. Gear Spd. to Eng. Spd. 1:1 with turbine No. of Teeth 69 Pitch N/A Helix Angle 00 Max. Output Torque 134 lbs.-ft. @ 1,700 RPM Figure 13.21.2 2024 Chevrolet LCF Note: Dimensions in inches Revision: 05/31/23 2024 Chevrolet Low Cab Forward Opening Diagram Aisin A460 Automatic Torque Converter Lock Up Function. In either the Stationary Preset PTO Mode or Stationary Variable PTO Mode, when engine rpm exceeds 1200 RPM, the torque converter will lock up. The engine rpm can not be modified and the lockup function cannot be turned off. Please not that with PTO applications that operate around 1200 RPM, the transmission software holds the torque converter in lockup until engine speed falls below 1100 RPM The lock up function will cancel if the transmission shift lever is moved from the park or neutral positions which will remove the trasmission from the stationary mode. 13. 22 Additional PTO Functions For certain applications the Automatic regeneration function can be inhibited (Example Airport Ground Support vehicles ). For certain applications the Automatic regeneration function can be enabled in the PTO stationary mode (Example Lawn care and carpet cleaning). For certain applications the Automatic regeneration function can be enabled in the PTO mobile mode (Example Line painting). Please refer to the PTO section of the BBG (section 17) for further details. PAGE 2024 Chevrolet LCF Figure 13.22.1 Revision: 05/31/23 2024 Chevrolet Low Cab Forward Diesel Fuel Fill Installation Instructions 1. Disconnect battery. 2. Loosen hose from the tie downs. Remove caps from plate on rail. 3. Install hoses onto the plate. 4. Extend hose out from the driver side of the rail to body rail. 5. The filler neck must be mounted to allow the fill plate bracket to be parallel to the frame horizontal. 6. Cover with protector wrap and secure with tie wraps. 7. Filler hose is set for 102 inches outside width body. 8. Filler neck (dimension A) must be between 6.85 inches and 8.5 inches above frame. 9. Secure the filler plate to the bottom of the body and check for leaks. 10. Ensure that fill hose does not sag, creating an area where the fuel could pool in the fill hose. 11. Reconnect battery. PAGE 13. 23 2024 Chevrolet LCF Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 13. 24 Rear View Fuel Fill Dimension: 6.75 - 8.5 inches (174-216mm) 2024 Chevrolet LCF Figure 13.24.1 Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 13. 25 Top View Fuel Fill Dimensions: B = 29.75 inches (756 mm) C = 34.00 inches (863 mm) D = 39.29 inches (998 mm) E = 33.86 inches (860 mm) F = 59.60 inches (1,514mm) 2024 Chevrolet LCF Figure 13.25.1 Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 13. 26 Hose Modification for Various Width Bodies and Fuel Fill Vent Protection Figure 13.26.1 "A" Dimensions: 102 inch wide body remove 0 inches 96 inch wide body remove 3 inches 90 inch wide body remove 5 inches 86 inch wide body remove 8 inches 80 inch wide body remove 8 inches "A" NOTE: Shorten hose by "A Dimension" based on chart at left. 2024 Chevrolet LCF Figure 13.26.2 Revision: 05/31/23 2024 Chevrolet Low Cab Forward Ultra Low Sulfur Diesel Label PAGE 13. 27 2024 Chevrolet LCF Figure 13.27.1 Revision: 05/31/23 2024 Chevrolet Low Cab Forward Through the Rail Fuel Fill Frame Hole PAGE 13. 28 2024 Chevrolet LCF Figure 13.28.1 Note: Dimensions in inches Revision: 05/31/23 2024 Chevrolet Low Cab Forward 4500XG-Diesel Fuel Filler Kit Instructions Please review these instructions prior to installation of the fuel filler kit. PARTS KIT: This a kit for the Chevrolet LCF diesel products. Fuel filler kit shown below is used for 14,500 lb and higher GVWR chassis 3500HD, 4500HG, 4500XG, 5500HG, 5500XG. Parts list is shown in FIGURE 13.29.2. Parts photos are shown in FIGURE 13.29.1. PAGE 13. 29 FUEL FILLER KIT ITEM # PART NAME PART # QTY 1 HOSE: FUEL FILLER NECK See Dealer 1 2 HOSE: FUEL FILLER 3 CAP: FILLER See Dealer 1 See Dealer 1 4 HOSE: ROLL-OVER VALVE See Dealer 1 5 NECK ASM: FUEL FILLER 6 CLIP: JOINT See Dealer 1 See Dealer 4 7 PROTECTOR: FILLER HOSE See Dealer 1 8 CLIP: BAND, HOSE FIXING See Dealer 2 9 CLIP: RUBBER, HOSE See Dealer 1 10 BRACKET: FILLER NECK See Dealer 1 11 SCREW: FILLER NECK 12 CAUTION PLATE See Dealer 3 See Dealer 1 13 SHUTTER: FUEL TANK See Dealer 1 Figure 13.29.2 Figure 13.29.1 2024 Chevrolet LCF Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 13. 30 Installation Instructions and Considerations: The fuel tank shutter valve (13) is meant to improve fuel splash-back performance of the fuel system. This valve (13) is on the inlet (outboard side ) of the fuel filler neck bulkhead assemble that is bolted to the left hand frame rail as shown in Figure 13.30.1. This valve snaps into place in the inlet of the frame mounted fuel pipe. The valve should be installed so that the plastic clip is at the top of the valve, so that the flap door opens up, as shown in Figures 13.30.2. UP Figure 13.30.1 Figure 13.30.2 The fuel filler hose should be installed flush against the tank. The clamp should be installed between 1/16"and 3/8" from the tank. This is shown in Figure 13.30.3 below. 2024 Chevrolet LCF Figure 13.30.3 Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 13. 31 Roll-Over Valve Tubing The roll-over valve has a hose attachment that will make this valve less sensitive to water intrusion. In order for the valve to work properly, it is critical that the hose be installed to the rollover valve. The proper assembly of the outer hose is shown in Figure 13.31.1. (1) Fuel Filler Hose Vent Hose (7) Protective Sleeve Figure 13.31.1 (4) Rollover Valve Hose Rollover Valve Filler Neck Installation: The fuel filler neck (5) must be installed with the proper orientation on the body. The neck should be installed with the roll-over valve pointing upward, with the bottom edge of the neck oriented parallel to the ground, plus 33 to minus 7 degrees. See FIGURE 13.31.2. for the proper orientation. 2024 Chevrolet LCF Rollover Valve pointing upward Filler Neck Base Angle Installed to Horizontal +33o -7o Figure 13.31.2 Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 14. 1 4500HG, 5500HG Crew Cab Diesel Specifications Model GVWR WB Engine Model/Displacement HP(Gross) Torque(Gross) Equipment Transmission Steering Front Axle Suspension GAWR Rear Axle Suspension GAWR Wheels Tires Brakes Fuel Tank Frame Cab Equipment Electrical 4500HG Diesel Crew Cab 14,500 lbs. 150 in, 176 in. 5500HG Diesel Crew Cab 17,950 lbs. Isuzu 4-cylinder, in-line 4-cycle, turbocharged, intercooled, direct injection diesel. 4HK1-TC/317 CID (5.19 liters) 215 HP @ 2,500 rpm 452 lb-ft torque @ 1,850 rpm Dry element air cleaner with vertical intake; 2 rows 564 square in2. radiator; 7 blade 20.1 in diameter fan with viscous drive. Cold weather starting device and an oil cooler. Engine oil level check. Engine warning system with audible warning for low oi l pressure, high coolant temperature, and low coolant level. Engine cruise control function. Aisin A465 6 speed automatic transmission with fifth and sixth gear overdrive with lock up in 2nd, 3rd, 4th, 5th and 6th, PTO capability automatic torque converter lockup in stationary PTO mode. Integral power steering 18.8-20.9:1 ratio. Tilt and telescoping steering column. Reverse Elliot "I"-Beam rated at 6,830 lbs. Semi-elliptical steel alloy tapered leaf springs with stabilizer bar and shock absorbers. 6,830 lbs. 7,275 lbs. Full-floating single speed with hypoid gearing rated at 14,550 lb. Semi-elliptical steel alloy multi-leaf springs and shock absorbers. 11,020 lbs. 14,550 lbs. 16 x 6.0-K 6-hole disc wheels, painted white. 19.5 x 6.0-K 215/85R 16-E (10 pr) (LRR) Low Rolling Resistancetubeless steel-belted radials, all-season front and rear. 225/70R-19.5E (12 ply) Dual circuit vacuum assisted hydraulic service brakes with EBD (Electronic Brake Distribu- Dual circuit vacuum assisted hydraulic service brakes with EBD (Electronic Brake Distribu- tion) system for load proportioning of the brake system front disc and self-ad just outboard tion) system for load proportioning of Brakes the brake system front disc and self-adjust mounted drum rear. The parking brake is a mechanical, cable actuated, internal expanding outboard mounted drum rear. The parking brake is a mechanical, cable actuated, internal drum type, transmission mounted. The exhaust brake is standard and is vacuum operated. expanding drum type, transmission mounted. The exhaust brake is standard and is vacuum 4 channel anti-lock brake system operated. 4 channel anti-lock brake system 30 gal. (Opt. 35 & 55 gal.) rectangular steel fuel tank mounted in frame rail behind rear axle. Fuel water separator with indicator light. Ladder type channel section straight frame rail 33.5 inches wide through the total length of the frame. Yield strength 44,000 psi, section modulus 11.89 in., RBM 523,160. All-steel 7 passenger low cab forward BBC 109.9 in. Tricot breathable cloth covered high back driver's seat with two occupant passenger seat. Four passenger rear bench seat. Dual cab mounted exterior mirrors with integral convex mirror. Tilt and telescoping steering column. Power windows and door locks, front floor mats, tinted glass. 12 Volt, negative ground, dual maintenance free batteries, 750 CCA each, 140 Amp alternator with integral regulator. NOTE: These selected specifications are subject to change without notice. 2024 Chevrolet LCF Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 14. 2 Vehicle Weights, Dimensions and Ratings Figure 14.2.1 2024 Chevrolet LCF Figure 14.2.2 4500HG Variable Chassis Dimensions: Unit WB CA* CE* OAL AF Inch 150 88.5 131.6 241.5 43.1 Inch 176 114.5 157.6 267.5 43.1 * Effective CA & CE are CA or CE less BOC. 4500HG Dimension Constants: Code Inches Code Inches AH 7.5 BW 83.3 AW 65.6 CW 65 BA 48.3 FW 33.5 BBC 109.9 OH 90.8 BOC 5.3 OW 81.3 FH 31.1 4500HG In-Frame Tank 14,500 lb. GVWR Automatic Transmission Model Chassis Cab and Maximum Payload Weights Model RPO WB Unit Front Rear T33043 EE3 150.0 in lb. 4415 2253 T34043 FNR 176.0 in lb. 4491 2243 Total Payload 6668 7832 6734 7766 Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 14. 3 Vehicle Weights, Dimensions and Ratings Figure 14.3.1 2024 Chevrolet LCF Figure 14.3.2 5500HG Variable Chassis Dimensions: Unit WB CA* CE* OAL AF Inch 150 88.5 131.6 241.5 43.1 Inch 176 114.5 157.6 267.5 43.1 * Effective CA & CE are CA or CE less BOC. 5500HG Dimension Constants: Code Inches Code Inches AH 7.5 BW 83.3 AW 65.6 CW 65 BA 48.3 FW 33.5 BBC 109.9 OH 92.4 BOC 5.3 OW 81.3 FH 33.0 5500HG In-Frame Tank 17,950 lb. GVWR Automatic Transmission Model Chassis Cab and Maximum Payload Weights Model RPO WB Unit Front Rear Total Payload T53043 EE3 150 in lb. 4640 2562 7202 10748 T54043 FNR 176 in lb. 4714 2556 7270 10680 Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 14. 4 Vehicle Weight Limits: 4500HG Vehicle Weight Limits 5500HG GVWR Designed Maximum 14,500 lbs. 17,950 lbs. GAWR, Front 5,360 lbs. 6,380 lbs. GAWR, Rear 9,880 lbs. 12,980 lbs. Technical Notes: Chassis Curb Weight includes standard equipment and fuel. Does not include driver, passenger, payload, body or special equipment. Maximum Payload Weight is the allowed maximum for equipment, body, payload, driver and passengers and is calculated by subtracting chassis curb weight from the GVWR. 9D2 9D2 9C2 9C2 9E2 9E2 ATG ATG 9B9 9B9 K05 K05 KPG KPG UIZ UIZ KQN KQN DB6 DB6 MTE MTE KPK KPK KPJ KPJ PTO PTO DB8 DB8 TBD TBD 9W8 9W8 IX2 IX2 UL5 UL5 KQJ KQJ UZF UZF V22 V22 2024 Chevrolet LCF Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 14. 5 Frame and Crossmember Specifications Wheelbase 150.0 176.0 Frame Thick 0.24 0.24 B 28.3 28.3 2024 Chevrolet LCF Figure 14.5.1 Crossmember Type/Location C D E 7.9 AA 46..5 BB 57.9 7.9 AA 46.5 BB 74.4 Figure 14.5.2 F CC 24.2 CC 24.2 G DD 33.8 DD 33.8 Note: Dimensions in inches Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 14. 6 Frame Chart Wheelbase 150.0 176.0 2024 Chevrolet LCF Figure 14.6.1 Frame FL 223.8 249.8 Figure 14.6.2 Frame Thickness 0.24 + 0.18 0.24 + 0.18 Note: Dimensions in inches Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 14. 7 4500HG, 5500HG Diesel Standard Crew Cab Top View Wb A B 150 67.0 101.6 176 76.5 111.1 2024 Chevrolet LCF Figure 14.7.1 Note: Dimensions in inches Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 14. 8 4500HG, 5500HG Diesel Standard Crew Cab Left Side View WB A 150 104.3 176 113.8 2024 Chevrolet LCF Figure 14.8.1 Note: Dimensions in inches Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 14. 9 4500HG, 5500HG Diesel Standard Cab Right Side View WB A 150 67.6 176 77.1 2024 Chevrolet LCF Figure 14.9.1 Note: Dimensions in inches Revision: 05/31/23 2024 Chevrolet Low Cab Forward SCR / DPF 4HK1-TC Front of chassis Outside edge of frame rail PAGE 14. 10 Figure 14.10.1 Outside edge of frame rail 2024 Chevrolet LCF Figure 14.10.1 Note: Dimensions in inches Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 14. 11 RPO NL1 35 Gal. & ND5 55 Gal. Optional Side Fuel Tanks in addition to the Standard In Rail Fuel Tank RPO NH4 Side View 176 Wheelbase 2024 Chevrolet LCF Figure 14.11.1 Figure 14.11.2 Note: Dimensions in inches Revision: 05/31/23 2024 Chevrolet Low Cab Forward Center of Gravity 4500HG 14. 12 5500HG PAGE Figure 14.12.1 The center of gravity of the completed vehicle with a full load should not exceed 63 inches above ground level for the 14,500 lbs. and 17,950 lbs. GVWR, and must be located horizontally between the centerlines of the front and rear axles. NOTE: The Final Manufacturer must ensure that the combined vertical center of gravity of the chassis, body, and available payload at full GVW does not exceed the maximum vertical center of gravity outlined in the Chevrolet LCF Incomplete Vehicle Document and the GM Upfitter site. The maximum dimensions for a body installed on the LCF Series chassis are 102 inches wide (outside*) by 91 inches high (inside). Any larger body applications must be approved by GM Upfitter Engineering. Contact us on gmupfitter.com. * With 102 inches wide mirror brackets installed in place of standard mirror brackets 2024 Chevrolet LCF Note: Dimensions in inches Revision: 05/31/23 2024 Chevrolet Low Cab Forward Turning Diameters TURNING DIAMETERS The LCF Series Diesel steering also features a 46.50 inside wheel cut angle. This, coupled with the integral power steering, makes the LCF Series Diesel an extremely maneuverable truck. B=MINIMUM TURNING DIAMETER CURB TO CURB C=MINIMUM TURNING DIAMETER WALL TO WALL Turning Diameters (design value) WB 109.0 132.0 150.0 176.0 200.0 212.0 B curb to curb 32.8 40.0 45.3 52.5 61.0 66.0 C (ft. wall to wall (ft.) 38.7 44.9 50.2 58.1 67.2 73.0 14. 13 B C PAGE 2024 Chevrolet LCF Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 14. 14 Front Axle Chart 4500HG Figure 14.14.1 Formulas for calculating height dimensions: A = C = D = CH = DH = Tire Loaded Radius B Centerline of Axle to Top of Frame Rail at Curb Position Centerline of Axle to Top of Frame Rail at Design Load C + Tire Unloaded Radius D + Tire Loaded Radius Tire GVWR GAWR A B C 215/85R 16E 14,500 lbs. 5,360 lbs. 7.5 6.6 11.9 D 11.7 CH 26.5 DH 25.8 Track 65.5 Tire Radius Unload Load 14.6 14.1 2024 Chevrolet LCF Figure 14.14.2 Note: Dimensions in inches Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 14. 15 Front Axle Chart 5500HG Figure 14.15.1 Formulas for calculating height dimensions: A = C = D = CH = DH = Tire Loaded Radius B Centerline of Axle to Top of Frame Rail at Curb Position Centerline of Axle to Top of Frame Rail at Design Load C + Tire Unloaded Radius D + Tire Loaded Radius Tire GVWR GAWR A B C D CH DH Track Tire Radius Unload Load 225/70R 19.5F 17,950 lbs. 6,830 lbs. 8.6 6.6 12.3 11.5 28.4 26.7 65.5 16.1 15.24 Figure 14.15.2 Note: Dimensions in inches 2024 Chevrolet LCF Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 14. 16 Rear Axle Chart 4500HG 2024 Chevrolet LCF Figure 14.16.1 Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 14. 17 Definitions Rear Frame Height: A Centerline of axle to bottom of axle bowl. DH Vertical distance between the normal top of frame rail and the ground-line through the centerline of the rear axle at design load. B Centerline of axle to top of frame rail at metal-to-metal position. DW Minimum distance between the inner surfaces of the rear tires. C Centerline of axle to top of frame rail at curb position. EW Maximum Rear Width: Overall width of the vehicle measured at the outermost surface of the rear tires. D Centerline of axle to top of frame rail at design load. Rear Tire Clearance: HH Minimum clearance between the rear axle and the ground-line. Rear Tire Clearance: Dual Tire Spacing: Minimum clearance required for tires and chain measured from the Distance between the centerlines of the minimum distance required for tire bounce E top of the frame at the vehicle centerline of the rear axle, when rear HW as measured from the centerline of the rear axle and the top of the rear tire when wheels on one side ride over a high spot. one wheel rides over a high spot. Rear Frame Height: Track Dual Rear Wheel Vehicle: CH Vertical distance between the normal top of frame rail and the CW Distance between the centerlines of the dual wheels measured at the ground-line. ground-line through the centerline of the rear axle at curb position. Tire Section, Tire Radius, Tire Loaded Radius, Tire Clearance See Chart for values. Figure 14.17.1 CW = Track CH = Tire loaded radius + C DH = Tire loaded radius + D DW = Track + 2 tire sections tire clearance EW = Track + 2 tire sections + tire clearance Formulas for Calculating Rear Width and Height Dimensions HH = Tire loaded radius A JH = KH B KH = Tire radius + 3.00 inches KW = DW 5.00 inches LW = 1.00-inch minimum clearance between tires and springs NOTE: Track and overall width may vary with optional equipment. Figure 14.17.2 Tire GAWR Track CW A 215/85R-16E 9,880 lbs. 65.0 6.5 B C 9.3 15.3 Figure 14.17.3 D E 13.0 7.8 Note: Dimensions in inches 2024 Chevrolet LCF Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 14. 18 Rear Axle Chart 5500HG 2024 Chevrolet LCF Figure 14.18.1 Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 14. 19 Definitions Rear Frame Height: A Centerline of axle to bottom of axle bowl. DH Vertical distance between the normal top of frame rail and the ground-line through the centerline of the rear axle at design load. B Centerline of axle to top of frame rail at metal-to-metal position. DW Minimum distance between the inner surfaces of the rear tires. C Centerline of axle to top of frame rail at curb position. EW Maximum Rear Width: Overall width of the vehicle measured at the outermost surface of the rear tires. D Centerline of axle to top of frame rail at design load. Rear Tire Clearance: HH Minimum clearance between the rear axle and the ground-line. Rear Tire Clearance: Dual Tire Spacing: Minimum clearance required for tires and chain measured from the Distance between the centerlines of the minimum distance required for tire bounce E top of the frame at the vehicle centerline of the rear axle, when rear HW as measured from the centerline of the rear axle and the top of the rear tire when wheels on one side ride over a high spot. one wheel rides over a high spot. Rear Frame Height: Track Dual Rear Wheel Vehicle: CH Vertical distance between the normal top of frame rail and the CW Distance between the centerlines of the dual wheels measured at the ground-line. ground-line through the centerline of the rear axle at curb position. Tire Section, Tire Radius, Tire Loaded Radius, Tire Clearance See Chart for values. Figure 14.19.1 CW = Track CH = Tire loaded radius + C DH = Tire loaded radius + D DW = Track + 2 tire sections tire clearance EW = Track + 2 tire sections + tire clearance Formulas for Calculating Rear Width and Height Dimensions HH = Tire loaded radius A JH = KH B KH = Tire radius + 3.00 inches KW = DW 5.00 inches LW = 1.00-inch minimum clearance between tires and springs NOTE: Track and overall width may vary with optional equipment. Figure 14.19.2 Tire GAWR Track CW A 225/70R-19.5F 12,980 lbs. 65.0 7.7 B C 9.3 15.5 Figure 14.19.3 D E 13.4 8.4 Note: Dimensions in inches 2024 Chevrolet LCF Revision: 05/31/23 2024 Chevrolet Low Cab Forward 4500HG Suspension Deflection Charts PAGE 14. 20 2024 Chevrolet LCF Figure 14.20.1 Figure 14.20.2 Revision: 05/31/23 2024 Chevrolet Low Cab Forward 5500HG Suspension Deflection Charts PAGE 14. 21 2024 Chevrolet LCF Figure 14.21.1 Figure 14.21.2 Revision: 05/31/23 2024 Chevrolet Low Cab Forward Tire Tire Size 215/85R 16E Tire and Disc Wheel Chart 4500HG Tire Load Limit and Cold Inflation Pressures Single Dual Lbs. PSI Lbs. PSI 2,680 80 2,470 80 Maximum Tire Load Limits (lbs.) Front Rear 2 Single 4 Dual 5,360 9,880 PAGE 14. 22 GVWR (Lbs.) 14,500 Tire Size 215/85R 16E GVWR (Lbs.) 14,500 Figure 14.22.1 Front 14.1 Tire Radius Loaded Unloaded Rear Front Rear 14.1 14.6 14.6 Tire Section Width 8.2 Tire Clearance 18 Design Rim Width 6.0 Disc Wheel Wheel Size Bolt Holes 16.6 x 6 K 6 JIS *O.D. Wrench Sizes Bolt Circle Dia. 8.75 Ft./Rr. Nut Size· 1.6142 (41 mm) BUD HEX Figure 14.22.2 Rear Stud Size· 0.8268 (21 mm) SQUARE Nut/Stud Torque Specs. Inner Circle 289 ft.-lb. (392 N·m) 6.46 Figure 14.22.3 Outside Offset Disc Rim Type Thickness Material Mfg. 5.0 0.39 50 DC Steel TOPY 2024 Chevrolet LCF Figure 14.22.4 Note: Dimensions in inches Revision: 05/31/23 2024 Chevrolet Low Cab Forward Tire Tire Size 225/70R 19.5F Tire and Disc Wheel Chart 5500HG Tire Load Limit and Cold Inflation Pressures Single Dual Lbs. PSI Lbs. PSI 3,450 90 3,245 90 Maximum Tire Load Limits (lbs.) Front Rear 2 Single 4 Dual 6,900 12,980 PAGE 14. 23 GVWR (Lbs.) 17,950 Figure 14.23.1 Tire Size 225/70R 19.5F GVWR (Lbs.) 17,950 Tire Radius Loaded Unloaded Front Rear Front Rear 14.93 14.98 16 16 Tire Section Width 8.7 Tire Clearance 1.3 Design Rim Width 6.0 Disc Wheel Wheel Size Bolt Holes 19.5x 6.00 6 JIS *O.D. Wrench Sizes Bolt Circle Dia. 8.75 Ft./Rr. Nut Size· 1.6142 (41 mm) BUD HEX Figure 14.23.2 Rear Stud Size· 0.8268 (21 mm) SQUARE Nut/Stud Torque Specs. Inner Circle 325 ft.-lb. (440 N·m) 6.46 Figure 14.23.3 Outside Offset Disc Rim Type Thickness Material Mfg. 5.0 0.35 15 0 DC Steel TOPY 2024 Chevrolet LCF Figure 14.23.4 Note: Dimensions in inches Revision: 05/31/23 2024 Chevrolet Low Cab Forward Propeller Shaft 4500HG, 5500HG PAGE 14. 24 4500HG Figure 14.24.1 5500HG WheelBase Top View Side View (in.) A B D E Trans. Rear Axle WheelBase Top View Side View (in.) A B D E Trans. Rear Axle 150 0º 2.7º 2.6º 8.0º 2.5º 2.5º 176 0º 1.8º 2.1º 5.4º 2.5º 2.5º 150 0º 3.2º 2.6º 8.0º 2.5º 2.7º 176 0º 2.2º 2.1º 5.6º 2.5º 2.7º Figure 14.24.2 Figure 14.24.3 Note: 1. Angles provided in table are relative to the frame angle. Please take this into consideration for service measurements. 2. Driveline angles are based on the chassis curb weight which includes standard fuel but no driver, body, or payload 2024 Chevrolet LCF Revision: 05/31/23 2024 Chevrolet Low Cab Forward Automatic Transmission Trans. Type Wheel base 4500HG 6 Automatic Transmission 150 176 No. of Shafts Shaft #1 O.D. Thickness Length Type 2 3.25'' 0.0906'' 34.25'' B 2 3.25'' 0.0906'' 43.74'' B Shaft #2 O.D. Thickness Length Type 3.25'' 0.0906'' 34.17'' C 3.25'' 0.0906'' 50.71'' C Figure 14.25.1 Type Description 5500HG 36.53 C Figure 14.25.2 Illustration Type B 1st shaft in 2-piece driveline L PAGE 14. 25 52.93 C Type C 2nd shaft in 2-piece driveline L Figure 14.25.3 2024 Chevrolet LCF Revision: 05/31/23 2024 Chevrolet Low Cab Forward Brake System Diagram 14,500 GVW Vacuum Over Hydraulic Please refer to introduction section of book for antilock system cautions and wheelbase modification requirements. Legend for 3500, 3500HD, 4500, 4500HG, 4500XG (1) Electronic Hydraulic Control Unit (EHCU) (2) Rear Wheel Cylinder (3) Vacuum Pump (4) Check Valve (5) Exhaust Brake Valve (6) Magnetic Valve (7) Check Valve (One-way Valve) (8) Vacuum Tank (9) 4-Way Connector (10) With Metering Valve (11) W/O Metering Valve (12) Brake Fluid Reservoir (13) Electric Vacuum Pump (14) Master Cylinder (15) Vacuum Booster (Servo Unit) (16) Front Wheel Cylinder 2024 Chevrolet LCF Figure 14.26.1 PAGE 14. 26 Revision: 05/31/23 2024 Chevrolet Low Cab Forward Brake System Diagram 17,950 GVW Full Hydraulic Please refer to introduction section of book for antilock system cautions and wheelbase modification requirements. Legend for 5500HG, 5500XG Brake System (1) Electronic Hydraulic Control Unit (EHCU) (2) Rear Wheel Cylinder (3) Hydraulic Booster Oil Pump (4) Hydraulic Booster Reservoir (5) Cooler Pipe (6) Pipe Connector (7) Brake Fluid Reservoir (8) Master Cylinder (9) Hydraulic Booster Unit (10) Front Wheel Cylinder PAGE 14. 27 2024 Chevrolet LCF Figure 14.27.1 Revision: 05/31/23 2024 Chevrolet Low Cab Forward PTO Location, Drive Gear and Opening Information AUTOMATIC TRANSMISSION PAGE 14. 28 Figure 14.28.1 Trans. Aisin (1) Opening Bolt A B CD E F Location Pattern Left (Dr 2) 12.35 36.89 0 7.85 7.31 2.50 H 5.16 PTO Drive Gear Location PTO Gear Ratio of PTO Drv. Gear Spd. to Eng. Spd. 1:1 with turbine No. of Teeth 69 Pitch N/A Helix Angle 00 Max. Output Torque 134 lbs.-ft. @ 1,700 RPM Figure 14.28.2 2024 Chevrolet LCF Note: Dimensions in inches Revision: 05/31/23 2024 Chevrolet Low Cab Forward Opening Diagram Aisin A460 Automatic Torque Converter Lock Up Function. In either the Stationary Preset PTO Mode or Stationary Variable PTO Mode, when engine rpm exceeds 1200 RPM, the torque converter will lock up. The engine rpm can not be modified and the lockup function cannot be turned off. Please not that with PTO applications that operate around 1200 RPM, the transmission software holds the torque converter in lockup until engine speed falls below 1100 RPM The lock up function will cancel if the transmission shift lever is moved from the park or neutral positions which will remove the trasmission from the stationary mode. 14. 29 Additional PTO Functions For certain applications the Automatic regeneration function can be inhibited (Example Airport Ground Support vehicles ). For certain applications the Automatic regeneration function can be enabled in the PTO stationary mode (Example Lawn care and carpet cleaning). For certain applications the Automatic regeneration function can be enabled in the PTO mobile mode (Example Line painting). Please refer to the PTO section of the BBG (section 17) for further details. PAGE 2024 Chevrolet LCF Figure 14.29.1 Revision: 05/31/23 2024 Chevrolet Low Cab Forward Diesel Fuel Fill Installation Instructions 1. Disconnect battery. 2. Loosen hose from the tie downs. Remove caps from plate on rail. 3. Install hoses onto the plate. 4. Extend hose out from the driver side of the rail to body rail. 5. The filler neck must be mounted to allow the fill plate bracket to be parallel to the frame horizontal. 6. Cover with protector wrap and secure with tie wraps. 7. Filler hose is set for 102 inches outside width body. 8. Filler neck (dimension A) must be between 6.85 inches and 8.5 inches above frame. 9. Secure the filler plate to the bottom of the body and check for leaks. 10. Ensure that fill hose does not sag, creating an area where the fuel could pool in the fill hose. 11. Reconnect battery. PAGE 14. 30 2024 Chevrolet LCF Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 14. 31 Rear View Fuel Fill Dimension: 6.75 - 8.5 inches (174-216mm) 2024 Chevrolet LCF Figure 14.31.1 Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 14. 32 Top View Fuel Fill Dimensions: B = 29.75 inches (756 mm) C = 34.00 inches (863 mm) D = 39.29 inches (998 mm) E = 33.86 inches (860 mm) F = 59.60 inches (1,514mm) 2024 Chevrolet LCF Figure 14.32.1 Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 14. 33 Hose Modification for Various Width Bodies and Fuel Fill Vent Protection Figure 14.33.1 "A" Dimensions: 102 inch wide body remove 0 inches 96 inch wide body remove 3 inches 90 inch wide body remove 5 inches 86 inch wide body remove 8 inches 80 inch wide body remove 8 inches "A" NOTE: Shorten hose by "A Dimension" based on chart at left. Figure 14.33.2 2024 Chevrolet LCF Revision: 05/31/23 2024 Chevrolet Low Cab Forward Ultra Low Sulfur Diesel Label PAGE 14. 34 2024 Chevrolet LCF Figure 14.34.1 Revision: 05/31/23 2024 Chevrolet Low Cab Forward Through the Rail Fuel Fill Frame Hole PAGE 14. 35 2024 Chevrolet LCF Figure 14.35.1 Note: Dimensions in inches Revision: 05/31/23 2024 Chevrolet Low Cab Forward LCF-Diesel Fuel Filler Kit Instructions Please review these instructions prior to installation of the fuel filler kit. PARTS KIT: Fuel filler kit shown below is used for 14,500 lb and higher GVWR chassis 4500HG, 4500XG, 5500HG, 5500XG. Parts list is shown in Figure 14.36.2. Parts photos are shown in Figure 14.36.1. PAGE 14. 36 FUEL FILLER KIT ITEM # PART NAME PART # QTY 1 HOSE: FUEL FILLER NECK See Dealer 1 2 HOSE: FUEL FILLER 3 CAP: FILLER See Dealer 1 See Dealer 1 4 HOSE: ROLL-OVER VALVE See Dealer 1 5 NECK ASM: FUEL FILLER 6 CLIP: JOINT See Dealer 1 See Dealer 4 7 PROTECTOR: FILLER HOSE See Dealer 1 8 CLIP: BAND, HOSE FIXING See Dealer 2 9 CLIP: RUBBER, HOSE See Dealer 1 10 BRACKET: FILLER NECK See Dealer 1 11 SCREW: FILLER NECK 12 CAUTION PLATE See Dealer 3 See Dealer 1 13 SHUTTER: FUEL TANK See Dealer 1 Figure 14.36.2 Figure 14.36.1 2024 Chevrolet LCF Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 14. 37 Installation Instructions and Considerations: The fuel tank shutter valve (13) was a new component for 2011 model year. This component is meant to improve fuel splash-back performance of the fuel system. This valve (13) is on the inlet (outboard side ) of the fuel filler neck bulkhead assemble that is bolted to the left hand frame rail as shown in Figure 14.37.1. This plastic valve snaps into place in the inlet of the frame mounted fuel pipe. The valve should be installed so that the plastic clip is at the top of the valve, so that the flap door opens up, as shown in Figures 14.37.2. UP Figure 14.37.1 Figure 14.37.2 The fuel filler hose should be installed flush against the tank. The clamp should be installed between 1/16"and 3/8" from the tank. This is shown in Figure 14.37.3 below. 2024 Chevrolet LCF Figure 14.37.3 Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 14. 38 Roll-Over Valve Tubing The roll-over valve has a hose attachment that will make this valve less sensitive to water intrusion. In order for the valve to work properly, it is critical that the hose be installed to the rollover valve. The proper assembly of the outer hose is shown in FIGURE 14.38.1. (1) Fuel Filler Hose Vent Hose (7) Protective Sleeve Figure 14.38.1 (4) Rollover Valve Hose Rollover Valve Filler Neck Installation: The fuel filler neck (5) must be installed with the proper orientation on the body. The neck should be installed with the roll-over valve pointing upward, with the bottom edge of the neck oriented parallel to the ground, plus 33 to minus 7 degrees. See FIGURE 14.38.2. for the proper orientation. 2024 Chevrolet LCF Rollover Valve pointing upward Filler Neck Base Angle Installed to Horizontal +33o -7o Figure 14.38.2 Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 15. 1 5500XG Diesel - STD Cab Specification Model 5500XG - STD Cab GVWR 19,500 lbs. WB 109 in., 132.5 in., 150 in., 176 in., 200 in., 212 in Engine Isuzu 4-cylinder, in-line 4-cycle, turbocharged, intercooled, direct injection diesel. Model/Displacement 4HK1-TC/317 CID (5.19 liters) HP (Gross) 215 HP/2500 RPM w auto transmission Torque (Gross) 452 lb ft torque/1850 RPM w auto transmission Equipment Dry element air cleaner with vertical intake; 2 rows 564 square in. radiator; 7 blade 20.1in diameter fan with viscous drive. Cold weather starting device and an oil cooler. Engine oil level check switch and light. Engine warning system with audible warning for low oil pressure, high coolant temperature, and low coolant level. Engine cruise control function. Rear engine cover. Transmission Aisin A465 6 speed automatic transmission with fifth and sixth gear overdrive with lock up in 2nd, 3rd, 4th, 5th and 6th, PTO capability. Steering Integral power steering 18.8-20.9:1 ratio. Tilt and telescoping steering column. Front Axle Reverse Elliot "I" -Beam rated at 7,275 lbs. Suspension Semi-elliptical steel alloy tapered leaf springs with stabilizer bar and shock absorbers. GAWR 7,275 lbs. Rear Axle Full floating single speed with hypoid gearing rated at 14,550 lbs. Suspension Semi-elliptical steel alloy multi-leaf springs and shock absorbers. GAWR 14,550 lbs. Wheels 19.5x6.0-K 6 hole disc wheels, painted white. Tires 225/70R-19.5E (12 pr) LRR (Low Rolling Resistance) tubeless steel belted radials, all season tread front and rear. Brakes Dual circuit power assisted hydraulic service brakes with EBD (Electronic Brake Distribution) system for load proportioning of the brake system front disc and self-adjust outboard mounted drum rear. The parking brake is mechanical, cable actuated, internal expanding drum type, transmission mounted. The exhaust brake is standard and is vacum operated. 4 channell anti-lock brake system. Fuel Tank 30 gal. (Opt. 35 & 55 gal.) rect. steel fuel tank mounted in frame rail behind rear axle. Fuel water separator with dash mounted indicator light. Frame Ladder type channel section straight frame rail 33.5 in wide through the total length of the frame. Yield strength 44,000 psi, section modulus 7.20 in3. RBM 316,800. Cab All steel low cab forward, BBC 70.9 in, 45o mechanical tilt with torsion assist. TRICOT breathable cloth covered high back driver's seat with two occupant passenger seat. Equipment Dual cab mounted exterior mirrors with integral convex mirror. Tilt and telescoping steering column. Power windows and door locks, floor mats, tinted glass, AM/FM CD stereo radio. Electrical 12 Volt, negative ground, dual Delco maintenance free batteries, 750 CCA each, 140 Amp alternator with integral regulator. Options See last page for options. NOTE: These selected specifications are subject to change without notice. 2024 Chevrolet LCF Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 15. 2 Vehicle Weights, Dimensions and Ratings Figure 15.2.1 2024 Chevrolet LCF Figure 15.2.2 In-Frame Tank 19,500 lb. GVWR Automatic Transmission Model Chassis Curb and Maximum Payload Weights Eng. Mode RPO WB Unit Front T61003 EB4 109.0 in lb. 4145 T62003 FNJ 132.5 in lb. 4237 T63003 FWH 150.0 in lb. 4299 T64003 FNR 176.0 in lb. 4361 T65003 EMZ 200.0 in lb. 4524 T66003 EL5 212.0 in lb. 4534 Rear 2480 2484 2466 2463 2662 2672 Total Payload 6625 12875 6721 12779 6765 12735 6824 12676 7186 12314 7206 12294 Side Mounted Tank 19,500 lb. GVWR Automatic Transmission Model Chassis Curb and Maximum Payload Weights Model WB Unit Front Rear Total Payload NU4 176.0 in lb. 4496 2340 6836 12664 Vertical Exhaust Option Dimensions: Variable Chassis Dimensions: Unit WB EFF CA* EFF CE* OAL Inch 109.0 62.5 105.6 200.5 Inch 132.5 86.0 153.1 224.0 Inch 150.0 103.5 146.6 241.5 Inch 176.0 129.5 172.6 267.5 AF 43.1 43.1 43.1 43.1 * Effective CA & CE listed are standard CA or CE less vertical exhaust BOC of 24 inches. Vertical Exhaust BOC = 24 inches Variable Chassis Dimensions: Unit WB CA* CE* OAL AF Inch 109.0 86.5 129.6 200.5 43.1 Inch 132.5 110.0 153.1 224.0 43.1 Inch 150.0 127.5 170.6 241.5 43.1 Inch 176.0 153.5 196.6 267.5 43.1 Inch 200.0 177.5 220.6 291.5 43.1 Inch 212.0 189.5 232.6 303.5 43.1 * Effective CA & CE are CA or CE less BOC. Dimension Constants: Code Inches Code AH 7.5 BW AW 65.6 CW BA 48.3 FW BBC 70.7 OH BOC 7.7 OW FH 33.0 Inches 83.3 65 33.5 92.4 81.3 Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 15. 3 Truck Weight Limits: Truck Weight Limits GVWR Designed Maximum 19,500 lbs. GAWR, Front 7,275 lbs. GAWR, Rear 13,660 lbs. Technical Notes: Chassis Curb Weight reflects standard equipment and fuel, but no driver or payload. Maximum Payload Weight is the allowed maximum for equipment, body, payload and driver and is calculated by subtracting chassis curb weight from the GVWR NPV 9D2 9C2 9E2 AIG 9B9 15K K05 KPG UIZ KQN DB6 IF4 MTE KPK KPJ NLX PTO DB8 TBD 9W8 IX2 UL5 KQJ UZF V22 2024 Chevrolet LCF Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 15. 4 Frame and Crossmember Specifications Wheelbase 109 132.5 150 176 200 212 Frame Thickness 0.24 0.24 0.24 0.24 0.24 0.24 2024 Chevrolet LCF Figure 15.4.1 Crossmember Type/Location B C D 28.3 7.9 AA 46.5 28.3 7.9 AA 46.5 28.3 7.9 AA 46.5 28.3 7.9 AA 46.5 28.3 7.9 AA 46.5 28.3 7.9 AA 46.5 E - BB 57.5 BB 57.9 BB 74.4 BB 98.4 BB 110.4 Figure 15.4.2 E2 - - - - BB 74.4 BB 74.4 F CC 24.2 CC 24.2 CC 24.2 CC 24.2 CC 24.2 CC 24.2 G DD 33.8 DD 33.8 DD 33.8 DD 33.8 DD 33.8 DD 33.8 Note: Dimensions in inches Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 15. 5 Frame Chart Wheelbase 109.0 132.5 150.0 176.0 200.0 212.0 2024 Chevrolet LCF Figure 15.5.1 Frame FL 182.5 206.1 223.8 249.8 273.8 285.8 Figure 15.5.2 Frame Thickness 0.24 0.24 0.24 0.24 0.24 0.24 Note: Dimensions in inches Revision: 05/31/23 2024 Chevrolet Low Cab Forward 5500XG Diesel Standard Cab - Top View WB 109 132.5 150 176 200 212 A 43.4 49.7 43.4 43.4 43.4 43.4 B 78.0 84.3 78.0 78.0 78.0 78.0 PAGE 15. 6 2024 Chevrolet LCF Figure 15.6.1 Note: Dimensions in inches Revision: 05/31/23 2024 Chevrolet Low Cab Forward 5500XG Diesel Standard Cab - Left Side View WB A 109 80.7 132.5 87.0 150 80.7 176 80.7 200 80.7 212 80.7 PAGE 15. 7 2024 Chevrolet LCF Figure 15.7.1 Note: Dimensions in inches Revision: 05/31/23 2024 Chevrolet Low Cab Forward 5500XG Diesel Standard Cab - Right Side View WB A 109 44.0 132.5 50.3 150 44.0 176 44.0 200 44.0 212 44.0 PAGE 15. 8 2024 Chevrolet LCF Figure 15.8.1 Note: Dimensions in inches Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 15. 9 SCR / DPF 4HK1-TC Front of Chassis Outside edge of frame rail Outside edge of frame rail Figure 15.9.1 2024 Chevrolet LCF Figure 15.9.2 Note: Dimensions in inches Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 15. 10 RPO NL1 35 Gal. & ND5 55 Gal. Optional Side Fuel Tanks in addition to the Standard In Rail Fuel Tank RPO NH4 Side View 150 Wheelbase 2024 Chevrolet LCF Figure 15.10.1 Figure 15.10.2 Note: Dimensions in inches Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 15. 11 RPO NL1 35 Gal. & ND5 55 Gal. Optional Side Fuel Tanks in addition to the Standard In Rail Fuel Tank RPO NH4 Side View 176 Wheelbase Figure 15.11.1 Figure 15.11.1 2024 Chevrolet LCF Figure 15.11.2 Note: Dimensions in inches Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 15. 12 RPO NL1 35 Gal. & ND5 55 Gal. Optional Side Fuel Tanks in place of the Standard In Rail Fuel Tank on RPO NH4 Side View 176 Wheelbase 2024 Chevrolet LCF Figure 15.12.1 Note: Dimensions in inches Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 15. 13 RPO NL1 35 Gal. & ND5 55 Gal. Optional Side Fuel Tanks in addition to the Standard In Rail Fuel tank RPO NH4 (150 and 176 wb LH rail only) RPO NL1 35 Gal. & ND5 55 Gal. Optional Side Fuel Tanks replacing standard In Rail Fuel tank RPO NH4 (176 wb only RH rail only) 2024 Chevrolet LCF Figure 15.13.1 Note: Dimensions in inches Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 15. 14 Cab Tilt Figure 15.14.1 2024 Chevrolet LCF Figure 15.14.1 Note: Dimensions in inches Revision: 05/31/23 2024 Chevrolet Low Cab Forward Turning Diameters TURNING DIAMETERS The LCF Series Diesel steering also features a 46.50 inside wheel cut angle. This, coupled with the integral power steering, makes the LCF Series Diesel an extremely maneuverable truck. B=MINIMUM TURNING DIAMETER CURB TO CURB C=MINIMUM TURNING DIAMETER WALL TO WALL Turning Diameters (design value) WB 109.0 132.0 150.0 176.0 200.0 212.0 B curb to curb 32.8 40.0 45.3 52.5 61.0 66.0 C (ft. wall to wall (ft.) 38.7 44.9 50.2 58.1 67.2 73.0 15. 15 B C PAGE 2024 Chevrolet LCF Revision: 05/31/23 2024 Chevrolet Low Cab Forward Center of Gravity Center of Gravity The center of gravity of the chassis cab. Horizontal and Vertical CG of Chassis WB 110 132.5 150 176 200 212 V 23.4 23.3 23.4 23.4 23.4 23.2 H in frame tank 38 44.6 49.5 61.4 73.3 85.2 H side tank N/A N/A N/A 56.7 N/A N/A Figure 15.16.1 PAGE 15. 16 The maximum vertical center of gravity specified be- low must not be exceeded at maximum GVWR and rated front and rear GAWR. The Center of Gravity (CG) maximum is 63" (1600 mm) above the ground.(LCF Cab Chassis and LCF Stripped Chassis). Figure 15.16.2 NOTE: The Final Manufacturer must ensure that the combined vertical center of gravity of the chassis, body, and available payload at full GVW does not exceed the maximum vertical center of gravity outlined in the Chevrolet LCF Incomplete Vehicle Document and the GM Body Builders Guide. The maximum dimensions for a body installed on the N Series chassis are 102 inches wide (outside*) by 91 inches high (inside). Any larger body applications must be approved by GM Upfitters Engineering. Contact us on gmupfitter.com. Note: Dimensions in inches * With 102 inches wide mirror brackets installed in place of standard mirror brackets 2024 Chevrolet LCF Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 15. 17 Front Axle Chart Figure 15.17.1 Formulas for calculating height dimensions: A = C = D = CH = DH = Tire Loaded Radius B Centerline of Axle to Top of Frame Rail at Curb Position Centerline of Axle to Top of Frame Rail at Design Load C + Tire Unloaded Radius D + Tire Loaded Radius Tire GVWR GAWR A B 225/70R 19.5F 19,500 lbs. 7,275 lbs. 8.3 6.6 C 12.3 D 11.5 CH 28.3 DH 26.4 Track 65.5 Tire Radius Unload Load 16 14.91 2024 Chevrolet LCF Figure 15.17.2 Note: Dimensions in inches Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 15. 18 Rear Axle Chart 2024 Chevrolet LCF Figure 15.18.1 Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 15. 19 Definitions Definitions Rear Frame Height: A Centerline of axle to bottom of axle bowl. DH Vertical distance between the normal top of frame rail and the ground-line through the centerline of the rear axle at design load. B Centerline of axle to top of frame rail at metal-to-metal position. DW Minimum distance between the inner surfaces of the rear tires. C Centerline of axle to top of frame rail at curb position. EW Maximum Rear Width: Overall width of the vehicle measured at the outermost surface of the rear tires. D Centerline of axle to top of frame rail at design load. Rear Tire Clearance: HH Minimum clearance between the rear axle and the ground-line. Rear Tire Clearance: Dual Tire Spacing: Minimum clearance required for tires and chain measured from the HW Distance between the centerlines of the tires in a set of dual tires. E top of the frame at the vehicle centerline of the rear axle, when rear KW Tire Bounce Clearance: wheels on one side ride over a high spot. Minimum distance required for tire bounce as measured from the centerline of the rear axle and the top of the rear tire when one wheel rides over a high spot. Rear Frame Height: Track Dual Rear Wheel Vehicle: CH Vertical distance between the normal top of frame rail and the CW Distance between the centerlines of the dual wheels measured at the ground-line. ground-line through the centerline of the rear axle at curb position. Tire Section, Tire Radius, Tire Loaded Radius, Tire Clearance See Tire Chart for values. Figure 15.19.1 CW = Track CH = Tire loaded radius + C DH = Tire loaded radius + D DW = Track + 2 tire sections tire clearance EW = Track + 2 tire sections + tire clearance Formulas for Calculating Rear Width and Height Dimensions HH = Tire loaded radius A JH = KH B KH = Tire radius + 3.00 inches KW = DW 5.00 inches LW = 1.00-inch minimum clearance between tires and springs NOTE: Track and overall width may vary with optional equipment. Figure 15.19.2 Tire GAWR Track CW A 225/70R 19.5F 13,660 lbs. 65.0 7.7 B C 9.3 15.6 Figure 15.19.2 2024 Chevrolet LCF D E 13.4 8.4 Note: Dimensions in inches Revision: 05/31/23 2024 Chevrolet Low Cab Forward 5500XG Suspension Deflection Charts PAGE 15. 20 2024 Chevrolet LCF Figure 15.20.1 Figure 15.20.2 Revision: 05/31/23 2024 Chevrolet Low Cab Forward Tire Tire Size 225/70R 19.5F Tire and Disc Wheel Chart Tire Load Limit and Cold Inflation Pressures Single Dual Lbs. PSI Lbs. PSI 3,640 95 3,415 95 Maximum Tire Load Limits (Lbs.) Front Rear 2 Single 4 Dual 7,280 13,660 PAGE 15. 21 GVWR (Lbs.) 19,500 Tire Size 225/70R 19.5F GVWR (Lbs.) 19,500 Figure 15.21.1 Tire Radius Loaded Unloaded Front Rear Front Rear 14.91 14.96 16.00 16.00 Tire Section Width 8.7 Tire Clearance 1.3 Design Rim Width 6.0 Disc Wheel Wheel Size Bolt Holes 19.5 x 6.00 K 6 JIS Bolt Circle Dia. 8.75 *O.D. Wrench Sizes Ft./Rr. Nut Size* 1.6142 (41 mm) BUD HEX Figure 15.21.2 Rear Stud Size* 0.8268 (21 mm) SQUARE Nut/Stud Torque Specs. Inner Circle 325 ft.-lb. (440 N·m) 6.46 Figure 15.21.3 Outside Offset Disc Thickeness 5.0 0.35 Rim Type 150 DC Material Mfg. Steel TOPY 2024 Chevrolet LCF Figure 15.21.4 Note: Dimensions in inches Revision: 05/31/23 2024 Chevrolet Low Cab Forward Propeller Shaft 5500XG E G PAGE 15. 22 Figure 15.22.1 Figure 15.22.2 Figure 15.22.3 Wheel Base (in.) A 109 3.4º 132.5 0º 150 0º 176 0º 200 0º 212 0º Top View B C - - 3.3º - 3.2º - 2.2º - 0º 2.2º 0º 2.2º D 11.4º 5.3º 2.6º 2.1º 2.1º 2.1º Side View E F Trans. Rear Axle - - 2.5º 2.5º 7.8º - 2.5º 2.5º 8.1º - 2.5º 2.5º 5.6º - 2.5º 2.5º 0.0º 5.6º 2.5º 2.5º 0.0º 5.6º 2.5º 2.5º Note: 1. Angles provided in table are relative to the frame angle. Please take this into consideration for service measurements. 2. Driveline angles are based on the chassis curb weight which includes standard fuel but no driver, body, or payload. 2024 Chevrolet LCF Revision: 05/31/23 2024 Chevrolet Low Cab Forward Automatic Transmission Trans. Type Wheelbase No. of Shafts Shaft #1 O.D. Thickness Length Type Shaft #2 O.D. Thickness Length Type Shaft #3 O.D. Thickness Length Type 109 1 3.54 0.126 37.00 A N/A N/A N/A N/A N/A N/A N/A N/A 6 Automatic. Transmission 132.5 150 2 3.54 0.126 22.91 B 2 3.54 0.126 40.24 B 3.54 0.126 36.13 C 3.54 0.126 36.50 C N/A N/A N/A N/A N/A N/A N/A N/A Figure 15.23.1 176 2 3.54 0.126 49.69 B 3.54 0.126 52.90 C N/A N/A N/A N/A 200 2 3.54 0.126 49.69 B 3.54 0.126 24.00 B 3.54 0.126 52.90 C Type Description Illustration Type A 1st shaft in 1-piece driveline L Type B 1st shaft in 2-piece driveline L Type C 2nd shaft in 2-piece driveline L 2024 Chevrolet LCF Figure 15.23.2 PAGE 15. 23 212 2 3.54 0.126 49.69 B 3.54 0.126 36.00 B 3.54 0.126 52.90 C Note: Dimensions in inches Revision: 05/31/23 2024 Chevrolet Low Cab Forward Brake System Diagram, Hydraulic Brake Booster Please refer to Introduction Section of book for antilock system cautions and wheelbase modification requirements. Legend for 5000HG, 5500XG Brake System (1) Electronic Hydraulic Control Unit (EHCU) (2) Rear Wheel Cylinder (3) Hydraulic Booster OilPump (4) Hydraulic BoosterReservoir (5) Cooler Pipe (6) Pipe Connector (7) Brake Fluid Reservoir (8) Master Cylinder (9) Hydraulic Booster Unit (10) Front Wheel Cylinder PAGE 15. 24 2024 Chevrolet LCF Figure 15.24.1 Revision: 05/31/23 2024 Chevrolet Low Cab Forward PTO Location, Drive Gear and Opening Information AUTOMATIC TRANSMISSION PAGE 15. 25 Figure 15.25.1 Trans. Aisin (1) Opening Bolt A B CD E F Location Pattern Left (Dr 2) 12.35 36.89 0 7.85 7.31 2.50 H 5.16 PTO Drive Gear Location PTO Gear Ratio of PTO Drv. Gear Spd. to Eng. Spd. 1:1 with turbine No. of Teeth 69 Pitch N/A Helix Angle 00 Max. Output Torque 134 lbs.-ft. @ 1,700 RPM Figure 15.25.2 2024 Chevrolet LCF Note: Dimensions in inches Revision: 05/31/23 2024 Chevrolet Low Cab Forward Opening Diagram Aisin A460 Automatic Torque Converter Lock Up Function. In either the Stationary Preset PTO Mode or Stationary Variable PTO Mode, when engine rpm exceeds 1200 RPM, the torque converter will lock up. The engine rpm can not be modified and the lockup function cannot be turned off. Please not that with PTO applications that operate around 1200 RPM, the transmission software holds the torque converter in lockup until engine speed falls below 1100 RPM The lock up function will cancel if the transmission shift lever is moved from the park or neutral positions which will remove the trasmission from the stationary mode. 15. 26 Additional PTO Functions For certain applications the Automatic regeneration function can be inhibited (Example Airport Ground Support vehicles ). For certain applications the Automatic regeneration function can be enabled in the PTO stationary mode (Example Lawn care and carpet cleaning). For certain applications the Automatic regeneration function can be enabled in the PTO mobile mode (Example Line painting). Please refer to the PTO section of the BBG (section 17) for further details. PAGE 2024 Chevrolet LCF Figure 15.26.1 Revision: 05/31/23 2024 Chevrolet Low Cab Forward Diesel Fuel Fill Installation Instructions 1. Disconnect battery. 2. Loosen hose from the tie downs. Remove caps from plate on rail. 3. Install hoses onto the plate. 4. Extend hose out from the driver side of the rail to body rail. 5. The filler neck must be mounted to allow the fill plate bracket to be parallel to the frame horizontal. 6. Cover with protector wrap and secure with tie wraps. 7. Filler hose is set for 102 inches outside width body. 8. Filler neck (dimension A) must be between 6.85 inches and 8.5 inches above frame. 9. Secure the filler plate to the bottom of the body and check for leaks. 10. Ensure that fill hose does not sag, creating an area where the fuel could pool in the fill hose. 11. Reconnect battery. PAGE 15. 27 2024 Chevrolet LCF Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 15. 28 Rear View Fuel Fill Dimension: 6.75 - 8.5 inches (174-216mm) 2024 Chevrolet LCF Figure 15.28.1 Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 15. 29 Top View Fuel Fill Dimensions: B = 29.75 inches (756 mm) C = 34.00 inches (863 mm) D = 39.29 inches (998 mm) E = 33.86 inches (860 mm) F = 59.60 inches (1,514mm) 2024 Chevrolet LCF Figure 15.29.1 Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 15. 30 Hose Modification for Various Width Bodies and Fuel Fill Vent Protection Figure 15.30.1 "A" Dimensions: 102 inch wide body remove 0 inches 96 inch wide body remove 3 inches 90 inch wide body remove 5 inches 86 inch wide body remove 8 inches 80 inch wide body remove 8 inches "A" NOTE: Shorten hose by "A Dimension" based on chart at left. Figure 15.30.2 2024 Chevrolet LCF Revision: 05/31/23 2024 Chevrolet Low Cab Forward Ultra Low Sulfur Diesel Label PAGE 15. 31 2024 Chevrolet LCF Figure 15.31.1 Revision: 05/31/23 2024 Chevrolet Low Cab Forward Through the Rail Fuel Fill Frame Hole PAGE 15. 32 2024 Chevrolet LCF Figure 15.32.1 Note: Dimensions in inches Revision: 05/31/23 2024 Chevrolet Low Cab Forward LCF-Diesel Fuel Filler Kit Instructions Please review these instructions prior to installation of the fuel filler kit. PARTS KIT: Fuel filler kit shown below is used for 14,500 lb and higher GVWR chassis 4500HG, 4500XG, 5500HG, 5500XG. Parts list is shown in FIGURE 15.32.2. Parts photos are shown in FIGURE 15.32.1. PAGE 15. 33 FUEL FILLER KIT ITEM # PART NAME PART # QTY 1 HOSE: FUEL FILLER NECK See Dealer 1 2 HOSE: FUEL FILLER 3 CAP: FILLER See Dealer 1 See Dealer 1 4 HOSE: ROLL-OVER VALVE See Dealer 1 5 NECK ASM: FUEL FILLER 6 CLIP: JOINT See Dealer 1 See Dealer 4 7 PROTECTOR: FILLER HOSE See Dealer 1 8 CLIP: BAND, HOSE FIXING See Dealer 2 9 CLIP: RUBBER, HOSE See Dealer 1 10 BRACKET: FILLER NECK See Dealer 1 11 SCREW: FILLER NECK 12 CAUTION PLATE See Dealer 3 See Dealer 1 13 SHUTTER: FUEL TANK See Dealer 1 Figure 15.33.2 Figure 15.33.1 2024 Chevrolet LCF Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 15. 34 Installation Instructions and Considerations: The fuel tank shutter valve (13) is meant to improve fuel splash-back performance of the fuel system. This valve (13) is relocated on the fuel tank inlet to the inlet (outboard side ) of the fuel filler neck bulkhead assemble that is bolted to the left hand frame rail as shown in FIGURE 15.34.1. This plastic valve snaps into place in the inlet of the frame mounted fuel pipe. The valve should be installed so that the plastic clip is at the top of the valve, so that the flap door opens up, as shown in FIGURE 15.34.2. UP Figure 15.34.1 Figure 15.34.2 The fuel filler hose should be installed flush against the tank. The clamp should be installed between 1/16"and 3/8" from the tank. This is shown in FIGURE 15.34.3 below. 2024 Chevrolet LCF Figure 15.34.3 Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 15. 35 Roll-Over Valve Tubing The roll-over valve has a hose attachment that will make this valve less sensitive to water intrusion. In order for the valve to work properly, it is critical that the hose be installed to the rollover valve. The proper assembly of the outer hose is shown in FIGURE 15.35.1. (1) Fuel Filler Hose Vent Hose (7) Protective Sleeve Figure 15.35.1 (4) Rollover Valve Hose Rollover Valve Filler Neck Installation: The fuel filler neck (5) must be installed with the proper orientation on the body. The neck should be installed with the roll-over valve pointing upward, with the bottom edge of the neck oriented parallel to the ground, plus 33 to minus 7 degrees. See FIGURE 15.35.2. for the proper orientation. 2024 Chevrolet LCF Rollover Valve pointing upward Filler Neck Base Angle Installed to Horizontal +33o -7o Figure 15.35.2 Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 16. 1 Vertical Exhaust LCF Diesel Only Chevrolet LCF 16MY Vertical Exhaust 16MY = Orange 2024 Chevrolet LCF · Available on 4500HG, 4500XG, 5500HG, 5500XG · Vertical exhaust is available on 109, 132.5, 150, 176, 200, and 212 inch wheelbases · Option Code NPV · Not available with 6.0L Gas Engine · Available as a port installed option only · Available with Automatic transmission only · Available with in rail fuel tank only · Available with single cab only Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 16.2 DRAWING TO COME 2024 Chevrolet LCF Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 17. 1 Single Cab Side View 2024 Chevrolet LCF Figure 17.1.1 Dimensions in inches Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 17. 2 Single Cab Front View 2024 Chevrolet LCF Figure 17.2.1 Dimensions in inches Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 17. 3 Single Cab Rear View Note: Top of window to top of roof 7.64 inches Top of window to cab top of roof lights 9.64 inches 2024 Chevrolet LCF Figure 17.3.1 Dimensions in inches Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 17. 4 Crew Cab Cab Side View 2024 Chevrolet LCF Figure 17.4.1 Dimensions in inches Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 17. 5 Crew Cab Front View 2024 Chevrolet LCF Figure 17.5.1 Dimensions in inches Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 17. 6 Crew Cab Rear View 2024 Chevrolet LCF Figure 17.6.1 Dimensions in inches Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 17. 7 Single Cab - Front and Side View (Air Shield on Single Cab only) 2024 Chevrolet LCF Figure 17.7.1 Dimensions in inches Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 18.1 6500XD/7500XD Diesel Specifications Model GVWR/GCWR WB Engine Model/Displacement HP (Gross) Torque (Gross) Equipment Transmission Steering Front GAWR Front Axle Front Suspension Rear GAWR Rear Axle Rear Suspension Wheels Tires Brakes Fuel Tank Frame Cab Cab Equipment Electrical Options 6500XD/7500XD 25,950 lbs. / 33,000 lbs. 152 in., 170 in., 188 in., 200 in., 212 in., 224 in., 236 in., 248 in. Cummins 6-cylinder, in-line 4-cycle, Turbocharged, Intercooled, Direct injection diesel. B6.7-TC / 409 CID (6.71 liters) 260 HP at 2100 RPM 660 ft-lb. torque with automatic transmission Dry element air cleaner with vertical intake; 2 rows 679 in 2 radiator; 9 blade 20.1in diameter fan with viscous drive. Cold weather starting device and an oil cooler. Engine oil level check switch and light. Engine warning system with audible warning for lo w oil pressure, high coolant temperature, and low coolant level. Engine cruise control function, coolant temperature, and low coolant level. Engine cruise control function. Allison 2550 RDS 6 speed automatic transmission. A single PTO opening on the left hand side of the transmission with a maximum torque value of 250 lb-ft. Integral power steering. Tilt and Telescoping steering column. Steering ratio of 22.4:1 12,000 lbs. Dana E-1254W reverse Elliot "I"-Beam type steer axle rated at 12,000 lbs. Semi-elliptical steel alloy tapered leaf springs with stabilizer bar and shock absorbers, rated at 12,000 lbs. 19,000 lbs. / 21,000 lbs. Dana S19-140 single-speed, 21,000 lbs. capacity drive axle. Semi-elliptical steel alloy multi-leaf springs rated at 21,000 lbs. / 21,000 lbs. Air spring suspension with single leveling valve, dual shock absorbers, and an in cab dump/fill switch rated at 23,000 lbs. 22.5 x 8.25 inch 10 hole disc wheels Low rolling resistance tubeless steel belted radials, premium highway tread front tread and premium highway traction rear tre ad. Dual circuit S-CAM drum air service brakes with 4 channel anti-lock brake system. An air operated exhaust brake, air controlled parking brake, heated air dryer, and automatic slack adjusters are standard. 50 / 100 gal. 6500XD / 100-gal.-7500XD rectangular aluminum fuel tank mounted on left hand frame. Includes a fuel water separator with indicator light. Ladder type channel section straight frame rail, 33.5 in wide along the total length of the frame. Yield strength 80,000 psi; Section Modulus 12.69 cub. In, RBM 1,015,000 lb-in All steel low cab forward, BBC 81.5 in, 45 degree mechanical tilt with torsion assist. TRICOT breathable cloth covered high back air ride driver's seat with rigid passenger seat and center seat with fold down ba ck. Dual cab mounted exterior mirrors with integral convex mirror. Tilt and telescoping steering column. Power windows and door locks, floor mats, tinted glass, AM/FM/CD stereo radio with Bluetooth. Rear body dome lamp switch. 12 Volt, negative ground, dual maintenance free batteries with threaded posts, 750 CCA each, 140 Amp alternator with integral regulator. See page 6 for options NOTE: These selected specifications are subject to change without notice. 2024 Chevrolet LCF Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 18.2 Vehicle Weights, Dimensions and Ratings Multi-Leaf Suspension Figure 1 CHASSIS DIMENSIONS (in) MODEL WB CA[1] CE[2] AF MT1 152 127 192.9 65.9 MT2 170 145 220 75 MT3 188 163 247 84.1 MT4 200 175 264.9 90 MT5 212 187 283.1 96.1 MT6 224 199 301 102 MT7 236 211 319.1 108.1 MT8 248 223 337 114 DIMENSION CONSTANTS (in) AW = Front axle track BA = Front bumper to centerline of axle BBC = Bumper to back of cab BOC = Back of cab clearance BW = Overall width across rear axle CW = Rear axle track FW = Frame width OW = Overall width across cab (without mirrors) DIMENSIONS BY TIRE SIZE (in.) AH = Ground to bottom of axle FH = Frame height (unladen) at E.O.F.[3] FH = Frame height (unladen) at R/A[4] FH = Frame height (laden) at R/A[5] OH = Overall height (without clearance lights) FL 270.5 297.6 324.6 342.5 360.6 378.5 396.7 414.6 OAL 274.4 301.5 328.5 346.4 364.6 382.5 400.6 418.5 11R22.5G 10 42.5 41 37.5 112 81.1 56.5 81.5 10.4 96 72.2 33.5 93.5 255/70R22.5H 7.7 39.9 39.2 36.4 110.2 Notes: [1] Effective CA is CA less BOC. [2] Effective CE is CE less BOC. [3] Measured at the end of the frame from the top of the frame to the ground at curb weight. [4] Measured at the rear axle from the top of the frame to the ground with the chassis at curb [5] Measured at the rear axle from the top of the frame to the ground with the chassis loaded to GV WR. Figure 2 2024 Chevrolet LCF Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 18.3 Vehicle Weights, Dimensions and Ratings Air Spring Suspension Figure 3 CHASSIS DIMENSIONS (in) MODEL WB CA[1] CE[2] AF MT1 152 127 192.9 65.9 MT2 170 145 220 75 MT3 188 163 247 84.1 MT4 200 175 264.9 90 MT5 212 187 283.1 96.1 MT6 224 199 301 102 MT7 236 211 319.1 108.1 MT8 248 223 337 114 DIMENSION CONSTANTS (in) AW = Front axle track BA = Front bumper to centerline of axle BBC = Bumper to back of cab BOC = Back of cab clearance BW = Overall width across rear axle CW = Rear axle track FW = Frame width OW = Overall width across cab (without mirrors) DIMENSIONS BY TIRE SIZE (in.) AH = Ground to bottom of axle FH = Frame height (unladen) at E.O.F.[3] FH = Frame height (unladen) at R/A[4] FH = Frame height (laden) at R/A[5] OH = Overall height (without clearance lights) FL 270.5 297.6 324.6 342.5 360.6 378.5 396.7 414.6 OAL 274.4 301.5 328.5 346.4 364.6 382.5 400.6 418.5 11R22.5G 10 38.2 38.2 38.2 108.6 81.1 56.5 81.5 10.4 96 72.2 33.5 93.5 255/70R22.5H 7.7 35.9 35.9 35.9 107 Notes: [1] Effective CA is CA less BOC. [2] Effective CE is CE less BOC. [3] Measured at the end of the frame from the top of the frame to the ground at curb weight. [4] Measured at the rear axle from the top of the frame to the ground with the chassis at curb [5] Measured at the rear axle from the top of the frame to the ground with the chassis loaded to GV WR. Figure 4 2024 Chevrolet LCF Revision: 05/31/23 2024 Chevrolet Low Cab Forward Vehicle Weights, Dimensions and Ratings Multi-leaf Suspension Rating GVWR Designed Maximum GCWR Combined Maximum Front GAWR Rear GAWR VEHICLE WEIGHT LIMITS Tire All tire options All tire options 11R22.5G tires 255/70R22.5H tires All tire options Capacity 25,950 lb 30,000 lb 12,000 lb 11,000 lb 19,000 lb FINAL WEIGHT CHART PENDING PAGE 18.4 2024 Chevrolet LCF Notes: [1] Chassis Curb Weight reflects standard equipment and fuel, but no driver or payload. [2] Maximum Payload Weight is the allowed maximum for equipment, body, payload and driver and is calculated by subtracting chassis curb weight from the GVWR. Revision: 05/31/23 2024 Chevrolet Low Cab Forward Vehicle Weights, Dimensions and Ratings Air-spring Suspension Rating GVWR Designed Maximum GCWR Combined Maximum Front GAWR Rear GAWR VEHICLE WEIGHT LIMITS Tire All tire options All tire options 11R22.5G tires 255/70R22.5H tires All tire options Capacity 25,950 lb 30,000 lb 12,000 lb 11,000 lb 19,000 lb PAGE 18.5 FINAL WEIGHT CHART PENDING Notes: [1] Chassis Curb Weight reflects standard equipment and fuel, but no driver or payload. 2024 Chevrolet LCF [2] Maximum Payload Weight is the allowed maximum for equipment, body, payload and driver and is calculated by subtracting chassis curb weight from the GVWR. Revision: 05/31/23 2024 Chevrolet Low Cab Forward Optional Equipment Weights Code I0Z I1L I2L I3L I4L I4K I3Z IY9 I9A I2Q I3Q I4Q I5Q I6Q IF6 I8P I5W I3W I3V IH2 IL9 IV8 UZF V22 I4H I6K I5L I7V I8V IY4 I1V I2V I7L I8L I4V OPTION WEIGHTS Description Spartan Modification Center Ship Thru Code Speed limited to 58 MPH Speed limited to 65 MPH Speed limited to 68 MPH Speed limited to 70 MPH Keyless entry Spare keys (2 additional, 4 keys in total) Engine idle shutdown (timer set at 3 minutes for engine shutdown) Engine idle shutdown (timer set at 5 minutes for engine shutdown) 96" wide heated mirrors (flat & convex) 96" wide heated remote mirrors (heated flat & convex, remote flat only) 102'' wide standard mirror heads 102" wide heated mirrors (flat & convex) 102" wide heated remote mirrors (heated flat & convex, remote flat only) Fire extinguisher (2.5 lbs) and triangle kit Fire extinguisher (5 lbs) and triangle kit Engine oil pan heater with receptacle (125V 300W) Cold Weather Package I (includes block heater with receptacle and heated fuel filter) Cold Weather Package II (includes block heater + oil pan heater with receptacle and heated fuel filter) Engine emergency shutdown system HWT, LWL, LOP PTO enable switch and engine idle up switch recommended for PTO and idle applications only Seat covers Back up alarm Chrome grille CAN interface converter Lockable DEF fill cap Lockable DEF fill cap (all keyed alike on multiple chassis ordered together) Aluminum wheels: 4 aluminum wheels + 2 steel rear inner wheels Aluminum wheels: 6 aluminum wheels Delete radio Audio system with 7" diagonal color touch screen Audio system with 7" diagonal color touch screen with backup camera (camera shipped loose) High visibility seat belt (red color, driver seat only) High visibility seat belt (red color, driver and RH passenger seat only) Forward collision and lane departure warning (Mobileye) Front / Rear (lbs) 0 / 0 0 / 0 0 / 0 0 / 0 0 / 0 1 / 0 0 / 0 0 / 0 0 / 0 1 / 0 2 / 0 2 / 0 2 / 0 3 / 0 22 / 0 27 / 0 3 / 0 2 / 0 4 / 0 0 / 0 0 / 0 6 / 0 0 / 1 1 / 0 0 / 0 0 / 0 0 / 0 0 / -112 -56 / -112 -3 / 0 2 / 0 2 / 2 0 / 0 0 / 0 2 / 0 PAGE 18.6 2024 Chevrolet LCF Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 18.7 Frame and Crossmember Specifications WHEEL BASE 152 170 188 200 212 224 236 248 OVERALL LENGTH 270.5 297.6 324.6 342.5 360.6 378.5 396.7 414.6 FRAME THICKNESS 0.31 A 50.2 50.2 50.2 50.2 A-A 50.2 50.2 50.2 50.2 NOTE: Dimensions in inches B 35.6 35.6 35.6 35.6 B-B 35.6 35.6 35.6 35.6 Figure 5 C 44.8 44.8 44.8 44.8 C-C 44.8 44.8 44.8 44.8 D 87.0 87.0 87.0 87.0 D-D 87.0 87.0 87.0 87.0 CROSSMEMBER TYPE / LOCATION E F - - 58.1 - - 76.1 - - 81.2 - E-E 100.1 - 68.4 E-E 112.1 E-E 68.4 124.1 83.1 136.1 83.1 G LEAF AIR 28.3 18.4 28.3 18.4 28.3 18.4 28.3 18.4 28.3 18.4 28.3 18.4 28.3 18.4 28.3 18.4 Figure 6 H LEAF AIR 29.6 27.5 29.6 27.5 29.6 27.5 29.6 27.5 E-E 29.6 27.5 29.6 27.5 29.6 27.5 29.6 27.5 I - - 63.1 72.1 78.1 E-E 84.2 90.1 96.2 102.1 J - 65.9 - 75.0 - 84.0 - 90.0 - 96.1 - 102.0 - 108.1 - 114.0 2024 Chevrolet LCF Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 18.8 Frame Chart Wheelbase 152 170 188 200 212 224 236 248 2024 Chevrolet LCF Figure 7 Frame Length 270.5 297.6 324.6 342.5 360.6 378.5 396.7 414.6 Figure 8 0.315 0.315 0.315 0.315 0.315 0.315 0.315 0.315 Note: Dimensions in inches Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 18.9 Diesel Multi-Leaf Spring Suspension - Top View 2024 Chevrolet LCF Figure 9 Note: Dimensions in inches Revision: 05/31/23 2024 Chevrolet Low Cab Forward Diesel Multi-Leaf Spring Suspension - Left Side View PAGE 18.10 2024 Chevrolet LCF Figure 10 Note: Dimensions in inches Revision: 05/31/23 2024 Chevrolet Low Cab Forward Diesel Multi-Leaf Spring Suspension - Right Side View PAGE 18.11 2024 Chevrolet LCF Figure 11 Note: Dimensions in inches Revision: 05/31/23 2024 Chevrolet Low Cab Forward Diesel Air Spring Suspension - Top View PAGE 18.12 2024 Chevrolet LCF Figure 12 Revision: 05/31/23 2024 Chevrolet Low Cab Forward Diesel Air Spring Suspension - Driver Side View PAGE 18.13 2024 Chevrolet LCF Figure 13 Revision: 05/31/23 2024 Chevrolet Low Cab Forward Diesel Air Spring Suspension - Passenger Side View PAGE 18.14 Note: Chassis shown with 255/70R22.5H tires Figure 14 2024 Chevrolet LCF Revision: 05/31/23 2024 Chevrolet Low Cab Forward Exhaust System Dimensions SCR / DPF 4HK1-TC Front of chassis Outside edge of frame rail PAGE 18.15 Note: As viewed from top Figure 15 2024 Chevrolet LCF Outside edge of frame rail Note: As viewed from front Figure 16 Note: Dimensions in inches Revision: 05/31/23 2024 Chevrolet Low Cab Forward Fuel Tank Dimensions - 100 Gallon Tank PAGE 18.16 2024 Chevrolet LCF Figure 17 Note: Dimensions in inches Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 18.17 Cab Tilt 2024 Chevrolet LCF Figure 18 Note: Dimensions in inches Revision: 05/31/23 2024 Chevrolet Low Cab Forward Turning Diameter The 6500XD Diesel steering features a 50 degree inside wheel cut angle. PAGE 18.18 Figure 19 Wheelbase in 152 170 188 200 212 224 236 248 Curb---to---Curb ft 43.7 47.4 51.8 54.7 56.5 59.3 62.2 65.0 WALL- -TO--WALL (Bumper) ft 48.7 52.5 56.9 59.9 61.7 64.6 67.5 70.3 WALL---TO---WALL (96" Mirrors) ft 48.6 52.5 56.9 59.8 61.6 64.5 67.3 70.2 WALL---TO---WALL (102" Mirrors) ft 49.0 52.9 57.2 60.2 62.0 64.8 67.7 70.6 2024 Chevrolet LCF Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 18.19 Center of Gravity Model Code MT1 MT2 MT3 MT4 MT5 MT6 MT7 MT8 Horizontal and Vertical Center of Gravity of Chassis Wheelbase (in) Vertical CG -V(in) Horizontal CG - H(in) 152 55.3 170 61.9 188 69.2 200 31.0 73.6 212 (laden at GVWR) 78.1 224 82.5 236 87.0 248 91.5 Figure 20 NOTE: The Final Manufacturer must ensure that the combined vertical center of gravity of the chassis, body, and available payload at full GVW does not exceed the maximum vertical center of gravity outlined in the Chevrolet Incomplete Vehicle Document (IVD). The maximum vertical center of gravity of the total vehicle at maximum GVWR is not to exceed 70 inches (1778 mm) above the ground. If a higher completed vehicle vertical center of gravity is required, please contact Chevrolet Commercial Truck application engineering. 2024 Chevrolet LCF Note: Dimensions in inches Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 18.20 Front Axle Chart Formulas for calculating height dimensions: A = C = D = CH = DH = Tire Loaded Radius B Centerline of Axle to Top of Frame Rail at Curb Position Centerline of Axle to Top of Frame Rail at Design Load C + Tire Unloaded Radius D + Tire Loaded Radius TIRE GVWR GAWR A B C D CH DH TRACK 11R22.5G 25,950 lb. 12,000 lb. 10.0 9.4 20.0 18.6 40.8 38.0 81.4 255/70R22.5H 25,950 lb. 11,000 lb. 7.7 9.4 20.0 18.6 38.3 35.7 81.4 2024 Chevrolet LCF Figure 21 Note: Dimensions in inches Revision: 05/31/23 2024 Chevrolet Low Cab Forward Rear Axle Chart Definitions A Centerline of axle to bottom of axle bowl. B Centerline of axle to top of frame rail at metal-to-metal position. C Centerline of axle to top of frame rail at curb position. D Centerline of axle to top of frame rail at design load. Rear Tire Clearance: Minimum clearance required for tires measured from the top of the E frame at the vehicle centerline of the rear axle, when rear wheels on one side ride over a high spot. CH Rear Frame Height (Curb Load): Vertical distance between the normal top of frame rail and the ground-line through the centerline of the rear axle at curb position. DH Rear Frame Height (Design Load): Vertical distance between the normal top of frame rail and the ground-line through the centerline of the rear axle at design position. DW Minimum distance between the inner surfaces of the rear tires. EW Minimum Rear Width: Overall width of the vehicle measured at the outermost surfaces of the rear tires. HH Rear Tire Clearance: Minimum clearance between the rear axle and the ground-line. HW Dual Tire Spacing: Distance between the centerlines of the tires in a set of dual tires. KH Tire Bounce Clearance: Minimum distance required for tire bounce as measured from the centerline of the rear axle and the top of the rear tire when one wheel rides over a high spot. CW Track Dual Rear Wheel Vehicle: Distance between the centerlines of the dual wheels measured at the ground-line. KW Clearance between body and tires. Equations CH = Tire loaded radius + C DH = Tire loaded radius + D DW = CW + 2 tire sections - tire clearance EW = CW + 2 tire sections + tire clearance HH = Tire loaded radius - A JH = KH - B KH = Tire radius + 3.0 inches KW = DW - 5.0 inches LW = 1.0 inch minimum clearance between tires and springs SUSPENSION TYPE TIRE SIZE CW A B C D E[1] MULTI-LEAF AIR SPRING 11R22.5G 255/70R22.5H 11R22.5G 255/70R22.5H 11.4 72.1 8.1 13.8 20.8 17.9 10.8 5.0 15.7 18.6 18.6 3.2 Notes: [1] Includes 2.5" of tire chain clearance 2024 Chevrolet LCF 18.21 Figure 22 Revision: 05/31/23 PAGE 2024 Chevrolet Low Cab Forward Multi-leaf Spring Suspension Deflection Charts PAGE 18.22 2024 Chevrolet LCF Figure 23 Figure 24 Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 18.23 Tire and Disc Wheel Chart Tire Brand Bridgestone Size Revolutions Per Mile 11R22.5G 500 Max Load Per Tire (lb) Single Dual 6175 5840 Cold Inflation Pressure (psi) 105 GVWR (lb) 25,950 Radius (in) Loaded Unloaded 19.4 20.8 Loaded Section Width (in) Tire Clearance (in) Design Rim Width (in) 12.3 0.92 8.25 Continental 11R22.5G 498 Yokohama RY023 (Front Tire) 255/70R22.5 570 6175 5510 5840 5070 105 25,950 19.4 20.8 120 25,950[1] 17.1 18.25 12.0 10 0.20 2.83 8.25 7.5 Yokohama TY303 (Drive Tire) 255/70R22.5 563 5510 5070 120 25,950 17.3 18.5 10 2.83 7.5 Disc Wheel Brand Accuride Size (in.) Material Rim Type Bolt Holes 22.5 x 8.25 2-piece welded steel Hub-piloted, dualmounting, 15 tubeless 10-Hole Bolt Circle Diameter (in) 11.25 Alcoa[3] 22.5 x 8.25 1-piece aluminum Hub-piloted, dualmounting, 15 tubeless 10-Hole 11.25 NOTES: [1] Front GAWR is reduced to 11,000 lb. with 255/70R22.5H tires equipped. [2] Outside dimension wrench size [3] Aluminum wheel options will include (4) wheel spacers to prevent dissimilar metal corrosion Front & Rear Nut Size[2] Front & Rear Stud Size Nut/Stud Torque Specs (ft-lb) Inner Circle (in) Wheel Outside Offset (in) Disc Thickness (in) 33mm Hex M22 x 1.5 475 (644 N-m) 8.66 6.60 0.437 33mm Hex M22 x 1.5 475 (644 N-m) 8.66 6.60 0.748 2024 Chevrolet LCF Figure 25 Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 18.24 Propeller Shaft Angles Figure 26 Figure 27 Wheel Base (in.) A 152 0 170 0 188 0 200 0 212 0 224 0 236 0 248 0 Top View B C 0.6 n/a 0.4 n/a 0.5 n/a 0 0.4 0 0.5 0 0.6 0 0.4 0 0.4 Side View D E F Trans. Rear Axle 4.9 8.20 n/a 4 4.3 5.2 5.6 n/a 4 4.3 4.6 4.7 n/a 4 4.3 5.2 4.4 3.4 4 4.3 3.1 4.8 4.3 4 4.3 3.1 3.3 4.5 4 4.3 3.1 3.6 3.4 4 4.3 3.1 2.7 3.4 4 4.3 Note: 1. Angles provided in table are relative to the frame angle. Please take this into consideration for service measurements. 2. Driveline angles are based on the chassis curb weight which includes standard fuel but no driver, body, or payload. 2024 Chevrolet LCF Revision: 05/31/23 2024 Chevrolet Low Cab Forward PAGE 18.25 Propeller Shaft Lengths Wheel Base No. of Shafts Shaft #1 O.D. Thickness Length Type Shaft #2 O.D. Thickness Length Type Shaft #3 O.D. Thickness Length Type 152 2 4.00 0.95 43.0 A 4.00 0.95 41.2 B N/A N/A N/A N/A 170 2 4.00 0.95 43.0 A 4.00 0.95 58.9 B N/A N/A N/A N/A 188 2 4.00 0.95 67.9 A 4.00 0.95 51.8 B N/A N/A N/A N/A 200 3 4.00 0.95 43.0 A 4.00 0.95 31.7 A 4.00 0.95 57.3 B 212 3 4.00 0.95 67.9 A 4.00 0.95 31.7 A 4.00 0.95 44.3 B 224 3 4.00 0.95 67.9 A 4.00 0.95 43.7 A 4.00 0.95 44.3 B 236 3 4.00 0.95 67.9 A 4.00 0.95 41.1 A 4.00 0.95 58.9 B 248 3 4.00 0.95 67.9 A 4.00 09.5 52.9 A 4.00 0.95 58.9 B Figure 28 Type Type A Type B 2024 Chevrolet LCF Description 1st shaft in 2 or 3-Piece Driveline 2nd shaft in 3-Piece Driveline 2nd shaft in 2-piece Driveline 3rd shaft in 3-Piece Driveline Figure 29 Illustration L L Note: Dimensions in inches Revision: 05/31/23 2024 Chevrolet Low Cab Forward Brake System Diagram Legend 6500XD Brake System Wheel Speed Sensors (WSS) Speed Sensor Rotor Right Front Brake Pressure Modulator Valve Electronic Brake Control Module (EBCM) Right Rear Brake Pressure Modulator Valve Left Front Brake Pressure Modulator Valve Left Rear Brake Pressure Modulator Valve PAGE 18.26 2024 Chevrolet LCF Figure 30 Revision: 05/31/23 2024 Chevrolet Low Cab Forward Paint Code Chart GM Ordering Color Name Exterior EXTERIOR PAINT CODE INFORMATION ISU695 ISU508 508 N/A 508 508 OEM Figure 19.1.1 PAGE 19. 1 2024 Chevrolet LCF Revision: 05/31/23Microsoft Word for Microsoft 365 Microsoft Word for Microsoft 365