Kenworth Heavy Duty Body Builder 2015 User Manual
Kenworth Heavy Duty
Body Builder Manual
2015
®
This page intentionally left blank.
Kenworth Heavy Duty
2.1m Cab
Body Builder Manual
®
Body Builder Manual
Contents
SECTION 1: INTRODUCTION 1-1
SAFETY SIGNALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
SECTION 2: SAFETY & COMPLIANCE 2-1
FEDERAL MOTOR VEHICLE SAFETY
STANDARDS COMPLIANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
DIMENSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
ABBREVIATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
TURNING RADIUS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
SECTION 3: DIMENSIONS 3-1
OVERALL DIMENSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
T680 STANDARD HOOD DAYCAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
T680 MX (SHORT) HOOD DAYCAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
T880 STANDARD HOOD DAYCAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
T880 MX (SHORT) HOOD DAYCAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
T880 STANDARD HOOD WITH 52” SLEEPER . . . . . . . . . . . . . . . . . . . . . . . .3-10
T880 MX (SHORT) HOOD WITH 52” SLEEPER . . . . . . . . . . . . . . . . . . . . . . . 3-11
RIDE HEIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
REAR SUSPENSION LAYOUTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
AG400L TANDEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
AG400 TANDEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-16
AG460 TANDEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-17
AG690 TRIDEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
REYCO 79KB SINGLE REAR AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19
REYCO 102 TANDEM REAR AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-20
NEWAY ADZ 123 SINGLE REAR AXLE. . . . . . . . . . . . . . . . . . . . . . . . . . . .3-21
NEWAY ADZ 246 TANDEM SUSPENSION . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22
NEWAY ADZ 369 TRIDEM SUSPENSION . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23
HENDRICKSON PRIMAAX EX TANDEM SUSPENSION . . . . . . . . . . . . . . . . . . .3-24
HENDRICKSON PRIMAAX EX TRIDEM SUSPENSION . . . . . . . . . . . . . . . . . . . 3-25
HENDRICKSON HMX TANDEM SUSPENSION . . . . . . . . . . . . . . . . . . . . . . . 3-26
HENDRICKSON RT TANDEM SUSPENSION. . . . . . . . . . . . . . . . . . . . . . . . .3-27
CHALMERS 856-46 TANDEM SUSPENSION. . . . . . . . . . . . . . . . . . . . . . . . .3-28
LIFT AXLES (PUSHERS AND TAGS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-30
AXLE TRACK AND TIRE WIDTH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33
PTO CLEARANCES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-37
T680/880 TRANSMISSION PTO APPLICATION GUIDE . . . . . . . . . . . . . . . . . . .3-39
EXHAUST AND AFTER-TREATMENT INFORMATION . . . . . . . . . . . . . . . . . . . . 4-1
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Body Builder Manual
Contents
SECTION 4: EXHAUST & AFTERTREATMENT 4-1
GENERAL GUIDELINES FOR DEF SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . 4-3
MEASUREMENT REFERENCE POINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
GENERAL EXHAUST INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
FRAME LAYOUTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
SECTION 5: FRAME LAYOUTS 5-1
COMMON OPTIONAL COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
FRAME LAYOUT INDEX. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
FRAME INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
SECTION 6: BODY MOUNTING 6-1
CRITICAL CLEARANCES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
BODY MOUNTING USING BRACKETS. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
MOUNTING HOLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
BODY MOUNTING USING U–BOLTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
FRAME MODIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
DRILLING RAILS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
SECTION 7: FRAME MODIFICATIONS 7-1
MODIFYING FRAME LENGTH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
CHANGING WHEELBASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
CROSSMEMBERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
WELDING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
TORQUE REQUIREMENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
ELECTRICAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
SECTION 8: ELECTRICAL 8-1
BODY BUILDER CONNECTION POINTS . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
LIFT AXLES (PUSHERS & TAG) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-16
ROUTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
SECTION 9: ROUTING 9-1
ROUTING REQUIREMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2
APPENDIX A: VEHICLE IDENTIFICATION A-1
VEHICLE IDENTIFICATION LABELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2
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Figures
FIGURE 2-1. Incomplete Vehicle Certication Document . . . . . . . . . . . . . . . . . . . 2-2
FIGURE 2-2. Locations of Certication Labels - Driver’s Door and Frame . . . . . . . . . . 2-2
FIGURE 2-3: Aerodynamic Mirror OAT Sensor Location . . . . . . . . . . . . . . . . . . . 2-7
FIGURE 2-4: Instrument Cluster for T680/T880 . . . . . . . . . . . . . . . . . . . . . . . . 2-7
FIGURE 3-1: Prospecter Turn Circle Analysis . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
FIGURE 3-2: Single Acting and Dual Acting PTOs . . . . . . . . . . . . . . . . . . . . . . 3-40
FIGURE 3-3: Single-Acting Eaton PTO . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-41
FIGURE 3-4: Double-Acting Eaton PTO . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-42
FIGURE 3-5: Allison Transmission-Mounted PTOs . . . . . . . . . . . . . . . . . . . . . . 3-42
FIGURE 3-6: Auto Susp Dump w/ Allison mtd PTO . . . . . . . . . . . . . . . . . . . . . . 3-44
FIGURE 3-7: EoA Reversible PTO Example . . . . . . . . . . . . . . . . . . . . . . . . . 3-45
FIGURE 3-8: Air Actuated PTO (No Interlock). . . . . . . . . . . . . . . . . . . . . . . . .3-45
FIGURE 3-9: Rear Axle Declutch Telltale . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-46
FIGURE 3-10: Split Shaft PTO Example #1 . . . . . . . . . . . . . . . . . . . . . . . . . .3-46
FIGURE 3-11: Pump Mode Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-47
FIGURE 3-12: Sample Chassis Node and EOA Manifold . . . . . . . . . . . . . . . . . . .3-48
FIGURE 3-13: Wiring Diagram for Chassis Node, Cab Switches, and EOA Manifold. . . . . 3-49
FIGURE 4-1: Measurement Location of DEF Supply Module (Pump). . . . . . . . . . . . . 4-5
FIGURE 4-2: Measurement Location of DEF Dosing Module (Injector) . . . . . . . . . . . . 4-5
FIGURE 4-3: Orientation of Dosing Module . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
FIGURE 4-4: RH Under Cab Exhaust with Small, Medium, or Large Tanks. . . . . . . . . . 4-6
FIGURE 4-5: Horizontal Exhaust with Small, Medium, or Large Tanks . . . . . . . . . . . . 4-7
FIGURE 4-6: Vertical Exhaust with Small, Medium, or Large Tanks. . . . . . . . . . . . . . 4-7
FIGURE 4-7: Routing DEF Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
FIGURE 4-8: Supply Module Allowed Clocking Angles . . . . . . . . . . . . . . . . . . . . 4-8
FIGURE 4-9: Isometric view of Right Hand Under DPF/SCR with
Single Side of Cab Tailpipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
FIGURE 4-10: Isometric view of Right Hand Under DPF/SCR with
Single Side of Cab Tailpipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
FIGURE 4-11: Right view of Right Hand Under DPF/SCR with
Single Side of Cab Tailpipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
FIGURE 4-12: Back view of Right Hand Under DPF/SCR with
Single Side of Cab Tailpipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
FIGURE 4-13: Isometric view of Right Hand Under DPF/SCR with
Dual Side of Cab Tailpipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-12
FIGURE 4-14: Isometric view of Right Hand Under DPF/SCR with
Dual Side of Cab Tailpipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-12
FIGURE 4-15: Right View of Right Hand Under DPF/SCR with Dual Side of Cab Tailpipe . . 4-13
FIGURE 4-16: Back View of Right Hand Under DPF/SCR with Dual Side of Cab Tailpipe . . 4-13
FIGURE 4-17: Isometric View of Right Hand Under DPF/SCR with
Single Back of Cab Tailpipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-14
FIGURE 4-18: Isometric View of Right Hand Under DPF/SCR with
Single Back of Cab Tailpipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-14
FIGURE 4-19: Right View of Right Hand Under DPF/SCR with
Single Back of Cab Tailpipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-15
FIGURE 4-20: Back View of Right Hand Under DPF/SCR with Single Back of Cab Tailpipe . 4-15
FIGURE 4-21: Isometric View of Right Hand Under DPF/SCR
with Ground-Dump Tailpipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-16
FIGURE 4-22: Isometric View of Right Hand Under DPF/SCR with
Ground-Dump Tailpipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
FIGURE 4-23: Right View of Right Hand Under DPF/SCR with Ground-Dump Tailpipe . . . 4-17
FIGURE 4-24: Back View of Right Hand Under DPF/SCR with Ground-Dump Tailpipe. . . .4-17
FIGURE 4-25: Isometric View of Independent Back of Cab DPF/SCR with
Back of Cab Tailpipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18
08/12
iv
Figures
FIGURE 4-26: Isometric View of Independent Back of Cab DPF/SCR with
Back of Cab Tailpipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18
FIGURE 4-27: Right View of Independent Back of Cab DPF/SCR with
Back of Cab Tailpipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19
FIGURE 4-28: Back View of Independent Back of Cab DPF/SCR with
Back of Cab Tailpipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19
FIGURE 4-29: Isometric View of Horizontal Crossover DPF/SCR with
Ground-Dump Tailpipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20
FIGURE 4-30: Isometric View of Horizontal Crossover DPF/SCR with
Ground-Dump Tailpipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20
FIGURE 4-31: Right View of Horizontal Crossover DPF/SCR with
Ground-Dump Tailpipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21
FIGURE 4-32: Back View of Horizontal Crossover DPF/SCR with Ground-Dump Tailpipe . . 4-21
FIGURE 4-33: Isometric View of Right Hand Under DPF/SCR with
Single Side of Cab Tailpipe (52” Sleeper). . . . . . . . . . . . . . . . . . . . . . . . .4-22
FIGURE 4-34: Isometric View of Right Hand Under DPF/SCR with
Single Side of Cab Tailpipe (52” Sleeper). . . . . . . . . . . . . . . . . . . . . . . . .4-22
FIGURE 4-35: Right View of Right Hand Under DPF/SCR with
Single Side of Cab Tailpipe (52” Sleeper). . . . . . . . . . . . . . . . . . . . . . . . .4-23
FIGURE 4-36: Rear View of Right Hand Under DPF/SCR with
Single Side of Cab Tailpipe (52” Sleeper) . . . . . . . . . . . . . . . . . . . . . . . . 4-23
FIGURE 4-37: Isometric View of Right Hand Under DPF/SCR with
Dual Side of Cab Tailpipe (52” Sleeper) . . . . . . . . . . . . . . . . . . . . . . . . . 4-24
FIGURE 4-38: Isometric View of Right Hand Under DPF/SCR with
Dual Side of Cab Tailpipe (52” Sleeper) . . . . . . . . . . . . . . . . . . . . . . . . . 4-24
FIGURE 4-39: Right View of Right Hand Under DPF/SCR with
Dual Side of Cab Tailpipe (52” Sleeper) . . . . . . . . . . . . . . . . . . . . . . . . . 4-25
FIGURE 4-40: Rear View of Right Hand Under DPF/SCR with
Dual Side of Cab Tailpipe (52” Sleeper) . . . . . . . . . . . . . . . . . . . . . . . . . 4-25
FIGURE 4-41: Isometric View of Right Hand Under DPF/SCR with
Single Back of Sleeper Tailpipe (52” Sleeper) . . . . . . . . . . . . . . . . . . . . . . 4-26
FIGURE 4-42: Isometric View of Right Hand Under DPF/SCR with
Single Back of Sleeper Tailpipe (52” Sleeper) . . . . . . . . . . . . . . . . . . . . . . 4-26
FIGURE 4-43: Right View of Right Hand Under DPF/SCR with
Single Back of Sleeper Tailpipe (52” Sleeper) . . . . . . . . . . . . . . . . . . . . . . 4-27
FIGURE 4-44: Rear View of Right Hand Under DPF/SCR with
Single Back of Sleeper Tailpipe (52” Sleeper) . . . . . . . . . . . . . . . . . . . . . . 4-27
FIGURE 4-45: Isometric View of Right Hand Under DPF/SCR with
Dual Back of Sleeper Tailpipes (52” Sleeper) . . . . . . . . . . . . . . . . . . . . . . .4-28
FIGURE 4-46: Isometric View of Right Hand Under DPF/SCR with
Dual Back of Sleeper Tailpipes (52” Sleeper) . . . . . . . . . . . . . . . . . . . . . . .4-28
FIGURE 4-47: Right View of Right Hand Under DPF/SCR with
Dual Back of Sleeper Tailpipes (52” Sleeper) . . . . . . . . . . . . . . . . . . . . . . .4-29
FIGURE 4-48: Rear View of Right Hand Under DPF/SCR with
Dual Back of Sleeper Tailpipes (52” Sleeper) . . . . . . . . . . . . . . . . . . . . . . .4-29
FIGURE 4-49: Isometric View of Horizontal Crossover DPF/SCR with
Single Back of Sleeper Tailpipe (52” Sleeper) . . . . . . . . . . . . . . . . . . . . . . 4-30
FIGURE 4-50: Isometric View of Horizontal Crossover DPF/SCR with
Single Back of Sleeper Tailpipe (52” Sleeper) . . . . . . . . . . . . . . . . . . . . . . 4-30
FIGURE 4-51: Right View of Horizontal Crossover DPF/SCR with
Single Back of Sleeper Tailpipe (52” Sleeper) . . . . . . . . . . . . . . . . . . . . . . 4-31
FIGURE 4-52: Rear View of Horizontal Crossover DPF/SCR with
Single Back of Sleeper Tailpipe (52” Sleeper) . . . . . . . . . . . . . . . . . . . . . . 4-31
FIGURE 4-53: Isometric View of Horizontal Crossover DPF/SCR with
Dual Back of Sleeper Tailpipes (52” Sleeper) . . . . . . . . . . . . . . . . . . . . . . .4-32
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Figures
FIGURE 4-54: Isometric View of Horizontal Crossover DPF/SCR with
Dual Back of Sleeper Tailpipes (52” Sleeper) . . . . . . . . . . . . . . . . . . . . . . .4-32
FIGURE 4-55: Right View of Horizontal Crossover DPF/SCR with
Dual Back of Sleeper Tailpipes (52” Sleeper) . . . . . . . . . . . . . . . . . . . . . . .4-33
FIGURE 4-56: Rear View of Horizontal Crossover DPF/SCR with
Dual Back of Sleeper Tailpipes (52” Sleeper) . . . . . . . . . . . . . . . . . . . . . . .4-33
FIGURE 4-57. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-34
FIGURE 4-58. Dimension A = Top of Rail Frame Height from Prospector – Frame Depth. . . 4-35
FIGURE 5-1. DEF TANK DIMENSIONS.. . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
FIGURE 6-1. Minimum Clearance Between Top Of Rear Tires And Body Structure Overhang. 6-2
FIGURE 6-2. Minimum Back of Cab Clearance . . . . . . . . . . . . . . . . . . . . . . . . 6-3
FIGURE 6-3. Spacer Between Frame Sill and Body Rail - Rubber or Plastic . . . . . . . . . 6-4
FIGURE 6-4. High Compression Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FIGURE 6-5. Rubber Spacer Between Brackets Between the Mounting Bolt
and Upper Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
FIGURE 6-6. Crossmember-Gusset Hole Pattern Requirements . . . . . . . . . . . . . . . 6-5
FIGURE 6-7. Acceptable U-Bolt Mounting with Wood and Fabricated Spacers . . . . . . . 6-6
FIGURE 6-8. Clearance Space for Air Lines and Cables . . . . . . . . . . . . . . . . . . . 6-7
FIGURE 6-9. Example of Fishplate Bracket at Rear End of Body, used with U-Bolts . . . . . 6-8
FIGURE 7-1. Detail of Frame Extension and Joint Welding . . . . . . . . . . . . . . . . . . 7-2
FIGURE 7-2. Frame Insert. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
FIGURE 7-3. Comparison of Original, Shortened, and Extended Wheelbases.. . . . . . . . 7-4
FIGURE 7-4. Crossmember Added When Distance Exceeds 60 Inches (1524 mm) . . . . . 7-5
FIGURE 8-1. NAMUX 4 System Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
FIGURE 8-2. 12 Pin Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
FIGURE 8-3. Spare circuit connector detail . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
FIGURE 8-4. Spare circuit location under-dash (P096) . . . . . . . . . . . . . . . . . . . . 8-3
FIGURE 8-5. Spare circuit location on Power Distribution Center (Dash-Side, P001). . . . . 8-4
FIGURE 8-6. Spare circuit diagram (P001 and P096) . . . . . . . . . . . . . . . . . . . . . 8-5
FIGURE 8-7. Electric Engaged Equipment Connector . . . . . . . . . . . . . . . . . . . . 8-6
FIGURE 8-8. Air Solenoid Bank and Chassis Node . . . . . . . . . . . . . . . . . . . . . . 8-6
FIGURE 8-9. Rear Axle Controls and Sensors Connector . . . . . . . . . . . . . . . . . . 8-7
FIGURE 8-10. B-CAN Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7
FIGURE 8-11. Chassis Harness From Cab Mount to Front of Frame . . . . . . . . . . . . . 8-8
FIGURE 8-12. Chassis Harness From Cab Mount to BOC . . . . . . . . . . . . . . . . . . 8-9
FIGURE 8-13. Connectors Near Front Cab Mount . . . . . . . . . . . . . . . . . . . . . . 8-9
FIGURE 8-14. Connector Near BOC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-10
FIGURE 8-15. VCAN Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-10
FIGURE 8-16. Firewall Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-10
FIGURE 8-17. Chassis Node and Electric Over Air Solenoid Bank . . . . . . . . . . . . . . 8-11
FIGURE 8-18. Installing Additional Switches onto the Chassis Side . . . . . . . . . . . . . 8-12
FIGURE 8-19. Installing Additional Gauges on the Dash . . . . . . . . . . . . . . . . . . . 8-13
FIGURE 8-20. Installing Sensors on the Chassis Side for Gauges . . . . . . . . . . . . . . 8-14
FIGURE 8-21. Typical Installation of Sensors Diagram . . . . . . . . . . . . . . . . . . . . 8-15
FIGURE 8-22. Spare Power Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-15
FIGURE 8-23. Truck Lift Axles (Separate Switches). . . . . . . . . . . . . . . . . . . . . .8-16
FIGURE 8-20. Truck Lift Axles (Single Switch) . . . . . . . . . . . . . . . . . . . . . . . . 8-16
FIGURE 8-24. EoA Trailer Lift Axles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-17
FIGURE 8-25. Mating Connector: Packard PN 12020786 . . . . . . . . . . . . . . . . . . .8-25
FIGURE 8-26. Junction Box BOC or EOF . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-25
FIGURE 8-27. Dash Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-26
FIGURE 8-28. Engine Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-26
FIGURE 8-29. J1939 Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-27
08/12
vi
Figures
FIGURE 8-30. J1939 Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-27
FIGURE 8-31. J1939 Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-28
FIGURE 8-32. Trim Panel Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-29
FIGURE 8-33. Gauge Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-29
FIGURE 8-34. Switch Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-30
FIGURE 8-35. Cluster Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-30
FIGURE 8-36. Telltale Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-31
FIGURE 9-1. Clamp and Buttery Clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
FIGURE 9-2. Buttery Tie . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
FIGURE 9-3. Tie Strap. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
FIGURE 9-4. Heavy Duty (HD) Mount. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2
FIGURE 9-5. Denition of measurements.. . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4
FIGURE A-1. Vehicle Identication Number (VIN). . . . . . . . . . . . . . . . . . . . . . . A-1
FIGURE A-2. Drivers Door and Door Frame Labels . . . . . . . . . . . . . . . . . . . . . . A-2
FIGURE A-3. Front Axle Identication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-3
FIGURE A-4. Rear Axle Identication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-4
vii
08/12
Tables
TABLE 3-1. Abbreviations Used . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
TABLE 3-2. Turning Radius . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
TABLE 3-3. Ride Heights. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
TABLE 3-4. Rear Suspension Options . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-15
TABLE 3-18. Axle Width Calculation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-33
TABLE 3-19. Ground Clearance for Fuel Tanks . . . . . . . . . . . . . . . . . . . . . . . .3-35
TABLE 3-20. Ground Clearance for Battery Boxes . . . . . . . . . . . . . . . . . . . . . .3-36
TABLE 3-21. Current single-acting PTOs . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-40
TABLE 3-23. Reversible PTO States to Ports . . . . . . . . . . . . . . . . . . . . . . . . . 3-45
TABLE 3-24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-50
TABLE 3-25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-51
TABLE 3-26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-52
TABLE 4-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
TABLE 4-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-34
TABLE 5-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
TABLE 5-2. Fuel Tank Overall Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
TABLE 5-3. Battery Box Centerframe Lengths . . . . . . . . . . . . . . . . . . . . . . . . 5-2
TABLE 5-5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
TABLE 5-6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
TABLE 5-7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
TABLE 5-8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
TABLE 5-9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-10
TABLE 5-10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-11
TABLE 5-11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-12
TABLE 5-12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-13
TABLE 5-13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-14
TABLE 5-14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-15
TABLE 5-15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-16
TABLE 5-16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-17
TABLE 5-17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-18
TABLE 5-18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-19
TABLE 5-19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-20
TABLE 5-20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-21
TABLE 5-21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-22
TABLE 5-22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-23
TABLE 6-1. Single Steel Rails . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
TABLE 6-2. Inserted Steel Rails . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
TABLE 7-1. Customary Grade 8 UNF or UNC. . . . . . . . . . . . . . . . . . . . . . . . . 7-7
TABLE 7-2. U.S. Customary – Grade 8. Metric Class 10.9 . . . . . . . . . . . . . . . . . . 7-7
TABLE 8-1. Truck Lift Axle Logic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-17
TABLE 8-2. Air Solenoid Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-17
TABLE 8-3. MX engine (P111C/J111C) . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-18
TABLE 8-4. ISX Remote Throttle/PTO Connector P111A/J111A . . . . . . . . . . . . . . . 8-19
TABLE 8-5. EoA Chassis Node Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-19
TABLE 8-6. EoA CECU Guide. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-19
TABLE 8-7. CECU Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-20
TABLE 8-8. Interlocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-22
TABLE 9-1. Exhaust – System Clearance. . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4
Section 1
Introduction
This manual was created to provide body builders with appropriate information and guidelines
useful in the body planning and installation process. This information will be helpful when installing
bodies or other associated equipment.
This manual contains appropriate dimensional information, guidelines for mounting bodies, guidelines for modifying frames, electrical wiring information, and other information useful in the body
installation process. This manual is specic to chassis with 2013 EPA emissions engines.
The Body Builder Manual can be very useful when specifying a vehicle, particularly when the body
builder is involved in the vehicle denition and ordering process. Early in the process, professional
body builders can often contribute valuable information that reduces the ultimate cost of the body
installation.
In the interest of continuing product development, Kenworth reserves the right to change specications or products at any time without prior notice. It is the responsibility of the user to ensure
that he is working with the latest released information. Check Kenworth.com for the latest released
version.
If you require additional information or reference materials, please contact your local Kenworth
dealer.
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Section 2
Safety & Compliance
SAFETY SIGNALS
We’ve put a number of alerting messages in this book. Please read and follow them. They are there for your protection
and information. These alerting messages can help you avoid injury to yourself or others and help prevent costly damage to the vehicle.
Key symbols and “signal words” are used to indicate what kind of message is going to follow. Pay special attention to
comments prefaced by “WARNING”, “CAUTION”, and “NOTE.” Please don’t ignore any of these alerts.
Warnings, cautions, and notes
WARNING
Example:
WARNING! Be sure to use a circuit breaker designed to meet liftgate amperage requirements. An incor-
rectly specied circuit breaker could result in a electrical overload or re situation. Follow the liftgate
installation instructions and use a circuit breaker with the recommended capacity.
CAUTION
Example:
CAUTION: Never use a torch to make a hole in the rail. Use the appropriate drill bit.
NOTE
When you see this word and symbol, the message that follows is especially vital. It signals a
potentially hazardous situation which, if not avoided, could result in death or serious injury.
This message will tell you what the hazard is, what can happen if you don’t heed the warning,
and how to avoid it.
Signals a potentially hazardous situation which, if not avoided, could result in minor or moderate injury or damage to the vehicle.
Provides general information: for example, the note could warn you on how to avoid damaging
your vehicle or how to drive the vehicle more efciently.
Example:
Note: Be sure to provide maintenance access to the battery box and fuel tank ll neck.
Please take the time to read these messages when you see them, and remember:
WARNING
Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.
CAUTION
Signals a potentially hazardous situation which, if not avoided, could result in minor or moderate
injury or damage to the vehicle.
NOTE
Useful information that is related to the topic being discussed.
2-1
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Section 2
Safety & Compliance
FEDERAL MOTOR VEHICLE SAFETY STANDARDS COMPLIANCE
As an Original Equipment Manufacturer (OEM), Kenworth Truck Co. ensures that our products comply with all applicable
U.S. or Canadian Federal Motor Vehicle Safety Standards. However, the fact that this vehicle has no fth wheel and that a
Body Builder (Intermediate or Final Stage Manufacturer) will be doing additional modications means that the vehicle was
incomplete when it left the build plant. See next section and Appendix A for additional information.
Incomplete Vehicle Certication
An Incomplete Vehicle Document is shipped with the vehicle, certifying that the vehicle is not complete. See Figure 2–1.
In addition, afxed to the driver’s side door frame or edge is an Incomplete Vehicle Certication label. See Figure 2–2. For
further information on Vehicle Certication and Identication, see APPENDIX A “VEHICLE IDENTIFICATION.”
NOTE
These documents list the U.S. or Canadian Federal Motor Vehicle Safety Standard regulations that the
vehicle complied with when it left the build plant. You should be aware that if you add, modify or alter any
of the components or systems covered by these regulations, it is your responsibility as the Intermediate or
Final Stage Manufacturer to ensure that the complete vehicle is in compliance with the particular regula-
tions upon completion of the modications.
U.S. EPA Noise Label (U.S. registered vehicles only)
Final Stage Manufacturer
Label to be Installed by
Final Stage Manufacturer
Chassis Serial
Number
Vehicle Emission Control
Information Label
FIGURE 2-1. Incomplete Ve-
hicle Certication Document
Tire, Rim and
Weight Rating
Data label
Safety Mark (Canadian
Registry Only)
Incomplete Vehicle
Certication Label
Major Components and
Weights Label
FIGURE 2-2. Locations of Certica-
tion Labels - Driver’s Door and Frame
As the Intermediate or Final Stage Manufacturer, you should retain the Incomplete Vehicle Document for your records. In
addition, you should record and retain the manufacturer and serial number of the tires on the vehicle. Upon completion
of the vehicle (installation of the body and any other modications), you should afx your certication label to the vehicle
as required by Federal law. This tag identies you as the “Intermediate or Final Stage Manufacturer” and certies that the
vehicle complies with Federal Motor Vehicle Safety Standards. (See Figure 2–2.) Be advised that regulations affecting the
intermediate and nal stage manufacturer may change without notice. Ensure you are referencing the most updated copy
of the regulation during the certication and documentation processes.
In part, if the nal stage manufacturer can complete and certify the vehicle within the instruction in the incomplete vehicle
document (IVD) the certication label would need a statement that reads, “This vehicle has been completed in accordance
with the prior manufacturers‚ IVD where applicable. This vehicle conforms to all applicable Federal Motor Vehicle Safety
Standards [and Bumper and Theft Prevention Standards if applicable] in effect in (month, year).”
However, if the vehicle can not be completed and certied with in the guidance provided in the IVD, the nal stage manufacturer must ensure the vehicle conforms to all applicable Federal Motor Vehicle Safety Standards (FMVSS). The nal
stage manufactures certication label would need a statement that reads, “This vehicle conforms to all applicable Federal
Motor Vehicle Safety Standards [and Bumper and Theft Prevention Standards if applicable] in effect in (month, year).”
02/15
2-2
Section 2
Safety & Compliance
These statements are just part of the changes to the new certication regulation. Please refer to the Feb 15, 2005 nal
rule for all of the details related to this regulation. You can contact NTEA Technical Services Department at 1-800-441NTEA for a copy of the nal rule (DocID 101760).
For Canadian nal stage manufacturers see:
http://www.gazette.gc.ca/index-eng.html; and
http://www.tc.gc.ca/eng/acts-regulations/menu.htm for the regulations.
Or contact:
Transport Canada
Tower C, Place de Ville, 330 Sparks Street
Ottawa, Ontario K1A 0N5
(613) 990-2309
TTY: 1-888-675-6863
Noise and Emissions Requirements
NOTE
This truck may be equipped with specic emissions control components/systems* in order to
meet applicable Federal and California noise and exhaust emissions requirements. Tampering
with these emissions control components/systems* is against the rules that are established by the
U.S Code of Federal Regulations, Environment Canada Regulations and California Air Resources
Board (CARB). These emissions control components/systems* may only be replaced with original
equipment parts.
Additionally, most vehicles in North America will be equipped with a Greenhouse Gas (GHG)
“Vehicle Emission Control Information” door label indicating its certied conguration. The vehicle
components listed on this label (as shown in Figure 2-3) are considered emission control devices.
Modifying (i.e. altering, substituting, relocating) any of the emissions control components/sys-
tems dened above will affect the noise and emissions performance/certication. Modications
that alter the overall shape and aerodynamic performance of a tractor will also affect the emis-
sion certication. If modications are required, they must rst be approved by the manufacturer.
Unapproved modications could negatively affect emissions performance/certication. There is no
guarantee that proposed modications will be approved.
Tires may be substituted provided the new tires possess a Coefcient of rolling resistance (Crr)
equal to or lower than Crr of the original tires. Consult with your tire supplier(s) for appropriate
replacement tires.
Contact the engine manufacturer for any requirements and restrictions prior to any modications.
• For Cummins Contact 1-800-DIESELS or your local Cummins distributor. Reference AEB 21.102.
It is possible to relocate the DEF tank, however the relocation requirements need to be followed. Any variance from the
relocation requirements may cause the emissions control components/systems to operate improperly potentially resulting
in engine de-rate. See page 4-3 for relocation requirements.
NOTE
All 2013 engine emissions certied vehicles will be equipped with an On-Board Diagnostics
(OBD) system. The OBD system is designed to detect malfunctions of any engine or vehicle component that may increase exhaust emissions or interfere with the proper performance of the OBD
system itself.
2-3
02/15
Section 2
Safety & Compliance
All diesel engines will be equipped with an On-Board Diagnostics (OBD) system. The OBD
system consists of computer program on one or more of the vehicle’s Electronic Control Units
(ECUs). This program uses information from the control system and from additional sensors to
detect malfunctions. When a malfunction is detected, information is stored in the ECU(s) for diagnostic purposes. A Malfunction Indicator Light (MIL) is illuminated in the dash to alert the driver of
the need for service of an emission-related component or system.
To ensure compliance to emissions regulations, the nal conguration of certain features of the completed vehicle
must meet specic requirements. This section describes requirements relevant for only the most common or critical modications done by body builders. For a complete description of acceptable modications, see the application
guidance available from the manufacturer of the engine installed in the chassis.
Fuel System
The following are highlights of some of the more common or critical aspects of this system.
The overall system restriction may not exceed the restriction limitations set forth by the engine manufacturer for both
supply and return.
• Ensure that fuel lines are not pinched or can potentially be damaged when installed between body and frame
• Fuel lines must be routed and secured without dips or sags
• There must be easy access to lter(s) and ll cap
• The tank vent may not obstructed
• Added accessories (heaters, generators) cannot introduce air into system
• Fuel tank must be located so that the full level is not above cylinder head
• “Ultra Low Sulfur Fuel Only” labels must be present on the dash and fuel ll
• Modication of the pressure side secondary lter and plumbing is not allowed without engine manufacturer
approval
• Body installation of fuel tank or routing of lines must not cause signicant increase in fuel temperature
• Fuel hoses shall meet or exceed OEM supplied hose material construction specications
Compressed Air System
The following are highlights of some of the more common or critical aspects of this system.
• Air system modication must meet applicable FMVSS regulations
• Compressed Air tank may not be modied (exception – addition or removal of ttings or relocation of the tank)
02/15
• Added devices or bodywork may not interfere with or rub air lines
• Air supply to the engine doser may not be restricted or disconnected
• Air lines should be routed, protected from heat, and properly secured to prevent damage from other
components
• Care should be taken so that air lines do not rub against other components
• Care should be taken to protect the air system from heat sources.
2-4
Section 2
Safety & Compliance
Exhaust and Exhaust After-treatment System
The following are highlights of some of the more common or critical aspects of this system.
• The following after-treatment and exhaust system components may not be modied:
• DPF assembly
• SCR Catalyst assembly
• Exhaust pipes between the engine and after-treatment devices (DPF, SCR Catalyst) and between
after-treatment devices
• NOx Sensor
• The following modications may only be done within the guidelines of the “DEF System Relocation Guide.”
• Modications to Diesel Exhaust Fluid (DEF) throttle, suction, or pressure lines
• Modication or relocation of the DEF tank
• Modication of coolant lines to and from the DEF tank
• All DEF and coolant lines should be routed, protected, and properly secured to prevent damage during vehicle
operation or other components
• If relocation of the DCU or ACM is necessary, use existing frame brackets and mount inside of frame anges
where necessary. Do not extend the harnesses
• The DPF, the SCR catalyst, or their mounting may not be modied
• The NOx sensor may not been relocated or altered in any way
• Exhaust pipes used for tailpipes/stacks must be properly sized, and must prevent water from entering
• Ensure adequate clearance between the exhaust and body panels, hoses, and wire harnesses
• The body in the vicinity of the DPF must be able to withstand temperatures up to 400°C (750°F)
• Do not add thermal insulation to the external surface of the DPF
• The SCR water drain hole may not be blocked
• Allow adequate clearance (25mm (1 inch)) for servicing the DPF sensors, wiring, and clamped joints
• Drainage may not come in contact with the DPF, SCR catalyst, sensors or wiring
• Allow sufcient clearance for removing sensors from DPF. Thermistors require four inches. Other sensors
require one inch
• Wiring should be routed, protected from heat, and properly secured to prevent damage from
other components
• The exhaust system from an auxiliary power unit (APU) must not be connected to any part of the vehicle
after-treatment system or vehicle tail pipe.
Cooling System
The following are highlights of some of the more common or critical aspects of this system.
• Modications to the design or locations of ll or vent lines, heater or defroster core, and surge tank are not
recommended
• With the exception of post-thermostat installation, additional accessories plumbed into the engine cooling
system are not permitted, at the risk of voiding vehicle warranty
• Coolant level sensor tampering will void warranty
2-5
02/15
Section 2
Safety & Compliance
• When installing auxiliary equipment in front of the vehicle, or additional heat exchangers, ensure that
adequate air ow is available to the vehicle cooling system. Refer to engine manufacturer application guidelines for further detail
• When installing FEPTO drivelines, the lower radiator anti-recirculation seal must be retained with FEPTO
driveline clearance modication only
• Changes made to cooling fan circuit and controls are not allowed, with the exception of AC minimum fan on
time parameter
• See owner’s manual for appropriate winter front usage
Electrical System
The following are highlights of some of the more common or critical aspects of this system.
• Electrical harnesses providing battery power and electronic control signals to engine and emissions control/
vehicle OBD components including datalinks may not be spliced. These emissions control/vehicle OBD
components include the following:
• throttle pedal
• vehicle speed sensor
• after-treatment wiring
• If the alternator or battery is substituted, it must meet the requirements of the engine manufacture’s guidelines. This includes alternator ground voltage drop and alternator ground cable effectiveness. See the engine
manufacture’s guidelines for recommended test procedure. Additionally the maximum voltage differential and
the peak-peak voltage differential between the engine ECM block ground stud and battery negative terminal
may not exceed 500 mV under any combination of loads or operating conditions.
• Only an OBD compliant battery disconnect switch may be installed on vehicles equipped EPA 2013 and be-
yond compliant diesel engines. An OBD compliant switch and harness, even in the off position, supply a small
amount of power to the engine controller and enable certain emissions critical functions (e.g. DEF line purge).
Any modications to the electrical system which interrupt this power supply will cause OBD fault codes and
illumination of the MIL. In addition, such a modication will render the engine non-compliant with certain emis-
sion regulations. As a general rule of thumb, you can remove and replace the battery a battery disconnect
switch on a truck equipped with a battery disconnect switch at the factory. However, if a battery disconnect
switch was not installed in the factory a signicant harness modication is required before a battery disconnect switch can be added. Installation of aftermarket transfer-cases must address the vehicle speed sensor
position. The standard position of the speed sensor is at the transmission tail shaft. When a transfer-case is
added it is best to relocate the sensor to the axle side output shaft of the transfer-case. This is typically accomplished by adding a tone wheel into the driveline yoke assembly.
• Wiring extensions for the after-treatment wiring are available for relocating the DEF tank from your dealer via
Paccar Parts. For relocation of DEF tank, refer to the after-treatment section of this manual.
• The emission system requires an accurate Outside Air Temperature (OAT) reading in order to properly run
its control algorithms. The OAT sensor is located in the driver’s side mirror assembly on Kenworth trucks and
is shown in the gures below. If the body builder needs to modify the mirror assembly in any way, it is important the OAT sensor stay positioned on the mirror assembly. Running the vehicle without the OAT sensor
connected will cause the MIL lamp to illuminate. If needed, a replacement sensor can be ordered from your
Kenworth dealer.
02/15
2-6
FIGURE 2-3: Aerodynamic Mirror OAT Sensor Location
• Coolant Sensor considerations are given in the Cooling section above
• The OBD/Diagnostic connector port is located below the dash to the left of the steering wheel. This connector
and its location may not be changed.
Section 2
Safety & Compliance
• All vehicles equipped with EPA 2013 compliant diesel and bi-fueled engines must be equipped with a Malfunction Indicator Lamp (MIL) lamp. This lamp is required to be an engine outline symbol as dened by ISO (International Standards Organization). The gure below shows the instrument cluster and MIL lamp position. Note
this lamp location is xed with respect to the controls and its location may not be changed if you are updating
the warning lamp cards.
FIGURE 2-4: Instrument Cluster for T680/T880 used with EPA 2013 Emission compliant
engines. The Check Engine lamp and/or the MIL will appear in the Driver Performance
Center (#8). See T680/T880 Operator’s Manual for more information.
• In addition to the sensors and lamps above, the emission system also depends on signals from the exhaust
DPF (Diesel Particulate Filter), SCR (Selective Catalytic Reduction), and NOx sensor. Wiring between these
devices, the Dosing Control Unit (DCU) and engine ECM should not be tampered with or altered in any way.
2-7
02/15
Section 2
Safety & Compliance
Air Intake System
The following are highlights of some of the more common or critical aspects of this system.
• The air intake screen may not be blocked, either fully or partially
• Modication to the air intake system may not restrict airow. For example, pipe diameter may not be reduced
• All sensors must be retained in existing locations
• To retain system seal, proper clamp torque must be used. Refer to service manual for proper clamp torque
Charge Air Cooler System
The following are highlights of some of the more common or critical aspects of this system.
• The Charge Air Cooler may not be modied
• The installation of engine overspeed shutdown devices must not introduce restriction in the intake system
• All plumbing associated with the charge air cooler may not be modied
02/15
2-8
Section 3
Dimensions
DIMENSIONS
This section has been designed to provide enough information to successfully layout chassis in the body planning
process. Optional equipment may not be depicted. Please contact your local Kenworth dealer if more dimensional
information is desired.
ABBREVIATIONS
Throughout this section, and in other sections as well, abbreviations are used to describe certain characteristics on your
vehicle. The chart below lists the abbreviated terms used.
TABLE 3-1. Abbreviations Used
CA BACK OF CAB TO CENTERLINE OF REAR AXLE OR CENTERLINE OF TANDEMS ON TANDEM SUSPENSION
EOF FRAME RAIL OVERHANG BEHIND REAR AXLE – MEASURED FROM THE CENTERLINE OF TANDEMS
FS FRONT SUSPENSION HEIGHT
RS REAR SUSPENSION HEIGHT
WB WHEELBASE
SOC SIDE OF CAB
BOC BACK OF CAB
TURNING RADIUS
Approximate turning radius specications are listed in the following tables as a general guide. It is important to note that
optional components may alter the results.
TABLE 3-2. Turning Radius
Model Steering Gear Front Axle Front Wheel Front Tire
T680/T880
Single Gear
HD94 or
THP60
Dana Spicer
E-1202I 12K or
E13221 13.2K
Accuride 50487
or Alcoa 88367
22.5 X 8.25
295/75R22.5
Rear
Suspension
Tandem
52” Axle
Spacing
Wheel Base
(in.)
181 26.7
193 26.9
201 28.0
213 29.7
220 30.6
232 32.3
240 33.4
252 35.0
260 36.1
272 37.7
280 38.8
291 40.4
303 42.0
323 44.7
331 45.8
Turning
Radius (ft)
3-1
TABLE 3-2 CONTINUES ON NEXT PAGE…
02/15
Section 3
Dimensions
TABLE 3-2 CONTINUED
Model Steering Gear Front Axle Front Wheel Front Tire
T680/T880
T880
T880
Single Gear
HD94 or
THP60
Single Gear
SD110 or
TAS85
Dual Gears
HD94 or
THP60
Dana Spicer
E-12021 12K or
E-13221 13.2K
Dana Spicer
E-14621
Dana Spicer
D2000 20K
Standard Track
Accuride 50487
or Alcoa 88367
22.5 X 8.25
Alcoa 89365
22.5 X 9
Alcoa 89365
22.5 X 9
11R22.5
315/80R22.5
315/80R22.5
Rear
Suspension
Tandem
52” Axle
Spacing
Tandem
52” Axle
Spacing
Tandem
52” Axle
Spacing
Wheel Base
(in.)
181 26.9
193 27.4
201 28.5
213 30.2
220 31.2
232 32.9
240 34.0
252 35.7
260 36.8
272 38.4
280 39.6
291 41.1
303 42.8
323 45.6
331 46.7
181 26.9
193 26.9
201 27.9
213 29.6
220 30.5
232 32.2
240 33.2
252 34.0
260 35.1
272 36.7
280 37.8
291 39.2
303 40.8
323 43.4
331 44.5
181 28.1
193 28.6
201 29.7
213 31.5
220 32.5
232 34.2
240 35.3
252 35.2
260 36.3
272 38.0
280 39.1
291 40.6
303 42.2
323 45.0
331 46.0
Turning
Radius (ft)
02/15
TABLE 3-2 CONTINUES ON NEXT PAGE…
3-2
TABLE 3-2 CONTINUED
Section 3
Dimensions
Model Steering Gear Front Axle Front Wheel Front Tire
T880
T880
Dual Gears
HD94 or
THP60
Dual Gears
HD94 or
THP60
Dana Spicer
D2000 20K
Standard Track
Dana Spicer
D2000 20K
Standard Track
Alcoa 82362
22.5 X 12.25
Alcoa 82362
22.5 X 12.25
385/65R22.5
425/65R22.5
Rear
Suspension
Tandem
52” Axle
Spacing
Tandem
52” Axle
Spacing
Wheel Base
(in.)
181 28.1
193 28.6
201 29.8
213 31.5
220 32.5
232 34.2
240 35.4
252 35.3
260 36.4
272 38.0
280 39.1
291 40.6
303 42.2
323 45.0
331 46.1
181 28.1
193 28.6
201 29.8
213 31.5
220 32.5
232 34.2
240 35.4
252 36.7
260 37.8
272 39.5
280 40.7
291 42.2
303 43.9
323 46.8
331 47.9
Turning
Radius (ft)
3-3
02/15
Section 3
Dimensions
Prospector Turn Circle Analysis:
Please see Figure 3-2 as an example of Kenworth’s turn circle calculation made in Prospector for your specic chassis.
Your local Kenworth dealer can provide this information to you.
FIGURE 3-1. Prospecter Turn Circle Analysis
Please consult your local Kenworth Dealer for this information, as it is chassis specic.
02/15
3-4
Section 3
Dimensions
OVERALL DIMENSIONS
This section includes drawings and charts of the following Class 8 models: T680 and T880, including the 52” sleeper
On the pages that follow, detail drawings show particular views of each vehicle, all dimensions are in inches (in). They
illustrate important measurements critical to designing bodies of all types. See the “Contents” at the beginning of the
manual to locate the drawing that you need.
Note: To determine overall height please locate the chart Table 3-3 on page 3-12 and add that value to the height. All
heights are given from the bottom of the frame rail.
Kenworth also offers .dxf les and frame layouts of ordered chassis four weeks prior to build. Please speak with your
salesman to request this feature when specifying your chassis.
3-5
02/15
Section 3
82.5
Dimensions
T680 STANDARD HOOD DAYCAB
The following drawings are of a standard T680 Standard Hood Daycab, shown with standard chassis components.
142.9
124.5
CA
127.1
85.6
FS
50.5 92.4
77
119.6
97.3
74.1
WB
18.3
53.6
11.3
83.8
RS
EOF
11.3
33.3
02/15
79.9
91.5
34
74.8
98.5
3-6
Section 3
82.5
Dimensions
T680 MX (SHORT) HOOD DAYCAB
The following drawings are of a standard T680 MX (Short) Hood Daycab, shown with standard chassis components.
137
118.6
CA
127.1
76.8
FS
87.5
50.5
119.6
97.3
68.1
86.5
WB
18.3
53.6
11.3
83.8
RS
EOF
11.3
33.3
79.9
91.5
3-7
34
74.8
98.5
02/15
Section 3
Dimensions
T880 STANDARD HOOD DAYCAB
The following drawings are of a standard T880 Standard Hood Daycab, shown with standard chassis components.
122.5
82.5
CA
FS
48.4 74.1
77.9 WB EOF
119.7
82.5
11.3
33.3
18.3
53.6
83.8
RS
11.3
02/15
84.7
100.2
34
74.8
98.5
3-8
Section 3
Dimensions
T880 MX (SHORT) HOOD DAYCAB
The following drawings are of a standard T880 MX (Short) Hood Daycab, shown with standard chassis components.
116.6
CA
78.6
FS
77.9
48.4
119.7
68.2
WB EOF
82.5
11.3
33.3
18.3
53.6
11.3
83.8
RS
84.7
100.2
3-9
34
74.8
98.5
02/15
Section 3
Dimensions
T880 STANDARD HOOD WITH 52” SLEEPER
The following drawings are of a standard T880 Standard Hood with 52” Sleeper, shown with standard chassis components.
164.4
CA
104
82.5
FS
48.4
119.7
84.7
100.2
RS
116
94.7
36.4
19.5
50.3
34
74.8
98.5
02/15
3-10
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