Kenworth Heavy Duty Body Builder 2015 User Manual

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Page 1

Kenworth Heavy Duty

Body Builder Manual

2015

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Page 3

Kenworth Heavy Duty

2.1m Cab

Body Builder Manual

Page 4

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

iii

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Figures

FIGURE 2-1. Incomplete Vehicle Certication Document . . . . . . . . . . . . . . . . . . . 2-2

FIGURE 2-2. Locations of Certication 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

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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

Page 9

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 Buttery Clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1

FIGURE 9-2. Buttery Tie . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1

FIGURE 9-3. Tie Strap. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1

FIGURE 9-4. Heavy Duty (HD) Mount. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2

FIGURE 9-5. Denition of measurements.. . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4

FIGURE A-1. Vehicle Identication Number (VIN). . . . . . . . . . . . . . . . . . . . . . . A-1

FIGURE A-2. Drivers Door and Door Frame Labels . . . . . . . . . . . . . . . . . . . . . . A-2

FIGURE A-3. Front Axle Identication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-3

FIGURE A-4. Rear Axle Identication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-4

vii

08/12

Page 10

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

Page 11

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 specic 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 denition 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 specications 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.

1-1

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Page 12

This page intentionally left blank.

Page 13

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 specied 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 efciently.

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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Page 14

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 modications means that the vehicle was

incomplete when it left the build plant. See next section and Appendix A for additional information.

Incomplete Vehicle Certication

An Incomplete Vehicle Document is shipped with the vehicle, certifying that the vehicle is not complete. See Figure 2–1.

In addition, afxed to the driver’s side door frame or edge is an Incomplete Vehicle Certication label. See Figure 2–2. For further information on Vehicle Certication and Identication, 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 modications.

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 Certication Document

Tire, Rim and Weight Rating Data label

Safety Mark (Canadian Registry Only)

Incomplete Vehicle

Certication Label

Major Components and Weights Label

FIGURE 2-2. Locations of Certica- 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 modications), you should afx your certication label to the vehicle as required by Federal law. This tag identies you as the “Intermediate or Final Stage Manufacturer” and certies 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 certication 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 certication 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 certied 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 certication 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

Page 15

Section 2

Safety & Compliance

These statements are just part of the changes to the new certication 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 specic 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 certied conguration. 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 dened above will affect the noise and emissions performance/certication. Modications

that alter the overall shape and aerodynamic performance of a tractor will also affect the emis-

sion certication. If modications are required, they must rst be approved by the manufacturer. Unapproved modications could negatively affect emissions performance/certication. There is no guarantee that proposed modications will be approved.

Tires may be substituted provided the new tires possess a Coefcient 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 modications.

• 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 certied 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

Page 16

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 conguration of certain features of the completed vehicle must meet specic requirements. This section describes requirements relevant for only the most common or critical modications done by body builders. For a complete description of acceptable modications, 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

• Modication 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 signicant increase in fuel temperature

• Fuel hoses shall meet or exceed OEM supplied hose material construction specications

Compressed Air System

The following are highlights of some of the more common or critical aspects of this system.

• Air system modication must meet applicable FMVSS regulations

• Compressed Air tank may not be modied (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

Page 17

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 modied:

• 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 modications may only be done within the guidelines of the “DEF System Relocation Guide.”

• Modications to Diesel Exhaust Fluid (DEF) throttle, suction, or pressure lines

• Modication or relocation of the DEF tank

• Modication 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 modied

• 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 sufcient 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.

• Modications 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

Page 18

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 modication 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 modications to the electrical system which interrupt this power supply will cause OBD fault codes and illumination of the MIL. In addition, such a modication 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 signicant harness modication 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

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Page 19

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 dened 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

Page 20

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

• Modication to the air intake system may not restrict airow. 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 modied

• 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 modied

02/15

2-8

Page 21

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 specications 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

Page 22

Section 3

Dimensions

TABLE 3-2 CONTINUED

Model Steering Gear Front Axle Front Wheel Front Tire

T680/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

Rear

Suspension

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

Page 23

TABLE 3-2 CONTINUED

Section 3

Dimensions

Model Steering Gear Front Axle Front Wheel Front Tire

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

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

Page 24

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 specic 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 specic.

02/15

3-4

Page 25

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

Page 26

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

127.1

85.6

50.5 92.4

119.6

97.3

74.1

18.3

53.6

11.3

83.8

EOF

11.3

33.3

02/15

79.9

91.5

74.8

98.5

3-6

Page 27

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

127.1

76.8

87.5

50.5

119.6

97.3

68.1

86.5 WB

18.3

53.6

11.3

83.8

EOF

11.3

33.3

79.9

91.5

3-7

74.8

98.5

02/15

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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

48.4 74.1

77.9 WB EOF

119.7

82.5

11.3

33.3

18.3

53.6

83.8

11.3

02/15

84.7

100.2

74.8

98.5

3-8

Page 29

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

78.6

77.9

48.4

119.7

68.2 WB EOF

82.5

11.3

33.3

18.3

53.6

11.3

83.8

84.7

100.2

3-9

74.8

98.5

02/15

Page 30

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

104

82.5

48.4

119.7

84.7

100.2

116

94.7

36.4

19.5

50.3

74.8

98.5

02/15

3-10

Page 31

Section 3

Dimensions

T880 MX (SHORT) HOOD WITH 52” SLEEPER

The following drawings are of a standard T880 MX (Short) hood with 52” Sleeper, shown with standard chassis components.

158.5

104

78.6

48.4

119.7

84.7

100.2

110.1

94.7

36.4

19.5

50.3

74.8

98.5

3-11

02/15

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Section 3

Dimensions

RIDE HEIGHTS

The front (FS) and rear (RS) suspension ride heights are provided as a basic tool to determine the overall height of the cab, height of exhaust components, and frame heights. The heights are all calculated from the centerlines of the axles, please be sure to include the tire radius dimension to determine overall height. Note: the frame rail height itself will not affect the overall height as all components are located from the bottom of the frame rail.

82.5

TABLE 3-3. Ride Heights. To calculate the frame height use the following formulas:

Front Frame Height = FS + 1/2 Front Tire Diameter Rear Frame Height = RS + 1/2 Rear Tire Diameter

Front Suspension (T680/T880)

Front Suspension (FS) Laden: Unladen:

12K Taperleaf 10.3” 11.5”

13.2K Taperleaf 10.3” 11.5”

14.6K Taperleaf 10.3” 11.7” 16K Taperleaf 10.6” 12.3” 20K Taperleaf 10.4” 11.9” 22K Multi-stage Taperleaf 10.7” 12.7”

RSFS

02/15

3-12

Page 33

Section 3

Dimensions

Rear Suspension (All Models). Common Rear Suspensions are shown here, for detailed suspensions please use the Rear suspension layouts on pages 3-18 to 3-33.

Rear Suspension Laden: Unladen:

Kenworth AG400L 8.5” 8.5” Kenworth AG400 9” 9” Kenworth AG460 10.5” 10.5” Kenworth AG690 Tridem 10.5” 10.5” Reyco 79KB 23K Rating 8.3” 10.8” Reyco 102 38K Rating 9.2” 10.8” Chalmers 854-40-L-HS 40K Rating 9.6” 11” Chalmers 854-46-H 46K Rating 10.1” 12.4” Chalmers 854-50-H-HS 50K Rating 10.8” 12.5” Chalmers 865-65-XL 65K Rating 13” 15.7” Hend HMX400 16.5” Saddle 9.5” 10.6” Hend HMX400 17.5” Saddle 10.5” 11.6” Hend HMX460 46K 16.5” Saddle 9.5” 10.6” Hend HMX460 46K 17.5” Saddle 10.5” 11.6” Hendrickson Primaax EX 46K Rating 10” 10” Hendrickson RT463 46K Rating 10” 11.1” Hend RT523 52K 6” Saddle 9.9” 11” Neway ADZ246 46K Rating 10” or 12” 10” or 12” Neway ADZ252 52K Rating 10” or 12” 10” or 12” Neway ADZ369 69K Tridem 10” or 12” 10” or 12” Neway ADZ378 78K Tridem 10” 10”

3-13

02/15

Page 34

Section 3

Dimensions

REAR SUSPENSION LAYOUTS

The rear suspension layouts are provided as a tool to help layout bodies prior to arrival. The applicable dimensions are shown. Be sure to check the axle spacing that is shown, as alternate spacings may exist and could change some of the dimensions. The dimensions shown below are the most typical installations, in special cases some hole locations will

move. If you are planning on using the holes shown for your body installation, please conrm with your local KW dealer that the drawing below will be the installation used on your specic truck. Ensure that proper torque is used to reinstall any

suspension components. See Tables 7-1 and 7-2 on page 7-7.

It would be a good idea in this case to order the frame layout of your chassis along with your truck order. This can be done on any Kenworth truck, and will be provided 4 weeks ahead of the build schedule.

If there are hole locations that are not detailed please work with your local Kenworth Dealer to request that information.

Additionally optional axle spacings are shown in the charts, if you would like details on the frame drilling with optional spacings, please contact your local Kenworth dealer.

NOTE: Actual axle spacing can depart from nominal due to axle slant requirements. Final axle spacing can vary by more than an inch from nominal in some cases. If precise axle spacing is critical due to body installation or state/local regulatory requirements please contact Kenworth Applications/technical Support for assistance.

02/15

3-14

Page 35

AG400L TANDEM

Section 3

Dimensions

59.4

58.3

53.8

AG400L Suspensions

56.9

54.7

8.5

Axle Spacing

TABLE 3-4. Rear Suspension Options

Suspension Type Rating Axle Spacing

AG400L Tandem 40K 52" 8.5" 8.5"

AG400L Tandem 40K 54" 8.5" 8.5"

Laden Ride

Height

Unladen Ride

Height

3-15

02/15

Page 36

Section 3

Dimensions

AG400 TANDEM

60.6

AG400 Suspensions

58.5

48.0

45.9

Ride

Height

Axle Spacing

TABLE 3-5. Rear Suspension Options

Suspension Type Rating Axle Spacing

AG400 Tandem 40K 52" 9" 9"

AG400 Tandem 40K 54" 9" 9"

Laden Ride

Height

Unladen Ride

Height

02/15

3-16

Page 37

AG460 TANDEM

Section 3

Dimensions

67.7

65.8

AG460 Suspensions

52.0

49.9

10.5

60.0

TABLE 3-6. Rear Suspension Options

Suspension Type Rating Axle Spacing

AG460 Tandem 60" Spacing 46K 60" 10" 10"

Laden Ride

Height

Unladen Ride

Height

3-17

02/15

Page 38

Section 3

Dimensions

AG690 TRIDEM

87.6

85.5

54.0

AG690 Tridem Suspension

TABLE 3-7. Rear Suspension Options

Suspension Type Rating Axle Spacing

76.0

73.9

54.0

Laden Ride

Height

10.5

Unladen Ride

Height

AG690 Tridem 69K 108" (54" + 54") 10" 10"

02/15

3-18

Page 39

REYCO 79KB SINGLE REAR AXLE

30.2 30.1

28.7 29.0

Section 3

Dimensions

Ride Height

Optional Reyco 79KB Suspensions

TABLE 3-8. Rear Suspension Options

Suspension Type Rating Axle Spacing

Reyco 79KB single 20K - 8.3” 10.8”

Reyco 79KB single 23K - 8.3” 10.8”

Reyco 79KB single 26K - 8.2” 11.3”

Reyco 79KB single 31K - 9.6” 12.2”

Laden Ride

Height

Unladen Ride

Height

3-19

02/15

Page 40

Section 3

Dimensions

REYCO 102 TANDEM REAR AXLE

Shown with a 52” Axle Spacing

Reyco 102 Suspension Data

TABLE 3-9. Rear Suspension Options

Suspension Type Rating Axle Spacing Laden Ride Height

Reyco 102 Tandem 38K 52” 9.2” 10.8”

Unladen Ride

Height

02/15

3-20

Page 41

NEWAY ADZ 123 SINGLE REAR AXLE

30.8

29.8

27.8

Section 3

Dimensions

18.0

16.0

2.1

8.0

2.7

4.6

Optional Neway ADZ Single Suspensions

TABLE 3-10. Rear Suspension Options

18.8

26.4

24.3

RIDE HEIGHT

5.9

2.4

Suspension Type Rating Axle Spacing

Neway ADZ123 single 23K - 10” 10”

Neway ADZ126 single 26K - 10” 10”

Laden Ride

Height

Unladen Ride

Height

3-21

02/15

Page 42

Section 3

Dimensions

NEWAY ADZ 246 TANDEM SUSPENSION

Shown with a 54” Axle Spacing

57.7

56.7

54.7

44.9

42.9

52.1

50.7

2.7

4.6

8.0

AXLE SPACING

Optional Neway ADZ Tandem Suspensions

TABLE 3-11. Rear Suspension Options

Suspension Type Rating Axle Spacing

Neway ADZ246 tandem 46K 54” 10” 10”

Neway ADZ246 tandem 46K 60” 10” 10”

Laden Ride

Height

Unladen Ride

Height

RIDE HEIGHT

Neway ADZ246 tandem 46K 72” 10” 10”

Neway ADZ252 tandem 52K 54” 10” 10”

Neway ADZ252 tandem 52K 60” 10” 10”

Neway ADZ252 tandem 52K 60” 12” 12”

02/15

3-22

Page 43

NEWAY ADZ 369 TRIDEM SUSPENSION

Shown with 54” Axle Spacings

84.7

83.7

81.7

71.9

69.9

Section 3

Dimensions

79.1

77.7

72.9

5.4

2.4

2.7

4.6

8.0

AXLE SPACING

Optional Neway ADZ Tridem Suspensions

TABLE 3-12. Rear Suspension Options

Suspension Type Rating Axle Spacing

Laden Ride

Height

Neway ADZ369 tridem 69K 54” 10” 10”

Neway ADZ369 tridem 69K 60” 10” 10”

Unladen Ride

Height

RIDE HEIGHT

Neway ADZ369 tridem 69K 60” 12” 12”

Neway ADZ378 tridem 78K 54” 10” 10”

Neway AD378 tridem 78K 60” 10” 10”

3-23

02/15

Page 44

Section 3

Dimensions

HENDRICKSON PRIMAAX EX TANDEM SUSPENSION

Shown with 54” Axle Spacings

Optional Hendrickson Primaax EX Tandem Suspensions

TABLE 3-13. Rear Suspension Options

Suspension Type Rating Axle Spacing

Hendrickson Primaax Tandem 46K 54” 10” 10”

Hendrickson Primaax Tandem 46K 60” 10” 10”

Hendrickson Primaax Tandem 46K 72” 10” 10”

Laden Ride

Height

Unladen Ride

Height

02/15

3-24

Page 45

Section 3

Dimensions

HENDRICKSON PRIMAAX EX TRIDEM SUSPENSION

Shown with 54” Axle Spacings

Optional Hendrickson Primaax EX Tridem Suspensions

TABLE 3-14. Rear Suspension Options

Suspension Type Rating Axle Spacing

Hendrickson Primaax Tridem 69K 54” 10” 10”

Hendrickson Primaax Tridem 69K 60” 10” 10”

Laden Ride

Height

Unladen Ride

Height

3-25

02/15

Page 46

Section 3

Dimensions

HENDRICKSON HMX TANDEM SUSPENSION

Shown with 54” Axle Spacing

Optional Hendrickson HMX Tandem Suspensions

TABLE 3-15. Rear Suspension Options

Suspension Type Rating Axle Spacing

Hendrickson HMX400 16.5” saddle 40K 54” 9.5” 10.6”

Hendrickson HMX400 17.5” saddle 40K 54” 10.5” 11.6”

Hendrickson HMX460 16.5” saddle 46K 54” 9.5” 10.6”

Hendrickson HMX460 17.5” saddle 46K 54” 10.5” 11.6”

Laden Ride

Height

Unladen Ride

Height

02/15

3-26

Page 47

HENDRICKSON RT TANDEM SUSPENSION

Shown with a 54” Axle Spacing Without Track Rods

Section 3

Dimensions

Optional Hendrickson RT Tandem Suspensions

TABLE 3-16. Rear Suspension Options

Suspension Type Rating Axle Spacing

Hendrickson RT463 6” saddle 46K 52” 10.0” 11.1”

Hendrickson RT463 6” saddle 46K 54” 10.0” 11.1”

Hendrickson RT463 7.19” saddle 46K 54” 11.2” 12.5”

Hendrickson RT463 7.94” saddle 46K 54” 11.9” 13.3”

Hendrickson RT463 6” saddle 46K 60” 10.0” 11.1”

Hendrickson RT463 7.94” saddle 46K 60” 11.9” 13.0”

Hendrickson RTE463 7.19” saddle 46K 52” 10.5” 11.6”

Hendrickson RT523 6” saddle 52K 52” 9.9” 11.0”

Hendrickson RT523 6” saddle 52K 54” 9.9” 11.0”

Hendrickson RT523 7.19” saddle 52K 54” 11.1” 12.2”

Hendrickson RT523 11” saddle 52K 54” 14.9” 16.0”

Hendrickson RT523 6” saddle 52K 60” 9.9” 11.0”

Laden Ride

Height

Unladen Ride

Height

Hendrickson RT523 7.19” saddle 52K 60” 11.1” 12.2”

3-27

02/15

Page 48

Section 3

Dimensions

CHALMERS 856-46 TANDEM SUSPENSION

Shown with a 54” Axle Spacing

Optional Chalmers Tandem Suspensions

TABLE 3-17. Rear Suspension Options

Suspension Type Rating Axle Spacing

Chalmers 854-40-L 40K 54” 8.9” 11.1”

Chalmers 854-40-L-HS 40K 54” 9.6” 11.1”

Chalmers 854-40-H 40K 54” 10.2” 12.4”

Chalmers 854-40-H-HS 40K 54” 10.9” 12.4”

Chalmers 854-46-L 46K 54” 8.9” 11.3”

Chalmers 854-46-L-HS 46K 54” 9.6” 11.3”

Chalmers 854-46-H 46K 54” 10.1” 12.5”

Chalmers 854-46-H-HS 46K 54” 10.9” 12.5”

Chalmers 854-50-L 50K 54” 8.9” 11.3”

Laden Ride

Height

Unladen Ride

Height

Chalmers 854-50-L-HS 50K 54” 9.6” 11.3”

Chalmers 854-50-H 50K 54” 10.1” 12.5”

TABLE 3-17 CONTINUES ON NEXT PAGE…

02/15

3-28

Page 49

TABLE 3-17 CONTINUED

Section 3

Dimensions

Suspension Type Rating Axle Spacing

Chalmers 854-50-H-HS 50K 54” 10.9” 12.5”

Chalmers 854-52-L-HS 52K 54” 9.6” 11.3”

Chalmers 854-52-H-HS 52K 54” 10.9” 12.5”

Chalmers 860-40-L 40K 60” 8.9” 11.1”

Chalmers 860-46-L 46K 60” 8.9” 11.3”

Chalmers 860-46-L-HS 46K 60” 9.6” 11.3”

Chalmers 860-46-H 46K 60” 10.1” 12.5”

Chalmers 860-46-H-HS 46K 60” 10.9” 12.5”

Chalmers 860-52-H 52K 60” 10.9” 12.5”

Chalmers 872-46-H-HS 46K 72” 11.0” 12.5”

Laden Ride

Height

Unladen Ride

Height

3-29

02/15

Page 50

Section 3

Dimensions

LIFT AXLES (PUSHERS AND TAGS)

The rear pusher axle layouts are provided as a tool to help layout bodies prior to arrival. The applicable dimensions are shown. When using the pusher layouts to determine available frame space please be aware that clearances required are not shown. For information that may not be detailed in these drawings work with your local Kenworth Dealer to request that information.

Watson & Chalin 8K Steerable (SL0893SSR)

Watson & Chalin 10K Steerable (SL1093SSR)

02/15

3-30

Page 51

Section 3

Dimensions

Watson & Chalin Tru Track Alumilite 13.5K Steerable (SL1190SSR)

Watson & Chalin Tru Track 20K Steerable (SL2065)

3-31

02/15

Page 52

Section 3

Dimensions

Watson & Chalin 23K Steerable (SL2200) *Use with Duals Only*

Watson & Chalin Atlas 23K Non-Steerable (AL2200)

02/15

3-32

Page 53

Section 3

Dimensions

AXLE TRACK AND TIRE WIDTH

The dimensions provided in this section are representative of some typical product combinations. The purpose this section is to demonstrate some of the typical dimensions.

• Axle Track: The distance between the dual tire centerlines on a dual tire arrangement or the distance between the tire centerlines on a single tire arrangement.

• Width: The distance over the outermost tire sidewall to sidewall.

These dimensions may be signicant to the following:

• Appearance relative to other tires and chassis mounted equipment.

• Load carrying capacity. Different wheel disc offset can have a positive or negative impact on the axle carrying capacity of the axle.

TABLE 3-18. Axle Width Calculation.

Axle - Drive Wheel Tire Conguration

Dana Spicer D46-170(H)(P) 46K Dual

Dana Spicer D46-170W(H)(P) 46K Dual Wide Track

Dana Spicer D46-170(H)(P) 46K Dual

Dana Spicer D46-170W(H)(P) 46K Dual Wide Track

Alcoa 88367

22.5X8.25

Alcoa 98363

24.5X8.25

Alcoa 88367

22.5X8.25

Alcoa 98363

24.5X8.25

Alcoa 82262

22.5X12.25

Alcoa 82262

22.5X12.25

Track

Dim “A”

11R22.5 4-4 73.3" 97.8"

11R24.5 4-4 73.6" 98.0"

11R22.5 4-4 79.2" 103.7"

11R24.5 4-4 79.5" 103.9"

425/65R22.5 2-4 72.7 88.9"

425/65R22.5 2-4 78.7" 94.9"

Overall Width

Dim “B:

3-33

TABLE 3-18 CONTINUES ON NEXT PAGE…

02/15

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Section 3

Dimensions

TABLE 3-18 CONTINUED

Axle - Steer Wheel Tire

Dana Spicer E-1322I 13.2K Alcoa 98363

24.5X8.25

Dana Spicer E-1322W 13.2K Alcoa 98363

24.5X8.25

Dana Spicer D2000 20K Alcoa 82462

24.5X12.25

Dana Spicer D2000 20K Alcoa 82462

24.5X12.25

Lift Axle Model Wheel Tire

W&C SL0893SSR 8K Steerable

W&C SL1093SSR Steerable 10K

W&C SL1190SSR Steerable 13.5K

W&C SL2065 Steerable 20K

W&C SL2200 Steerable 23K

W&C AL2200-STD Track Non-Steerable 23K

W&C AL2200-Wide Track Non-Steerable 23K

Alcoa 66480

17.5x6

Alcoa 77349

19.5x7.5

Alcoa 88367

22.5x8.25

Alcoa 82362

22.5x12.25

Alcoa 88367

22.5x8.25

Alcoa 88367

22.5x8.25

Alcoa 82362

22.5x12.25

Alcoa 89465

22.5x9

Alcoa 84362

22.5x14

Brake Drum

Type

11R24.5 CAST 80.2" 91.0"

11R24.5 CAST 82.2" 93.0"

425/65R22.5 CAST 86.5" 102.7"

425/65R22.5 CAST 82.6" 98.8"

Wheel

Orientation

215/75R17.5 Same as FR 77.3" 85.8"

265/70R19.5 Same as FR 78.5" 88.5"

255/70R22.5 Same as FR 80.4" 90.7"

425/65R22.5 Same as FR 83.6" 99.8"

295/75R22.5

11R22.5

425/65R22.5

315/80R22.5

445/50R22.5

Same as RR,

dual

Same as RR,

dual

Same as RR,

single

Same as FR,

single

Same as RR,

single

Track

Dim “A”

Track

Dim “A”

78.2" 102.8"

72.2" 96.6"

78.4" 94.7"

64.7" 77.3"

80.6" 97.7"

Overall Width

Dim “B:

Overall Width

Dim “B”

02/15

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Section 3

Dimensions

GROUND CLEARANCE

This information is provided as a reference, not all optional equipment is included. In order to calculate the height on your

specic chassis, please use the ride height information provided on page 3-14. For comparison the FS value shown is

11.4” unladen and 10.4” laden.

TABLE 3-19. Ground Clearance for Fuel Tanks

Front

Suspension

20K

Taperleaf

Spring

Front Tires

425/65R22.5

Rear

Suspension

Hendrickson

HMX 460

17.5”

Saddle

Height

Rear Tires

11R24.5

Fuel Tank

Size

22”

Diameter

24.5”

Diameter

28.5”

Diameter

Dimension “B”

Dimension “A”

Component

Fuel Tank 16.3 17.2 14.9

DEF Tank 15.3 18.2 15.9

Fuel Tank 18.2 15.3 13

DEF Tank 15.8 17.7 15.4

Fuel Tank 21.4 12 9.7

DEF Tank 17.2 16.2 13.9

Distance from

Bottom of

Frame Rail (in)

Ground Clearance

(in)

Unladen Laden

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Dimensions

TABLE 3-20. Ground Clearance for Battery Boxes

Dimension

“A”

Front

Suspension

20K Taperleaf Spring

Dimensions shown are for daycabs with high route exhaust. Sleeper ground clearance is reduced by 1.3 inches.

Front Tires

425/65R22.5

Tires

Rear

Suspension

Hendrickson

HMX 460

17.5” Saddle Height

Rear Tires Component

Battery Box

with Air Tanks

Vocational

11R24.5

Battery Box

with Air Tanks

DPF1 Box 15.6 17.8 15.5

Distance

from

Bottom of

Frame Rail

(in)

17.3 16.2 13.9

17.8 15.7 13.4

Dimension “B” Ground

Clearance (in)

Unladen Laden

02/15

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Section 3

Dimensions

PTO CLEARANCES

The following visuals are provided to help aid in determining PTO locations and clearances. For specic dimensions

please work through your local Kenworth dealer. Note: Installations depict multiple PTOs.

In order to ensure the PTO area remains clear of air equipment, electrical and emissions equipment, Kenworth recommends always ordering PTO controls, even when installing the PTO aftermarket. Kenworth does offer a variety of factory installed PTOs. Contact your local dealer for assistance.

Manual Transmission:

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Dimensions

Allison Transmission:

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Section 3

Dimensions

T680/880 TRANSMISSION PTO APPLICATION GUIDE

This application guide indicates if a PTO has sufcient clearance to truck components in various mounting congurations. A green “ok” indicates that there is sufcient clearance to other truck components. A red “x” indicates that there minimal

or no clearance and the application is not recommended. The truck components investigated in this guide include frame rails, Set Back Front Axle (SBFA) rear shackle, SBFA Front Air Suspension (FAS) rear shackle, over-bell frame brace, coolant return manifold, transmission clutch actuator, and exhaust system components.

Usage Notes:

1. This application guide is only applicable to T680/880 trucks.

2. Only the specied PTO congurations have been analyzed. Please submit an OAR to review other models

and/or congurations.

3. Horizontal crossover exhaust limits access behind PTO’s for shaft drives and other PTO attachments.

4. Fuel tank cross bracing may interfere with PTO’s and/or PTO attachments (such as hydraulic pumps). If this is an issue, the cross brace may be moved to an alternate fuel tank support. “

5. Eaton FR transmissions require the use of a 30° adapter when installing Chelsea or Muncie transmission PTO’s in the right hand position.

6. Eaton RT & Ultrashift Plus transmissions require the use of a 49° adapter when installing Chelsea transmission PTO’s in the right hand position.

7. Eaton RT & Ultrashift Plus transmissions require the use of a 55° adapter when installing Muncie transmission PTO’s in the right hand position.

8. Eaton transmissions require the use of a 6 to 8 Bolt adapter when installing a 6 bolt PTO in the bottom position.

PTO Controls:

The T680/880 models have been designed to use electric in-dash switches to control air solenoids (Electric Over Air system, or EOA) which engage/disengage transmission PTOs. This system allows for increased control and interlock opportunities. This also keeps air lines for transmission PTO controls from routing inside the cab. In cab air valve actuators for

transmission PTO control are still available and are located on the cab oor on the LH side of the driver’s seat. Air valve style transmission PTO actuators should not be installed on the dash due to the difculty of air-line routing. Customer in-

stalled transmission PTO controls for use with customer installed transmission PTO’s include a chassis and dash harness pre-wire to ease the installation of in-dash transmission PTO controls at the body builder. It is strongly recommended that the truck be coded for this if transmission PTO(s) could be installed after initial in-service date.

The EOA system is used to control PTO engagement. There are three different types of PTOs supported in the EOA software:

Single-Acting PTOs – these types of PTOs have a single air control. A single chassis node output controls the air solenoid, tand the air pressure engages the PTO – the lack of air pressure at the control port disengages the PTO.

Double-Acting PTOs – these types of PTOs have a dual air control. One air signal controls the engagement and one air signal controls the disengagement. This can be achieved in one of two ways:

• A single-acting PTO is congured – the engage air control port is connected to the chassis node output and a

pilot inversion valve in the chassis air plumbing is connected to the second disengage air control port.

• Two chassis node outputs control the PTO. One chassis node output and solenoid is connected to the engage air control port of the PTO, and one chassis node output and solenoid is connected to the disengage air control port.

Reversible PTOs – have three different operational states. Inactive – not engaged to driveline (no air control ports active).

Main direction –engaged to driveline (main air control port pressureized). Opposite direction –engaged to driveline (opposite air control port pressurized). If the vehicle is specied with a pTO installation from the factory, a protected PTO on/off

switch will be used. It will connect to the instrument panel harness ith a switch connector labeled “EOA x” x eing a number between 1 and 10.

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PTO Functionality Description

Power Take-Off (PTO)

The PTO category covers both ‘Single-Acting’ and ‘Double-Acting’ PTOs. Single-acting PTOs require air pressure on the input cylinder to activate the function and will deactivate via an internal spring when air pressure is removed; air-on/springoff. Dual-acting PTOs require air pressure an input cylinder to activate and air pressure on a different input cylinder to

deactivate; air-on/air-off. This information is provided for additional clarication since the system appears identical from an

electronics-control aspect.

The PTO type depends on the actual brand and part number. Most examples in this document show double-acting. Whenever any PTO is engaged, a feedback signal will activate a single cluster telltale.

FIGURE 3-2. Single Acting and Dual Acting PTOs

TABLE 3-21. Current single-acting PTOs include:

Model Supplier Mounting Hyd. Clutch Actuator Actuator Type

238/489/680 Chelsea

CS/SH/TG8 Muncie

885 Chelsea Optional Single

230/236/442/660 Chelsea

CS/SH/TG6 Muncie

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RH Standard Single

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Standard Single

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TABLE 3-22. Current double-acting PTOs include:

Model Supplier Mounting Hyd. Clutch Actuator Actuator Type

823 Chelsea

828 Muncie

340 (reversible)

880 Optional Double

340 (reversible)

541 Back Any

Chelsea

Bottom

RH Standard

Eaton Transmission-Mounted PTO

When a PTO is ordered on an Eaton brand transmission it is controlled with EoA System. The PTO can be a single-acting or double-acting and have one or two PTOs attached to the transmission. Optional park brake interlocks are available via sales codes.

All PTOs have an engaged feedback signal that is routed to the cluster to illuminate a PTO. When any PTO is actively engaged the cluster telltale will illuminate.

Standard Double

Double

Figure 3-3 shows the system diagram for a single-acting Eaton mounted transmission PTO. Signal ow is as follows:

• The dash switch labelled “PTO Switch #1” is activated by the user.

• The signal is received by the CECU and the optional interlocks are checked and veried.

• The Chassis Node receives a multiplexed CAN message to activate and send a power signal to the appropriately assigned solenoid.

• The solenoid activates and allows supplied air pressure to ow to the piped PTO port.

• The PTO activates and the ball switch closes sending a hardwired signal.

• The CECU and Engine ECM received this signal.

• The CECU sends a CAN message to the Cluster to activate the PTO telltale and the Engine changes state to “PTO Mode”

FIGURE 3-3. Single-Acting Eaton PTO

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The signal ow is the same for double-acting PTOs. The difference is that an inversion dump valve provides air pressure to

the “off” port when the EoA solenoid is not being command on.

FIGURE 3-4. Double-Acting Eaton PTO

Allison Transmission-Mounted PTO (a.k.a. Electric-Over-Hydraulic)

When a transmission PTO is ordered on an Allison brand transmission, it is always Electric-over-Hydraulic (EoH). From the controls aspect, it looks like an “electric-only” type switch. The switch and telltales do not distinguish the difference between EoH and EoA.

FIGURE 3-5. Allison Transmission-Mounted PTOs

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Transmission PTO with Auto Suspension Dump/Inate

This feature requires Air Suspension Dump functionality. Upon PTO activation, if not already dumped, the NAMUX system

will command the air suspension to deate (“dump”) before the PTO is engaged. When the PTO switch is deactivated the air suspension will re-inate. This feature is an optional sales code, but coded standard on some applications; such as

those with boom cranes.

With Allison transmission mounted PTOs the CECU EoA system does not directly know when the PTO is active since the switch is wired directly to the TCM. In this case, the ECM is broadcasting a CAN messages indicating that the engine is in PTO Mode. This is used as a proxy for the CECU to know when the PTO is active.

For Eaton mounted PTOs all functionality occurs within the CECU. When either the PTO switch is activated or the CECU receives a message that the ECM is in PTO Mode CECU will begin the Auto Suspension Dump functionality. First, the CECU checks applicable interlocks. If appropriate, it will send a CAN message to the Chassis Node requesting PTO solenoid activation and Suspension Dump activation.

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FIGURE 3-6. Auto Susp Dump w/ Allison mtd PTO

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Reversible PTO (a.k.a. Fwd/Rev PTO, a.k.a. 2-Position PTO)

Some transmission-mounted PTOs have two directions of spin. The Reversible PTO switch provides two CECU inputs for

forward & reverse and there are two non-latching solenoids pressurizing two single-acting cylinders on the PTO, see the gure below.

FIGURE 3-7. EoA Reversible PTO Example

PTO States

Forward Reverse OFF

Fwd X

Ports

Rev X

TABLE 3-23. Reversible PTO States to Ports

Non-EoA Air Actuated PTOs

NGP models do not offer air controls mounted on the dash. In cases where the customer must have air controls, they are

mounted on the oor or side of seat. The block diagram is shown in Figure 3-8.

FIGURE 3-8. Air Actuated PTO (No Interlock)

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PTO (Split-Shaft, Transfer Case, etc.)

Split-shaft PTOs are gearboxes between the transmission and rear axles. Much like transmission mounted PTOs, they take driveline power from the transmission and divert it (“take it off”) to equipment such as pumps, winches, etc. Where

they differ is split-shaft PTOs are not mounted to the transmission and can handle signicantly more power and torque

than a traditional transmission-mounted PTO.

These gearboxes have a few different congurations; some split-shaft PTOs have a single pneumatic cylinder that simultaneously declutches the rear axle when activating the PTO,

Figure 3-10. This is known as “Pump Mode”. Other split-shaft PTOs have independently controls for PTO engagement and rear axle declutch. This allows the drive while the PTO is running. Others have an additional PTO output pad that is separate from the main PTO output gear.

Transmission mounted PTOs, split-shaft PTOs, and non-EoA controlled PTOs are not exclusive to the type and can be

combined in nearly any conguration.

When the Rear Axle Declutch function is active a positive feedback signal activates a telltale in the cluster editable area. The PTO active telltale is the same a transmission mounted PTO, see Figure 3-9..

FIGURE 3-9. Rear Axle Declutch Telltale

Figure 3-10 shows an example conguration where the customer has ordered a SS PTO with separate switches for Rear

Axle Declutch.

FIGURE 3-10. Split Shaft PTO Example #1

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Split-Shaft PTO - Pump Mode

When the PTO controls are specied/congured to have a single switch controlling both the PTO Engage and Rear Axle Declutch it is called “Pump Mode.” The controls and air piping architecture pressurizes the ports such that the PTO is

engaged and rear axle declutched at the same time. This is a common term used in the industry. When engaged, two separate telltales will illuminate (from actual wired feedback) indicating the state of both PTO and Rear Axle Declutch. Park Brake must be engaged to activate Pump Mode, if not, a popup message on the cluster will appear telling the driver to do so.

Note that the functions themselves are not unique. Controlling both functions with a single switch is convenient and offers additional interlocks. Positive feedback signals activate a PTO and Rear Axle Declutch telltales within the cluster editable telltale area.

In the example below, a Pump Mode conguration is shown with dual-acting PTO ports. Notice that this is similar to Figure

3-10 except the Rear Axle Declutch cylinder is plumbed to activate/deactivate at the same time with the PTO engage switch.

FIGURE 3-11. Pump Mode Example

Electric Over Air System Interlocking

By utilizing the Cab ECU to control the EOA system, the EOA switching has capabilities to be interlocked with other functions such as park brake application, vehicle speed, neutral gear selected, or a combination of these functions. Switch activation will only occur if the interlock criteria are met. If the Cab ECU detects the switch is in the on position and if applicable, the park brake interlock is validated by the Cab ECU, the Cab ECU will send a signal to the chassis node via F-CAN. The EOA valve will be the same number as on the dash switch. Electronic Service Application (ESA) can be used to add or remove the PTO engage park brake interlock. Depending on the application and the PTO type, the switches and wiring may differ.

For single-acting PTOs, the chassis node will energize the coil on the EOA valve allowing air to engage the PTO.

For dual-acting PTOs, the PTO’s pilot valve will provide the air function to switch the air between engage and disengage.

For reversible PTOs, a protected PTO forward and a protected PTO reverse switch will be present in the dash. Each switch controls a separate EOA solenoid, each solenoid is dedicated to either forward or reverse. If the Cab ECU detects both the forward and reverse switches in the on position the Cab ECU will ignore the switch input for the second switch thrown and

provide a message in the cluster display informing the operator of the non-valid switch conguration

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FIGURE 3-12. Sample Chassis Node and EOA Manifold. (congured to match Figure 3-13)

02/15

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FIGURE 3-13. Wiring Diagram for Chassis Node, Cab Switches, and EOA Manifold. (congured to match Figure 3-12)

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10-Bolt PTO’s for Allison Transmissions

TABLE 3-24.

4000 Series

Brand PTO Truck Model 1 o’clock 8 o’clock 1 o’clock 8 o’clock 4 o’clock 8 o’clock

267-M3XK All x x ok x x x

267-M5XK All ok ok ok x ok ok

T680/880 ok ok ok x ok ok

T680SH/880SH ok x ok x ok ok

T680/880 ok x ok x ok ok

T680SH/880SH ok x ok x x ok

T680/880 ok x ok x ok ok

T680SH/880SH ok x ok x x ok

T680/880 ok ok ok x ok ok

T680SH/880SH ok ok ok x x ok

T680/880 ok x x x ok x

T680SH/880SH ok x x x ok ok

Chelsea

Muncie

277-B5XS

859-B5XS All ok x x x x x

870X-B3RS All ok x ok x x x

870X-B5RS All ok x ok x x x

890-B5XS All ok x ok x x ok

CD05-M3CX All ok ok ok ok ok ok

CD10-M1CX, DX

CD10-M3CX, DX

CS10-P1CX, EX All x x x x x x

CS10-P3CX, EX All x x x x x x

CS24-P1BX, KX All ok x ok x x x

CS24-P3BX, KX

CS41-P1CX, EX All ok x x x x x

CS41-P3CX, EX All ok x x x x x

HS24-P1BX, KX

HS24-P3BX, KX All ok ok ok x x ok

3000 Series -

1 & 8 Housing

3000 Series -

4 & 8 Housing

02/15

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Section 3

Dimensions

6 & 8 Bolt PTO’s for Eaton Transmissions

TABLE 3-25.

FR RT Ultrashift Plus

Brand Style PTO Bottom Right Bottom Right Bottom Right

230-V3XD/XK ok ok1,2,3 ok ok1,2,3 ok ok1,2,3

Chelsea

6-Bolt

8-Bolt

236-V3XD/XK

270-B3XD/XK ok ok1,2,3 ok ok1,2,3 ok ok1,2,3

340-V5XD ok ok1,2,3 ok ok1,2,3 ok ok1,2,3

442-V3XK

660-V3XK

238-V3XD/XK ok n/a ok n/a ok n/a

489-V3XK ok n/a ok n/a ok n/a

680-V3XK ok n/a ok n/a ok n/a

823-V3XS ok n/a ok n/a ok n/a

880-V3XS/XV4 ok n/a ok n/a ok n/a

885-V3XS4 ok n/a ok n/a ok n/a

CS6-P1BX/KX

Recomend

238

Recomend

489

Recomend

680

Recomend

CS8

ok1,2,3

Recomend

238

Recomend

489

Recomend

680

Recomend

CS8

ok1,2,3

ok1,2,3 x ok1,2,3

Recomend

238

Recomend

489

Recomend

680

ok1,2,3

6-Bolt

Muncie

8-Bolt

NOTES:

1) Not available with AG130 Front Air Suspension

2) Not available with Horizontal Crossover or Right Hand Behind Fairing Exhaust Systems

3) Restricted PTO access with RH Cab Step Assembly DPF-SCR exhaust systems with Vertical BOS tailpipes or RH Hori-

zontal Tailpipe below rail

4) The Optional Hydraulic Clutch Orientation must be used with this PTO

SH6-P1BX/KX

TG6-P1BX/KX

828S-U1CX/EG ok n/a ok n/a x n/a

CS8-P1BX/KX ok n/a ok n/a ok n/a

SH8-P1BX/KX ok n/a ok n/a ok n/a

TG8S-P1BX/KX ok n/a ok n/a ok n/a

Recomend

SH8

Recomend

TG8

ok1,2,3

Recomend

SH8

Recomend

TG8

ok1,2,3 x ok1,2,3

ok1,2,3

Recomend

TG8

ok1,2,3

3-51

02/15

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Section 3

Dimensions

Dual PTO Compatibility for Eaton Transmissions

TABLE 3-26.

Chelsea Muncie

RH (6-Bolt) PTO’s

RT FR Ultrashift+ RT FR Ultrashift+

Model

230/236-V3

340X-V5

442/660-V3

230/236-V3

340X-V5

442/660-V3

340X-V5

230/236-V3 S S S S S S ok ok 828S-U1 S S S S ok ok

238-V3 S S S S S S ok ok CS/SH8-P1 S S S S

340X-V5 S S S S S S ok ok TG8S-P1 S S S S ok ok

442/660-V3 S S S S S S ok ok

489/680-V3 S S S S S S ok ok

823-V3 S S S S S S ok ok

880-V3 x x O x O x ok ok

LH (6 & 8-Bolt) PTO’s

885-V3 x x O x O x ok ok

S = Standard Hydraulic Clutch Actuator Conguration O = Optional Hydraulic Clutch Actuator Conguration

Model

442/660-V3

CS/SH6-P1

TG6-P1

CS/SH6-P1

TG6-P1

CS/SH6-P1

ok ok

TG6-P1

02/15

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HYDRAULIC CLUTCH ACTUATOR CONFIGURATIONS:

Only used with T680/880 trucks with Eaton FR or RT transmissions

The Clutch Actuator Conguration is driven by the PTO informational sales codes. There is not a specic sales code which species the conguration.

Standard Conguration Optional Conguration

Air assist connection faces driver’s side Air assist connection faces passenger’s side Used with All but Chelsea 880 and 885 PTOs Used with Chelsea 880 and 885 PTOs

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02/15

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Section 4 Exhaust & Aftertreatment

EXHAUST AND AFTER-TREATMENT INFORMATION

The following section is designed to give you information regarding the exhaust and after-treatment systems on Kenworth chassis.

All Kenworth’s equipped with 2013 emission level engines will utilize Selective Catalyst Reduction (SCR). SCR is a process in which Diesel Exhaust Fluid (DEF) is injected into the exhaust down stream of the engine. DEF is converted to ammonia by the heat of the exhaust system. Inside of the SCR canister a catalyst causes a chemical reaction to occur be-

tween the ammonia and NOx, turning it into water and nitrogen. For more information on the specic details of how SCR

works, please contact your local Kenworth dealer.

DEF System Schematic:

On most Kenworth chassis the DEF Supply Module (or pump) is integrated into the DEF tank. Kenworth does not allow relocation of this pump. The following schematic details how the DEF lines route to the after-treatment system.

DEF Tank

(11-gallon shown)

DEF Return Line

(Backow from

Supply Module)

Coolant Draw

(from Draw Tee)

DEF Draw Line (Inlet to Supply Module)

See Detail A

Coolant Return (to Coolant Valve)

Detail A

Scale 1:2

DEF Return Line (Backow)

DEF Draw Line (Inlet)

DEF Supply Module

(Pump)

DEF Pressure Line (Outlet)

DEF Dosing Module (Injector)

4-1

02/15

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Exhaust & Aftertreatment

DEF will freeze at approximately 11° F. In order to keep DEF from freezing all tanks will be heated with engine coolant. The following schematic shows the routing of these lines. The coolant lines that run to and from the SCR system must not be tampered with, or used for a source of heat and/or cooling for other components on the chassis. It is critical that the system is not compromised in any manner.

DEF Tank

(Small Tank Shown)

5/8” Coolant Hose

(Green - Draw)

Return Tee Draw Tee

DEF Tank Heating Element

3/8” Coolant Hose

(Blue - Return)

Draw Port Return Port

2/2 Coolant Valve

3/8” Coolant Hose (Green - Draw)

DEF Dosing Module (Injector)

Coolant Bulkhead (Framemounted)

5/8” Coolant Hose (Blue - Return)

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GENERAL GUIDELINES FOR DEF SYSTEM

The installation of the DEF tank is a critical component of the SCR system. While Kenworth does not recommended relocating the DEF tank, there are applications and body installations that will require it. The guidelines below must be strictly followed by any entity relocating the tank. Failure to follow the guidelines completely and accurately may result in engine shutdown situations.

PACCAR-approved DEF hoses are required when retrotting for system to function properly. The use of unapproved hoses

for DEF lines will void warranty and may cause engine shutdown situations. The DEF pump (or Supply Module) can not be relocated from the DEF tank.

Kenworth offers a variety of DEF tank sizes to meet every application. The DEF tank volume is regulated by the E.P.A. Kenworth advises against modifying the tank volume after the truck has been delivered from the factory. These are esti-

mated nominal (published) maximum fuel capacities for various DEF tanks, engines, and ll ratios. Dosing rates for these

calculations are also shown.

TABLE 4-1.

Nominal Fuel Volume (Gallons)

DEF Tank Standard Fill Ration

(˜2:1)

ISX15 ISX12 MX PX ISX15 ISX12 MX PX

Small 165 175 125 205 205 220 170 225

Optional Fill Ratio

(1:1-2:1 Code)

Medium 305 325 235 380 415 440 320 510

Tanks

Round

Large 460 490 355 570 625 660 480 770

Medium Aero 310 330 240 385 420 445 345 520

Aero

Large Aero 395 415 305 485 575 610 470 710

Tanks

Rectangular 110 115 85 135 160 170 115 195

CBOC 100 110 80 125 150 160 125 190

Other

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INSTALLATION REQUIREMENTS AND DIMENSIONS FOR DEF SYSTEM

When relocating any DEF system components, the locations must meet the guidelines below. Failure to comply may result in non-conformance to EPA standards and engine shutdown.

DEF piping relative heights: In order to ensure proper functionality of DEF system, the height differences in the guidelines below must be followed during line routing and component placement.

With all relocating procedures, general clearances and routing guidelines must be followed. See section 9 of this manual for general routing guidelines.

When relocating the components the maximum pressure DEF hose length, from Supply module to Dosing Module, is 3 meters (118”).

Maintain a minimum of 3” clearance to shielded exhaust components when routing DEF lines to prevent possible melting.

If the DEF tank is relocated the coolant lines will need to be modied. During this process if the tank is moved forward on

the chassis (ie closer to the engine) it is necessary to remove excess coolant lines and maintain the original routing path. If the tank is moved rearward on the chassis the additional length of cooling line required to complete the installation must

be installed in a straight section of the existing coolant routing lines. This process will minimizes the change in coolant ow

by minimizing changes in restrictions. Changes in restriction are added with excessive line length and bends. Work with

your local Kenworth dealer if you are unsure about the coolant line modications.

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MEASUREMENT REFERENCE POINTS

For the all relocation procedures, the measurement points will referenced in the guidelines are taken from the following

specic points:

Supply Module: The supply module is commonly called a pump. The measurement point on the supply module is the top

of the DEF uid pressure line. See Figure 4-1.

FIGURE 4-1: Measurement Location of DEF Supply Module (Pump)

Dosing Module: The dosing module is commonly called an injector, this injector is located on the SCR mixing pipe which

is between the DPF and SCR canister. The measurement point on the dosing module is the top of the DEF uid pressure

line. See Figure 4-2.

FIGURE 4-2: Measurement Location of DEF Dosing Module (Injector)

The following relocation guidelines are dependant on exhaust conguration and DEF tank type and location.

The Dosing Module should not ever need to be relocated, however if it is removed for any reason, it is critical that the module be reinstalled at the correct orientation. Figure 4-3 below illustrates the correct installation orientations. The angle references the vertical plane.

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FIGURE 4-3: Orientation of Dosing Module

Right Hand Under DPF and SCR with Small, Medium, or Large DEF Tanks

FIGURE 4-4: RH Under Cab Exhaust with Small, Medium, or Large Tanks.

The height differential between the supply module and dosing module can not exceed one meter. The supply module is integrated into the DEF tank assembly, separation of the module from the tank is not allowed.

When relocating the components the maximum pressure DEF hose length, from Supply module to Dosing Module, is 3 meters (118”).

DEF Pressure hose must include a “trap” in the routing if Dosing Module is below the highest point of the Supply Module (See Figure 4-9 on page 4-9).

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Horizontal (Crossover) DPF and SCR with Small, Medium, or Large DEF Tanks

FIGURE 4-5: Horizontal Exhaust with Small, Medium, or Large Tanks.

When relocating the components the maximum pressure DEF hose length, from Supply module to Dosing Module, is 3 meters (118”).

Vertical DPF and SCR with Small, Medium, or Large DEF Tanks

FIGURE 4-6: Vertical Exhaust with Small, Medium, or Large Tanks.

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

Exhaust & Aftertreatment

When relocating the components the maximum pressure DEF hose length, from Supply module to Dosing Module, is 3 meters (118”).

Routing to the Dosing Module (Injector)

A DEF pressure line “trap” is no longer required after EPA 2013 emissions level engine. The dosing module (injector) is now able to be the lowest point in the presure line routing. See Figure 4-7 below for typical routing with RHUC exhaust and

RH DEF tank shown. Also shown in this gure is the coolant line routing for T680 and T880 models.

FIGURE 4-7: Routing DEF Lines

DEF Supply Module Mounting Requirements

The Supply Module (or Pump) standard mounting location is on the DEF tank assembly. Body builders may need to relocate this component, and should follow the location and length restrictions above. Additionally the mounting and the orientation of the Supply Module must not exceed 45° (from vertical) in two directions as shown in Figure 4-8 below.

FIGURE 4-8: Supply Module Allowed Clocking Angles

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GENERAL EXHAUST INFORMATION

Kenworth will offer three main DPF and SCR exhaust systems on heavy duty chassis in 2013. A Right Hand Under DPF and SCR system, in which both canisters are located underneath the cab access step. A horizontal system with both the DPF and SCR located horizontally with a cross over pipe in the frame, and an Independent DPF and SCR located vertically back of cab on stanchion brackets.

RH Under DPF and SCR Horizontal DPF and SCR Independent Back of Cab

The following images depict the typical exhaust routings for each system, and can be used to determine exhaust routing paths for systems you choose. Dimensional information can be found in Section 5 of this manual.

Body Builders must not modify (including altering, substituting, and relocating) the DPF and SCR canisters. The exhaust

piping after it exits the SCR canister may be modied, however using smaller diameter piping or piping with numerous

bends is not recommend as the backpressure requirements of the system may be exceeded.

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Right Hand Under DPF/SCR on DayCav with Single Side of Cab Tailpipe

FIGURE 4-9: Isometric view of Right Hand Under DPF/SCR with Single Side of Cab Tailpipe

FIGURE 4-10: Isometric view of Right Hand Under DPF/SCR with Single Side of Cab Tailpipe

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FIGURE 4-11: Right view of Right Hand Under DPF/SCR with Single Side of Cab Tailpipe

FIGURE 4-12: Back view of Right Hand Under DPF/SCR with Single Side of Cab Tailpipe

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Right Hand Under DPF/SCR on DayCab with Dual Side of Cab Tailpipes

FIGURE 4-13: Isometric view of Right Hand Under DPF/SCR with Dual Side of Cab Tailpipe

FIGURE 4-14: Isometric view of Right Hand Under DPF/SCR with Dual Side of Cab Tailpipe

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FIGURE 4-15: Right View of Right Hand Under DPF/SCR with Dual Side of Cab Tailpipe

FIGURE 4-16: Back View of Right Hand Under DPF/SCR with Dual Side of Cab Tailpipe

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Right Hand Under DPF/SCR on DayCab with Single Back of Cab Tailpipe

FIGURE 4-17: Isometric View of Right Hand Under DPF/SCR with Single Back of Cab Tailpipe

FIGURE 4-18: Isometric View of Right Hand Under DPF/SCR with Single Back of Cab Tailpipe

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FIGURE 4-19: Right View of Right Hand Under DPF/SCR with Single Back of Cab Tailpipe

FIGURE 4-20: Back View of Right Hand Under DPF/SCR with Single Back of Cab Tailpipe

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Right Hand Under DPF/SCR on DayCab with Ground-Dump Tailpipe

FIGURE 4-21: Isometric View of Right Hand Under DPF/SCR with Ground-Dump Tailpipe

FIGURE 4-22: Isometric View of Right Hand Under DPF/SCR with Ground-Dump Tailpipe

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FIGURE 4-23: Right View of Right Hand Under DPF/SCR with Ground-Dump Tailpipe

FIGURE 4-24: Back View of Right Hand Under DPF/SCR with Ground-Dump Tailpipe

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Independent Back of Cab DPF/SCR on DayCab with Back of Cab Tailpipe

FIGURE 4-25: Isometric View of Independent Back of Cab DPF/SCR with Back of Cab Tailpipe

FIGURE 4-26: Isometric View of Independent Back of Cab DPF/SCR with Back of Cab Tailpipe

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FIGURE 4-27: Right View of Independent Back of Cab DPF/SCR with Back of Cab Tailpipe

FIGURE 4-28: Back View of Independent Back of Cab DPF/SCR with Back of Cab Tailpipe

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Horizontal Crossover DPF/SCR on DayCab with Ground-Dump Tailpipe

FIGURE 4-29: Isometric View of Horizontal Crossover DPF/SCR with Ground-Dump Tailpipe

FIGURE 4-30: Isometric View of Horizontal Crossover DPF/SCR with Ground-Dump Tailpipe

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FIGURE 4-31: Right View of Horizontal Crossover DPF/SCR with Ground-Dump Tailpipe

FIGURE 4-32: Back View of Horizontal Crossover DPF/SCR with Ground-Dump Tailpipe

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Right Hand Under DPF/SCR on 52” Sleeper with Single Side of Cab Tailpipe

FIGURE 4-33: Isometric View of Right Hand Under DPF/SCR with Single Side of Cab Tailpipe (52” Sleeper)

FIGURE 4-34: Isometric View of Right Hand Under DPF/SCR with Single Side of Cab Tailpipe (52” Sleeper)

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FIGURE 4-35: Right View of Right Hand Under DPF/SCR with Single Side of Cab Tailpipe (52” Sleeper)

FIGURE 4-36: Rear View of Right Hand Under DPF/SCR with Single Side of Cab Tailpipe (52” Sleeper)

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Right Hand Under DPF/SCR on 52” Sleeper with Dual Side of Cab Tailpipe

FIGURE 4-37: Isometric View of Right Hand Under DPF/SCR with Dual Side of Cab Tailpipe (52” Sleeper)

FIGURE 4-38: Isometric View of Right Hand Under DPF/SCR with Dual Side of Cab Tailpipe (52” Sleeper)

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FIGURE 4-39: Right View of Right Hand Under DPF/SCR with Dual Side of Cab Tailpipe (52” Sleeper)

FIGURE 4-40: Rear View of Right Hand Under DPF/SCR with Dual Side of Cab Tailpipe (52” Sleeper)

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Right Hand Under DPF/SCR on 52” Sleeper with Single Back of Sleeper Tailpipe

FIGURE 4-41: Isometric View of Right Hand Under DPF/SCR with Single Back of Sleeper Tailpipe (52” Sleeper)

FIGURE 4-42: Isometric View of Right Hand Under DPF/SCR with Single Back of Sleeper Tailpipe (52” Sleeper)

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