Kenworth T470, T440 0 User Manual

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Page 1

2010

Kenworth T440/T470

Body Builder Manual

Page 2

2010 Emissions

Kenworth T440/T470

Body Builder Manual

Page 3

T470/T440 Body Builder

Manual Contents

SECTION 1: INTRODUCTION 1-1 SECTION 2: SAFETY AND COMPLIANCE 2-1

SAFETY SIGNALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

FEDERAL MOTOR VEHICLE SAFETYSTANDARDS COMPLIANCE . . . . . . . . . . . . 2-2

SECTION 3: DIMENSIONS 3-1

DIMENSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

ABBREVIATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

TURNING RADIUS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

KENWORTH AXLE TRACK/TIRE WIDTH SUMMARY . . . . . . . . . . . . . . . . . . . . 3-4

OVERALL DIMENSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

T470 FIXED GRILLE HOOD W/O EXTENDED FRONT FRAME . . . . . . . . . . . . . . . 3-6

T440 DAYCAB. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7

T470 FIXED GRILLE HOOD WITH EXTENDED FRONT FRAME . . . . . . . . . . . . . . 3-9

38” AEROCAB. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-10

RIDE HEIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-12

REAR SUSPENSION LAYOUTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-14

REYCO 79KB SINGLE REAR AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14

REYCO 102 TANDEM REAR AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-15

NEWAY AD 123 SINGLE REAR AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-16

NEWAY AD 246 TANDEM SUSPENSION . . . . . . . . . . . . . . . . . . . . . . . . . . .3-17

HENDRICKSON PRIMAAX TANDEM SUSPENSION. . . . . . . . . . . . . . . . . . . . . 3-18

HENDRICKSON HMX TANDEM SUSPENSION . . . . . . . . . . . . . . . . . . . . . . .3-19

HENDRICKSON RT TANDEM SUSPENSION. . . . . . . . . . . . . . . . . . . . . . . . .3-20

KENWORTH AG 380 TANDEM SUSPENSION . . . . . . . . . . . . . . . . . . . . . . . .3-22

KENWORTH AG 400/460 TANDEM SUSPENSION. . . . . . . . . . . . . . . . . . . . . .3-23

KENWORTH AG 400L TANDEM SUSPENSION . . . . . . . . . . . . . . . . . . . . . . .3-24

KENWORTH AG 460 TANDEM SUSPENSION . . . . . . . . . . . . . . . . . . . . . . . .3-25

CHALMERS 856-46 TANDEM SUSPENSION. . . . . . . . . . . . . . . . . . . . . . . . .3-26

PUSHER AXLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-27

PTO CLEARANCES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-32

SECTION 4: EXHAUST AND AFTERTREATMENT 4-1

EXHAUST AND AFTER-TREATMENT INFORMATION. . . . . . . . . . . . . . . . . . . . 4-1

GENERAL GUIDELINES FOR DEF SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . 4-3

INSTALLATION REQUIREMENTS AND DIMENSIONS FOR DEF SYSTEM . . . . . . . . . 4-3

MEASUREMENT REFERENCE POINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

GENERAL EXHAUST INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-10

EXHAUST INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-19

SECTION 5: FRAME LAYOUTS 5-1

FRAME LAYOUTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

COMMON OPTIONAL COMPONENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

FRAME LAYOUT INDEX. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4

CHARTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5

SECTION 6: BODY MOUNTING 6-1

FRONT FRAME DIMENSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

FRAME INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

BODY MOUNTING USING BRACKETS. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3

MOUNTING HOLES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5

BODY MOUNTING USING U–BOLTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6

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T470/T440 Body Builder

Manual Contents

SECTION 7: FRAME MODIFICATIONS 7-1

FRAME MODIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

MODIFYING FRAME LENGTH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2

CHANGING WHEELBASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3

CROSSMEMBERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5

WELDING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6

TORQUE REQUIREMENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7

SECTION 8: ELECTRICAL 8-1

ELECTRICAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1

MULTIPLEX INSTRUMENTATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1

ACCESSING GAUGES AND SWITCHES. . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9

TELLTALE SYMBOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-17

SPARE RELAYS BODY BUILDER INSTALLED(FOR LOADS EXCEEDING 20 AMPS) . . . 8-23

ADDITIONAL SPARE CIRCUITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-25

REMOTE PTO/THROTTLE HARNESS . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-27

MULTIFUNCTION TURN SIGNAL STALK, CHASSIS NODE & CHASSIS LOAD CENTER .8-28

CHASSIS LOAD CENTER DIMENSIONS. . . . . . . . . . . . . . . . . . . . . . . . . . .8-30

2010 ELECTRICAL HARDWARE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-31

TRAILER CABLE CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-35

FACTORY INSTALLED SNOW PLOW LIGHT WIRING . . . . . . . . . . . . . . . . . . . .8-37

SECTION 9: ROUTING 9-1

ROUTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1

ROUTING REQUIREMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2

APPENDIX A: VEHICLE IDENTIFICATION A-1

VEHICLE IDENTIFICATION LABELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2

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Figures

FIGURE 2-1: INCOMPLETE VEHICLE CERTIFICATION DOCUMENT . . . . . . . . . . 2-2

FIGURE 2-2: LOCATIONS OF CERTIFICATION LABELS . . . . . . . . . . . . . . . . . 2-2

FIGURE 2-3: WEST COAST MIRROR OAT SENSOR, . . . . . . . . . . . . . . . . . . . 2-6

FIGURE 2-4: AERODYNAMIC MIRROR OAT SENSOR LOCATION. . . . . . . . . . . . 2-7

FIGURE 2-5: INSTRUMENT CLUSTER FOR T440/T470 USED WITH

EPA2010 EMISSION COMPLIANT ENGINES. . . . . . . . . . . . . . . . 2-7

FIGURE 3-1: PROSPECTOR TURN CIRCLE ANALYSIS . . . . . . . . . . . . . . . . . 3-3

FIGURE 4-1: MEASUREMENT LOCATION OF DEF SUPPLY MODULE (PUMP). . . . . 4-4

FIGURE 4-2: MEASUREMENT LOCATION OF DEF DOSING MODULE (INJECTOR) . . 4-4

FIGURE 4-3: ORIENTATION OF DOSING MODULE . . . . . . . . . . . . . . . . . . . 4-5

FIGURE 4-4: RH UNDER CAB EXHAUST WITH SMALL, MEDIUM, OR LARGE TANKS. 4-5

FIGURE 4-5: VERTICAL EXHAUST WITH SMALL, MEDIUM, OR LARGE TANKS.. . . . 4-6

FIGURE 4-6: RH UNDER CAB EXHAUST WITH CLEAR BACK OF CAB TANK. . . . . . 4-7

FIGURE 4-7: VERTICAL WITH CLEAR BACK OF CAB TANK. . . . . . . . . . . . . . . 4-8

FIGURE 4-8: ROUTING DEF LINES AND DEF TRAP . . . . . . . . . . . . . . . . . . . 4-9

FIGURE 4-9: SUPPLY MODULE ALLOWED CLOCKING ANGLES . . . . . . . . . . . . 4-9

FIGURE 4-10: ISOMETRIC VIEW OF RIGHT HAND UNDER DPF AND SCR

WITH SINGLE SOC TAILPIPE . . . . . . . . . . . . . . . . . . . . . . . . 4-11

FIGURE 4-11: TOP VIEW OF RIGHT HAND UNDER DPF AND SCR

WITH SINGLE SOC TAILPIPE . . . . . . . . . . . . . . . . . . . . . . . . 4-11

FIGURE 4-12: RIGHT VIEW OF RIGHT HAND UNDER DPF AND SCR

WITH SINGLE SOC TAILPIPE . . . . . . . . . . . . . . . . . . . . . . . . 4-12

FIGURE 4-13: BACK VIEW OF RIGHT HAND UNDER DPF AND SCR

WITH SINGLE SOC TAILPIPE . . . . . . . . . . . . . . . . . . . . . . . . 4-12

FIGURE 4-14: ISOMETRIC VIEW OF RIGHT HAND UNDER DPF AND SCR

WITH SINGLE BACK OF CAB TAILPIPE . . . . . . . . . . . . . . . . . .4-13

FIGURE 4-15: TOP VIEW OF RIGHT HAND UNDER DPF AND SCR

WITH SINGLE BACK OF CAB TAILPIPE . . . . . . . . . . . . . . . . . .4-13

FIGURE 4-16: RIGHT VIEW OF RIGHT HAND UNDER DPF AND SCR

WITH SINGLE BACK OF CAB TAILPIPE . . . . . . . . . . . . . . . . . .4-14

FIGURE 4-17: BACK VIEW OF RIGHT HAND UNDER DPF AND SCR

WITH SINGLE BACK OF CAB TAILPIPE . . . . . . . . . . . . . . . . . .4-14

FIGURE 4-18: ISOMETRIC VIEW OF VERTICAL DPF AND SCR . . . . . . . . . . . . . 4-15

FIGURE 4-19: TOP VIEW OF VERTICAL DPF AND SCR . . . . . . . . . . . . . . . . .4-15

FIGURE 4-20: RIGHT VIEW OF VERTICAL DPF AND SCR . . . . . . . . . . . . . . . .4-16

FIGURE 4-21: BACK VIEW OF VERTICAL DPF AND SCR . . . . . . . . . . . . . . . .4-16

FIGURE 4-22: ISOMETRIC VIEW OF RIGHT HAND UNDER DPF AND SCR ON

AEROCAB WITH SINGLE SOC TAILPIPE. . . . . . . . . . . . . . . . . . 4-17

FIGURE 4-23: TOP VIEW OF RIGHT HAND UNDER DPF AND SCR ON

AEROCAB WITH SINGLE SOC TAILPIPE. . . . . . . . . . . . . . . . . . 4-17

FIGURE 4-24: RIGHT VIEW OF RIGHT HAND UNDER DPF AND SCR ON

AEROCAB WITH SINGLE SOC TAILPIPE. . . . . . . . . . . . . . . . . . 4-17

FIGURE 4-25: BACK VIEW OF RIGHT HAND UNDER DPF AND SCR ON

AEROCAB WITH SINGLE SOC TAILPIPE. . . . . . . . . . . . . . . . . . 4-18

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 . . . . . . . . . . . . 6-4

FIGURE 6-4: HIGH COMPRESSION SPRING. . . . . . . . . . . . . . . . . . . . . . . 6-4

FIGURE 6-5: RUBBER SPACER BETWEEN BRACKETS BETWEEN THE

MOUNTING BOLT AND UPPER BRACKET. . . . . . . . . . . . . . . . . 6-4

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Figures

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: KENWORTH T440/T470 DASH . . . . . . . . . . . . . . . . . . . . . . . 8-2

FIGURE 8-2: DIESEL EXHAUST FLUID GAUGE . . . . . . . . . . . . . . . . . . . . . 8-2

FIGURE 8-3: MULTIPLEXED INSTRUMENTATION BLOCK DIAGRAM.. . . . . . . . . . 8-3

FIGURE 8-4: CECU LOCATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4

FIGURE 8-5: INSTRUMENT CLUSTER COMPONENTS . . . . . . . . . . . . . . . . . 8-5

FIGURE 8-6: CVSG GAUGES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6

FIGURE 8-7: FIREWALL AIR JUNCTION BLOCK (VIEW FROM INSIDE OF CAB). . . . 8-7

FIGURE 8-8: AIR FILTER RESTRICTION SENSOR ON FIREWALL

AIR JUNCTION BLOCK (VIEW FROM ENGINE) . . . . . . . . . . . . . . 8-7

FIGURE 8-9: FUEL FILTER RESTRICTION PRESSURE GAUGE SENSOR LOCATION

(TYPICAL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8

FIGURE 8-10: TELLTALE SYMBOL STANDARD CARDS. . . . . . . . . . . . . . . . . .8-17

FIGURE 8-11: BLANK TELLTALE CARD . . . . . . . . . . . . . . . . . . . . . . . . . .8-18

FIGURE 8-12: TELLTALE ICONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-19

FIGURE 8-13: KENWORTH SPARE SWITCHES . . . . . . . . . . . . . . . . . . . . . .8-20

FIGURE 8-14: SPARE SWITCH HARNESS . . . . . . . . . . . . . . . . . . . . . . . . .8-21

FIGURE 8-15: SPECIALTY SWITCHES . . . . . . . . . . . . . . . . . . . . . . . . . . .8-22

FIGURE 8-16: SPARE RELAY CONNECTORS . . . . . . . . . . . . . . . . . . . . . . .8-23

FIGURE 8-17: SPARE RELAY HARNESSES . . . . . . . . . . . . . . . . . . . . . . . .8-24

FIGURE 8-18: SPARE BULLET CONNECTORS . . . . . . . . . . . . . . . . . . . . . .8-25

FIGURE 8-19: SPARE PIGTAIL CONNECTOR . . . . . . . . . . . . . . . . . . . . . . .8-26

FIGURE 8-21: CHASSIS POWER DISTRIBUTION CENTER DIMENSIONS . . . . . . . .8-30

FIGURE 8-22: DAYCAB HARDWARE LOCATIONS . . . . . . . . . . . . . . . . . . . . .8-31

FIGURE 8-23: AEROCAB STANDARD HARDWARE LOCATIONS . . . . . . . . . . . . . 8-31

FIGURE 8-25: CHASSIS NODE DIMENSIONS . . . . . . . . . . . . . . . . . . . . . . .8-32

FIGURE 8-25: SAE J560 TRAILER CONNECTOR . . . . . . . . . . . . . . . . . . . . . . .

FIGURE 8-26: ISO 3731 TRAILER CONNECTOR . . . . . . . . . . . . . . . . . . . . .8-35

FIGURE 8-27: JUNCTION BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-36

FIGURE 8-31: SNOW PLOW ICON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-37

FIGURE 8-32: CIRCUIT LOCATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-37

FIGURE 9-1: CLAMP AND BUTTERFLY CLAMP . . . . . . . . . . . . . . . . . . . . . 9-1

FIGURE 9-2: BUTTERFLY TIE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1

FIGURE 9-3: TIE STRAP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1

FIGURE 9-4: HEAVY DUTY (HD) MOUNT.. . . . . . . . . . . . . . . . . . . . . . . . . 9-2

FIGURE 9-5: DEFINITION OF MEASUREMENTS. . . . . . . . . . . . . . . . . . . . . 9-4

FIGURE A-1: VEHICLE IDENTIFICATION NUMBER (VIN). . . . . . . . . . . . . . . . . A-1

FIGURE A-2: DRIVERS DOOR AND DOOR FRAME LABELS . . . . . . . . . . . . . . A-2

FIGURE A-4: FRONT AXLE IDENTIFICATION. . . . . . . . . . . . . . . . . . . . . . . A-4

FIGURE A-5: REAR AXLE IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . A-4

vii

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Page 7

Tables

TABLE 3-1: ABBREVIATIONS USED . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

TABLE 3-2: TURNING RADIUS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

TABLE 3-3: AXLE TRACK. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

TABLE 3-4: RIDE HEIGHTS IN INCHES . . . . . . . . . . . . . . . . . . . . . . . . . .3-12

TABLE 3-5: REAR SUSPENSION OPTIONS. . . . . . . . . . . . . . . . . . . . . . . .3-14

TABLE 3-6: REAR SUSPENSION OPTIONS. . . . . . . . . . . . . . . . . . . . . . . .3-15

TABLE 3-7: REAR SUSPENSION OPTIONS. . . . . . . . . . . . . . . . . . . . . . . .3-16

TABLE 3-8: REAR SUSPENSION OPTIONS. . . . . . . . . . . . . . . . . . . . . . . .3-17

TABLE 3-9: REAR SUSPENSION OPTIONS. . . . . . . . . . . . . . . . . . . . . . . .3-18

TABLE 3-10: REAR SUSPENSION OPTIONS. . . . . . . . . . . . . . . . . . . . . . . . 3-19

TABLE 3-11: REAR SUSPENSION OPTIONS. . . . . . . . . . . . . . . . . . . . . . . . 3-20

TABLE 3-13: REAR SUSPENSION OPTIONS. . . . . . . . . . . . . . . . . . . . . . . . 3-22

TABLE 3-14: REAR SUSPENSION OPTIONS. . . . . . . . . . . . . . . . . . . . . . . . 3-23

TABLE 3-15: REAR SUSPENSION OPTIONS. . . . . . . . . . . . . . . . . . . . . . . . 3-24

TABLE 3-16: REAR SUSPENSION OPTIONS. . . . . . . . . . . . . . . . . . . . . . . . 3-25

TABLE 3-17: REAR SUSPENSION OPTIONS. . . . . . . . . . . . . . . . . . . . . . . . 3-26

TABLE 3-18: GROUND CLEARANCE FOR FUEL TANKS. . . . . . . . . . . . . . . . . .3-29

TABLE 3-19: GROUND CLEARANCE FOR BATTERY BOXES . . . . . . . . . . . . . . .3-30

TABLE 3-20: GROUND CLEARANCE FOR BATTERY BOXES . . . . . . . . . . . . . . .3-31

TABLE 5-1: ABBREVIATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

TABLE 5-2: FUEL TANK OVERALL LENGTH (IN) . . . . . . . . . . . . . . . . . . . . . 5-2

TABLE 5-3: BATTERY BOX CENTERFRAME LENGTHS (IN) . . . . . . . . . . . . . . . 5-2

TABLE 5-4: DEF TANKS SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

TABLE 6-1: SINGLE STEEL RAILS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

TABLE 6-2: INSERTED STEEL RAILS . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

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: TELLTALES POSITION AND COLOR . . . . . . . . . . . . . . . . . . . . .8-18

TABLE 8-3: CHASSIS NODE GUIDELINE . . . . . . . . . . . . . . . . . . . . . . . . .8-28

TABLE 8-4: WIRE NUMBER GENERAL CATEGORIES . . . . . . . . . . . . . . . . . .8-33

TABLE 8-6: SAE J560 CONNECTOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-34

TABLE 8-7: ISO 3731 CONNECTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-35

TABLE 9-1: EXHAUST – SYSTEM CLEARANCE . . . . . . . . . . . . . . . . . . . . . 9-4

TABLE A-1: MODEL YEAR (CODE) DESIGNATIONS. . . . . . . . . . . . . . . . . . . . A-1

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Page 8

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 speciﬁ c to chassis with 2010 engines.

The Body Builder Manual can be very useful when specifying a vehicle, particularly when the body builder is involved in the vehicle deﬁ 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 speciﬁ 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.

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Section 2

Safety & Compliance

SAFETY SIGNALS

We’ve put a number of alerting messages in this book. Please read and follow them. They are there for your protection and information. These alerting messages can help you avoid injury to yourself or others and help prevent costly damage to the vehicle.

Key symbols and “signal words” are used to indicate what kind of message is going to follow. Pay special attention to comments prefaced by “WARNING”, “CAUTION”, and “NOTE.” Please don’t ignore any of these alerts.

Warnings, cautions, and notes

WARNING

Example:

WARNING! Be sure to use a circuit breaker designed to meet liftgate amperage requirements. An incorrectly speciﬁ ed circuit breaker could result in a electrical overload or ﬁ 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 efﬁ ciently.

Example: Note: Be sure to provide maintenance access to the battery box and fuel tank ﬁ 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.

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Section 2

Safety & Compliance

FEDERAL MOTOR VEHICLE SAFETY STANDARDS COMPLIANCE

As an Original Equipment Manufacturer (OEM), Kenworth Truck Co. ensures that our products comply with all applicable U.S. or Canadian Federal Motor Vehicle Safety Standards. However, the fact that this vehicle has no ﬁ fth wheel and that a Body Builder (Intermediate or Final Stage Manufacturer) will be doing additional modiﬁ cations means that the vehicle was incomplete when it left the build plant. See next section and Appendix A for additional information.

Incomplete V ehicle Certiﬁ cation

An Incomplete Vehicle Document is shipped with the vehicle, certifying that the vehicle is not complete. See Figure 2–1. In addition, afﬁ xed to the driver’s side door frame or edge is an Incomplete Vehicle Certiﬁ cation label. See Figure 2–2. For further information on Vehicle Certiﬁ cation and Identiﬁ 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 regulations upon completion of the modiﬁ 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

FIGURE 2-1. Incomplete Vehicle Certiﬁ cation Document

Tire, Rim and Weight Rating Data label

Safety Mark (Canadian Registry Only)

Incomplete Vehicle Certiﬁ cation Label

Major Components and Weights Label

FIGURE 2-2. Locations of Certiﬁ 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 modiﬁ cations), you should afﬁ x your certiﬁ cation label to the vehicle as required by Federal law. This tag identiﬁ es you as the “Intermediate or Final Stage Manufacturer” and certiﬁ es that the vehicle complies with Federal Motor Vehicle Safety Standards. (See Figure 2–2.) Be advised that regulations affecting the intermediate and ﬁ nal stage manufacturer may change without notice. Ensure you are referencing the most updated copy of the regulation during the certiﬁ cation and documentation processes.

In part, if the ﬁ nal stage manufacturer can complete and certify the vehicle within the instruction in the incomplete vehicle document (IVD) the certiﬁ 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 certiﬁ ed with in the guidance provided in the IVD, the ﬁ nal stage manu- facturer must ensure the vehicle conforms to all applicable Federal Motor Vehicle Safety Standards (FMVSS). The ﬁ nal stage manufactures certiﬁ 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).”

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Section 2

Safety & Compliance

These statements are just part of the changes to the new certiﬁ cation regulation. Please refer to the Feb 15, 2005 ﬁ nal rule for all of the details related to this regulation. You can contact NTEA Technical Services Department at

1-800-441-NTEA for a copy of the ﬁ nal rule (DocID 101760). For Canadian ﬁ nal stage manufacturers see: http://www.gazette.gc.ca/archives/p2/2002/2002-02-13/html/sor-dors55-eng.html; and

http://www.tc.gc.ca/acts-regulations/regulations/crc-c1038/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

For Cummins Contact: Please call 1-800-DIESELS or contact 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

This truck may be equipped with speciﬁ 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.

Modifying (i.e. altering, substituting, relocating) any of the emissions control components/systems deﬁ ned above will affect the noise and emissions performance/certiﬁ cation. If modiﬁ cations are required, they must ﬁ rst be approved by the engine manufacturer. Unapproved modiﬁ cations could negatively effect emissions performance/certiﬁ cation. There is no guarantee that proposed modiﬁ cations will be approved.

Contact the engine manufacturer for any requirements and restrictions prior to any modiﬁ cations.

Some 2010 engine emissions certiﬁ 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.

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.

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Section 2

Safety & Compliance

To ensure compliance to emissions regulations, the ﬁ nal conﬁ guration of certain features of the completed vehicle must meet speciﬁ c requirements. This section describes requirements relevant for only the most common or critical modiﬁ - cations done by body builders. For a complete description of acceptable modiﬁ 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 ﬁ lter(s) and ﬁ 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 ﬁ ll • Modiﬁ cation of the pressure side secondary ﬁ lter and plumbing is not allowed without engine manufacturer •

approval Body installation of fuel tank or routing of lines must not cause signiﬁ cant increase in fuel temperature• Fuel hoses shall meet or exceed OEM supplied hose material construction speciﬁ cations•

Compressed Air System

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

Air system modiﬁ cation must meet applicable FMVSS regulations• Compressed Air tank may not be modiﬁ ed (exception – addition or removal of ﬁ ttings or relocation of the tank) • 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.•

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 modiﬁ ed:•

DPF assembly• SCR Catalyst assembly• Exhaust pipes between the engine and after-treatment devices (DPF, SCR Catalyst) and between • after-treatment devices

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Page 13

NO•

Sensor

The following modiﬁ cations may only be done within the guidelines of the “DEF System Relocation Guide.”•

Modiﬁ cations to Diesel Exhaust Fluid (DEF) throttle, suction, or pressure lines• Modiﬁ cation or relocation of the DEF tank• Modiﬁ 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 ﬂ anges • where necessary. Do not extend the harnesses

Exhaust pipes between the engine and after-treatment devices or between after-treatment devices may not be • modiﬁ ed or replaced

The DPF, the SCR catalyst, or their mounting may not be modiﬁ ed•

Section 2

Safety & Compliance

The NO• Exhaust pipes used for tailpipes/stacks must be properly sized, and must prevent water from entering the •

exhaust system 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 sufﬁ 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.

sensor may not been relocated or altered in any way

Cooling System

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

Modiﬁ cations to the design or locations of ﬁ 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, and may void vehicle warranty

Coolant level sensor tampering will void warranty• When installing auxiliary equipment in front of the vehicle, or additional heat exchangers, ensure that •

adequate air ﬂ 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 modiﬁ cation only

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Section 2

Safety & Compliance

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 guide-• lines. 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.

Installation of aftermarket transfer-cases must address the vehicle speed sensor position. The standard posi-• tion 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 ﬁ gures below. If the body builder needs to modify the mirror assembly in any way, it is im- portant 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.

FIGURE 2-3: West Coast Mirror OAT sensor, located in overmold on mirror harness.

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Page 15

FIGURE 2-4: 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 •

or its location may not be changed.

Section 2

Safety & Compliance

Vehicles using EPA 2010 compliant engines must be equipped with a Malfunction Indicator Lamp (MIL) lamp. • This lamp is required to be an engine outline symbol as deﬁ ned by ISO (International Standards Organiza- tion). The ﬁ gure below shows the instrument cluster and MIL lamp position. Note this lamp location is ﬁ xed with respect to the controls and its location may not be changed if you are updating the warning lamp cards.

FIGURE 2-5: Instrument Cluster for T440/T470 used with EPA2010 Emission compliant engines. The Check Engine lamp is symbol 21 and the MIL is symbol 8.

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.

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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• Modiﬁ cation to the air intake system may not restrict airﬂ 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 modiﬁ 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 modiﬁ ed•

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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

AF AFTER FRAME – FRAME RAIL OVERHANG BEHIND REAR AXLE OR MEASURED FROM CENTERLINE OF TANDEM 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 speciﬁ 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

T440/T470

Single

TAS 65

Dana Spicer E-1202I 12K

Accuride 28487

22.5 X 8.25

Bridgestone

R287

295/75R22.5

Rear

Suspension

Tandem 52” Axle Spacing

Wheel Base

181 28 193 29.5 201 30.5 213 32 220 33 232 34.5 240 35.5 252 37 260 38 272 39.5 280 40.5 291 42 303 43.5 323 46 331 47

Est Curb to

Curb T urning

Radius (ft)

3-1

TABLE 3-2 CONTINUES ON NEXT PAGE…

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Section 3

Dimensions

TABLE 3-2 CONTINUED

Model Steering Gear Front Axle Front Wheel Front Tire

T440/T470

Dual

TAS 65

Dana Spicer

D2000 20K

Standard T rac k

Alcoa 82365

22.5 X 12.25

Bridgestone

M844

425/65R22.5

Rear

Suspension

Tandem 52” Axle Spacing

Wheel Base

181 31.5 193 33.5 201 34.5 213 36.5 220 37.5 232 39 240 40 252 42 260 43 272 45 280 46 291 47.5 303 49.5 323 52.5 331 53.5

Est Curb to

Curb T urning

Radius (ft)

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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 speciﬁ c chassis. Your local Kenworth dealer can provide this information to you.

T470

FIGURE 3-1. Prospector Turn Circle Analysis

Please consult your local Kenworth Dealer for this information, as it is chassis speciﬁ c.

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Section 3

Dimensions

AXLE TRACK AND TIRE WIDTH

The dimensions provided in this section are representative of some typical product combinations. The purpose of 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 signiﬁ 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 capac-•

ity of the axle.

KENWORTH AXLE TRACK/TIRE WIDTH SUMMARY

TABLE 3-3. Axle Track

Axle - Drive Wheel Tire Conﬁ guration Track Dim ”A” Overall Width Dim ”B”

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

Axle - Steer Wheel Tire Brake Drum Type Track Dim ”A” Overall Width Dim ”B”

Dana Spicer E-1322I 13.2K Alcoa 98364

Dana Spicer E-1322W 13.2K Alcoa 98364

Dana Spicer D2000 20K Alcoa 82365

Dana Spicer D2000 20K Alcoa 82364

Alcoa 88364

22.5X8.25

Alcoa 98364

24.5X8.25

Alcoa 88364

22.5X8.25

Alcoa 98364

24.5X8.25

Alcoa 82360

22.5X12.25

Alcoa 82360

22.5X12.25

24.5X8.25

24.5X12.25

BR M726EL

11R22.5

BR M726EL

11R24.5

BR M726EL

11R22.5

BR M726EL

11R24.5

BR M844F

425/65R22.5

BR M844F

425/65R22.5

BR R250F

11R24.5

BR R250F

11R24.5

BR M844F

425/65R22.5

BR M844F

425/65R22.5

4-4 73.3” 97.8”

4-4 73.6” 98.0”

4-4 79.2” 103.7”

4-4 79.5” 103.9”

2-4 72.7” 88.9”

2-4 78.7” 94.9”

Cast 80.2” 91.0”

Cast 82.2” 93.0”

Cast 86.5” 102.7”

Cast 82.6” 98.8”

Axle - Pusher Non-Steerable Wheel Tire Wheel Orientation “Track Dim ”A” “Overall Width Dim ”B”

NS PSHR: WCAL ATLAS Std Track (72.5”) 16K GAWR

NS PSHR: WCAL ATLAS Wide T rac k (77.5”)

12/09

Alcoa 82365

24.5X12.25

“Alcoa 82365

24.5X12.25

BR M844F

425/65R22.5

BR M844F

425/65R22.5

3-4

Default-

Same as RR

Option

Same as FR

79.4” 95.6”

71.1” 87.3”

Page 21

Section 3

Dimensions

OVERALL DIMENSIONS

This section includes drawings and charts. The Extended Day Cab is also included. 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 3-4 on page 3-8 and 3-9 and add that value to the height. All heights are given from the bottom of the frame rail.

Kenworth also offers .dxf ﬁ 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.

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Section 3

Dimensions

T470 FIXED GRILLE HOOD W/O EXTENDED FRONT FRAME

The following drawings are shown with standard chassis components and the T470 ﬁ xed grille hood.

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Section 3

Dimensions

T440 DAYCAB

The following drawings are shown with standard chassis components and the T440 daycab.

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Section 3

Dimensions

T440 EXTENDED DAYCAB

The following drawings are shown with standard chassis components and the T440 extended daycab.

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Section 3

Dimensions

T470 FIXED GRILLE HOOD WITH EXTENDED FRONT FRAME

The following drawings are of a T470 ﬁ xed grille hood with the optional extended front frame. These extended frame rails can be used with or without FEPTO adapters.

3-9

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Section 3

Dimensions

38” AEROCAB

The 38” Aerocab is shown on a standard T440 chassis. It is important to note that the 38” will increase any of the models bumper to back of cab dimension and front axle to back of cab dimension by 28”. The height (from the bottom of the frame rail) will be 93.2” across the models.

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Page 27

Section 3

Dimensions

EXTENDED DAY CAB

It is important to note that the Extended Day Cab will increase any of the models bumper to back of cab dimension and front axle to back of cab dimension by 5.7”. The height (from the bottom of the frame rail) will be 86.9”. Below drawings shown with T470 ﬁ xed grille hood.

Suspension heights are measured from the centerlines of the axle spindle to the bottom of the frame rail. Add the tire radius dimension to determine overall height to the bottom of the frame rail. Note: The frame rail height itself will not affect the overall cab height as all components are located from the bottom of the frame rail.

3-11

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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. Ride height information is also available in Prospector.

TABLE 3-4. Ride Heights In Inches

To calculate Frame Heights use the following formula: Front Frame Height = FS + 1/2 Front Tire Diameter

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

Front Suspension 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”

Rear Suspensions

Kenworth AG380 38K Rating 8.5” 8.5” Kenworth AG400L 40K Rating 8.5” 8.5” Kenworth AG400 40K Rating 9.0” 9.0” Kenworth AG460 46K Rating 10.5” 10.5” Reyco 79KB 21K Rating 6.6” 9.0” Reyco 79KB 23K Rating 8.3” 10.8”

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Section 3

Dimensions

Reyco 79KB 26K Rating 8.2” 11.3” Reyco 102 38K Rating 9.2” 10.8” Reyco 102 40 K Rating 9.2” 10.8” Chalmers 854-40-L-HS 40K Rating 9.6” 11.0” Chalmers 854-40-H-HS 40K Rating 10.9” 12.4” Chalmers 854-46-L 46K Rating 8.9” 11.3” Chalmers 854-46-L-HS 46K Rating 9.6” 11.3” Chalmers 854-46-H 46K Rating 10.1” 12.4” Chalmers 854-46-H-HS 46K Rating 10.9” 12.5” Chalmers 860-46-H-HS 46K Rating 10.9” 12.5” Chalmers 872-46-H-HS 46K Rating 11.0” 12.5” Hendrickson HAS 230 23K Rating 10.0” 10.0” Hend HMX460 16.5” Saddle 46K Rating 9.5” 10.6” Hend HMX460 17.5” Saddle 46K Rating 10.5” 11.6” Hend HMX460 18.5” Saddle 46K Rating 11.5” 12.6” Hendrickson Primaax 46K Rating 10.0” 10.0” Hendrickson RT403 40K Rating 9.7” 10.7” Hendrickson RT463 6.0” Saddle 46K Rating 10.0” 11.1” Hendrickson RT463 7.19 Saddle 46K Rating 11.2” 12.5” Hendrickson RT463 7.94 Saddle 46K Rating 11.9” 13.3” Neway AD123 23K Rating 10.0” 10.0” Neway AD126 26K Rating 10.0” 10.0” Neway AD246 46K Rating 10.0” 10.0”

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Section 3

Dimensions

REAR SUSPENSION LAYOUTS

The rear suspension layouts are provided as a tool to help layout bodies prior to arrival. 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 conﬁ rm with your local KW dealer that the drawing below will be the installation used on your speciﬁ c truck. Ensure that proper torque is used to reinstall any suspension components. See Tables 5-1 and 5-2 on page 5-7.

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.

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KENWORTH AG 380 TANDEM SUSPENSION

Shown with a 52” Axle Spacing

Section 3

Dimensions

Kenworth AG 380 Suspension Data

TABLE 3-5. Rear Suspension Options

Suspension Type Rating Axle Spacing

AG 380 38K 52” 8.5” 8.5”

Laden Ride

Height

Unladen Ride

Height

3-15

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Section 3

Dimensions

KENWORTH AG 400/460 TANDEM SUSPENSION

Shown with a 52” Axle Spacing

Optional Kenworth Tandem Suspensions

TABLE 3-6. Rear Suspension Options

Suspension Type Rating Axle Spacing

Kenworth AG 400 40K 52” 9” 9” Kenworth AG 400 40K 54” 9” 9’ Kenworth AG 460 46K 54” 10.5” 10.5”

Laden Ride

Height

Unladen Ride

Height

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KENWORTH AG 400L TANDEM SUSPENSION

Shown with a 52” Axle Spacing

Section 3

Dimensions

Optional Kenworth Tandem Suspensions

TABLE 3-7. Rear Suspension Options

Suspension Type Rating Axle Spacing

Kenworth AG 400L 40K 52” 8.5” 8.5” Kenworth AG 400L 40K 54” 8.5” 8.5”

Laden Ride

Height

Unladen Ride

Height

3-17

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Section 3

Dimensions

KENWORTH AG 460 TANDEM SUSPENSION

Shown with a 60” Axle Spacing

Optional Kenworth Tandem Suspensions

TABLE 3-8. Rear Suspension Options

Suspension Type Rating Axle Spacing

Kenworth AG 460 46K 60” 10.5” 10.5”

Laden Ride

Height

Unladen Ride

Height

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Page 35

REYCO 79KB SINGLE REAR AXLE

Section 3

Dimensions

Optional Reyco 79KB Suspensions

TABLE 3-9. Rear Suspension Options

Suspension Type Rating Axle Spacing

Reyco 79KB single 21K - 8.3” 10.8”

Reyco 79KB single 23K - 8.3” 10.8”

Reyco 79KB single 26K - 8.2” 11.3”

Reyco 79KB single 30K - 8.9” 11.7”

Laden Ride

Height

Unladen Ride

Height

3-19

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Section 3

Dimensions

REYCO 102 TANDEM REAR AXLE

Shown with a 52” Axle Spacing

Reyco 102 Suspension Data

TABLE 3-10. Rear Suspension Options

Suspension Type Rating Axle Spacing Laden Ride Height

Reyco 102 Tandem 38K 52” 9.2” 10.8”

Reyco 102 Tandem 40K 52” 9.2” 10.8”

Unladen Ride

Height

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Page 37

NEWAY AD 123 SINGLE REAR AXLE

Section 3

Dimensions

Optional Neway AD Single Suspensions

TABLE 3-11. Rear Suspension Options

Suspension Type Rating Axle Spacing

Neway AD123 single 23K - 10” 10”

Neway AD126 single 26K - 10” 10”

Laden Ride

Height

Unladen Ride

Height

3-21

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Section 3

Dimensions

NEWAY AD 246 TANDEM SUSPENSION

Shown with a 54” Axle Spacing

Optional Neway AD Tandem Suspensions

TABLE 3-12. Rear Suspension Options

Suspension Type Rating Axle Spacing

Neway AD246 tandem 46K 54” 10” 10”

Neway AD246 tandem 46K 60” 10” 10”

Laden Ride

Height

Unladen Ride

Height

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HENDRICKSON PRIMAAX TANDEM SUSPENSION

Shown with 54” Axle Spacings

Section 3

Dimensions

Optional Hendrickson Primaax 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

3-23

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Section 3

Dimensions

HENDRICKSON HAS 230 SINGLE REAR SUSPENSION

Optional Hendrickson HAS 230 Suspensions

TABLE 3-14. Rear Suspension Options

Suspension Type Rating Axle Spacing

Hendrickson HAS 230 23K – 10.0” 10.0”

Laden Ride

Height

Unladen Ride

Height

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Page 41

HENDRICKSON HMX TANDEM SUSPENSION

Shown with 54” Axle Spacing

Section 3

Dimensions

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”

Hendrickson HMX460 18.5” saddle 46K 54” 11.5” 12.6”

Hendrickson HMX460 18.5” saddle 46K 60” 11.5” 12.6”

Laden Ride

Height

Unladen Ride

Height

3-25

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Section 3

Dimensions

HENDRICKSON RT TANDEM SUSPENSION

Shown with a 54” Axle Spacing Without Track Rods

Optional Hendrickson RT Tandem Suspensions

TABLE 3-16. Rear Suspension Options

Suspension Type Rating Axle Spacing

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 RT403 7.19” saddle 40K 52” 9.7” 10.7”

Laden Ride

Height

Unladen Ride

Height

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Page 43

CHALMERS 856-46 TANDEM SUSPENSION

Shown with a 54” Axle Spacing

Section 3

Dimensions

Optional Chalmers Tandem Suspensions

TABLE 3-17. Rear Suspension Options

Suspension Type Rating Axle Spacing

Chalmers 854-40-H 40K 54” 10.2” 12.4” 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-HS 40K 54” 10.9” 12.4” Chalmers 854-40-H-SR 40K 54” 10.5” 12.4” Chalmers 854-40-L-SR 40K 54” 9.2” 11.1” Chalmers 854-46-L 46K 54” 8.9” 11.3” Chalmers 854-46-L-HS 46K 54” 9.6” 11.3” Chalmers 854-46-L-SR 46K 54” 9.2” 11.3” Chalmers 854-46-H 46K 54” 10.1” 12.5” Chalmers 854-46-H-HS 46K 54” 10.9” 12.5” Chalmers 854-46-H-SR 46K 54” 10.5” 12.2”

Laden Ride

Height

Unladen Ride

Height

Chalmers 860-46-H 46K 60” 10.1” 12.5” Chalmers 860-46-H-HS 46K 60” 10.9” 12.5” Chalmers 872-46-H-HS 46K 72” 11.0” 12.5”

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Section 3

Dimensions

PUSHER AXLES

The rear pusher axle layouts are provided as a tool to help layout bodies prior to arrival. 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 Tru Track Alumilite 13.2K Steerable Pusher

Watson & Chalin Tru Track 20K Steerable Pusher

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Dimensions

Watson & Chalin Atlas 22.5K Non-Steerable Pusher

Section 3

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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 speciﬁ 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 3-18. Ground Clearance for Fuel Tanks

Front

Suspension

20K Taperleaf Spring

Front Tires

M844F

425/65R22.5

Tires

Rear

Suspension

Hendrickson

HMX 460

17.5” Saddle Height

Rear Tires Component

11R24.5

M711

Dimension

“A”

Distance

from

Bottom of

Frame Rail

(in)

22” Fuel Tank 16.3 17.2 14.9

24.5” Fuel Tank

18.2 15.3 13

Dimension “B” Ground

Clearance (in)

Unladen Laden

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Section 3

Dimensions

TABLE 3-19. Ground Clearance for Battery Boxes

Front

Suspension

20K Taperleaf Spring

Front Tires

M844F

425/65R22.5

Tires

Rear

Suspension

Hendrickson

HMX 460

17.5” Saddle Height

Rear Tires Component

M711

11R24.5

Battery Box

with Air Tanks

Vocational

Battery Box

with Air Tanks

Single DPF

Box

Dimension

“A”

Distance

from

Bottom of

Frame Rail

(in)

17.3 16.2 13.9

17.8 15.7 13.4

15.5 17.9 15.6

Dimension “B” Ground

Clearance (in)

Unladen Laden

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Section 3

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

M844F

425/65R22.5

Tires

Rear

Suspension

Hendrickson

HMX 460

17.5” Saddle Height

Rear Tires Component

Battery Box

with Air Tanks

M711

11R24.5

Vocational

Battery Box

with Air Tanks

Box 15.6 17.8 15.5

DPF

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

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Section 3

Dimensions

PTO CLEARANCES

The following visuals are provided to help aid in determining PTO locations and clearances. For speciﬁ c dimensions please work through your local Kenworth dealer. Multiple PTO’s are shown for layout purposes only. Power equipment, i.e., drive shafts & power pumps are not included. Body builders should select the appropriate PTO for their application and customer requirements. NOTE: Installations depict multiple PTOs. PTO locations shown below are for reference only. Some PTOs may interfere with frame rail and/or other components.

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 T ransmission:

3-33

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Section 3

Dimensions

Allison T ransmission:

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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 2010 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 between the ammonia and NOx, turning it into water and nitrogen. For more information on the speciﬁ 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 T ank

(10-gallon shown)

DEF Return Line

(Backﬂ 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 (Backﬂ ow)

DEF Draw Line (Inlet)

DEF Supply Module

(Pump)

DEF Pressure Line (Outlet)

DEF Dosing Module (Injector)

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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 T ank

(Small T ank Shown)

5/8” Coolant Hose

(Green - Draw)

Return T ee Draw Tee

DEF T ank 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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Exhaust & Aftertreatment

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.

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.

• Total DEF capacity must meet or exceed 6% of the usable fuel capacity on the truck. The calculation to determine DEF capacity is:

Minimum DEF Tank Volume = Useable Fuel Capacity (gal) x 0.06 Example: For a truck with 200 useable gallons of fuel, the equation is

DEF required = 200 x 0.06 = 12 gallons or more of DEF.

PACCAR-approved DEF hoses are required when retroﬁ 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.

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 modiﬁ 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 ﬂ ow by minimizing changes in restrictions. Increases in restriction occur with excessive line length and bends. Work with your local Kenworth dealer if you are unsure about the coolant line modiﬁ cations.

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Exhaust & Aftertreatment

MEASUREMENT REFERENCE POINTS

For all relocation procedures, the measurement points referenced in the guidelines are taken from the following speciﬁ 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 ﬂ 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 ﬂ 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 conﬁ guration and DEF tank type and location. The Dosing Module should not 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

Section 4

Exhaust & Aftertreatment

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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Exhaust & Aftertreatment

Horizontal (Crossover) DPF and SCR with Rectangular Small or Medium DEF T anks

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

The height differential between the supply module and dosing module cannot e xceed one meter. The supply module is integrated into the DEF tank assembly, separation of the module frm 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”).

Vertical DPF and SCR with Rectangular Small or Medium DEF Tanks

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

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

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Exhaust & Aftertreatment

Right Hand Under DPF and SCR with Clear Back of Cab DEF Tank

FIGURE 4-7: RH Under Cab Exhaust with Clear Back of Cab Tank.

The installation and design of the Clear Back of Cab (CBOC) tank is highly integrated into the chassis and cooling system. Kenworth does not allow relocation of this tank, only relocation of the supply module.

The height differential between the supply module and dosing module can not exceed one meter. The CBOC tank does not have an integrated supply module. The standard KW installation is a supply module located inside of the frame rail. When relocating either the supply module or the tank, the maximum height differential between the supply module and the bottom of the tank is one meter. The maximum line length is 2 meters between supply module and DEF tank sending unit.

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 4-8 on page 4-9).

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Section 4

Exhaust & Aftertreatment

Vertical DPF and SCR with Clear Back of Cab DEF Tank

FIGURE 4-7: Vertical with Clear Back of Cab Tank

The height differential between the supply module and dosing module can not exceed one meter. The Clear Back of Cab (CBOC) tank does not have an integrated supply module. The standard KW installation is a supply module located inside of the frame rail. When relocating either the supply module or the tank, the maximum height differential between the supply module and the bottom of the tank is one meter. The maximum line length is 2 meters between supply module and DEF tank sending unit.

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)

It is important for the function of the dosing module to ensure that the dosing module is not routed downstream of DEF lines or components. If this is unavoidable (for example on RH under exhaust systems) a routing trap must be installed. A minimum of 12” of line length must be routed below the dosing module, in order to catch any leftover DEF when system is purged.

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Section 4

Exhaust & Aftertreatment

Minimum 12” Line

Length Below

Dosing Module

FIGURE 4-8: Routing DEF Lines and DEF Trap

Clear Back of Cab Supply Module

The CBOC Supply Module (or Pump) standard mounting location is inside of the frame rail back of cab. 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 4-9 below.

FIGURE 4-9: Supply Module Allowed Clocking Angles

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Section 4

Exhaust & Aftertreatment

GENERAL EXHAUST INFORMATION

Kenworth will offer two main DPF and SCR exhaust systems on T440/T470 chassis in 2010. A Right Hand Under DPF and SCR system, in which both canisters are located underneath the cab access step, and an Independent DPF and SCR located vertically back of cab on stanchion brackets.

RH Under 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 modiﬁ 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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Section 4

Exhaust & Aftertreatment

Right Hand Under DPF and SCR on Daycab with Single Side of Cab T ailpipe

FIGURE 4-10: Isometric View of Right Hand Under DPF and SCR with Single SOC Tailpipe

FIGURE 4-11: Top View of Right Hand Under DPF and SCR with Single SOC Tailpipe

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Exhaust & Aftertreatment

FIGURE 4-12: Right View of Right Hand Under DPF and SCR with Single SOC Tailpipe

FIGURE 4-13: Back View of Right Hand Under DPF and SCR with Single SOC Tailpipe

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Exhaust & Aftertreatment

Right Hand Under DPF and SCR with Single Back of Cab Tailpipe

FIGURE 4-14: Isometric View of Right Hand Under DPF and SCR with Single Back of Cab Tailpipe

FIGURE 4-15: Top view of Right Hand Under DPF and SCR with Single Back of Cab Tailpipe

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FIGURE 4-16: Right view of Right Hand Under DPF and SCR with Single Back of Cab Tailpipe

FIGURE 4-17: Back view of Right Hand Under DPF and SCR with Single Back of Cab Tailpipe

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Exhaust & Aftertreatment

Vertical Independent DPF and SCR with Horizontal Tailpipe

FIGURE 4-18: Isometric View of Vertical DPF and SCR

FIGURE 4-19: Top View of Vertical DPF and SCR

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Exhaust & Aftertreatment

FIGURE 4-20: Right View of Vertical DPF and SCR

FIGURE 4-21: Back View of Vertical DPF and SCR

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Exhaust & Aftertreatment

Right Hand Under DPF and SCR on Aerocabs with Single Side of Cab T ailpipe

FIGURE 4-22: Isometric View of Right Hand Under DPF and SCR on Aerocab with Single SOC Tailpipe

FIGURE 4-23: Top View of Right Hand Under DPF and SCR on Aerocab with Single SOC Tailpipe

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Exhaust & Aftertreatment

FIGURE 4-24: Right View of Right Hand Under DPF and SCR on Aerocab with Single SOC Tailpipe

FIGURE 4-25: Back View of Right Hand Under DPF and SCR on Aerocab with Single SOC Tailpipe

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Section 4

Exhaust & Aftertreatment

EXHAUST INFORMATION

This section includes information on how to calculate tailpipe heights, and reference information for PTO clearance. Optional equipment is not shown.

Tailpipe Stack Height Calculation

TABLE 4-1. Stack Height

Dimension A

Tailpipes side of Aerocab, RH

under DPF

Tailpipes independent back of

sleeper, RH under DPF

DPF mounted independent back

of cab or sleeper

Tailpipes side of cab mount,

DPF RH under

Tailpipes back of cab mount, w/

side extenders, DPF RH under

Tailpipes back of cab mount, w/o

side extenders, DPF RH under

DIMENSION “B” IS THE T AILPIPE LENGTH.

Cummins

(not ISL)

78.0”

75.0”

75.0” Cummins

ISL

75.0”

68.5”

68.0”

TABLE 4-2. Unladen Stack Height

For approximate unladen stack height (12,000 pound springs) use the following frame heights:

Tire Size Top of Rail Ft. Suspension

11R24.5

11R22.5 285/75R24.5 295/75R22.5 425/65R22.5 385/65R22.5

43.5” 12K

42.5” 12K 42” 12K

41.5” 12K

43.2 20K

42.4 20K

*Use Prospector frame heights for more accurate results. Sample: Tailpipe height 13’6” = Desired overall stack height = 162.0”

(–) Prospector frame height (–) 43.5” (+) Frame rail depth (+) 10.6” (–) Dimension ‘A’ from chart (–) 68.6” = Tail pipe length = 60.5”

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Exhaust & Aftertreatment

This page intentionally left blank.

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Section 5

Frame Layouts

FRAME LAYOUTS

The dimensions in the frame layout section are intended to aid in layout of the chassis, and to help determine the best possible combination of fuel tanks, battery boxes, the diesel particulate ﬁ lter (DPF), SCR canister, and Diesel Exhaust Fluid (DEF) tank. For your application, the layouts focus on the under cab area, with appropriate dimensional information included for pertinent back of cab components. Not all optional equipment is included in this section. Additional components may be placed on the rail behind components shown. The Back of Cab components are shown primarily for reference. For more speciﬁ c requirements please work with your local Kenworth Dealer. Please read the instructions carefully.

The following dimensions are consistent across the entire section to aid in the comparison of one layout option versus another.

TABLE 5-1.

B = Battery box D = DEF tank E = Exhaust F1 = Fuel Tank RHS F2 = Fuel Tank LHS T = Tool Box

The layouts are organized by type, speciﬁ cally the arrangement of under cab components. The visual index that follows will give you a quick overview of the layouts that are included. Using the index locate the layout that you are interested in, then turn to the speciﬁ ed pages. The charts that follow are then model speciﬁ c. It is important that the correct chart is used for accurate dimensional information.

Visual Index

Symbol Description Symbol Description

RHUC DPF/SCR Tool Box

Vertical DPF/SCR DEF Tank

Parallel Battery Box, Standard Length Clear BOC DEF Tank

In Cab Battery Box Fuel Tank

Cantilever Battery Box

5-1

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Section 5

Frame Layouts

COMMON OPTIONAL COMPONENTS

The frame layouts that follow contain the minimum frame requirements to be operational (fuel tanks, battery box, and after-treatment components). All layouts are shown with standard length battery boxes unless otherwise noted. Dimensions for these components have been provided below to help complete the frame layout for chassis with more fuel tanks, additional tool boxes, etc.

TABLE 5-2. Fuel Tank Overall Length (in)

Fuel Tank Overall Length (in)

Fuel T ank Diameter

Gallons 22” 24.5”

45 N/A 23.0 56 35.6 N/A 60 38.0 30.6 75 47.3 38.5

90 N/A 45.5 100 62.2 50.0 105 N/A N/A 110 N/A 55.0

120 74.3 60.6 135 N/A 67.2 150 N/A 74.5 177 N/A N/A

TABLE 5-3. Battery Box Centerframe Lengths (in)

Battery Box Centerframe Lengths (in)

T440/T470

Parallel Short 34.8 Parallel Extended 42.0 Parallel BOC 34.8 Cantilever 17.8 Vocational 15.2

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Section 5

Frame Layouts

FIGURE 5-1. DEF Tank Dimensions.

TABLE 5-4. DEF Tanks Systems

Description

Small DEF Tank 9

Medium DEF Tank 18

Large DEF Tank 27

Usable V olume,

Gallons

Fuel T ank

Diameter

22” 27.4 15.3

24.5” 27.4 15.8 22” 27.7 15.0

24.5” 27.7 15.5 22” 27.7 15.0

24.5” 27.7 15.5

Acronyms Index

Throughout the Frame Layout section you will see these acronyms. They are deﬁ ned here to help you decode the layouts.

BOC Back Of Cab DSOC Dual Side Of Cab BOS Back Of Sleeper LHUC Left Hand Under Cab CBOC Clear Back Of Cab RHUC Right Hand Under Cab DEF Diesel Exhaust Fluid SOAC Side Of AeroCab DSOAC Dual Side Of AeroCab SOC Side Of Cab

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Frame Layouts

FRAME LAYOUT INDEX Day Cab Chassis Layout Options

D1 is used with RHUC DPF/SCR, LHUC fuel tank, RH BOC DEF tank, and LH BOC cantilever battery box. Chart located

on page 5–8.

D2 is used with RHUC DPF/SCR, LHUC fuel tank, RH BOC cantilever battery box, and LH BOC DEF tank. Chart located on page 5–9.

D3 is used with RHUC DPF/SCR, LHUC battery box, RH BOC DEF tank, and LH BOC fuel tank. Chart located on page 5–10.

D4 is used with RHUC DPF/SCR, LHUC battery box, LH BOC DEF tank, and RH BOC fuel tank. Chart located on page 5–11.

D5 is used with RHUC DPF/SCR, LHUC fuel tank, RH BOC DEF tank, and in cab battery box. Chart located on page 5–12.

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Frame Layouts

D6 is used with RHUC DPF/SCR, LHUC fuel tank, Clear BOC DEF tank, and in cab battery box. Chart located on page 5–13.

D7 is used with Vertical-Vertical DPF/SCR, LH vertical tailpipe, RHUC fuel tank, LHUC battery box, and LH BOC DEF tank. Charts located on page 5–14.

D8 is used with Vertical-Vertical DPF/SCR, LH vertical tailpipe, RHUC fuel tank, LHUC battery box, and RH BOC DEF tank. Chart located on page 5–15.

D9 is used with Vertical-Vertical DPF/SCR, LH vertical tailpipe, LHUC & RHUC fuel tanks, RH BOC cantilever battery box, and LH BOC DEF tank. Chart located on page 5–16.

D10 is used with Vertical-Vertical DPF/SCR, LH vertical tailpipe, LHUC fuel tank, RHUC battery box, and Clear BOC DEF tank. Charts located on page 5–17.

5-5

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Section 5

Frame Layouts

Sleeper Chassis Layout Options

S1 is used with 38” AeroCab sleeper with RHUC DPF/SCR, LHUC fuel tank, RH BOC DEF tank, and LH BOC cantilever

battery box. Chart located on page 5–18.

S2 is used with 38” AeroCab sleeper with RHUC DPF/SCR, LHUC fuel tank, LH BOC DEF tank, and RH BOC cantilever battery box. Chart located on page 5–19.

S3 is used with 38” AeroCab sleeper with RHUC DPF/SCR, LHUC battery box, RH BOC DEF tank, and LH BOC fuel tank. Chart located on page 5–20.

S4 is used with 38” AeroCab sleeper with RHUC DPF/SCR, LHUC battery box, LH BOC DEF tank, and RH BOC fuel tank. Chart located on page 5–21.

S5 is used with 38” AeroCab sleeper with Vertical-Vertical DPF/SCR, LH vertical tailpipe, RHUC fuel tank, LHUC battery box, and LH BOC DEF tank. Chart located on page 5–22.

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Frame Layouts

S6 is used with 38” AeroCab sleeper with Vertical-Vertical DPF/SCR, LH vertical tailpipe, RHUC fuel tank, LHUC battery box, and RH BOC DEF tank. Chart located on page 5–23.

S7 is used with 38” AeroCab sleeper with Vertical-Vertical DPF/SCR, LH vertical tailpipe, RHUC & LHUC fuel tanks, LH BOC DEF tank and RH BOC cantilever battery box. Chart located on page 5–24.

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Frame Layouts

D1—Use with the following models: T470/T440

Dimension E (BOC to DPF/SCR)* = 0.4in

TABLE 5-5.

T470/T440

Fuel T ank Size

Diameter Gallons Length (in)

56 35.5 -3.7 17.0

22”

Diameter

Tank

24.5”

Diameter

Tank

*Subtract 5.7 inches for the extended Daycab. NOTE: DIMENSION “B” IS CALCULATED USING A CANTILEVER SIZED BATTERY BOX. OPTIONAL BOXES WILL AFFECT THIS DIMENSION.

60 38.0 -1.2 19.5

75 47.3 8.1 28.8 100 62.2 23.0 43.7 120 74.2 35.0 55.7

60 30.5 -8.7 12.0

75 38.5 -0.7 20.0

90 45.5 6.3 27.0 100 50.0 10.8 31.5 110 54.9 15.7 36.4 120 60.5 21.3 42.0 135 67.2 28.0 48.7 150 74.5 35.3 56.0

Dimension F

BOC to Fuel Tank,

Daycab* (in)

Dimension B

BOC to Battery Box,

Daycab* (in)

BOC to DEF Tank, Daycab* (in)

Small Medium Large

18.4 24.8 32.9

Dimension D

DEF T ank Size

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D2—Use with the following models: T470/T440

Dimension E (BOC to DPF/SCR)* = 0.4in Dimension B (BOC to Cantilever Battery Box)* = 21.8in

Section 5

Frame Layouts

TABLE 5-6.

T470/T440

Dimension D

Fuel T ank Size

Diameter Gallons Length (in) Small Medium Large

56 35.5 -3.7 7.4 17.1 25.2 60 38.0 -1.2 10.1 19.3 27.4

22” Diameter Tank

24.5” Diameter Tank

*Subtract 5.7 inches for the extended Daycab. NOTE: DIMENSION “B” IS CALCULATED USING A CANTILEVER SIZED BATTERY BOX. OPTIONAL BOXES WILL AFFECT THIS DIMENSION.

75 47.3 8.1 23.9 28.2 36.2 100 62.2 23.0 34.9 44.7 52.8 120 74.2 35.0 46.0 55.7 63.8

60 30.5 -8.7 1.9 11.6 19.7

75 38.5 -0.7 10.1 19.3 27.4

90 45.5 6.3 18.4 28.2 36.2 100 50.0 10.8 23.9 30.9 39.0 110 54.9 15.7 29.4 36.4 44.5 120 60.5 21.3 34.9 42.0 50.0 135 67.2 28.0 40.5 47.5 55.5 150 74.5 35.3 46.0 55.7 63.8

Dimension F

BOC to Fuel Tank,

Daycab* (in)

BOC to DEF Tank* (in)

DEF T ank Size

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Section 5

Frame Layouts

D3—Use with the following models: T470/T440

Dimension E (BOC to DPF/SCR)* = .04in Dimension B (BOC to Battery Box)* = -4.5in

TABLE 5-7.

T470/T440

Dimension D

Fuel T ank Size

Diameter Gallons Length (in) Small Medium Large

56 35.5 33.0

60 38.0 35.5

22” Diameter Tank

24.5” Diameter Tank

*Subtract 5.7 inches for the extended Daycab. NOTE: DIMENSIONS “B” AND “F” ARE CALCULATED USING A STANDARD BATTERY BOX. OPTIONAL EXTENDED BOXES WILL CHANGE DIMENSIONS “B” AND “F”

75 47.3 44.8 100 62.2 59.7 120 74.2 71.7

60 30.5 28.0

75 38.5 36.0

90 45.5 43.0 100 50.0 47.5 110 54.9 52.4 120 60.5 58.0 135 67.2 64.7

150 74.5 72.0

Dimension F

BOC to Fuel Tank,

Daycab* (in)

BOC to DEF Tank, Daycab* (in)

DEF T ank Size

18.4 24.8 32.9

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D4—Use with the following models: T470/T440

Dimension E (BOC to DPF/SCR)* = 0.4in Dimension B (BOC to Battery Box)* = -4.5in

Section 5

Frame Layouts

TABLE 5-8.

T440/T470

Fuel T ank Size

Diameter Gallons Length (in) Small Medium Large

56 35.5 38.6

60 38.0 41.1

22” Diameter Tank

24.5” Diameter Tank

*Subtract 5.7 inches for the extended Daycab. NOTE: DIMENSIONS “B” AND “D” ARE CALCULATED USING A STANDARD BATTERY BOX. OPTIONAL EXTENDED BOXES WILL CHANGE DIMENSIONS “B” AND “D”

75 47.3 50.4 100 62.2 65.3 120 74.2 77.3

60 30.5 33.6

75 38.5 41.6

90 45.5 48.6 100 50.0 53.1 110 54.9 58.0 120 60.5 63.6 135 67.2 70.3

150 74.5 77.6

Dimension F

BOC to Fuel Tank,

Daycab* (in)

BOC to DEF Tank, Daycab* (in)

7.4 17.1 25.2

Dimension D

DEF T ank Size

5-11

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Section 5

Frame Layouts

D5—Use with the following models: T470/T440 and In-cab battery box.

Dimension E (BOC to DPF/SCR)* = 0.4in

TABLE 5-9.

Diameter Gallons Length (in) Small Medium Large

22” Diameter Tank

24.5” Diameter Tank

Fuel T ank Size

56 35.5 -3.7

60 38.0 -1.2

75 47.3 8.1 100 62.2 23.0 120 74.2 35.0

60 30.5 -8.7

75 38.5 -0.7

90 45.5 6.3 100 50.0 10.8 110 54.9 15.7 120 60.5 21.3 135 67.2 28.0 150 74.5 35.3

T440/T470

Dimension F

BOC to Fuel Tank,

Daycab* (in)

Dimension D

BOC to DEF Tank, Daycab* (in)

DEF T ank Size

18.4 24.8 32.9

*Subtract 5.7 inches for the extended Daycab.

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Frame Layouts

D6—Use with the following models: T470/T440 and In-cab battery box.

Dimension E (BOC to DPF/SCR)* = 0.4in Dimension D (BOC to DEF tank)* = 0.7in

Section 5

TABLE 5-10.

T440/T470

Fuel Tank Size Dimension F

Diameter Gallons Length (in)

56 35.5 -3.7

60 38.0 -1.2

22” Diameter Tank

24.5” Diameter Tank

*Subtract 5.7 inches for the extended Daycab.

75 47.3 8.1 100 62.2 23.0 120 74.2 35.0

60 30.5 -8.7

75 38.5 -0.7

90 45.5 6.3 100 50.0 10.8

BOC to Fuel Tank,

Daycab* (in)

5-13

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Section 5

Frame Layouts

D7—Use with the following models: T470/T440

Dimension B (BOC to Battery Box)* = -4.5in Dimension E (BOC to DPF/SCR) = 19.6in

TABLE 5-11.

T440/T470

Fuel T ank Size

Diameter Gallons Length (in) Small Medium Small Medium

56 35.5 -3.7

22”

Diameter

Tank

24.5”

Diameter

Tank

*Subtract 5.7 inches for the extended Daycab. NOTE: DIMENSIONS “B” AND “D” ARE CALCULATED USING A STANDARD BATTERY BOX. OPTIONAL EXTENDED BOXES WILL CHANGE DIMENSIONS “B” AND “D”

60 38.0 -1.2 -6.9

75 47.3 8.1 2.4 100 62.2 23.0 17.3 120 74.2 35.0 29.3

60 30.5 -8.7 -14.4

75 38.5 -0.7 -6.4

90 45.5 6.3 0.6 100 50.0 10.8 5.1 110 54.9 15.7 10.0 120 60.5 21.3 15.6 135 67.2 28.0 22.3 150 74.5 35.3 29.6

Dimension F

BOC to

Fuel T ank,

Daycab (in)

BOC to DEF Tank, Daycab (in)

Dimension D

DEF T ank Size DEF Tank Size

7.4 39.2

Dimension F

BOC to Fuel

Tank, Ext.

Daycab (in)

-9.4

BOC to DEF Tank, Ext. Daycab (in)

Dimension D

1.7 39.0

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Page 85

D8—Use with the following models: T470/T440

Dimension B (BOC to Battery Box)* = -4.5in Dimension E (BOC to DPF/SCR) = 19.6in

Section 5

Frame Layouts

TABLE 5-12.

T440/T470

Fuel Tank Size

Diameter Gallons Length (in) Small Medium Small Medium

56 35.5 -3.7 18.4 39.2 -9.4 18.2 39.0

22”

Diameter

Tank

24.5”

Diameter

Tank

60 38.0 -1.2 18.4 39.2 -6.9 18.2 39.0

75 47.3 8.1 29.4 39.2 2.4 18.2 39.0 100 62.2 23.0 34.9 42.6 17.3 29.2 36.9 120 74.2 35.0

60 30.5 -8.7 18.4 39.2 -14.4 18.2 39.0

75 38.5 -0.7 18.4 39.2 -6.4 18.2 39.0

90 45.5 6.3 18.4 39.2 0.6 18.2 39.0 100 50.0 10.8 29.4 39.2 5.1 18.2 39.0 110 54.9 15.7 29.4 39.2 10.0 29.2 39.0 120 60.5 21.3 34.9 42.6 15.6 29.2 36.9 135 67.2 28.0 150 74.5 35.3 46.0 55.7 29.6 40.3 50.0

Dimension F

BOC to

Fuel Tank,

Daycab (in)

BOC to DEF Tank, Daycab (in)

Dimension D

DEF Tank Size DEF Tank Size

46.0 55.7

40.5 55.7

Dimension F

BOC to Fuel

Tank, Ext.

Daycab (in)

29.3

22.3

BOC to DEF Tank, Ext. Daycab (in)

Dimension D

40.3 50.0

34.8 50.0

*Subtract 5.7 inches for the extended Daycab. NOTE: DIMENSION “B” IS CALCULATED USING A STANDARD BATTERY BOX. OPTIONAL EXTENDED BOXES WILL CHANGE DIMENSION “B”

5-15

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Section 5

Frame Layouts

D9—Use with the following models: T470/T440

Dimension E (BOC to DPF/SCR) = 19.6in

TABLE 5-13.

T440/T470

Dimension

Fuel Tank Size

Diameter Gallons Length (in) Small Medium Small Medium

F1 & F2 BOC to

Fuel Tank,

Daycab (in)

Dimension B

BOC to

Battery Box,

Daycab (in)

BOC to DEF Tank, Daycab (in)

Dimension D

DEF Tank Size DEF Tank Size

Dimension

F1 & F2

BOC to Fuel

Tank, Ext.

Daycab (in)

Dimension B

BOC to

Battery Box,

Ext Daycab (in)

56 35.5 -3.7 24.1 7.4 39.2 -9.4 24.1 1.7 39.0

22”

Diameter

Tank

60 38.0 -1.2 24.1 18.4 39.2 -6.9 24.1 4.4 39.0

75 47.3 8.1 29.6 29.4 39.2 2.4 24.1 18.2 39.0 100 62.2 23.0 43.7 34.9 44.7 17.3 29.3 29.2 39.0 120 74.2 35.0 55.7

46.0 55.7

29.3 50.0 60 30.5 -8.7 24.1 1.9 39.2 -14.4 24.1 -3.8 39.0 75 38.5 -0.7 24.1 18.4 39.2 -6.4 24.1 4.4 39.0 90 45.5 6.3 29.6 18.4 39.2 0.6 29.6 18.2 39.0

24.5”

Diameter

Tank

100 50.0 10.8 35.1 29.4 39.2 5.1 29.6 18.2 39.0 110 54.9 15.7 36.4 29.4 39.2 10.0 35.1 29.2 39.0 120 60.5 21.3 42.0 34.9 42.0 15.6 35.1 29.2 39.0 135 67.2 28.0 48.7

40.5 47.5

22.3 43.0

150 74.5 35.3 56.0 46.0 55.7 29.6 50.3 40.2 50.0

Dimension D

BOC to DEF Tank,

Ext. Daycab (in)

40.3 50.0

34.8 41.8

NOTE: DIMENSION “B” IS CALCULATED USING A CANTILEVER SIZED BATTERY BOX. OPTIONAL BOXES WILL AFFECT THIS DIMENSION.

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Page 87

D10—Use with the following models: T470/T440

Dimension B (BOC To Battery Box)* = -4.5in Dimension E (BOC to DPF/SCR) = 19.6in Dimension D (BOC to DEF tank)* = 0.7in

Section 5

Frame Layouts

TABLE 5-14.

T440/T470

Fuel T ank Size

Diameter Gallons Length (in)

56 35.5 -3.7 -9.4 60 38.0 -1.2 -6.9

22” Diameter Tank

24.5” Diameter Tank

*Subtract 5.7 inches for the extended Daycab. NOTE: DIMENSION “B” IS CALCULATED USING A STANDARD BATTERY BOX. OPTIONAL EXTENDED BOXES WILL CHANGE DIMENSION “B”

75 47.3 8.1 2.4 100 62.2 23.0 17.3 120 74.2 35.0 29.3

60 30.5 -8.7 -14.4

75 38.5 -0.7 -6.4

90 45.5 6.3 0.6 100 50.0 10.8 5.1

Dimension F

BOC to Fuel Tank,

Daycab (in)

Dimension F

BOC to Fuel Tank,

Extended Daycab (in)

5-17

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Page 88

Section 5

Frame Layouts

S1—Use with the following models: T470/T440 38”

Dimension E (BOS to DPF/SCR) = -17..9in.

TABLE 5-15.

T440/T470 38”

Fuel T ank Size

Diameter Gallons Length (in) Small Medium Large

56 35.5 -31.7 0.9 60 38.0 -29.2 0.9

22” Diameter Tank

24.5” Diameter Tank

NOTE: DIMENSION “B” IS CALCULATED USING A CANTILEVER SIZED BATTERY BOX. OPTIONAL BOXES WILL AFFECT THIS DIMENSION.

75 47.3 -19.9 0.9 100 62.2 -5.0 18.4 120 74.2 7.0 27.7

60 30.5 -36.7 -16.0

75 38.5 -28.7 0.9

90 45.5 -21.7 0.9 100 50.0 -17.2 18.4 110 54.9 -12.3 18.4 120 60.5 -6.7 18.4 135 67.2 0.0 18.4 150 74.5 7.3 28.0

Dimension F

BOS to

Fuel T ank (in)

Dimension B

BOS to

Battery Box (in)

12.7 17.0 25.1

Dimension D

BOS to DEF Tank (in)

DEF T ank Size

12/09

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Page 89

S2—Use with the following models: T470/T440 38”

Dimension E (BOS to DPF/SCR) = -17.9in Dimension B (BOS to Cantilever Battery Box) = 2.9in

Section 5

Frame Layouts

TABLE 5-16.

Diameter Gallons Length (in) Small Medium Large

22” Diameter Tank

24.5” Diameter Tank

Fuel T ank Size

56 35.5 -31.7 -20.6 -10.9 25.1

60 38.0 -29.2 -15.1 17.0 25.1

75 47.3 -19.9 12.7 17.0 25.1 100 62.2 -5.0 12.7 17.0 25.1 120 74.2 7.0 18.0 27.7 35.8

60 30.5 -36.7 -26.1 -16.4 25.1

75 38.5 -28.7 -15.1 17.0 25.1

90 45.5 -21.7 12.7 17.0 25.1 100 50.0 -17.2 12.7 17.0 25.1 110 54.9 -12.3 12.7 17.0 25.1 120 60.5 -6.7 12.7 17.0 25.1 135 67.2 0.0 12.7 19.5 27.5 150 74.5 7.3 18.0 27.7 35.8

T440/T470 38”

Dimension F

BOS to Fuel Tank (in)

Dimension D

BOS to DEF Tank (in)

DEF T ank Size

NOTE: DIMENSION “B” IS CALCULATED USING A CANTILEVER SIZED BATTERY BOX. OPTIONAL BOXES WILL AFFECT THIS DIMENSION.

5-19

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Section 5

Frame Layouts

S3—Use with the following models: T470/T440 38”

Dimension E (BOS to DPF/SCR) = -17.9in Dimension B (BOS to Battery Box) = -32.5in

TABLE 5-17.

Diameter Gallons Length (in) Small Medium Large

22” Diameter Tank

24.5” Diameter Tank

Fuel T ank Size

56 35.5 5.0

60 38.0 7.5

75 47.3 16.8 100 62.2 31.7 120 74.2 43.7

60 30.5 0.0

75 38.5 8.0

90 45.5 15.0 100 50.0 19.5 110 54.9 24.4 120 60.5 30.0 135 67.2 36.7 150 74.5 44.0

T440/T470 38”

Dimension F

BOS to Fuel Tank (in)

Dimension D

BOS to DEF Tank (in)

DEF T ank Size

12.7 17.0 25.1

NOTE: DIMENSIONS “B” AND “F” ARE CALCULATED USING A STANDARD BATTERY BOX. OPTIONAL EXTENDED BOXES WILL CHANGE DIMENSIONS “B” AND “F”

12/09

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Page 91

S4—Use with the following models: T470/T440 38”

Dimension E (BOS to DPF/SCR) = -17.9in Dimension B (BOS to Battery Box) = -32.5in

Section 5

Frame Layouts

TABLE 5-18.

Diameter Gallons Length (in) Small Medium Large

22” Diameter Tank

24.5” Diameter Tank

Fuel T ank Size

56 35.5 20.3

60 38.0 22.8

75 47.3 32.1 100 62.2 47.0 120 74.2 59.0

60 30.5 15.3

75 38.5 23.3

90 45.5 30.3 100 50.0 34.8 110 54.9 39.7 120 60.5 45.3 135 67.2 52.0 150 74.5 59.3

T440/T470 38”

Dimension F

BOS to Fuel Tank (in)

Dimension D

BOS to DEF Tank (in)

DEF T ank Size

-20.6 -10.9 -2.8

NOTE: DIMENSIONS “B” AND “D” ARE CALCULATED USING A STANDARD BATTERY BOX. OPTIONAL EXTENDED BOXES WILL CHANGE DIMENSIONS “B” AND “D”

5-21

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Page 92

Section 5

Frame Layouts

S5—Use with the following models: T470/T440 38”

Dimension B (BOS to Battery Box) = -32.5in Dimension E (BOS to DPF/SCR) = 19.6in

TABLE 5-19.

Diameter Gallons Length (in) Small Medium

22” Diameter Tank

24.5” Diameter Tank

Fuel T ank Size

56 35.5 -31.7

60 38.0 -29.2

75 47.3 -19.9 100 62.2 -5.0 120 74.2 7.0

60 30.5 -36.7

75 38.5 -28.7

90 45.5 -21.7 100 50.0 -17.2 110 54.9 -12.3 120 60.5 -6.7 135 67.2 0.0 150 74.5 7.3

T440/T470 38”

Dimension F

BOS to Fuel Tank (in)

Dimension D

BOS to DEF Tank (in)

DEF T ank Size

-20.6 -10.9

NOTE: DIMENSIONS “B” AND “D” ARE CALCULATED USING A STANDARD BATTERY BOX. OPTIONAL EXTENDED BOXES WILL CHANGE DIMENSIONS “B” AND “D”

12/09

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Page 93

S6—Use with the following models: T470/T440 38”

Dimension B (BOS to Battery Box) = -32.5in Dimension E (BOS to DPF/SCR) = 19.6in

Section 5

Frame Layouts

TABLE 5-20.

Diameter Gallons Length (in) Small Medium

22” Diameter Tank

24.5” Diameter Tank

Fuel T ank Size

56 35.5 -31.7 -20.6 -9.4

60 38.0 -29.2 -17.9 -9.4

75 47.3 -19.9 29.3 39.0 100 62.2 -5.0 29.3 39.0 120 74.2 7.0 29.3 39.0

60 30.5 -36.7 -26.1 -9.4

75 38.5 -28.7 -17.9 -9.4

90 45.5 -21.7 29.3 39.0 100 50.0 -17.2 29.3 39.0 110 54.9 -12.3 29.3 39.0 120 60.5 -6.7 29.3 39.0 135 67.2 0.0 29.3 39.0 150 74.5 7.3 29.3 39.0

T440/T470 38”

Dimension F

BOS to Fuel Tank (in)

Dimension D

BOS to DEF Tank (in)

DEF T ank Size

NOTE: DIMENSION “B” IS CALCULATED USING A STANDARD BATTERY BOX. OPTIONAL EXTENDED BOXES WILL CHANGE DIMENSION “B”

5-23

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Page 94

Section 5

Frame Layouts

S7—Use with the following models: T470/T440 38”

Dimension E (BOS to DPF/SCR) = 19.6in

TABLE 5-21.

T440/T470 38”

Fuel T ank Size

Diameter Gallons Length (in) Small Medium

56 35.5 -31.7 0.9 -20.6 -10.9

22” Diameter

Tank

24.5” Diameter Tank

60 38.0 -29.2 0.9 -17.9 39.0

75 47.3 -19.9 0.9 18.2 39.0 100 62.2 -5.0 37.1 18.2 39.0 120 74.2 7.0 37.1 18.2 39.0

60 30.5 -36.7 -16.0 -26.1 -16.4

75 38.5 -28.7 0.9 -17.9 39.0

90 45.5 -21.7 0.9 18.2 39.0 100 50.0 -17.2 37.1 18.2 39.0 110 54.9 -12.3 37.1 18.2 39.0 120 60.5 -6.7 37.1 18.2 39.0 135 67.2 0.0 37.1 18.2 39.0 150 74.5 7.3 37.1 18.2 39.0

Dimension F1 & F2

BOS to

Fuel T ank (in)

Dimension B

BOS to

Battery Box (in)

Dimension D

BOS to DEF Tank (in)

DEF T ank Size

NOTE: DIMENSION “B” IS CALCULATED USING A CANTILEVER SIZED BATTERY BO X. OPTIONAL BOXES WILL AFFECT THIS DIMENSION.

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Page 95

Section 6

Body Mounting

FRONT FRAME DIMENSIONS

This section includes drawings of the T470 extended front frame (73”) and standard (50.5”) front frame settings. All dimensions are in inches (in). They illustrate measurements useful to the installation of front frame equipment and bumpers. Kenworth also offers .dxf ﬁ les and frame layouts of ordered chassis four weeks prior to build. Please work with your Kenworth sales representative to request this feature when specifying your chassis.

Extended Front Frame Standard Front Frame

44.8” 44.8” 27.0”27.0”

10.2”

72.8”

50.3”

10.2”

Extended Front Frame Standard Front Frame

6-1

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Page 96

Section 6

Body Mounting

FRAME INFORMATION

Frame information provided is per rail, some speciﬁ cations are written for RBM requirements per pair of rails. Make sure to know the requirement before deciding on the frame rail.

TABLE 6-1. Single Steel Rails

Rail Height Flange Width Web Thickness Section Modulus RBM (in lbs) Weight (lbs/in)*

H W T S R W

10 - 5/8” x 3 -1/2” x 5/16” 14.80 1,776,000 2.90 10 - 3/4” x 3 -1/2” x 3/8” 17.80 2,132,000 3.46 10 - 11/16” x 3 -1/2” x 1/2” 22.35 2,683,000 4.53 11 - 5/8” x 3 -7/8” x 3/8” 21.43 2,572,000 3.80

* Per pair of rails.

TABLE 6-2. Inserted Steel Rails

Rail Height Insert Material Section Modulus RBM (in lbs) Weight (lbs/in)*

10 - 5/8” Single 9-7/8”x 2-7/8” x 1/4” 24.37 2,925,000 4.96 10 - 3/4” Single 9-7/8”x 2-7/8” x 1/4” 27.33 3,280,000 5.53 11 - 5/8” Single 10-3/4”x 3-1/2” x 3/8” 39.20 4,704,000 7.28

* Per pair of rails.

CRITICAL CLEARANCES Rear Wheels and Cab

CAUTION:

Normal suspension movement could cause contact between the tires and the body. To prevent this, mount the body so that the minimum clearance between the top of the tire and the bottom of the body is 8 inches (203 mm). This should be measured with the body empty. See Figure 6–1.

Insufﬁ cient clearance between rear tires and body structure may cause damage to the body during suspension movement. Allow at least 8 inches clearance (See Figure 6–1.)

FIGURE 6-1. Minimum Clearance Between Top Of Rear Tires And Body Structure Overhang.

CAUTION:

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Maintain adequate clearance between back of cab and the front (leading edge) of mounted body. Failure to comply may result in equipment damage. See Figure 6–2.

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Section 6

Body Mounting

Note:

FIGURE 6-2. Minimum Back of Cab Clearance

Be sure to provide maintenance access to battery box and fuel tank ﬁ ll neck.

4”

WARNING:

If the frame rail ﬂ anges are modiﬁ ed or damaged, the rail may fail prematurely and cause an accident. When mounting a body to the chassis, DO NOT drill holes in the upper or lower ﬂ ange of the frame rail. Mount the body using body mounting brackets or U–bolts. Failure to comply may result in personal injury, death, equipment or property damage.

BODY MOUNTING USING BRACKETS

CAUTION:

Installation of a spacer between the body subframe and the top ﬂ ange of the frame rail will help prevent premature wear of the components due to chaﬁ ng or corrosion.

Always install a spacer between the body subframe and the top ﬂ ange of the frame rail. Failure to do so may result in corrosion due to dissimilar materials and equipment damage.

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Section 6

Body Mounting

Frame Sill

If the body is mounted to the frame with brackets, we recommend that the frame sill spacer be made from a strip of rubber or plastic (delrin or nylon). These materials will not undergo large dimensional changes during periods of high or low humidity. The strip will be less likely to fall out during extreme relative motion between body and chassis. See Figure 6–3.

Body Subframe (Rail)

Spacer

Chassis Frame (Rail) Sill

FIGURE 6-3. Spacer Between Frame Sill and Body Rail - Rubber or Plastic

Brackets

When mounting a body to the chassis with brackets, we recommend designs that offer limited amount of relative movement, bolted securely but not too rigid. Brackets should allow for slight movement between the body and the chassis. For instance, Figure 6–4 shows a high compression spring between the bolt and the bracket.

Spring

Rubber Spacer

FIGURE 6-4. High Compression Spring FIGURE 6-5. Rubber Spacer Between Brackets Between the Mounting Bolt and Upper Bracket

Another possibility is mounting a rubber spacer between the brackets. See Figure 6–5. These designs will allow relative movement between the body and the chassis during extreme frame racking situations.

Extreme frame racking, and mountings that are too rigid, could cause damage to the body. This is particularly true with tanker installations.

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Page 99

Section 6

Body Mounting

MOUNTING HOLES

When installing the lower bracket on frame rails the mounting holes in the chassis frame bracket and frame rail must comply with the general spacing and location guidelines illustrated in Figure 6–6. The hole diameter should not exceed the bolt diameter by more than .060 inches (1.5 mm).

5.63

(143mm)

2.0

(50mm)

4 HOLES

.63 IN. DIA.

.5 IN. DIA.

(12.7mm)

(16mm)

5.5

(140mm)

6 HOLES

.63 IN. DIA.

.5 IN. DIA.

(12.7mm)

11.0

(279mm)

(16mm)

(140mm)

FIGURE 6-6. Crossmember-Gusset Hole Pattern Requirements. [inch (mm)]

Frame Drilling

WARNING:

When mounting a body to the chassis, DO NOT drill holes in the upper or lower ﬂ ange of the frame rail. If the frame rail ﬂ anges are modiﬁ ed or damaged, the rail may fail prematurely. Mount the body us- ing body mounting brackets or U–bolts. Failure to comply may result in personal injury, death, equipment or property damage.

5.5

5.63

(143mm)

2.0

(50mm)

WARNING:

Use care when drilling the frame web so the wires and air lines routed inside the rail are not damaged, failure to do so may cause an inoperable electrical or air system circuit. Failure to comply may result in personal injury, death, equipment or property damage.

Do not drill closely spaced holes in the frame rail. Hole centers of two adjacent holes should be spaced no less than twice the diameter of the largest hole. Closer spacing may induce a failure between the holes. Failure to comply may result in personal injury, death, equipment or property damage.

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Page 100

Section 6

Body Mounting

BODY MOUNTING USING U–BOLTS Spacers

If the body is mounted to the frame with U–bolts, use a hardwood sill (minimum 1/2 inch (12 mm) thick) between the frame rail and body frame to protect the top surface of the rail ﬂ ange.

WARNING:

Use a hardwood spacer between the bottom ﬂ ange and the U–bolt to prevent the U–bolt from notching the frame ﬂ ange. See Figure 6–7.

Wood Sill 0.5 (12) Minimum

Frame Rail Spacer

(Fabricated Steel or

FIGURE 6-7. Acceptable U-Bolt Mounting with Wood and Fabricated Spacers [inch (mm)]

Do not allow the frame rails or ﬂ anges to deform when tightening the U–bolts. It will weak- en the frame. Use suitable spacers made of steel or hardwood on the inside of the frame rail to prevent collapse of the frame ﬂ anges. Failure to comply may result in personal injury, death, equipment or property damage.

Body Structure

Truck Frame

Hardwood)

U-Bolt

U-Bolt Spacer (Hardwood)

WARNING:

CAUTION:

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Do not allow spacers and other body mounting parts to interfere with brake lines, fuel lines, or wiring harnesses routed inside the frame rail. Crimped or damaged brake lines, fuel lines, or wiring may result in loss of braking, fuel leaks, electrical overload or a ﬁ re. Carefully inspect the installation to ensure adequate clearances for air brake lines, fuel lines, and wiring. Failure to comply may result in personal injury, death, equipment or property damage. See Figure 6–8.

Mount U–bolts so they do not chafe on frame rail. Failure to do so may result in premature wear of the U-bolt or frame rail.

6-6