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Kenworth Heavy Duty Body Builder Manual

1. AG690 Tridem Suspension TABLE 3 7 Rear Suspension Options l i Laden Ride Unladen Ride Suspension Type Axle Spacing Height Height NOTE Actual axle spacing can depart from nominal due to axle slant requirements Final axle spacing can vary by more than an inch from nominal in some cases If precise axle spacing is critical due to body installation or state local regulatory requirements please contact Kenworth Applications technical Support for assistance 08 12 3 22 Section 3 Dimensions REYCO 79KB SINGLE REAR AXLE A 30 2 301 28 7 pa 290 RIDE HEIGHT Optional Reyco 79KB Suspensions TABLE 3 8 Rear Suspension Options Suspension Type Axle Svacin Laden Ride Unladen Ride d del P g Height Height 3 23 08 12 Section 3 Dimensions REYCO 102 TANDEM REAR AXLE Shown with a 52 Axle Spacing 54 7 m i 50 5 e 499 493 me 489 _ n AE pe a p re A il oe ha o a wie i 4 Te re al J e a o A ei oP her lo F Ma ks A i e hal Fa i a ES OFA je gt ay O a ae ee he ae 19 x de F j J aaa i 4 A A F Po a in Ma En li A if gt a A a 1 i Fa Na A y AS i A l y A El wN th i a dl i E aj w h A a a a I 7 A i IYD RIDE r h th l T i i 1s Al j YY HEIGHT j T i I 1 il i n d i il i F i
2. 08 12 3 12 Section 3 Dimensions C500 The following drawings are of the C500 shown with standard chassis components Shown with optional wheels and tires r 130 5 A 85 6 89 2 Y gt y FS RS 88 6 T WB an EOF E 113 0 AS dq 3 13 08 12 Section 3 Dimensions EXTENDED DAY CAB The Extended Day Cab is shown on a standard T800 chassis It is important to note that the Extended Day 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 across the models 08 12 32 14 Section 3 Dimensions 38 AEROCAB The 38 Aerocab is shown on a standard T800 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 i DT LAs pa Foe i 3 15 08 12 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 ple
3. ECN ES y y LI r Dimension B BOC To Battery Box 10 6in Dimension E BOC to DPF SCR 19 6in Dimension D BOC to DEF tank 1 0in TABLE 5 59 Fuel Tank Size Dimension F Dimension F BOC to Fuel Tank BOC to Fuel Tank Daycab in Extended Daycab in 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 63 08 12 Section 5 Frame Layouts D13E Use with the following models W900L o o aN LIO a Saa LI EC D13 Charts ECN ES y y LI r Dimension B BOC To Battery Box 10 6in Dimension E BOC to DPF SCR 19 6in Dimension D BOC to DEF tank 1 0in TABLE 5 60 Fuel Tank Size Dimension F Dimension F BOC to Fuel Tank BOC to Fuel Tank Daycab in Extended Daycab in 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 08 12 5 64 Section 5 Frame Layouts 1A Use with the following models T800SH 38 Dimension E BOS to DPF SCR 24 9in TABLE 5 61 Fuel Tank Size ___Diameter___ Gallons Length in T8SH 38 Dimension B BOS to Battery Box
4. FIGURE A 3 Front Axle Identification A 3 08 12 Appendix A Vehicle Identification Rear Axle Identification The rear axle identification numbering system includes two labels or stamps 1 Axle Housing Number Tag located on the left forward side of the housing arm This tag identifies the axle housing 2 Axle Differential Carrier Identification located on the top side of the differential carrier The following information is either stamped or marked with a metal tag Model No Carrier Production Assembly No Carrier Assembly Serial No Gear Ratio Axle Specifications Number and OEM part number and country of origin FIGURE A 4 Rear Axle Identification Note Illustrated identification tag locations are typical Actual locations may vary by axle manu facturer and with single versus tandem axles 08 12 A 4 Appendix A Vehicle Identification This page intentionally left blank A 5 08 12 08 12 KENWORTH A PACCAR COMPANY Kenworth Truck Company P O Box 1000 Kirkland WA 98083 425 828 5000
5. D2 Charts Dimension E BOC to DPF SCR 3 1in Dimension B BOC to Cantilever Battery Box 24 5in TABLE 5 10 Dimension D Fuel Tank Size Dimension F BOC to DEF Tank in BOC to Fuel Tank DEF Tank Size eee smar s as OOO ar ED A T ra ra or A o 75 287 105 19 116 197 66 184 282 362 29 45 555 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 7 4 7 4 1 9 4 28 5 Diameter Tank 08 12 5 14 Section 5 Frame Layouts D2B Use with the following models T800B and C500B seyo cd Dimension E BOC to DPF SCR 0 3in Dimension B BOC to Cantilever Battery Box 21 7in TABLE 5 11 T8B C5B l Dimension D Fuel Tank Size Dimension F BOC to DEF Tank in AO UE TEDS DEF Tank Size Diameter Gallons Length in 0P mal 60 so a1 101 193 274 22 Diameter Tank 60 305 es 74 m1 197 7 ses 06 129 193 274 ass 64 184 282 362 75 9 l 4 20 oO 7 287 104 19 16 197 e 342 49 74 174 252 28 5 Diameter Tank i77 661 270 475 555 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
6. P27 1040 06 SYMBOL PTC444 D d o CONTACT NONE PLATING STYLE LONG TOGGLE INDICATOR NONE COLOR P27 1040 07 SYMBOL TEXT SPARE CONTACT NONE PLATING STYLE ROCKER INDICATOR GREEN COLOR P27 1040 08 FOG LAMPS UPPER SW PANEL L 1 9 P27 1040 08 P27 1040 09 FOG LAMPS CENTER SW PANEL 1 She SYMBOL PTCI52 P27 1123 007 SPARE SWITCH 9 1 ps A CONTACT NONE PLATING STYLE SHORT TOGGLE INDICATOR NONE COLOR P21 1040 09 R P27 1040 10 DOME LAMP e SYMBOL PTC152 CONTACT NONE PLATING STYLE ROCKER INDICATOR GREEN COLOR P27 1123 024 TRAILER HOTLINE P27 1040 10 Re P27 1040 11 FLOOD LAMPS CAB MOUNTED SYMBOL PTC169 P27 1123 036 PTO R3 P27 1123 007 SPST UP MIDDLE DOWN ON NONE OFF 2B 3 TEXT SPARE CONTACT PLATING NONE STYLE ROCKER INDICATOR COLOR GREEN PROTECTION INDICATOR P27 1123 024 SPST UP MIDDLE DOWN ON NONE OFF 2B 3 PTCA56 HOTLINE OO P27 1040 12 ISO 3131 SPARE FL
7. SHEYD ES F Dimension E BOS to DPF SCR 27 7in Dimension B BOS to Battery Box 38 6in TABLE 5 71 W9B 38 Fuel Tank Size Dimension F BOS to DEF Tank in BOS to Fuel Tank in DEF Tank Size Diameter Gallons Length in Smali Medium Large _ as AA o o Pa 120 re ar 7 es to o ass fa os ess 22 10 ss ez 28 5 Diameter Tank teo NOTE DIMENSIONS B AND F ARE CALCULATED USING A STANDARD BATTERY BOX OPTIONAL EXTENDED BOXES WILL CHANGE DIMENSIONS B AND F 5 85 08 12 Section 5 Frame Layouts S3F Use with the following models W900B 42 S3 Charts F iM Dimension E BOS to DPF SCR 43 7in Dimension B BOS to Battery Box 54 6in TABLE 5 72 W9B 42 Fuel Tank Size Dimension F BOS to DEF Tank in BOS to Fuel Tank in ___Diameter__ _Gallons_ Length in _ Small Medium Large _ as AA o f so f e w ee se ea O IICA 21 9 ao aso s2 as NOTE DIMENSIONS B AND F ARE CALCULATED USING A STANDARD BATTERY BOX OPTIONAL EXTENDED BOXES WILL CHANGE DIMENSIONS B AND F 08 12 5 86 Section 5 Frame Layouts 3G Use with the following models W900L 38 SHEYD ES F h Dimension E BOS to DPF SCR 27 7in Dimension B BOS to Battery Box 38 6in TABLE 5 73 W9L 38 Fuel Tank Size Dimension F BOS to DEF Tank in BOS to Fuel Tank in DEF Tank Size ___Di
8. 0 0 ee ee nn ee kk ek a 3 15 RIDE HEIGHTS 2 2 2 2 0 a a a ek kn kk nk ke ee 3 16 REAR SUSPENSION LAYOUTS 2 0 0 ee ee ee ee ek ek ee 3 18 AG400L TANDEM 2 0 ce eee ee ee en a a 3 19 AG400 TANDEM 2 0 ee ee ee ee kk kn kn kk ke ee 3 20 AG460 TANDEM 0 0 ee ee ee ee kk kn kk ke 3 21 AG690 TRIDEM 2 a a a kk a ke 3 22 REYCO 79KB SINGLE REAR AXLE 3 23 REYCO 102 TANDEM REARAXLE a 3 24 NEWAY AD 123 SINGLE REAR AXLE 3 25 NEWAY AD 246 TANDEM SUSPENSION oaa aaa a a a ee ens 3 26 NEWAY AD 369 TRIDEM SUSPENSION 2 2 2 2 2 2 0 2 2 a ee ees 3 27 HENDRICKSON PRIMAAX TANDEM SUSPENSION oaa 2 28484 3 28 HENDRICKSON PRIMAAX TRIDEM SUSPENSION 2 2 2 2 2 2 2 2 285 3 29 HENDRICKSON HMX TANDEM SUSPENSION 2 2 2 2 2 2 2 2 8284 3 30 HENDRICKSON RT TANDEM SUSPENSION 2 2 2 2 2 2 00 08 2 eons 3 31 CHALMERS 856 46 TANDEM SUSPENSION 2 2 2 2 2 2 0 0 ee eons 3 32 PUSHER AXLES 2 0 0 0 eee ee ee ee ek kk kn nk ke 3 34 AXLE TRACK AND TIRE WIDTH 2 0 0 ee ee ee eek ee ke ee 3 36 PTO CLEARANCES 0 0 eee ee ee ee kk kk a kn kk eg 3 40 SECTION 4 EXHAUST amp AFTERTREATMENT 4 1 EXHAUST AND AFTER TREATMENT INFORMATION 2 2 2 2 2 8084 4 1 GENERAL GUIDELINES FOR DEF SYSTEM 2 885
9. 08 12 5 106 Section 5 Frame Layouts 7C Use with the following models T800B and C500B 38 F E ll a EN o m La LIO CC SHEYD ZS ET EZY E L N Dimension B BOS to Battery Box 32 5in Dimension E BOS to DPF SCR 19 6in TABLE 5 93 T8B and C5B 38 Dimension D Fuel Tank Size Dimension F BOS to Fuel Tank in Diameter____ Gallons Length in _ Smali Medium __ 6 380 24 eo os ee o ass ete 120 605 66 eo eae NOTE DIMENSIONS B AND D ARE CALCULATED USING A STANDARD BATTERY BOX OPTIONAL EXTENDED BOXES WILL CHANGE DIMENSIONS B AND D 5 107 08 12 Section 5 Frame Layouts 7D Use with the following models T800B and C500B 42 F E ll a EN La LIO CC S7 Charts C EZY gt Y E L N Dimension B BOS to Battery Box 48 5in Dimension E BOS to DPF SCR 19 6in TABLE 5 94 T8B and C5B 42 Fuel Tank Size Dimension F BOS to DEF Tank in BOS to Fuel Tank in __Diameter_____ Gallons Length in _ sman Medium o 30 2 eo m2 eo sos e o ass r o a IEA Y NOTE DIMENSIONS B AND D ARE CALCULATED USING A STANDARD BATTERY BOX OPTIONAL EXTENDED BOXES WILL CHANGE DIMENSIONS B AND D 08 12 5 108 Section 5 Frame Layouts S8A Use with the following models T80
10. 08 12 5 56 Section 5 Frame Layouts D12C Use with the following models W900S seyo cta Dimension E BOC to DPF SCR 19 6in TABLE 5 53 i i Dimension D i i i i ene Dimension Dimension Dimension B BOC to DEF Tank Dimension B i BOC to DEF Tank Daycab in Fuel Tank Size F1 amp F2 BOC to ycab in F1 amp F2 BOC to Ext Daycab in BOC to BOC to Fuel Battery Box Fuel Tank Pattery Box Tank Ext Ext Daycab Daycab in Pea Un ma Daycab in in Small Medium a1 208 IEC 7 2 6 NOTE DIMENSION B IS CALCULATED USING A CANTILEVER SIZED BATTERY BOX OPTIONAL BOXES WILL AFFECT THIS DIMENSION 2 2 1 1 08 12 5 57 Section 5 Frame Layouts D12D Use with the following models W900B D12 Charts Dimension E BOC to DPF SCR 19 6in TABLE 5 54 Di f Dimension D Di Dimension D imension mension Fuel Tank Si e Fo Dimension B 50C to DEF Tank Daycab in Ea 8 a Dimension B BOC to DEF Tank uel Tank Size BOC to i BOC to Ext Daycab in O Battery Box i POCIO UR Battery Box Fuel Tank Teor DEF Tank Size Tank Ext y Box DEF Tank Size a Daycab in Daycab in man medium Daycab in Ext Daycab in mal Diameter 549 20 9 18 2 NOTE DIMENSION B IS CALCULATED USING A CANTILEVER SIZED BATTERY BOX OPTIONAL BOXES WILL AFFECT THIS DIMENSION 1 5 1 5 Y 7 2 2 2 08 12 5 58 Section 5
11. Dimension E BOC to DPF SCR 0 3in Dimension B BOC to Cantilever Battery Box 21 7in TABLE 5 14 Dimension D Fuel Tank Size Dimension F BOC to DEF Tank in BOC to Fuel Tank DEF Tank Size Diameter Gallons Length in 0 o so 22 Diameter Tank o s 120 120 65 90 a2 28 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 1 08 12 5 18 Section 5 Frame Layouts D3A Use with the following models T800SH SHEYD ead Dimension E BOC to DPF SCR 3 1in Dimension B BOC to Battery Box 4 5in TABLE 5 15 l l Dimension D Fuel Tank Size Dimension F BOC to DEF Tank Daycab in BOC to Fuel Tank fi DEF Tank Size Daycab in Diameter Gallons Length in 24 5 Diameter Tank 28 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 5 19 08 12 Section 5 Frame Layouts D3B Use with the following models T800B and C500B D3 Charts Dimension E BOC to DPF SCR 0 3in Dimension B BOC to Battery Box 4 5in TABLE 5 16 T8B C5B
12. FIGURE 4 3 Orientation of Dosing Module Right Hand Under DPF and SCR with Small Medium or Large DEF Tanks 1 0m l r Height Differential 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 4 5 08 12 Section 4 Exhaust amp Aftertreatment Horizontal Crossover DPF and SCR with Small Medium or Large DEF Tanks 4 0m Height Differential FIGURE 4 5 Horizontal 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 Vertical DPF and SCR with Small Medium or Large DEF Tanks 1 0m Height Differential FIGURE 4 6 Vertical Exhaust with Small Medium or Large Tanks
13. 08 12 4 6 Section 4 Exhaust amp Aftertreatment 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 Right Hand Under DPF and SCR with Clear Back of Cab DEF Tank 1 0m Height Differential Supply Module 1 0m Height fo Tank Differential Bottom Supply Module te Dosing Module 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 11
14. 3 4 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 HORIZONTAL EXHAUST WITH SMALL MEDIUM OR LARGE TANKS 4 6 FIGURE 4 6 VERTICAL EXHAUST WITH SMALL MEDIUM OR LARGE TANKS 4 6 FIGURE 4 7 RH UNDER CAB EXHAUST WITH CLEAR BACK OF CAB TANK 4 7 FIGURE 4 8 VERTICAL WITH CLEAR BACK OF CAB TANK 4 8 FIGURE 4 9 ROUTING DEF LINES AND DEF TRAP 4 9 FIGURE 4 10 SUPPLY MODULE ALLOWED CLOCKING ANGLES 4 9 FIGURE 4 11 ISOMETRIC VIEW OF RIGHT HAND UNDER DPF AND SCR WITH SINGLE SOC TAILPIPE 0 22000020002 2004 4 11 FIGURE 4 12 TOP VIEW OF RIGHT HAND UNDER DPF AND SCR WITH SINGLE SOC TAILPIPE 2234226 53 48 8500 Bee ere ee ee FS oS ee ee we 4 11 FIGURE 4 13 RIGHT VIEW OF RIGHT HAND UNDER DPF AND SCR WITH SINGLE SOG IAILPIPE seec gheacteeeaee4 Reb oe Eee bee bee Ge ee SS 4 12 FIGURE 4 14 BACK VIEW OF RIGHT HAND UNDER DPF AND SCR WITH SINGLE SOC TAIEPIPE oo RS RBH ER EERE Ree OEReeEe EEE RED ESE S 4 12 FIGURE 4 15 ISOMETRIC VIEW OF RIGHT HAND UNDER DPF AND SCR WITH DUAL SOC TAILPIPES 24250846668 6654 82 Se Re oe be a a o a 4 13 FIGURE 4 16 TOP VIEW OF RIGHT HAND UNDER DPF AND SCR WITH DUAL DOC TAIEPIPES wsaseae
15. 45 64 184 19 Ak o a ae 7a wa 28 5 Diameter Tank 177 661 270 480 Subtract 5 7 inches for the extended Daycab 08 12 5 44 Section 5 Frame Layouts D10A Use with the following models T800SH gt _ Jo i gt i Dimension B BOC to Battery Box 4 5in Dimension E BOC to DPF SCR 19 6in TABLE 5 41 T8SH Dimension D Dimension D Fuel Tank Size Dimension F BOC to DEF Tank Daycab in Dimension F BOC to DEF Tank Ext Daycab in BOC to BOC to Fuel Fuel Tank DEF Tank Size Tank Ext DEF Tank Size Diameter Tank 7 4 39 2 1 7 39 0 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 5 45 08 12 seyo ola D10 Charts Section 5 Frame Layouts D10B Use with the following models T800B and C500B Dimension B BOC to Battery Box 4 5in Dimension E BOC to DPF SCR 19 6in TABLE 5 42 Fuel Tank Size Diameter Gallons Length in 7 Dimension F BOC to Fuel Tank Daycab in a eo 0s 26 rs ass 06 so ess 04 24 5 Diameter Tank so as ao Subtract 5 7 inches for the extended Daycab 2 4 28 5 Diameter Tank Dimension D BOC to DEF Tank Daycab in DEF Tank Size 7 4 gt _ i gt i T8B
16. DEF gauge See Figure 8 2 FIGURE 8 2 Diesel Exhaust Fluid Gauge Note The information contained in this manual is specific to chassis with 2010 engines For pre 2010 il engines please work with your local Kenworth dealer 08 12 8 2 Section 8 Electrical Data Bus Communication The multiplexed instrumentation system uses several different data links to transmit input output data from other systems to the Cab Electronic Control Unit CECU and ultimately to the Central Instrument Cluster and CVSG Gauges See Fig ure 8 3 Multiplexed Instrumentation Block Diagram on page 8 3 SOLIDARIOS D CAN Diagnostic Connector MCS OOOOOOO D D I CAN m 2 C 0 CVGS Bus e DOOOOCOD DPOSOOOSOOSOOOD F CAN Chassis Node DOOODOODCODOODCOD OCOD OD SOO DOOD OCR OOOH Firewall FIGURE 8 3 Multiplexed Instrumentation Block Diagram e V CAN Vehicle Controller Area Network The V CAN also referred to as the J1939 is used to transmit data between the transmission ABS system engine etc to the Cab Electronic Control Unit CECU e B CAN Body Builder Controller Area Network the B Can provided the body builder access to J1939 data at a convenient back of cab harness location This optional har ness is available on all models e CAN Instrumentation Controller Area Network The I CAN provides data link communication from the Cab Electronic Control Uni
17. 08 12 5 40 Section 5 Frame Layouts D8A Use with the following models T800SH seyo 8d El Dimension B BOC to Battery Box 4 5in Dimension E1 BOC to DPF SCR 53 6in Dimension T BOC to Tool Box 4 5in Dimension E2 BOC to Diffuser 67 4in TABLE 5 37 l l Dimension D Fuel Tank Size DimensionF BOC to DEF Tank in BOC to Fuel Tank ei DEF Tank Size Daycab in Diameter Gallons Length in Small Medium _ 60 380 355 22 Diameter Tank 60 305 280 9 455 43 0 so too 24 5 Diameter Tank a 75 388 363 28 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 P 5 41 08 12 Section 5 Frame Layouts D8B Use with the following models T800B D8 Charts El Dimension B BOC to Battery Box 4 5in Dimension E1 BOC to DPF SCR 53 6in Dimension T BOC to Tool Box 4 5in Dimension E2 BOC to Diffuser 67 4in TABLE 5 38 l l Dimension D Fuel Tank Size DimensionF BOC to DEF Tank in BOC to Fuel Tank ki DEF Tank Size Daycab in Diameter Gallons Length in Small __ Medium _ 60 380 355 22 Diameter Tank 60 305 280 9 455 43 0 so too 24 5 Diameter
18. A 1 DRIVERS DOOR AND DOOR FRAME LABELS A 2 FRONT AXLE IDENTIFICATION o e e e A 3 REAR AXLE IDENTIFICATION aoaaa 0 e e e A 4 vi TABLE 3 1 ABBREVIATIONS USED 2 e o eo 3 1 TABLE 3 2 TURNING RADIUS 0 2 202200 2208 3 1 TABLE 3 3 RIDE HEIGHTS 0 e o 2 220002207 3 17 TABLE 3 4 REAR SUSPENSION OPTIONS 2 2 00 004 3 19 TABLE 3 18 AXLE WIDTH CALCULATION 0 3 36 TABLE 3 19 GROUND CLEARANCE FOR FUEL TANKS 3 38 TABLE 3 20 GROUND CLEARANCE FOR BATTERY BOXES 3 39 TABLE 5 1 ABBREVIATIONS 0 00200002 ee ee 5 1 TABLE 5 2 FUEL TANK OVERALL LENGTH IN o 5 2 TABLE 5 3 BATTERY BOX CENTERFRAME LENGTHS IN 5 2 TABLE 5 4 DEF TANKS SYSTEMS e eo 5 3 TABLE 6 1 SINGLE STEEL RAILS e eo 6 1 TABLE 6 2 INSERTED STEEL RAILS lt lt e 6 1 TABLE 7 1 CUSTOMARY GRADE 8 UNF OR UNC 2 7 TABLE 7 2 U S CUSTOMARY GRADE 8 METRIC CLASS 109 2 7 TABLE 8 1 TELLTALES POSITION AND COLOR o 8 18 TABLE 8 3 CHASSIS NODE GUIDELINE e e 8 28 TABLE 8 4 WIRE NUMBER GENERAL CATEGORIES 8 33 TABLE 8 6 SAE J560 CONNECTOR 0 0 e e 8 34 T
19. AeroCab or 42 Modular sleeper with horizontal DPF SCR RHUC fuel tank LHUC battery box and RH BOC DEF tank Charts located on pages 5 97 through 5 100 08 12 5 7 x puj inoAe7 ewes Section 5 Frame Layouts S6 is used with 38 AeroCab or 42 Modular sleeper with horizontal DPF SCR RHUC tool box LHUC battery box RH BOC DEF tank and LH BOC fuel tank Charts located on pages 5 101 through 5 104 Frame Layout Index S7 is used with 38 AeroCab or 42 Modular sleeper with Vertical Vertical DPF SCR LH vertical tailpipe RHUC fuel tank LHUC battery box and LH BOC DEF tank Charts located on pages 5 105 through 5 108 S8 is used with 38 AeroCab or 42 Modular sleeper with Vertical Vertical DPF SCR LH vertical tailpipe RHUC fuel tank LHUC battery box and RH BOC DEF tank Charts located on pages 5 109 through 5 112 H J e Co S9 is used with 38 AeroCab or 42 Modular sleeper with Vertical Vertical DPF SCR LH vertical tailpipe RHUC amp LHUC fuel tanks LH BOC DEF tank and RH BOC cantilever battery box Charts located on pages 5 113 through 5 116 08 12 5 8 Section 5 Frame Layouts D1A Use with the following models T800SH seyo La Dimension E BOC to DPF SCR 3 1in TABLE 5 5 l Dimension D PUETA Sas Dimension F Dimension B BOC to DEF Tank Daycab in cn baca e
20. BOC o Font Tonk Diameter Gallons Length in eo eo OO r o ss m2 24 5 Diameter Tank 5 20 o a asa Subtract 5 7 inches for the extended Daycab 08 12 5 32 Section 5 Frame Layouts D5E Use with the following models W900L and In cab battery box D m seyo sa Dimension E BOC to DPF SCR 0 3in TABLE 5 29 l l Dimension D Fuel Tank Size Dimension F BOC to DEF Tank Daycab in a Diameter____ Gallons Length in _ 60 3o 14 o 4 amp 5 39 O too 500 06 24 5 Diameter Tank m o a2 ES 28 5 Diameter Tank 414 aso s2 es Subtract 5 7 inches for the extended Daycab 5 1 4 6 7 5 33 08 12 Section 5 Frame Layouts D6 A Use with the following models T800SH and In cab battery box D6 Charts Dimension E BOC to DPF SCR 3 1in Dimension D BOC to DEF tank 1 0in TABLE 5 30 Dimension F BOC to Fuel Tank Daycab in 24 5 Diameter Tank Subtract 5 7 inches for the extended Daycab 08 12 5 34 Section 5 Frame Layouts D6B Use with the following models T800B and C500B and In cab battery box E a Dimension E BOC to DPF SCR 0 3in Dimension D BOC to DEF tank 1 0in TABLE 5 31 T8B C5B Fuel Tank Size Dimension F 24 5 Diameter Tank Subtract 5 7 inches for the extended
21. Jie a oa i ny r f l a So F La E e i A i te F a F WEHT SELL La ji dd ra Bhat Rh Eh H a BERBERS ES eee SEE eee A PACCAR COMPANY iri J L er Manual ty ul ee This page intentionally left blank Kenworth Heavy Duty Body Builder Manual A PACCAR COMPANY Body Builder Manual Contents SECTION 1 INTRODUCTION 1 1 SECTION 2 SAFETY AND COMPLIANCE 2 1 SAFETY SIGNALS 0 0 0 eee ee ee a ee kk ek kn kk ne ns 2 1 FEDERAL MOTOR VEHICLE SAFETYSTANDARDS COMPLIANCE 2 2 SECTION 3 DIMENSIONS 3 1 DIMENSIONS 3 lt 26824 hk wwe Bee Bee Awe ER added HG 3 1 ABBREVIATIONS 2 2 a ee ee ek ek kn kk kk ee 3 1 TURNING RADIUS 2 2 20 a eee ee a kn kk kk ke a 3 1 OVERALL DIMENSIONS 2 2 2 2 0 2 eee ee ee a a ke a 3 5 10 ae e e e a ewer ee eae eae eeaseeeaee ehaee oe nee hee 3 5 1800 WITH SPLIT FENDERS 2 2 2 02 2 2 2 0 2 ee ee ee ee ee ee 3 6 T800 SHORT HOOD 2 0 0 ee ee ek kk kk kn kk ke a 3 7 T800 WITH FEPTO FRONT ENGINE POWER TAKE OFF 3 8 T800 WIDE HOOD 0 2 ee ee kk a kk ee 3 9 W900S nk kn ne ek kn a 3 10 W9O00B a a en en nn kn kk ek eee 3 11 W900L 2 2 ee a kk nn nn kn ek kk kn ek kn 3 12 C500 2eheeaeeeme tee tae eeeeeeearetawet eae eeaeeeaeeete 3 13 EXTENDED DAY CAB 2 0 0 eee ee ee a kn ke kk kk eg 3 14 38 AEROCAB
22. 08 12 ii 5 15 Section 5 Frame Layouts D2C Use with the following models W900S D2 Charts Dimension E BOC to DPF SCR 0 3in Dimension B BOC to Cantilever Battery Box 21 7in TABLE 5 12 Dimension D Fuel Tank Size Dimension F BOC to DEF Tank in BOC to Fuel Tank DEF Tank Size Diameter Gallons Length in 4 o so 22 Diameter Tank o s 24 5 Diameter Tank o a oa 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 08 12 5 16 Section 5 Frame Layouts D2D Use with the following models W900B seyo cd Dimension E BOC to DPF SCR 0 3in Dimension B BOC to Cantilever Battery Box 21 7in TABLE 5 13 Dimension D Fuel Tank Size Dimension F BOC to DEF Tank in BOC to Fuel Tank DEF Tank Size Diameter Gallons Length in 4 Small 6 so 177 s7 ne 197 22 Diameter Tank o o22 65 104 281 362 se as 102 19 ne 197 100 120 Cow os as tea ess as o a2 sa ar er 142 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 65 8 5 5 17 08 12 Section 5 Frame Layouts D2E Use with the following models W900L D2 Charts
23. 1 PTO RESUME GRA3163 MN K982 YL PTO SET GRA3162 i K980 PK COMMON RIN 1 REMOTE THROTTLE PTO ON OFF GRA3511 K999 GN REMOTE THROTTLE SWITCHED POWER IGN ORN1229 ORN1299 2 80 GROUND WHT1513 WHT1513 TORQUE LIMIT SWITCH GRA3149 yy G841 GN REMOTE THROTTLE SUPPLY 5V woos orn REMOTE THROTTLE 8 29 08 12 Section 8 Electrical FIGURE 8 21 2010 Cummins ISX15 Routing Diagram The location of the optional multi function engine connector is noted below The remote PTO throttle harness pin out connection will only be installed if the multi funtion engine connector is ordered It can be found on the ISX15 engine as noted in the diagrams below It is from this location the remote throttle chassis harness is in stalled If the engine specified from the factory includes the optional factory installed body builder harness the remote PTO throttle harness is capped off ral 7 i in F IL a A sod ATL walt a fi i w Fi SE Sait a a a 4 Bo Jipa CA APTA To REMOTE PIOVTHEGTTLE COMTEOLS WEAN CUEEM BESI5 TOR SCALE I i CIO EQTATED FOR CLARITT 08 12 8 30 Section 8 Electrical FIGURE 8 22 2010 Cummins ISX12 Routing Diagram The location of the remote PTO throttle harness pin out connection can be found on the ISX12 engine as noted in the diagrams below It is from this location the remote throttle chassis harness is installed If the engine specified from the factory does not include the
24. 19 6in TABLE 5 97 T8B amp C5B 38 Dimension D Fuel Tank Size Dimension F BOS to DEF Tank in BOS to Fuel Tank in 24 5 Diameter Tank 28 5 Diameter Tank NOTE DIMENSION B IS CALCULATED USING A STANDARD BATTERY BOX OPTIONAL EXTENDED BOXES WILL CHANGE DIMENSION B 5 111 08 12 Section 5 Frame Layouts S8D Use with the following models T800B and C500B 42 J A a O if S8 Charts md 3 Y i M Dimension B BOS to Battery Box 48 5in Dimension E BOS to DPF SCR 19 6in TABLE 5 98 T8B amp C5B 42 Dimension D BOS to Fuel Tank in DEF Tank Size Diameter___ Gallons _ 22 Diameter Tank 24 5 Diameter Tank 28 5 Diameter Tank i NOTE DIMENSION B IS CALCULATED USING A STANDARD BATTERY BOX OPTIONAL EXTENDED BOXES WILL CHANGE DIMENSION B 08 12 5 112 Section 5 Frame Layouts S9A Use with the following models T800SH 38 ll IN SHEYD 6S CC 52 L m Y JO L Dimension E BOS to DPF SCR 19 6in TABLE 5 99 T8SH 38 Fuel Tank Size Dimension F1 amp F2 Dimension B BOS to BOS to Fuel Tank in Battery Box in _Diameter__ Gallons Length in i s ss Oo or o 60 380 292 1 22 Diameter Tank 75 as 199 os w2 900 eo s sz 60 261 1
25. Before welding on vehicles with electronic engines the following precautions should be observed 1 Disconnect all electrical connections to the vehicle batteries 2 Disconnect all ECM connectors 3 Do no use the ECM or engine ground stud for the ground of the welding probe 4 Ensure that the ground connection for the welder is as close to the weld point as possible This ensures maxi mum weld current and minimum risk to damage electrical components on the vehicle 5 Turn off key Note Bosch ABS and Wabco ABS Disconnect ECU 08 12 7 6 Section 7 Frame Modifications TORQUE REQUIREMENTS TABLE 7 1 Customary Grade 8 UNF or UNC tener ore SSS size A Torque values apply to fasteners with clean threads lightly libricated with hardened steel washers and nylon insert nuts TABLE 7 2 U S Customary Grade 8 Metric Class 10 9 e C Fasien A A 1 1 08 12 Section 7 Frame Modifications This page intentionally left blank 08 12 7 8 Section 8 Electrical ELECTRICAL Information in this section will cover the following topics e Overview of Kenworth s 2010 multiplex instrumentation e Access instructions for the dash gauges and switches e Wiring instructions for alarm and telltale warning lights e Reconfiguring telltale cards e Spare Switches standard and adding e Spare Relays e Multifunction turn signal stalk chassis load center chassis node e Remote PTO Throttle harness e Electric
26. C5B Dimension F BOC to Fuel Tank Ext Daycab in 9 2 es o 60 Dimension D BOC to DEF Tank Ext Daycab in DEF Tank Size NOTE DIMENSIONS B AND D ARE CALCULATED USING A STANDARD BATTERY BOX OPTIONAL EXTENDED BOXES WILL CHANGE DIMENSIONS B AND D 08 12 5 46 D10C Use with the following models W900S gt _ i gt i Dimension B BOC to Battery Box 10 6in Dimension E BOC to DPF SCR 19 6in TABLE 5 43 Dimension D Fuel Tank Size Dimension F BOC to DEF Tank Daycab in las DEF Tank Si Fuel Tank Length in Paycab in so ss as Diameter aa 48 45 45 8 4 5 Diameter 50 8 05 Subtract 5 7 inches for the extended Daycab Section 5 Frame Layouts Dimension F BOC to Fuel Tank Ext Daycab in INTI Dimension D BOC to DEF Tank Ext Daycab in DEF Tank Size NOTE DIMENSIONS B AND D ARE CALCULATED USING A STANDARD BATTERY BOX OPTIONAL EXTENDED BOXES WILL CHANGE DIMENSIONS B AND D 5 47 08 12 seyo ola Section 5 Frame Layouts D10D Use with the following models W900B D10 Charts lt a Dimension B BOC to Battery Box 10 6in Dimension E BOC to DPF SCR 19 6in TABLE 5 44 Dimension D Dimension D Fuel Tank Size Dimension F BOC to DEF Tank Daycab in Dimension F BOC to DEF Tank Ext Daycab in BOC to 7 BOC to
27. Frame Layouts D12E Use with the following models W900L Dimension E BOC to DPF SCR 19 6in TABLE 5 55 Dimension D p Dimension D Dimension Dimension l BOC to DEF Tank Dimension B Dimension B Fuel Tank Size F1 amp F2 BOC to DEF Tank Daycab in Fy amp F2 BOC to BOC to Ext Daycab in BOC to BOC to Fuel Battery Box DEF Tank Size Battery Box DEF Tank Size Fuel Tank Tank Ext Daycab in Ext Daycab in Length in Paycab in Daycab in 1 i 1 7 7 9 4 9 9 A 9 9 A 4 9 9 A ame ros sos NOTE DIMENSION B IS CALCULATED USING A CANTILEVER SIZED BATTERY BOX OPTIONAL BOXES WILL AFFECT THIS DIMENSION 5 59 08 12 seyo cra Section 5 Frame Layouts D13A Use with the following models T800SH p E AS O rea o 3 Y l L r Dimension B BOC To Battery Box 4 5in Dimension E BOC to DPF SCR 19 6in Dimension D BOC to DEF tank 1 0in TABLE 5 56 Fuel Tank Size Dimension F Dimension F BOC to Fuel Tank BOC to Fuel Tank Daycab in Extended Daycab in 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 08 12 5 60 D13B Use with the following models T800B and C500B EII Y E
28. OINJ O 48 5 IJN co N o Oo 99 O O O O Y 181 NO O 40 5 42 5 N mb oO Mh PM DP BR PM O Nn o 47 5 49 5 N O O N NO al al NO NO Ol bi OQ 0Op por or o a Bh nB B BPB B O O0OQ O0O O O B a B ah oO OI NIO a rm o NN Or By MO OO CO OD ajlo D O O N O 272 280 54 5 291 56 5 303 58 5 323 62 331 63 Ol oo Dana Spicer Bridgestone Tandem W900B me D200020K sexto o M844 52 Axle Standard Track 425 65R22 5 Spacing TABLE 3 2 CONTINUES ON NEXT PAGE 08 12 3 2 Section 3 Dimensions TABLE 3 2 CONTINUED Rear Wheel Base Sie Curb tO Steering Gear Front Tire Suspension in Curb Turning p i Radius ft Standard Track 425 65R22 5 Spacing Dana Spicer Bridgestone Tandem W900S ES D2000 20K pee ree M844 52 Axle Standard Track 425 65R22 5 Spacing 181 Dana Spicer Bridgestone Tandem W900B oe D2000 20K o M844 52 Axle Standard Track 425 65R22 5 Spacing 272 280 291 303 323 331 78 N O O 33 35 201 36 28 220 39 i Dual Dana Spicer Alcoa 82364 Bridgestone Tandem eee D2000 20K pate ees M844 52 Axle o 20 OO m UJUI INININ w INIOJOJ OJN 2 gt 0 0O O N 181 NO O h UIOOINININIJIN MO MM PM N O jOo o0O J O B oOo n o O O0O _ O N O O N O O wm N hb O 0 9 O O Y NO Oo mb MO MM DM NM 01 AIIN O N O N O OD O N Oo 72 76 N al O N
29. Section 5 Frame Layouts D11 is used with Vertical Vertical DPF SCR LH vertical tailpipe RHUC fuel tank LHUC battery box and RH BOC DEF tank Charts located on pages 5 50 through 5 54 Frame Layout Index D12 is used with Vertical Vertical DPF SCR LH vertical tailpipe LHUC RHUC fuel tanks RH BOC cantilever battery box and LH BOC DEF tank Charts located on pages 5 55 through 5 59 D13 is used with Vertical Vertical DPF SCR LH vertical tailpipe LHUC fuel tank RHUC battery box and Clear BOC DEF tank Charts located on pages 5 60 through 5 64 08 12 5 6 Section 5 Frame Layouts Sleeper Chassis Layout Options S1 is used with 38 AeroCab or 42 Modular sleeper with RHUC DPF SCR LHUC fuel tank RH BOC DEF tank and LH BOC cantilever battery box Charts located on pages 5 65 through 5 72 p j re ker S2 is used with 38 AeroCab or 42 Modular sleeper with RHUC DPF SCR LHUC fuel tank LH BOC DEF tank and RH BOC cantilever battery box Charts located on pages 5 73 through 5 80 S3 is used with 38 AeroCab or 42 Modular sleeper with RHUC DPF SCR LHUC battery box RH BOC DEF tank and LH BOC fuel tank Charts located on pages 5 81 through 5 88 S4 is used with 38 AeroCab or 42 Modular sleeper with RHUC DPF SCR LHUC battery box LH BOC DEF tank and RH BOC fuel tank Charts located on pages 5 89 through 5 96 eff DPFISCR sw E S5 is used with 38
30. 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 com ply with the general spacing and location guidelines illustrated in Figure 6 10 The hole diameter should not exceed the bolt diameter by more than 060 inches 1 5 mm 4 Holes 6 Holes 13 2 mm diameter 13 2 mm diameter 05 0 5 280 mm 11 FIGURE 6 10 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 flange of the frame rail If the frame rail flanges are AN modified or damaged the rail could fail prematurely and cause an accident Mount the body using body mounting brackets or U bolts CAUTION Use care when drilling the frame web so the wires and air lines routed inside the rail are f not damaged Failure to do so could cause an inoperable electrical or air system circuit WARNING 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 could AN induce a failure between the holes 08 12 6 6 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
31. Tea CIRCUIT WEE NUBE y a Misc wagon j 1333 41 Smig Pa 1943 1 TELE PIO mrsEcas AE D 206 0003 COMINO ME k141 3544 104 iPods a RIRIK a D408 0035 s R dl 1091 jf MOSEMALL CLOSED Tet HERE Su o J i FER NAP ORMATIGR FOR 1333 343 Ta ma f EIOTRT TERM CUECUIT WIRE HUMBER a RIO ay n Eyri a Righe wiregggs par 1947 2 iPod SmITCH b RIDIRT WIRE OO WCRMALLT 1333 33 gt OFEN i J03 OST AELE Pa N ra e K333 544 104 J Pisi aa FFERI rob ESE E co ho TAG HERE Pos TIISE TERN INFORMATION FOR Fi Ear 54 lta OPS J A ji 4 3 A SWITCH E Pita way 4 Page Lar E j i WPM LY aaa ai GSE Ps Pa AN kiosk px a ds Pai 158 AT Pal Pii w O w TAS FERE SS RISCH NG ETS xa Sd 104 KORC NIRBEA amat A ROSE P9 194T 4 IP Switch BIOTA WIEL CON WISE Gold Spain RIOTEY FIGURE 8 17 Spare Relay Harnesses 08 12 8 24 Section 8 Electrical ADDITIONAL SPARE CIRCUITS If you just need spare power wire into one of 18 spare circuits we provide WARNING Do not install an electrical circuit that requires more amperage electrical capacity than what is available in the specific chassis circuit An overloaded circuit could cause a fire M Compare the amperage requirements of the new circuit to the electrical current capaci
32. The rear suspension layouts are provided as a tool to help layout bodies prior to arrival The applicable dimensions are shown Be sure to check the axle spacing that is shown as alternate spacings may exist and could change some of the dimensions The dimensions shown below are the most typical installations in special cases some hole locations will move If you are planning on using the holes shown for your body installation please confirm with your local KW dealer that the drawing below will be the installation used on your specific truck Ensure that proper torque is used to reinstall any suspension components See Tables 7 1 and 7 2 on page 7 7 It would be a good idea in this case to order the frame layout of your chassis along with your truck order This can be done on any Kenworth truck and will be provided 4 weeks ahead of the build schedule If there are hole locations that are not detailed please work with your local Kenworth Dealer to request that information Additionally optional axle spacings are shown in the charts if you would like details on the frame drilling with optional spacings please contact your local Kenworth dealer NOTE Actual axle spacing can depart from nominal due to axle slant requirements Final axle spacing can vary by more than an inch from nominal in some cases If precise axle spacing is critical due to body installation or state local regulatory requirements please contact Kenworth Applications technical Supp
33. Y i J i A i I hy i ps i gt A F sy E a a ff hig Pa Pit i ae 7 E a a E EN 4 a E ih k YA Y a an a a ls pa ain AXLE SPACING m Reyco 102 Suspension Data TABLE 3 9 Rear Suspension Options Suspension Type Axle Spacing Laden Ride Height ae NOTE Actual axle spacing can depart from nominal due to axle slant requirements Final axle spacing can vary by more than an inch from nominal in some cases If precise axle spacing is critical due to body installation or state local regulatory requirements please contact Kenworth Applications technical Support for assistance 08 12 3 94 Section 3 Dimensions NEWAY ADZ 123 SINGLE REAR AXLE ad lt E a m 1 j i it ji 7 1 eS ere K T al ra T i z y i i FA RIDE 54 HEIGHT Optional Neway AD Single Suspensions TABLE 3 10 Rear Suspension Options E Laden Ride Unladen Ride Suspension Type Axle Spacing Height Height 3 25 08 12 Section 3 Dimensions NEWAY ADZ 246 TANDEM SUSPENSION Shown with a 54 Axle Spacing ad l rJ RIDE ka 41 i laos all l Fi HEIGHT AXLE SPACING Optional Neway AD Tandem Suspensions TABLE 3 11 Rear Suspension Options euenensionivee Axe Spacci Laden Ride Unladen Ride p yP p g Height Height reee E ww CC NOTE Actual axle spacing can depart from nominal due to axle slant requirements Final axle spacing ca
34. between the frame rail and body frame to protect the top surface of the rail flange WARNING Do not allow the frame rails or flanges to deform when tightening the U bolts It will weaken the frame and could cause an accident Use suitable spacers made of steel or AN hardwood on the inside of the frame rail to prevent collapse of the frame flanges Use a hardwood spacer between the bottom flange and the U bolt to prevent the U bolt from notching the frame flange See Figure 6 11 Body Structure U Bolt Wood Sill 0 5 12 Minimum Truck Frame U Bolt Spacer Hardwood Frame Rail Spacer Fabricated Steel or Hardwood 01018 FIGURE 6 11 Acceptable U Bolt Mounting with Wood and Fabricated Spacers inch mm WARNING 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 AN fuel lines or wiring could result in loss of braking fuel leaks electrical overload or a fire Carefully inspect the installation to ensure adequate clearances for air brake lines fuel lines and wiring See Figure 6 12 CAUTION Mount U bolts so they do not chafe on frame rail Failure to do so could result in premature wear of the U bolt or frame rail 6 7 08 12 Section 6 Body Mounting Frame Rail TEM U Bolt Air Lines and Wiring Frame Rail Spacer Harness Hardwood or Steel Check Clearance
35. 1 5 mm A Oversized holes could result in excessive frame wear around the hole 7 1 08 12 Section 7 Frame Modifications MODIFYING FRAME LENGTH The frame cutoff after the rear axle can be shortened to match a particular body length Using a torch is acceptable however heat from a torch will affect the material characteristics of the frame rail The affected material will normally be confined to within 1 to 2 inches 25 to 50 mm of the flame cut and may not adversely affect the strength of the chassis or body installation The frame cutoff can be lengthened by adding frame extenders When extending 10 5 frame rails the additional sections can be welded to the existing rails The joint should be welded and reinforced as illustrated in Figure 7 1 Note See page 7 6 for more information on welding frames il Frame Insert A frame insert must be added after welding a frame rail extension to compensate for lost strength The insert should be of the same material as the frame member or of steel and at least equal to the frame rail in thickness Attachment of the insert to the frame should be made with Ream Fit heat treated bolts 5 8 in 16 mm dia or the next larger size Both the reinforcement and frame holes should be reamed to provide a fit of from 001 in to 003 in 025 to 076 mm clear ance Do not weld reinforcing members The insert should span a distance of at least 24 in 610 mm on either side of the joi
36. 8 Electrical TRAILER CABLE CONNECTIONS Kenworth offers many different trailer connection options The SAE J560 connector is shown in Figure 8 30 the ISO 3731 connector is shown in Figure 8 31 FIGURE 8 30 SAE J560 Trailer Connector FIGURE 8 31 ISO 3731 Trailer Connector There are three basic configurations for trailer connections they are detailed below Work with your local Kenworth dealer to identify which setup will be ideal for your intended application Your local dealer can also identify and provide the wiring diagrams for any chassis that has been built For the configurations below the following circuits will be dedicated pin locations TABLE 8 7 SAE J560 Connector TABLE 8 8 ISO 3731 Connector Trailer ABS Warning Lamp AS Stop Lamp Trailer A Optional Switched Circuit o 6 o Tail Lamp Trailer 7 Trailer ABS Power a 7 Trailer ABS Power Trailer Hotline Below is a description of how the cab ABS and trailer ABS control units interface to turn on the trailer ABS warning lamp When there is no direct connection the Power Line Carrier PLC is used to transmit the signal PLC defines that the trailer and cab ABS controllers are communicating via signals transmitted on their power circuits 1 J560 with Full Truck amp or Tractor Kit This option provides a single SAE J560 connector at the noted location s Trailer ABS power is on pin 7 of the SAE J560 connector Trailer ABS signal is on pin 7 of the SAE J560
37. A mi 71 6 82 0 a yeh ray 3 7 08 12 Section 3 Dimensions 1800 WITH FEPTO FRONT ENGINE POWER TAKE OFF The following drawings are of a T800 with the optional FEPTO package Note the extended frame rails be 147 0 a 84 0 A nn R32 8 ES 82 0 R3 4 73 SHOWN ll 74 1 OPT 66 pe 87 8 08 12 3 8 Section 3 Dimensions 1800 WIDE HOOD The following drawings are of a T800 Wide Hood which allows for the 1780 square inch radiator 3 9 08 12 Section 3 Dimensions W9005 The following drawings are of the W900 Sloped Hood chassis shown with some optional components m 120 0 62 0 ld 08 12 3 10 Section 3 Dimensions W900B The following drawings are of the W900B Straight Hood chassis shown with standard chassis components ma 1215 OPT 3 11 08 12 Section 3 Dimensions W900L The following drawings are of the W900L shown with standard chassis components 88 9 82 0 771 WB an EOF F 113 0
38. BOX OPTIONAL EXTENDED BOXES WILL CHANGE DIMENSIONS B AND D ss 3s ee Se o ne se eo os ea a e IEA Co es as 24 5 Diameter Tank ze TE 74 5 ar es 342 38 8 5 89 08 12 SHEYD 7S Section 5 Frame Layouts S4B Use with the following models T800SH 42 S4 Charts Dimension E BOS to DPF SCR 40 9in Dimension B BOS to Battery Box 48 5in TABLE 5 76 T8SH 42 Fuel Tank Size Dimension F BOS to DEF Tank in BOS to Fuel Tank in __Diameter___ Gallons Length in Small Medium Large _ Ts 35 ar Se a eos pa 75 385 AA e D Z 24 5 Diameter Tank zie TE 74 5 as ez eo 3a as os SS 28 5 Diameter Tank 120 45 8 50 8 562 66 1 NOTE DIMENSIONS B AND D ARE CALCULATED USING A STANDARD BATTERY BOX OPTIONAL EXTENDED BOXES WILL CHANGE DIMENSIONS B AND D 08 12 5 90 Section 5 Frame Layouts 4C Use with the following models T800B and C500B 38 SHEYD 7S Dimension E BOS to DPF SCR 26 2in Dimension B BOS to Battery Box 32 5in TABLE 5 77 T8B C5B 38 Fuel Tank Size Dimension F BOS to DEF Tank in BOS to Fuel Tank in DEF Tank Size __ Diameter____ Gallons Length in Small Medium Large _ se EI oo o eo o 130 22 Diameter Tank 75 473 223 oao ree s eo ws ss Ooo B5 O o f ss a
39. CANTILEVER SIZED BATTERY BOX OPTIONAL BOXES WILL AFFECT THIS DIMENSION 5 69 08 12 Section 5 Frame Layouts 1F Use with the following models W900B 42 S1 Charts Dimension E BOS to DPF SCR 43 7in TABLE 5 56 W900B 42 Dimension D Fuel Tank Size Dimension F Dimension B BOS to DEF Tank in poe ae DEF Tank Size Fuel Tank in Battery Box in Diameter Gallons Length in Smali Medium Large _ 22 Diameter Tank i 24 5 Diameter Tank i 31 1 21 4 13 3 28 5 Diameter Tank NOTE DIMENSION B IS CALCULATED USING A CANTILEVER SIZED BATTERY BOX OPTIONAL BOXES WILL AFFECT THIS DIMENSION 08 12 5 70 Section 5 Frame Layouts 1G Use with the following models W900L 38 SHEYD LS Dimension E BOS to DPF SCR 27 7in TABLE 5 57 W900L 38 Dimension D Fuel Tank Size Dimension F Dimension B BOS to DEF Tank in rnd Fuel Tank in Battery Box in DEF Tank Size Diameter Gallons Length in ee eet ee eo seo 004 te7 24 5 Diameter Tank s9 228 os ao 1 o E 28 8 20 4658 316 09 28 5 Diameter Tank teo s8 266 os s2 a2 os 66 1 NOTE DIMENSION B IS CALCULATED USING A CANTILEVER SIZED BATTERY BOX OPTIONAL BOXES WILL AFFECT THIS DIMENSION 5 71 08 12 Section 5 Frame Layouts 1H Use with the following models W900L 42 S1 Charts Dimension E BOS to DPF SCR 43
40. Dimension D Fuel Tank Size Dimension F BOC to DEF Tank Daycab in BOC to Fuel Tank DEF Tank Size Daycab in ___ Diameter____ Gallons Length in Small_ Medium Large _ 6 380 355 22 Diameter Tank 60 305 280 A a EE 129 227 307 28 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 P 08 12 5 20 Section 5 Frame Layouts D3C Use with the following models W900S SHEYD ed Dimension E BOC to DPF SCR 0 3in Dimension B BOC to Battery Box 10 6in TABLE 5 17 Dimension D Fuel Tank Size Dimension F BOC to DEF Tank Daycab in BOC to Fuel Tank DEF Tank Size Daycab in ___ Diameter____ Gallons Length in eo 380 esa 24 5 Diameter Tank 28 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 5 24 08 12 Section 5 Frame Layouts D3D Use with the following models W900B D3 Charts Dimension E BOC to DPF SCR 0 3in Dimension B BOC to Battery Box 10 6in TABLE 5 18 Dimension D Fuel Tank Size Dimension F BOC to DEF Tank Daycab in patents nia Daycab in
41. Dimension D Fuel Tank Size Dimension F BOS to DEF Tank in BOS to Fuel Tank in DEF Tank Size __ Diameter_____ Gallons _ Length in _ Small Medium __ 60 380 f ai f 8 22 Diameter Tank 11 8 62 2 ma see a 60 305 42 1 38 5 31 1 90 455 25 6 24 5 Diameter Tank 100 a a 54 9 11 8 5 60 5 9 as 135 67 2 4 3 745 86 27 28 7 42 1 32 4 0 342 36 6 38 8 31 1 28 5 Diameter Tank 45 8 25 6 50 8 11 8 56 2 11 8 66 1 NOTE DIMENSION B IS CALCULATED USING A STANDARD BATTERY BOX OPTIONAL EXTENDED BOXES WILL CHANGE DIMENSION B 08 12 5 100 mb Section 5 Frame Layouts S6A Use with the following models T800SH 38 SHEYD 9S Dimension B BOS to Battery Box 32 5in Dimension E1 BOS to DPF SCR 13 6in Dimension E2 BOS to Diffuser 27 5in TABLE 5 87 T8SH 38 Fuel Tank Size Dimension F BOS to DEF Tank in BOS to Fuel Tank in DEFTankSize DEF Tank DEFTankSize Diameter___ Gallons Length in _ Small Medium Large _ se 35 50 oo 3o 75 22 DiameterTank 75 478 168 120 7a2 s7 eo as o oo Se eo ass BO S 100 er RA ies 287 s o em 7 ee a 28 5 Diameter Tank NOTE DIMENSIONS B AND F ARE CALCULATED USING A STANDARD BATTERY BOX OPTIONAL EXTENDED BOXES WILL CHANGE DIMENSIONS B AND F 5 101 08 12 Section 5 Frame Layouts S6B Use with the
42. Dimension F BOC to DEF Tank Daycab in Bo te ue Ti Diameter 60 380o 22 Diameter Tank 60 os 00 45 24 5 Diameter Tank o o e 28 5 Diameter Tank Subtract 5 7 inches for the extended Daycab 5 29 08 12 Section 5 Frame Layouts D5B Use with the following models T800B and C500B and In cab battery box D m D5 Charts Dimension E BOC to DPF SCR 0 3in TABLE 5 26 T8B C5B l l Dimension D Fuel Tank Size Dimension F BOC to DEF Tank Daycab in BOC to Fuel Tank DEF Tank Size Daycab in ___Diameter____ Gallons Length in 22 Diameter Tank 24 5 Diameter Tank 28 5 Diameter Tank Subtract 5 7 inches for the extended Daycab 08 12 5 30 Section 5 Frame Layouts D5C Use with the following models W900S and In cab battery box D m seyo sa Dimension E BOC to DPF SCR 0 3in TABLE 5 27 l l Dimension D Fuel Tank Size Dimension F BOC to DEF Tank Daycab in aa n Daycab in ___ Diameter____ Gallons Length in 60 so as o 45 as 24 5 Diameter Tank m o a2 161 6 Subtract 5 7 inches for the extended Daycab 5 31 08 12 Section 5 Frame Layouts D5D Use with the following models W900B and In cab battery box D m D5 Charts Dimension E BOC to DPF SCR 0 3in TABLE 5 28 l l Dimension D Fuel Tank Size Dimension F BOC to DEF Tank Daycab in
43. Dimensions OVERALL DIMENSIONS This section includes drawings and charts of the following Class 8 models T800 T800 with Split Fenders T800 Short Hood T800 with FEPTO T800 Wide Hood W900S W900B C500 and W900L The Extended Day Cab and 38 AeroCab are 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 3 on page 3 16 and add that value to the height All heights are given from the bottom of the frame rail Kenworth also offers dxf files and frame layouts of ordered chassis four weeks prior to build Please speak with your salesman to request this feature when specifying your chassis T800 The following drawings are of a standard T800 shown with standard chassis components e 122 6 BLO 08 12 Section 3 Dimensions 1800 WITH SPLIT FENDERS The following drawings are of a standard T800 with the optional of the Split Fender hood shown with standard chassis components 1226 08 12 3 6 Section 3 Dimensions T800 SHORT HOOD The following drawings are of a T800 Short Hood shown with standard chassis components m 115 9
44. Dosing Control Unit DCU and engine ECM should not be tampered with or altered in any way 2 7 08 12 Section 2 Safety amp Compliance Air Intake System The following are highlights of some of the more common or critical aspects of this system e The air intake screen may not be blocked either fully or partially e Modification to the air intake system may not restrict airflow For example pipe diameter may not be reduced e All sensors must be retained in existing locations e 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 e The Charge Air Cooler may not be modified e The installation of engine overspeed shutdown devices must not introduce restriction in the intake system e All plumbing associated with the charge air cooler may not be modified 08 12 2 8 Section 3 Dimensions DIMENSIONS This section has been designed to provide enough information to successfully layout chassis in the body planning process Optional equipment may not be depicted Please contact your local Kenworth dealer if more dimensional information is desired ABBREVIATIONS Throughout this section and in other sections as well abbreviations are used to describe certain characteristics on your vehicle The chart below lists the abbreviated terms used TABLE 3 1 Abbreviati
45. E i ae E Ns ats a e o A T o EUA o 0 EF Tol Hi i y A A o o Fl E 5 a ee a ES i 59 RIDE NN o e 24 81 HEIGHT n 3 T j I M F l E AXLE SPACING Optional Hendrickson HMX Tandem Suspensions TABLE 3 15 Rear Suspension Options Laden Ride Unladen Ride Suspension Type Axle Spacing Height Height NOTE Actual axle spacing can depart from nominal due to axle slant requirements Final axle spacing can vary by more than an inch from nominal in some cases lf precise axle spacing is critical due to body installation or state local regulatory requirements please contact Kenworth Applications technical Support for assistance 08 12 3 30 Section 3 Dimensions HENDRICKSON RT TANDEM SUSPENSION Shown with a 54 Axle Spacing Without Track Rods 606 50 a a ra AO a E Y il j ty T 1 Sh A a f TE 1 i J ADONAN AONA _l j ot a ae ee A PASPA Nie Y uE 24A RIDE ry i Me Aly Bi HEIGHT l EM LA ah AXLE SPACING _ Optional Hendrickson RT Tandem Suspensions TABLE 3 16 Rear Suspension Options ewe ae Height Height Hendrickson RT463 6 saddle Hendrickson RT463 6 saddle Hendrickson RT463 7 19 saddle Hendrickson RT463 7 94 saddle Hendrickson RT463 6 saddle P 46K YO ttt Hendrickson RT463 7 94 saddle p aK CY Ott 18 0 Hendrickson RTE463 7 19 saddle Hendrickson RT523 6 saddle A O Hendrickson RT523 6 saddle NS gh tt Hendrickson RT523 7 19
46. F BOC to Fuel Daycab in ma os 162 390 09 162 390 NOTE DIMENSION B IS CALCULATED USING A STANDARD BATTERY BOX OPTIONAL EXTENDED BOXES WILL CHANGE DIMENSION B 5 53 08 12 seyo LLa Section 5 Frame Layouts D11E Use with the following models W900L y EN D11 Charts md Y y L N Dimension B BOC to Battery Box 10 6in Dimension E BOC to DPF SCR 19 6in TABLE 5 50 W9L Dimension D Dimension D Fuel Tank Size Dimension F BOC to DEF Tank Daycab in Dimension F BOC to DEF Tank Ext Daycab in BOC to DEF Tank Size BOC to Fuel DEF Tank Size Fuel Tank Tank Ext canons Length in Daycab in Daycab in se os 189 1 22 Diameter Tank 56 715 Co ess as Co 2 asa 160 s2 6s 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 Diameter 7 08 12 5 54 Section 5 Frame Layouts D12A Use with the following models T800SH seyo cta Dimension E BOC to DPF SCR 19 6in TABLE 5 51 i Dimension D Dimension A Dimension Dimension B Dimensio D Dimension B BOC to DEF Tank i F1 amp F2 i F1 amp F2 Fuel Tank Size BOC t BOC to DEF Tank Daycab in BOC t BOC to Edo BOC to Fuel OC to Ext Daycab in O oo BOX Tank Exe Bo
47. Fuel 7 Fuel Tank DEF Tank Size Tank Ext DEF Tank Size esten MC ute CI NOTE DIMENSIONS B AND D ARE CALCULATED USING A STANDARD BATTERY BOX OPTIONAL EXTENDED BOXES WILL CHANGE DIMENSIONS B AND D Diameter pos Diameter Tank 1 9 39 2 Tog Diameter Tank Subtract 5 7 inches for the extended Daycab 08 12 5 48 D10E Use with the following models W900L gt _ i gt i Dimension B BOC to Battery Box 10 6in Dimension E BOC to DPF SCR 19 6in TABLE 5 45 W9L Dimension D Fuel Tank Size Dimension F BOC to DEF Tank Daycab in BOC to 7 Fuel Tank DEF Tank Size so es 39 100 2 39 2 Y Diameter o aa NE Subtract 5 7 inches for the extended Daycab 5 49 Section 5 Frame Layouts Dimension F BOC to Fuel Tank Ext Daycab in o 1 NOTE DIMENSIONS B AND D ARE CALCULATED USING A STANDARD BATTERY BOX OPTIONAL EXTENDED BOXES WILL CHANGE DIMENSIONS B AND D Dimension D BOC to DEF Tank Ext Daycab in DEF Tank Size 08 12 seyo ola D11 Charts Section 5 Frame Layouts D11A Use with the following models Dimension B BOC to Battery Box 4 5in Dimension E BOC to DPF SCR 19 6in TABLE 5 46 Fuel Tank Size 56 Dimension F BOC to Fuel Tank Daycab in 100 23 0 7 7 Subtract 5 7 inches for the extended Daycab 24 5 Diameter T
48. INSTALLED FOR LOADS EXCEEDING 20 AMPS 8 23 ADDITIONAL SPARE CIRCUITS 2 2 2 2 2 2 0 0 0 2 eee ee ee et ee 8 25 REMOTE PTO THROTTLE HARNESS 2 0 2 ee ee ee ee ees 8 27 MULTIFUNCTION TURN SIGNAL STALK CHASSIS NODE 4 CHASSIS LOAD CENTER 8 28 CHASSIS LOAD CENTER DIMENSIONS 2 2 2 2 0 2 2 0 2 ee eas 8 30 2010 ELECTRICAL HARDWARE 2 2 0 0 ee ee ee ee en ke ee 8 31 TRAILER CABLE CONNECTIONS 2 2 2 2 2 2 0 0 2 eee ee ee he eg 8 35 BENDIX ELECTRONIC STABILITY PROGRAM 00 08 sens 8 37 FACTORY INSTALLED SNOW PLOW LIGHT WIRING 2 2 2 2 2 2 2 2 2 2248 8 38 SECTION 9 ROUTING 9 1 ROUTING 0 00 0 ee ek kn kn nk kk kg 9 1 ROUTING REQUIREMENTS 2 2 2 2 2 0 0 0 ee eee ee a ke 9 2 APPENDIX A VEHICLE IDENTIFICATION A 1 VEHICLE IDENTIFICATION NUMBER 2 2 2 2 2 a ee ee A 1 VEHICLE IDENTIFICATION LABELS 2 2 2 2 202 2 2 0 eee ee ee A 2 COMPONENT IDENTIFICATION 2 2 2 2 2 0 0 2 ee ee ee ee ee ke A 3 iii 08 12 08 12 FIGURE 2 1 INCOMPLETE VEHICLE CERTIFICATION DOCUMENT 2 2 FIGURE 2 2 LOCATIONS OF CERTIFICATION LABELS DRIVER S DOOR AND FRAME 2 2 FIGURE 2 3 VWEST COAST MIRROR OAT SENSOR 2 6 FIGURE 2 4 AERODYNAMIC MIRROR OAT SENSOR LOCATION 2 7 FIGURE 2 5 INSTRUMENT CLUSTER FOR T4 T6 T8 W9 C5 2 7 FIGURE 3 1 PROSPECTER TURN CIRCLE ANALYSIS
49. L r Dimension B BOC To Battery Box 4 5in Dimension E BOC to DPF SCR 19 6in Dimension D BOC to DEF tank 1 0in TABLE 5 57 T8B amp C5B Fuel Tank Size 22 Diameter Tank Dimension F BOC to Fuel Tank Daycab in 24 5 Diameter Tank Subtract 5 7 inches for the extended Daycab Section 5 Frame Layouts Dimension F BOC to Fuel Tank Extended Daycab in NOTE DIMENSION B IS CALCULATED USING A STANDARD BATTERY BOX OPTIONAL EXTENDED BOXES WILL CHANGE DIMENSION B 5 61 08 12 SHEYD eta Section 5 Frame Layouts D13C Use with the following models W900S i IN LI COTA D13 Charts CC ECN Y l L r Dimension B BOC To Battery Box 10 6in Dimension E BOC to DPF SCR 19 6in Dimension D BOC to DEF tank 1 0in TABLE 5 58 Fuel Tank Size Dimension F Dimension F Di L h di BOC to Fuel Tank BOC to Fuel Tank amergi ength in Daycab in Extended Daycab in 56 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 08 12 5 62 Section 5 Frame Layouts D13D Use with the following models W900B o o aN LIO a Saa LI EC SHEYD eta
50. O OD OI JO a 2 JN YJ J D DO O DO OI OI OaI OaI aoa a2 aEA Oo oa o a a a BTR NO 0 O N O O0O OI O O N N OI N 0 O E IN JO O COIO COI N O O NJN OI 2 N 08 12 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 specific chassis Your local Kenworth dealer can provide this information to you PROSPECTORA Salen Toa KENWORTH Pre ntabiona Mea Pret ntan n Edit Sascihca bon Presantabtion Info Report Petar Loren o Cutbarr t EDEPECTOR 1g C ki a Tuning Radius Papii Lat Tum Radis Wid 2005 Curb lo Curb 46 9 0 ok ttc fi You stional Analysen Engine Than 10m From Axis Rear Ante Rear Axle Suspensions Additional Axles Selected Tires and Wheel Frame Fuel Tanki Cab Lights and Signal A Au Equipment bare Special Equipment e gt ee p y A Warranty and PM es A E asf Paini y Wolkscteens gt Truck Oe CONVENTIONAL FULL TRUCK Whew Gare 24 in Aois Froni Aste 30 000 Iba Gane Epicor C2000 Weenie 74000 Iba Fue FRARIDGESTONE MaJ4F 426658725 200 we i Wheel FRWHLALCOA 673656 225x1215 AL Aan Spang all Curt TEO C 044099575 PERFORMANCE HPO NARRATIVES 7ATOR 1008 Complete FIGURE 3 1 Prospecter Turn Circle Analysis Please consult your local Kenworth Dealer for this information as it is chassis specific 08 12 3 4 Section 3
51. USING A CANTILEVER SIZED BATTERY BOX OPTIONAL BOXES WILL AFFECT THIS DIMENSION 08 12 5 78 Section 5 Frame Layouts 2G Use with the following models W900L 38 SHEYD cS Dimension E BOS to DPF SCR 27 7in Dimension B BOS to Cantilever Battery Box 0 9in TABLE 5 65 WS900L 38 Dimension D Fuel Tank Size Dimension F BOS to DEF Tank in BOS to Fuel Tank in DEF Tank Size __ Diameter___ Gallons _ Length in Small Large 35 5 213 5 24 5 Diameter Tank 54 9 17 0 NOTE DIMENSION B IS CALCULATED USING A CANTILEVER SIZED BATTERY BOX OPTIONAL BOXES WILL AFFECT THIS DIMENSION 08 12 9 79 Section 5 Frame Layouts S2H Use with the following models W900L 42 S2 Charts Dimension E BOS to DPF SCR 43 7in Dimension B BOS to Cantilever Battery Box 22 3in TABLE 5 66 WS900L 42 Dimension D Fuel Tank Size Dimension F BOS to DEF Tank in BOS to Fuel Tank in DEF Tank Size __ Diameter___ Gallons_ Length in Small Large 35 5 375 60 380 324 7 22 Diameter Tank 6 5 62 103 74 2 0 7 TE 324 eo 4s 26 9 50 0 21 4 24 5 Diameter Tank 54 9 19 2 60 5 187 74 5 0 7 o 342 373 38 8 32 4 50 8 21 4 e1 as as NOTE DIMENSION B IS CALCULATED USING A CANTILEVER SIZED BATTERY BOX OPTIONAL BOXES WILL AFFECT THIS DIMENSION 08 12 5 80 Section 5 Frame Layouts S3A Use with the following mod
52. ___ Diameter____ Gallons Length in 60 380 294 90 4 amp 5 39 24 5 Diameter Tank mp o a2 256 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 P 08 12 5 22 Section 5 Frame Layouts D3E Use with the following models W900L SHEYD ed Dimension E BOC to DPF SCR 0 3in Dimension B BOC to Battery Box 10 6in TABLE 5 19 Dimension D Fuel Tank Size Dimension F BOC to DEF Tank Daycab in BOC to Fuel Tank Daycab in ee B E a ae a ae ME 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 P 5 23 08 12 Section 5 Frame Layouts D4A Use with the following models T800SH D4 Charts aD Dimension E BOC to DPF SCR 3 1in Dimension B BOC to Battery Box 4 5in TABLE 5 20 Dimension D Fuel Tank Size Dimension F BOC to DEF Tank Daycab in BOC to Fuel Tank DEF Tank Size Daycab in ___ Diameter_____ Gallons Length in 24 5 Diameter Tank 28 5 Diameter Tank Subtract 5 7 inches for the extended Daycab NOTE DIMENSIONS B AND D ARE CALCULA
53. a as i is AN rigs La a a i 08 12 8 12 11 Pinch to unlock connectors from switches 13 Unscrew gauge collar to remove gauge Y d Gauge Collar Torque to Cy A 36 44 in lb Gauge 4 Uf AR fbi LO jes amp Section 8 Electrical 08 12 Section 8 Electrical and then push switch out of plate on top side Push A o aaa Plate then flip over and do the same on the bottom side 15 Push down to unhook connector from switch to unhook 08 12 o 8 14 Section 8 Electrical 17 Pinch to unlock connector and remove Upper Switch Cluster then flip over and do the same on the bottom side 8 15 08 12 Section 8 Electrical 19 Push down to unhook connector from switch ACCESSING SWITCHES IN THE KEY SWITCH PANEL 20 Insert key into the ignition switch turn to ACC and pull The tabs which hold the trim piece to the dash will release The switches can be serviced by following steps 18 19 08 12 8 16 Section 8 Electrical TELLTALE SYMBOLS Kenworth s interior allows Body Builders to customize the dash telltale symbols warning lights The editable telltale symbols are located on removable cards inside the baseline cluster This section will describe how to replace and insert editable cards as well as how to activate the telltale lights Note the numbers 1 16 on Figure 8 10 These are how the positions are identified in tab
54. and nitrogen For more information on the specific details of how SCR works please contact your local Kenworth dealer DEF System Schematic On most Kenworth chassis the DEF Supply Module or pump is integrated into the DEF tank Kenworth does not allow relocation of this pump The following schematic details how the DEF lines route to the after treatment system DEF Tank 10 gallon shown DEF Return Line Backflow from Supply Module DEF Draw Line Inlet to Supply Module See Detail A Coolant Draw from Draw Tee Coolant Return to Coolant Valve Detail A Scale 1 2 DEF Return Line Backflow DEF Draw Line Inlet po DEF Supply Module Pump DEF Pressure Line Outlet DEF Dosing Module Injector 4 1 08 12 Section 4 Exhaust amp Aftertreatment DEF will freeze at approximately 11 F In order to keep DEF from freezing all tanks will be heated with engine coolant The following schematic shows the routing of these lines The coolant lines that run to and from the SCR system must not be tampered with or used for a source of heat and or cooling for other components on the chassis It is critical that the system is not compromised in any manner DEF Tank Small Tank Shown DEF Tank Heating Element 5 8 Coolant Hose Green Draw C NS Eh Return Tee Draw Tee m j a el 7 Coolant Bulkhead 3 8 Coolant H
55. are highlights of some of the more common or critical aspects of this system Modifications to the design or locations of fill or vent lines heater or defroster core and surge tank are not recommended With the exception of post thermostat installation additional accessories plumbed into the engine cooling system are not permitted at the risk of voiding vehicle warranty Coolant level sensor tampering will void warranty When installing auxiliary equipment in front of the vehicle or additional heat exchangers ensure that adequate air flow is available to the vehicle cooling system Refer to engine manufacturer application guide lines for further detail When installing FEPTO drivelines the lower radiator anti recirculation seal must be retained with FEPTO driveline clearance modification only Changes made to cooling fan circuit and controls are not allowed with the exception of AC minimum fan on time parameter 2 5 08 12 Section 2 Safety amp Compliance 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 08 12 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 e throttle pedal e vehicle soeed sensor e after trea
56. following models T800SH 42 S6 Charts Dimension B BOS to Battery Box 48 5in Dimension E1 BOS to DPF SCR 11 4in Dimension E2 BOS to Diffuser 25 2in TABLE 5 88 T8SH 42 Fuel Tank Size Dimension F BOS to DEF Tank in BOS to Fuel Tank in ___Diameter___ Gallons Length in 24 5 Diameter Tank NOTE DIMENSIONS B AND F ARE CALCULATED USING A STANDARD BATTERY BOX OPTIONAL EXTENDED BOXES WILL CHANGE DIMENSIONS B AND F 08 12 5 102 Section 5 Frame Layouts S6C Use with the following models T800B 38 SHEYD 9S Dimension B BOS to Battery Box 32 5in Dimension E1 BOS to DPF SCR 13 6in Dimension E2 BOS to Diffuser 27 5in TABLE 5 89 T8B 38 Fuel Tank Size Dimension F BOS to DEF Tank in BOS to Fuel Tank in ____Diameter___ Gallons Length in _ Small Medium Large _ 24 5 Diameter Tank 28 5 Diameter Tank NOTE DIMENSIONS B AND F ARE CALCULATED USING A STANDARD BATTERY BOX OPTIONAL EXTENDED BOXES WILL CHANGE DIMENSIONS B AND F 5 103 08 12 Section 5 Frame Layouts S6D Use with the following models T800B 42 S6 Charts Dimension B BOS to Battery Box 48 5in Dimension E1 BOS to DPF SCR 11 4in Dimension E2 BOS to Diffuser 25 2in TABLE 5 90 T8B 42 Fuel Tank Size Dimension F BOS to DEF Tank in BOS to Fuel Tank in ___Diamete
57. 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 08 12 4 8 Section 4 Exhaust amp Aftertreatment Minimum 12 Line Length Below Dosing Module FIGURE 4 9 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 10 below Permitted Mounting position 45 FIGURE 4 10 Supply Module Allowed Clocking Angles 4 9 08 12 Section 4 Exhaust amp Aftertreatment GENERAL EXHAUST INFORMATION Kenworth will offer three main DPF and SCR exhaust systems on heavy duty chassis in 2010 A Right Hand Under DPF and SCR system in which both canisters are located underneath the cab access step A horizontal system with both the DPF and SCR located horizontally with a cross over pipe in the frame and an Independent DPF and SCR located verti cally back of cab on stanchion brackets RH Under DPF and SCR Horizontal DPF and SCR Independent Back of Cab The following images depict the typical exhaust routings for each s
58. in Dimension F BOS to Fuel Tank in 38 0 47 3 62 2 74 2 30 5 38 5 45 5 50 0 54 9 60 5 67 2 74 5 28 7 34 2 38 8 45 8 50 8 56 2 66 1 22 Diameter Tank 60 90 24 5 Diameter Tank 1 28 5 Diameter Tank TAN 202 0g Ce a7 g ars oo j a os 24 08 Caas f o o Dimension D BOS to DEF Tank in DEF Tank Size NOTE DIMENSION B IS CALCULATED USING A CANTILEVER SIZED BATTERY BOX OPTIONAL BOXES WILL AFFECT THIS DIMENSION 5 65 08 12 SHEYD LS Section 5 Frame Layouts 1B Use with the following models T800SH 42 S1 Charts Dimension E BOS to DPF SCR 40 9in TABLE 5 62 T8SH 42 Dimension D Fuel Tank Size Dimension F Dimension B BOS to DEF Tank in ao ane DEF Tank Size Fuel Tank in Battery Box in Diameter Gallons _ Length in Smali Medium Large _ Ts es a7 aro so f o f a es 287 75 90 342 28 28 5 Diameter Tank 45 8 50 8 56 2 e1 om se NOTE DIMENSION B IS CALCULATED USING A CANTILEVER SIZED BATTERY BOX OPTIONAL BOXES WILL AFFECT THIS DIMENSION 08 12 5 66 Section 5 Frame Layouts 1C Use with the following models T800B and C500B 38 SHEYD LS Dimension E BOS to DPF SCR 26 2in TABLE 5 63 T8B amp C5B 38 Dimension D Fuel Tank Size een F mae B BOS to DEF Tank in ae DEF Tank Size Fuel
59. saddle Hendrickson RT523 11 saddle Hendrickson RT523 6 saddle NI OF gt Hendrickson RT523 7 19 saddle E A o oe NOTE Actual axle spacing can depart from nominal due to axle slant requirements Final axle spacing can vary by more than an inch from nominal in some cases lf precise axle spacing is critical due to body installation or state local regulatory requirements please contact Kenworth Applications technical Support for assistance 3 31 08 12 Section 3 Dimensions CHALMERS 856 46 TANDEM SUSPENSION Shown with a 54 Axle Spacing 60 6 e i 56 5 m 50 ie i i yi E T F 24 RIDE f iA HEIGHT f i Bi j y P eg AXLE SPACING i Optional Chalmers Tandem Suspensions TABLE 3 17 Rear Suspension Options Suspemiontyn A Height Height mn CO ae ramersaseaoies a w e omms e IC ee omms e e o omms EI ECC e TABLE 3 17 CONTINUES ON NEXT PAGE 08 12 3 32 Section 3 Dimensions TABLE 3 17 CONTINUED TJ A EA Height Height ECO NC e EE w O A EE AI mf en EE we e meee E ACI EIC CCE EI e CEE E AC EIC or e EI MC EC e EE CO CO e E ACI EIC CEE EI ACI EIC oe e E ACI EIC or e EE ACI we e omw x er e ommen ACI wr e e EE e AC ere NOTE Actual axle spacing can depart from nominal due to axle slant requirements Final axle spacing can vary by more than an inch from nominal in some cases lf precise axle spacing is critical due to body
60. the fuel filter see Figure 8 9 j rRQOAT SECONDARY k P a ff oo amp be H q a i A FIGURE 8 7 Firewall Air Junction Block View from inside of cab FIGURE 8 8 Air Filter Restriction Sensor on Firewall Air Junction Block view from engine 8 7 08 12 Section 8 Electrical FIGURE 8 9 Fuel Filter Restriction Pressure Gauge Sensor Location typical 08 12 8 8 Section 8 Electrical ACCESSING GAUGES AND SWITCHES In order to access and install components described later on in the manual you will need to know how to correctly remove the dash panels without causing damage 1 Remove trim bezel by prying upward at one of the four pry points Carefully pry the remaining clips SPEEDO AND TACH PANEL 2 Remove 4 screws to remove Speedo Tach panel 8 9 08 12 3 Unclip harness and remove Speedo Tach panel ACCESSING RIGHT HAND GAUGE 8 SWITCH PANEL 4 Remove 7 screws to remove right gauge panel 08 12 8 10 Section 8 Electrical 6 Pinch to unlock connector and remove right gauge panel _ Gauge Collar 2 7 Torque to pT 36 44 in lb hy 7 a and then push switch out of plate on top side 8 11 08 12 Section 8 Electrical then flip over and do the same on the bottom side 9 Push down to unhook connector from switch e to unhook ACCESSING LEFT HAND GAUGE amp SWITCH PANEL 10 Remove 4 screws to remove left gauge panel
61. via PLC for trucks Ground is on pin 1 of the SAE J560 connector 2 J560 amp ISO 3731 with Full Truck amp or Tractor Kit This option provides two connectors a SAE J560 and an ISO 3731 connector at the noted location s Trailer ABS power is on pin 7 of the SAE J560 amp ISO 3731 connectors Trailer ABS signal is on pin 7 of the SAE J560 amp ISO 3731 via PLC for trucks 08 12 8 40 Section 8 Electrical Trailer ABS warning lamp circuit is on pin 3 of the ISO 3731 connector Ground is on pin 1 of the SAE J560 amp ISO 3731 connectors 3 J560 Hotline ISO 3731 with Full Truck amp or Tractor Kit This option provides two connectors a SAE J560 and a ISO 3731 connector at the noted location s Trailer ABS power is on pin 7 of the ISO 3731 connector Trailer ABS signal is on pin 7 of the ISO 3731 via PLC for trucks Trailer ABS warning lamp circuit is on pin 3 of the ISO 3731 connector Trailer Hotline is provided on pin 7 of the SAE J560 connector This may be either battery powered or switched Ground is on pin 1 of both the SAE J560 amp ISO 3731 connectors Note Kenworth provides option variations within the above combinations This may include up to 2 il spare circuits on pins 2 amp 4 of the ISO 3731 connector which may or may not be switched In addition to these configurations an optional junction box is available mounted either behind the cab or at the end of f
62. 0 T8SH 42 Dimension D Fuel Tank Size Dimension F BOS to Fuel Tank in __ Diameter___ Gallons Length in Medium Large _ 355 36 6 38 0 33 9 22 Diameter Tank 47 3 20 1 62 2 oi o7 88 198 O 8 8 o 20 19 8 42 1 33 9 25 6 ml 20 1 24 5 Diameter Tank 14 6 91 20 60 5 5 5 20 36 6 31 1 28 5 Diameter Tank 25 6 20 1 148 NOTE DIMENSION B IS CALCULATED USING A CANTILEVER SIZED BATTERY BOX OPTIONAL BOXES WILL AFFECT THIS DIMENSION 7 3 5 11 5 5 08 12 5 74 Section 5 Frame Layouts 2C Use with the following models T800B and C500B 38 SHEYD cS Dimension E BOS to DPF SCR 26 2in Dimension B BOS to Cantilever Battery Box 0 9in TABLE 5 61 T8B amp C5B 38 Dimension D Fuel Tank Size Dimension F BOS to Fuel Tank in Diameter Gallons Length in Medium Large _ 35 5 20 6 38 0 15 1 22 Diameter Tank 47 3 12 7 O _ 12 7 17 0 358 28 5 Diameter Tank 12 7 NOTE DIMENSION B IS CALCULATED USING A CANTILEVER SIZED BATTERY BOX OPTIONAL BOXES WILL AFFECT THIS DIMENSION 08 12 5 75 Section 5 Frame Layouts 2D Use with the following models T800B and C500B 42 S2 Charts Dimension E BOS to DPF SCR 43 7in Dimension B BOS to Cantilever Battery Box 22 3in TABLE 5 62 T8B C5B 42 Dimension D Fuel Tank Size Dimension F BOS to Fuel Tank in
63. 0SH 38 J A a O if md a Y i M Dimension B BOS to Battery Box 32 5in Dimension E BOS to DPF SCR 19 6in TABLE 5 95 T8SH 38 Dimension D Fuel Tank Size Dimension F BOS to DEF Tank in BOS to Fuel Tank in DEF Tank Size Diameter___ Gallons _ Smal 22 Diameter Tank 28 5 Diameter Tank 30 NOTE DIMENSION B IS CALCULATED USING A STANDARD BATTERY BOX OPTIONAL EXTENDED BOXES WILL CHANGE DIMENSION B 24 5 Diameter Tank 5 109 08 12 SHEYD 8S Section 5 Frame Layouts S8B Use with the following models T800SH 42 J A a O if S8 Charts md 3 Y i M Dimension B BOS to Battery Box 48 5in Dimension E BOS to DPF SCR 19 6in TABLE 5 96 T8SH 42 Fuel Tank Size Dimension F BOS to DEF Tank in BOS to Fuel Tank in ___Diameter___ Gallons _ Medium 22 Diameter Tank 24 5 Diameter Tank te 28 5 Diameter Tank NOTE DIMENSION B IS CALCULATED USING A STANDARD BATTERY BOX OPTIONAL EXTENDED BOXES WILL CHANGE DIMENSION B 08 12 5 110 Section 5 Frame Layouts 8C Use with the following models T800B and C500B 38 J A SHEYD 8S a O if md a Y i M Dimension B BOS to Battery Box 32 5in Dimension E BOS to DPF SCR
64. 4 28 TOP VIEW OF HORIZONTAL DPF AND SCR WITH HORIZONTAL TAILPIPE e 4 19 FIGURE 4 29 RIGHT VIEW OF HORIZONTAL DPF AND SCR WITH HORIZONTAL TAILPIPE 2 2 2 02 a a e a n a a a a 4 20 FIGURE 4 30 BACK VIEW OF HORIZONTAL DPF AND SCR WITH HORIZONTAL TAILPIPE 2 a 4 20 FIGURE 4 31 ISOMETRIC VIEW OF VERTICAL DPF ANDSCR 4 21 FIGURE 4 32 TOP VIEW OF VERTICAL DPF ANDSCR 0 4 21 FIGURE 4 33 RIGHT VIEW OF VERTICAL DPF AND SCR 4 22 FIGURE 4 34 BACK VIEW OF VERTICAL DPF AND SCR 4 22 FIGURE 5 1 DEF TANKS SYSTEMS oouo aaa 5 3 FIGURE 6 1 ISOMETRIC VIEW OF T800 FEPTO FRONT END WITH 66 BUMPER SETTING oaoa aaa a a 6 1 FIGURE 6 2 T800 FEPTO FRONT END WITH 66 BUMPER SETTING 6 2 FIGURE 6 3 ISOMETRIC VIEW OF T800 FEPTO FRONT END WITH 73 BUMPER SETTING 0 0000 cee ee ee 6 2 FIGURE 6 4 T800 FEPTO FRONT END WITH 73 BUMPER SETTING 6 2 FIGURE 6 5 MINIMUM CLEARANCE BETWEEN TOP OF REAR TIRES AND BODY STRUCTURE OVERHANG 0000 epee eee eee 6 3 FIGURE 6 6 MINIMUM BACK OF CABCLEARANCE 00 6 4 FIGURE 6 7 SPACER BETWEEN FRAME SILL AND BODY RAIL RUBBER OR PLASTIC 6 5 FIGURE 6 8 HIGH COMPRESSION SPRING 000e0 0 eee 6 5 FIGURE 6 9 RUBBER SPACER BETWEEN BRACKETSBETWEEN THE MOUNTING BOLT AND UPPER BRACKET 0 00000 cette eens 6 5 FIGURE 6 10 CROSSMEMBER GUSSET HOLE PATTERN REQUIRE
65. 4 3 INSTALLATION REQUIREMENTS AND DIMENSIONS FOR DEF SYSTEM 4 3 MEASUREMENT REFERENCE POINTS 2 2 0 2 0 0 eee ee eons 4 4 GENERAL EXHAUST INFORMATION 2 2 0 ee ee a ek es 4 10 EXHAUST INFORMATION 2 2 0 0 ee ee ee ee ke ke nk kk ee 4 23 SECTION 5 FRAME LAYOUTS 5 1 FRAME LAYOUTS 2 2 0 0 eee ee ee ke ek kn kn en kk eg 5 1 FRAME LAYOUT INDEX 5 4 08 12 il Body Builder Manual Contents SECTION 6 BODY MOUNTING 6 1 FRAME INFORMATION 2 a ee eee ee ee ee a kn kk ke 6 1 CRITICAL CLEARANCES 2 a ee ee ee ee ee kk kk es 6 3 BODY MOUNTING USING BRACKETS 2 2 0 ee ee eee eee 6 4 MOUNTING HOLES 2 2 2 2 0 0 ee ee ee ek kn kk nk ke 6 6 BODY MOUNTING USING U BOLTS 2 004 eee ee eee 6 7 SECTION 7 FRAME MODIFICATIONS 7 1 FRAME MODIFICATIONS 0 0 0 ee ee ee ee ee kn kk kk kk eg 7 1 DRILLING RAILS a 0 a a a a a a a 7 1 MODIFYING FRAME LENGTH 2 2 2 a ee a a a eg 7 2 CHANGING WHEELBASE 0 0 ee ee a a a a 7 3 CROSSMEMBERS 0 a a a a a a 7 5 WEDDING 7 6 TORQUE REQUIREMENTS saaa aaa 2 2 0 0 ee ee a kk ke 7 7 SECTION 8 ELECTRICAL 8 1 ELECTRICAL 0 ee ee ee ek kn kk nk kk ee 8 1 ACCESSING GAUGES AND SWITCHES 2 2 2 2 2 0 0 02 25 2 ee 8 9 TELLTALE SYMBOLS 2 02 2 0 0 0 0 eee ee ee ee en a a ke 8 17 SPARE RELAYS BODY BUILDER
66. 4 U Bolt Spacer Space for Air A Lines and Wiring Pe FIGURE 6 12 Clearance Space for Air Lines and Cables WARNING Do not notch frame rail flanges to force a U bolt fit Notched or damaged frame flanges could result in premature frame failure Use a larger size U bolt Use a hardwood spacer as AN shown in Figure 6 11 08 12 6 8 Section 6 Body Mounting Rear Body Mount When U bolts are used to mount a body we recommend that the last body attachment be made with a fishplate bracket See Figure 6 13 This provides a firm attaching point and helps prevent any relative fore or aft movement between the body and frame Body Structure Frame Rail FIGURE 6 13 Example of Fishplate Bracket at Rear End of Body used with U Bolts 6 9 08 12 Section 6 Body Mounting This page intentionally left blank 08 12 6 10 Section 7 Frame Modifications FRAME MODIFICATIONS Introduction Kenworth offers customer specified wheelbases So in most cases frame modifications to produce a certain wheelbase should not be necessary However some installations may require slight modifications while other installations will require extensive modifications Sometimes an existing dealer stock chassis may need to have the wheelbase changed to better fit a customer s applica tion The modifications may be as simple as shortening or lengthening the frame cutoff or they may be as com
67. 5 26 Section 5 Frame Layouts D4D Use with the following models W900B syeyo va Dimension E BOC to DPF SCR 0 3in Dimension B BOC to Battery Box 10 6in TABLE 5 23 Dimension D Fuel Tank Size Dimension F BOC to DEF Tank Daycab in BOC to Fuel Tank DEF Tank Size Daycab in ___ Diameter_____ Gallons Length in 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 5 97 08 12 Section 5 Frame Layouts D4E Use with the following models W900L D4 Charts Dimension E BOC to DPF SCR 0 3in Dimension B BOC to Battery Box 10 6in TABLE 5 24 Dimension D Fuel Tank Size Dimension F BOC to DEF Tank Daycab in BOC to Fuel Tank DEF Tank Size Daycab in Diameter_____ Gallons Length in 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 08 12 5 28 Section 5 Frame Layouts D5A Use with the following models T800SH and In cab battery box seyo Sd Dimension E BOC to DPF SCR 3 1in TABLE 5 25 Dimension D Fuel Tank Size
68. 6 008 53 1106 009 EE a w e ES e O 00 WAIT EA ALTERNATOR FASTEN ETHER START ENGINE HEATER 5TH WHEEL WAIT TO START INTER AXLE LOCK SERVICE TRUCK BODY UP 53 1106 010 SEAT BELT S53 1106 012 S53 1106 013 SLIDE S53 1106 015 S53 106 016 C53 106 017 5 3 1106 018 53 1106 011 53 1106 014 ig ay am I PUM Gop 8333 PTO PTO BRAKESAVER TRAILER BODY UP AUXILIARY OVER SPEED CENTRAL TIRE PUMP MODE EXHAUST BRAKE TRANSMISSION 853 1106 019 53 1106 020 53 1106 021 TRANSMISSION 53 1106 023 INFLATION 53 1 106 025 53 1106 026 FILTER 53 1106 022 53 1106 024 eer le Sp Yad ua a 200 NODO 00 TRANSMISSION BLANK FUEL PRESSURE HIGH BEAM LEFT TURN RIGHT TURN mio Due TRAILER DUMP TRAILER DUMP TEMPERATURE S93 1106 000 53 1106 058 853 1106 029 ARROW ARROW FRO n REAR 53 1106 028 553 1106 030 853 1106 031 53 foe 032 53 1106 53 1106 034 O Y lor SA 8 5 ode WORN BRAKE DUAL REAR AXLES REMOTE SWITCH FRONT REAR AXLE REAR REAR AXLE FILTER STABILITY AIR SUSPENSION CRANE UP 53 1106 035 DIFFERENTIAL LOCK ENGINE OFF DIFFERENTIAL LOCK DIFFERENTIAL LOCK REGENERATION CONTROL DUMP WARNING 53 1106 036 S93 1106 031 53 1106 040 53 1106 041 S33 1106 042 53 1 106 038 53 1106 039 6552 106 043 o i Ra A WY LY iG AY RANGE O OO Y LVD INFIBIT RESET OVERSPEED WINCH EMISSION TRACTION MALFUNCTION LOW VOLTAGE SERVICE R INHIBIT SHUTDOWN S53 1106 045 SYSTEM ENHANCEMENT IN
69. 64 Ps s 7 os ws o o 45 a7 os tez 300 as era oo amn tez 380 o a2 so os 26 109 Con ea as si so NOTE DIMENSION B IS CALCULATED USING A CANTILEVER SIZED BATTERY BOX OPTIONAL BOXES WILL AFFECT THIS DIMENSION 5 113 08 12 Section 5 Frame Layouts S9B Use with the following models T800SH 42 ll IN S9 Charts CC 52 L om Y E L Dimension E BOS to DPF SCR 19 6in TABLE 5 100 T8SH 42 Fuel Tank Size Dimension F1 amp F2 Dimension B BOS to BOS to Fuel Tank in Battery Box in __Diameter _ Gallons Length in 35 5 36 6 biomas 82 380 339 aay 47 3 35 9 15 2 20 1 15 8 62 2 9 1 742 90 352 20 o sos 42 38 5 33 9 24 5 Diameter 100 50 0 20 1 1 5 i i 60 5 91 67 2 35 745 2 0 90 a 26 6 a 308 a 28 5 Diameter 499 458 256 50 8 20 56 2 146 66 1 NOTE DIMENSION B IS CALCULATED USING A CANTILEVER SIZED BATTERY BOX OPTIONAL BOXES WILL AFFECT THIS DIMENSION 7 yank 54 9 14 6 7 08 12 5 114 Section 5 Frame Layouts 9C Use with the following models T800B and C500B 38 ll IN SHEYD 6S CC L m Y JO L ECY Dimension E BOS to DPF SCR 19 6in TABLE 5 101 T8B amp C5B 38 Fuel Tank Size Dimension F1 amp F2 Dim
70. 7in TABLE 5 58 W900L 42 Dimension D Fuel Tank Size Dimension F Dimension B BOS to DEF Tank in id ae DEF Tank Size Fuel Tank in Battery Box in Diameter Gallons Length in Smali Medium Large _ 22 Diameter Tank 24 5 Diameter Tank 31 1 21 4 13 3 28 5 Diameter Tank NOTE DIMENSION B IS CALCULATED USING A CANTILEVER SIZED BATTERY BOX OPTIONAL BOXES WILL AFFECT THIS DIMENSION 08 12 5 72 Section 5 Frame Layouts S2A Use with the following models T800SH 38 SHEYD cS Dimension E BOS to DPF SCR 24 9in Dimension B BOS to Cantilever Battery Box 0 9in TABLE 5 59 T8SH 38 Dimension D Fuel Tank Size Dimension F BOS to Fuel Tank in Diameter___ Gallons Length in Medium Large _ 35 5 20 6 38 0 15 1 22 Diameter Tank 47 3 12 7 18 0 IE O 36 7 26 1 a 127 170 358 28 5 Diameter Tank 12 7 NOTE DIMENSION B IS CALCULATED USING A CANTILEVER SIZED BATTERY BOX OPTIONAL BOXES WILL AFFECT THIS DIMENSION 0 7 08 12 5 73 Section 5 Frame Layouts S2B Use with the following models T800SH 42 S2 Charts Dimension E BOS to DPF SCR 40 9in Dimension B BOS to Cantilever Battery Box 19 5in TABLE 5 6
71. 8 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 08 12 4 7 Section 4 Exhaust Aftertreatment Vertical DPF and SCR with Clear Back of Cab DEF Tank 11 0m Differential Supply Module to Dosing 1 0m Height Module Supply Module to Tank Bottom FIGURE 4 8 Vertical 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 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 sup ply 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
72. 8 6 for instructions on physically mov ing the gauge The connector will require a firm pull to remove it When reinstalling the connector ensure that it is fully inserted Both connector sockets on the rear of the gauge are the same either one can be used Gauos 5 held fo panal wilh Mreaded lock collar Back of 2 inch Gauges Panel ts held to dash wilh four screws FIGURE 8 6 CVSG Gauges 08 12 8 6 Section 8 Electrical Sensors Kenworth s chassis contain standard connectors in the wiring harnesses for gauges even when they were not specified on a particular chassis This allows you to easily locate connectors to add gauges To add an electronic gauge install the sen sor available from your local Kenworth dealer in the noted location plug in the wiring harness and then install the gauge in the dash The gauge will then need to be activated Your local Kenworth dealer can easily activate the gauge using Kenworth s Electronic Service Analyst ESA The following diagrams show the location of sensors on the firewall junction block This is to aid in locating these sensors The primary air sensor is located on the primary air block the Secondary Air Sensor is located on the secondary air block the Application Air Sensor is located by the brake application block See Figure 8 7 The Air Filter Restriction Sensor is located near the brake application sensor see Figure 8 8 The Fuel Filter Restriction Sensor is located near
73. 8SH 42 Dimension D Fuel Tank Size Dimension F BOS to DEF Tank in BOS to Fuel Tank in DEF Tank Size Diameter Gallons Length ny small Medium 253 eo eso sz am 20 22 Diameter Tank x 120 re oo f eo wos T St o ass a ase 24 5 Diameter Tank 00 13 1 3 9 as a 20 42 o ose wo se 28 5 Diameter Tank NOTE DIMENSION B IS CALCULATED USING A STANDARD BATTERY BOX OPTIONAL EXTENDED BOXES WILL CHANGE DIMENSION B 08 12 5 98 Section 5 Frame Layouts 5C Use with the following models T800B 38 Seya GS Dimension B BOS to Battery Box 32 5in Dimension E1 BOS to DPF SCR 13 6in Dimension E2 BOS to Diffuser 27 5in TABLE 5 85 T8B 38 Fuel Tank Size Dimension F BOS to Fuel Tank in Diameter Gallons Length ny 0 38 62 o os rs s 5D 15 54 9 05 s6 ter 277 s8 67 2 745 287 o 34 2 38 8 28 5 Diameter Tank 15 8 50 8 56 2 661 o 27 s NOTE DIMENSION B IS CALCULATED USING A STANDARD BATTERY BOX OPTIONAL EXTENDED BOXES WILL CHANGE DIMENSION B 08 12 127 277 24 5 Diameter Tank zie 50 0 127 277 358 5 99 Section 5 Frame Layouts 5D Use with the following models T800B 42 S5 Charts Dimension B BOS to Battery Box 48 5in Dimension E1 BOS to DPF SCR 11 4in Dimension E2 BOS to Diffuser 25 2in TABLE 5 86 T8B 42
74. ABLE 8 7 ISO 3731 CONNECTOR e o 8 35 TABLE 9 1 EXHAUST SYSTEM CLEARANCE 9 4 TABLE A 1 MODEL YEAR CODE DESIGNATIONS o A 1 vil 08 12 This page intentionally left blank 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 guide lines for modifying frames electrical wiring information and other information useful in the body installation process This manual is specific 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 definition and ordering process Early in the process professional body builders can often contribute valuable information that reduces the ultimate cost of the body installation In the interest of continuing product development Kenworth reserves the right to change speci fications 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 Kenwo
75. D2 is used with RHUC DPF SCR LHUC fuel tank RH BOC cantilever battery box and LH BOC DEF tank Charts lo cated on pages 5 14 through 5 18 D3 is used with RHUC DPF SCR LHUC battery box RH BOC DEF tank and LH BOC fuel tank Charts located on pages 5 19 through 5 23 D4 is used with RHUC DPF SCR LHUC battery box LH BOC DEF tank and RH BOC fuel tank Charts located on pages 5 24 through 5 28 D5 is used with RHUC DPF SCR LHUC fuel tank RH BOC DEF tank and in cab battery box Charts located on pages 5 29 through 5 33 08 12 5 4 Section 5 Frame Layouts n n 5 i D6 is used with RHUC DPF SCR LHUC fuel tank Clear BOC DEF tank and in cab battery box Charts located on pages 5 34 through 5 38 D7 is used with horizontal DPF SCR RHUC fuel tank LHUC battery box and RH BOC DEF tank Charts located on pages 5 39 through 5 40 3 a Toot DPFISCR ES mE D8 is used with horizontal DPF SCR RHUC tool box LHUC battery box RH BOC DEF tank and LH BOC fuel tank Charts located on pages 5 41 through 5 42 ee DPFISCR D9 is used with horizontal DPF SCR RHUC LHUC fuel tanks RH BOC DEF tank and in cab battery box Charts lo cated on pages 5 43 through 5 44 D10 is used with Vertical Vertical DPF SCR LH vertical tailpipe RHUC fuel tank LHUC battery box and LH BOC DEF tank Charts located on pages 5 45 through 5 49 08 12 5 5 x puj inoAe7 owes
76. DICATOR a DISCONNECT LVD TRANSMISSION a WARNING MIL S53 H06 046 53 1106 048 ke ES Av BRAKE AAAA BRAKE FAILURE SIDE AIRBAG DIESEL EXHAUST HILL HOLD WATER IN FUEL 53 1106 053 53 1106 054 FLUID DEF 53 1106 056 53 1106 057 853 1106 055 FIGURE 8 12 Telltale Icons The telltales can then be peeled off of the sheet and applied directly to the card The color of the telltale is controlled by the light all of the icons are clear Please see TABLE 8 1 to determine the position and color of the telltales Positions are shown on Figure 8 9 8 19 08 12 Section 8 Electrical ALARMS There are four spare Alarm female 4 slide connector breakouts behind the speedo tach cluster near the speedo tach connector labeled e Alarm 1A e Alarm 1B e Alarm 1C e Alarm 2 When these circuits are either grounded or powered an alarm sound in the dash will turn on Alarm 1 and Alarm 2 have two different tones SPARE SWITCHES FACTORY INSTALLED Kenworth provides the option of coding for up to 5 spare switches with standard fuse locations in the central electrical panel These switches receive power from the Accessory bus Switches 1 3 are fused by separate 15A circuit protection devices fuse or circuit breaker Switches 4 amp 5 share a common 20A circuit protection device The location of these cir cuit protection devices are labeled on the central electrical panel cover For example SPARE SW 1 is the label for spare switc
77. Daycab 5 35 08 12 SHEYD 90 Section 5 Frame Layouts D6 C Use with the following models W900S and In cab battery box E a D6 Charts Dimension E BOC to DPF SCR 0 3in Dimension D BOC to DEF tank 1 0in TABLE 5 32 Fuel Tank Size Dimension F Subtract 5 7 inches for the extended Daycab 08 12 5 36 Section 5 Frame Layouts D6D Use with the following models W900B and In cab battery box E a Dimension E BOC to DPF SCR 0 3in Dimension D BOC to DEF tank 1 0in TABLE 5 33 Fuel Tank Size Dimension F BOC to Fuel Tank Length in Daycab in s ss 60 380 Diameter teo 742 rs ses 24 5 Diameter Tank 90 455 Subtract 5 7 inches for the extended Daycab 22 DiameterTank 75 4738 56 75 120 15 5 37 08 12 SHEYD 90 Section 5 Frame Layouts D6 E Use with the following models W900L and In cab battery box E a D6 Charts Dimension E BOC to DPF SCR 0 3in Dimension D BOC to DEF tank 1 0in TABLE 5 34 W9OL Fuel Tank Size Dimension F BOC to Fuel Tank Length in Daycab in 0568 355 60 seo Diameter teo 7 2 7 ses 24 5 Diameter Tank 90 455 Subtract 5 7 inches for the extended Daycab 22 DiameterTank 75 473 56 75 120 15 08 12 5 38 Section 5 Frame Layouts D7A Use with the following models T800S
78. Diameter Gallons Length in Medium Large _ 35 5 36 6 38 0 33 9 22 Diameter Tank 47 3 20 1 62 2 9 5 O T a6 a 28 5 Diameter Tank 25 6 NOTE DIMENSION B IS CALCULATED USING A CANTILEVER SIZED BATTERY BOX OPTIONAL BOXES WILL AFFECT THIS DIMENSION 08 12 5 76 Section 5 Frame Layouts S2E Use with the following models W900B 38 SHEYD cS Dimension E BOS to DPF SCR 27 7in Dimension B BOS to Cantilever Battery Box 0 9in TABLE 5 63 W900B 38 Dimension D Fuel Tank Size Dimension F BOS to DEF Tank in BOS to Fuel Tank in DEF Tank Size __ Diameter___ Gallons _ Length in Small Large 35 5 213 60 38 0 16 4 100 12 75 oo 62 17 0 ses 164 50 0 10 9 24 5 Diameter Tank 54 9 17 0 60 17 0 67 2 17 0 o 84 219 28 8 164 50 8 10 9 562 17 0 e1 2 NOTE DIMENSION B IS CALCULATED USING A CANTILEVER SIZED BATTERY BOX OPTIONAL BOXES WILL AFFECT THIS DIMENSION 08 12 5 77 Section 5 Frame Layouts S2F Use with the following models W900B 42 S2 Charts Dimension E BOS to DPF SCR 43 7in Dimension B BOS to Cantilever Battery Box 22 3in TABLE 5 64 W900B 42 Fuel Tank Size Dimension F BOS to DEF Tank in BOS to Fuel Tank in Diameter___ Gallons Length in Small Medium Large 22 Diameter Tank 24 5 Diameter Tank as ss NOTE DIMENSION B IS CALCULATED
79. ENSION 08 12 Section 5 Frame Layouts D1D Use with the following models W900B D1 Charts Dimension E BOC to DPF SCR 0 3in TABLE 5 8 Dimension D Fuel Tank Size Dimension F Dimension B BOC to DEF Tank Daycab in BOC to Fuel Tank BOC to Battery DEF Tank Size Daycab in Box Daycab in _Diameter Gallons Length in Smali Medium Large _ Ce p es EC o 7s es ons J ee o f ss f m f o os Co f a 58 ss eS _ ass 98 we 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 08 12 5 12 Section 5 Frame Layouts D1E Use with the following models W900L seyo La Dimension E BOC to DPF SCR 0 3in TABLE 5 9 Dimension D Fuel Tank Size Dimension F Dimension B BOC to DEF Tank Daycab in BOC to Fuel Tank BOC to Battery DEF Tank Size Daycab in Box Daycab in Diameter Gallons _ Length in Smali Medium Large se a5 AR rs ses 09 CO so 5s as 168 o ae se o o Diameter Tank 1so ses 68 275 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 5 13 08 12 Section 5 Frame Layouts D2A Use with the following models T800SH
80. ENWORTH SPARE SWITCHES 00004 8 20 FIGURE 8 14 SPARE SWITCH HARNESS 2000000 4 8 21 FIGURE 8 15 SPECIALTY SWITCHES 000 000 eee eeees 8 22 FIGURE 8 16 SPARE RELAY CONNECTORS 8 23 FIGURE 8 17 SPARE RELAY HARNESSES 0 8 24 FIGURE 8 18 SPARE BULLET CONNECTORS o 8 25 08 12 08 12 FIGURE 8 19 FIGURE 8 21 FIGURE 8 22 FIGURE 8 23 FIGURE 8 25 FIGURE 8 25 FIGURE 8 26 FIGURE 8 27 FIGURE 8 31 FIGURE 8 32 FIGURE 9 1 FIGURE 9 2 FIGURE 9 3 FIGURE 9 4 FIGURE 9 5 FIGURE A 1 FIGURE A 2 FIGURE A 3 FIGURE A 4 SPARE PIGTAIL CONNECTOR 0 2 20000000058 8 26 CHASSIS POWER DISTRIBUTION CENTER DIMENSIONS 8 30 DAYCAB HARDWARE LOCATIONS 0 4 8 31 AEROCAB STANDARD HARDWARE LOCATIONS 8 31 CHASSIS NODE DIMENSIONS 8 32 SAE J560 TRAILER CONNECTOR e e 8 35 ISO 3731 TRAILER CONNECTOR naaa 8 35 JUNCTION BOX esaerari rrid 2 ee 8 36 SNOW PLOW ICON 2 m sa eu bone tee Re oe ee eee we De 8 38 ica eee teen eee eee eee eter eee eee ea eaae 8 38 CLAMP AND BUTTERFLY CLAMP 9 1 POTTE RPE WE Beene eeaeot eae ha eee eee eee ee Se ee 9 1 WE SERAP geese Bee eee ee ee eke ee ee ee 9 1 HEAVY DUTY HD MOUNT 2 022 2020048 9 2 DEFINITION OF MEASUREMENTS 0 9 4 VEHICLE IDENTIFICATION NUMBER VIN
81. G A STANDARD BATTERY BOX OPTIONAL EXTENDED BOXES WILL CHANGE DIMENSIONS B AND D 5 93 08 12 Section 5 Frame Layouts S4F Use with the following models W900B 42 S4 Charts Dimension E BOS to DPF SCR 43 7in Dimension B BOS to Battery Box 54 6in TABLE 5 80 W900B 42 Fuel Tank Size Dimension F BOS to DEF Tank in BOS to Fuel Tank in ___ Diameter___ Gallons Length in Small_ Medium Large _ s ass oo ICI sso E as 0 o p e E 135 26 2 so 2 es 78 gt Diameter tank 150 s2 48 177 ei 98 NOTE DIMENSIONS B AND D ARE CALCULATED USING A STANDARD BATTERY BOX OPTIONAL EXTENDED BOXES WILL CHANGE DIMENSIONS B AND D 08 12 5 94 Section 5 Frame Layouts 4G Use with the following models W900L 38 SHEYD 7S Dimension E BOS to DPF SCR 27 7in Dimension B BOS to Battery Box 38 6in TABLE 5 81 W900L 38 Fuel Tank Size Dimension F BOS to DEF Tank in BOS to Fuel Tank in ___ Diameter___ Gallons Length in Small_ Medium Large _ s IET NE ICI EEC CI teo re ars a ls is so ess se o IEEE IT 120 IEC CC 28 5 Diameter Tank 120 NOTE DIMENSIONS B AND D ARE CALCULATED USING A STANDARD BATTERY BOX OPTIONAL EXTENDED BOXES WILL CHANGE DIMENSIONS B AND D 5 95 08 12 Section 5 Frame Layouts S4H Use with the following models W900L 42 S4 Ch
82. H seyo Za Dimension B BOC to Battery Box 4 5in Dimension E1 BOC to DPF SCR 53 6in Dimension E2 BOC to Diffuser 67 4in TABLE 5 35 l l Dimension D Fuel Tank Size DimensionF BOC to DEF Tank in BOC to Fuel Tank DEF Tank Size Daycab in Diameter____ Gallons_ Length in Smal o n 56 35 37 74 171 6 380 42 129 420 22 Diameter Tank 60 305 87 74 118 ve 455 6 10 75 24 5 Diameter Tank _1 7 4 7 4 1 9 4 3 735 IC 90 342 50 74 171 28 5 Diameter Tank 120 458 66 184 420 177 661 29 481 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 39 08 12 Section 5 Frame Layouts D7B Use with the following models T800B D7 Charts Dimension B BOC to Battery Box 4 5in Dimension E1 BOC to DPF SCR 53 6in Dimension E2 BOC to Diffuser 67 4in TABLE 5 36 Fuel Tank Size Dimension F BOC to DEF Tank in e Daycab in Diameter Gallons Length in 60 seo 22 Diameter Tank 60 305 e 4 amp 5 Di 10 24 5 Diameter Tank e 342 28 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
83. INFORMATION Frame information provided is per rail some specifications 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 Rai Height Flange Width Web Thickness Section Modulus RBM in Ibs Weight bsn sa wo 10 58 10 314 10 1116 31 2 11 5 8 3 7 8 21 43 2 572 000 TABLE 6 2 Inserted Steel Rails Single 9 7 8 2 718 x10 Single 9 7 8 2 718 x 1 4 Single 10 8 4 x 9 1 2 x 1 4 7 Double one 10 3 4 x 3 1 2 x 1 4 AS and one 9 7 8 x 2 7 8 x 1 4 5 853 000 The T800 FEPTO front frame extensions are reinforced parent frame rails with an RBM value of 1 88M in lbs per side for an approximate total of 3 76M for both rails The figures below are designed to help install front end equipment for more detailed information please work directly with your Kenworth dealer FIGURE 6 1 Isometric View of T800 FEPTO front end with 66 Bumper Setting 6 1 08 12 Section 6 Body Mounting oe FRONT SUSPENSION FIGURE 6 2 T800 FEPTO front end with 66 Bumper Setting FRONT 10 6 SUSPENSION FIGURE 6 4 T800 FEPTO front end with 73 Bumper Setting 08 12 6 2 Section 6 Body Mounting CRITICAL CLEARANCES Rear Wheels and Cab CAUTION Insufficient clearance between rear tires and body structure could cause
84. Kenworth also offers flat panel inserts that can be easily modified or removed to add switches or gauges The small panel is 5 x 5 and the large panel is 7 5 x 5 To add these to a chassis order work with your local Kenworth dealer Kenworth offers a variety of pre labeled switches See Figure 8 15 below for details of all switches offered and the switch diagram Please note when switching relay coils only use P27 1123 XXX switches 8 21 08 12 P27 1040 01 HE ADLAMP r She 2B 39 P27 1040 02 PARKLAMPS P27 1040 03 MARKER CLEAR 1D 7 By 9 oo Le 2B 32 2 P27 1040 05 MARKER CLEAR 1D CAB SEP SWITCH LR 2B 39 oe P27 1040 06 MARKER CLEAR 1D RAILER SEP SW P27 1040 07 SPARE SWITCH RR 1 Le Section 8 Electrical P21 1040 01 SYMBOL PTC145 E E Ea a CONTACT NONE PLATING STYLE LONG TOGGLE INDICATOR NONE COLOR P27 1040 02 SYMBOL PTCI5 Ze PS CONTACT NONE PLATING STYLE SHORT TOGGLE INDICATOR NONE COLOR P27 1040 03 SYMBOL PTCISO A D ds a CONTACT NONE PLATING STYLE LONG TOGGLE INDICATOR NONE COLOR P21 1040 05 SYMBOL PTCISO gt D Q CONTACT NONE PLATING STYLE SHORT TOGGLE INDICATOR NONE COLOR
85. MENTS INCH MM 00 a 6 6 FIGURE 6 11 ACCEPTABLE U BOLT MOUNTING WITH WOOD AND FABRICATED SPACERS INCH MM 6 7 FIGURE 6 12 CLEARANCE SPACE FOR AIR LINES AND CABLES 6 8 FIGURE 6 13 EXAMPLE OF FISHPLATE BRACKET AT REAR END OF BODY USED WITH U BOLTS 000 eee ee 6 9 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 0000 ce eee eee ey 7 4 FIGURE 7 4 CROSSMEMBER ADDED WHEN DISTANCE EXCEEDS 60 INCHES 1524MM 0 000 ee ee ee ee 7 5 FIGURE 8 1 KENWORTH B CABDASH 000 0 00 eee eens 8 2 FIGURE 8 2 DIESEL EXHAUST FLUID GAUGE 00004 8 2 FIGURE 8 3 MULTIPLEXED INSTRUMENTATION BLOCK DIAGRAM 8 3 FIGURE 8 4 CECU LOCATION 000000 eee ees 8 4 FIGURE 8 5 INSTRUMENT CLUSTER COMPONENTS 20 8 5 FIGURE 8 6 CVSG GAUGES 0 0000 a eee eee 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 VIEWFROMENGINE 0 0000 eee eee ey 8 7 FIGURE 8 9 FUEL FILTER RESTRICTION PRESSURE GAUGE SENSOR LOCATION TYPICAL 2 a 8 8 FIGURE 8 10 TELLTALE SYMBOL STANDARD CARDS 00 8 17 FIGURE 8 11 BLANK TELLTALECARD 0000 eee eeees 8 18 FIGURE 8 12 TELLTALEICONS 0000 cece eee eee ees 8 19 FIGURE 8 13 K
86. OOD LAMPS FIGURE 8 15 Specialty Switches 08 12 P27 1123 039 THIRD AXLE LIFT 9 7 3 ra 2 gS CONTACT NONE PLATING STYLE ROCKER INDICATOR NONE COLOR P27 1040 11 SYMBOL PTCI58 s AN OS 00 CONTACT NONE PLATING STYLE ROCKER INDICATOR GREEN COLOR P27 1040 12 SYMBOL PTC442 P27 1123 040 TRAILER AIR SUSPENSION 23B 3 po 58 bem T B 9 PA S es NS OO CONTACT ONE PLATING STYLE ROCKER INDICATOR AMBER COLOR 8 22 CONTACT PLATING NONE STYLE ROCKER INDICATOR COLOR GREEN PROTECTION INDICATOR P27 1123 036 DPST UP MIDDLE DOWN ON ONE OFF 2B 3 5B 6 PTC267 PTO CONTACT PLATING NONE STYLE ROCKER INDICATOR COLOR AMBER PROTECTIO INDICATOR P27 1123 039 DPST UP MIDDLE DOWN ON NONE OFF 2B 3 58 6 PTC452 Oe O CONTACT PLATING NONE STYLE ROCKER INDICATOR COLOR GREEN PROTECTION INDICATOR P27 1123 040 DPST UP MIDDLE DOWN ON NONE OFF 2B 3 58 6 PTC459 CONTACT PLATING NONE STYLE ROCKER INDICATOR COLO
87. PACING Optional Hendrickson Primaax EX Tandem Suspensions TABLE 3 13 Rear Suspension Options Suspension Type Axia Spaci Laden Ride Unladen Ride i i ne Height Height NOTE Actual axle spacing can depart from nominal due to axle slant requirements Final axle spacing can vary by more than an inch from nominal in some cases If precise axle spacing is critical due to body installation or state local regulatory requirements please contact Kenworth Applications technical Support for assistance 08 12 3 28 Section 3 Dimensions HENDRICKSON PRIMAAX EX TRIDEM SUSPENSION Shown with 54 Axle Spacings ll 78 7 al 85 9 713 iif 84 4 ll 725 mei AXLE SPACING AXLE SPACING Optional Hendrickson Primaax EX Tridem Suspensions TABLE 3 14 Rear Suspension Options l Laden Ride Unladen Ride Suspension Type Axle Spacing Height Height NOTE Actual axle spacing can depart from nominal due to axle slant requirements Final axle spacing can vary by more than an inch from nominal in some cases If precise axle spacing is critical due to body installation or state local regulatory requirements please contact Kenworth Applications technical Support for assistance 3 29 08 12 Section 3 Dimensions HENDRICKSON HMX TANDEM SUSPENSION Shown with 54 Axle Spacing 606 495 pe 85 48 4 i 50 435 _ FA E a a Se oA El
88. R RED PROTECTION INDICATOR P27 1123 BELLY DUMP DPST UP MIDDLE DOWN 1 5 9 ON NONE OFF AA 28 3 5B 6 op 3 PTC454 a ne 58 Se mee ac CONTACT PLATING NONE r STYLE ROCKER 8 310 INDICATOR COLOR TRED PROTECTION INDICATOR P27 1123 045 REAR TRAILER P21 1123 045 DUMPGATE DPST UP MIDDLE DOWN 1 5 9 ON NONE OFF ZN 28 3 5B 6 ae Vo 58 be 100 a S CONTACT PLATING NONE r STYLE ROCKER 8 T To INDICATOR COLOR RED PROTECTION INDICATOR P27 1123 047 FRONT TRAILER P27 1123 047 DUMPGATE DPST UP MIDDLE DOWN L 3 9 ON ONE OFF ARA 2B 3 5B 6 e ua 58 6 4 JO a S CONTACT PLATING NONE Nr STYLE ROCKER 8 L3 io INDICATOR COLOR RED PROTECTION INDICATOR P27 054 de ens P27 1123 054 SPARE SPST UP MIDDLE DOWN 1 359 ON NONE OFF Ne 2B 3 2 gt TRLR SPARE Y T CONTACT PLATING NONE STYLE ROCKER INDICATOR COLOR GREEN PROTECTION INDICATOR P27 1123 055 FRONT AXLE P21 1123 055 ENGAGEMENT DPST UP MIDDLE DOWN E ON NONE OF F ZN 2B 3 58 6 z oR 3 amp PTC316 m COL im MN 58 6 ao LJ 4 BB CONTACT PLATING NONE NE STYLE ROCKER g LT io INDICATOR COLOR AMBER PROTECTION INDICATOR Section 8 Electrical SPARE RELAYS BODY BUILDER INSTALLED For loads exceeding 20 amps There are two spare relay locations in the central electrical panel To access these relays there are two spare relay breakouts behind the LH gauge cl
89. RE 8 36 Connector Pin outs 1 Rear Right Speaker Fuse 1 Not Used 2 Front Right Speaker 2 Not Used 3 Front Left Speaker 3 Not Used 4 Rear Left Speaker 4 Not Used 5 Rear Right Speaker 5 CAN High 6 Front Right Speaker 6 Not Used 7 Front Left Speaker 7 Not Used 8 Rear Left Speaker 8 Not Used 9 Key On Signal 9 Not Used 10 Not Used 10 Not Used 11 Not Used 11 CAN Low 12 Battery 12 Not Used 13 Not Used 14 Not Used 15 Ground 16 Ground 1 Video In 1 USB Connector Color Coding Green a eee Connector information ida l ION gt RO e TYCO MQS Socket Housing 2 USB2 DM VO 4 Video In 3 Part number 12141768 2 3 USB2 DP I O 5 Video In 4 Mating Connector P20 6221 4 GROUND 6 Not Used 7 Video In 1 Video Connector Color Coding Brown 8 Video In 2 1 TFT Power 12V 9 Not Used 2 Ground 10 Video In 3 3 LVDS I O 11 Video In 4 4 LVDSP3 12 Not Used Aux in Connector Color Coding Blue 1 A12 AUX REF 2 A12 AUXLI 3 A12 AUXR I 4 WAKE UP I O 8 45 08 12 Section 8 Electrical This page intentionally left blank 08 12 8 46 Section 9 Routing ROUTING Introduction This section specifies the general requirements for securing hoses and electrical wires to present an orderly appearance facilitate inspection and maintenance and prevent potential damage to these lines Definitions Bundle Two or more air electrical fuel or other lines tied together to form a unitized assembly C
90. SHR WCAL ATLAS Std Alcoa 82365 BR M844F Default 79 4 95 6 Track 72 5 16K GAWR 24 5X12 25 425 65R22 5 Same as RR NS PSHR WCAL ATLAS Wide Alcoa 82365 BR M844F Option 74 4 87 3 Track 77 5 24 5X12 25 425 65R22 5 Same as FR 3 37 08 12 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 specific 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 o P TABLE 3 19 Ground Clearance for Fuel Tanks Dimension B nas Ground Clearance Dimension A in Fuel l Front Rear Rear Distance from Front Tires i Tank Component Suspension Suspension Tires Size Bottom of Frame Rail in Hendrickson M711 11 Taperleaf 425 65R22 5 17 5 Spring Saddle Height 08 12 3 38 TABLE 3 20 Ground Clearance for Battery Boxes Front Front Tires near Rear Tires Component Suspension Suspension Battery Box with Air Tanks Hendrickson 20K Taper VOS MX 460 M711 a da 425 65R22 5 i Battery Box leaf Spring 17 5 Saddle 11R24 5 ee Tires Height with Air Tanks DPF Box Section 3 Dimensions Dimension on Distance from Bottom of Frame Rail Dimension B Ground Clearance in 1 Dimensions shown are for daycabs with high route exhaust Sle
91. TED USING A STANDARD BATTERY BOX OPTIONAL EXTENDED BOXES WILL CHANGE DIMENSIONS B AND D 08 12 5 24 Section 5 Frame Layouts D4B Use with the following models T800B and C500B syeyo va Dimension E BOC to DPF SCR 0 3in Dimension B BOC to Battery Box 4 5in TABLE 5 21 T8B C5B Dimension D Fuel Tank Size Dimension F BOC to DEF Tank Daycab in BOC to Fuel Tank DEF Tank Size Daycab in ___ Diameter_____ Gallons Length in 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 5 25 08 12 Section 5 Frame Layouts D4C Use with the following models W900S D4 Charts Dimension E BOC to DPF SCR 0 3in Dimension B BOC to Battery Box 10 6in TABLE 5 22 Dimension D Fuel Tank Size Dimension F BOC to DEF Tank Daycab in BOC to Fuel Tank DEF Tank Size Daycab in Diameter_____ Gallons Length in Small Medium Large _ eo aso 410 22 Diameter Tank Co ss ass 24 5 Diameter Tank to ae tes eo eas are 120 28 5 Diameter Tank teo 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 08 12
92. Tank a 75 388 3863 28 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 P 08 12 5 42 Section 5 Frame Layouts D9A Use with the following models T800SH and In cab battery box D seyo 60 Dimension E1 BOC to DPF SCR 53 6in Dimension E2 BOC to Diffuser 67 4in TABLE 5 39 Dimension F1 amp Fuel Tank Size F2 BOC to Fuel Tank Diameter___ Gallons Length in _Paycab in Small Medium _ eo 3o 42 129 420 22 Diameter Tank 6 35 87 74 16 9 4 amp 5 63 184 420 P e 32 so 74 oma 28 5 Diameter Tank 120 458 66 184 420 177 661 29 481 Subtract 5 7 inches for the extended Daycab 5 43 08 12 Section 5 Frame Layouts D9B Use with the following models T800B and In cab battery box El gt D D9 Charts Dimension E1 BOC to DPF SCR 53 6in Dimension E2 BOC to Diffuser 67 4in TABLE 5 40 Dimension F1 amp Dimension D Fuel Tank Size F2 BOC to BOC to DEF Tank in Fuel Tank DEF Tank Size __Diameter____ Gallons Length in _Paycab in Small Medium _ 6 3o 11 129 9 22 Diameter Tank 6 35 86 19 16 o 75 385 06 129 205 90
93. Tank in Battery Box in __ Diameter____ _Gallons_ Length in Small Medium Large 75 l 75 887 38 8 283 09 28 5 Diameter Tank 45 8 213 09 50 8 66 1 NOTE DIMENSION B IS CALCULATED USING A CANTILEVER SIZED BATTERY BOX OPTIONAL BOXES WILL AFFECT THIS DIMENSION 08 12 5 67 Section 5 Frame Layouts 1D Use with the following models T800B and C500B 42 S1 Charts Dimension E BOS to DPF SCR 43 7in TABLE 5 64 T8B C5B 42 Dimension D Fuel Tank Size o F mae B BOS to DEF Tank in ae DEF Tank Size Fuel Tank in Battery Box in __ Diameter____ _Gallons_ Length in Small Medium Large 355 o 22 Diameter Tank 47 3 62 2 60 305 9 455 54 9 ai oa as 67 2 38 8 28 5 Diameter Tank 45 8 50 8 66 1 NOTE DIMENSION B IS CALCULATED USING A CANTILEVER SIZED BATTERY BOX OPTIONAL BOXES WILL AFFECT THIS DIMENSION 08 12 5 68 Section 5 Frame Layouts 1E Use with the following models W900B 38 SHEYD LS Dimension E BOS to DPF SCR 27 7in TABLE 5 65 W900B 38 Dimension D Fuel Tank Size Dimension F Dimension B BOS to DEF Tank in poe ae DEF Tank Size Fuel Tank in Battery Box in Diameter Gallons Length in Smali Medium Large _ 22 Diameter Tank 24 5 Diameter Tank 15 1 17 0 35 8 28 5 Diameter Tank NOTE DIMENSION B IS CALCULATED USING A
94. ail Use the appropriate drill bit NOTE Provides general information for example the note could warn you on how to avoid damaging your vehicle or how to drive the vehicle more efficiently Example Note Be sure to provide maintenance access to the battery box and fuel tank fill 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 9 1 08 12 Section 2 Safety amp 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 fifth wheel and that a Body Builder Intermediate or Final Stage Manufacturer will be doing additional modifications means that the vehicle was incomplete when it left the build plant See next section and Appendix A for additional information Incomplete Vehicle Certification An Incomplete Vehicle Document is shipped with the vehicle certifying that the vehicle is not complete See Figure 2 1 In addition affixed to the driver s si
95. ailpipe Stack Height Calculation Tailpipes side of Aerocab RH 75 0 under DPF l Tailpipes independent back of 75 0 sleeper RH under DPF l Cummins Cummins not ISL 78 0 DPF mounted independent back of cab or sleeper Bae side of cab mount DPF RH Bae Tailpipes back of cab mount w side extenders DPF RH under Tailpipes back of cab mount w o 68 0 side extenders DPF RH under DIMENSION B IS THE TAILPIPE LENGTH For approximate unladen stack height 12 000 pound springs use the following frame heights Use Prospector frame heights for more accurate results Sample Tailpipe height 196 Desired overall stack height 162 0 Prospector frame height 43 5 Frame rail depth 10 6 Dimension A from chart 68 6 fail pipe length 60 5 4 93 08 12 Section 4 Exhaust Aftertreatment This page intentionally left blank 08 12 4 24 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 filter 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 Addit
96. al wire number and color e Trailer cable connections e Bendix electronic stability program ESP e After treatment Control Modules e Factory Installed Snow Plow Lights MULTIPLEX INSTRUMENTATION Kenworth utilizes Multiplex instrumentation and wiring to continuously improve our quality and the capability of our trucks Multiplexing utilizes the industry standard Society of Automotive Engineering SAE J1939 data bus to send multiple signals over a single twisted pair of wires instead of individual wires for each function The advantages are fewer wires sensors and connections that provide greater consistency improved reliability and the ability to use ESA to troubleshoot the instrumentation The following information is provided to increase your awareness about the Kenworth product it may be useful in installing telltales warning lights and gauges and coordination with other installed equipment WARNING Don t cut or tap into green yellow twisted pairs Only use T connectors and only add f approved J1939 components with validated software 8 1 08 12 Section 8 Electrical INTERIOR IDENTIFICATION Kenworth began production of this interior in 2005 Chassis with this new interior can be identified by appearance see Figure 8 1 All dashes that resemble the following picture will utilize multiplex wiring FIGURE 8 1 Kenworth B Cab Dash A 2010 Chassis can quickly be identified by the presence of the Diesel Exhaust Fluid
97. ameter____ Gallons Length in Smali Medium Large _ se os AR o mo ts 120 re rs rs a o ass es o a2 o 120 e p oo 28 5 Diameter Tank teo NOTE DIMENSIONS B AND F ARE CALCULATED USING A STANDARD BATTERY BOX OPTIONAL EXTENDED BOXES WILL CHANGE DIMENSIONS B AND F 08 12 5 87 Section 5 Frame Layouts S3H Use with the following models W900L 42 S3 Charts F iM Dimension E BOS to DPF SCR 43 7in Dimension B BOS to Battery Box 54 6in TABLE 5 74 W9L 42 Fuel Tank Size Dimension F BOS to DEF Tank in BOS to Fuel Tank in DEF Tank Size ___Diameter____ Gallons Length in Smali Medium Large _ as AE o mo f mar a Co es o ooo o 90 28 5 Diameter Tank iso e ooo NOTE DIMENSIONS B AND F ARE CALCULATED USING A STANDARD BATTERY BOX OPTIONAL EXTENDED BOXES WILL CHANGE DIMENSIONS B AND F 08 12 5 88 Section 5 Frame Layouts 4A Use with the following models T800SH 38 Dimension E BOS to DPF SCR 24 9in Dimension B BOS to Battery Box 32 5in TABLE 5 75 T8SH 38 Fuel Tank Size Dimension F BOS to DEF Tank in BOS to Fuel Tank in DEF Tank Size ___Diameter____ Gallons Length in Smali Medium Large _ 28 5 Diameter Tank NOTE DIMENSIONS B AND D ARE CALCULATED USING A STANDARD BATTERY
98. ank 100 110 28 5 Diameter Tank T800SH pii EN a Po E LI L md Y y L N T8SH Dimension D BOC to DEF Tank Daycab in Dimension F DEF Tank Size BOC to Fuel Tank Ext Daycab in Dimension D BOC to DEF Tank Ext Daycab in DEF Tank Size NOTE DIMENSION B IS CALCULATED USING A STANDARD BATTERY BOX OPTIONAL EXTENDED BOXES WILL CHANGE DIMENSION B 08 12 5 50 Section 5 Frame Layouts D11B Use with the following models T800B and C500B e E D gt oi o 0 0 ei 0 0 0 i nia T Pel N SU JU IP 9 to F r o LIZ CIO 1 md lt 3 Y J LN Dimension B BOC to Battery Box 4 5in T8 Dimension E BOC to DPF SCR 19 6in TABLE 5 47 T8B C5B Dimension D Dimension D Fuel Tank Size Dimension F BOC to DEF Tank Daycab in Dimension F BOC to DEF Tank Ext Daycab in BOC to BOC to Fuel l Fuel Tank DEF Tank Size Tank Ext DEF Tank Size Gallons Length in Paycab in Daycab in 6 Diameter 7 4 24 5 Diameter o ee 75 oe Co ess 64 so 2 49 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 51 08 12 seyo LLa D11 Charts Section 5 Frame Layouts D11C Use
99. ao _ gt a SHEYD ES F Dimension E BOS to DPF SCR 26 2in Dimension B BOS to Battery Box 32 5in TABLE 5 69 T8B amp C5B 38 Fuel Tank Size Dimension F BOS to DEF Tank in BOS to Fuel Tank in DEF Tank Size ___Diameter____ Gallons Length in Smali Medium Large _ ae as 50 ME ee 0 a2 E 75 385 eo 45 so 24 5 Diameter Tank 54 9 ae 120 60 5 74 5 28 7 a7 28 5 Diameter Tank NOTE DIMENSIONS B AND F ARE CALCULATED USING A STANDARD BATTERY BOX OPTIONAL EXTENDED BOXES WILL CHANGE DIMENSIONS B AND F 5 83 08 12 Section 5 Frame Layouts 3D Use with the following models T800B and C500B 42 S3 Charts F Dimension E BOS to DPF SCR 43 7in Dimension B BOS to Battery Box 48 5in TABLE 5 70 T8B amp C5B 42 Fuel Tank Size Dimension F BOS to DEF Tank in BOS to Fuel Tank in DEF Tank Size ___Diameter____ Gallons Length in Smali Medium Large _ NOTE DIMENSIONS B AND F ARE CALCULATED USING A STANDARD BATTERY BOX OPTIONAL EXTENDED BOXES WILL CHANGE DIMENSIONS B AND F 08 12 5 84 e ss ECT 6 3o 85 22 Diameter Tank s as o e ae rr o 30s ooo 2 75 85 BO 90 ss 510 24 5 Diameter Tank 54 9 a aa oe ee 60 5 74 5 287 342 28 5 Diameter Tank Section 5 Frame Layouts S3E Use with the following models W900B 38
100. arts Dimension E BOS to DPF SCR 43 7in Dimension B BOS to Battery Box 54 6in TABLE 5 82 W90O0L 42 Fuel Tank Size Dimension F BOS to DEF Tank in BOS to Fuel Tank in ___ Diameter___ Gallons Length in Small Medium Large _ as ass oo ICI sso E teo e as os D E fas 135 26 2 Co pa f ee Diameter tank 150 s2 48 177 et os NOTE DIMENSIONS B AND D ARE CALCULATED USING A STANDARD BATTERY BOX OPTIONAL EXTENDED BOXES WILL CHANGE DIMENSIONS B AND D 08 12 5 96 Section 5 Frame Layouts 5A Use with the following models T800SH 38 SHeEYD GS Dimension B BOS to Battery Box 32 5in Dimension E1 BOS to DPF SCR 13 6in Dimension E2 BOS to Diffuser 27 5in TABLE 5 83 T8SH 38 Fuel Tank Size Dimension F BOS to Fuel Tank in Diameter Gallons Length in 22 Diameter Tank o os resi sl es Co ss a7 aer 27 s8 an 435 ere ies er es o a sso 208 s1 38 28 5 Diameter Tank Con ar lee NOTE DIMENSION B IS CALCULATED USING A STANDARD BATTERY BOX OPTIONAL EXTENDED BOXES WILL CHANGE DIMENSION B 08 12 5 97 Section 5 Frame Layouts S5B Use with the following models T800SH 42 S5 Charts Dimension B BOS to Battery Box 48 5in Dimension E1 BOS to DPF SCR 11 4in Dimension E2 BOS to Diffuser 25 2in TABLE 5 84 T
101. ase 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 TABLE 3 3 Ride Heights To calculate the frame height use the following formulas Front Frame Height FS 1 2 Front Tire Diameter Rear Frame Height RS 1 2 Rear Tire Diameter Front Suspension T800 T800SHW900B Tapar 13 2K Tapert 14 6K Tapereat 20K Taperleat 16K Taperlea 22K Multistage Taperlea 08 12 3 16 Section 3 Dimensions Front Suspension W900L 13 2K Taperleai Rear Suspension All Models Common Rear Suspensions are shown here for detailed suspensions please use the Rear suspension layouts on pages 3 18 to 3 33 peso Yes e Kenworth AG400 O S P Kenworth AG460 Kenworth AG690 Tridem Reyco 79KB 23K Rating Reyco 102 38K Rating Chalmers 854 40 L HS 40K Rating 96 aP Chalmers 854 46 H 46K Rating Chalmers 854 50 H HS 50K Rating Chalmers 865 65 XL 65K Rating P AA Hend HMX400 16 5 Saddle Hend HMX400 17 5 Saddle Hend HMX460 46K 16 5 Saddle Hend HMX460 46K 17 5 Saddle Hendrickson Primaax 46K Rating Hendrickson RT463 46K Rating Hend RT523 52K 6 Saddle as Neway AD369 Tider a EA Neway AD246 46K Rating Neway AD369 69K Rating 3 13 5 5 10 10 10 10 10 3 17 08 12 Section 3 Dimensions REAR SUSPENSION LAYOUTS
102. avy duty tie straps 0 50in 12 7mm wide Tyton T255ROHIR or similar shall be used ote whenever HD mounts are specified although 0 25in 6 4mm tie straps may be used in some specified applications FIGURE 9 4 Heavy Duty HD Mount Excess of material More than 3 inches of slack for every 14 inch section of hose routing except for air conditioner hoses See section 4 1 3 for air conditioner hose requirements Shortness of material Less than 1 inch of slack on a 14 inch section of hose routing ROUTING REQUIREMENTS Wiring Electrical ground wire terminals must be securely attached and the complete terminal surface must contact a clean bare metal surface See R414 558 for grounding wire connection practice Apply electrical contact corrosion inhibitor Nyogel 759G grease made by William F Nye Inc New Bedford MA per R414 558 Don t bend wires or use tie straps within 3 inches 75 mm of connected wire connectors or plugs Wires in Bundles Electrical wires other than the exceptions covered below running parallel with air or coolant hose bundles may be in cluded in the bundle if they are isolated from the hoses with a covering of convoluted plastic tubing EXCEPTIONS Battery cables including jump start cables may be bundled with or tied to the charging wire harness They shall not be bundled with or tied directly to any other components including hoses wires or bundles They shall be separated from other routed
103. cing can depart from nominal due to axle slant requirements Final axle spacing can vary by more than an inch from nominal in some cases If precise axle spacing is critical due to body installation or state local regulatory requirements please contact Kenworth Applications technical Support for assistance 08 12 3 20 Section 3 Dimensions AG460 TANDEM AG460 Suspensions TABLE 3 6 Rear Suspension Options Suspension Type Axle Svacin Laden Ride Unladen Ride d dl p g Height Height AG460 Tandem 60 Spacing e e e NOTE Actual axle spacing can depart from nominal due to axle slant requirements Final axle spacing can vary by more than an inch from nominal in some cases If precise axle spacing is critical due to body installation or state local regulatory requirements please contact Kenworth Applications technical Support for assistance 3 21 08 12 Section 3 Dimensions AG690 TRIDEM lo XA AE BA A AAA AAA Da 2 ayo r E 2 51 3 AS PL 2 AS Ed 2 4 P B y E p ymad SE vE Y
104. components using butterfly ties at intervals not exceeding 14 inches 356 mm Battery strap W84 1000 tie down shall be used without exception to secure battery cables to frame mounted or other major component e g engine tmsn etc mounted standoffs at intervals not exceeding 14 inches 356 mm The positive battery cable shall be covered with convoluted plastic tubing from terminal to terminal 110 220 volt wires for engine heaters oil pan heaters transmission oil heaters and battery pad warm ers shall not be included in any hose wire bundle with a fuel hose Individual heater wires not in a bundle shall be separated from other components by using butterfly clamps or butterfly ties at intervals not exceeding 14 inches 356 mm Heater wires with a secondary covering shall be covered with con voluted tubing whether they are in bundles or not 08 12 9 2 Section 9 Routing Wires Crossing other Components Electrical wires crossing over other components such as lines bolt heads fittings engine components lifting eyes engine block cylinder head etc close enough to rub shall be isolated with a covering of convoluted tubing and separated from the component by using butterfly clamps butterfly ties or plastic sheathing 110 220 volt engine heater wiring shall be installed with butterfly ties or butterfly clamps Piping Use no street elbows in air brake water fuel or hydraulic systems unless specified on the piping diagram an
105. created Consult the driveline manufacturer for appropriate recommendations WARNING When changing the wheelbase a continuous blank frame insert outsert must be added in the area of the new rear suspension mounting bolts All new mounting holes must pass AN through the original rail and the insert outsert Failure to do so could cause excessive stress in the original rail due to additional holes Before the rear suspension is relocated check the new location of the spring hanger brackets The new holes for the spring hanger brackets must not overlap existing holes and should not come any closer than 2 inches 50 mm to existing holes in the frame WARNING When relocating a suspension bracket do not mount it on the extended added section of a frame rail The suspension loading could result in premature failure of the added section AN splice This could cause an accident Use care when planning the wheelbase so that the rear suspension bracket is always mounted on the original rail section See Figure 7 3 7 3 08 12 Section 7 Frame Modifications When reducing the wheelbase we recommend that the suspension be moved forward and relocated on the original rail The rail behind the suspension can then be cut to achieve the desired frame cutoff See Figure 7 3 WARNING Do not drill new holes any closer than 2 inches 50 mm to existing holes Frame drilling affects the strength of the rails Before the rear suspension is reloca
106. d go back to pointing at zero e Atthe same time all LED indicators are switched on together and then switched off together Additional CVSG gauge information body builders should be aware of e The CECU sends 2 inch electronic gauges information over a data link blue wire between the CECU and the gauge e 2 inch electronic gauges get their power from the CECU e Yellow Power wire 9 16 volts e White Ground return wire 8 5 08 12 Section 8 Electrical e 4 way jumper harnesses link each 2 inch gauge together Ping Color Function S t Blue Data backlighting for Electronic Gauges 2 Brown Backiighting for Mechanical Gauges o 3 White Ground Return 4 Yellow Power e Backlighting for 2 inch electronic gauges is sent from the CECU to the gauges via the data link blue wire e Optional mechanical gauge i e air suspension needles are driven mechanically with air pressure There is no red warning lamp and the backlighting is powered through the brown wire from the CECU a pulse width modulated signal The 4 way jumper harness is still used to pass all 4 circuits through the gauge to the next gauge in the chain e Specialty CVSG gauges i e clock PTO hour meter are stand alone gauges and are independent of the CECU e Gauges can be relocated to any position in the dash To relocate a gauge unhook the connector at the back and move it to the desired position Plug the jumper wire in See Figure
107. d the build instructions Use no elbows in the air brake system unless specified on the air piping diagram and the build instructions Hoses Crossing Components Hoses crossing over other components close enough to rub shall be protected with a secured covering of convoluted plas tic tubing KW part number K344 813 another section of hose or plastic sheathing KW part number K213 1312 The usage of butterfly ties or butterfly clamps are also recommended Air Compressor Discharge Hoses Wires or hoses shall not be tied to the high temperature air compressor discharge hose Hoses and wires may be routed across the air compressor discharge hose at a distance of 18 inches 457 mm or greater from the compressor discharge port In this case the crossing hoses and wires shall be butterfly clamped to the air compressor discharge hose and cov ered with convoluted tubing at the clamp point use high temperature clamps on the compressor hose Bundles HD mount and tie strap or clamp shall be located at intervals not to exceed 14 inches 356 mm along the bundle Regular tie straps shall be located at intervals not to exceed 7 inches 178 mm between HD mount or clamps Extra tie straps may be used as needed to contain the hoses and wires in the bundle Routing of Wires and Hoses near Moving Components Wires and Hoses shall be routed away from moving components such as fans shackle links drivelines steering linkages etc so that the
108. damage to the A body during suspension movement Allow at least 8 inches clearance See Figure 6 5 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 5 8 in 203mm FIGURE 6 5 Minimum Clearance Between Top Of Rear Tires And Body Structure Overhang CAUTION Maintain adequate clearance between back of cab and the front leading edge of mounted A body See Figure 6 6 Note Be sure to provide maintenance access to battery box and fuel tank fill neck il 6 3 08 12 Section 6 Body Mounting FIGURE 6 6 Minimum Back of Cab Clearance WARNING If the frame rail flanges are modified or damaged the rail could fail prematurely and cause an accident When mounting a body to the chassis DO NOT drill holes in the upper or AN lower flange of the frame rail Mount the body using body mounting brackets or U bolts BODY MOUNTING USING BRACKETS CAUTION Always install a spacer between the body subframe and the top flange of the frame rail A Failure to do so could result in corrosion due to dissimilar materials Installation of a spacer between the body subframe and the top flange of the frame rail will help prevent premature wear of the components due to chafing or corrosion 08 12 6 4 Sec
109. de door frame or edge is an Incomplete Vehicle Certification label See Figure 2 2 For further information on Vehicle Certification and Identification 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 il of the components or systems covered by these regulations it is your responsibility as the Intermediate or Final Stage Manufacturer to ensure that the complete vehicle is in compliance with the particular regula tions upon completion of the modifications U S EPA Noise Label U S registered vehicles only me m a oes ee A TE PE A a p a p a 1t teti yt pm m Final Stage Manufacturer Label to be Installed by Final Stage Manufacturer Tire Rimand GETER en Weight Rating Data label Chassis Serial Number Major Components and rhea Safety Mark Canadian Lae Weights Label Registry Only Incomplete Vehicle a i Certification Label FIGURE 2 1 Incomplete Ve FIGURE 2 2 Locations of Certifica hicle Certification Document 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 t
110. e added with excessive line length and bends Work with your local Kenworth dealer if you are unsure about the coolant line modifications 08 12 4 3 Section 4 Exhaust amp Aftertreatment MEASUREMENT REFERENCE POINTS For the all relocation procedures the measurement points will referenced in the guidelines are taken from the following specific points Supply Module The supply module is commonly called a pump The measurement point on the supply module is the top of the DEF fluid 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 fluid pressure line See Figure 4 2 FIGURE 4 2 Measurement Location of DEF Dosing Module Injector The following relocation guidelines are dependant on exhaust configuration and DEF tank type and location The Dosing Module should not ever need to be relocated however if it is removed for any reason it is critical that the module be reinstalled at the correct orientation Figure 4 3 below illustrates the correct installation orientations The angle references the vertical plane 08 12 4 4 Section 4 Exhaust Aftertreatment Installation orientation of Dosing Module Between 45 and 85 Between 45 and 85
111. ection 8 Electrical FACTORY INSTALLED SNOW PLOW LIGHT WIRING This options provides the ability to switch between operating lights mounted on a snow plow versus the standard lights on the hood A switch is mounted in the dash to allow the operator to select the mode See Figure 8 31 for the snow plow switch icon Circuits provided to the body builder are e Park Lamp Circuit code YEL2411 e RH Turn Circuit code YEL2312 e LH Turn Circuit code YEL2311 e Ground Circuit code WHT2000 e RH High Beam Circuit code YEL2122 e LH High Beam Circuit code YEL2121 e LH Low Beam Circuit code YEL2111 e RH Low Beam Circuit code YEL2112 These 8 circuits are coiled up inside the forward LH rail the breakout length is 5 meters in length A relay module containing four relays is mounted under the hood near the washer bottle See Figure 8 33 C CL LO FIGURE 8 33 Snow plow icon FIGURE 8 34 8 43 08 12 Section 8 Electrical NAVPLUS HEAD UNIT INFORMATION For aftermarket installation of cameras for display on the NavPlus screen or replacement parts you will need to be famil lar with the pin outs in the back of the head unit FIGURE 8 35 PACCAR Head Unit Main Wireless Data RFU Display Power Ground CAN Green Reserved for Furture Use Blue Brown Speakers etc TERMINA SDARS Antenna AM FM WB GPS Antenna Yellow Antenna White Blue 08 12 8 44 Section 8 Electrical FIGU
112. ekee ee cteonaeeeeerp eee eeaees kee eee 4 13 FIGURE 4 17 RIGHT VIEW OF RIGHT HAND UNDER DPF AND SCR WITH DUAL SOC IAILPIFES setas ui bee SRR eka meee eee eee aes A oe ee 4 14 FIGURE 4 18 BACK VIEW OF RIGHT HAND UNDER DPF AND SCR WITH DUAL SOG TAILPIFES feateneeeeaceatedhedbeneaae tee ae ge oo os 4 14 FIGURE 4 19 ISOMETRIC VIEW OF RIGHT HAND UNDER DPF AND SCR ON AEROCAB WITH SINGLE SOC TAILPIPE 0 4 15 FIGURE 4 20 TOP VIEW OF RIGHT HAND UNDER DPF AND SCR ON AEROCAB WITH SINGLE SOC TAILPIPE 0 2 000000 0222 eG 4 15 FIGURE 4 21 RIGHT VIEW OF RIGHT HAND UNDER DPF AND SCR ON AEROCAB WITH SINGLE SOC TAILPIPE 0 2 20020 00 0000008 4 16 FIGURE 4 22 BACK VIEW OF RIGHT HAND UNDER DPF AND SCR ON AEROCAB WITH SINGLE SOC TAILPIPE 2000000052 2 eee 4 16 FIGURE 4 23 ISOMETRIC VIEW OF RIGHT HAND UNDER DPF AND SCR ON AEROCAB WITH DUAL SOC TAILPIPES 2 e o 4 17 FIGURE 4 24 TOP VIEW OF RIGHT HAND UNDER DPF AND SCR ON AEROCAB WITH DUAL SOC TAILPIPES 2 nadasa 00002 eee 4 17 FIGURE 4 25 RIGHT VIEW OF RIGHT HAND UNDER DPF AND SCR ON AEROCAB WITH DUAL SOC TAILPIPES 000000052 2 eee 4 18 FIGURE 4 26 BACK VIEW OF RIGHT HAND UNDER DPF AND SCR ON AEROCAB WITH DUAL SOC TAILPIPES 2 000000 2 eee 4 18 FIGURE 4 27 ISOMETRIC VIEW OF HORIZONTAL DPF AND SCR WITH HORIZONTAL TAILPIPE 2 2 d o a a a a a a a a a a 4 19 FIGURE
113. elow 08 12 8 4 Section 8 Electrical Telltale cards pre installed in slots on both sides of cluster Saselne Cluster lt i Eh gis LE a hr YA LH A e lt EN 4 Standard card A i Single electrical conmectian on back of cluster Card locks info placa installation tab breaks off A The cluster is installed with four screws Editable card Talliale cards FIGURE 8 5 Instrument Cluster Components CVSG Gauges The right and left instrument panel gauges used with the multiplexed instrumentation are commonly referred to as Com mercial Vehicle Smart Gauges CVSG Like the central instrument cluster the 2 inch gauges also receive input data directly from the CECU CVSQ s are electronic and mechanical The electronic CVSG s receive digital data from the CECU via the CVSG data bus The mechanical gauges i e suspension air pressure etc are driven directly from the air pres sure Both types of gauges receive backlighting signals from the CECU via a 4 wire daisy chained jumper harness that links one gauge to another When the ignition key is first turned ON all the electronic 2 inch gauges will perform a calibration power on self test Note The mechanical CVSG do not perform a power on self test il Power On Self Test e ignition key turned ON e The gauge pointers move from pointing at zero counter clockwise to their mechanical limit approx 5 stay there for one second an
114. els T800SH 38 Dimension E BOS to DPF SCR 24 9in Dimension B BOS to Battery Box 32 5in TABLE 5 67 T8SH 38 Dimension D Fuel Tank Size Dimension F BOS to Fuel Tank in ___Diameter____ Gallons Length in Small Medium Large _ e IET o o f eo oo 20 ne a 24 5 Diameter Tank 28 5 Diameter Tank NOTE DIMENSIONS B AND F ARE CALCULATED USING A STANDARD BATTERY BOX OPTIONAL EXTENDED BOXES WILL CHANGE DIMENSIONS B AND F 5 81 08 12 SHEYD ES Section 5 Frame Layouts S3B Use with the following models T800SH 42 S3 Charts Dimension E BOS to DPF SCR 40 9in Dimension B BOS to Battery Box 48 5in TABLE 5 68 T8SH 42 Fuel Tank Size Dimension F BOS to DEF Tank in BOS to Fuel Tank in DEF Tank Size ___Diameter___ Gallons Length in Smali Medium Large _ e IET o o 6 3830 85 22 Diameter Tank s as o 24 5 Diameter Tank 25 6 19 2 11 1 Co p a IC aa sos ME a NOTE DIMENSIONS B AND F ARE CALCULATED USING A STANDARD BATTERY BOX OPTIONAL EXTENDED BOXES WILL CHANGE DIMENSIONS B AND F 08 12 5 82 Section 5 Frame Layouts 3C Use with the following models T800B and C500B 38 E rT yi o
115. ension B BOS to BOS to Fuel Tank in Battery Box in Diameter Gallons Length in ss ess as os 208 94 so aso gt os we 94 2 75 as 198 08 182 30 120 75 75 20 22 Diameter Tank ws s 288 os 79 o o 455 as os tez o awo eos 66 sn tez 300 7s 7 04 77 281 94 so a2 s9 os 26 04 aim fei as s so NOTE DIMENSION B IS CALCULATED USING A CANTILEVER SIZED BATTERY BOX OPTIONAL BOXES WILL AFFECT THIS DIMENSION 5 115 08 12 Section 5 Frame Layouts 9D Use with the following models T800B and C500B 42 ll IN S9 Charts CC 52 L m Y JO L Dimension E BOS to DPF SCR 19 6in TABLE 5 102 T8B amp C5B 42 Fuel Tank Size Dimension F1 amp F2 Dimension B BOS to BOS to Fuel Tank in Battery Box in __Diameter _ Gallons Length in 35 5 36 6 biomas 82 380 33 9 aaa 47 3 35 8 15 1 20 1 15 8 62 2 9 7142 89 352 20 o sos 42 38 5 33 9 24 5 Diameter 100 50 0 20 1 1 5 605 x 67 2 36 as s6 s2 2o o a 36 6 ml 28 8 a 28 5 Diameter 129 48 8 25 6 50 8 20 1 56 2 145 66 1 NOTE DIMENSION B IS CALCULATED USING A CANTILEVER SIZED BATTERY BOX OPTIONAL BOXES WILL AFFECT THIS DIMENSION 7 yank 54 9 14 6 7 08 12 5 116 Section 6 Body Mounting FRAME
116. eper ground clearance is reduced by 1 3 inches 3 39 08 12 PTO CLEARANCES The following visuals are provided to help aid in determining PTO locations and clearances For specific dimensions please work through your local Kenworth dealer Note Installations depict multiple PTOs In order to ensure the PTO area remains clear of air equipment electrical and emissions equipment Kenworth recom mends always ordering PTO controls even when installing the PTO aftermarket Kenworth does offer a variety of factory installed PTOs Contact your local dealer for assistance Manual Transmission Bottom View 08 12 3 40 Allison Transmission Forward 3 RH Top MTD LH Side MTD L Front View LH Side MTD Bottom View 3 41 08 12 Section 3 Dimensions This page intentionally left blank 08 12 3 42 Section 4 Exhaust amp 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 be tween the ammonia and NOx turning it into water
117. er bottle Do not relocate the chassis load center See Figure 8 25 ke H e H B Tm i del 6 265 7 FIGURE 8 25 Chassis Power Distribution Center Dimensions 8 35 08 12 2010 ELECTRICAL HARDWARE Kenworth incorporated new electrical hardware to enhance the truck capabilities and performance The locations of the hardware are shown here for reference The chassis node is mounted above the LH frame rail under the cab on Day Cabs or Extended Day Cabs For chassis equipped with sleepers the chassis node is mounted inside the LH frame rail at the back of cab Al alternate location inside of the LH frame rail in the transmission area is only used on 38 Aerocabs speci fied with horizontal exhaust Do not relocate the chassis node The dosing control unit DCU and after treatment control module ACM are shown for reference only Not all chassis will be equipped with both DCUs and ACMs If the locations of these components are critical to body installation please work with your local Kenworth dealer Do not relocate either of these modules FORWARL DOCIVACN Modules FIGURE 8 27 Aerocab Standard Hardware Locations 08 12 8 36 Section 8 Electrical FIGURE 8 28 Aerocab Alternate Hardware Location Ana FIGURE 8 29 Chassis Node Dimensions 8 37 08 12 Section 8 Electrical ELECTRICAL WIRE NUMBER AND COLOR GENERAL WIRE LABELS Kenworth introduced a new electrica
118. es on a dual tire arrangement or the distance between the tire centerlines on a single tire arrangement e Width The distance over the outermost tire sidewall to sidewall These dimensions may be significant to the following e Appearance relative to other tires and chassis mounted equipment e Load carrying capacity Different wheel disc offset can have a positive or negative impact on the axle carry ing capacity of the axle a a Toms Dim B P j del en Width IS Dim A Track Track TABLE 3 18 Axle Width Calculation Track Overall Width Dana Spicer D46 170 H P Alcoa 88367 BR M726EL i i 46K Dual 22 5X8 25 11R22 5 ae ie ene Dana Spicer D46 170 H P Alcoa 98364 BR M726EL f i i 46K Dual 24 5X8 25 11R24 5 ue oon Dana Spicer D46 170W H P Alcoa 88367 BR M726EL 79 9 103 7 46K Dual Wide Track 22 5X8 25 11R22 5 Dana Spicer D46 170 H P Alcoa 82360 BR M844F 46K Dual 22 5X12 25 425 65R22 5 Dana Spicer D46 170W H P Alcoa 82360 BR M844F 46K Dual Wide Track 22 5X12 25 425 65R22 5 Dana Spicer D46 170W H P Alcoa 98364 BR M726EL 79 5 103 9 46K Dual Wide Track 24 5X8 25 11R24 5 TABLE 3 18 CONTINUES ON NEXT PAGE 08 12 3 36 Section 3 Dimensions TABLE 3 18 CONTINUED Type Dim A Dim B Dana Spicer D2000 20K Alcoa 82364 BR M844F i Axle Pusher Tire Wheel Track Overall Width Non Steerable Orientation Dim A Dim B NS P
119. f welding nullifies the special heat treatment of the rails greatly reducing the tensile strength of the frame rail If a fame member becomes cracked from overloading fatigue surface damage or a collision the only permanent repair is to replace the damaged frame member with a new part The following information is provided for temporary emergency repair Prior to welding a cracked frame rail the area should be beveled V d out to allow for a better weld To prevent spreading of the crack a 7 to 9 mm 1 4 in to 3 8 in dia hole should be drilled at the end of the crack Widen the crack along its full length by using two hack saw blades together When welding steel frames use the shielded arc method When welding aluminum frames use either the tungsten inert gas TIG or consumable electrode method Be sure to obtain full weld penetration along the entire length of the crack Precautions CAUTION Before welding disconnect the negative terminal battery cable C AUTION Before welding disconnect the alternator terminals Failure to do so could result in damage to the voltage regulator and or alternator A C AUTION To prevent damage to electrical equipment disconnect battery cables before arc welding on a truck and be sure that the welding ground lead is connected to the frame Bearings A and other parts will be damaged if current must pass through them in order to complete the circuit Welding Precautions All Electronic Engines
120. factory installed body builder harness the remote PTO throttle harness is capped off it an he ea Lal calms Fi LET i Pep TRE ETNI y Pd O rad aii i F Cid imie DHH EE i 4315 RL A HE AE 000 DAD HE Fil aa jl ieee 4 5 FRA TA tLe DEIA i i hi Fi aa Jiti Votan CLE BEST JYI Y CAN APORTA E l OT FT Coat 8 31 08 12 Section 8 Electrical FIGURE 8 23 2010 Cummins ISL PX 8 Routing Diagram The location of the remote PTO throttle harness pin out connection can be found on the ISL PX 8 engine as noted in the diagrams below It is from this location the remote throttle chassis harness is installed If the engine specified from the factory does not include the factory installed body builder harness the remote PTO throttle harness is capped off inl da AE HENNE SS A Ly A TE E jig da rh i d E ee F i i r ee Ry 10 BESTE PID CONTEDLS an i E gt 10 Cea r Me 08 12 8 32 Section 8 Electrical MULTIFUNCTION TURN SIGNAL STALK CHASSIS NODE amp CHASSIS LOAD CENTER Kenworth introduced the chassis node and chassis load center with 2010 emissions The information that follows covers the functions of the chassis node along with guidelines for installing additional lights on the chassis Exterior Lighting Circuit Limits The multifunction turn signal stalk communicates to the CECU inside the cab which sends information to the Chassis Node
121. fication If modifications are required they must first be approved by the engine manufacturer Unapproved modifications could negatively effect emissions performance certification There is no guarantee that proposed modifications will be approved Contact the engine manufacturer for any requirements and restrictions prior to any modifications e For Cummins Contact 1 800 DIESELS or your local Cummins distributor Reference AEB 21 102 It is possible to relocate the DEF tank however the relocation requirements need to be followed Any variance from the relocation requirements may cause the emissions control components systems to operate improperly potentially resulting in engine de rate See page 4 3 for relocation requirements NOTE Some 2010 engine emissions certified vehicles will be equipped with an On Board Diagnostics OBD system The OBD system is designed to detect malfunctions of any engine or vehicle com ponent 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 di agnostic purposes A Malfunction Indicator Light MIL is illuminated in the dash to alert the driver of the need for service of an emi
122. ft Prevention Standards if applicable in effect in month year 08 12 2 2 Section 2 Safety amp Compliance These statements are just part of the changes to the new certification regulation Please refer to the Feb 15 2005 final 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 final rule DocID 101760 For Canadian final 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 ON5 613 990 2309 TTY 1 888 675 6863 Noise and Emissions Requirements NOTE This truck may be equipped with specific emissions control components systems in order to meet applicable Federal and California noise and exhaust emissions requirements Tampering il 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 sys tems defined above will affect the noise and emissions performance certi
123. h 1 These switches will be connected to backlighting power and ground A male 1 4 slide connector breakout is taped back to the harness This is the switched power output connect this to power your load SPARE SWITCHES BODY BUILDER INSTALLED You can purchase additional spare switches from your local Kenworth dealer Part number P27 1023 007 for single throw See Figure 8 13 These switches are rated to 20A If you need to switch more then 20A see the next section about spare relays To connect to these switches you can use harness P92 2552 available from you local Kenworth Dealer See Figure 8 14 This harness will allow you to connect to instrument backlighting spare power and a male 14 slide connector breakout is taped back to the harness This is the switched power output connect this to power your load FIGURE 8 13 Kenworth Spare Switches 08 12 8 20 Section 8 Electrical W FOB g 7 LE d ERIL SPAR Perr MELO eat MN ds ETE Fie om Pal EN Pig igi TPg FH i ae i LAR ErBzorr wie BURDA I iPod i NIFLODID rF ipi WIFLOOGE E pee a Te ME TPORE RT Lith ies 2a A fi bia HETE TERS IHORA ida TOR FEB 1491 39 110 gn _ ETA q gt IE AA IEA E EE TT PLE MIFLEJDS rods e CAC miero FIELEGOA PeE 1 Cus IGHL E 15 TALLO RIZIK TERM IO ioe Poe PFD 2 ee ee EIEL HUME Gm i I J Fillo FIELODE I 16 SPARE Sel De Maa oS FIGURE 8 14 Spare Switch Harness
124. he 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 2 6 Section 2 Safety Compliance 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 and its location may not be changed 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 defined by ISO International Standards Organiza tion The figure below shows the instrument cluster and MIL lamp position Note this lamp location is fixed with respect to the controls and its location may not be changed if you are updating the warning lamp cards 1 2 3 4 5 6 7 8 amp 9 207 25 r 23 22 21 20 19 FIGURE 2 5 Instrument Cluster for T4 T6 T8 W9 C5 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
125. he standard cards cover most warning light require ments editable cards can be used for less common components that also require warning lights The central instrument cluster receives input data from the CECU via the I CAN see Figure 8 3 data bus When the ignition key is first turned ON the cluster will perform a calibration power on self test Please see pages 8 18 through 8 20 for more detailed information Power On Self Test e Ignition key turned ON e The speedometer and tachometer gauge pointers move from pointing at zero counter clockwise to their mechanical limit approx 8 stay there for one second and go back to pointing at zero e Atthe same time all LED indicators and telltales are switched on together and then switched off together e A Warning sound sequence is also activated five times without break The warning lamps in the cluster are all activated by the CECU except for Telltale Position 5 usually Refrigerator and Position 11 editable which are wired directly to the cluster The CECU receives direct wire inputs for all warning lamps with the exception of the Low Coolant Level warning and the Traction Control Stability Control lamp These lamp inputs are received via the J1939 Vehicle CAN data link The CECU typically receives the Trailer ABS warnings via the J1939 Vehicle CAN data link however it can also be direct wired to the CECU from the ABS unit on the trailer if required See Figure 8 5 b
126. he vehicle Upon completion of the vehicle installation of the body and any other modifications you should affix your certification label to the vehicle as required by Federal law This tag identifies you as the Intermediate or Final Stage Manufacturer and certifies that the vehicle complies with Federal Motor Vehicle Safety Standards See Figure 2 2 Be advised that regulations affecting the intermediate and final stage manufacturer may change without notice Ensure you are referencing the most updated copy of the regulation during the certification and documentation processes In part if the final stage manufacturer can complete and certify the vehicle within the instruction in the incomplete vehicle document IVD the certification 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 certified with in the guidance provided in the IVD the final stage manu facturer must ensure the vehicle conforms to all applicable Federal Motor Vehicle Safety Standards FMVSS The final stage manufactures certification label would need a statement that reads This vehicle conforms to all applicable Federal Motor Vehicle Safety Standards and Bumper and The
127. hese 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 LL Fuel Tank Diameter TABLE 5 3 Battery Box Centerframe Lengths in AT Too Tesh woe woL wos 660 1700 08 12 5 2 Section 5 Frame Layouts SMALL DEF TANK CLEAR BOC DEF TANK 9 GALLON USABLE VOLUME 5 6 GALLON USABLE VOLUME 104 193 H 19 6 16 4 l MEDIUM DEF TANK LARGE DEF TANK 18 GALLON USABLE VOLUME 27 GALLON USABLE VOLUME 18 9 FIGURE 5 1 DEF Tank Dimensions TABLE 5 4 DEF Tanks Systems emon PO Tr Gallons Diameter Large DEF Tank Acronyms Index Throughout the Frame Layout section you will see these acronyms They are defined here to help you decode the layouts Back Of Cab Back Of Sleeper DSOC Dual Side Of Cab LHUC Left Hand Under Cab CBOC Clear Back Of Cab Diesel Exhaust Fluid DSOAC Dual Side Of AeroCab RHUC Right Hand Under Cab SOAC Side Of AeroCab Side Of Cab 08 12 9 3 Frame Layout Index Section 5 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 Charts located on pages 5 9 through 5 13
128. i pan i DEF Tank Size Diameter Diameter Tank Diameter 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 08 12 5 9 Section 5 Frame Layouts D1B Use with the following models T800B and C500B D m D1 Charts Dimension E BOC to DPF SCR 0 3in TABLE 5 6 T8B 8 C5B Dimension D Fuel Tank Size Dimension F Dimension B BOC to DEF Tank Daycab in BOC to Fuel Tank BOC to Battery DEF Tank Size Daycab in Box Daycab in _Diameter Gallons Length in Diameter Tank Diameter Tank 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 08 12 5 10 Section 5 Frame Layouts D1C Use with the following models W900S seyo La Dimension E BOC to DPF SCR 0 3in TABLE 5 7 Dimension D Fuel Tank Size Dimension F Dimension B BOC to DEF Tank Daycab in BOC to Fuel Tank BOC to Battery DEF Tank Size Daycab in Box Daycab in _Diameter Gallons _ Length in Smali Medium Large _ rs es 18 soo so 5 48 169 o E ea Y 28 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 DIM
129. icle serial number 6 See Figure A 1 SAMPLE VIN 1JxJp PlHlz 7 x x RIM o 1 06 3 o E 0 do Manufacturer Identifier Vehicle Attributes Check Digit Model Y ear GO Assembly Plant Serial Number Chassis Number FIGURE A 1 Vehicle Identification Number VIN The model year 4 is designated by an alphanumeric code in the tenth character position in the VIN See Table A 1 and Figure A 1 TABLE A 1 Model Year Code Designations VIN Location The VIN is marked on the Incomplete Vehicle Certification Label on trucks It is located either on the driver s door edge or door frame See Figure A 2 Chassis Number Locations The Chassis Number comprises the last six characters of the VIN The vehicle chassis number is shown in multiple locations Left side of cab lower right corner of door frame stamped plate Tire Rim and Weight Rating Data label Major Components and Weights label Noise Emission label Paint Identification label A 1 08 12 Appendix A Vehicle Identification VEHICLE IDENTIFICATION LABELS Vehicle Identification Labels are located on the driver s side door edge or on either the driver s or passenger s side door frames See Figure A 2 Labels include Vehicle Certification Components and Weights Tire Rim and Weight Rating Data Noise Emissions a
130. ilpipes 08 12 4 14 Right Hand Under DPF and SCR on Aerocabs with Single Side of Cab Tailpipe FIGURE 4 20 Top View of Right Hand Under DPF and SCR on Aerocab with Single SOC Tailpipe 4 15 08 12 08 12 4 16 Right Hand Under DPF and SCR on Aerocabs with Dual Side of Cab Tailpipes FIGURE 4 24 Top View of Right Hand Under DPF and SCR on Aerocab with Dual SOC Tailpipes 4 17 08 12 FIGURE 4 25 Right View of Right Hand Under DPF and SCR on Aerocab with Dual SOC Tailpipes FIGURE 4 26 Back View of Right Hand Under DPF and SCR on Aerocab with Dual SOC Tailpipes 08 12 4 18 Horizontal DPF and SCR with Horizontal Tailpipe FIGURE 4 27 Isometric View of Horizontal DPF and SCR with Horizontal Tailpipe FIGURE 4 28 Top View of Horizontal DPF and SCR with Horizontal Tailpipe 4 19 08 12 FIGURE 4 30 Back View of Horizontal DPF and SCR with Horizontal Tailpipe 08 12 4 20 Vertical Independent DPF and SCR with Horizontal Tailpipe FIGURE 4 31 Isometric View of Vertical DPF and SCR FIGURE 4 32 Top View of Vertical DPF and SCR 08 12 4 21 FIGURE 4 33 Right View of Vertical DPF and SCR FIGURE 4 34 Back View of Vertical DPF and SCR 08 12 4 22 Section 4 Exhaust amp Aftertreatment EXHAUST INFORMATION This section includes information on how to calculate tailpipe heights and reference information for PTO clearance Optional equipment is not shown T
131. installation or state local regulatory requirements please contact Kenworth Applications technical Support for assistance 3 33 08 12 Section 3 Dimensions PUSHER AXLES The rear pusher axle layouts are provided as a tool to help layout bodies prior to arrival The applicable dimensions are shown When using the pusher layouts to determine available frame space please be aware that clearances required are not shown For information that may not be detailed in these drawings work with your local Kenworth Dealer to request that information Watson amp Chalin Super Lite 8K Steerable Pusher 249 7X 20 68 lt 193 _ Y 8 1 y kh d 215X75R17 5 24 lt 276 LIFTED 151 228 DOWN Watson amp Chalin Tru Track Alumilite 13 2K Steerable Pusher FX 10 0 68 _ 21 9 m i Bl y 295 75R225 A _ 23 7 LIFTED m Ol n 18 9 DOWN 08 12 3 34 Section 3 Dimensions Watson Chalin Tru Track 20K Steerable Pusher 445 65R225 378 LIFTED a 22 9 35 9 DOWN Watson amp Chalin Atlas 22 5K Non Steerable Pusher 8X 0 68 p i a 295 75R22 5 e 34 1 LIFTED a 338 DOWN 3 35 08 12 Section 3 Dimensions AXLE TRACK AND TIRE WIDTH The dimensions provided in this section are representative of some typical product combinations The purpose this sec tion is to demonstrate some of the typical dimensions e Axle Track The distance between the dual tire centerlin
132. ional compo nents may be placed on the rail behind components shown The Back of Cab components are shown primarily for refer ence For more specific 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 specifically 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 specified pages The charts that follow are then model specific It is important that the correct chart is used for accurate dimensional information Visual Index RHUC DPF SCR Horizontal DPF SCR Cantilever Battery Box Tool Box DEF Tank Clear BOC DEF Tank Vertical DPF SCR Parallel Battery Box Standard Length In Cab Battery Box Fuel Tank 5 1 08 12 Frame Layout Index 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 other wise noted Dimensions for t
133. k e Modification 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 flanges where necessary Do not extend the harnesses The DPF the SCR catalyst or their mounting may not be modified The NO sensor may not been relocated or altered in any way Exhaust pipes used for tailpipes stacks must be properly sized and must prevent water from entering Ensure adequate clearance between the exhaust and body panels hoses and wire harnesses The body in the vicinity of the DPF must be able to withstand temperatures up to 400 C 750 F Do not add thermal insulation to the external surface of the DPF The SCR water drain hole may not be blocked Allow adequate clearance 25mm 1 inch for servicing the DPF sensors wiring and clamped joints Drainage may not come in contact with the DPF SCR catalyst sensors or wiring Allow sufficient clearance for removing sensors from DPF Thermistors require four inches Other sensors require one inch Wiring should be routed protected from heat and properly secured to prevent damage from other components The exhaust system from an auxiliary power unit APU must not be connected to any part of the vehicle after treatment system or vehicle tail pipe Cooling System The following
134. l wire numbering system in 2007 This wire number system uses only 10 different colors and only one striped wire color These colors determine a circuits FUNCTION as follows RED ProiscedBaten Power ore 1ONADO San Power BAN ndatortinaion Beckghng GN Sensor commen ror connected to GND Each wire has at a minimum a 7 character label the first three characters are the circuits color as listed above the re maining four are numerical which relate to the load the wire services See TABLE 6 4 for the general categories TABLE 8 5 Wire Number General Categories To identify similarly labeled wires a suffix can be added For example YEL2950 1 would be a yellow wire indicating it is activated power The 2950 indicates the load in this case fog lamps the 1 is a suffix used to differentiate similarly labeled circuit 08 12 8 38 Section 8 Electrical DATA BUS WIRE COLORS Data Bus wiring has its own color scheme as follows e Data bus high side wires VIO J1587 amp J1708 ORG J1922 YEL J1939 RED OEM GRY CAN BLU Single wire bus e Data bus low side wires GRN All Data bus low side wires TRAILER BODY BUILDER WIRE COLORS Trailer Wires have their own wiring scheme as follows TABLE 8 6 Trailer Wire Colors Stop lamps Light green Right turn lamps Light blue ABS power Auxiliary To identify specific circuits contact your local Kenworth Dealer 8 39 08 12 Section
135. lamp A cushioned rigid or semi rigid anti chafing device for containing the bundle and securing it to the frame or other structural support Standard clamps have a black elastomer lining High temperature clamps e g those used with com pressor discharge hose have a white or red elastomer lining most applications for these are called out in the bills of material An assembly of two clamps fastened together to separate components is referred to as a butterfly clamp Note the metal portion of clamps shall be stainless steel or otherwise made capable through plating or other means of passing a 200 hour salt spray test per ASTM B117 without rusting ro y FIGURE 9 1 Clamp and Butterfly Clamp Butterfly Tie A tough plastic nylon or equivalent locking dual clamp tie strap used to separate bundles or single lines hoses etc These straps must be UV stable Tyton DCT11 FIGURE 9 2 Butterfly Tie Tie Strap A tough plastic nylon or equivalent locking strap used to tie the lines in a bundle together between clamps or to otherwise secure hoses and wires as noted below These straps must be UV stable FIGURE 9 3 Tie Strap Heavy Duty HD Mount A black rigid device used for securing a tie strap to the frame or other structural support Mounts are made of impact modified heat stabilized UV resistant nylon capable of continuous operation between tem peratures 220 F 150 and 40 F 40 9 1 08 12 Section 9 Not He
136. le 8 1 and on the instrument panel harness breakouts for the editable telltales behind the right hand cluster To remove the editable cards follow steps 1 3 in the instructions for accessing gauges and switches page 8 9 Remove the rubber access cover on the side of the cluster by pulling by hand The access cards have a positive lock To remove the card pry upwards on the lock with a small screwdriver and pull the card out with pliers See Figure 8 10 below that details the cards To reinstall a card slide it in either by hand or with pliers New cards will come with the installation tab as shown in the figure After installing the card simply break off the tab by bending FIGURE 8 10 Telltale Symbol Standard Cards 8 17 08 12 Section 8 Electrical TABLE 8 1 Telltales Position and Color Light Editable or Position Standard Function Color Fixed a Fithwheeiside Red mes a KingPintock Rea table e Pame Rea Fea z Check Transmission Red Eatabie a Transmission Temp Yelow Edtabe o Pampmede Green table io FastonSeatbet Red Fred 11 Matfnction indicator Lamp Yelow Frea 19 BthaustTemp Waring Yelow Fixed a MessageWeting Green Edtabe C e Teens Avetock Green Fixed O e TralerBoay Up Red Fea Note Only the positions labeled as editable in the chart above can be changed You must apply the il standard icons on the editable card on all
137. n vary by more than an inch from nominal in some cases lf precise axle spacing is critical due to body installation or state local regulatory requirements please contact Kenworth Applications technical Support for assistance 08 12 3 26 Section 3 Dimensions NEWAY ADZ 369 TRIDEM SUSPENSION Shown with 54 Axle Spacings HaT i Tit bao jam 73 im n ES i i y e y a olla tt do fa 2 5 r F F ad 5 Gd i j i ih ir O ze fod i oo a o y fof fo om oe a lafi f il i kytt e a A e y 4 F ma wi mere 4 Tg i I i i s wy gt i Je ii j 54 fi Y LE i i A 24 p 1 1 rat de y il i f i y Li L al 1 I Y I ES I F RIGE 1 A F j 4 f i MlEMSHT F lg af F Ta z r as m AXLE SPACING T ALE SPACING Optional Neway AD Tridem Suspensions TABLE 3 12 Rear Suspension Options Suspension Type Axle Svacin Laden Ride Unladen Ride i ia s Height Height NOTE Actual axle spacing can depart from nominal due to axle slant requirements Final axle spacing can vary by more than an inch from nominal in some cases lf precise axle spacing is critical due to body installation or state local regulatory requirements please contact Kenworth Applications technical Support for assistance 3 27 08 12 Section 3 Dimensions HENDRICKSON PRIMAAX EX TANDEM SUSPENSION Shown with 54 Axle Spacings AXLE S
138. nd Body Information To demonstrate that the ESP system has been tested and disabled the ESP ATC warning lamp will illuminate solidly and remain on after the truck has been driven at speeds greater than 30 miles per hour The Body Builder Final Stage Manufacturer is responsible for certifying that the Bendix ESP is functioning properly after the body is installed Bendix will provide training and software that are required to enable the ESP pre wire system For the ESP system to function properly the body builder must install the body specified on the Kenworth Sales Order and not make any changes to any of the main chassis components wheelbase front rear axle front rear suspension steering gear front rear brakes add remove axle or lift axles etc Please contact Bendix Commercial Vehicle Systems LLC if any questions exist After the ESP system has been enabled the ESP warning labels must be applied to the chassis The warning labels are shipped loose with the chassis along with an installation drawing Remove the label on the dash that says Replace When ESP is Enabled and replace it with the ESP dash warning label Apply the remaining warning labels in conjunction with the warning label installation drawing Please notify Kenworth or Bendix if there are any changes to the body configurations that have been certified in the ESP program In order to approve configurations for ESP a validation test at Bendix is required 08 12 8 42 S
139. nd Paint Identification Quantity and location of labels may differ based on Complete Incomplete vehicle and Single Dual certification Labels Tire Rim amp Weight Rating Certification Major Components amp Weights Paint Canadian Safety Mark Canadian registry only U S EPA Noise Patent and others Note Final Stage yy Manufacturer Label to be Installed by Final Stage A Lze Manufacturer on driver s A door edge or driver s door frame Chassis Serial Number FIGURE A 2 Drivers Door and Door Frame Labels Tire Rim and Weight Rating Data Label The Tire Rim and Weight Rating Data Label is used in conjunction with the Incomplete Vehicle Certification Label on Incomplete Vehicles It contains chassis serial number and the following information e GVWR Gross Vehicle Weight Rating e GAWR FRONT and REAR Gross Axle Weight Ratings for Front and Rear Axle e TIRE RIM SIZES AND INFLATION PRESSURES Tire Rim Sizes and Cold Pressure Minimums Note GVWR is the TOTAL WEIGHT the vehicle is designed to carry This includes the weight of the empty vehicle loading platform occupants fuel and any load Incomplete Vehicle Certification Label The Incomplete Vehicle Certification Label contains the chassis VIN date of manufacture and listing of applicable motor vehicle safety standards Components and Weights Label The Major Components and Weights Label includes chassis weight and gro
140. ns 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 modified 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 flow by minimizing changes in restrictions Changes in restriction ar
141. nt to insure an even distribution of stresses Cut the ends of the insert at 45 as shown in Figure 7 2 unless the insert extends to the end of the frame 1in 205 mm 7 9 in 62 mm 200 mim A a4 15 IN 4 mm gt WELD FRAME RAILS ON THE OUTSIDE ONLY FIGURE 7 1 Detail of Frame Extension and Joint Welding 08 12 1 2 Section 7 Frame Modifications RA ni WELDED JOINT y ae TE matey 2 N 24 Inch A re Minimum REE T 61 0 m m FIGURE 7 2 Frame Insert Where possible use existing bolt holes to attach the insert to the frame Bolt holes must not be located closer to the frame flanges than the present bolt pattern If the insert is placed in a section of the main frame where few bolts are located additional bolts are required Use the fol lowing guideline for locating additional bolt holes CHANGING WHEELBASE We do not recommend modifying the wheelbase Occasionally however a chassis wheelbase will need to be reduced or lengthened When this needs to be done there are a few guidelines that should to be considered l WARNING When changing the wheelbase be sure to follow the driveline manufacturer s recom AN mendations for driveline length or angle changes Incorrectly modified drivelines can fail prematurely due to excessive vibration Before changing the wheelbase the driveline angles of the proposed wheelbase need to be examined to ensure that no harmful vibrations are
142. ons Used BACK OF CAB TO CENTERLINE OF REAR AXLE OR CENTERLINE OF TANDEMS ON TANDEM SUSPENSION FRAME RAIL OVERHANG BEHIND REAR AXLE MEASURED FROM THE CENTERLINE OF TANDEMS FRONT SUSPENSION HEIGHT REAR SUSPENSION HEIGHT WHEELBASE SIDE OF CAB BACK OF CAB TURNING RADIUS Approximate turning radius specifications 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 Rear Wheel Base ecu Steering Gear Front Tire Sievencion in Curb Turning p i Radius ft NO 00 GQ N T800 Bridgestone Tandem Dana Spicer Accuride 28487 n TONON E 12021 12K 22 5 X 8 25 eee 92 re T800SH 295 75R22 5 Spacing io 00 D NO A gt NIO N TABLE 3 2 CONTINUES ON NEXT PAGE 3 1 08 12 Section 3 Dimensions TABLE 3 2 CONTINUED Rear Wheel Base Est Curb to Steering Gear Front Tire Suerendon in Curb Turning p l Radius ft 30 T800 Dual Dana Spicer Alcoa 82365 Bridgestone Tandem 29 T800W TAS 65 D2000 20K 29 5 X 12 95 M844 52 Axle 252 T800SH 181 Dana Spicer Bridgestone Tandem W900S ee D2000 20K o M844 52 Axle Standard Track 425 65R22 5 Spacing Standard Track 425 65R22 5 Spacing NO PO PM PO O O0O NJ O gt O DND O 47 5 49 5 52 5 53 5 w 0 NIO w amp N mb oO 9 O oO h N O Mh PM DP BR DM O Nn o NM PM DP CO N
143. ort for assistance 08 12 3 18 Section 3 Dimensions AG400L TANDEM e 59 4 E 58 3 si 56 9 53 8 da 54 7 B ee E Sos gt LON gt gt a X gt aar ma 5S fi Se So gt O 7 laO ry FAVE AN ro O 4 AINA ES E F kD amp 191 OY NO AS IN ANO NN Md VE 5 A n EAA a de i EZ A fy t E A 3 AA Palo gt jo o Ao oc S__ op Lie RF 9 o o o U gt OU LO y O 0 2 Z5 a CIERNA J J 8 5 AXLE SPACING AG400L Suspensions TABLE 3 4 Rear Suspension Options Laden Ride Unladen Ride Suspension Type Axle Spacing Height Height NOTE Actual axle spacing can depart from nominal due to axle slant requirements Final axle spacing can vary by more than an inch from nominal in some cases If precise axle spacing is critical due to body installation or state local regulatory requirements please contact Kenworth Applications technical Support for assistance 3 19 08 12 Section 3 Dimensions AG400 TANDEM GELS RIDE HEIGHT AXLE SPACING AG400 Suspensions TABLE 3 5 Rear Suspension Options Laden Ride Unladen Ride Suspension Type Axle Spacing Height Height NOTE Actual axle spa
144. ose Frame i ae 2 2 Coolant mounted Blue Return o Su Valve e 3 8 Coolant Hose al Green Draw DEF Dosing Module Draw Port Return Port Injector 5 8 Coolant Hose Blue Return ENGINE 08 12 4 2 Section 4 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 relo cating 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 PA Kenworth advises against modifying the tank volume after the truck has been delivered from the factory e Total DEF capacity must meet or exceed 6 of the usable fuel capacity on the truck The calcula tion 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 retrofitting for system to function properly The use of unapproved hoses for DEF lines will void warranty and may cause engine shutdown situatio
145. over the F CAN bus The Chassis Node then activates the load requested drawing power from the chassis PDC The Chassis Node is designed to operate within specific current limits for e Headlamps e Fog lamps e Vehicle stop turn signal lamps e Trailer turn vehicle forward side facing turn signal lamps e Back Up Alarm e Windshield Washer Pump If the current limits for any of these circuits are exceeded the Chassis Node will default to a protection mode causing the lamps to not function properly but still providing sufficient lighting for safe operation of the vehicle See TABLE 6 3 for load limits The vehicle can exceed current ratings on a particular circuit in two ways e Installing too many lamps on a circuit e Using bulbs of excessive wattage The following table is a recommended guideline to avoid exceeding the current limits of the Chassis Node The Chassis Node receives power from the chassis PDC see Figure 8 24 TABLE 8 4 Chassis Node Guideline Sou eee Se er Center Name Node Circuit Node Pin Limit CN8 Back Up Alarm Windshield Washer Pump Ge C15 16 6 Electric Over Air A maximum wattage of 65W should not be exceeded for either low or high beam headlamps 8 33 08 12 Section 8 Electrical FIGURE 8 24 Chassis Power Distribution Center Mounting Above Washer Bottle 08 12 8 34 Section 8 Electrical CHASSIS LOAD CENTER DIMENSIONS The chassis load center is mounted on the firewall near the wash
146. plex as changing the wheelbase DRILLING RAILS Location and Hole Pattern If holes need to be drilled to attach anything to the rail see SECTION 6 BODY MOUNTING for more information Follow the general spacing and hole location guidelines on Page 6 5 Figure 6 6 WARNING When mounting a body to the chassis DO NOT drill holes in the upper or lower flange of the frame rail If the frame rail flanges are modified or damaged the rail could fail prema AN turely and cause an accident Mount the body using body mounting brackets or U bolts WARNING Do not drill closely spare holes in the web of the frame Hole centers of two adjacent holes should be spaced no less than twice the diameter of the largest hole Closer spacing could AN induce a failure between the holes CAUTION An appropriately sized bolt and nut must be installed and torqued properly in all unused frame holes Failure to do so could result in frame crack initiation around the hole C AUTION Use care when drilling the frame web so the wires and air lines routed inside the rail are not damaged Failure to do so could cause an inoperable electrical or air system circuit C AUTION Never use a torch to make holes in the rail Use the appropriate diameter drill bit Heat from a torch will affect the material properties of the frame rail and could result in frame rail A cracks CAUTION Hole diameter should not exceed the bolt diameter by more than 060 inches
147. r___ Gallons Length in 24 5 Diameter Tank NOTE DIMENSIONS B AND F ARE CALCULATED USING A STANDARD BATTERY BOX OPTIONAL EXTENDED BOXES WILL CHANGE DIMENSIONS B AND F 08 12 5 104 Section 5 Frame Layouts S7A Use with the following models T800SH 38 cl Seya ZS C EZY gt Y E L N Dimension B BOS to Battery Box 32 5in Dimension E BOS to DPF SCR 19 6in TABLE 5 91 T8SH 38 Dimension D Fuel Tank Size Dimension F BOS to Fuel Tank in ___ Diameter___ Gallons Length in Small Medium __ o f eo o eo os er o f ss TEA oe mas era 90 342 330 NOTE DIMENSIONS B AND D ARE CALCULATED USING A STANDARD BATTERY BOX OPTIONAL EXTENDED BOXES WILL CHANGE DIMENSIONS B AND D 5 105 08 12 Section 5 Frame Layouts 7B Use with the following models T800SH 42 cl S7 Charts EZY gt Y E L N Dimension B BOS to Battery Box 48 5in Dimension E BOS to DPF SCR 19 6in TABLE 5 92 T8SH 42 Dimension D Fuel Tank Size Dimension F BOS to Fuel Tank in ___Diameter___ Gallons Length in Small Medium 6 383o 52 o re so eo l os er eo ss or eo a ao NOTE DIMENSIONS B AND D ARE CALCULATED USING A STANDARD BATTERY BOX OPTIONAL EXTENDED BOXES WILL CHANGE DIMENSIONS B AND D
148. rame See Figure 8 32 E Min er i a a m m a ia ri 7 i E a a b FIGURE 8 32 Junction Box Circuits provided inside the junction box are e Ground Circuit code WHT1512 8AWG e Tail Lamp Trailer Circuit code YEL2421 12AWG e Marker Lamp Trailer Circuit code YEL9130 12AWG e Left Turn Trailer Circuit code YEL9111 12AWG e Stop Lamp Trailer Circuit code YEL9120 8AWG e Right Turn Trailer Circuit code YEL9112 12AWG e ABS Power switched Circuit code ORN5100 8AWG These circuits terminated with ring terminals attached to one side of a terminal strip To connect to the circuits use a ring terminal for a 10 screw 8 41 08 12 Section 8 Electrical BENDIX ELECTRONIC STABILITY PROGRAM Kenworth is offering Bendix Electronic Stability Program ESP as a pre wire option on specific Bendix approved full truck configurations Work with your local Kenworth dealer to determine if ESP is approved for your application The Kenworth pre wire option includes all the Bendix ESP system components installed and tested but because Kenworth is the incom plete vehicle manufacturer the ESP system cannot receive final verification until the body is installed ESP functionality will be disabled when the vehicle leaves the Kenworth manufacturing facility The ESP system will be programmed with con figuration specific information provided to Kenworth on the sales order this data includes the Body Type Body Builder a
149. re is at least 0 5 inches 12 7 mm clearance when the component is operating at its maximum travel limits A minimum clearance of 1 0 inchs 25 4 shall be maintained between steering axle tires and associated rotating parts in all positions and routed components such as hoses oil lines wires pipes etc 9 3 08 12 Section 9 Routing Routing of Wires and Hoses near Exhaust System TABLE 9 1 Exhaust System Clearance Shielded __ Unshielded Coolant hoses HVAC hoses and tubing and electrical wires within 15 of the turbo and or over 15 from the turbo 2 minimum 3 minimum Fuel hoses within 15 of the turbo n a 4 minimum over 15 from the turbo 2 minimum 3 minimum Fuel tanks and hydraulic tanks crossing tank 2 minimum parallel to tank 2 minimum end of tank 1 minimum aluminum ceramic coated exhaust pipe crossing tank 1 5 minimum Air hose nylon 3 minimum 8 minimum wire braid 2 minimum 3 minimum Shielded dimension Unshielded dimension Component Heatshield or blanket Exhaust system pipe muffler FIGURE 9 5 Definition of measurements 08 12 9 4 Appendix A Vehicle Identification VEHICLE IDENTIFICATION NUMBER A 17 character number numeral and letter combination forms the Vehicle Identification Number VIN which includes the Chassis Number It contains among other information the model year 4 assembly plant 5 and veh
150. rth dealer 1 1 08 12 This page intentionally left blank Section 2 Safety amp 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 dam age 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 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 AN This message will tell you what the hazard is what can happen if you don t heed the warning and how to avoid it Example WARNING Be sure to use a circuit breaker designed to meet liftgate amperage requirements An incor rectly specified circuit breaker could result in a electrical overload or fire situation Follow the liftgate installation instructions and use a circuit breaker with the recommended capacity CAUTION Signals a potentially hazardous situation which if not avoided could result in minor or mod erate injury or damage to the vehicle Example CAUTION Never use a torch to make a hole in the r
151. s 120 60 5 35 5 28 5 Diameter Tank NOTE DIMENSIONS B AND D ARE CALCULATED USING A STANDARD BATTERY BOX OPTIONAL EXTENDED BOXES WILL CHANGE DIMENSIONS B AND D 5 91 08 12 Section 5 Frame Layouts 4D Use with the following models T800B and C500B 42 S4 Charts Dimension E BOS to DPF SCR 43 7in Dimension B BOS to Battery Box 48 5in TABLE 5 78 T8B C5B 42 Fuel Tank Size Dimension F BOS to DEF Tank in BOS to Fuel Tank in DEF Tank Size __ Diameter____ Gallons Length in Small Medium Large _ 2 56 385 55 6 3o 0 22 DiameterTank 75 473 68 io a s2 E a as ee as earn ee A 54 9 wee See ane 60 5 19 5 67 2 74 5 28 7 IET 28 5 Diameter Tank ME ICC 152 E NOTE DIMENSIONS B AND D ARE CALCULATED USING A STANDARD BATTERY BOX OPTIONAL EXTENDED BOXES WILL CHANGE DIMENSIONS B AND D 08 12 5 92 Section 5 Frame Layouts S4E Use with the following models W900B 38 SHEYD 7S Dimension E BOS to DPF SCR 27 7in Dimension B BOS to Battery Box 38 6in TABLE 5 79 W900B 38 Fuel Tank Size Dimension F BOS to DEF Tank in BOS to Fuel Tank in ___ Diameter___ Gallons Length in Small_ Medium Large _ e ass 0 ICI 80 30 teo ae a as o so ess ws o EI s 120 IEC IE 28 5 Diameter Tank 120 NOTE DIMENSIONS B AND D ARE CALCULATED USIN
152. s Options that extend the wiring to the end of frame also exist however controls are not provided A 12 pin Deutsch connector Deutsch P N DT06 12SA P012 is included See Table 8 2 below for wiring harness connector pin outs If customers need PTO controls electrical connection between the PTO switch and engine recommend the factory utilize sales codes to install PTO controls Adding Electrical Options WARNING Follow the engine manufacturer s guidelines for use of these circuits See your engine manufacturer to verify that the engine is programmed correctly for the intended AN applications Failure to properly program the engine or wire these circuits could cause an accident TABLE 8 2 2010 PACCAR MX Corresponding Common Body Builder Mating View Contact Circuit No with y no Harness Circuit Cummins Number REMOTE PTO RESUME GRA3513 K982 YL REMOTE PTO SET GRA3512 K980 PK COMMON RIN 1 SWITCH GRN4500 REMOTE THROTTLE SIGNAL BLU3144 MA a MO PTO ON OFF K999 GN a 9 E AN MN E H795 PK G845 PU U O U O o IGNITION POWER ORN1299 GROUND WHT1513 AN G841 GN POWER SUPPLY 5V G844 PK O 993 BR E718 PK COMMON 12VDC ENGINE SYSTEM POWER EL3911 8 27 08 12 Section 8 Electrical FIGURE 8 20 2010 PACCAR MX Routing Diagram The location of the remote PTO throttle harness pin out connection can be found on the MX engine as noted in the diagrams below It is from this location
153. ss weight information as well as model and serial numbers for the vehicle engine transmission and axles 08 12 A 2 Appendix A Vehicle Identification Noise Emission Label The Noise Emission Label contains the chassis serial number date of manufacture and information regarding US noise emission regulations This label is not provided on Canadian registered vehicles Paint Identification Label The Paint Identification Label contains the paint colors used by the factory to paint the truck It lists frame wheels cab in terior and exterior colors This label is located either underneath the dash to the left of the steering column support inside the glovebox or on the passenger s door frame COMPONENT IDENTIFICATION Each of the following components has their own identification label Engine Identification The engine serial number is stamped on a plate located on the left front of the engine For further information please refer to the Engine Operation and Maintenance Manual included in the glove compartment of each vehicle Transmission Identification The transmission identification number is stamped on a tag affixed to the right forward side of the transmission case It includes among other specifications the transmission model serial and part number Front Axle Identification The front axle has a identification tag located on the front axle beam It includes the axle model part number and serial number 4
154. ssion related component or system 2 3 08 12 Section 2 Safety amp Compliance To ensure compliance to emissions regulations the final configuration of certain features of the completed vehicle must meet specific 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 modifications 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 filter s and fill 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 fill Modification of the pressure side secondary filter and plumbing is not allowed without engine manufacturer approval Body installation of fuel tank or routing of lines must not cause significant increase in fuel tempera
155. t CECU to the Central Instrument Clus ter e F CAN Frame Controller Area Network The F CAN provides a data link communication from the Cab Electronic Control Unit CECU to the Chassis Node to control lighting functions e CVSG Bus The CVSG bus is a private data bus used to transmit data from the Cab Electronic Control Unit CECU to the individual 2 inch gauges A series of daisy chained jumper harnesses link each gauge to one another 8 3 08 12 Section 8 Electrical Functional Description Cab Electronic Control Unit CECU The heart of the multiplexed instrumentation system is the Cab Electronic Control Unit CECU The CECU is located behind the center console See Figure 8 4 cu FIGURE 8 4 CECU Location Vehicle component inputs are sent to the CECU through the J1939 data bus or conventional wiring The CECU interprets the various inputs and monitors controls the functions for each input through the CECU software Output signals from the CECU provide data for the gauges warning lamps audible alarms and displays inside the cluster Central Instrument Cluster The central instrument cluster includes the speedometer including odometer and trip meter and tachometer including engine hour meter and outside temperature display plus pre installed standard and or editable warning light symbols called telltale cards Each telltale card slides into the left and right sides of the cluster T
156. ted check the new location of the spring hanger brackets The new holes for the spring hanger brackets must not overlap existing holes and should not come any closer than 2 inches 50 mm to existing holes Mount the suspension Brackets On the Original Rail see frame insert section amp Figures 7 1 and 7 2 Do Not Mount the Suspension Bracket On the Added Frame Rail Original Wheelbase Relocated Rear Suspension VES E Cut Frame at Rear to Shortened Wheelbase Obtain Desired Cutoff FIGURE 7 3 Comparison of Original Shortened and Extended Wheelbases 08 12 7 4 Section 7 Frame Modifications CROSSMEMBERS After changing a wheelbase an additional crossmember may be required to maintain the original frame strength The maximum allowable distance between adjacent crossmembers is 60 inches 1524 mm If the distance between adja cent crossmembers exceeds this dimension add a crossmember between them See Figure 7 4 Less Than 60 _____ C C J Before Wheelbase is Lengthened Greater Than 60 _ Co _ als Es E LITE I al il i KNIT fl Y E Additional Crossmember Co FIGURE 7 4 Crossmember Added When Distance Exceeds 60 Inches 1524 mm 7 5 08 12 Section 7 Frame Modifications WELDING Kenworth DOES NOT recommend frame welding The high heat o
157. that the optional remote throttle chassis harness is installed If engine specified from the factory does not include the factory installed body builder harness the remote PTO throttle harness is capped off h y abo a 1 5 ek ro a fe f vf d TO TEE pair SOLA TE PL AE EpL oF pj Amin HER TETE 1 1 i j I lj d SEIE tsk foe ote lt a cria Botaf s ay Coca at a peels iim EL EEIET 08 12 8 28 Section 8 Electrical REMOTE PTO THROTTLE HARNESS This option provides a connection from the engine ECU for remote control of engine throttle and PTOs Options that extend the wiring to the end of frame also exist however controls are not provided A 12 pin Deutsch connector Deutsch P N DT06 12SA P012 is included See Table 8 3 below for wiring harness connector pin outs If customers need PTO controls electrical connection between the PTO switch and engine recommend the factory utilize sales codes to install PTO controls Adding Electrical Options WARNING Follow the engine manufacturer s guidelines for use of these circuits See your engine manufacturer to verify that the engine is programmed correctly for the intended AN applications Failure to properly program the engine or wire these circuits could cause an accident TABLE 8 3 2010 Cummins ISX15 ISX12 ISL PX 8 Corresponding ae Common Body Builder Mating View Contact Circuit No with MX Harness Circuit Number
158. the positions that read fixed The wait to start and malfunction indicator lamp are part of the emission control system They must not be removed or altered In order to activate the editable lights either on the standard card or the editable card locate the wiring connections on pigtail connectors behind the right hand side gauge panel The wires will be labeled and tagged with position numbers For example for position 12 the breakout label will be yellow and have the following text TELLTALE POS 12 The color of the tag corresponds to the color of the light When these circuits are either grounded or powered the light in the dash will turn on All cards come with standard editable telltale lights even if the chassis you have was not ordered with related components The standard cards are shown above in Figure 8 9 Editable cards are also available from your local Kenworth dealer The left side editable card is shown in Figure 8 11 below FIGURE 8 11 Blank Telltale Card 08 12 8 18 Section 8 Electrical Your local Kenworth dealer will also sell a sheet of telltale light icons to install on the editable card The symbols that are available are shown in Figure 8 12 below 20005900868 ENGINE BRAKE PARK BRAKE REFRIGERATOR CHECK FLUIDS DON T SHIFT CHECK TRANSMISSION KINGPIN LOCK FUEL HEATER MESSAGE WAITING 53 1106 001 53 1106 002 53 1106 003 53 1106 004 53 1106 005 53 1106 006 53 1106 007 53 110
159. tion 6 Body Mounting Frame Sill If the body is mounted to the frame with brackets we recommend that the frame sill soacer be made from a strip of rub ber 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 7 Body Subframe Rail Spacer Chassis Frame Rail Sill lt FIGURE 6 7 Spacer Between Frame Sill and Body Rail Rubber or Plastic 01014 Brackets When mounting a body to the chassis with brackets we recommend designs that offer limited amount of relative move ment bolted securely but not too rigid Brackets should allow for slight movement between the body and the chassis For instance Figure 6 8 shows a high compression spring between the bolt and the bracket spring gt LOS Rubber Spacer a PU gt 7 5 FIGURE 6 8 High Compression Spring FIGURE 6 9 Rubber Spacer Between Brackets Between the Mounting Bolt and Upper Bracket Another possibility is mounting a rubber spacer between the brackets See Figure 6 9 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 6 5 08 12
160. tment 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 figures below If the body builder needs to modify the mirror assembly in any way it is im portant the OAT sensor stay positioned on t
161. ture Fuel hoses shall meet or exceed OEM supplied hose material construction specifications Compressed Air System The following are highlights of some of the more common or critical aspects of this system Air system modification must meet applicable FMVSS regulations Compressed Air tank may not be modified exception addition or removal of fittings 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 08 12 The following after treatment and exhaust system components may not be modified e DPF assembly e SCR Catalyst assembly e Exhaust pipes between the engine and after treatment devices DPF SCR Catalyst and between after treatment devices 2 4 Section 2 Safety amp Compliance e NO Sensor The following modifications may only be done within the guidelines of the DEF System Relocation Guide e Modifications to Diesel Exhaust Fluid DEF throttle suction or pressure lines e Modification or relocation of the DEF tan
162. ty of the existing chassis circuit before adding the body or other equipment The central electrical panel CEP has a total of 18 spare circuits 2 of which can be connected to spare relays on the CEP They include e 8spare battery circuits e 2 spare low voltage disconnect circuits e 4spare accessory circuits e 4 spare ignition circuits Note Some spare circuits may be used with factory installed options For specific chassis questions il please work with your Kenworth Dealer Spare Circuit Bullet Connectors 1 Remove the LH gauge panel above ignition key switch 2 From behind the gauge panel locate one of the 18 spare BATT LVD ACC or IGN bullet connectors not currently be ing used See Figure 8 18 l j A gt f FIGURE 8 18 Spare Bullet Connectors 8 25 08 12 Section 8 Electrical 3 Plug one end of a K333 127 2 pigtail harness into the appropriate spare circuit bullet connector See Figure 8 19 K333 64 2 Pigtail Connector 14 ga FIGURE 8 19 Spare Pigtail Connector 4 Connect the other end of the pigtail harness to the accessory 5 Install the correct rated fuse or circuit breaker for the gauge of wire going to your accessory into the fuse socket that corresponds to the spare circuit selected in step 2 08 12 8 26 Section 8 Electrical REMOTE PTO THROTTLE HARNESS This option provides a connection from the engine ECU for remote control of engine throttle and PTO
163. uster labeled SPARE RELAY 1 and SPARE RELAY 2 To connect to these relays you can use one of two harnesses also available from you local Kenworth Part Department P92 1947 1 3 for accessing the normally OPEN contact of the relay 87 or P92 1947 2 4 for accessing the normally closed contact of the relay 87a See Figure 8 17 1 Remove the LH gauge panel above ignition key switch 2 From behind the gauge panel locate one of the spare relay connectors not currently used See Figure 8 16 FIGURE 8 16 Spare Relay Connectors Plug one end of a spare relay harness P92 1947 X into the appropriate spare relay circuit connector 4 The breakout labeled SWITCH should be connected to a switch By grounding this circuit the relay will be activated coil will energize 5 The breakout labeled COMMON should be connected to power The 3 amp 4 versions allow you to connect directly to one of the 18 available spare power breakouts See ADDITIONAL SPARE CIRCUITS section 6 The breakout labeled NORMALLY OPEN or NORMALLY CLOSED is the switched power from the relay 7 Insert a K301 179 relay in the central electrical panel corresponding to the breakout use 8 23 08 12 Section 8 Electrical PEE eT EE ETE COMBOA ploii N Ah LA TN RICH A A KIN g3 kargas Pa m Fa b 406 00035 io k CRMALLT OHER DN TAG TRE A N ALEL Lr VET ORMA TIC FOR 139 449 104 1601 y
164. with the following models W900S Dimension B BOC to Battery Box 10 6in Dimension E BOC to DPF SCR 19 6in TABLE 5 48 Dimension F Fuel Tank Size Fuel Tank Length in Daycab in 00 75 Diameter 7s 5 me so ess 40 Co 42 61 as Diameter Tank 6 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 08 12 y EN a Po E LI L md Y y L N 5 52 Dimension F BOC to DEF Tank Ext Daycab in pta Tank Ext 60 82 390 tor oo gt 30 D11D Use with the following models W900B Dimension B BOC to Battery Box 10 6in Dimension E BOC to DPF SCR 19 6in TABLE 5 49 Dimension D Fuel Tank Size Dimension F BOC to DEF Tank Daycab in BOC to 7 Fuel Tank DEF Tank Size Diameter alons Length in Paveab in man e IICA EEC a oo eo 77 164 rs ara ea 164 22 Diameter Tank rs sas ams 164 so ass 102 164 Diameter 56 75 75 Tank Co 42 asa 164 28 5 Subtract 5 7 inches for the extended Daycab 5 os as 5 y EN C L md e Ya E e 39 2 39 2 39 2 39 2 39 2 39 2 39 2 39 2 39 2 39 2 39 2 39 2 39 2 39 2 39 2 39 2 39 2 39 2 Section 5 Frame Layouts Dimension D Dimension
165. x DEF Tank Size Daycab in i Ext Daycab in ENE oye 1 1 39 0 18 2 29 2 40 3 4 7 4 8 6 18 2 18 2 29 2 29 2 34 8 40 2 i 72 18 2 18 2 NOTE DIMENSION B IS CALCULATED USING A CANTILEVER SIZED BATTERY BOX OPTIONAL BOXES WILL AFFECT THIS DIMENSION 4 7 4 9 Diameter 9 4 5 55 08 12 Section 5 Frame Layouts D12B Use with the following models T800B and C500B D12 Charts Dimension E BOC to DPF SCR 19 6in TABLE 5 52 T8B C5B mencion Dimension D Dimension Dimension BOC to DEF Tank Dimension B Dimension B F1 amp F2 BOC to DEF Tank Daycab in F1 amp F2 Fuel Tank Size ees BOC to BOC to Ext Daycab in BOC to Fuel Fuel Tank B2tte Y BO DEF Tank Size Tank Ext Battery Box DEF Tank Size Daycab in Ext Daycab in aa o Sid sman Medium 75 a2 9 24 392 29 6 39 2 Diameter 3 5 1 1 Diameter 8 2 23 1 35 1 2 43 8 44 7 17 4 Y 4 a IE 02 143 63 7 2 2 5 7 2 0 24 1 39 2 6 4 S 110 15 8 120 21 4 150 35 4 75 10 4 49 03 Diameter 120 6 7 Tank 11 7 0 5 4 9 36 5 39 2 42 1 42 0 29 7 9 16 1 4 10 6 150 17 1 37 8 36 4 11 4 27 0 97 45 218 420 8 NOTE DIMENSION B IS CALCULATED USING A CANTILEVER SIZED BATTERY BOX OPTIONAL BOXES WILL AFFECT THIS DIMENSION 56 1 55 7 24 1 39 0 24 1 39 0 24 1 39 0 29 6 39 0 35 1 39 0 1
166. ystem 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 modified however using smaller diameter piping or piping with numerous bends is not recommend as the backpressure requirements of the system may be exceeded 08 12 4 10 Right Hand Under DPF and SCR on Daycab with Single Side of Cab Tailpipe FIGURE 4 11 Isometric View of Right Hand Under DPF and SCR with Single SOC Tailpipe FIGURE 4 12 Top View of Right Hand Under DPF and SCR with Single SOC Tailpipe 08 12 e E t q q E is E s E ai Lirias imis uupa atn EPer Graner AS A A ppr f E y sl all FIGURE 4 13 Right View of Right Hand Under DPF and SCR with Single SOC Tailpipe FIGURE 4 14 Back View of Right Hand Under DPF and SCR with Single SOC Tailpipe 08 12 4 12 Right Hand Under DPF and SCR on Daycab with Dual Side of Cab Tailpipes FIGURE 4 15 Isometric View of Right Hand Under DPF and SCR with Dual SOC Tailpipes ig ee es FIGURE 4 16 Top View of Right Hand Under DPF and SCR with Dual SOC Tailpipes 4 13 08 12 a atada A E ETA Fo 5 i l 3 J 1 J a I 5 ji l J J 4 i FIGURE 4 18 Back View of Right Hand Under DPF and SCR with Dual SOC Ta

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