2010 Kenworth T440/T470 Body Builder Manual

2010 Kenworth T440/T470 Body Builder Manual
2010
Kenworth T440/T470
Body Builder Manual
®
2010 Emissions
Kenworth T440/T470
Body Builder Manual
T470/T440 Body Builder
Manual Contents
SECTION 1: INTRODUCTION
1-1
SECTION 2: SAFETY AND COMPLIANCE
2-1
SAFETY SIGNALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
FEDERAL MOTOR VEHICLE SAFETYSTANDARDS COMPLIANCE . . . . . . . . . . . . 2-2
SECTION 3: DIMENSIONS
DIMENSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . .
ABBREVIATIONS . . . . . . . . . . . . . . . . . . . . . . . . .
TURNING RADIUS . . . . . . . . . . . . . . . . . . . . . . . .
KENWORTH AXLE TRACK/TIRE WIDTH SUMMARY . . . . . .
OVERALL DIMENSIONS . . . . . . . . . . . . . . . . . . . . .
T470 FIXED GRILLE HOOD W/O EXTENDED FRONT FRAME .
T440 DAYCAB . . . . . . . . . . . . . . . . . . . . . . . . . . .
T470 FIXED GRILLE HOOD WITH EXTENDED FRONT FRAME
38” AEROCAB . . . . . . . . . . . . . . . . . . . . . . . . . . .
RIDE HEIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . .
REAR SUSPENSION LAYOUTS . . . . . . . . . . . . . . . . .
REYCO 79KB SINGLE REAR AXLE . . . . . . . . . . . . . . .
REYCO 102 TANDEM REAR AXLE . . . . . . . . . . . . . . . .
NEWAY AD 123 SINGLE REAR AXLE . . . . . . . . . . . . . .
NEWAY AD 246 TANDEM SUSPENSION . . . . . . . . . . . . .
HENDRICKSON PRIMAAX TANDEM SUSPENSION . . . . . . .
HENDRICKSON HMX TANDEM SUSPENSION . . . . . . . . .
HENDRICKSON RT TANDEM SUSPENSION. . . . . . . . . . .
KENWORTH AG 380 TANDEM SUSPENSION . . . . . . . . . .
KENWORTH AG 400/460 TANDEM SUSPENSION . . . . . . . .
KENWORTH AG 400L TANDEM SUSPENSION . . . . . . . . .
KENWORTH AG 460 TANDEM SUSPENSION . . . . . . . . . .
CHALMERS 856-46 TANDEM SUSPENSION. . . . . . . . . . .
PUSHER AXLES . . . . . . . . . . . . . . . . . . . . . . . . .
PTO CLEARANCES . . . . . . . . . . . . . . . . . . . . . . . .
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3-1
. 3-1
. 3-1
. 3-1
. 3-4
. 3-5
. 3-6
. 3-7
. 3-9
. 3-10
. 3-12
. 3-14
. 3-14
. 3-15
. 3-16
. 3-17
. 3-18
. 3-19
. 3-20
. 3-22
. 3-23
. 3-24
. 3-25
. 3-26
. 3-27
. 3-32
SECTION 4: EXHAUST AND AFTERTREATMENT
EXHAUST AND AFTER-TREATMENT INFORMATION . . . . . . . . . . . .
GENERAL GUIDELINES FOR DEF SYSTEM . . . . . . . . . . . . . . . .
INSTALLATION REQUIREMENTS AND DIMENSIONS FOR DEF SYSTEM .
MEASUREMENT REFERENCE POINTS . . . . . . . . . . . . . . . . . . .
GENERAL EXHAUST INFORMATION . . . . . . . . . . . . . . . . . . . .
EXHAUST INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . .
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4-1
. 4-1
. 4-3
. 4-3
. 4-4
. 4-10
. 4-19
SECTION 5: FRAME LAYOUTS
FRAME LAYOUTS . . . . . . . . . . . .
COMMON OPTIONAL COMPONENTS .
FRAME LAYOUT INDEX. . . . . . . . .
CHARTS . . . . . . . . . . . . . . . . .
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5-1
5-1
5-2
5-4
5-5
SECTION 6: BODY MOUNTING
FRONT FRAME DIMENSIONS . . . . .
FRAME INFORMATION . . . . . . . . .
BODY MOUNTING USING BRACKETS.
MOUNTING HOLES . . . . . . . . . . .
BODY MOUNTING USING U–BOLTS . .
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6-1
6-1
6-2
6-3
6-5
6-6
12/09
iv
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T470/T440 Body Builder
Manual Contents
SECTION 7: FRAME MODIFICATIONS
FRAME MODIFICATIONS . . .
MODIFYING FRAME LENGTH
CHANGING WHEELBASE . .
CROSSMEMBERS . . . . . .
WELDING . . . . . . . . . . .
TORQUE REQUIREMENTS. .
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SECTION 8: ELECTRICAL
ELECTRICAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MULTIPLEX INSTRUMENTATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ACCESSING GAUGES AND SWITCHES . . . . . . . . . . . . . . . . . . . . . . . . . .
TELLTALE SYMBOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPARE RELAYS BODY BUILDER INSTALLED(FOR LOADS EXCEEDING 20 AMPS) . .
ADDITIONAL SPARE CIRCUITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REMOTE PTO/THROTTLE HARNESS . . . . . . . . . . . . . . . . . . . . . . . . . . .
MULTIFUNCTION TURN SIGNAL STALK, CHASSIS NODE & CHASSIS LOAD CENTER
CHASSIS LOAD CENTER DIMENSIONS. . . . . . . . . . . . . . . . . . . . . . . . . .
2010 ELECTRICAL HARDWARE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TRAILER CABLE CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FACTORY INSTALLED SNOW PLOW LIGHT WIRING . . . . . . . . . . . . . . . . . . .
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7-1
7-1
7-2
7-3
7-5
7-6
7-7
8-1
. 8-1
. 8-1
. 8-9
. 8-17
. 8-23
. 8-25
. 8-27
. 8-28
. 8-30
. 8-31
. 8-35
. 8-37
SECTION 9: ROUTING
9-1
ROUTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
ROUTING REQUIREMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2
APPENDIX A: VEHICLE IDENTIFICATION
A-1
VEHICLE IDENTIFICATION LABELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2
v
12/09
Figures
FIGURE 2-1:
FIGURE 2-2:
FIGURE 2-3:
FIGURE 2-4:
FIGURE 2-5:
FIGURE 3-1:
FIGURE 4-1:
FIGURE 4-2:
FIGURE 4-3:
FIGURE 4-4:
FIGURE 4-5:
FIGURE 4-6:
FIGURE 4-7:
FIGURE 4-8:
FIGURE 4-9:
FIGURE 4-10:
FIGURE 4-11:
FIGURE 4-12:
FIGURE 4-13:
FIGURE 4-14:
FIGURE 4-15:
FIGURE 4-16:
FIGURE 4-17:
FIGURE 4-18:
FIGURE 4-19:
FIGURE 4-20:
FIGURE 4-21:
FIGURE 4-22:
FIGURE 4-23:
FIGURE 4-24:
FIGURE 4-25:
FIGURE 5-1:
FIGURE 6-1:
FIGURE 6-2:
FIGURE 6-3:
FIGURE 6-4:
FIGURE 6-5:
12/09
INCOMPLETE VEHICLE CERTIFICATION DOCUMENT . . . . . . . . . . 2-2
LOCATIONS OF CERTIFICATION LABELS . . . . . . . . . . . . . . . . . 2-2
WEST COAST MIRROR OAT SENSOR, . . . . . . . . . . . . . . . . . . . 2-6
AERODYNAMIC MIRROR OAT SENSOR LOCATION. . . . . . . . . . . . 2-7
INSTRUMENT CLUSTER FOR T440/T470 USED WITH
EPA2010 EMISSION COMPLIANT ENGINES. . . . . . . . . . . . . . . . 2-7
PROSPECTOR TURN CIRCLE ANALYSIS . . . . . . . . . . . . . . . . . 3-3
MEASUREMENT LOCATION OF DEF SUPPLY MODULE (PUMP). . . . . 4-4
MEASUREMENT LOCATION OF DEF DOSING MODULE (INJECTOR) . . 4-4
ORIENTATION OF DOSING MODULE . . . . . . . . . . . . . . . . . . . 4-5
RH UNDER CAB EXHAUST WITH SMALL, MEDIUM, OR LARGE TANKS. 4-5
VERTICAL EXHAUST WITH SMALL, MEDIUM, OR LARGE TANKS. . . . . 4-6
RH UNDER CAB EXHAUST WITH CLEAR BACK OF CAB TANK. . . . . . 4-7
VERTICAL WITH CLEAR BACK OF CAB TANK . . . . . . . . . . . . . . . 4-8
ROUTING DEF LINES AND DEF TRAP . . . . . . . . . . . . . . . . . . . 4-9
SUPPLY MODULE ALLOWED CLOCKING ANGLES . . . . . . . . . . . . 4-9
ISOMETRIC VIEW OF RIGHT HAND UNDER DPF AND SCR
WITH SINGLE SOC TAILPIPE . . . . . . . . . . . . . . . . . . . . . . . . 4-11
TOP VIEW OF RIGHT HAND UNDER DPF AND SCR
WITH SINGLE SOC TAILPIPE . . . . . . . . . . . . . . . . . . . . . . . . 4-11
RIGHT VIEW OF RIGHT HAND UNDER DPF AND SCR
WITH SINGLE SOC TAILPIPE . . . . . . . . . . . . . . . . . . . . . . . . 4-12
BACK VIEW OF RIGHT HAND UNDER DPF AND SCR
WITH SINGLE SOC TAILPIPE . . . . . . . . . . . . . . . . . . . . . . . . 4-12
ISOMETRIC VIEW OF RIGHT HAND UNDER DPF AND SCR
WITH SINGLE BACK OF CAB TAILPIPE . . . . . . . . . . . . . . . . . . 4-13
TOP VIEW OF RIGHT HAND UNDER DPF AND SCR
WITH SINGLE BACK OF CAB TAILPIPE . . . . . . . . . . . . . . . . . . 4-13
RIGHT VIEW OF RIGHT HAND UNDER DPF AND SCR
WITH SINGLE BACK OF CAB TAILPIPE . . . . . . . . . . . . . . . . . . 4-14
BACK VIEW OF RIGHT HAND UNDER DPF AND SCR
WITH SINGLE BACK OF CAB TAILPIPE . . . . . . . . . . . . . . . . . . 4-14
ISOMETRIC VIEW OF VERTICAL DPF AND SCR . . . . . . . . . . . . . 4-15
TOP VIEW OF VERTICAL DPF AND SCR . . . . . . . . . . . . . . . . . 4-15
RIGHT VIEW OF VERTICAL DPF AND SCR . . . . . . . . . . . . . . . . 4-16
BACK VIEW OF VERTICAL DPF AND SCR . . . . . . . . . . . . . . . . 4-16
ISOMETRIC VIEW OF RIGHT HAND UNDER DPF AND SCR ON
AEROCAB WITH SINGLE SOC TAILPIPE . . . . . . . . . . . . . . . . . . 4-17
TOP VIEW OF RIGHT HAND UNDER DPF AND SCR ON
AEROCAB WITH SINGLE SOC TAILPIPE . . . . . . . . . . . . . . . . . . 4-17
RIGHT VIEW OF RIGHT HAND UNDER DPF AND SCR ON
AEROCAB WITH SINGLE SOC TAILPIPE . . . . . . . . . . . . . . . . . . 4-17
BACK VIEW OF RIGHT HAND UNDER DPF AND SCR ON
AEROCAB WITH SINGLE SOC TAILPIPE . . . . . . . . . . . . . . . . . . 4-18
DEF TANK DIMENSIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
MINIMUM CLEARANCE BETWEEN TOP OF REAR TIRES
AND BODY STRUCTURE OVERHANG.. . . . . . . . . . . . . . . . . . . 6-2
MINIMUM BACK OF CAB CLEARANCE . . . . . . . . . . . . . . . . . . 6-3
SPACER BETWEEN FRAME SILL AND BODY RAIL . . . . . . . . . . . . 6-4
HIGH COMPRESSION SPRING . . . . . . . . . . . . . . . . . . . . . . . 6-4
RUBBER SPACER BETWEEN BRACKETS BETWEEN THE
MOUNTING BOLT AND UPPER BRACKET . . . . . . . . . . . . . . . . . 6-4
vi
Figures
FIGURE 6-6:
FIGURE 6-7:
FIGURE 6-8:
FIGURE 6-9:
FIGURE 7-1:
FIGURE 7-2:
FIGURE 7-3:
FIGURE 7-4:
FIGURE 8-1:
FIGURE 8-2:
FIGURE 8-3:
FIGURE 8-4:
FIGURE 8-5:
FIGURE 8-6:
FIGURE 8-7:
FIGURE 8-8:
FIGURE 8-9:
FIGURE 8-10:
FIGURE 8-11:
FIGURE 8-12:
FIGURE 8-13:
FIGURE 8-14:
FIGURE 8-15:
FIGURE 8-16:
FIGURE 8-17:
FIGURE 8-18:
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-4:
FIGURE A-5:
CROSSMEMBER-GUSSET HOLE PATTERN REQUIREMENTS.. . . . . . 6-5
ACCEPTABLE U-BOLT MOUNTING WITH WOOD AND
FABRICATED SPACERS . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
CLEARANCE SPACE FOR AIR LINES AND CABLES . . . . . . . . . . . 6-7
EXAMPLE OF FISHPLATE BRACKET AT REAR END OF BODY,
USED WITH U-BOLTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
DETAIL OF FRAME EXTENSION AND JOINT WELDING. . . . . . . . . . 7-2
FRAME INSERT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
COMPARISON OF ORIGINAL, SHORTENED, AND
EXTENDED WHEELBASES.. . . . . . . . . . . . . . . . . . . . . . . . . 7-4
CROSSMEMBER ADDED WHEN DISTANCE
EXCEEDS 60 INCHES (1524 MM). . . . . . . . . . . . . . . . . . . . . . 7-5
KENWORTH T440/T470 DASH . . . . . . . . . . . . . . . . . . . . . . . 8-2
DIESEL EXHAUST FLUID GAUGE . . . . . . . . . . . . . . . . . . . . . 8-2
MULTIPLEXED INSTRUMENTATION BLOCK DIAGRAM.. . . . . . . . . . 8-3
CECU LOCATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
INSTRUMENT CLUSTER COMPONENTS . . . . . . . . . . . . . . . . . 8-5
CVSG GAUGES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6
FIREWALL AIR JUNCTION BLOCK (VIEW FROM INSIDE OF CAB) . . . . 8-7
AIR FILTER RESTRICTION SENSOR ON FIREWALL
AIR JUNCTION BLOCK (VIEW FROM ENGINE) . . . . . . . . . . . . . . 8-7
FUEL FILTER RESTRICTION PRESSURE GAUGE SENSOR LOCATION
(TYPICAL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8
TELLTALE SYMBOL STANDARD CARDS . . . . . . . . . . . . . . . . . . 8-17
BLANK TELLTALE CARD . . . . . . . . . . . . . . . . . . . . . . . . . . 8-18
TELLTALE ICONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-19
KENWORTH SPARE SWITCHES . . . . . . . . . . . . . . . . . . . . . . 8-20
SPARE SWITCH HARNESS . . . . . . . . . . . . . . . . . . . . . . . . . 8-21
SPECIALTY SWITCHES . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-22
SPARE RELAY CONNECTORS . . . . . . . . . . . . . . . . . . . . . . . 8-23
SPARE RELAY HARNESSES . . . . . . . . . . . . . . . . . . . . . . . . 8-24
SPARE BULLET CONNECTORS . . . . . . . . . . . . . . . . . . . . . . 8-25
SPARE PIGTAIL CONNECTOR . . . . . . . . . . . . . . . . . . . . . . . 8-26
CHASSIS POWER DISTRIBUTION CENTER DIMENSIONS . . . . . . . . 8-30
DAYCAB HARDWARE LOCATIONS . . . . . . . . . . . . . . . . . . . . . 8-31
AEROCAB STANDARD HARDWARE LOCATIONS . . . . . . . . . . . . . 8-31
CHASSIS NODE DIMENSIONS . . . . . . . . . . . . . . . . . . . . . . . 8-32
SAE J560 TRAILER CONNECTOR . . . . . . . . . . . . . . . . . . . . . . .
ISO 3731 TRAILER CONNECTOR . . . . . . . . . . . . . . . . . . . . . 8-35
JUNCTION BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-36
SNOW PLOW ICON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-37
CIRCUIT LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-37
CLAMP AND BUTTERFLY CLAMP . . . . . . . . . . . . . . . . . . . . . 9-1
BUTTERFLY TIE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
TIE STRAP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
HEAVY DUTY (HD) MOUNT.. . . . . . . . . . . . . . . . . . . . . . . . . 9-2
DEFINITION OF MEASUREMENTS. . . . . . . . . . . . . . . . . . . . . 9-4
VEHICLE IDENTIFICATION NUMBER (VIN). . . . . . . . . . . . . . . . . A-1
DRIVERS DOOR AND DOOR FRAME LABELS . . . . . . . . . . . . . . A-2
FRONT AXLE IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . A-4
REAR AXLE IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . A-4
vii
12/09
Tables
TABLE 3-1:
TABLE 3-2:
TABLE 3-3:
TABLE 3-4:
TABLE 3-5:
TABLE 3-6:
TABLE 3-7:
TABLE 3-8:
TABLE 3-9:
TABLE 3-10:
TABLE 3-11:
TABLE 3-13:
TABLE 3-14:
TABLE 3-15:
TABLE 3-16:
TABLE 3-17:
TABLE 3-18:
TABLE 3-19:
TABLE 3-20:
TABLE 5-1:
TABLE 5-2:
TABLE 5-3:
TABLE 5-4:
TABLE 6-1:
TABLE 6-2:
TABLE 7-1:
TABLE 7-2:
TABLE 8-1:
TABLE 8-3:
TABLE 8-4:
TABLE 8-6:
TABLE 8-7:
TABLE 9-1:
TABLE A-1:
12/09
ABBREVIATIONS USED . . . . . . . . . . . . . . . .
TURNING RADIUS . . . . . . . . . . . . . . . . . . .
AXLE TRACK. . . . . . . . . . . . . . . . . . . . . .
RIDE HEIGHTS IN INCHES . . . . . . . . . . . . . .
REAR SUSPENSION OPTIONS . . . . . . . . . . . .
REAR SUSPENSION OPTIONS . . . . . . . . . . . .
REAR SUSPENSION OPTIONS . . . . . . . . . . . .
REAR SUSPENSION OPTIONS . . . . . . . . . . . .
REAR SUSPENSION OPTIONS . . . . . . . . . . . .
REAR SUSPENSION OPTIONS . . . . . . . . . . . .
REAR SUSPENSION OPTIONS . . . . . . . . . . . .
REAR SUSPENSION OPTIONS . . . . . . . . . . . .
REAR SUSPENSION OPTIONS . . . . . . . . . . . .
REAR SUSPENSION OPTIONS . . . . . . . . . . . .
REAR SUSPENSION OPTIONS . . . . . . . . . . . .
REAR SUSPENSION OPTIONS . . . . . . . . . . . .
GROUND CLEARANCE FOR FUEL TANKS. . . . . .
GROUND CLEARANCE FOR BATTERY BOXES . . .
GROUND CLEARANCE FOR BATTERY BOXES . . .
ABBREVIATIONS . . . . . . . . . . . . . . . . . . .
FUEL TANK OVERALL LENGTH (IN) . . . . . . . . .
BATTERY BOX CENTERFRAME LENGTHS (IN) . . .
DEF TANKS SYSTEMS . . . . . . . . . . . . . . . .
SINGLE STEEL RAILS . . . . . . . . . . . . . . . . .
INSERTED STEEL RAILS . . . . . . . . . . . . . . .
CUSTOMARY GRADE 8 UNF OR UNC. . . . . . . . .
U.S. CUSTOMARY – GRADE 8. METRIC CLASS 10.9
TELLTALES POSITION AND COLOR . . . . . . . . .
CHASSIS NODE GUIDELINE . . . . . . . . . . . . .
WIRE NUMBER GENERAL CATEGORIES . . . . . .
SAE J560 CONNECTOR . . . . . . . . . . . . . . . .
ISO 3731 CONNECTOR . . . . . . . . . . . . . . . .
EXHAUST – SYSTEM CLEARANCE . . . . . . . . .
MODEL YEAR (CODE) DESIGNATIONS. . . . . . . .
viii
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. 3-1
. 3-1
. 3-4
. 3-12
. 3-14
. 3-15
. 3-16
. 3-17
. 3-18
. 3-19
. 3-20
. 3-22
. 3-23
. 3-24
. 3-25
. 3-26
. 3-29
. 3-30
. 3-31
. 5-1
. 5-2
. 5-2
. 5-3
. 6-2
. 6-2
. 7-7
. 7-7
. 8-18
. 8-28
. 8-33
. 8-34
. 8-35
. 9-4
. A-1
Section 1
Introduction
This manual was created to provide body builders with appropriate information and guidelines
useful in the body planning and installation process. This information will be helpful when installing
bodies or other associated equipment.
This manual contains appropriate dimensional information, guidelines for mounting bodies, guidelines for modifying frames, electrical wiring information, and other information useful in the body
installation process. This manual is 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 specifications or products at any time without prior notice. It is the responsibility of the user to ensure
that he is working with the latest released information. Check Kenworth.com for the latest released
version.
If you require additional information or reference materials, please contact your local Kenworth
dealer.
1-1
12/09
Section 2
Safety & Compliance
SAFETY SIGNALS
We’ve put a number of alerting messages in this book. Please read and follow them. They are there for your protection
and information. These alerting messages can help you avoid injury to yourself or others and help prevent costly damage to the vehicle.
Key symbols and “signal words” are used to indicate what kind of message is going to follow. Pay special attention to
comments prefaced by “WARNING”, “CAUTION”, and “NOTE.” Please don’t ignore any of these alerts.
Warnings, cautions, and notes
WARNING
When you see this word and symbol, the message that follows is especially vital. It signals a
potentially hazardous situation which, if not avoided, could result in death or serious injury.
This message will tell you what the hazard is, what can happen if you don’t heed the warning,
and how to avoid it.
Example:
WARNING! Be sure to use a circuit breaker designed to meet liftgate amperage requirements. An incorrectly 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 moderate injury or damage to the vehicle.
Example:
CAUTION: Never use a torch to make a hole in the rail. Use the appropriate drill bit.
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.
NOTE
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.
2-1
12/09
Section 2
Safety & Compliance
FEDERAL MOTOR VEHICLE SAFETY
STANDARDS COMPLIANCE
As an Original Equipment Manufacturer (OEM), Kenworth Truck Co. ensures that our products comply with all applicable
U.S. or Canadian Federal Motor Vehicle Safety Standards. However, the fact that this vehicle has no 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 side 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
of the components or systems covered by these regulations, it is your responsibility as the Intermediate or
Final Stage Manufacturer to ensure that the complete vehicle is in compliance with the particular regulations upon completion of the modifications.
U.S. EPA Noise Label (U.S. registered vehicles only)
Tire, Rim and
Weight Rating
Data label
Final Stage Manufacturer
Label to be Installed by
Final Stage Manufacturer
Chassis Serial
Number
Safety Mark (Canadian
Registry Only)
FIGURE 2-1. Incomplete Vehicle Certification Document
Incomplete Vehicle
Certification Label
Major Components and
Weights Label
FIGURE 2-2. Locations of Certification Labels - Driver’s Door and Frame
As the Intermediate or Final Stage Manufacturer, you should retain the Incomplete Vehicle Document for your records. In
addition, you should record and retain the manufacturer and serial number of the tires on the vehicle. Upon completion
of the vehicle (installation of the body and any other 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 manufacturer 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 Theft Prevention Standards if applicable] in effect in (month, year).”
12/09
2-2
Section 2
Safety & 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 0N5
(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
with these emissions control components/systems* is against the rules that are established by the
U.S Code of Federal Regulations, Environment Canada Regulations and California Air Resources
Board (CARB). These emissions control components/systems* may only be replaced with original
equipment parts.
Modifying (i.e. altering, substituting, relocating) any of the emissions control components/systems defined above will affect the noise and emissions performance/certification. 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.
•
For Cummins Contact: Please call 1-800-DIESELS or contact your local Cummins Distributor Reference
AEB 21.102.
It is possible to relocate the DEF tank, however the relocation requirements need to be followed. Any variance from the
relocation requirements may cause the emissions control components/systems to operate improperly potentially resulting
in engine de-rate. See page 4-3 for relocation requirements.
NOTE
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
component that may increase exhaust emissions or interfere with the proper performance of the
OBD system itself.
The OBD system consists of computer program on one or more of the vehicle’s Electronic Control
Units (ECUs). This program uses information from the control system and from additional sensors
to detect malfunctions. When a malfunction is detected, information is stored in the ECU(s) for
diagnostic purposes. A Malfunction Indicator Light (MIL) is illuminated in the dash to alert the
driver of the need for service of an emission-related component or system.
2-3
12/09
Section 2
Safety & 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 modifications 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 temperature
•
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.
•
The following after-treatment and exhaust system components may not be modified:
•
•
•
12/09
DPF assembly
SCR Catalyst assembly
Exhaust pipes between the engine and after-treatment devices (DPF, SCR Catalyst) and between
after-treatment devices
2-4
Section 2
Safety & Compliance
•
•
NOx Sensor
The following modifications may only be done within the guidelines of the “DEF System Relocation Guide.”
•
•
•
Modifications to Diesel Exhaust Fluid (DEF) throttle, suction, or pressure lines
Modification or relocation of the DEF tank
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
•
Exhaust pipes between the engine and after-treatment devices or between after-treatment devices may not be
modified or replaced
•
The DPF, the SCR catalyst, or their mounting may not be modified
•
The NOx sensor may not been relocated or altered in any way
•
Exhaust pipes used for tailpipes/stacks must be properly sized, and must prevent water from entering the
exhaust system
•
Ensure adequate clearance between the exhaust and body panels, hoses, and wire harnesses
•
The body in the vicinity of the DPF must be able to withstand temperatures up to 400°C (750°F)
•
Do not add thermal insulation to the external surface of the DPF
•
The SCR water drain hole may not be blocked
•
Allow adequate clearance (25mm (1 inch)) for servicing the DPF sensors, wiring, and clamped joints
•
Drainage may not come in contact with the DPF, SCR catalyst, sensors or wiring
•
Allow 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 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, and may void vehicle warranty
•
Coolant level sensor tampering will void warranty
•
When installing auxiliary equipment in front of the vehicle, or additional heat exchangers, ensure that
adequate air flow is available to the vehicle cooling system. Refer to engine manufacturer application
guidelines for further detail
•
When installing FEPTO drivelines, the lower radiator anti-recirculation seal must be retained with FEPTO
driveline clearance modification only
2-5
12/09
Section 2
Safety & Compliance
•
Changes made to cooling fan circuit and controls are not allowed, with the exception of AC minimum fan on
time parameter
•
See owner’s manual for appropriate winter front usage
Electrical System
The following are highlights of some of the more common or critical aspects of this system.
•
Electrical harnesses providing battery power and electronic control signals to engine and emissions control/
vehicle OBD components including datalinks may not be spliced. These emissions control/vehicle OBD
components include the following:
•
•
•
throttle pedal
vehicle speed sensor
after-treatment wiring
•
If the alternator or battery is substituted, it must meet the requirements of the engine manufacture’s guidelines. This includes alternator ground voltage drop and alternator ground cable effectiveness. See the engine
manufacture’s guidelines for recommended test procedure. Additionally the maximum voltage differential and
the peak-peak voltage differential between the engine ECM block ground stud and battery negative terminal
may not exceed 500 mV under any combination of loads or operating conditions.
•
Installation of aftermarket transfer-cases must address the vehicle speed sensor position. The standard position of the speed sensor is at the transmission tail shaft. When a transfer-case is added it is best to relocate
the sensor to the axle side output shaft of the transfer-case. This is typically accomplished by adding a tone
wheel into the driveline yoke assembly.
•
Wiring extensions for the after-treatment wiring are available for relocating the DEF tank from your dealer via
Paccar Parts. For relocation of DEF tank, refer to the after-treatment section of this manual.
•
The emission system requires an accurate Outside Air Temperature (OAT) reading in order to properly run
its control algorithms. The OAT sensor is located in the driver’s side mirror assembly on Kenworth trucks and
is shown in the figures below. If the body builder needs to modify the mirror assembly in any way, it is important the OAT sensor stay positioned on the mirror assembly. Running the vehicle without the OAT sensor
connected will cause the MIL lamp to illuminate. If needed, a replacement sensor can be ordered from your
Kenworth dealer.
FIGURE 2-3: West Coast Mirror OAT sensor, located in overmold on mirror harness.
12/09
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
or 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 Organization). 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.
FIGURE 2-5: Instrument Cluster for T440/T470 used with EPA2010 Emission compliant
engines. The Check Engine lamp is symbol 21 and the MIL is symbol 8.
•
In addition to the sensors and lamps above, the emission system also depends on signals from the exhaust
DPF (Diesel Particulate Filter), SCR (Selective Catalytic Reduction), and NOx sensor. Wiring between these
devices, the Dosing Control Unit (DCU) and engine ECM should not be tampered with or altered in any way.
2-7
12/09
Section 2
Safety & Compliance
Air Intake System
The following are highlights of some of the more common or critical aspects of this system.
•
The air intake screen may not be blocked, either fully or partially
•
Modification to the air intake system may not restrict airflow. For example, pipe diameter may not be reduced
•
All sensors must be retained in existing locations
•
To retain system seal, proper clamp torque must be used. Refer to service manual for proper clamp torque
Charge Air Cooler System
The following are highlights of some of the more common or critical aspects of this system.
12/09
•
The Charge Air Cooler may not be modified
•
The installation of engine overspeed shutdown devices must not introduce restriction in the intake system
•
All plumbing associated with the charge air cooler may not be modified
2-8
Section 3
Dimensions
DIMENSIONS
This section has been designed to provide enough information to successfully layout chassis in the body planning
process. Optional equipment may not be depicted. Please contact your local Kenworth dealer if more dimensional
information is desired.
ABBREVIATIONS
Throughout this section, and in other sections as well, abbreviations are used to describe certain characteristics on your
vehicle. The chart below lists the abbreviated terms used.
TABLE 3-1. Abbreviations Used
AF
AFTER FRAME – FRAME RAIL OVERHANG BEHIND REAR AXLE OR MEASURED FROM CENTERLINE OF TANDEM
CA
BACK OF CAB TO CENTERLINE OF REAR AXLE OR CENTERLINE OF TANDEMS ON TANDEM SUSPENSION
EOF
FRAME RAIL OVERHANG BEHIND REAR AXLE – MEASURED FROM THE CENTERLINE OF TANDEMS
FS
FRONT SUSPENSION HEIGHT
RS
REAR SUSPENSION HEIGHT
WB
WHEELBASE
SOC
SIDE OF CAB
BOC
BACK OF CAB
TURNING RADIUS
Approximate turning radius 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
Model
T440/T470
Steering Gear
Single
TAS 65
Front Axle
Dana Spicer
E-1202I 12K
Front Wheel
Front Tire
Accuride 28487
22.5 X 8.25
Bridgestone
R287
295/75R22.5
Rear
Suspension
Tandem
52” Axle
Spacing
Wheel Base
Est Curb to
Curb Turning
Radius (ft)
181
28
193
29.5
201
30.5
213
32
220
33
232
34.5
240
35.5
252
37
260
38
272
39.5
280
40.5
291
42
303
43.5
323
46
331
47
TABLE 3-2 CONTINUES ON NEXT PAGE…
3-1
12/09
Section 3
Dimensions
TABLE 3-2 CONTINUED
Model
T440/T470
12/09
Steering Gear
Dual
TAS 65
Front Axle
Dana Spicer
D2000 20K
Standard Track
Front Wheel
Front Tire
Bridgestone
M844
425/65R22.5
Alcoa 82365
22.5 X 12.25
3-2
Rear
Suspension
Tandem
52” Axle
Spacing
Wheel Base
Est Curb to
Curb Turning
Radius (ft)
181
31.5
193
33.5
201
34.5
213
36.5
220
37.5
232
39
240
40
252
42
260
43
272
45
280
46
291
47.5
303
49.5
323
52.5
331
53.5
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.
T470
T470
FIGURE 3-1. Prospector Turn Circle Analysis
Please consult your local Kenworth Dealer for this information, as it is chassis specific.
3-3
12/09
Section 3
Dimensions
AXLE TRACK AND TIRE WIDTH
The dimensions provided in this section are representative of some typical product combinations. The purpose of this section is to demonstrate some of the typical dimensions.
•
Axle Track: The distance between the dual tire centerlines on a dual tire arrangement or the distance between the tire
centerlines on a single tire arrangement.
•
Width: The distance over the outermost tire sidewall to sidewall.
These dimensions may be significant to the following:
•
Appearance relative to other tires and chassis mounted equipment.
•
Load carrying capacity. Different wheel disc offset can have a positive or negative impact on the axle carrying capacity of the axle.
KENWORTH AXLE TRACK/TIRE WIDTH SUMMARY
TABLE 3-3. Axle Track
Axle - Drive
Wheel
Tire
Configuration
Track Dim ”A”
Overall Width Dim ”B”
Dana Spicer D46-170(H)(P)
46K Dual
Alcoa 88364
22.5X8.25
BR M726EL
11R22.5
4-4
73.3”
97.8”
Dana Spicer D46-170(H)(P)
46K Dual
Alcoa 98364
24.5X8.25
BR M726EL
11R24.5
4-4
73.6”
98.0”
Dana Spicer D46-170W(H)(P)
46K Dual Wide Track
Alcoa 88364
22.5X8.25
BR M726EL
11R22.5
4-4
79.2”
103.7”
Dana Spicer D46-170W(H)(P)
46K Dual Wide Track
Alcoa 98364
24.5X8.25
BR M726EL
11R24.5
4-4
79.5”
103.9”
Dana Spicer D46-170(H)(P)
46K Dual
Alcoa 82360
22.5X12.25
BR M844F
425/65R22.5
2-4
72.7”
88.9”
Dana Spicer D46-170W(H)(P)
46K Dual Wide Track
Alcoa 82360
22.5X12.25
BR M844F
425/65R22.5
2-4
78.7”
94.9”
Axle - Steer
Wheel
Tire
Brake Drum Type
Track Dim ”A”
Overall Width Dim ”B”
Dana Spicer E-1322I 13.2K
Alcoa 98364
24.5X8.25
BR R250F
11R24.5
Cast
80.2”
91.0”
Dana Spicer E-1322W 13.2K
Alcoa 98364
24.5X8.25
BR R250F
11R24.5
Cast
82.2”
93.0”
Dana Spicer D2000 20K
Alcoa 82365
24.5X12.25
BR M844F
425/65R22.5
Cast
86.5”
102.7”
Dana Spicer D2000 20K
Alcoa 82364
24.5X12.25
BR M844F
425/65R22.5
Cast
82.6”
98.8”
Axle - Pusher Non-Steerable
Wheel
Tire
Wheel Orientation
“Track Dim ”A”
“Overall Width Dim ”B”
NS PSHR: WCAL ATLAS
Std Track (72.5”) 16K GAWR
Alcoa 82365
24.5X12.25
BR M844F
425/65R22.5
DefaultSame as RR
79.4”
95.6”
NS PSHR: WCAL ATLAS
Wide Track (77.5”)
“Alcoa 82365
24.5X12.25
BR M844F
425/65R22.5
Option
Same as FR
71.1”
87.3”
12/09
3-4
Section 3
Dimensions
OVERALL DIMENSIONS
This section includes drawings and charts. The Extended Day Cab is also included.
On the pages that follow, detail drawings show particular views of each vehicle, all dimensions are in inches (in). They
illustrate important measurements critical to designing bodies of all types. See the “Contents” at the beginning of the
manual to locate the drawing that you need.
Note: To determine overall height please locate the chart Table 3-4 on page 3-8 and 3-9 and add that value to the height.
All heights are given from the bottom of the frame rail.
Kenworth also offers .dxf 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.
3-5
12/09
Section 3
Dimensions
T470 FIXED GRILLE HOOD W/O EXTENDED FRONT FRAME
The following drawings are shown with standard chassis components and the T470 fixed grille hood.
12/09
3-6
Section 3
Dimensions
T440 DAYCAB
The following drawings are shown with standard chassis components and the T440 daycab.
3-7
12/09
Section 3
Dimensions
T440 EXTENDED DAYCAB
The following drawings are shown with standard chassis components and the T440 extended daycab.
12/09
3-8
Section 3
Dimensions
T470 FIXED GRILLE HOOD WITH EXTENDED FRONT FRAME
The following drawings are of a T470 fixed grille hood with the optional extended front frame. These extended frame rails
can be used with or without FEPTO adapters.
3-9
12/09
Section 3
Dimensions
38” AEROCAB
The 38” Aerocab is shown on a standard T440 chassis. It is important to note that the 38” will increase any of the models
bumper to back of cab dimension and front axle to back of cab dimension by 28”. The height (from the bottom of the frame
rail) will be 93.2” across the models.
12/09
3-10
Section 3
Dimensions
EXTENDED DAY CAB
It is important to note that the Extended Day Cab will increase any of the models bumper to back of cab dimension and
front axle to back of cab dimension by 5.7”. The height (from the bottom of the frame rail) will be 86.9”. Below drawings
shown with T470 fixed grille hood.
Suspension heights are measured from the centerlines of the axle spindle to the bottom of the frame rail. Add the tire
radius dimension to determine overall height to the bottom of the frame rail. Note: The frame rail height itself will not affect
the overall cab height as all components are located from the bottom of the frame rail.
3-11
12/09
Section 3
Dimensions
RIDE HEIGHTS
The front (FS) and rear (RS) suspension ride heights are provided as a basic tool to determine the overall height of the
cab, height of exhaust components, and frame heights. The heights are all calculated from the centerlines of the axles,
please be sure to include the tire radius dimension to determine overall height. Note: the frame rail height itself will not
affect the overall height as all components are located from the bottom of the frame rail. Ride height information is also
available in Prospector.
TABLE 3-4. Ride Heights In Inches
To calculate Frame Heights use the following formula:
Front Frame Height = FS + 1/2 Front Tire Diameter
Rear Frame Height = RS + 1/2 Rear Tire Diameter
Front Suspension
Laden
Unladen
12K Taperleaf
10.3”
11.5”
13.2K Taperleaf
10.3”
11.5”
14.6K Taperleaf
10.3”
11.7”
16K Taperleaf
10.6”
12.3”
20K Taperleaf
10.4”
11.9”
22K Multi-stage Taperleaf
10.7”
12.7”
Kenworth AG380 38K Rating
8.5”
8.5”
Kenworth AG400L 40K Rating
8.5”
8.5”
Kenworth AG400 40K Rating
9.0”
9.0”
Kenworth AG460 46K Rating
10.5”
10.5”
Reyco 79KB 21K Rating
6.6”
9.0”
Reyco 79KB 23K Rating
8.3”
10.8”
Rear Suspensions
12/09
3-12
Section 3
Dimensions
Reyco 79KB 26K Rating
8.2”
11.3”
Reyco 102 38K Rating
9.2”
10.8”
Reyco 102 40 K Rating
9.2”
10.8”
Chalmers 854-40-L-HS 40K Rating
9.6”
11.0”
Chalmers 854-40-H-HS 40K Rating
10.9”
12.4”
Chalmers 854-46-L 46K Rating
8.9”
11.3”
Chalmers 854-46-L-HS 46K Rating
9.6”
11.3”
Chalmers 854-46-H 46K Rating
10.1”
12.4”
Chalmers 854-46-H-HS 46K Rating
10.9”
12.5”
Chalmers 860-46-H-HS 46K Rating
10.9”
12.5”
Chalmers 872-46-H-HS 46K Rating
11.0”
12.5”
Hendrickson HAS 230 23K Rating
10.0”
10.0”
Hend HMX460 16.5” Saddle 46K Rating
9.5”
10.6”
Hend HMX460 17.5” Saddle 46K Rating
10.5”
11.6”
Hend HMX460 18.5” Saddle 46K Rating
11.5”
12.6”
Hendrickson Primaax 46K Rating
10.0”
10.0”
Hendrickson RT403 40K Rating
9.7”
10.7”
Hendrickson RT463 6.0” Saddle 46K Rating
10.0”
11.1”
Hendrickson RT463 7.19 Saddle 46K Rating
11.2”
12.5”
Hendrickson RT463 7.94 Saddle 46K Rating
11.9”
13.3”
Neway AD123 23K Rating
10.0”
10.0”
Neway AD126 26K Rating
10.0”
10.0”
Neway AD246 46K Rating
10.0”
10.0”
3-13
12/09
Section 3
Dimensions
REAR SUSPENSION LAYOUTS
The rear suspension layouts are provided as a tool to help layout bodies prior to arrival. Be sure to check the axle spacing
that is shown, as alternate spacings may exist and could change some of the dimensions. The dimensions shown below
are the most typical installations, in special cases some hole locations will move. If you are planning on using the holes
shown for your body installation, please 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 5-1 and
5-2 on page 5-7.
It would be a good idea in this case to order the frame layout of your chassis along with your truck order. This can be done
on any Kenworth truck, and will be provided 4 weeks ahead of the build schedule.
If there are hole locations that are not detailed please work with your local Kenworth Dealer to request that information.
Additionally optional axle spacings are shown in the charts, if you would like details on the frame drilling with optional
spacings, please contact your local Kenworth dealer.
12/09
3-14
Section 3
Dimensions
KENWORTH AG 380 TANDEM SUSPENSION
Shown with a 52” Axle Spacing
Kenworth AG 380 Suspension Data
TABLE 3-5. Rear Suspension Options
Suspension Type
AG 380
Rating
Axle Spacing
Laden Ride
Height
Unladen Ride
Height
38K
52”
8.5”
8.5”
3-15
12/09
Section 3
Dimensions
KENWORTH AG 400/460 TANDEM SUSPENSION
Shown with a 52” Axle Spacing
Optional Kenworth Tandem Suspensions
TABLE 3-6. Rear Suspension Options
Suspension Type
Rating
Axle Spacing
Laden Ride
Height
Unladen Ride
Height
Kenworth AG 400
40K
52”
9”
9”
Kenworth AG 400
40K
54”
9”
9’
Kenworth AG 460
46K
54”
10.5”
10.5”
12/09
3-16
Section 3
Dimensions
KENWORTH AG 400L TANDEM SUSPENSION
Shown with a 52” Axle Spacing
Optional Kenworth Tandem Suspensions
TABLE 3-7. Rear Suspension Options
Suspension Type
Rating
Axle Spacing
Laden Ride
Height
Unladen Ride
Height
Kenworth AG 400L
40K
52”
8.5”
8.5”
Kenworth AG 400L
40K
54”
8.5”
8.5”
3-17
12/09
Section 3
Dimensions
KENWORTH AG 460 TANDEM SUSPENSION
Shown with a 60” Axle Spacing
Optional Kenworth Tandem Suspensions
TABLE 3-8. Rear Suspension Options
Suspension Type
Rating
Axle Spacing
Laden Ride
Height
Unladen Ride
Height
Kenworth AG 460
46K
60”
10.5”
10.5”
12/09
3-18
Section 3
Dimensions
REYCO 79KB SINGLE REAR AXLE
Optional Reyco 79KB Suspensions
TABLE 3-9. Rear Suspension Options
Suspension Type
Rating
Axle Spacing
Laden Ride
Height
Unladen Ride
Height
Reyco 79KB single
21K
-
8.3”
10.8”
Reyco 79KB single
23K
-
8.3”
10.8”
Reyco 79KB single
26K
-
8.2”
11.3”
Reyco 79KB single
30K
-
8.9”
11.7”
3-19
12/09
Section 3
Dimensions
REYCO 102 TANDEM REAR AXLE
Shown with a 52” Axle Spacing
Reyco 102 Suspension Data
TABLE 3-10. Rear Suspension Options
Rating
Axle Spacing
Laden Ride Height
Unladen Ride
Height
Reyco 102 Tandem
38K
52”
9.2”
10.8”
Reyco 102 Tandem
40K
52”
9.2”
10.8”
Suspension Type
12/09
3-20
Section 3
Dimensions
NEWAY AD 123 SINGLE REAR AXLE
Optional Neway AD Single Suspensions
TABLE 3-11. Rear Suspension Options
Rating
Axle Spacing
Laden Ride
Height
Unladen Ride
Height
Neway AD123 single
23K
-
10”
10”
Neway AD126 single
26K
-
10”
10”
Suspension Type
3-21
12/09
Section 3
Dimensions
NEWAY AD 246 TANDEM SUSPENSION
Shown with a 54” Axle Spacing
Optional Neway AD Tandem Suspensions
TABLE 3-12. Rear Suspension Options
Rating
Axle Spacing
Laden Ride
Height
Unladen Ride
Height
Neway AD246 tandem
46K
54”
10”
10”
Neway AD246 tandem
46K
60”
10”
10”
Suspension Type
12/09
3-22
Section 3
Dimensions
HENDRICKSON PRIMAAX TANDEM SUSPENSION
Shown with 54” Axle Spacings
Optional Hendrickson Primaax Tandem Suspensions
TABLE 3-13. Rear Suspension Options
Rating
Axle Spacing
Laden Ride
Height
Unladen Ride
Height
Hendrickson Primaax Tandem
46K
54”
10”
10”
Hendrickson Primaax Tandem
46K
60”
10”
10”
Hendrickson Primaax Tandem
46K
72”
10”
10”
Suspension Type
3-23
12/09
Section 3
Dimensions
HENDRICKSON HAS 230 SINGLE REAR SUSPENSION
Optional Hendrickson HAS 230 Suspensions
TABLE 3-14. Rear Suspension Options
Suspension Type
Hendrickson HAS 230
12/09
Rating
Axle Spacing
Laden Ride
Height
Unladen Ride
Height
23K
–
10.0”
10.0”
3-24
Section 3
Dimensions
HENDRICKSON HMX TANDEM SUSPENSION
Shown with 54” Axle Spacing
Optional Hendrickson HMX Tandem Suspensions
TABLE 3-15. Rear Suspension Options
Rating
Axle Spacing
Laden Ride
Height
Unladen Ride
Height
Hendrickson HMX400 16.5” saddle
40K
54”
9.5”
10.6”
Hendrickson HMX400 17.5” saddle
40K
54”
10.5”
11.6”
Hendrickson HMX460 16.5” saddle
46K
54”
9.5”
10.6”
Hendrickson HMX460 17.5” saddle
46K
54”
10.5”
11.6”
Hendrickson HMX460 18.5” saddle
46K
54”
11.5”
12.6”
Hendrickson HMX460 18.5” saddle
46K
60”
11.5”
12.6”
Suspension Type
3-25
12/09
Section 3
Dimensions
HENDRICKSON RT TANDEM SUSPENSION
Shown with a 54” Axle Spacing Without Track Rods
Optional Hendrickson RT Tandem Suspensions
TABLE 3-16. Rear Suspension Options
Rating
Axle Spacing
Laden Ride
Height
Unladen Ride
Height
Hendrickson RT463 6” saddle
46K
54”
10.0”
11.1”
Hendrickson RT463 7.19” saddle
46K
54”
11.2”
12.5”
Hendrickson RT463 7.94” saddle
46K
54”
11.9”
13.3”
Hendrickson RT463 6” saddle
46K
60”
10.0”
11.1”
Hendrickson RT403 7.19” saddle
40K
52”
9.7”
10.7”
Suspension Type
12/09
3-26
Section 3
Dimensions
CHALMERS 856-46 TANDEM SUSPENSION
Shown with a 54” Axle Spacing
Optional Chalmers Tandem Suspensions
TABLE 3-17. Rear Suspension Options
Rating
Axle Spacing
Laden Ride
Height
Unladen Ride
Height
Chalmers 854-40-H
40K
54”
10.2”
12.4”
Chalmers 854-40-L
40K
54”
8.9”
11.1”
Chalmers 854-40-L-HS
40K
54”
9.6”
11.1”
Chalmers 854-40-H-HS
40K
54”
10.9”
12.4”
Chalmers 854-40-H-SR
40K
54”
10.5”
12.4”
Chalmers 854-40-L-SR
40K
54”
9.2”
11.1”
Chalmers 854-46-L
46K
54”
8.9”
11.3”
Chalmers 854-46-L-HS
46K
54”
9.6”
11.3”
Chalmers 854-46-L-SR
46K
54”
9.2”
11.3”
Chalmers 854-46-H
46K
54”
10.1”
12.5”
Chalmers 854-46-H-HS
46K
54”
10.9”
12.5”
Chalmers 854-46-H-SR
46K
54”
10.5”
12.2”
Chalmers 860-46-H
46K
60”
10.1”
12.5”
Chalmers 860-46-H-HS
46K
60”
10.9”
12.5”
Chalmers 872-46-H-HS
46K
72”
11.0”
12.5”
Suspension Type
3-27
12/09
Section 3
Dimensions
PUSHER AXLES
The rear pusher axle layouts are provided as a tool to help layout bodies prior to arrival. When using the pusher layouts to
determine available frame space please be aware that clearances required are not shown. For information that may not be
detailed in these drawings work with your local Kenworth Dealer to request that information.
Watson & Chalin Tru Track Alumilite 13.2K Steerable Pusher
Watson & Chalin Tru Track 20K Steerable Pusher
12/09
3-28
Section 3
Dimensions
Watson & Chalin Atlas 22.5K Non-Steerable Pusher
3-29
12/09
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.
A
B
TABLE 3-18. Ground Clearance for Fuel Tanks
Front
Suspension
20K Taperleaf Spring
12/09
Front Tires
M844F
425/65R22.5
Tires
Rear
Suspension
Hendrickson
HMX 460
17.5” Saddle
Height
Rear Tires
M711
11R24.5
Component
Dimension
“A”
Distance
from
Bottom of
Frame Rail
(in)
Dimension “B” Ground
Clearance (in)
Unladen
Laden
22” Fuel Tank
16.3
17.2
14.9
24.5” Fuel
Tank
18.2
15.3
13
3-30
Section 3
Dimensions
A
B
TABLE 3-19. Ground Clearance for Battery Boxes
Front
Suspension
20K Taperleaf Spring
Front Tires
M844F
425/65R22.5
Tires
Rear
Suspension
Hendrickson
HMX 460
17.5” Saddle
Height
Rear Tires
M711
11R24.5
Component
Dimension
“A”
Distance
from
Bottom of
Frame Rail
(in)
Dimension “B” Ground
Clearance (in)
Unladen
Laden
Battery Box
with Air Tanks
17.3
16.2
13.9
Vocational
Battery Box
with Air Tanks
17.8
15.7
13.4
Single DPF
Box
15.5
17.9
15.6
3-31
12/09
Section 3
Dimensions
A
B
TABLE 3-20. Ground Clearance for Battery Boxes
Front
Suspension
20K Taperleaf Spring
1
Front Tires
M844F
425/65R22.5
Tires
Rear
Suspension
Hendrickson
HMX 460
17.5” Saddle
Height
Rear Tires
M711
11R24.5
Component
Dimension
“A”
Distance
from
Bottom of
Frame Rail
(in)
Dimension “B” Ground
Clearance (in)
Unladen
Laden
Battery Box
with Air Tanks
17.3
16.2
13.9
Vocational
Battery Box
with Air Tanks
17.8
15.7
13.4
DPF1 Box
15.6
17.8
15.5
Dimensions shown are for daycabs with high route exhaust. Sleeper ground clearance is reduced by 1.3 inches.
12/09
3-32
Section 3
Dimensions
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. Multiple PTO’s are shown for layout purposes only. Power equipment,
i.e., drive shafts & power pumps are not included. Body builders should select the appropriate PTO for their application
and customer requirements. NOTE: Installations depict multiple PTOs. PTO locations shown below are for reference only.
Some PTOs may interfere with frame rail and/or other components.
In order to ensure the PTO area remains clear of air equipment, electrical and emissions equipment, Kenworth recommends always ordering PTO controls, even when installing the PTO aftermarket. Kenworth does offer a variety of factory
installed PTOs. Contact your local dealer for assistance.
Manual Transmission:
3-33
12/09
Section 3
Dimensions
Allison Transmission:
12/09
3-34
Section 4
Exhaust & Aftertreatment
EXHAUST AND AFTER-TREATMENT INFORMATION
The following section is designed to give you information regarding the exhaust and after-treatment systems on Kenworth
chassis.
All Kenworth’s equipped with 2010 emission level engines will utilize Selective Catalyst Reduction (SCR). SCR is a
process in which Diesel Exhaust Fluid (DEF) is injected into the exhaust down stream of the engine. DEF is converted to
ammonia by the heat of the exhaust system. Inside of the SCR canister a catalyst causes a chemical reaction to occur
between the ammonia and NOx, turning it into water and nitrogen. For more information on the 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)
DEF Supply Module
(Pump)
DEF Pressure Line
(Outlet)
DEF Dosing Module
(Injector)
4-1
12/09
Section 4
Exhaust & Aftertreatment
DEF will freeze at approximately 11° F. In order to keep DEF from freezing all tanks will be heated with engine coolant.
The following schematic shows the routing of these lines. The coolant lines that run to and from the SCR system must not
be tampered with, or used for a source of heat and/or cooling for other components on the chassis. It is critical that the
system is not compromised in any manner.
DEF Tank
(Small Tank Shown)
DEF Tank
Heating
Element
5/8” Coolant Hose
(Green - Draw)
Return Tee
Draw Tee
3/8” Coolant Hose
(Blue - Return)
2/2 Coolant
Valve
Coolant
Bulkhead
(Framemounted)
3/8” Coolant Hose
(Green - Draw)
Draw Port
12/09
DEF Dosing Module
(Injector)
Return Port
4-2
5/8” Coolant Hose
(Blue - Return)
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 relocating the DEF tank, there are applications and body installations that will require it. The guidelines below must be strictly
followed by any entity relocating the tank. Failure to follow the guidelines completely and accurately may result in engine
shutdown situations.
Kenworth offers a variety of DEF tank sizes to meet every application. The DEF tank volume is regulated by the E.P.A.
Kenworth advises against modifying the tank volume after the truck has been delivered from the factory.
•
Total DEF capacity must meet or exceed 6% of the usable fuel capacity on the truck. The calculation to determine DEF capacity is:
Minimum DEF Tank Volume = Useable Fuel Capacity (gal) x 0.06
Example: For a truck with 200 useable gallons of fuel, the equation is
DEF required = 200 x 0.06 = 12 gallons or more of DEF.
PACCAR-approved DEF hoses are required when retrofitting for system to function properly. The use of unapproved hoses
for DEF lines will void warranty and may cause engine shutdown situations. The DEF pump (or Supply Module) can not be
relocated from the DEF tank.
INSTALLATION REQUIREMENTS AND DIMENSIONS FOR DEF SYSTEM
When relocating any DEF system components, the locations must meet the guidelines below. Failure to comply may result
in non-conformance to EPA standards and engine shutdown.
DEF piping relative heights: In order to ensure proper functionality of DEF system, the height differences in the guidelines
below must be followed during line routing and component placement.
With all relocating procedures, general clearances and routing guidelines must be followed. See section 9 of this manual
for general routing guidelines.
When relocating the components the maximum pressure DEF hose length, from Supply module to Dosing Module, is 3
meters (118”).
Maintain a minimum of 3” clearance to shielded exhaust components when routing DEF lines to prevent possible melting.
If the DEF tank is relocated the coolant lines will need to be 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. Increases in restriction occur with excessive line length and bends. Work with your
local Kenworth dealer if you are unsure about the coolant line modifications.
4-3
12/09
Section 4
Exhaust & Aftertreatment
MEASUREMENT REFERENCE POINTS
For all relocation procedures, the measurement points 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 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.
12/09
4-4
Section 4
Exhaust & Aftertreatment
FIGURE 4-3: Orientation of Dosing Module
Right Hand Under DPF and SCR with Small, Medium, or Large DEF Tanks
FIGURE 4-4: RH Under Cab Exhaust with Small, Medium, or Large Tanks.
The height differential between the supply module and dosing module can not exceed one meter. The supply module is
integrated into the DEF tank assembly, separation of the module from the tank is not allowed.
When relocating the components the maximum pressure DEF hose length, from Supply module to Dosing Module, is 3
meters (118”).
DEF Pressure hose must include a “trap” in the routing if Dosing Module is below the highest point of the Supply Module
(See Figure 4-9 on page 4-9).
4-5
12/09
Section 4
Exhaust & Aftertreatment
Horizontal (Crossover) DPF and SCR with Rectangular Small or Medium DEF Tanks
FIGURE 4-5: Horizontal Exhaust with Small or Medium Tanks.
The height differential between the supply module and dosing module cannot exceed one meter. The supply module is
integrated into the DEF tank assembly, separation of the module frm the tank is not allowed.
When relocating the components the maximum pressure DEF hose length, from Supply module to Dosing Module is
3 meters (118”).
Vertical DPF and SCR with Rectangular Small or Medium DEF Tanks
FIGURE 4-6: Vertical Exhaust with Small or Medium Tanks.
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”).
12/09
4-6
Section 4
Exhaust & Aftertreatment
Right Hand Under DPF and SCR with Clear Back of Cab DEF Tank
FIGURE 4-7: RH Under Cab Exhaust with Clear Back of Cab Tank.
The installation and design of the Clear Back of Cab (CBOC) tank is highly integrated into the chassis and cooling system.
Kenworth does not allow relocation of this tank, only relocation of the supply module.
The height differential between the supply module and dosing module can not exceed one meter. The CBOC tank does
not have an integrated supply module. The standard KW installation is a supply module located inside of the frame rail.
When relocating either the supply module or the tank, the maximum height differential between the supply module and the
bottom of the tank is one meter. The maximum line length is 2 meters between supply module and DEF tank sending unit.
When relocating the components the maximum pressure DEF hose length, from Supply module to Dosing Module, is 3
meters (118”).
DEF Pressure hose must include a “trap” in the routing if Dosing Module is below the highest point of the Supply Module
(See Figure 4-8 on page 4-9).
4-7
12/09
Section 4
Exhaust & Aftertreatment
Vertical DPF and SCR with Clear Back of Cab DEF Tank
FIGURE 4-7: Vertical with Clear Back of Cab Tank
The 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 supply module and the bottom of the tank is one meter. The maximum line length is 2 meters between supply module and
DEF tank sending unit.
When relocating the components the maximum pressure DEF hose length, from Supply module to Dosing Module, is 3
meters (118”).
Routing to the Dosing Module (Injector)
It is important for the function of the dosing module to ensure that the dosing module is not routed downstream of DEF
lines or components. If this is unavoidable (for example on RH under exhaust systems) a routing trap must be installed. A
minimum of 12” of line length must be routed below the dosing module, in order to catch any leftover DEF when system is
purged.
12/09
4-8
Section 4
Exhaust & Aftertreatment
Minimum 12” Line
Length Below
Dosing Module
FIGURE 4-8: Routing DEF Lines and DEF Trap
Clear Back of Cab Supply Module
The CBOC Supply Module (or Pump) standard mounting location is inside of the frame rail back of cab. Body builders
may need to relocate this component, and should follow the location and length restrictions above. Additionally the
mounting and the orientation of the Supply Module must not exceed 45° (from vertical) in two directions as shown in
Figure 4-9 below.
FIGURE 4-9: Supply Module Allowed Clocking Angles
4-9
12/09
Section 4
Exhaust & Aftertreatment
GENERAL EXHAUST INFORMATION
Kenworth will offer two main DPF and SCR exhaust systems on T440/T470 chassis in 2010. A Right Hand Under DPF
and SCR system, in which both canisters are located underneath the cab access step, and an Independent DPF and SCR
located vertically back of cab on stanchion brackets.
RH Under DPF and SCR
Independent Back of Cab
The following images depict the typical exhaust routings for each system, and can be used to determine exhaust routing
paths for systems you choose. Dimensional information can be found in Section 5 of this manual.
Body Builders must not modify (including altering, substituting, and relocating) the DPF and SCR canisters. The exhaust
piping after it exits the SCR canister may be modified, however using smaller diameter piping or piping with numerous
bends is not recommend as the backpressure requirements of the system may be exceeded.
12/09
4-10
Section 4
Exhaust & Aftertreatment
Right Hand Under DPF and SCR on Daycab with Single Side of
Cab Tailpipe
FIGURE 4-10: Isometric View of Right Hand Under DPF and SCR with Single SOC Tailpipe
FIGURE 4-11: Top View of Right Hand Under DPF and SCR with Single SOC Tailpipe
4-11
12/09
Section 4
Exhaust & Aftertreatment
FIGURE 4-12: Right View of Right Hand Under DPF and SCR with Single SOC Tailpipe
FIGURE 4-13: Back View of Right Hand Under DPF and SCR with Single SOC Tailpipe
12/09
4-12
Section 4
Exhaust & Aftertreatment
Right Hand Under DPF and SCR with Single Back of Cab Tailpipe
FIGURE 4-14: Isometric View of Right Hand Under DPF and SCR with Single Back of Cab Tailpipe
FIGURE 4-15: Top view of Right Hand Under DPF and SCR with Single Back of Cab Tailpipe
4-13
12/09
Section 4
Exhaust & Aftertreatment
FIGURE 4-16: Right view of Right Hand Under DPF and SCR with Single Back of Cab Tailpipe
FIGURE 4-17: Back view of Right Hand Under DPF and SCR with Single Back of Cab Tailpipe
12/09
4-14
Section 4
Exhaust & Aftertreatment
Vertical Independent DPF and SCR with Horizontal Tailpipe
FIGURE 4-18: Isometric View of Vertical DPF and SCR
FIGURE 4-19: Top View of Vertical DPF and SCR
4-15
12/09
Section 4
Exhaust & Aftertreatment
FIGURE 4-20: Right View of Vertical DPF and SCR
FIGURE 4-21: Back View of Vertical DPF and SCR
12/09
4-16
Section 4
Exhaust & Aftertreatment
Right Hand Under DPF and SCR on Aerocabs with Single Side of
Cab Tailpipe
FIGURE 4-22: Isometric View of Right Hand Under DPF and SCR on Aerocab with Single SOC Tailpipe
FIGURE 4-23: Top View of Right Hand Under DPF and SCR on Aerocab with Single SOC Tailpipe
4-17
12/09
Section 4
Exhaust & Aftertreatment
FIGURE 4-24: Right View of Right Hand Under DPF and SCR on Aerocab with Single SOC Tailpipe
FIGURE 4-25: Back View of Right Hand Under DPF and SCR on Aerocab with Single SOC Tailpipe
12/09
4-18
Section 4
Exhaust & Aftertreatment
EXHAUST INFORMATION
This section includes information on how to calculate tailpipe heights, and reference information for PTO clearance.
Optional equipment is not shown.
Tailpipe Stack Height Calculation
TABLE 4-1. Stack Height
Dimension A
Tailpipes side of Aerocab, RH
under DPF
75.0”
Tailpipes independent back of
sleeper, RH under DPF
75.0”
Cummins
(not ISL)
78.0”
DPF mounted independent back
of cab or sleeper
Tailpipes side of cab mount,
DPF RH under
Cummins
ISL
75.0”
68.5”
Tailpipes back of cab mount, w/
side extenders, DPF RH under
Tailpipes back of cab mount, w/o
side extenders, DPF RH under
68.0”
DIMENSION “B” IS THE TAILPIPE LENGTH.
TABLE 4-2. Unladen Stack Height
For approximate unladen stack height (12,000 pound springs) use the following frame heights:
Tire Size
Top of Rail
Ft. Suspension
11R24.5
43.5”
12K
11R22.5
42.5”
12K
285/75R24.5
42”
12K
295/75R22.5
41.5”
12K
425/65R22.5
43.2
20K
385/65R22.5
42.4
20K
*Use Prospector frame heights for more accurate results.
Sample: Tailpipe height 13’6” =
(–)
(+)
(–)
=
Desired overall stack height
Prospector frame height
Frame rail depth
Dimension ‘A’ from chart
Tail pipe length
4-19
=
(–)
(+)
(–)
=
162.0”
43.5”
10.6”
68.6”
60.5”
12/09
Section 4
Exhaust & Aftertreatment
This page intentionally left blank.
12/09
4-20
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. Additional components may be placed on the rail behind components shown. The Back of Cab components are shown primarily for reference. 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
Symbol
Description
Symbol
Description
RHUC DPF/SCR
Tool Box
Vertical DPF/SCR
DEF Tank
Parallel Battery Box, Standard Length
Clear BOC DEF Tank
In Cab Battery Box
Fuel Tank
Cantilever Battery Box
5-1
12/09
Section 5
Frame Layouts
COMMON OPTIONAL COMPONENTS
The frame layouts that follow contain the minimum frame requirements to be operational (fuel tanks, battery
box, and after-treatment components). All layouts are shown with standard length battery boxes unless otherwise noted. Dimensions for these components have been provided below to help complete the frame layout for
chassis with more fuel tanks, additional tool boxes, etc.
TABLE 5-2. Fuel Tank Overall Length (in)
Fuel Tank Overall Length (in)
Fuel Tank Diameter
Gallons
22”
24.5”
45
N/A
23.0
56
35.6
N/A
60
38.0
30.6
75
47.3
38.5
90
N/A
45.5
100
62.2
50.0
105
N/A
N/A
110
N/A
55.0
120
74.3
60.6
135
N/A
67.2
150
N/A
74.5
177
N/A
N/A
TABLE 5-3. Battery Box Centerframe Lengths (in)
Battery Box Centerframe Lengths (in)
T440/T470
Parallel Short
34.8
Parallel Extended
42.0
Parallel BOC
34.8
Cantilever
17.8
Vocational
15.2
12/09
5-2
Section 5
Frame Layouts
FIGURE 5-1. DEF Tank Dimensions.
TABLE 5-4. DEF Tanks Systems
Description
Usable Volume,
Gallons
Small DEF Tank
9
Medium DEF Tank
18
Large DEF Tank
27
Fuel Tank
Diameter
A
B
22”
27.4
15.3
24.5”
27.4
15.8
22”
27.7
15.0
24.5”
27.7
15.5
22”
27.7
15.0
24.5”
27.7
15.5
Acronyms Index
Throughout the Frame Layout section you will see these acronyms. They are defined here to help you decode
the layouts.
BOC
Back Of Cab
DSOC
Dual Side Of Cab
BOS
Back Of Sleeper
LHUC
Left Hand Under Cab
CBOC
Clear Back Of Cab
RHUC
Right Hand Under Cab
DEF
Diesel Exhaust Fluid
SOAC
Side Of AeroCab
DSOAC
Dual Side Of AeroCab
SOC
Side Of Cab
5-3
12/09
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. Chart located
on page 5–8.
D2 is used with RHUC DPF/SCR, LHUC fuel tank, RH BOC cantilever battery box, and LH BOC DEF tank. Chart
located on page 5–9.
D3 is used with RHUC DPF/SCR, LHUC battery box, RH BOC DEF tank, and LH BOC fuel tank. Chart located on
page 5–10.
D4 is used with RHUC DPF/SCR, LHUC battery box, LH BOC DEF tank, and RH BOC fuel tank. Chart located on
page 5–11.
D5 is used with RHUC DPF/SCR, LHUC fuel tank, RH BOC DEF tank, and in cab battery box. Chart located on
page 5–12.
12/09
5-4
Section 5
Frame Layouts
D6 is used with RHUC DPF/SCR, LHUC fuel tank, Clear BOC DEF tank, and in cab battery box. Chart located on
page 5–13.
D7 is used with Vertical-Vertical DPF/SCR, LH vertical tailpipe, RHUC fuel tank, LHUC battery box, and LH BOC DEF
tank. Charts located on page 5–14.
D8 is used with Vertical-Vertical DPF/SCR, LH vertical tailpipe, RHUC fuel tank, LHUC battery box, and RH BOC DEF
tank. Chart located on page 5–15.
D9 is used with Vertical-Vertical DPF/SCR, LH vertical tailpipe, LHUC & RHUC fuel tanks, RH BOC cantilever battery box,
and LH BOC DEF tank. Chart located on page 5–16.
D10 is used with Vertical-Vertical DPF/SCR, LH vertical tailpipe, LHUC fuel tank, RHUC battery box, and Clear BOC DEF
tank. Charts located on page 5–17.
5-5
12/09
Section 5
Frame Layouts
Sleeper Chassis Layout Options
S1 is used with 38” AeroCab sleeper with RHUC DPF/SCR, LHUC fuel tank, RH BOC DEF tank, and LH BOC cantilever
battery box. Chart located on page 5–18.
S2 is used with 38” AeroCab sleeper with RHUC DPF/SCR, LHUC fuel tank, LH BOC DEF tank, and RH BOC cantilever
battery box. Chart located on page 5–19.
S3 is used with 38” AeroCab sleeper with RHUC DPF/SCR, LHUC battery box, RH BOC DEF tank, and LH BOC fuel tank.
Chart located on page 5–20.
S4 is used with 38” AeroCab sleeper with RHUC DPF/SCR, LHUC battery box, LH BOC DEF tank, and RH BOC fuel tank.
Chart located on page 5–21.
S5 is used with 38” AeroCab sleeper with Vertical-Vertical DPF/SCR, LH vertical tailpipe, RHUC fuel tank, LHUC battery
box, and LH BOC DEF tank. Chart located on page 5–22.
12/09
5-6
Section 5
Frame Layouts
S6 is used with 38” AeroCab sleeper with Vertical-Vertical DPF/SCR, LH vertical tailpipe, RHUC fuel tank, LHUC battery
box, and RH BOC DEF tank. Chart located on page 5–23.
S7 is used with 38” AeroCab sleeper with Vertical-Vertical DPF/SCR, LH vertical tailpipe, RHUC & LHUC fuel tanks, LH
BOC DEF tank and RH BOC cantilever battery box. Chart located on page 5–24.
5-7
12/09
Section 5
Frame Layouts
D1—Use with the following models: T470/T440
Dimension E (BOC to DPF/SCR)* = 0.4in
TABLE 5-5.
T470/T440
Fuel Tank Size
Diameter
22”
Diameter
Tank
24.5”
Diameter
Tank
Gallons
Length (in)
Dimension F
BOC to Fuel Tank,
Daycab* (in)
Dimension B
BOC to Battery Box,
Daycab* (in)
56
35.5
-3.7
17.0
60
38.0
-1.2
19.5
75
47.3
8.1
28.8
100
62.2
23.0
43.7
120
74.2
35.0
55.7
60
30.5
-8.7
12.0
75
38.5
-0.7
20.0
90
45.5
6.3
27.0
100
50.0
10.8
31.5
110
54.9
15.7
36.4
120
60.5
21.3
42.0
135
67.2
28.0
48.7
150
74.5
35.3
56.0
Dimension D
BOC to DEF Tank, Daycab* (in)
DEF Tank Size
Small
Medium
Large
18.4
24.8
32.9
*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.
12/09
5-8
Section 5
Frame Layouts
D2—Use with the following models: T470/T440
Dimension E (BOC to DPF/SCR)* = 0.4in
Dimension B (BOC to Cantilever Battery Box)* = 21.8in
TABLE 5-6.
T470/T440
Fuel Tank Size
Diameter
22” Diameter Tank
24.5” Diameter Tank
Gallons
56
60
75
100
120
60
75
90
100
110
120
Length (in)
35.5
38.0
47.3
62.2
74.2
30.5
38.5
45.5
50.0
54.9
60.5
135
150
Dimension F
BOC to Fuel Tank,
Daycab* (in)
Dimension D
BOC to DEF Tank* (in)
DEF Tank Size
-3.7
-1.2
8.1
23.0
35.0
-8.7
-0.7
6.3
10.8
15.7
21.3
Small
7.4
10.1
23.9
34.9
46.0
1.9
10.1
18.4
23.9
29.4
34.9
Medium
17.1
19.3
28.2
44.7
55.7
11.6
19.3
28.2
30.9
36.4
42.0
Large
25.2
27.4
36.2
52.8
63.8
19.7
27.4
36.2
39.0
44.5
50.0
67.2
28.0
40.5
47.5
55.5
74.5
35.3
46.0
55.7
63.8
*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.
5-9
12/09
Section 5
Frame Layouts
D3—Use with the following models: T470/T440
Dimension E (BOC to DPF/SCR)* = .04in
Dimension B (BOC to Battery Box)* = -4.5in
TABLE 5-7.
T470/T440
Fuel Tank Size
Diameter
22” Diameter Tank
24.5” Diameter Tank
Dimension F
BOC to Fuel Tank,
Daycab* (in)
Gallons
56
Length (in)
35.5
60
75
100
120
38.0
47.3
62.2
74.2
35.5
44.8
59.7
71.7
60
75
90
100
110
120
135
30.5
38.5
45.5
50.0
54.9
60.5
67.2
28.0
36.0
43.0
47.5
52.4
58.0
64.7
150
74.5
72.0
Dimension D
BOC to DEF Tank, Daycab* (in)
DEF Tank Size
Small
Medium
Large
18.4
24.8
32.9
33.0
*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”
12/09
5-10
Section 5
Frame Layouts
D4—Use with the following models: T470/T440
Dimension E (BOC to DPF/SCR)* = 0.4in
Dimension B (BOC to Battery Box)* = -4.5in
TABLE 5-8.
T440/T470
Fuel Tank Size
Diameter
22” Diameter Tank
24.5” Diameter Tank
Dimension F
BOC to Fuel Tank,
Daycab* (in)
Gallons
56
Length (in)
35.5
60
75
100
120
38.0
47.3
62.2
74.2
41.1
50.4
65.3
77.3
60
75
90
100
110
120
135
30.5
38.5
45.5
50.0
54.9
60.5
67.2
33.6
41.6
48.6
53.1
58.0
63.6
70.3
150
74.5
77.6
Dimension D
BOC to DEF Tank, Daycab* (in)
DEF Tank Size
Small
Medium
Large
7.4
17.1
25.2
38.6
*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”
5-11
12/09
Section 5
Frame Layouts
D5—Use with the following models: T470/T440 and In-cab battery box.
Dimension E (BOC to DPF/SCR)* = 0.4in
TABLE 5-9.
T440/T470
Fuel Tank Size
Diameter
22” Diameter Tank
24.5” Diameter Tank
Gallons
Length (in)
Dimension F
BOC to Fuel Tank,
Daycab* (in)
56
35.5
-3.7
60
38.0
-1.2
75
47.3
8.1
100
62.2
23.0
120
74.2
35.0
60
30.5
-8.7
75
38.5
-0.7
90
45.5
6.3
100
50.0
10.8
110
54.9
15.7
120
60.5
21.3
135
67.2
28.0
150
74.5
35.3
*Subtract 5.7 inches for the extended Daycab.
12/09
5-12
Dimension D
BOC to DEF Tank, Daycab* (in)
DEF Tank Size
Small
Medium
Large
18.4
24.8
32.9
Section 5
Frame Layouts
D6—Use with the following models: T470/T440 and In-cab battery box.
Dimension E (BOC to DPF/SCR)* = 0.4in
Dimension D (BOC to DEF tank)* = 0.7in
TABLE 5-10.
T440/T470
Fuel Tank Size
Diameter
22” Diameter Tank
24.5” Diameter Tank
Gallons
Length (in)
Dimension F
BOC to Fuel Tank,
Daycab* (in)
56
35.5
-3.7
60
38.0
-1.2
75
47.3
8.1
100
62.2
23.0
120
74.2
35.0
60
30.5
-8.7
75
38.5
-0.7
90
45.5
6.3
100
50.0
10.8
*Subtract 5.7 inches for the extended Daycab.
5-13
12/09
Section 5
Frame Layouts
D7—Use with the following models: T470/T440
Dimension B (BOC to Battery Box)* = -4.5in
Dimension E (BOC to DPF/SCR) = 19.6in
TABLE 5-11.
T440/T470
Gallons
Length (in)
Dimension F
BOC to
Fuel Tank,
Daycab (in)
56
35.5
-3.7
-9.4
60
38.0
-1.2
-6.9
75
47.3
8.1
2.4
100
62.2
23.0
17.3
120
74.2
35.0
29.3
60
30.5
-8.7
-14.4
75
38.5
-0.7
Fuel Tank Size
Diameter
22”
Diameter
Tank
24.5”
Diameter
Tank
Dimension D
BOC to DEF Tank, Daycab (in)
DEF Tank Size
Small
Medium
7.4
39.2
Dimension F
BOC to Fuel
Tank, Ext.
Daycab (in)
-6.4
90
45.5
6.3
0.6
100
50.0
10.8
5.1
110
54.9
15.7
10.0
120
60.5
21.3
15.6
135
67.2
28.0
22.3
150
74.5
35.3
29.6
Dimension D
BOC to DEF Tank, Ext. Daycab (in)
DEF Tank Size
Small
Medium
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”
12/09
5-14
Section 5
Frame Layouts
D8—Use with the following models: T470/T440
Dimension B (BOC to Battery Box)* = -4.5in
Dimension E (BOC to DPF/SCR) = 19.6in
TABLE 5-12.
T440/T470
Diameter
22”
Diameter
Tank
24.5”
Diameter
Tank
Dimension D
BOC to DEF Tank, Daycab (in)
Dimension D
BOC to DEF Tank, Ext. Daycab (in)
Small
Medium
Dimension F
BOC to Fuel
Tank, Ext.
Daycab (in)
-3.7
18.4
39.2
-9.4
38.0
-1.2
18.4
39.2
-6.9
18.2
39.0
47.3
8.1
29.4
39.2
2.4
18.2
39.0
100
62.2
23.0
34.9
42.6
17.3
29.2
36.9
120
74.2
35.0
46.0
55.7
29.3
40.3
50.0
60
30.5
-8.7
18.4
39.2
-14.4
18.2
39.0
75
38.5
-0.7
18.4
39.2
-6.4
18.2
39.0
90
45.5
6.3
18.4
39.2
0.6
18.2
39.0
100
50.0
10.8
29.4
39.2
5.1
18.2
39.0
Gallons
Length (in)
Dimension F
BOC to
Fuel Tank,
Daycab (in)
56
35.5
60
75
Fuel Tank Size
DEF Tank Size
DEF Tank Size
Small
Medium
18.2
39.0
110
54.9
15.7
29.4
39.2
10.0
29.2
39.0
120
60.5
21.3
34.9
42.6
15.6
29.2
36.9
135
67.2
28.0
40.5
55.7
22.3
34.8
50.0
150
74.5
35.3
46.0
55.7
29.6
40.3
50.0
*Subtract 5.7 inches for the extended Daycab.
NOTE: DIMENSION “B” IS CALCULATED USING A STANDARD BATTERY BOX. OPTIONAL EXTENDED BOXES WILL CHANGE DIMENSION “B”
5-15
12/09
Section 5
Frame Layouts
D9—Use with the following models: T470/T440
Dimension E (BOC to DPF/SCR) = 19.6in
TABLE 5-13.
T440/T470
Gallons
Length (in)
Dimension
F1 & F2
BOC to
Fuel Tank,
Daycab (in)
56
35.5
-3.7
60
38.0
-1.2
24.1
75
47.3
8.1
29.6
100
62.2
23.0
43.7
120
74.2
35.0
55.7
60
30.5
-8.7
24.1
75
38.5
-0.7
24.1
90
45.5
6.3
29.6
100
50.0
10.8
35.1
110
54.9
15.7
120
60.5
21.3
135
67.2
150
74.5
Fuel Tank Size
Diameter
22”
Diameter
Tank
24.5”
Diameter
Tank
Dimension
Dimension D
Dimension B
Dimension B
F1 & F2
BOC
to
DEF
Tank,
Daycab
(in)
BOC to
BOC to
BOC to Fuel
Battery Box,
Battery Box,
Tank, Ext.
DEF Tank Size
Daycab (in)
Ext Daycab (in)
Daycab (in)
Small
Medium
24.1
7.4
24.1
Dimension D
BOC to DEF Tank,
Ext. Daycab (in)
DEF Tank Size
Small
Medium
1.7
39.0
39.2
-9.4
18.4
39.2
-6.9
24.1
4.4
39.0
29.4
39.2
2.4
24.1
18.2
39.0
34.9
44.7
17.3
29.3
29.2
39.0
46.0
55.7
29.3
50.0
40.3
50.0
1.9
39.2
-14.4
24.1
-3.8
39.0
18.4
39.2
-6.4
24.1
4.4
39.0
18.4
39.2
0.6
29.6
18.2
39.0
29.4
39.2
5.1
29.6
18.2
39.0
36.4
29.4
39.2
10.0
35.1
29.2
39.0
42.0
34.9
42.0
15.6
35.1
29.2
39.0
28.0
48.7
40.5
47.5
22.3
43.0
34.8
41.8
35.3
56.0
46.0
55.7
29.6
50.3
40.2
50.0
NOTE: DIMENSION “B” IS CALCULATED USING A CANTILEVER SIZED BATTERY BOX. OPTIONAL BOXES WILL AFFECT THIS DIMENSION.
12/09
5-16
Section 5
Frame Layouts
D10—Use with the following models: T470/T440
Dimension B (BOC To Battery Box)* = -4.5in
Dimension E (BOC to DPF/SCR) = 19.6in
Dimension D (BOC to DEF tank)* = 0.7in
TABLE 5-14.
T440/T470
Fuel Tank Size
Diameter
22” Diameter Tank
24.5” Diameter Tank
Gallons
Length (in)
Dimension F
BOC to Fuel Tank,
Daycab (in)
Dimension F
BOC to Fuel Tank,
Extended Daycab (in)
56
35.5
-3.7
-9.4
60
38.0
-1.2
-6.9
75
47.3
8.1
2.4
100
62.2
23.0
17.3
120
74.2
35.0
29.3
60
30.5
-8.7
-14.4
75
38.5
-0.7
-6.4
90
45.5
6.3
0.6
100
50.0
10.8
5.1
*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”
5-17
12/09
Section 5
Frame Layouts
S1—Use with the following models: T470/T440 38”
Dimension E (BOS to DPF/SCR) = -17..9in.
TABLE 5-15.
T440/T470 38”
Fuel Tank Size
Diameter
22” Diameter Tank
24.5” Diameter Tank
Gallons
56
60
75
100
120
Length (in)
35.5
38.0
47.3
62.2
74.2
60
75
90
100
110
120
135
150
30.5
38.5
45.5
50.0
54.9
60.5
67.2
74.5
Dimension F
BOS to
Fuel Tank (in)
Dimension B
BOS to
Battery Box (in)
-31.7
-29.2
-19.9
-5.0
7.0
0.9
0.9
0.9
18.4
27.7
-36.7
-28.7
-21.7
-17.2
-12.3
-6.7
0.0
7.3
-16.0
0.9
0.9
18.4
18.4
18.4
18.4
28.0
Dimension D
BOS to DEF Tank (in)
DEF Tank Size
Small
Medium
Large
12.7
17.0
25.1
NOTE: DIMENSION “B” IS CALCULATED USING A CANTILEVER SIZED BATTERY BOX. OPTIONAL BOXES WILL AFFECT THIS DIMENSION.
12/09
5-18
Section 5
Frame Layouts
S2—Use with the following models: T470/T440 38”
Dimension E (BOS to DPF/SCR) = -17.9in
Dimension B (BOS to Cantilever Battery Box) = 2.9in
TABLE 5-16.
T440/T470 38”
Fuel Tank Size
Diameter
22” Diameter Tank
24.5” Diameter Tank
Dimension F
BOS to Fuel Tank (in)
Gallons
Length (in)
56
35.5
60
Dimension D
BOS to DEF Tank (in)
DEF Tank Size
Small
Medium
Large
-31.7
-20.6
-10.9
25.1
38.0
-29.2
-15.1
17.0
25.1
75
47.3
-19.9
12.7
17.0
25.1
100
62.2
-5.0
12.7
17.0
25.1
120
74.2
7.0
18.0
27.7
35.8
60
30.5
-36.7
-26.1
-16.4
25.1
75
38.5
-28.7
-15.1
17.0
25.1
90
45.5
-21.7
12.7
17.0
25.1
100
50.0
-17.2
12.7
17.0
25.1
110
54.9
-12.3
12.7
17.0
25.1
120
60.5
-6.7
12.7
17.0
25.1
135
67.2
0.0
12.7
19.5
27.5
150
74.5
7.3
18.0
27.7
35.8
NOTE: DIMENSION “B” IS CALCULATED USING A CANTILEVER SIZED BATTERY BOX. OPTIONAL BOXES WILL AFFECT THIS DIMENSION.
5-19
12/09
Section 5
Frame Layouts
S3—Use with the following models: T470/T440 38”
Dimension E (BOS to DPF/SCR) = -17.9in
Dimension B (BOS to Battery Box) = -32.5in
TABLE 5-17.
T440/T470 38”
Fuel Tank Size
Diameter
22” Diameter Tank
24.5” Diameter Tank
Gallons
Dimension F
BOS to Fuel Tank (in)
Length (in)
56
35.5
5.0
60
38.0
7.5
75
47.3
16.8
100
62.2
31.7
120
74.2
43.7
60
30.5
0.0
75
38.5
8.0
90
45.5
15.0
100
50.0
19.5
110
54.9
24.4
120
60.5
30.0
135
67.2
36.7
150
74.5
44.0
Dimension D
BOS to DEF Tank (in)
DEF Tank Size
Small
Medium
Large
12.7
17.0
25.1
NOTE: DIMENSIONS “B” AND “F” ARE CALCULATED USING A STANDARD BATTERY BOX. OPTIONAL EXTENDED BOXES WILL CHANGE
DIMENSIONS “B” AND “F”
12/09
5-20
Section 5
Frame Layouts
S4—Use with the following models: T470/T440 38”
Dimension E (BOS to DPF/SCR) = -17.9in
Dimension B (BOS to Battery Box) = -32.5in
TABLE 5-18.
T440/T470 38”
Fuel Tank Size
Diameter
22” Diameter Tank
24.5” Diameter Tank
Dimension F
BOS to Fuel Tank (in)
Gallons
Length (in)
56
35.5
20.3
60
38.0
22.8
75
47.3
32.1
100
62.2
47.0
120
74.2
59.0
60
30.5
15.3
75
38.5
23.3
90
45.5
30.3
100
50.0
34.8
110
54.9
39.7
120
60.5
45.3
135
67.2
52.0
150
74.5
59.3
Dimension D
BOS to DEF Tank (in)
DEF Tank Size
Small
Medium
Large
-20.6
-10.9
-2.8
NOTE: DIMENSIONS “B” AND “D” ARE CALCULATED USING A STANDARD BATTERY BOX. OPTIONAL EXTENDED BOXES WILL CHANGE
DIMENSIONS “B” AND “D”
5-21
12/09
Section 5
Frame Layouts
S5—Use with the following models: T470/T440 38”
Dimension B (BOS to Battery Box) = -32.5in
Dimension E (BOS to DPF/SCR) = 19.6in
TABLE 5-19.
T440/T470 38”
Fuel Tank Size
Diameter
22” Diameter Tank
24.5” Diameter Tank
Dimension F
BOS to Fuel Tank (in)
Gallons
Length (in)
56
35.5
-31.7
60
38.0
-29.2
75
47.3
-19.9
100
62.2
-5.0
120
74.2
7.0
60
30.5
-36.7
75
38.5
-28.7
90
45.5
-21.7
100
50.0
-17.2
110
54.9
-12.3
120
60.5
-6.7
135
67.2
0.0
150
74.5
7.3
Dimension D
BOS to DEF Tank (in)
DEF Tank Size
Small
Medium
-20.6
-10.9
NOTE: DIMENSIONS “B” AND “D” ARE CALCULATED USING A STANDARD BATTERY BOX. OPTIONAL EXTENDED BOXES WILL CHANGE
DIMENSIONS “B” AND “D”
12/09
5-22
Section 5
Frame Layouts
S6—Use with the following models: T470/T440 38”
Dimension B (BOS to Battery Box) = -32.5in
Dimension E (BOS to DPF/SCR) = 19.6in
TABLE 5-20.
T440/T470 38”
Fuel Tank Size
Diameter
22” Diameter Tank
24.5” Diameter Tank
Dimension F
BOS to Fuel Tank (in)
Gallons
Length (in)
56
35.5
60
Dimension D
BOS to DEF Tank (in)
DEF Tank Size
Small
Medium
-31.7
-20.6
-9.4
38.0
-29.2
-17.9
-9.4
75
47.3
-19.9
29.3
39.0
100
62.2
-5.0
29.3
39.0
120
74.2
7.0
29.3
39.0
60
30.5
-36.7
-26.1
-9.4
75
38.5
-28.7
-17.9
-9.4
90
45.5
-21.7
29.3
39.0
100
50.0
-17.2
29.3
39.0
110
54.9
-12.3
29.3
39.0
120
60.5
-6.7
29.3
39.0
135
67.2
0.0
29.3
39.0
150
74.5
7.3
29.3
39.0
NOTE: DIMENSION “B” IS CALCULATED USING A STANDARD BATTERY BOX. OPTIONAL EXTENDED BOXES WILL CHANGE DIMENSION “B”
5-23
12/09
Section 5
Frame Layouts
S7—Use with the following models: T470/T440 38”
Dimension E (BOS to DPF/SCR) = 19.6in
TABLE 5-21.
T440/T470 38”
Fuel Tank Size
Diameter
22” Diameter
Tank
24.5” Diameter
Tank
Dimension F1 & F2
BOS to
Fuel Tank (in)
Dimension B
BOS to
Battery Box (in)
Gallons
Length (in)
56
35.5
-31.7
60
38.0
-29.2
Dimension D
BOS to DEF Tank (in)
DEF Tank Size
Small
Medium
0.9
-20.6
-10.9
0.9
-17.9
39.0
75
47.3
-19.9
0.9
18.2
39.0
100
62.2
-5.0
37.1
18.2
39.0
120
74.2
7.0
37.1
18.2
39.0
60
30.5
-36.7
-16.0
-26.1
-16.4
75
38.5
-28.7
0.9
-17.9
39.0
90
45.5
-21.7
0.9
18.2
39.0
100
50.0
-17.2
37.1
18.2
39.0
110
54.9
-12.3
37.1
18.2
39.0
120
60.5
-6.7
37.1
18.2
39.0
135
67.2
0.0
37.1
18.2
39.0
150
74.5
7.3
37.1
18.2
39.0
NOTE: DIMENSION “B” IS CALCULATED USING A CANTILEVER SIZED BATTERY BOX. OPTIONAL BOXES WILL AFFECT THIS DIMENSION.
12/09
5-24
Section 6
Body Mounting
FRONT FRAME DIMENSIONS
This section includes drawings of the T470 extended front frame (73”) and standard (50.5”) front frame settings. All
dimensions are in inches (in). They illustrate measurements useful to the installation of front frame equipment and
bumpers. Kenworth also offers .dxf files and frame layouts of ordered chassis four weeks prior to build. Please work with
your Kenworth sales representative to request this feature when specifying your chassis.
Extended Front Frame
44.8”
Standard Front Frame
27.0”
44.8” 27.0”
72.8”
50.3”
10.2”
Extended Front Frame
10.2”
Standard Front Frame
6-1
12/09
Section 6
Body Mounting
FRAME 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
Rail Height
H
10 - 5/8”
x
Flange Width
Web Thickness
Section Modulus
RBM (in lbs)
Weight (lbs/in)*
W
T
S
R
W
5/16”
14.80
1,776,000
2.90
3 -1/2”
x
10 - 3/4”
x
3 -1/2”
x
3/8”
17.80
2,132,000
3.46
10 - 11/16”
x
3 -1/2”
x
1/2”
22.35
2,683,000
4.53
11 - 5/8”
x
3 -7/8”
x
3/8”
21.43
2,572,000
3.80
* Per pair of rails.
TABLE 6-2. Inserted Steel Rails
Rail Height
Insert Material
Section Modulus
RBM (in lbs)
Weight (lbs/in)*
10 - 5/8”
Single 9-7/8”x 2-7/8” x 1/4”
24.37
2,925,000
4.96
10 - 3/4”
Single 9-7/8”x 2-7/8” x 1/4”
27.33
3,280,000
5.53
11 - 5/8”
Single 10-3/4”x 3-1/2” x 3/8”
39.20
4,704,000
7.28
* Per pair of rails.
CRITICAL CLEARANCES
Rear Wheels and Cab
CAUTION:
Insufficient clearance between rear tires and body structure may cause damage to the
body during suspension movement. Allow at least 8 inches clearance (See Figure 6–1.)
Normal suspension movement could cause contact between the tires and the body. To prevent this, mount the body so
that the minimum clearance between the top of the tire and the bottom of the body is 8 inches (203 mm). This should be
measured with the body empty. See Figure 6–1.
FIGURE 6-1. Minimum Clearance Between Top Of Rear Tires And Body Structure Overhang.
CAUTION:
12/09
Maintain adequate clearance between back of cab and the front (leading edge) of mounted
body. Failure to comply may result in equipment damage. See Figure 6–2.
6-2
Section 6
Body Mounting
Note:
Be sure to provide maintenance access to battery box and fuel tank fill neck.
4”
FIGURE 6-2. Minimum Back of Cab Clearance
WARNING:
If the frame rail flanges are modified or damaged, the rail may fail prematurely and cause
an accident. When mounting a body to the chassis, DO NOT drill holes in the upper or
lower flange of the frame rail. Mount the body using body mounting brackets or U–bolts.
Failure to comply may result in personal injury, death, equipment or property damage.
BODY MOUNTING USING BRACKETS
CAUTION:
Always install a spacer between the body subframe and the top flange of the frame
rail. Failure to do so may result in corrosion due to dissimilar materials and equipment
damage.
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.
6-3
12/09
Section 6
Body Mounting
Frame Sill
If the body is mounted to the frame with brackets, we recommend that the frame sill spacer be made from a strip of rubber or plastic (delrin or nylon). These materials will not undergo large dimensional changes during periods of high or low
humidity. The strip will be less likely to fall out during extreme relative motion between body and chassis. See Figure 6–3.
Body Subframe
(Rail)
Spacer
Chassis Frame
(Rail) Sill
FIGURE 6-3. Spacer Between Frame Sill and Body Rail - Rubber or Plastic
Brackets
When mounting a body to the chassis with brackets, we recommend designs that offer limited amount of relative movement, bolted securely but not too rigid. Brackets should allow for slight movement between the body and the chassis. For
instance, Figure 6–4 shows a high compression spring between the bolt and the bracket.
Spring
Rubber Spacer
FIGURE 6-4. High Compression Spring
Between the Mounting Bolt and Upper Bracket
FIGURE 6-5. Rubber Spacer Between Brackets
Another possibility is mounting a rubber spacer between the brackets. See Figure 6–5.
These designs will allow relative movement between the body and the chassis during extreme frame racking situations.
Extreme frame racking, and mountings that are too rigid, could cause damage to the body. This is particularly true with
tanker installations.
12/09
6-4
Section 6
Body Mounting
MOUNTING HOLES
When installing the lower bracket on frame rails the mounting holes in the chassis frame bracket and frame rail must comply with the general spacing and location guidelines illustrated in Figure 6–6. The hole diameter should not exceed the bolt
diameter by more than .060 inches (1.5 mm).
4 HOLES
4 HOLES
.63 IN.
DIA.
.5 IN.
DIA.
(12.7mm)
(16mm)
6 HOLES
6 HOLES
IN. DIA.
.5.63
IN. DIA.
(12.7mm)
(16mm)
5.63
(143mm)
5.63
(143mm)
2.0
(50mm)
2.0
(50mm)
5.5
(140mm)
5.5
(140mm)
11.0
(279mm)
FIGURE 6-6. Crossmember-Gusset Hole Pattern Requirements. [inch (mm)]
Frame Drilling
WARNING:
When mounting a body to the chassis, DO NOT drill holes in the
upper or lower flange of the frame rail. If the frame rail flanges are
modified or damaged, the rail may fail prematurely. Mount the body using body mounting brackets or U–bolts. Failure to comply may result
in personal injury, death, equipment or property damage.
WARNING:
Use care when drilling the frame web so the wires and air lines routed inside the rail are
not damaged, failure to do so may cause an inoperable electrical or air system circuit.
Failure to comply may result in personal injury, death, equipment or property damage.
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 may
induce a failure between the holes. Failure to comply may result in personal injury, death,
equipment or property damage.
6-5
12/09
Section 6
Body Mounting
BODY MOUNTING USING U–BOLTS
Spacers
If the body is mounted to the frame with U–bolts, use a hardwood sill (minimum 1/2 inch (12 mm) thick) between the frame
rail and body frame to protect the top surface of the rail flange.
WARNING:
Do not allow the frame rails or flanges to deform when tightening the U–bolts. It will weaken the frame. Use suitable spacers made of steel or hardwood on the inside of the frame
rail to prevent collapse of the frame flanges. Failure to comply may result in personal
injury, death, equipment or property damage.
Use a hardwood spacer between the bottom flange and the U–bolt to prevent the U–bolt from notching the frame flange.
See Figure 6–7.
U-Bolt
Body Structure
Wood Sill 0.5 (12) Minimum
Truck Frame
U-Bolt Spacer (Hardwood)
Frame Rail Spacer
(Fabricated Steel or
Hardwood)
FIGURE 6-7. 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,
fuel lines, or wiring may 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. Failure to comply may result in personal injury, death, equipment or
property damage. See Figure 6–8.
CAUTION:
Mount U–bolts so they do not chafe on frame rail. Failure to do so may result in
premature wear of the U-bolt or frame rail.
12/09
6-6
Section 6
Body Mounting
Frame Rail
Air Lines and Wiring
Harness
Check Clearance
Space for Air
Lines and Wiring
U-Bolt
Frame Rail Spacer
(Hardwood or Steel
U-Bolt Spacer
FIGURE 6-8. 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
may result in premature frame failure. Use a larger size U–bolt. Use a hardwood spacer as
shown in Figure 6-7. Failure to comply may result in personal injury, death, equipment or
property damage.
6-7
12/09
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 6–9. 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 6-9. Example of Fishplate Bracket at Rear End of Body, used with U-Bolts
12/09
6-8
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 application. The modifications may be as simple as shortening or lengthening the frame cutoff, or they may be as complex 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 may fail prematurely. Mount the body using body mounting brackets or U–bolts. Failure to comply may result
in personal injury, death, equipment or property damage.
WARNING!
Do not drill closely spaced 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
may induce a failure between the holes. Failure to comply may result in personal injury,
death, equipment or property damage.
CAUTION:
An appropriately sized bolt and nut must be installed and torqued properly in all unused
frame holes. Failure to do so may result in frame crack initiation around the hole and
equipment damage.
WARNING!
Use care when drilling the frame web so the wires and air lines routed inside the rail are
not damaged, failure to do so may cause an inoperable electrical or air system circuit.
Failure to comply may result in personal injury, death, equipment or property damage.
CAUTION:
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 may result in frame rail
cracks and equipment damage.
CAUTION:
Hole diameter should not exceed the bolt diameter by more than .060 inches (1.5 mm).
Oversized holes may result in excessive frame wear around the hole and equipment
damage.
7-1
12/09
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.
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) clearance. Do not weld reinforcing members. The insert should span a distance of at least 24 in. (610 mm) on either side of the
joint 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.
FIGURE 7-1. Detail of Frame Extension and Joint Welding
12/09
7-2
Section 7
Frame Modifications
WELDED
JOINT
24 Inch
Minimum
(610 mm)
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 following 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.
WARNING!
When changing the wheelbase, be sure to follow the driveline manufacturer’s recommendations for driveline length or angle changes. Incorrectly modified drivelines may fail prematurely due to excessive vibration. Failure to comply may result in personal injury, death,
equipment or property damage.
Before changing the wheelbase the driveline angles of the proposed wheelbase need to be examined to ensure that no
harmful vibrations are 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
through the original rail and the insert/outsert. Failure to do so may cause excessive
stress in the original rail due to additional holes. Failure to comply may result in personal
injury, death, equipment or property damage.
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 may result in premature failure of the added section splice. Use care when planning the wheelbase so that the rear suspension bracket is
always mounted on the original rail section. See Figure 7–3. Failure to comply may result
in personal injury, death, equipment or property damage.
7-3
12/09
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. Failure to comply may result in personal injury, death,
equipment or property damage.
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.
Mount the suspension Brackets On the
Original Rail (see frame insert section &
Figures 7-1 and 7-2)
Extended Wheelbase
Do Not Mount the
Suspension Bracket
On the Added
Frame Rail
Original Wheelbase
Relocated Rear
Suspension
Cut Frame at Rear to
Obtain Desired Cutoff
Shortened Wheelbase
FIGURE 7-3. Comparison of Original, Shortened, and Extended Wheelbases.
12/09
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
adjacent crossmembers exceeds this dimension, add a crossmember between them. See Figure 7–4.
Less Than 60”
Before Wheelbase is Lengthened
Greater Than 60”
Additional Crossmember
FIGURE 7-4. Crossmember Added When Distance Exceeds 60 Inches (1524 mm)
7-5
12/09
Section 7
Frame Modifications
WELDING
Kenworth DOES NOT recommend frame welding. The high heat of welding nullifies the special heat treatment of the
rails, greatly reducing the tensile strength of the frame rail. If a frame 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:
CAUTION:
CAUTION:
Before welding, disconnect the negative terminal battery cable. Failure to comply may
result in equipment damage.
Before welding, disconnect the alternator terminals. Failure to do so may result in
damage to the voltage regulator and/or alternator.
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
and other parts will be damaged if current must pass through them in order to complete
the circuit.
Welding Precautions: All Electronic Engines
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 maximum weld current and minimum risk to damage electrical components on the vehicle.
5. Turn off key.
Note:
12/09
Bendix ABS, Bosch ABS and Wabco ABS: Disconnect ECU.
7-6
Section 7
Frame Modifications
TORQUE REQUIREMENTS
TABLE 7-1. Customary Grade 8 UNF or UNC.
Fastener
Torque
Size
Nm
Lb.-Ft
5/16
22–30
16–22
3/8
41–54
30–40
7/16
77–88
57–65
1/2
109–122
80–90
9/16
156–190
117-140
5/8
226–265
167–195
3/4
396–462
290–340
7/8
517–626
380–460
1
952–1129
800–830
1-1/8
1346–1591
990–1170
1-1/4
1877–2217
1380–1630
Torque values apply to fasteners with clean threads, lightly lubricated, with hardened steel washers, and nylon-insert nuts.
TABLE 7-2. U.S. Customary – Grade 8. Metric Class 10.9
Torque
Fastener
Nm
Lb-Ft
M6
9–15
7–11
M8
23–31
17–23
M10
33–43
26–32
M12
77–101
57–75
M14
136–164
99–121
M16
163–217
120–160
M20
352–460
260–340
7-7
12/09
This page intentionally left blank.
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.
Clamp: 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 compressor 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.
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 temperatures 220°F (150°) and -40°F (-40°).
9-1
12/09
Section 9
Routing
Heavy duty tie straps 0.50in (12.7mm) wide (Tyton T255ROHIR or similar) shall be used
whenever HD mounts are specified, although 0.25in (6.4mm) tie straps may be used in
some specified applications.
Note:
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 included 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 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 warmers, 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 convoluted tubing whether they are in bundles or not.
12/09
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 and 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 plastic 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 covered 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 there 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
12/09
Section 9
Routing
Routing of Wires and Hoses near Exhaust System
TABLE 9-1. Exhaust – System Clearance
Description
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
over 15” from the turbo
n/a
4” minimum
2” minimum 3” minimum
Fuel tanks and hydraulic tanks
crossing tank
parallel to tank
end of tank
aluminum/ceramic-coated exhaust pipe crossing tank
n/a
n/a
n/a
n/a
Air hose
nylon
wire braid
3” minimum 8” minimum
2” minimum 3” minimum
2” minimum
2” minimum
1” minimum
1.5” minimum
Shielded dimension
Unshielded dimension
Component
Heatshield (or blanket)
Exhaust system
(pipe, muffler)
FIGURE 9-5. Definition of measurements.
12/09
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 vehicle serial number
(6). See Figure A–1.
M
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.
Code
5
6
7
8
Year
2005
2006
2007
2008
9
2009
Code
A
B
C
D
Year
2010
2011
2012
2013
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
12/09
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, and Paint Identification. Quantity and location of labels may differ based on Complete/Incomplete
vehicle, and Single/Dual certification.
Labels:
Tire, Rim & Weight Rating,
Certification,
Major Components &
Weights,
Paint,
Canadian Safety Mark (Canadian registry only),
U.S. EPA Noise,
Patent, and others.
Chassis Serial
Number
Note: Final Stage
Manufacturer Label to be
installed by Final Stage
Manufacturer on driver’s
door edge or driver’s door
frame.
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:
•
•
•
GVWR — Gross Vehicle Weight Rating
GAWR FRONT and REAR — Gross Axle Weight Ratings for Front and Rear Axle
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 gross weight information, as well as model and
serial numbers for the vehicle, engine, transmission, and axles.
12/09
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 interior 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).
Engine Identification
Location
(PACCAR PX-8 Shown)
Figure A-3. Engine Identification Location
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.
A-3
12/09
Appendix A
Vehicle Identification
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.
FIGURE A-4. Front Axle 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.
2
1
FIGURE A-5. Rear Axle Identification
Note:
12/09
Illustrated identification tag locations are typical. Actual locations may vary by axle manufacturer and with single versus tandem axles.
A-4
Appendix A
Vehicle Identification
This page intentionally left blank.
A-5
12/09
Appendix A
Vehicle Identification
®
Kenworth Truck Company
P.O. Box 1000
Kirkland, WA 98083
(425) 828-5000
12/09
A-6
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