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Kenworth Heavy Duty Body Builder Manual
2019
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Kenworth Heavy Duty 2.1m Cab
Body Builder Manual
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Body Builder Manual Contents
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SECTION 1: INTRODUCTION 1-1
SECTION 2: SAFETY & COMPLIANCE 2-1 SAFETY SIGNALS 2-1 FEDERAL MOTOR VEHICLE SAFETY
STANDARDS COMPLIANCE 2-2
SECTION 3: DIMENSIONS 3-1 DIMENSIONS 3-1 ABBREVIATIONS 3-1 TURNING RADIUS 3-1 OVERALL DIMENSIONS 3-5 T680 STANDARD HOOD DAYCAB 3-6 T680 MX (SHORT) HOOD DAYCAB 3-7 T880 STANDARD HOOD DAYCAB 3-8 T880S SFFA (SHORT) HOOD DAYCAB 3-9 T680 STANDARD HOOD 40 SLEEPER 3-10 T680 MX (SHORT) HOOD 40 SLEEPER 3-11 T880 STANDARD HOOD 40 SLEEPER 3-12 T880S SFFA (SHORT) HOOD 40 SLEEPER 3-13 T680 STANDARD HOOD 52 SLEEPER 3-14 T680 MX (SHORT) HOOD 52 SLEEPER 3-15 T880 STANDARD HOOD WITH 52 SLEEPER 3-16 T880 MX (SHORT) HOOD WITH 52 SLEEPER 3-17 T680 STANDARD HOOD WITH 76 HIGH-ROOF SLEEPER 3-18 T680 MX (SHORT) HOOD WITH 76 HIGH-ROOF SLEEPER 3-19 T680 STANDARD HOOD WITH 76 MID-ROOF SLEEPER 3-20 T680 MX (SHORT) HOOD WITH 76 MID-ROOF SLEEPER 3-21 T880 STANDARD HOOD WITH 76 MID-ROOF SLEEPER 3-22 T880 MX (SHORT) HOOD WITH 76 MID-ROOF SLEEPER 3-23 RIDE HEIGHTS 3-24 REAR SUSPENSION LAYOUTS 3-26 AG400L TANDEM 3-27 AG400 OR AG460 TANDEM 3-28 AG460 TANDEM 3-29 AG690 TRIDEM 3-30 REYCO 79KB SINGLE REAR AXLE 3-31 REYCO 102 TANDEM REAR AXLE 3-32 NEWAY ADZ 123 SINGLE REAR AXLE 3-33 NEWAY ADZ 246 TANDEM SUSPENSION 3-34 NEWAY ADZ 369 TRIDEM SUSPENSION 3-35 HENDRICKSON PRIMAAX EX TANDEM SUSPENSION 3-36 HENDRICKSON PRIMAAX EX TRIDEM SUSPENSION 3-37 HENDRICKSON UMX TANDEM SUSPENSION 3-38 HENDRICKSON RT TANDEM SUSPENSION 3-39 CHALMERS 856-46 TANDEM SUSPENSION 3-40 LIFT AXLES (PUSHERS AND TAGS) 3-42 AXLE TRACK AND TIRE WIDTH 3-45
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SECTION 4: PTO MOUNTING & PROGRAMMING 4-1 4-1 PTO MOUNTING 4-1 4-2 PTO TELLTALE: 4-3 PTO WIRING DIAGRAM 4-6 4-3 PTO CLEARANCES 4-8 4-4 T680/880 TRANSMISSION PTO APPLICATION GUIDE 4-10 4 5 PTO CONTROLS: 4-14 4-6 ELECTRIC OVER AIR SYSTEM INTERLOCKING 4-22 4-7 PACCAR MX ENGINES - PTO PROGRAMMING: 4-25
SECTION 5: EXHAUST & AFTERTREATMENT 5-1 EXHAUST AND AFTER-TREATMENT INFORMATION 5-1 GENERAL GUIDELINES FOR DEF SYSTEM 5-3 GENERAL EXHAUST INFORMATION 5-7
SECTION 6: FRAME LAYOUTS 6-1 FRAME LAYOUTS 6-1 COMMON OPTIONAL COMPONENTS 6-2 FRAME LAYOUT INDEX 6-4
SECTION 7: BODY MOUNTING 7-1 FRAME INFORMATION 7-1 CRITICAL CLEARANCES 7-2 BODY MOUNTING USING BRACKETS 7-3 MOUNTING HOLES 7-5 BODY MOUNTING USING UBOLTS 7-6
SECTION 8: FRAME MODIFICATIONS 8-1 FRAME MODIFICATIONS 8-1 DRILLING RAILS 8-1 MODIFYING FRAME LENGTH 8-2 CHANGING WHEELBASE 8-3 CROSSMEMBERS 8-5 WELDING 8-6 TORQUE REQUIREMENTS 8-7
SECTION 9: ELECTRICAL 9-1 ELECTRICAL 9-1 BODY BUILDER CONNECTION POINTS 9-3 LIFT AXLES (PUSHERS & TAG) 9-19
SECTION 10: ROUTING 10-1 ROUTING 10-1 ROUTING REQUIREMENTS 10-2
APPENDIX A: VEHICLE IDENTIFICATION 1 VEHICLE IDENTIFICATION LABELS 2
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Figures
FIGURE 2-1. Incomplete Vehicle Certification Document 2-2 FIGURE 2-2. Locations Of Certification Labels - Drivers Door And Frame 2-2 FIGURE 2-3: Aerodynamic Mirror Oat Sensor Location 2-8 FIGURE 2-4: Instrument Cluster For T680/T880 2-8 FIGURE 3-1. Prospecter Turn Circle Analysis 3-4 FIGURE 4-1. Medium Duty Manual Transmission Ptos 4-1 FIGURE 4-2. Heavy Duty Manual Transmission Ptos 4-1 FIGURE 4-3. Thru-Shaft Pto 4-2 FIGURE 4-4. Allison 4000 Series Transmission Pto Locations 4-2 FIGURE 4-5. Allison 3000 Series Transmission Pto Locations 4-2 FIGURE 4-6. Repto Location Shown 4-3 FIGURE 4-7. Pto Icon 4-3 FIGURE 4-8. Pto Telltale Location 4-4 FIGURE 4-9. Relay Wiring Diagram 4-4 FIGURE 4-10. 2013+ Mx-11 And Mx-13 Pin-Out 4-5 FIGURE 4-11. 2013+ Isx15, Isx12, Px-9 Pin-Out 4-5 FIGURE 4-12. Pto Wiring Diagram 4-6 FIGURE 4-13. Single Acting And Dual Acting Ptos 4-15 FIGURE 4-14. Single-Acting Eaton Pto 4-17 FIGURE 4-15. Double-Acting Eaton Pto 4-17 FIGURE 4-16. Allison Transmission-Mounted Ptos 4-18 FIGURE 4-17. Auto Susp Dump W/ Allison Mtd Pto 4-19 FIGURE 4-18. Eoa Reversible Pto Example 4-20 FIGURE 4-19. Air Actuated Pto (No Interlock) 4-20 FIGURE 4-20. Rear Axle Declutch Telltale 4-21 FIGURE 4-21. Split Shaft Pto Example #1 4-21 FIGURE 4-22. Pump Mode Example 4-22 FIGURE 4-23. Sample Chassis Node And Eoa Manifold. 4-23 FIGURE 4-24. Wiring Diagram For Chassis Node, Cab Switches, And Eoa Manifold 4-24 FIGURE 4-25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-27 FIGURE 4-26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-28 FIGURE 4-27. In-Cab Pto Control For T680/T880 4-29 FIGURE 4-28. In-Cab Pto Control Esa Settings For T680/T880 4-30 FIGURE 4-29. Hard-Wired Remote Pto Control 4-31 FIGURE 4-30. Hardwired Remote Pto Control Esa Settings For T680/T880 4-33 FIGURE 4-31. Remote Pto Control Over Bcan With Pto On/Off Switch Hardwired To Cecu 4-34 FIGURE 4-32. Remote Pto Control Over Bcan With Hardwired Pto Engagement Feedback
To Engine Esa Settings T680/T880 4-36 FIGURE 4-33. Remote Pto Control Over Bcan With Hardwired Pto Engagement Feedback
To Engine Esa Settings T680/T880 4-37 FIGURE 4-34. Remote Pto Control Over Bcan With Pto On/Off Switch Signal Over Bcan 4-38 FIGURE 4-35. Remote Pto Control Over Bcan With Pto On/Off Switch Signal Over Bcan
Esa Settings For T680/T880 4-40 FIGURE 4-36. Remote Pto Control Over Bcan With Pto On/Off Switch Signal Over Bcan
Esa Settings For T680/T880 4-41 FIGURE 4-37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-42 FIGURE 4-38 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-43 FIGURE 5-1. Routing Def And Coolant Lines 5-5 FIGURE 5-2. Supply Module Allowed Clocking Angle Limit Scribes A 90 Inverted Cone. 5-6 FIGURE 5-3. Isometric View Of Right Hand Under Dpf/Scr With Single Side Of Cab Tailpipe 5-8 FIGURE 5-4. Isometric View Of Right Hand Under Dpf/Scr With Single Side Of Cab Tailpipe 5-8 FIGURE 5-5. Right View Of Right Hand Under Dpf/Scr With Single Side Of Cab Tailpipe 5-9 FIGURE 5-6. Back View Of Right Hand Under Dpf/Scr With Single Side Of Cab Tailpipe 5-9 FIGURE 5-7. Isometric View Of Right Hand Under Dpf/Scr With Dual Side Of Cab Tailpipe 5-10 FIGURE 5-8. Isometric View Of Right Hand Under Dpf/Scr With Dual Side Of Cab Tailpipe 5-10
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FIGURE 5-9. Right View Of Right Hand Under Dpf/Scr With Dual Side Of Cab Tailpipe 5-11 FIGURE 5-10. Back View Of Right Hand Under Dpf/Scr With Dual Side Of Cab Tailpipe 5-11 FIGURE 5-11. Isometric View Of Right Hand Under Dpf/Scr With Single
Back Of Cab Tailpipe 5-12 FIGURE 5-12. Isometric View Of Right Hand Under Dpf/Scr With Single
Back Of Cab Tailpipe 5-12 FIGURE 5-13. Right View Of Right Hand Under Dpf/Scr With Single Back Of Cab Tailpipe 5-13 FIGURE 5-14. Back View Of Right Hand Under Dpf/Scr With Single Back Of Cab Tailpipe 5-13 FIGURE 5-15. Isometric View Of Right Hand Under Dpf/Scr With Ground-Dump Tailpipe 5-14 FIGURE 5-16. Isometric View Of Right Hand Under Dpf/Scr With Ground-Dump Tailpipe 5-14 FIGURE 5-17. Right View Of Right Hand Under Dpf/Scr With Ground-Dump Tailpipe 5-15 FIGURE 5-18. Back View Of Right Hand Under Dpf/Scr With Ground-Dump Tailpipe 5-15 FIGURE 5-19. Isometric View Of Independent Back Of Cab Dpf/Scr With
Back Of Cab Tailpipe 5-16 FIGURE 5-20. Isometric View Of Independent Back Of Cab Dpf/Scr With
Back Of Cab Tailpipe 5-16 FIGURE 5-21. Right View Of Independent Back Of Cab Dpf/Scr With Back Of Cab Tailpipe 5-17 FIGURE 5-22. Back View Of Independent Back Of Cab Dpf/Scr With Back Of Cab Tailpipe 5-17 FIGURE 5-23. Isometric View Of Horizontal Dpf/Scr With Ground-Dump Tailpipe 5-18 FIGURE 5-24. Isometric View Of Horizontal Dpf/Scr With Ground-Dump Tailpipe 5-18 FIGURE 5-25. Right View Of Horizontal Dpf/Scr With Ground-Dump Tailpipe 5-19 FIGURE 5-26. Back View Of Horizontal Dpf/Scr With Ground-Dump Tailpipe 5-19 FIGURE 5-27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20 FIGURE 5-28. Dimension A = Top Of Rail Frame Height From Prospector Frame Depth. 5-21 FIGURE 6-1. Def Tank Dimensions. 6-3 FIGURE 7-1. Minimum Clearance Between Top Of Rear Tires And Body Structure Overhang. 7-2 FIGURE 7-2. Minimum Back Of Cab Clearance 7-3 FIGURE 7-3. Spacer Between Frame Sill And Body Rail - Rubber Or Plastic 7-4 FIGURE 7-4. High Compression Spring 7-4 FIGURE 7-5. Rubber Spacer Between BracketsBetween The Mounting Bolt
And Upper Bracket 7-4 FIGURE 7-6. Crossmember-Gusset Hole Pattern Requirements. [Inch (Mm)] 7-5 FIGURE 7-7. Acceptable U-Bolt Mounting With Wood And Fabricated Spacers [Inch (Mm)] 7-6 FIGURE 7-8. Clearance Space For Air Lines And Cables 7-7 FIGURE 7-9. Example Of Fishplate Bracket At Rear End Of Body, Used With U-Bolts 7-8 FIGURE 8-1. Detail Of Frame Extension And Joint Welding 8-2 FIGURE 8-2. Frame Insert 8-3 FIGURE 8-3. Comparison Of Original, Shortened, And Extended Wheelbases. 8-4 FIGURE 8-4. Crossmember Added When Distance Exceeds 60 Inches (1524 Mm) 8-5 FIGURE 9-1. Namux 4 System Diagram 9-1 FIGURE 9-2. Diagnostic Connector Comparison 9-2 FIGURE 9-3. 2016+ Service Environment 9-2 FIGURE 9-4. 12 Pin Connector 9-3 FIGURE 9-5. Spare Circuit Connector Detail 9-3 FIGURE 9-6. Grounding Buss Bar Design 9-4 FIGURE 9-7. Grounding Point - Cab Interior Behind Drivers Side Kick Panel 9-4 FIGURE 9-8. Grounding Point - Cab Exterior Lh Side Of Firewall 9-4 TABLE 9-1. Wire Number General Categories 9-5 FIGURE 9-9. Spare Circuit Location Under-Dash (P096) 9-6 FIGURE 9-10. Spare Circuit Location On Power Distribution Center (Dash-Side, P001) 9-7 FIGURE 9-11. Spare Circuit Diagram (P001 And P096) 9-8 FIGURE 9-12. Electric Engaged Equipment Connector 9-9 FIGURE 9-13. Air Solenoid Bank And Chassis Node 9-9 FIGURE 9-14. Rear Axle Controls And Sensors Connector 9-10 FIGURE 9-15. B-Can Connector 9-11
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FIGURE 9-16. Chassis Harness From Cab Mount To Front Of Frame 9-11 FIGURE 9-17. Chassis Harness From Cab Mount To Boc 9-12 FIGURE 9-18. Connectors Near Front Cab Mount 9-12 FIGURE 9-19. Connector Near Boc 9-13 FIGURE 9-20. Vcan Connectors 9-13 FIGURE 9-21. Firewall Connectors 9-13 FIGURE 9-22. Chassis Node And Electric Over Air Solenoid Bank 9-14 FIGURE 9-23. Installing Additional Switches Onto The Chassis Side 9-15 FIGURE 9-24. Installing Additional Gauges On The Dash 9-16 FIGURE 9-25. Installing Sensors On The Chassis Side For Gauges 9-17 FIGURE 9-26. Typical Installation Of Sensors Diagram 9-18 FIGURE 9-27. Spare Power Connector 9-18 FIGURE 9-28. Truck Lift Axles (Separate Switches) 9-19 FIGURE 9-29. Truck Lift Axles (Single Switch) 9-19 FIGURE 9-30. Eoa Trailer Lift Axles 9-20 FIGURE 9-31. Mx-13 Connection Location. 9-22 FIGURE 9-32. Mx-11 Connection Location. 9-22 FIGURE 9-33. Isx15 Connection Location 9-23 FIGURE 9-34. Isx12 Connection Location. 9-23 FIGURE 9-35. Mating Connector: Packard Pn 12020786 9-30 FIGURE 9-36. Junction Box Boc Or Eof 9-30 FIGURE 9-37. Dash Access 9-31 FIGURE 9-38. Engine Access 9-31 FIGURE 9-39. J1939 Access 9-32 FIGURE 9-40. J1939 Access 9-32 FIGURE 9-41. J1939 Access 9-33 FIGURE 9-42. Trim Panel Removal 9-34 FIGURE 9-43. Gauge Installation 9-34 FIGURE 9-44. Switch Installation 9-35 FIGURE 9-45. Cluster Removal 9-35 FIGURE 9-46. Telltale Installation Diagnostics & Service Tool Connection 9-36 FIGURE 10-1. Clamp And Butterfly Clamp 10-1 FIGURE 10-2. Butterfly Tie 10-1 FIGURE 10-3. Tie Strap 10-1 FIGURE 10-4. Heavy Duty (Hd) Mount. 10-2 FIGURE 10-5. Definition Of Measurements. 10-4
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Tables
TABLE 3-1. Abbreviations Used 3-1 TABLE 3-2. Turning Radius 3-1 TABLE 3-3. Ride Heights. To calculate the frame height use the following formulas: 3-24 TABLE 3-4. Rear Suspension Options 3-27 TABLE 3-5. Rear Suspension Options 3-28 TABLE 3-6. Rear Suspension Options 3-29 TABLE 3-7. Rear Suspension Options 3-30 TABLE 3-8. Rear Suspension Options 3-31 TABLE 3-9. Rear Suspension Options 3-32 TABLE 3-10. Rear Suspension Options 3-33 TABLE 3-11. Rear Suspension Options 3-34 TABLE 3-12. Rear Suspension Options 3-35 TABLE 3-13. Rear Suspension Options 3-36 TABLE 3-14. Rear Suspension Options 3-37 TABLE 3-15. Rear Suspension Options 3-38 TABLE 3-16. Rear Suspension Options 3-39 TABLE 3-17. Rear Suspension Options 3-40 TABLE 3-18. Axle Width Calculation. 3-45 TABLE 3-19. Ground Clearance for Fuel Tanks 3-47 TABLE 3-20. Ground Clearance for Battery Boxes 3-48 TABLE 4-1. 4-11 TABLE 4-2. 4-12 TABLE 4-3. 4-13 TABLE 4-4. Current single-acting PTOs include: 4-16 TABLE 4-6. Reversible PTO States to Ports 4-20 TABLE 4-7. PACCAR PTO TSC1 Message Requirements 4-26 TABLE 4-8. In cab PTO Control ESA Settings for T680/T880 4-29 TABLE 4-9. In-Cab PTO Control PEP Settings 4-31 TABLE 4-10. J1939 signals from CECU (SA 0x31) to Engine over VCAN 4-32 TABLE 4-11. Hard-wired Remote PTO Control ESA Settings for T680/T880 4-32 TABLE 4-12. Hardwired Remote PTO Control PEP Settings 4-34 TABLE 4-13. J1939 signals from CECU (SA 0x31) to Engine over VCAN 4-35 TABLE 4-14. Engine Fault Codes 4-35 TABLE 4-15. Remote PTO Control over BCAN with hardwired PTO Engagement
Feedback to Engine ESA Settings T680/T880 4-35 TABLE 4-16. Hardwired Remote PTO Control PEP Settings 4-37 TABLE 4-17. J1939 signals from CECU (SA 0x31) to Engine over VCAN 4-39 TABLE 4-18 4-39 TABLE 4-19. Remote PTO Control over BCAN with PTO ON/OFF Switch Signal over
BCAN ESA Settings for T680/T880 4-39 TABLE 4-20. Hardwired Remote PTO Control PEP Settings 4-44 TABLE 4-21. PACCAR BCAN Message Requirements 4-44 TABLE 5-1. 5-3 TABLE 5-2. 5-20 TABLE 6-1. 6-1 TABLE 6-2. Fuel Tank Overall Length (in) 6-2 TABLE 6-3. Battery Box Centerframe Lengths (in) 6-2 TABLE 6-5. 6-6 TABLE 6-6. 6-7 TABLE 6-7. 6-8 TABLE 6-8. 6-9 TABLE 6-9. 6-10 TABLE 6-10. 6-11 TABLE 6-11. 6-12 TABLE 6-12. 6-13
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TABLE 6-13. 6-14 TABLE 6-14. 6-15 TABLE 6-15. 6-16 TABLE 6-16. 6-17 TABLE 6-17. 6-18 TABLE 6-18. 6-19 TABLE 6-19. 6-20 TABLE 7-1. Single Steel Rails 7-1 TABLE 7-2. Inserted Steel Rails 7-1 TABLE 8-1. Customary Grade 8 UNF or UNC. 8-7 TABLE 8-2. U.S. Customary Grade 8. Metric Class 10.9 8-7 TABLE 9-2. Truck Lift Axle Logic 9-20 TABLE 9-3. Air Solenoid Types 9-20 TABLE 9-4. MX engine (P111C/J111C) 9-21 TABLE 9-5. ISX Remote Throttle/PTO Connector P111A/J111A: 9-23 TABLE 9-6. EoA Chassis Node Guide 9-24 TABLE 9-7. EoA CECU Guide 9-24 TABLE 9-8. CECU Parameters 9-25 TABLE 9-9. Interlocks 9-27 TABLE 10-1. Exhaust System Clearance 10-4
Tables
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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, guide- lines for modifying frames, electrical wiring information, and other information useful in the body installation process. This manual is specific to chassis with 2017 EPA emissions engines.
The Body Builder Manual can be very useful when specifying a vehicle, particularly when the body builder is involved in the vehicle definition and ordering process. Early in the process, professional body builders can often contribute valuable information that reduces the ultimate cost of the body installation.
In the interest of continuing product development, Kenworth reserves the right to change speci- fications or products at any time without prior notice. It is the responsibility of the user to ensure that he is working with the latest released information. Check Kenworth.com for the latest released version.
If you require additional information or reference materials, please contact your local Kenworth dealer.
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Section 2 Safety & Compliance
SAFETY SIGNALS Weve put a number of alerting messages in this book. Please read and follow them. They are there for your protection and information. These alerting messages can help you avoid injury to yourself or others and help prevent costly dam- age to the vehicle.
Key symbols and signal words are used to indicate what kind of message is going to follow. Pay special attention to comments prefaced by WARNING, CAUTION, and NOTE. Please dont ignore any of these alerts.
Warnings, cautions, and notes
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 dont heed the warning, and how to avoid it.
Example:
WARNING! Be sure to use a circuit breaker designed to meet liftgate amperage requirements. An incor- rectly specified circuit breaker could result in a electrical overload or fire situation. Follow the liftgate installation instructions and use a circuit breaker with the recommended capacity.
Signals a potentially hazardous situation which, if not avoided, could result in minor or mod- erate injury or damage to the vehicle.
Example:
CAUTION: Never use a torch to make a hole in the 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.
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.
WARNING
CAUTION
NOTE
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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 21. In addition, affixed to the drivers side door frame or edge is an Incomplete Vehicle Certification label. See Figure 22. For further information on Vehicle Certification and Identification, see APPENDIX A VEHICLE IDENTIFICATION.
These documents list the U.S. or Canadian Federal Motor Vehicle Safety Standard regulations that the vehicle complied with when it left the build plant. You should be aware that if you add, modify or alter any of the components or systems covered by these regulations, it is your responsibility as the Intermediate or Final Stage Manufacturer to ensure that the complete vehicle is in compliance with the particular regula- tions upon completion of the modifications.
FIGURE 2-1. Incomplete Ve- hicle Certification Document
FIGURE 2-2. Locations of Certifica- tion Labels - Drivers Door and Frame
NOTE
U.S. EPA Noise Label (U.S. registered vehicles only)
Final Stage Manufacturer Label to be Installed by Final Stage Manufacturer
Chassis Serial Number
Major Components and Weights Label
Incomplete Vehicle Certification Label
Safety Mark (Canadian Registry Only)
Tire, Rim and Weight Rating Data label
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 22.) Be advised that regulations affecting the intermediate and final stage manufacturer may change without notice. Ensure you are referencing the most updated copy of the regulation during the certification and documentation processes.
In part, if the final stage manufacturer can complete and certify the vehicle within the instruction in the incomplete vehicle document (IVD) the certification label would need a statement that reads, This vehicle has been completed in accordance with the prior manufacturers IVD where applicable. This vehicle conforms to all applicable Federal Motor Vehicle Safety Standards [and Bumper and Theft Prevention Standards if applicable] in effect in (month, year).
However, if the vehicle can not be completed and certified with in the guidance provided in the IVD, the final stage manu- facturer must ensure the vehicle conforms to all applicable Federal Motor Vehicle Safety Standards (FMVSS). The final stage manufactures certification label would need a statement that reads, This vehicle conforms to all applicable Federal Motor Vehicle Safety Standards [and Bumper and Theft Prevention Standards if applicable] in effect in (month, year).
Vehicle Emission Control Information Label
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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/index-eng.html; and http://www.tc.gc.ca/eng/acts-regulations/menu.htm for the regulations.
Or contact:
Transport Canada Tower C, Place de Ville, 330 Sparks Street Ottawa, Ontario K1A 0N5 (613) 990-2309 TTY: 1-888-675-6863
Noise and Emissions Requirements
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. Additionally, most vehicles in North America will be equipped with a Greenhouse Gas (GHG) Vehicle Emission Control Information door label indicating its certified configuration. The vehicle components listed on this label are considered emission control devices.
Modifying (i.e. altering, substituting, relocating) any of the emissions control components/sys- tems defined above will affect the noise and emissions performance/certification. Modifications that alter the overall shape and aerodynamic performance of a tractor will also affect the emis- sion certification. If modifications are required, they must first be approved by the manufacturer. Unapproved modifications could negatively affect emissions performance/certification. There is no guarantee that proposed modifications will be approved.
Tires may be substituted provided the new tires possess a Coefficient of rolling resistance (Crr) equal to or lower than Crr of the original tires. Consult with your tire supplier(s) for appropriate replacement tires. Contact the engine manufacturer for any requirements and restrictions prior to any modifications.
For Cummins Contact 1-800-DIESELS or your local Cummins distributor. Reference AEB 21.102.
It is possible to relocate the DEF tank, however the relocation requirements need to be followed. Any variance from the relocation requirements may cause the emissions control components/systems to operate improperly potentially resulting in engine de-rate. See page 4-3 for relocation requirements.
All 2017 engine emissions certified vehicles will be equipped with an On-Board Diagnostics (OBD) system. The OBD system is designed to detect malfunctions of any engine or vehicle com- ponent that may increase exhaust emissions or interfere with the proper performance of the OBD system itself.
NOTE
NOTE
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All diesel engines will be equipped with an On-Board Diagnostics (OBD) system. The OBD system consists of computer program on one or more of the vehicles 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 diag- nostic purposes. A Malfunction Indicator Light (MIL) is illuminated in the dash to alert the driver of the need for service of an emission-related component or system.
To ensure compliance to emissions regulations, the final configuration of certain features of the completed vehicle must meet specific requirements. This section describes requirements relevant for only the most common or critical modifi- cations done by body builders. For a complete description of acceptable modifications, see the application guidance available from the manufacturer of the engine installed in the chassis.
Fuel System The following are highlights of some of the more common or critical aspects of this system.
The overall system restriction may not exceed the restriction limitations set forth by the engine manufacturer for both supply and return.
Ensure that fuel lines are not pinched or can potentially be damaged when installed between body and frame
Fuel lines must be routed and secured without dips or sags
There must be easy access to filter(s) and fill cap
The tank vent may not obstructed
Added accessories (heaters, generators) cannot introduce air into system
Fuel tank must be located so that the full level is not above cylinder head
Ultra Low Sulfur Fuel Only labels must be present on the dash and fuel fill
Modification of the pressure side secondary filter and plumbing is not allowed without engine manufacturer approval
Body installation of fuel tank or routing of lines must not cause significant increase in fuel temperature
Fuel hoses shall meet or exceed OEM supplied hose material construction specifications
Formed nylon fuel lines with quick-connects are installed underneath the cab and hood along the frame rail. Behind the cab from the fuel tee to tanks are wirebraid-reinforced rubber lines. Supply and return fittings are poka-yoked to prevent incorrect assembly.
Nylon Wirebraid-reinforced rubber
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PARTS
Replacement nylon fuel line assemblies are available based on individual chassis and fuel system hardware. For other chassis changes, individual parts are listed below.
DESCRIPTION USE PART NO. Supply Tee All ports open Dual LH and RH fuel tanks K38-1057
Supply Tee RH port closed Only LH fuel tank(s) K38-1058
Supply Tee LH port closed Only RH fuel tank(s) K38-1059
Return Tee All ports open Dual LH and RH fuel tanks K38-1060
Return Tee RH port closed Only LH fuel tank(s) K38-1061
Return Tee LH port closed Only RH fuel tank(s) K38-1062
Supply Fitting Straight Nylon line assemblies K38-1069-001
Supply Fitting 90 Nylon line assemblies K38-1069-002
Return Fitting Straight Nylon line assemblies K38-1069-003
Return Fitting 90 Nylon line assemblies K38-1069-004
Supply Union Short-term repair, 12mm ID K38-1069-010
Return Union Short-term repair, 10mm ID K38-1069-009
Supply Rubber Line Assembly Fuel tee to fuel tank lines, xxx in inches
V50-14860082111xxx
Return Rubber Line Assembly Fuel tee to fuel tank lines, xxx in inches
V50-14860063111xxx
Supply Steel Fitting Straight Rubber line assemblies, 1/2 barb K38-1069-007
Return Steel Fitting Straight Rubber line assemblies, 3/8 barb K38-1069-008
Retaining Clip Collar on steel rubber hose fittings K38-1069-015
Bulk Supply Nylon Line Short-term repair, 12mm ID, xxxx in mm
V50-1178-1xxxx
Bulk Return Nylon Line Short-term repair, 10mm ID, xxxx in mm
V50-1178-2xxxx
Supply APU Fitting Additional fuel-powered unit, install in-line at tee
K38-1055
Return APU Fitting Additional fuel-powered unit, install in-line at tee
K38-1056
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.
NPT Port
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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:
DPF assembly SCR Catalyst assembly Exhaust pipes between the engine and after-treatment devices (DPF, SCR Catalyst) and between
after-treatment devices NOx Sensors PM 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
The DPF, the SCR catalyst, or their mounting may not be modified
The NOx sensor may not be relocated or altered in any way; this includes re-clocking the aftertreatement canister or reorienting the sensor(s)
Exhaust pipes used for tailpipes/stacks must be properly sized, and must prevent water from entering
Ensure adequate clearance between the exhaust and body panels, hoses, and wire harnesses
The body in the vicinity of the DPF must be able to withstand temperatures up to 400C (750F)
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
Additional accessories plumbed into the engine cooling system are not permitted, at the risk of voiding vehicle warranty
Coolant level sensor tampering will void warranty
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When installing auxiliary equipment in front of the vehicle, or additional heat exchangers, ensure that adequate air flow is available to the vehicle cooling system. Refer to engine manufacturer application guide- lines for further detail
When installing FEPTO drivelines, the lower radiator anti-recirculation seal must be retained with FEPTO driveline clearance modification only
Changes made to cooling fan circuit and controls are not allowed, with the exception of AC minimum fan on time parameter
See owners 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 9-pin OBD Connector CAN Communication / OBD Diagnostic wiring
If the alternator or battery is substituted, it must meet the requirements of the engine manufactures guide- lines. This includes alternator ground voltage drop and alternator ground cable effectiveness. See the engine manufactures guidelines for recommended test procedure. Additionally the maximum voltage differential and the peak-peak voltage differential between the engine ECM block ground stud and battery negative terminal may not exceed 500 mV under any combination of loads or operating conditions.
Only an OBD compliant battery disconnect switch may be installed on vehicles equipped EPA 2013 and beyond compliant diesel engines. An OBD compliant switch and harness, even in the off position, supply a small amount of power to the engine controller and enable certain emissions critical functions (e.g. DEF line purge). Any modifications to the electrical system which interrupt this power supply will cause OBD fault codes and illumination of the MIL. In addition, such a modification will render the engine non-compliant with certain emission regulations. As a general rule of thumb, you can remove and replace a battery disconnect switch on a truck equipped with a battery disconnect switch at the factory. However, if a battery disconnect switch was not installed in the factory a significant harness modification is required before a battery disconnect switch can be added.
Installation of aftermarket transfer-cases must address the vehicle speed sensor position. The standard posi- tion of the speed sensor is at the transmission tail shaft. When a transfer-case is added it is best to relocate the sensor to the axle side output shaft of the transfer-case. This is typically accomplished by adding a tone wheel into the driveline yoke assembly.
Wiring extensions for the after-treatment wiring are available for relocating the DEF tank from your dealer via Paccar Parts. For relocation of DEF tank, refer to the after-treatment section of this manual.
The emission system requires an accurate Outside Air Temperature (OAT) reading in order to properly run its control algorithms. The OAT sensor is located in the drivers side mirror assembly on Kenworth trucks and is shown in the figures below. If the body builder needs to modify the mirror assembly in any way, it is im- portant the OAT sensor stay positioned on 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.
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FIGURE 2-3: Aerodynamic Mirror OAT Sensor Location
Coolant Sensor considerations are given in the Cooling section above
The OBD/Diagnostic connector port is located below the dash to the left of the steering wheel. This connector and its location may not be changed.
All vehicles equipped with EPA 2013 compliant diesel and bi-fueled engines must be equipped with a Malfunc- tion Indicator Lamp (MIL) lamp. This lamp is required to be an engine outline symbol as defined by ISO (Inter- national 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 2-4: Instrument Cluster for T680/T880 used with EPA 2013 Emission compliant engines. The Check Engine lamp and/or the MIL will appear in the Driver Performance Center (#8). See T680/T880 Operators Manual for more information.
In addition to the sensors and lamps above, the emission system also depends on signals from the exhaust DPF (Diesel Particulate Filter), SCR (Selective Catalytic Reduction), and NOx sensor. Wiring between these devices, the Dosing Control Unit (DCU) and engine ECM should not be tampered with or altered in any way.
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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.
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
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Section 3 Dimensions
DIMENSIONS This section has been designed to provide enough information to successfully layout chassis in the body planning process. Optional equipment may not be depicted. Please contact your local Kenworth dealer if more dimensional information is desired.
ABBREVIATIONS Throughout this section, and in other sections as well, abbreviations are used to describe certain characteristics on your vehicle. The chart below lists the abbreviated terms used.
TABLE 3-1. Abbreviations Used
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 Steering Gear Front Axle Front Wheel Front Tire Rear Suspension
Wheel Base (in.)
Turning Radius (ft)
T680/T880 Single Gear
HD94 or THP60
Dana Spicer E-1202I 12K or E13221 13.2K
Accuride 50487 or Alcoa 88367
22.5 X 8.25 295/75R22.5
Tandem 52 Axle Spacing
181 26.7
193 26.9
201 28.0
213 29.7
220 30.6
232 32.3
240 33.4
252 35.0
260 36.1
272 37.7
280 38.8
291 40.4
303 42.0
323 44.7
331 45.8
TABLE 3-2 CONTINUES ON NEXT PAGE
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Model Steering Gear Front Axle Front Wheel Front Tire Rear Suspension
Wheel Base (in.)
Turning Radius (ft)
T680/T880 Single Gear
HD94 or THP60
Meritor MFS12 or
MFS13
Dana Spicer E-12021 12K or E-13221 13.2K
Accuride 50487 or Alcoa 88367
22.5 X 8.25 11R22.5
Tandem 52 Axle Spacing
181 26.9
193 27.4
201 28.5
213 30.2
220 31.2
232 32.9
240 34.0
252 35.7
260 36.8
272 38.4
280 39.6
291 41.1
303 42.8
323 45.6
331 46.7
T880 Single Gear SD110 or
TAS85
Meritor MFS14
Dana Spicer E-14621
Alcoa 89365 22.5 X 9
315/80R22.5 Tandem 52 Axle Spacing
181 26.9
193 26.9
201 27.9
213 29.6
220 30.5
232 32.2
240 33.2
252 34.0
260 35.1
272 36.7
280 37.8
291 39.2
303 40.8
323 43.4
331 44.5
T880 Dual Gears
HD94 or THP60
Meritor MFS20
Standard Track
Dana Spicer D2000 20K
Standard Track
Alcoa 89365 22.5 X 9
315/80R22.5 Tandem 52 Axle Spacing
181 28.1
193 28.6
201 29.7
213 31.5
220 32.5
232 34.2
240 35.3
252 35.2
260 36.3
272 38.0
280 39.1
291 40.6
303 42.2
323 45.0
331 46.0
TABLE 3-2 CONTINUED
TABLE 3-2 CONTINUES ON NEXT PAGE
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Model Steering Gear Front Axle Front Wheel Front Tire Rear Suspension
Wheel Base (in.)
Turning Radius (ft)
T880 Dual Gears
HD94 or THP60
Meritor MFS20
Standard Track
Dana Spicer D2000 20K
Standard Track
Alcoa 82362 22.5 X 12.25
385/65R22.5 Tandem 52 Axle Spacing
181 28.1
193 28.6
201 29.8
213 31.5
220 32.5
232 34.2
240 35.4
252 35.3
260 36.4
272 38.0
280 39.1
291 40.6
303 42.2
323 45.0
331 46.1
T880 Dual Gears
HD94 or THP60
Meritor MFS20
Standard Track
Dana Spicer D2000 20K
Standard Track
Alcoa 82362 22.5 X 12.25
425/65R22.5 Tandem 52 Axle Spacing
181 28.1
193 28.6
201 29.8
213 31.5
220 32.5
232 34.2
240 35.4
252 36.7
260 37.8
272 39.5
280 40.7
291 42.2
303 43.9
323 46.8
331 47.9
TABLE 3-2 CONTINUED
