Paccar Kenworth T680 2019 Manual Download

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Kenworth Heavy Duty

Body Builder Manual

2019

Summary of Contents for Kenworth T680 2019

Page 1: ...Kenworth Heavy Duty Body Builder Manual 2019 ...

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Page 3: ...Kenworth Heavy Duty 2 1m Cab Body Builder Manual ...

Page 4: ...ER 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 AG4...

Page 5: ...N 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 U BOLTS 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 CROSSMEMB...

Page 6: ...URE 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 Har...

Page 7: ...URE 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 BracketsB...

Page 8: ... 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 ...

Page 9: ...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 ...

Page 10: ... 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 Cl...

Page 11: ...issions 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 rig...

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Page 13: ...te 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 h...

Page 14: ...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...

Page 15: ...sion 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 ...

Page 16: ...on 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 tan...

Page 17: ...k 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 ...

Page 18: ...ster 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 400 C 750 F Do not add thermal insulation to the external surface of the DPF The SCR water drain ho...

Page 19: ...liant 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 comp...

Page 20: ...ion 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...

Page 21: ...y 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 introduc...

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Page 23: ...AME 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 ...

Page 24: ...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...

Page 25: ...andem 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...

Page 26: ...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 FIGURE 3 1 Prospecter Turn Circle Analysis Please consult your local Kenworth Dealer for this information as it is chassis specific ...

Page 27: ... important measurements critical to designing bodies of all types See the Contents at the beginning of the manual to locate the drawing that you need Note To determine overall height please locate the chart Table 3 3 on page 3 12 and add that value to the height All heights are given from the bottom of the frame rail Kenworth also offers dxf files and frame layouts of ordered chassis four weeks pr...

Page 28: ...3 6 Section 3 Dimensions 2 17 T680 STANDARD HOOD DAYCAB The following drawings are of a standard T680 Standard Hood Daycab shown with standard chassis components ...

Page 29: ...3 7 Section 3 Dimensions 2 17 T680 MX SHORT HOOD DAYCAB The following drawings are of a standard T680 MX Short Hood Daycab shown with standard chassis components ...

Page 30: ...3 8 Section 3 Dimensions 2 17 T880 STANDARD HOOD DAYCAB The following drawings are of a standard T880 Standard Hood Daycab shown with standard chassis components ...

Page 31: ... drawings are of a standard T880S SFFA Short Hood Daycab shown with standard chassis components BBC BS 86 2 FS RS 83 8 WB EOF CA 77 1 61 4 37 3 T880S DIMENSIONS BS BBC MIXER TAPERED 28 114 4 DUMP TAPERED 29 5 115 8 BOX BUMPER 33 119 2 119 7 34 53 6 18 3 11 3 11 3 33 3 82 7 ...

Page 32: ...3 10 Section 3 Dimensions 2 17 T680 STANDARD HOOD 40 SLEEPER The following drawings are of a standard T680 Standard Hood 40 Sleeper shown with standard chassis components ...

Page 33: ...3 11 Section 3 Dimensions 2 17 T680 MX SHORT HOOD 40 SLEEPER The following drawings are of a standard T680 MX Short Hood 40 Sleeper shown with standard chassis components ...

Page 34: ...3 12 Section 3 Dimensions 2 17 T880 STANDARD HOOD 40 SLEEPER The following drawings are of a standard T880 Standard Hood 40 Sleeper shown with standard chassis components ...

Page 35: ...g drawings are of a standard T880S SFFA Short Hood 40 Sleeper shown with standard chassis components BS WB 37 2 EOF 87 2 RS 115 7 FS CA 77 1 61 4 18 2 BBS T880S DIMENSIONS BS BBS MIXER TAPERED 28 144 DUMP TAPERED 29 5 145 3 BOX BUMPER 33 148 8 119 7 18 1 11 1 35 11 1 51 34 94 7 ...

Page 36: ...3 14 Section 3 Dimensions 2 17 T680 STANDARD HOOD 52 SLEEPER The following drawings are of a standard T680 Standard Hood 52 Sleeper shown with standard chassis components ...

Page 37: ...3 15 Section 3 Dimensions 2 17 T680 MX SHORT HOOD 52 SLEEPER The following drawings are of a standard T880 MX Short Hood 52 Sleeper shown with standard chassis components ...

Page 38: ...3 16 Section 3 Dimensions 2 17 T880 STANDARD HOOD WITH 52 SLEEPER The following drawings are of a standard T880 Standard Hood with 52 Sleeper shown with standard chassis components ...

Page 39: ...3 17 Section 3 Dimensions 2 17 T880 MX SHORT HOOD WITH 52 SLEEPER The following drawings are of a standard T880 MX Short hood with 52 Sleeper shown with standard chassis components ...

Page 40: ...3 18 Section 3 Dimensions 2 17 T680 STANDARD HOOD WITH 76 HIGH ROOF SLEEPER The following drawings are of a standard T680 Standard Hood with 76 High Roof Sleeper shown with standard chassis components ...

Page 41: ...3 19 Section 3 Dimensions 2 17 T680 MX SHORT HOOD WITH 76 HIGH ROOF SLEEPER The following drawings are of a standard T680 MX Short hood with 76 High Roof Sleeper shown with standard chassis components ...

Page 42: ...3 20 Section 3 Dimensions 2 17 T680 STANDARD HOOD WITH 76 MID ROOF SLEEPER The following drawings are of a standard T680 Standard Hood with 76 Mid Roof Sleeper shown with standard chassis components ...

Page 43: ...3 21 Section 3 Dimensions 2 17 T680 MX SHORT HOOD WITH 76 MID ROOF SLEEPER The following drawings are of a standard T680 MX Short hood with 76 Mid Roof Sleeper shown with standard chassis components ...

Page 44: ...3 22 Section 3 Dimensions 2 17 T880 STANDARD HOOD WITH 76 MID ROOF SLEEPER The following drawings are of a standard T880 Standard Hood with 76 Mid Roof Sleeper shown with standard chassis components ...

Page 45: ...3 23 Section 3 Dimensions 2 17 T880 MX SHORT HOOD WITH 76 MID ROOF SLEEPER The following drawings are of a standard T880 MX Short hood with 76 Mid Roof Sleeper shown with standard chassis components ...

Page 46: ...rall 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 RS FS 82 5 TABLE 3 3 Ride Heights To calculate the frame height use the following formulas Front Frame Height FS 1 2 Front Tire Diameter Rear Frame Height RS 1 2 Rear Tire Diameter Front Suspension T680 T880 Front Suspension FS Laden Unladen 12K Taperleaf...

Page 47: ... Rating 9 6 11 Chalmers 854 46 H 46K Rating 10 1 12 4 Chalmers 854 50 H HS 50K Rating 10 8 12 5 Chalmers 865 65 XL 65K Rating 13 15 7 Hend HMX400 16 5 Saddle 9 5 10 6 Hend HMX400 17 5 Saddle 10 5 11 6 Hend HMX460 46K 16 5 Saddle 9 5 10 6 Hend HMX460 46K 17 5 Saddle 10 5 11 6 Hendrickson Primaax EX 46K Rating 10 10 Hendrickson RT463 6 Saddle 46K Rating 10 11 1 Hendrickson RT463 7 19 Saddle 46K Rati...

Page 48: ...ponents See Tables 7 1 and 7 2 on page 7 7 It would be a good idea in this case to order the frame layout of your chassis along with your truck order This can be done on any Kenworth truck and will be provided 4 weeks ahead of the build schedule If there are hole locations that are not detailed please work with your local Kenworth Dealer to request that information Additionally optional axle spaci...

Page 49: ...Tandem 40K 52 8 5 8 5 AG400L Tandem 40K 54 8 5 8 5 NOTE Actual axle spacing can depart from nominal due to axle slant requirements Final axle spacing can vary by more than an inch from nominal in some cases If precise axle spacing is critical due to body installation or state local regulatory requirements please contact Kenworth Applications technical Support for assistance 59 4 58 3 53 8 56 9 54 ...

Page 50: ...em 40K 54 9 9 AG460 Tandem 46K 54 10 5 10 5 NOTE Actual axle spacing can depart from nominal due to axle slant requirements Final axle spacing can vary by more than an inch from nominal in some cases If precise axle spacing is critical due to body installation or state local regulatory requirements please contact Kenworth Applications technical Support for assistance 60 6 58 5 48 0 45 9 Axle Spaci...

Page 51: ... 60 Spacing 46K 60 10 5 10 5 NOTE Actual axle spacing can depart from nominal due to axle slant requirements Final axle spacing can vary by more than an inch from nominal in some cases If precise axle spacing is critical due to body installation or state local regulatory requirements please contact Kenworth Applications technical Support for assistance 67 7 65 8 52 0 49 9 60 0 10 5 ...

Page 52: ...em 69K 108 54 54 10 5 10 5 NOTE Actual axle spacing can depart from nominal due to axle slant requirements Final axle spacing can vary by more than an inch from nominal in some cases If precise axle spacing is critical due to body installation or state local regulatory requirements please contact Kenworth Applications technical Support for assistance 87 6 85 5 76 0 73 9 54 0 10 5 54 0 ...

Page 53: ...KB Suspensions TABLE 3 8 Rear Suspension Options Suspension Type Rating Axle Spacing Laden Ride Height Unladen Ride Height Reyco 79KB single 20K 8 3 10 8 Reyco 79KB single 23K 8 3 10 8 Reyco 79KB single 26K 8 2 11 3 Reyco 79KB single 31K 9 6 12 2 30 2 30 1 28 7 29 0 Ride Height ...

Page 54: ...Ride Height Unladen Ride Height Reyco 102 Tandem 38K 52 9 2 10 8 NOTE Actual axle spacing can depart from nominal due to axle slant requirements Final axle spacing can vary by more than an inch from nominal in some cases If precise axle spacing is critical due to body installation or state local regulatory requirements please contact Kenworth Applications technical Support for assistance ...

Page 55: ...IDE HEIGHT 2 1 2 7 4 6 8 0 30 8 2 4 5 9 18 8 24 3 26 4 NEWAY ADZ123 SCALE 1 10 Optional Neway ADZ Single Suspensions TABLE 3 10 Rear Suspension Options Suspension Type Rating Axle Spacing Laden Ride Height Unladen Ride Height Neway ADZ123 single 23K 10 10 Neway ADZ126 single 26K 10 10 ...

Page 56: ...46 tandem 46K 54 10 10 Neway ADZ246 tandem 46K 60 10 10 Neway ADZ246 tandem 46K 72 10 10 Neway ADZ252 tandem 52K 54 10 10 Neway ADZ252 tandem 52K 54 12 12 Neway ADZ252 tandem 52K 60 10 10 Neway ADZ252 tandem 52K 60 12 12 NOTE Actual axle spacing can depart from nominal due to axle slant requirements Final axle spacing can vary by more than an inch from nominal in some cases If precise axle spacing...

Page 57: ...den Ride Height Unladen Ride Height Neway ADZ369 tridem 69K 54 10 10 Neway ADZ369 tridem 69K 54 12 12 Neway ADZ369 tridem 69K 60 12 12 Neway ADZ378 tridem 78K 54 10 10 Neway AD378 tridem 78K 60 10 10 NOTE Actual axle spacing can depart from nominal due to axle slant requirements Final axle spacing can vary by more than an inch from nominal in some cases If precise axle spacing is critical due to b...

Page 58: ... Height Hendrickson Primaax Tandem 46K 54 10 10 Hendrickson Primaax Tandem 46K 60 10 10 Hendrickson Primaax Tandem 46K 72 10 10 NOTE Actual axle spacing can depart from nominal due to axle slant requirements Final axle spacing can vary by more than an inch from nominal in some cases If precise axle spacing is critical due to body installation or state local regulatory requirements please contact K...

Page 59: ... Height Unladen Ride Height Hendrickson Primaax Tridem 69K 54 10 10 Hendrickson Primaax Tridem 69K 60 10 10 NOTE Actual axle spacing can depart from nominal due to axle slant requirements Final axle spacing can vary by more than an inch from nominal in some cases If precise axle spacing is critical due to body installation or state local regulatory requirements please contact Kenworth Applications...

Page 60: ... Hendrickson ULTIMAAX 460 18 25 Saddle Height 46K 60 11 12 5 Hendrickson ULTIMAAX 520 17 5 Saddle Height 52K 54 11 12 5 Hendrickson ULTIMAAX 520 18 25 Saddle Height 52K 54 11 12 5 Hendrickson ULTIMAAX 520 17 5 Saddle Height 52K 60 11 12 5 Hendrickson ULTIMAAX 520 18 25 Saddle Height 52K 60 11 12 5 NOTE Actual axle spacing can depart from nominal due to axle slant requirements Final axle spacing ca...

Page 61: ...1 Hendrickson RT463 7 94 saddle 46K 60 11 9 13 0 Hendrickson RTE463 7 19 saddle 46K 52 10 5 11 6 Hendrickson RT523 6 saddle 52K 52 9 9 11 0 Hendrickson RT523 6 saddle 52K 54 9 9 11 0 Hendrickson RT523 7 19 saddle 52K 54 11 1 12 2 Hendrickson RT523 11 saddle 52K 54 14 9 16 0 Hendrickson RT523 6 saddle 52K 60 9 9 11 0 Hendrickson RT523 7 19 saddle 52K 60 11 1 12 2 NOTE Actual axle spacing can depart...

Page 62: ...Height Chalmers 854 40 L 40K 54 8 9 11 1 Chalmers 854 40 L HS 40K 54 9 6 11 1 Chalmers 854 40 H 40K 54 10 2 12 4 Chalmers 854 40 H HS 40K 54 10 9 12 4 Chalmers 854 46 L 46K 54 8 9 11 3 Chalmers 854 46 L HS 46K 54 9 6 11 3 Chalmers 854 46 H 46K 54 10 1 12 5 Chalmers 854 46 H HS 46K 54 10 9 12 5 Chalmers 854 50 L 50K 54 8 9 11 3 Chalmers 854 50 L HS 50K 54 9 6 11 3 Chalmers 854 50 H 50K 54 10 1 12 5...

Page 63: ...46K 60 9 6 11 3 Chalmers 860 46 H 46K 60 10 1 12 5 Chalmers 860 46 H HS 46K 60 10 9 12 5 Chalmers 860 52 H 52K 60 10 9 12 5 Chalmers 872 46 H HS 46K 72 11 0 12 5 NOTE Actual axle spacing can depart from nominal due to axle slant requirements Final axle spacing can vary by more than an inch from nominal in some cases If precise axle spacing is critical due to body installation or state local regula...

Page 64: ... with your local Kenworth Dealer to request that information Kenworth will automatically install highest lift axle kit as applicable based on chassis frame height and loading conditions Lift axle available run range it utilized along with frame height and lift axle tire size to identify applicable kits that can be installed Installing highest lift axle kit will maximize ground clearance when axle ...

Page 65: ...3 43 Section 3 Dimensions 2 17 Watson Chalin Tru Track Alumilite 13 5K Steerable SL1190SSR Watson Chalin Tru Track 20K Steerable SL2065 ...

Page 66: ...3 44 Section 3 Dimensions 2 17 Watson Chalin 23K Steerable SL2200 Use with Duals Only Watson Chalin 23K Non Steerable AL2200 ...

Page 67: ...city of the axle TABLE 3 18 Axle Width Calculation Axle Drive Wheel Tire Configuration Track Dim A Overall Width Dim B Meritor RT46 160 P EH 46K Dual Dana Spicer D46 170 H P 46K Dual Alcoa 88367 22 5X8 25 11R22 5 4 4 73 3 97 8 Meritor RT46 160 P EH 46K Dual Dana Spicer D46 170 H P 46K Dual Alcoa 98363 24 5X8 25 11R24 5 4 4 73 6 98 0 Meritor RT46 160WT P EH 46K Dual Wide Track Dana Spicer D46 170W ...

Page 68: ...66480 17 5x6 215 75R17 5 Same as FR 77 3 85 8 W C SL1093SSR Steerable 10K Alcoa 77349 19 5x7 5 265 70R19 5 Same as FR 78 5 88 5 W C SL1190SSR Steerable 13 5K Alcoa 88367 22 5x8 25 255 70R22 5 Same as FR 80 4 90 7 W C SL2065 Steerable 20K Alcoa 82362 22 5x12 25 425 65R22 5 Same as FR 83 6 99 8 W C SL2200 Steerable 23K Alcoa 88367 22 5x8 25 295 75R22 5 Same as RR dual 78 2 102 8 W C AL2200 STD Track...

Page 69: ...en and 10 4 laden TABLE 3 19 Ground Clearance for Fuel Tanks Front Suspension Front Tires Rear Suspension Rear Tires Fuel Tank Size Component Dimension A Distance from Bottom of Frame Rail in Dimension B Ground Clearance in Unladen Laden 20K Taperleaf Spring 425 65R22 5 Hendrickson HMX 460 17 5 Saddle Height 11R24 5 22 Diameter Fuel Tank 16 3 17 2 14 9 DEF Tank 15 3 18 2 15 9 24 5 Diameter Fuel Ta...

Page 70: ...of Frame Rail in Dimension B Ground Clearance in Unladen Laden 20K Taper leaf Spring 425 65R22 5 Tires Hendrickson HMX 460 17 5 Saddle Height 11R24 5 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 1 Dimensions shown are for daycabs with high route exhaust Sleeper ground clearance is reduced by 1 3 inches ...

Page 71: ...ssaging Standard DTC Diagnostics Trouble Code SCM Standard Control Module ECM Engine Control Module SCR Selective Catalyst Reduction ECU Electrical Control Unit SPN Suspect Parameter Number EIST Engine Idle Shutdown Timer TCM Transmission Control Module EOA Electric Over Air TSC1 Torque Speed Control request EOH Electric Over Hydraulic VECU Vehicle Electrical Control Unit FIC Fast Idle Control J 1...

Page 72: ...a thru shaft PTO the counter shaft extends out through the back of the transmission which can be used to power a PTO When using a thru shaft PTO the vehicle must be spec d with the correct option as not all transmissions will be set up for use with thru shaft PTO s For more information go to www roadranger com and enter PTO Installation Guide in the search bar in the upper right corner MD Manual T...

Page 73: ...he 8 bolt bottom mount PTO will not have any issues unless you are running a driveshaft back to another component and the truck has a crossover style exhaust In this case the DPF and SCR would block any routing for the driveshaft If a wet kit is used in this scenario there is enough room to mount the PTO and the hy draulic pump without interfering with the exhaust On Allison 4000 series transmissi...

Page 74: ...1 The Paccar MX 13 REPTO turns at a rate of 1 2 1 The Paccar MX 11 REPTO turns at a rate of 1 3 1 FIGURE 4 4 REPTO Flywheel Housing 4 2 PTO TELLTALE With key switch to RUN position all the telltale icons will turn on briefly PTO icon below will be illuminated green to the left side of the Driver Performance Center FIGURE 4 5 PTO Icon If the factory did not install the PTO or did not install the PT...

Page 75: ... are taped to the instrument panel harness on the left side of the cup holder One of these 2 way connectors has a GREEN label with the text EDITABLE TELLTALE 2 P025 A gray wire goes to pin 2 of this connector When that gray wire is grounded the PTO icon will turn on No programing is needed and it can be easily tested before wiring with a ground wire jumper reference Section 9 Electrical for new te...

Page 76: ... work through your local Kenworth dealer Note Installations depict multiple PTOs In order to ensure the PTO area remains clear of air equipment electrical and emissions equipment Kenworth recom mends always ordering PTO controls even when installing the PTO aftermarket Kenworth does offer a variety of factory installed PTOs Contact your local dealer for assistance Manual Transmission ...

Page 77: ...4 7 Section 4 PTO Mounting Programming 9 18 Allison Transmission ...

Page 78: ...is application guide is only applicable to 2 1M trucks 2 Only the specified PTO configurations have been analyzed 3 Horizontal crossover exhaust limits access behind PTO s for shaft drives and other PTO attachments 4 Eaton FR transmissions require the use of a 30 adapter when installing Chelsea or Muncie transmission PTO s in the right hand position 5 Eaton RT Ultrashift Plus transmissions require...

Page 79: ...t Air Leaf Suspension 2 Not available with Horizontal Crossover or Right Hand behind Fairing Exhaust Systems 3 Restricted PTO access with RH Cab Step Assembly DPF SCR exhaust systems with Vertical BOS tailpipes or RH Horizontal Tailpipe below rail 4 The Optional Hydraulic Clutch Orientation must be used with this PTO NOTE ...

Page 80: ...UTCH ACTUATOR CONFIGURATIONS Only used with 2 1M models with Eaton FR or RT transmissions FIGURE 4 7 Standard Configuration Bottom Mount PTO Provisions Air assist connection faces driver s side Air assist connection faces passenger s side Used with all but Chelsea 880 and 885 PTOs Used with Chelsea 880 and 885 PTOs ...

Page 81: ... can be configured at the time of order or in the aftermar ket The PTO Mode switch can be used to activate PTO Mode independent of PTO engagement and may be useful for trucks with FEPTOs or REPTOs that need the ability to use PMC features PTO Mode Request over the CAN bus MX PTO MODE CONTROL LOCATION Vehicles can be configured to control PTO functionality from a cab location and or a remote locati...

Page 82: ...de PTO Mode Specific Engine Idle Shutdown Timer EIST Fan On in PTO Mode Adjustable PTO Engine Speed Governor Responsiveness for light or heavy varying loads MX PTO MODE PROTECTIONS AND LIMITS The following protections and limits are available when PTO Mode is active Protections and limits are active when PTO Mode is active and will continue to be active until PTO Mode is no longer active Max Vehic...

Page 83: ...Press Configurable to either command one unique preset when is pressed and a second unique preset when is pressed OR toggle through up to 6 presets Preset 1 2 3 3 Dedicated Presets with the following configuration options Latch Hold Preset Speed When Switch is Released Cancel Cancel PSC When Switch is Released The Remote PTO Inputs for Presets 1 2 3 can be configured to function when Cab PTO Mode ...

Page 84: ...ssed Custom Hardwired Interlock Configurable Polarity A custom hardwired interlock input is available that will allow a body builder to create a customized interlock for their specific application This interlock functions for both Cab and Remote Station PSC Many types of switches such as hand operated switches hydraulic pressure switches equipment position switches or pressure plate switches can a...

Page 85: ...e body builder to specify controller speeds of 250 kbps or 500 kbps FIGURE 4 9 MX PTO CAN functionality may be accessed in the cab through the RP1226 connector and remotely through the body connectors K CAN E 3375 021 and B CAN DTM06 2S EP10 Connectors MX PTO hardwired functionality may be accessed in the engine bay or on the frame through optional 12 Way and 8 Way connectors 12 Way Deutsch Connec...

Page 86: ... 16 Section 4 PTO Mounting Programming 9 18 PTO MODE CONTROL FLOW CHARTS FIGURE 4 11 Cab Controls FIGURE 4 12 Remote Hardwire Controls FIGURE 4 13 Remote CAN Controls FIGURE 4 14 Remote TSC1 CAN Controls ...

Page 87: ...y the heat of the exhaust system Inside of the SCR canister a catalyst causes a chemical reaction to occur be tween the ammonia and NOx turning it into water and nitrogen For more information on the 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...

Page 88: ...ill be heated with engine coolant The following schematic shows the routing of these lines It is critical that the system is not compromised in any manner Below numbers denote the order of the component in the flow 2017 DEF Tank Coolant Loop 2017 DEF Coolant Valve 2017 DEF Supply Pump 2017 CSM Back of Engine 2017 CRM 1 2 3 4 5 ...

Page 89: ...egulated by the E P A Kenworth advises against modifying the tank volume after the truck has been delivered from the factory These are esti mated nominal published maximum fuel capacities for various DEF tanks engines and fill ratios Dosing rates for these calculations are also shown TABLE 5 1 FUEL VOLUME ALLOWED USABLE GALLONS Standard DEF Fuel Ratio 2 1 Minimum Recommended DEF Fuel Ratio 1 1 No ...

Page 90: ...e 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 ...

Page 91: ...13 emissions level engine The dosing module injector no longer needs to be purged and relative heights of components is no longer critical See Figure 5 7 below for typical rout ing with RHUC exhaust and LH DEF tank shown Also shown in this figure is the coolant line routing for T680 and T880 models FIGURE 5 1 Routing DEF and Coolant Lines ...

Page 92: ...is on the DEF tank assembly Body builders may need to relocate this component and should follow the location and length restrictions above Additionally the mounting and the orientation of the Supply Module must not exceed 45 from vertical in any direction FIGURE 5 2 Supply Module Allowed Clocking Angle Limit Scribes a 90 Inverted Cone ...

Page 93: ...f cab on stanchion brackets RH Under DPF and SCR Horizontal DPF and SCR Independent Back of Cab The following images depict the typical exhaust routings for each system and can be used to determine exhaust routing paths for systems you choose Dimensional information can be found in Section 5 of this manual Body Builders must not modify including altering substituting and relocating the DPF and SCR...

Page 94: ... Right Hand Under DPF SCR on DayCav with Single Side of Cab Tailpipe FIGURE 5 3 Isometric view of Right Hand Under DPF SCR with Single Side of Cab Tailpipe FIGURE 5 4 Isometric view of Right Hand Under DPF SCR with Single Side of Cab Tailpipe ...

Page 95: ...17 5 9 Section 5 Exhaust Aftertreatment FIGURE 5 5 Right view of Right Hand Under DPF SCR with Single Side of Cab Tailpipe FIGURE 5 6 Back view of Right Hand Under DPF SCR with Single Side of Cab Tailpipe ...

Page 96: ...ent Right Hand Under DPF SCR on DayCab with Dual Side of Cab Tailpipes FIGURE 5 7 Isometric view of Right Hand Under DPF SCR with Dual Side of Cab Tailpipe FIGURE 5 8 Isometric view of Right Hand Under DPF SCR with Dual Side of Cab Tailpipe ...

Page 97: ... 17 5 11 Section 5 Exhaust Aftertreatment FIGURE 5 9 Right View of Right Hand Under DPF SCR with Dual Side of Cab Tailpipe FIGURE 5 10 Back View of Right Hand Under DPF SCR with Dual Side of Cab Tailpipe ...

Page 98: ... Right Hand Under DPF SCR on DayCab with Single Back of CabTailpipe FIGURE 5 11 Isometric View of Right Hand Under DPF SCR with Single Back of Cab Tailpipe FIGURE 5 12 Isometric View of Right Hand Under DPF SCR with Single Back of Cab Tailpipe ...

Page 99: ... 5 13 Section 5 Exhaust Aftertreatment FIGURE 5 13 Right View of Right Hand Under DPF SCR with Single Back of Cab Tailpipe FIGURE 5 14 Back View of Right Hand Under DPF SCR with Single Back of Cab Tailpipe ...

Page 100: ...rtreatment Right Hand Under DPF SCR on DayCab with Ground Dump Tailpipe FIGURE 5 15 Isometric View of Right Hand Under DPF SCR with Ground Dump Tailpipe FIGURE 5 16 Isometric View of Right Hand Under DPF SCR with Ground Dump Tailpipe ...

Page 101: ...2 17 5 15 Section 5 Exhaust Aftertreatment FIGURE 5 17 Right View of Right Hand Under DPF SCR with Ground Dump Tailpipe FIGURE 5 18 Back View of Right Hand Under DPF SCR with Ground Dump Tailpipe ...

Page 102: ... Independent Back of Cab DPF SCR on DayCab with Back of CabTailpipe FIGURE 5 19 Isometric View of Independent Back of Cab DPF SCR with Back of Cab Tailpipe FIGURE 5 20 Isometric View of Independent Back of Cab DPF SCR with Back of Cab Tailpipe ...

Page 103: ... 5 17 Section 5 Exhaust Aftertreatment FIGURE 5 21 Right View of Independent Back of Cab DPF SCR with Back of Cab Tailpipe FIGURE 5 22 Back View of Independent Back of Cab DPF SCR with Back of Cab Tailpipe ...

Page 104: ...aust Aftertreatment Horizontal DPF SCR on DayCab with Ground Dump Tailpipe FIGURE 5 23 Isometric View of Horizontal DPF SCR with Ground Dump Tailpipe FIGURE 5 24 Isometric View of Horizontal DPF SCR with Ground Dump Tailpipe ...

Page 105: ...2 17 5 19 Section 5 Exhaust Aftertreatment FIGURE 5 25 Right View of Horizontal DPF SCR with Ground Dump Tailpipe FIGURE 5 26 Back View of Horizontal DPF SCR with Ground Dump Tailpipe ...

Page 106: ...es Side of Sleeper RHUC DPF SCR 69 2 N A 36 42 Tailpipes Back of Cab RHUC DPF SCR 70 3 24 N A N A Tailpipes Back of Sleeper RHUC DPF SCR or Horizontal Crossover DPF SCR 86 N A 24 36 Tailpipes Back of Cab Independent DPF SCR Back of Cab 77 5 24 24 N A Natural Gas Tailpipes Side of Cab RHUC Catalyst 69 2 24 36 N A Tailpipe Back of Cab Independent Catalyst Back of Cab 74 24 N A N A TABLE 5 2 Utilize ...

Page 107: ...ension A FIGURE 5 28 Dimension A Top of Rail Frame Height from Prospector Frame Depth For approximate unladen stack height 12 000 pound springs use the following frame heights Tire Size Top of Rail 11R24 5 43 5 11R22 5 42 5 285 75R24 5 42 295 75R22 5 41 5 Use Prospector frame heights for more accurate results Sample Tailpipe height 13 6 Desired overall stack height 162 0 Prospector frame height 43...

Page 108: ...2 17 5 22 Section 5 Exhaust Aftertreatment This page intentionally left blank ...

Page 109: ...cal 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 6 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 gi...

Page 110: ...ith more fuel tanks additional tool boxes etc TABLE 6 2 Fuel Tank Overall Length in Fuel Tank Overall Length in Fuel Tank Diameter Gallons 22 24 5 28 5 45 N A 23 0 N A 56 35 6 N A N A 60 38 0 30 6 N A 75 47 3 38 5 28 7 90 N A 45 5 34 3 100 62 2 50 0 N A 105 N A N A 38 8 110 N A 55 0 N A 120 74 3 60 6 45 8 135 N A 67 2 50 9 150 N A 74 5 56 2 177 N A N A 66 1 TABLE 6 3 Battery Box Centerframe Length...

Page 111: ...ensions 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 27 7 15 7 10 1 27 8 15 5 28 2 28 0 15 5...

Page 112: ...ugh 6 8 D2 is used with RHUC DPF SCR LHUC fuel tank RH BOC cantilever battery box and LH BOC DEF tank Charts located on pages 6 9 through 6 11 D3 is used with RHUC DPF SCR LHUC battery box RH BOC DEF tank and LH BOC fuel tank Charts located on pages 6 12 through 6 14 D4 is used with RHUC DPF SCR LHUC battery box LH BOC DEF tank and RH BOC fuel tank Charts located on pages 6 15 through 6 17 Frame L...

Page 113: ...2 17 Section 6 Frame Layouts 6 5 D5 is used with RHUC DPF SCR LHUC fuel tank RH BOC DEF tank and in cab battery box Charts located on pages 6 18 through 6 20 Frame Layout Index ...

Page 114: ...29 6 39 8 60 38 0 0 4 21 4 75 47 3 9 6 31 3 100 62 2 24 5 47 0 120 74 3 36 6 58 8 24 5 Diameter Tank 60 30 6 6 5 15 5 75 38 5 0 6 23 4 90 45 5 7 7 31 3 100 50 0 12 2 23 0 110 55 0 17 2 41 1 120 60 6 22 8 45 1 135 67 2 29 4 52 9 150 74 5 36 7 58 8 28 5 Diameter Tank 75 28 7 8 8 13 9 90 34 3 3 3 19 5 105 38 8 0 4 23 4 110 42 4 4 0 25 4 120 45 8 7 4 29 3 135 50 9 12 5 35 2 150 56 2 17 8 41 1 177 66 1...

Page 115: ...2 3 29 6 39 8 60 38 0 0 4 21 4 75 47 3 9 6 31 3 100 62 2 24 5 47 0 120 74 3 36 6 58 8 24 5 Diameter Tank 60 30 6 6 5 15 5 75 38 5 0 6 23 4 90 45 5 7 7 31 3 100 50 0 12 2 23 0 110 55 0 17 2 41 1 120 60 6 22 8 45 1 135 67 2 29 4 52 9 150 74 5 36 7 58 8 28 5 Diameter Tank 75 28 7 8 8 13 9 90 34 3 3 3 19 5 105 38 8 0 4 23 4 110 42 4 4 0 25 4 120 45 8 7 4 29 3 135 50 9 12 5 35 2 150 56 2 17 8 41 1 177 ...

Page 116: ...OC to DEF Tank in Diameter Gallons Length in Small Medium Large 22 Diameter Tank 56 35 6 8 2 13 6 18 4 33 6 42 2 60 38 0 5 2 17 5 75 47 3 0 0 21 4 100 62 2 14 9 37 2 120 74 3 27 0 49 9 24 5 Diameter Tank 60 30 6 7 4 15 5 75 38 5 4 4 17 5 90 45 5 1 3 21 4 100 50 0 3 2 25 4 110 55 0 8 1 31 3 120 60 6 13 7 37 2 135 67 2 22 4 45 1 150 74 5 27 7 51 0 NOTE DIMENSION B IS CALCULATED USING A CANTILEVER SI...

Page 117: ...1 6 40 2 100 62 2 24 5 36 0 45 4 56 120 74 3 36 6 49 8 57 2 67 8 24 5 Diameter Tank 60 30 6 7 1 6 5 13 9 24 4 75 38 5 0 7 14 4 21 7 32 3 90 45 5 7 7 20 3 29 6 38 2 100 50 0 12 2 25 7 33 6 44 2 110 55 0 17 2 30 1 39 5 48 120 60 6 22 8 36 0 45 4 53 9 135 67 2 29 4 41 9 51 3 59 8 150 74 5 36 7 49 8 59 1 67 8 28 5 Diameter Tank 90 34 3 3 3 8 5 17 8 26 4 105 38 8 1 3 14 4 21 7 32 3 120 45 8 8 3 20 3 29...

Page 118: ...5 7 24 5 Diameter Tank 60 30 6 6 2 6 5 15 9 24 5 75 38 5 0 0 12 4 21 7 30 3 90 45 5 6 6 20 3 27 6 38 2 100 50 0 11 7 24 2 33 6 42 1 110 55 0 16 7 28 1 37 5 48 0 120 60 6 22 2 34 0 43 4 51 0 135 67 2 28 3 41 9 49 3 59 8 150 74 5 35 6 47 8 57 2 65 7 28 5 Diameter Tank 75 28 7 8 4 10 4 17 8 26 4 90 34 3 2 7 10 4 17 8 28 3 105 38 8 0 2 14 4 21 3 32 3 110 42 4 4 0 18 3 25 7 36 2 120 45 8 6 4 20 3 27 6 ...

Page 119: ... 0 5 2 6 5 13 4 22 4 75 47 3 0 0 12 4 21 7 30 3 100 62 2 14 9 28 1 36 5 46 1 120 74 3 27 0 39 9 47 3 55 9 24 5 Diameter Tank 60 30 6 3 6 6 5 13 4 22 4 75 38 5 0 9 8 5 17 8 28 3 90 45 5 1 3 10 4 19 8 28 3 100 50 0 3 2 15 8 25 1 34 2 110 55 0 8 1 20 3 29 6 38 2 120 60 6 13 7 26 2 35 5 44 1 135 67 2 22 4 32 2 41 6 52 150 74 5 27 7 39 9 49 3 57 9 NOTE DIMENSION B IS CALCULATED USING A CANTILEVER SIZED...

Page 120: ...in Diameter Gallons Length in Small Medium Large 22 Diameter Tank 56 35 6 39 7 20 4 29 6 40 2 60 38 0 42 75 47 3 51 100 62 2 66 120 74 3 78 24 5 Diameter Tank 60 30 6 35 75 38 5 43 90 45 5 50 100 50 0 54 5 110 55 0 59 5 120 60 6 65 135 67 2 71 7 150 74 5 78 8 28 5 Diameter Tank 75 28 7 32 6 90 34 3 38 2 105 38 8 42 7 110 42 4 46 3 120 45 8 49 7 135 50 9 54 8 150 56 2 60 1 177 66 1 70 NOTE DIMENSIO...

Page 121: ... Length in Small Medium Large 22 Diameter Tank 56 35 6 39 7 20 4 29 6 40 2 60 38 0 42 75 47 3 51 85 53 2 56 9 100 62 2 66 120 74 3 78 24 5 Diameter Tank 60 30 6 35 75 38 5 43 90 45 5 50 100 50 0 54 5 110 55 0 59 5 120 60 6 65 135 67 2 71 7 150 74 5 78 8 28 5 Diameter Tank 75 28 7 32 6 90 34 3 38 2 105 38 8 42 7 110 42 4 46 3 120 45 8 49 7 135 50 9 54 8 150 56 2 60 1 177 66 1 70 NOTE DIMENSIONS B A...

Page 122: ...r Gallons Length in Small Medium Large 22 Diameter Tank 56 35 6 36 3 17 4 27 6 38 2 60 38 0 38 7 75 47 3 48 100 62 2 62 9 120 74 3 74 9 24 5 Diameter Tank 60 30 6 31 9 75 38 5 39 7 90 45 5 46 7 100 50 0 51 2 110 55 0 56 2 120 60 6 61 8 135 67 2 68 5 150 74 5 75 7 28 5 Diameter Tank 75 28 7 29 4 90 34 3 35 105 38 8 39 5 110 42 4 43 1 120 45 8 46 5 135 50 9 51 6 150 56 2 56 9 177 66 1 66 9 NOTE DIME...

Page 123: ... in Diameter Gallons Length in Small Medium Large 22 Diameter Tank 56 35 6 40 9 13 4 26 2 34 8 60 38 0 43 3 75 47 3 52 4 100 62 2 67 2 120 74 3 79 2 24 5 Diameter Tank 60 30 6 36 1 75 38 5 44 1 90 45 5 51 1 100 50 0 55 5 110 55 0 60 5 120 60 6 66 1 135 67 2 72 8 150 74 5 80 1 28 5 Diameter Tank 75 28 7 33 8 90 34 3 39 3 105 38 8 43 9 110 42 4 47 5 120 45 8 50 9 135 50 9 55 9 150 56 2 61 3 177 66 1...

Page 124: ... Length in Small Medium Large 22 Diameter Tank 56 35 6 40 9 13 4 26 2 34 8 60 38 0 43 3 75 47 3 52 4 85 53 2 58 3 100 62 2 67 2 120 74 3 79 2 24 5 Diameter Tank 60 30 6 36 1 75 38 5 44 1 90 45 5 51 1 100 50 0 55 5 110 55 0 60 5 120 60 6 66 1 135 67 2 72 8 150 74 5 80 1 28 5 Diameter Tank 75 28 7 33 8 90 34 3 39 3 105 38 8 43 9 110 42 4 47 5 120 45 8 50 9 135 50 9 55 9 150 56 2 61 3 177 66 1 71 2 N...

Page 125: ... Gallons Length in Small Medium Large 22 Diameter Tank 56 35 6 38 8 9 9 17 8 28 3 60 38 0 41 2 75 47 3 50 4 100 62 2 65 3 120 74 3 77 3 24 5 Diameter Tank 60 30 6 34 1 75 38 5 42 1 90 45 5 49 1 100 50 0 53 5 110 55 0 58 5 120 60 6 64 1 135 67 2 70 8 150 74 5 78 1 28 5 Diameter Tank 75 28 7 31 8 90 34 3 37 3 105 38 8 41 9 110 42 4 45 5 120 45 8 48 9 135 50 9 53 9 150 56 2 59 3 177 66 1 69 2 NOTE DI...

Page 126: ...k in Diameter Gallons Length in Small Medium Large 22 Diameter Tank 56 35 6 2 1 22 3 29 6 39 8 60 38 0 0 4 75 47 3 9 6 100 62 2 24 5 120 74 3 36 6 24 5 Diameter Tank 60 30 6 6 5 75 38 5 0 6 90 45 5 7 7 100 50 0 12 2 110 55 0 17 2 120 60 6 22 8 135 67 2 29 4 150 74 5 36 7 28 5 Diameter Tank 75 28 7 8 8 90 34 3 3 3 105 38 8 0 4 110 42 4 4 0 120 45 8 7 4 135 50 9 12 5 150 56 2 17 8 177 66 1 27 7 N A ...

Page 127: ...n Small Medium Large 22 Diameter Tank 56 35 6 2 1 21 8 29 2 39 3 60 38 0 0 0 75 47 3 8 7 100 62 2 23 5 120 74 3 35 6 24 5 Diameter Tank 60 30 6 6 2 75 38 5 0 0 90 45 5 6 6 100 50 0 11 7 110 55 0 16 7 120 60 6 22 2 135 67 2 28 3 150 74 5 35 6 28 5 Diameter Tank 75 28 7 8 4 90 34 3 2 7 105 38 8 0 2 110 42 4 4 0 120 45 8 6 4 135 50 9 11 5 150 56 2 16 8 177 66 1 26 7 N A W DUAL SIDE OF CAB OR BACK OF ...

Page 128: ...Short Hood Fuel Tank Size Dimension F BOC to Fuel Tank Daycab in Dimension D in BOC to DEF Tank in Diameter Gallons Length in Small Medium Large 22 Diameter Tank 56 35 6 8 2 18 4 33 6 42 2 60 38 0 5 2 75 47 3 0 0 100 62 2 14 9 120 74 3 27 0 24 5 Diameter Tank 60 30 6 7 4 75 38 5 4 4 90 45 5 1 3 100 50 0 3 2 110 55 0 8 1 120 60 6 13 7 135 67 2 22 4 150 74 5 27 7 ...

Page 129: ... in H W T S R W 10 5 8 x 3 1 2 x 5 16 14 80 1 776 000 2 90 10 3 4 x 3 1 2 x 3 8 17 80 2 132 000 3 46 10 11 16 x 3 1 2 x 1 2 22 35 2 683 000 4 53 11 5 8 x 3 7 8 x 3 8 21 43 2 572 000 3 80 TABLE 7 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 ...

Page 130: ... 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 7 1 Minimum Clearance Between Top Of Rear Tires And Body Structure Overhang Maintain adequate clearance between back of cab and the front leading edge of mounted body See Figure 6...

Page 131: ...wer flange of the frame rail Mount the body using body mounting brackets or U bolts BODY MOUNTING USING BRACKETS Always install a spacer between the body subframe and the top flange of the frame rail Failure to do so could result in corrosion due to dissimilar materials Installation of a spacer between the body subframe and the top flange of the frame rail will help prevent premature wear of the c...

Page 132: ... limited amount of relative move ment bolted securely but not too rigid Brackets should allow for slight movement between the body and the chassis For instance Figure 6 4 shows a high compression spring between the bolt and the bracket FIGURE 7 4 High Compression Spring FIGURE 7 5 Rubber Spacer Between Brackets Between the Mounting Bolt and Upper Bracket Another possibility is mounting a rubber sp...

Page 133: ...ssis DO NOT drill holes in the upper or lower flange of the frame rail If the frame rail flanges are modified or damaged the rail could fail prematurely and cause an accident Mount the body using body mounting brackets or U bolts Use care when drilling the frame web so the wires and air lines routed inside the rail are not damaged Failure to do so could cause an inoperable electrical or air system...

Page 134: ...rom notching the frame flange See Figure 6 7 Body Structure Wood Sill 0 5 12 Minimum Truck Frame Frame Rail Spacer Fabricated Steel or Hardwood U Bolt Spacer Hardwood U Bolt FIGURE 7 7 Acceptable U Bolt Mounting with Wood and Fabricated Spacers inch mm Do not allow spacers and other body mounting parts to interfere with brake lines fuel lines or wiring harnesses routed inside the frame rail Crimpe...

Page 135: ... to force a U bolt fit Notched or damaged frame flanges could result in premature frame failure Use a larger size U bolt Use a hardwood spacer as shown in Figure 7 7 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 WARNING ...

Page 136: ...d 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 FIGURE 7 9 Example of Fishplate Bracket at Rear End of Body used with U Bolts Body Structure Frame Rail ...

Page 137: ...If the frame rail flanges are modified or damaged the rail could fail prema turely and cause an accident Mount the body using body mounting brackets or U bolts Do not drill closely spare holes in the web of the frame Hole centers of two adjacent holes should be spaced no less than twice the diameter of the largest hole Closer spacing could induce a failure between the holes An appropriately sized ...

Page 138: ...1 See page 8 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 n...

Page 139: ...lbase need to be examined to ensure that no harmful vibrations are created Consult the driveline manufacturer for appropriate recommendations 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 could cause excessive s...

Page 140: ...ear 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 Original Wheelbase Extended Wheelbase Shortened Wheelbase Cut Frame at Rear to Obtain Desired Cutoff Do Not Mount the Suspension Bracket On the Added Frame Rail Mount the su...

Page 141: ...rength The maximum allowable distance between adjacent crossmembers is 60 inches 1524 mm If the distance between adja cent crossmembers exceeds this dimension add a crossmember between them See Figure 7 4 Before Wheelbase is Lengthened Less Than 60 Greater Than 60 Additional Crossmember FIGURE 8 4 Crossmember Added When Distance Exceeds 60 Inches 1524 mm ...

Page 142: ... weld penetration along the entire length of the crack Precautions Before welding disconnect the negative terminal battery cable Before welding disconnect the alternator terminals Failure to do so could 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 lea...

Page 143: ...65 195 3 4 394 462 290 340 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 libricated with hardened steel washers and nylon insert nuts TABLE 8 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 24 32 M12 75 101 55 75 M14 134 164 99 121 M16 163...

Page 144: ...8 8 2 17 Section 8 Frame Modifications This page intentionally left blank ...

Page 145: ...is a two wire high speed network system that is far superior to conventional hardwired technologies to functional ity and reliability CAN is designed for real time requirements and can easily beat hardwire connections when it comes to short reaction times timely error detection quick error recovery and error repair Characteristics of Controller Area Network Is a serial networking technology for em...

Page 146: ...a vehicle network Typical controllers are the Engine Brake Transmission etc The messages exchanged between these units can be data such as vehicle road speed torque control message from the transmission to the engine oil temperature and many more Characteristics of J1939 Extended CAN identifier 29 bit Peer to peer and broadcast communication Network management Definition of parameter groups for co...

Page 147: ...are listed in SAE J1939 and defined in SAE J1939 71 a document containing parameter group definitions plus suspect parameter numbers SUSPECT PARAMETER NUMBER A Suspect Parameter Number is a number assigned by the SAE to a specific parameter within a parameter group It de scribes the parameter in detail by providing the following information Data Length in bytes Data Type Resolution Offset Range Re...

Page 148: ... Switch 64892 DPFC1 SCAN KCAN BCAN 3701 Aftertreatment Diesel Particulate Filter Status 64892 DPFC1 SCAN KCAN BCAN 3702 Filter Active Regen Inhibited Status 64892 DPFC1 SCAN KCAN BCAN 3704 Filter Active Regen Inhibited Due to Clutch Disengaged 64892 DPFC1 SCAN KCAN BCAN 3705 Filter Active Regen Inhibited Due to Service Brake Active 64892 DPFC1 SCAN KCAN BCAN 3706 Filter Active Regen Inhibited Due ...

Page 149: ...65266 LFE1 SCAN KCAN BCAN 184 Engine Instantaneous Fuel Economy 65266 LFE1 SCAN KCAN BCAN 183 Engine Fuel Rate 65266 LFE1 SCAN KCAN BCAN 51 Engine Throttle Valve1 Postion1 65266 LFE1 SCAN KCAN BCAN 171 Ambient Air Temperature 65269 AMB SCAN KCAN BCAN 108 Barometric Pressure 65269 AMB SCAN KCAN BCAN 173 Engine Exhaust Temperature 65270 IC1 SCAN KCAN BCAN 105 Engine Intake Manifold 1 Temperature 652...

Page 150: ...tch 65265 CCVS1 SCAN KCAN BCAN 84 Wheel Based Vehicle Speed 65265 CCVS1 SCAN KCAN BCAN 244 Trip Distance 65248 VD SCAN KCAN BCAN 245 Total Vehicle Distance 65248 VD SCAN KCAN BCAN 979 Engine Remote PTO Governor Preprogrammed spd Control Switch 65264 PTO SCAN KCAN BCAN 3447 Remote PTO Governor Preprogrammed spd Control Switch 2 65264 PTO SCAN KCAN BCAN 974 Remote Accelerator Pedal Position 61443 EE...

Page 151: ...he VECU system utilizing the VECU functions will make a cleaner installation and will maintain OEM functionality VECU expands controls to air operated devices by receiving input from dash switches re mote aftermarket switches sensors mounted to the aftermarket equipment and other vehicle parameters engine speed transmission status etc With the proper programming the VECU will then process the inpu...

Page 152: ...ite stripe R WXXXX Direct battery power Red REDXXXX Protected battery power Orange ORNXXXX Ignition Accessory Low Voltage Disconnect StartPower Yellow YELXXXX Activated Power White WHTXXXX Ground Black BLKXXXX Load Return Gray GRAXXXX Control Brown BRNXXXX Indicator Illumination Backlit Illumination Violet VIOXXXX Reference Voltage or 5VDC or Sensor Power Light Blue BLUXXXX Sensor Signal Light Gre...

Page 153: ...NATION J1939 14 500KBPS J1939 15 250KBPS B CAN 0813 Body Builder I CAN 0825 Instrumentation D CAN 0822 Diagnostics C CAN 0821 Cab F CAN 0819 Frame K CAN 0829 Telematics and Remote PTO G CAN 0825 Bendix ACB Antenna J CAN 0826 Solenoid Bank T CAN 0828 Transmission V CAN2 0823 Vehicle S CAN 0827 Sleeper ...

Page 154: ...10 4 9 18 Section 10 Electrical ELECTRICAL COMPONENT OVERVIEW Figure 10 2 Overview Diagram of Electrical Component Locations ...

Page 155: ...10 5 9 18 Section 10 Electrical Chassis Node Figure 10 3 Electrical Harness Overview ...

Page 156: ...of the steering wheel behind the dash near the OBD connec tor The RP1226 connector can be used for aftermarket telematics ELD body controls and PTO controls There will be multiple bus speeds available K CAN for 250kbps and S CAN for 500 kbps The RP1226 provides defined messages and major telematics supplier data for customer use FIGURE 10 4 ...

Page 157: ...10 7 9 18 Section 10 Electrical BODY CONNECTION POINTS LOCATION DIAGRAMS FOR VARIOUS BODY CONNECTORS ON THE MAIN CHASSIS HARNESS FIGURE 10 5 Isometric View FIGURE 10 6 Side View ...

Page 158: ...10 8 9 18 Section 10 Electrical FIGURE 10 7 Front Portion View FIGURE 10 8 Detail View Of Engine Compartment Body Connectors ...

Page 159: ...10 9 9 18 Section 10 Electrical FIGURE 10 9 Rear Portion View FIGURE 10 10 Detail View Of Boc Bos And Eof Body Connectors ...

Page 160: ...1 PTO ON OFF 3 PTO PUMP MODE SIGNAL 4 2 PTO ON OFF FIGURE 10 11 OPTIONAL 8 PIN PTO INPUT CONNECTOR Pin Function 1 12V IGNITION SIGNAL 2 PTO INTERLOCK INPUT Active Low 3 REMOTE PTO PRESET 3 Active High 4 REMOTE PTO PRESET 2 Active High 5 REMOTE PTO PRESET 1 Active High 6 REMOTE PTO PRESET INCREMENT Active High 7 REMOTE PTO PRESET DECREMENT Active High 8 VEHICLE GROUND FIGURE 10 12 Chassis Harness P...

Page 161: ...ly connect pins 2 and 3 for SET and pins 1 and 3 for Resume Engine speed will depend on how engine ECM is programmed Unless otherwise specified engine is set by default Pin Description 1 INPUT FOR REMOTE PTO RESUME Active Low 2 INPUT FOR REMOTE PTO SET Active Low 3 INPUT FOR NAMUX ANALOG RETURN TWISTED TRIPLE 4 INPUT FOR REMOTE THROTTLE SENSOR CIRCUIT TWISTED TRIPLE 5 PTO ENGAGED SIGNAL LOW ENGAGE...

Page 162: ...10 12 9 18 Section 10 Electrical FIGURE 10 14 MX 11 and MX 13 Connector Location ...

Page 163: ... ground on pins 2 and 1 will then increase decrease engine speed Engine speed will depend on how engine is programmed Unless otherwise specified engine is set by default for incremental speed increase Full remote throttle control can be achieved with a twisted triple to pin 4 10 and 11 Pin Description 1 INPUT FOR REMOTE PTO RESUME Active Low 2 INPUT FOR REMOTE PTO SET Active Low 3 INPUT FOR NAMUX ...

Page 164: ...10 14 9 18 Section 10 Electrical FIGURE 10 16 X15 Connection location FIGURE 10 17 ISX12 Connection location ...

Page 165: ...10 15 9 18 Section 10 Electrical FIGURE 10 18 Power Distribution Center ...

Page 166: ...10 16 9 18 Section 10 Electrical FIGURE 10 19 Engine Side Fuse Box Full Content Population ...

Page 167: ...10 17 9 18 Section 10 Electrical FIGURE 10 20 Dash Side Fuse Box Full Content Population ...

Page 168: ...s will generate and store faults to free up space for the VECU The standard chassis module can be diagnosed through DAVIE service tool There will be two standard chassis modules with one a primary chassis module on all trucks and a secondary for optional content The primary chassis module will be mounted as a primary chassis module under the cab on the left hand side of the over bell mounting brac...

Page 169: ...on Switch Remote PTO Throttle Control Inputs J CAN Multiplexed EOA Solenoid Bank Control Fuel Filter Gauges Main Transmission Oil Temp SECONDARY CHASSIS MODULE External Notification of DPF Regeneration AT1202 Aux Trans Neutral Switch Axle Temperature Gauges Center Rear Lift Axle Air Solenoid Controls 3rd Tag Rocker Panel Controls NAMCO FABCO Splitshaft PTO Transfer Case Sensors Aux Transmission Te...

Page 170: ... a bracket outside the cab The solenoids are designed to stack on each other so that they share a common air supply rail which reduces the amount of air lines on the vehicle The aftermarket installer final vehicle manufacturer needs to decide what type of valve to install and ensure that the docu mentation to the operator provides them with enough understanding of how the customized switches work ...

Page 171: ...10 21 9 18 Section 10 Electrical FIGURE 10 24 Overview Layout FIGURE 10 25 ...

Page 172: ...s able to improve troubleshooting with DAVIE Master Switch Module MSM CAN Communication to from VECU LIN Communication to from Switches FIGURE 10 27 Spare Switches Spare switches offer customers and body builders a convenient way to control power and air to various sources like a body or trailer They should be flexible and easily configurable to meet the vast and unique needs of body builders Kenw...

Page 173: ...ompted by DAVIE Cycle the key on and then off 12 Run Quick Check 13 Clear Inactive DTCs Diagnostics trouble code from MSM 14 Finished New switch installation instructions 1 Turn off the engine and put all switches into the off position 2 Remove the dash panels 3 Remove the switch blank 4 Add the new switch into the dash panel 5 Connect the LIN jumper between the last open switch to the newly insta...

Page 174: ... same LIN bus can be reordered in any configuration without needing a relearn with DAVIE tool Switches that are swapped across LI busses will need to be relearned with DAVIE LIN bus 1 consisted of all the switches on the A panel LIN bus 2 consist of all the switches on B and C panels FIGURE 10 30 Dash Layout ...

Page 175: ...th combined current draw of less than 30A to the firewall ground buss bar with appropriately sized wire cable for the load required FIGURE 10 31 Grounding Buss Bar Design FIGURE 10 32 Grounding Point Cab Interior Behind Driver s Side Kick Panel FIGURE 10 33 Grounding Point Cab Exterior LH Side of Firewall Post OEM components devices apparatus etc with combined current draw in excess of 30A ground ...

Page 176: ...itch or kick panel The mating harness is available from PACCAR parts with pre labeled pigtails P92 8916 000000001 Any spare power requiring more than 20 amps must go directly to the battery box not this spare circuit FIGURE 10 34 Spare Circuit Connector and Pinout Details FIGURE 10 35 Spare circuit location under dash P096 ...

Page 177: ...10 27 9 18 Section 10 Electrical FIGURE 10 36 Spare circuit location on Power Distribution Center Dash Side P001 ...

Page 178: ...10 28 9 18 Section 10 Electrical FIGURE 10 37 Spare circuit diagram P001 and P096 ...

Page 179: ...10 29 9 18 Section 10 Electrical JUNCTION BOX The junction box provides access to lighting signals FIGURE 10 38 Junction Box BOC or EOF ...

Page 180: ...il if no tail lights are provided FIGURE 10 39 Mating Connector Packard PN 12020786 SNOW PLOW LIGHTING When the optional switch and wiring for snow plow lights are ordered the truck will include a switch on the dash to control the snow plow lights and a body builder connection at the front of the chassis The body builder connection will provide electrical support for LH TURN FRONT DAYTIME RUNNING ...

Page 181: ...install telltale symbols or access other connectors to complete the installation FIGURE 10 40 Cluster Removal To install new telltales into the instrument cluster the cluster will need to be removed from the dash The instrument panel trim is removed after removing the panel immediately to the right of the instrument cluster Then 4 fasteners hold the in strument cluster to the dash structure ...

Page 182: ...10 32 9 18 Section 10 Electrical FIGURE 10 41 Telltale Installation Diagnostics Service Tool Connection ...

Page 183: ...erse Lift Switch is Inactive OR Park Brake Active OR Trans in Reverse Lift Switch is Active AND Park Brake Inactive AND Trans Not is Reverse Steerable Lift Axle with Auto Reverse OR Non Steerable Lift Axle w o Park Brake Lift Switch is Inactive OR Park Brake Active Lift Switch is Active AND Park Brake Inactive AND Non Steerable Lift Axle with Park Brake Lift Switch is Inactive AND Park Brake Inact...

Page 184: ...free the gauge or switch can be installed Gauges are held by a screwed on collar while switches have a plastic tab FIGURE 10 43 Optional gauges may be installed and connected to the CECU via a jumper harness See the Dash section below for additional information FIGURE 10 44 Installing Additional Gauges on the Dash ...

Page 185: ...her 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 11 1 Clamp and Butterfly Clamp Butterfly Tie A tough plastic nylon or equivalent locking dual clamp tie strap used to separate bundles or single li...

Page 186: ...r or coolant hose bundles may be in cluded in the bundle if they are isolated from the hoses with a covering of convoluted plastic tubing EXCEPTIONS Battery cables including jump start cables may be bundled with or tied to the charging wire harness They shall not be bundled with or tied directly to any other components including hoses wires or bundles They shall be separated from other routed comp...

Page 187: ...scharge Hoses Wires or hoses shall not be tied to the high temperature air compressor discharge hose Hoses and wires may be routed across the air compressor discharge hose at a distance of 18 inches 457 mm or greater from the compressor discharge port In this case the crossing hoses and wires shall be butterfly clamped to the air compressor discharge hose and cov ered with convoluted tubing at the...

Page 188: ...uel hoses within 15 of the turbo over 15 from the turbo n a 2 minimum 4 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 2 minimum 2 minimum 1 minimum 1 5 minimum Air hose nylon wire braid 3 minimum 2 minimum 8 minimum 3 minimum Exhaust system pipe muffler Heatshield or blanket Component S...

Page 189: ...nd Figure A 1 Code Year Code Year 5 2005 A 2010 6 2006 B 2011 7 2007 C 2012 8 2008 D 2013 9 2009 E 2014 F 2015 G 2016 H 2017 J 2018 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...

Page 190: ... 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 PR...

Page 191: ... s door frame COMPONENT IDENTIFICATION Each of the following components has their own identification label Engine Identification The engine serial number is stamped on a plate located on the left front of the engine For further information please refer to the Engine Operation and Maintenance Manual included in the glove compartment of each vehicle Transmission Identification The transmission ident...

Page 192: ...rential 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 1 2 FIGURE A 4 Rear Axle Identification Illustrated identification tag locations are typical Actual...

Page 193: ...A 5 2 17 Appendix A Vehicle Identification This page intentionally left blank ...

Page 194: ...A 6 2 17 Appendix A Vehicle Identification Kenworth Truck Company P O Box 1000 Kirkland WA 98083 425 828 5000 ...

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