Page 1 Kenworth Heavy Duty Body Builder Manual 2012 ®...
Page 2 This page intentionally left blank.
Page 3 Kenworth Heavy Duty Body Builder Manual ®...
Page 4 Body Builder Manual Contents Section 1: introduction Section 2: Safety and compliance SAFETY SIGNALS FEDERAL MOTOR VEHICLE SAFETYSTANDARDS COMPLIANCE Section 3: dimenSionS DIMENSIONS ABBREVIATIONS TURNING RADIUS OVERALL DIMENSIONS T800 T800 wITH SPLIT FENDERS T800 SHORT HOOD T800 wITH FEPTO (FRONT ENGINE POwER TAkE OFF) T800 wIDE HOOD w900S 3-10...
Page 5 Body Builder Manual Contents Section 6: Body mounting FRAME INFORMATION CRITICAL CLEARANCES BODY MOUNTING USING BRACkETS MOUNTING HOLES BODY MOUNTING USING U–BOLTS Section 7: frame modificationS FRAME MODIFICATIONS DRILLING RAILS MODIFYING FRAME LENGTH CHANGING wHEELBASE CROSSMEMBERS wELDING TORqUE REqUIREMENTS Section 8: electrical ELECTRICAL ACCESSING GAUGES AND SwITCHES TELLTALE SYMBOLS...
Page 6: Table Of Contents
Figures figure 2-1: INCOMPLETE VEHICLE CERTIFICATION DOCUMENT figure 2-2: LOCATIONS OF CERTIFICATION LABELS - DRIVER’S DOOR AND FRAME 2-2 figure 2-3:VwEST COAST MIRROR OAT SENSOR, figure 2-4: AERODYNAMIC MIRROR OAT SENSOR LOCATION figure 2-5: INSTRUMENT CLUSTER FOR T4/T6/T8/w9/C5 figure 3-1: PROSPECTER TURN CIRCLE ANALYSIS figure 4-1: MEASUREMENT LOCATION OF DEF SUPPLY MODULE (PUMP) figure 4-2: MEASUREMENT LOCATION OF DEF DOSING MODULE (INjECTOR) figure 4-3: ORIENTATION OF DOSING MODULE...
Page 7 Figures figure 4-30: BACk VIEw OF HORIzONTAL DPF AND SCR wITH HORIzONTAL TAILPIPE 4-20 figure 4-31: ISOMETRIC VIEw OF VERTICAL DPF AND SCR 4-21 figure 4-32: TOP VIEw OF VERTICAL DPF AND SCR 4-21 figure 4-33: RIGHT VIEw OF VERTICAL DPF AND SCR 4-22 figure 4-34: BACk VIEw OF VERTICAL DPF AND SCR 4-22...
Page 8 Figures Tables figure 8-19: SPARE PIGTAIL CONNECTOR 8-26 figure 8-21: CHASSIS POwER DISTRIBUTION CENTER DIMENSIONS 8-30 figure 8-22: DAYCAB HARDwARE LOCATIONS 8-31 figure 8-23: AEROCAB STANDARD HARDwARE LOCATIONS 8-31 figure 8-25: CHASSIS NODE DIMENSIONS 8-32 figure 8-25: SAE j560 TRAILER CONNECTOR 8-35 figure 8-26: ISO 3731 TRAILER CONNECTOR 8-35...
Page 9 Tables taBle 3-1: ABBREVIATIONS USED taBle 3-2: TURNING RADIUS taBle 3-3: RIDE HEIGHTS 3-17 taBle 3-4: REAR SUSPENSION OPTIONS 3-19 taBle 3-18: AXLE wIDTH CALCULATION 3-36 taBle 3-19: GROUND CLEARANCE FOR FUEL TANkS 3-38 taBle 3-20: GROUND CLEARANCE FOR BATTERY BOXES 3-39 taBle 5-1: ABBREVIATIONS taBle 5-2: FUEL TANk OVERALL LENGTH (IN)
Page 10 This page intentionally left blank...
Page 11 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.
Page 12 This page intentionally left blank...
Page 13 Section 2 Safety & Compliance SAFETY SIGNALS We’ve put a number of alerting messages in this book. Please read and follow them. They are there for your protection and information. These alerting messages can help you avoid injury to yourself or others and help prevent costly dam- age to the vehicle.
Page 14: Figure 2-1: Incomplete Vehicle Certification Document
Section 2 Safety & Compliance FEDERAL MOTOR VEHICLE SAFETY STANDARDS COMPLIANCE As an Original Equipment Manufacturer (OEM), Kenworth Truck Co. ensures that our products comply with all applicable U.S. or Canadian Federal Motor Vehicle Safety Standards. However, the fact that this vehicle has no fifth wheel and that a Body Builder (Intermediate or Final Stage Manufacturer) will be doing additional modifications means that the vehicle was incomplete when it left the build plant.
Page 15 Section 2 Safety & Compliance These statements are just part of the changes to the new certification regulation. Please refer to the Feb 15, 2005 final rule for all of the details related to this regulation. You can contact NTEA Technical Services Department at 1-800-441- NTEA for a copy of the final rule (DocID 101760).
Page 16 Section 2 Safety & Compliance To ensure compliance to emissions regulations, the final configuration of certain features of the completed vehicle must meet specific requirements. This section describes requirements relevant for only the most common or critical 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.
Page 17 Section 2 Safety & Compliance • 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 •...
Page 18 • 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.
Page 19: Figure 2-4: Aerodynamic Mirror Oat Sensor Location
Section 2 Safety & Compliance FIGURE 2-4: Aerodynamic Mirror OAT Sensor Location • Coolant Sensor considerations are given in the Cooling section above • The OBD/Diagnostic connector port is located below the dash to the left of the steering wheel. This connector and its location may not be changed.
Page 20 Section 2 Safety & Compliance Air Intake System The following are highlights of some of the more common or critical aspects of this system. • The air intake screen may not be blocked, either fully or partially • Modification to the air intake system may not restrict airflow. For example, pipe diameter may not be reduced •...
Page 21: Table 3-1: Abbreviations Used
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.
Page 22 Section 3 Dimensions TABle 3-2 COnTinUed Est Curb to Rear Wheel Base Model Steering Gear Front Axle Front Wheel Front Tire Curb Turning Suspension (in.) Radius (ft) 31.5 33.5 34.5 36.5 37.5 T800 dana spicer Bridgestone Tandem dual Alcoa 82365 T800W d2000 20K m844...
Page 23 Section 3 Dimensions TABle 3-2 COnTinUed Est Curb to Rear Wheel Base Model Steering Gear Front Axle Front Wheel Front Tire Curb Turning Suspension (in.) Radius (ft) T800 dana spicer Bridgestone Tandem dual Alcoa 82364 T800W d2000 20K m844 52” Axle TAs 65 22.5 x 12.25 T800sh...
Page 24: Figure 3-1: Prospecter Turn Circle Analysis
Section 3 Dimensions Prospector Turn Circle Analysis: Please see Figure 3-2 as an example of Kenworth’s turn circle calculation made in Prospector for your specific chassis. Your local Kenworth dealer can provide this information to you. FIGURE 3-1. Prospecter Turn Circle Analysis Please consult your local Kenworth Dealer for this information, as it is chassis specific.
Page 25 Section 3 Dimensions OVERALL DIMENSIONS This section includes drawings and charts of the following Class 8 models: T800, T800 with split fenders, T800 short hood, T800 with fePTO, T800 Wide hood, W900s, W900B, C500 and W900l. The extended day Cab and 38” AeroCab are also included.
Page 26 Section 3 Dimensions T800 WITh SPLIT FENDERS The following drawings are of a standard T800 with the optional of the split fender hood, shown with standard chassis components. 08/12...
Page 27 Section 3 Dimensions T800 ShORT hOOD The following drawings are of a T800 short hood, shown with standard chassis components. 08/12...
Page 28 Section 3 Dimensions T800 WITh FEPTO (FRONT ENGINE POWER TAkE OFF) The following drawings are of a T800 with the optional fePTO package. note the extended frame rails. 08/12...
Page 29 Section 3 Dimensions T800 WIDE hOOD The following drawings are of a T800 Wide hood, which allows for the 1780 square inch radiator. 08/12...
Page 30 Section 3 Dimensions W900S The following drawings are of the W900 sloped hood chassis, shown with some optional components. 3-10 08/12...
Page 31 Section 3 Dimensions W900B The following drawings are of the W900B straight hood chassis, shown with standard chassis components. 3-11 08/12...
Page 32 Section 3 Dimensions W900L The following drawings are of the W900l, shown with standard chassis components. 3-12 08/12...
Page 33 Section 3 Dimensions C500 The following drawings are of the C500, shown with standard chassis components. shown with optional wheels and tires. 3-13 08/12...
Page 34 Section 3 Dimensions EXTENDED DAY CAB The extended day Cab is shown on a standard T800 chassis. it is important to note that the extended day will increase any of the models bumper to back of cab dimension and front axle to back of cab dimension by 5.7”. The height (from the bottom of the frame rail) will be 86.9”...
Page 35 Section 3 Dimensions 38” AEROCAB The 38” Aerocab is shown on a standard T800 chassis. it is important to note that the 38” will increase any of the models bumper to back of cab dimension and front axle to back of cab dimension by 28”. The height (from the bottom of the frame rail) will be 93.2”...
Page 36: Table 3-3: Ride Heights
Section 3 Dimensions RIDE hEIGhTS The front (fs) and rear (rs) suspension ride heights are provided as a basic tool to determine the overall height of the cab, height of exhaust components, and frame heights. The heights are all calculated from the centerlines of the axles, please be sure to include the tire radius dimension to determine overall height.
Page 37 Section 3 Dimensions Front Suspension (W900L) Front Suspension (FS) Laden: Unladen: 12K Taperleaf 11.5” 12.4” 13.2K Taperleaf 11.1” 12.4” 14.6K Taperleaf 10.3” 11.7” 16K Taperleaf 10.3” 13.9” 18K Taperleaf 10.7” 13,6” Rear Suspension (All Models). Common rear suspensions are shown here, for detailed suspensions please use the rear suspension layouts on pages 3-18 to 3-33.
Page 38 Section 3 Dimensions REAR SUSPENSION LAYOUTS The rear suspension layouts are provided as a tool to help layout bodies prior to arrival. The applicable dimensions are shown. Be sure to check the axle spacing that is shown, as alternate spacings may exist and could change some of the dimensions.
Page 39: Table 3-4: Rear Suspension Options
Section 3 Dimensions AG400L TANDEM AG400L Suspensions TABLE 3-4. rear suspension Options Laden Ride Unladen Ride Suspension Type Rating Axle Spacing height height Ag400l Tandem 52" 8.5" 8.5" Ag400l Tandem 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.
Page 40 Section 3 Dimensions AG400 TANDEM AG400 Suspensions TABLE 3-5. rear suspension Options Laden Ride Unladen Ride Suspension Type Rating Axle Spacing height height Ag400 Tandem 52" 9" 9" Ag400 Tandem 54" 9" 9" 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.
Page 41 Section 3 Dimensions AG460 TANDEM AG460 Suspensions TABLE 3-6. rear suspension Options Laden Ride Unladen Ride Suspension Type Rating Axle Spacing height height Ag460 Tandem 60" spacing 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.
Page 42 Section 3 Dimensions AG690 TRIDEM AG690 Tridem Suspension TABLE 3-7. rear suspension Options Laden Ride Unladen Ride Suspension Type Rating Axle Spacing height height Ag690 Tridem 108" (54" + 54") 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.
Page 43 Section 3 Dimensions REYCO 79kB SINGLE REAR AXLE Optional Reyco 79kB Suspensions TABLE 3-8. rear suspension Options Laden Ride Unladen Ride Suspension Type Rating Axle Spacing height height reyco 79KB single 8.3” 10.8” reyco 79KB single 8.3” 10.8” reyco 79KB single 8.2”...
Page 44 Section 3 Dimensions REYCO 102 TANDEM REAR AXLE shown with a 52” Axle spacing Reyco 102 Suspension Data TABLE 3-9. rear suspension Options Unladen ride suspension Type rating Axle spacing laden ride height height reyco 102 Tandem 52” 9.2” 10.8” nOTe: Actual axle spacing can depart from nominal due to axle slant requirements.
Page 45 Section 3 Dimensions NEWAY ADz 123 SINGLE REAR AXLE Optional Neway AD Single Suspensions TABLE 3-10. rear suspension Options Laden Ride Unladen Ride Suspension Type Rating Axle Spacing height height neway Ad123 single 10” 10” neway Ad126 single 10” 10” 3-25 08/12...
Page 46 Section 3 Dimensions NEWAY ADz 246 TANDEM SUSPENSION shown with a 54” Axle spacing Optional Neway AD Tandem Suspensions TABLE 3-11. rear suspension Options Laden Ride Unladen Ride Suspension Type Rating Axle Spacing height height neway Ad246 tandem 54” 10” 10”...
Page 47 Section 3 Dimensions NEWAY ADz 369 TRIDEM SUSPENSION shown with 54” Axle spacings Optional Neway AD Tridem Suspensions TABLE 3-12. rear suspension Options Laden Ride Unladen Ride Suspension Type Rating Axle Spacing height height neway Ad369 tridem 54” 10” 10” neway Ad369 tridem 60”...
Page 48 Section 3 Dimensions hENDRICkSON PRIMAAX EX TANDEM SUSPENSION shown with 54” Axle spacings Optional hendrickson Primaax EX Tandem Suspensions TABLE 3-13. rear suspension Options Laden Ride Unladen Ride Suspension Type Rating Axle Spacing height height hendrickson Primaax Tandem 54” 10” 10”...
Page 49 Section 3 Dimensions hENDRICkSON PRIMAAX EX TRIDEM SUSPENSION shown with 54” Axle spacings Optional hendrickson Primaax EX Tridem Suspensions TABLE 3-14. rear suspension Options Laden Ride Unladen Ride Suspension Type Rating Axle Spacing height height hendrickson Primaax Tridem 54” 10” 10”...
Page 50 Section 3 Dimensions hENDRICkSON hMX TANDEM SUSPENSION shown with 54” Axle spacing Optional hendrickson hMX Tandem Suspensions TABLE 3-15. rear suspension Options Laden Ride Unladen Ride Suspension Type Rating Axle Spacing height height hendrickson hmx400 16.5” saddle 54” 9.5” 10.6” hendrickson hmx400 17.5”...
Page 51 Section 3 Dimensions hENDRICkSON RT TANDEM SUSPENSION shown with a 54” Axle spacing Without Track rods Optional hendrickson RT Tandem Suspensions TABLE 3-16. rear suspension Options Laden Ride Unladen Ride Suspension Type Rating Axle Spacing height height hendrickson rT463 6” saddle 52”...
Page 52 Section 3 Dimensions ChALMERS 856-46 TANDEM SUSPENSION shown with a 54” Axle spacing Optional Chalmers Tandem Suspensions TABLE 3-17. rear suspension Options Laden Ride Unladen Ride Suspension Type Rating Axle Spacing height height Chalmers 854-40-l 54” 8.9” 11.1” Chalmers 854-40-l-hs 54”...
Page 53 Section 3 Dimensions TABle 3-17 COnTinUed Laden Ride Unladen Ride Suspension Type Rating Axle Spacing height height Chalmers 854-50-l-hs 54” 9.6” 11.3” Chalmers 854-50-h 54” 10.1” 12.5” Chalmers 854-50-h-hs 54” 10.9” 12.5” Chalmers 854-50-xxh 54” 15.5” 17.3” Chalmers 854-52-l-hs 54” 9.6”...
Page 54 Section 3 Dimensions PUShER AXLES The rear pusher axle layouts are provided as a tool to help layout bodies prior to arrival. The applicable dimensions are shown. When using the pusher layouts to determine available frame space please be aware that clearances required are not shown.
Page 55 Section 3 Dimensions Watson & Chalin Tru Track 20k Steerable Pusher Watson & Chalin Atlas 22.5k Non-Steerable Pusher 3-35 08/12...
Page 56: Table 3-18: Axle Width Calculation
Section 3 Dimensions AXLE TRACk AND TIRE WIDTh The dimensions provided in this section are representative of some typical product combinations. The purpose this sec- tion is to demonstrate some of the typical dimensions. • Axle Track: The distance between the dual tire centerlines on a dual tire arrangement or the distance between the tire centerlines on a single tire arrangement.
Page 57 Section 3 Dimensions TABle 3-18 COnTinUed Brake Drum Track Overall Width Axle - Steer Wheel Tire Type Dim “A” Dim “B: dana spicer e-1322i 13.2K Alcoa 98364 Br r250f CAsT 80.2" 91.0" 24.5x8.25 11r24.5 dana spicer e-1322W 13.2K Alcoa 98364 Br r250f CAsT 82.2"...
Page 58: Table 3-19: Ground Clearance For Fuel Tanks
Section 3 Dimensions GROUND CLEARANCE This information is provided as a reference, not all optional equipment is included. in order to calculate the height on your specific chassis, please use the ride height information provided on page 3-14. For comparison the FS value shown is 11.4”...
Page 59: Table 3-20: Ground Clearance For Battery Boxes
Section 3 Dimensions TABLE 3-20. ground Clearance for Battery Boxes Dimension Dimension “B” Ground “A” Clearance (in) Distance Front Rear Front Tires Rear Tires Component from Suspension Suspension Bottom of Unladen Laden Frame Rail (in) Battery Box 17.3 16.2 13.9 with Air Tanks hendrickson m844f...
Page 60 Section 3 Dimensions PTO CLEARANCES The following visuals are provided to help aid in determining PTO locations and clearances. For specific dimensions please work through your local Kenworth dealer. 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.
Page 61 Section 3 Dimensions Allison Transmission: 3-41 08/12...
Page 62 Section 3 Dimensions This page intentionally left blank. 3-42 08/12...
Page 63 Section 4 Exhaust & Aftertreatment Exhaust and aftEr-trEatmEnt InformatIon The following section is designed to give you information regarding the exhaust and after-treatment systems on Kenworth chassis. All Kenworth’s equipped with 2010 emission level engines will utilize Selective Catalyst Reduction (SCR). SCR is a process in which Diesel Exhaust Fluid (DEF) is injected into the exhaust down stream of the engine.
Page 64 Section 4 Exhaust & Aftertreatment DEF will freeze at approximately 11° F. In order to keep DEF from freezing all tanks will be heated with engine coolant. The following schematic shows the routing of these lines. The coolant lines that run to and from the SCR system must not be tampered with, or used for a source of heat and/or cooling for other components on the chassis.
Page 65 DEF required = 200 x 0.06 = 12 gallons or more of DEF. PACCAR-approved DEF hoses are required when retrofitting for system to function properly. The use of unapproved hoses for DEF lines will void warranty and may cause engine shutdown situations. The DEF pump (or Supply Module) can not be relocated from the DEF tank.
Page 66: Figure 4-1: Measurement Location Of Def Supply Module (Pump)
Section 4 Exhaust & Aftertreatment mEasurEmEnt rEfErEncE PoInts For the all relocation procedures, the measurement points will referenced in the guidelines are taken from the following specific points: Supply Module: The supply module is commonly called a pump. The measurement point on the supply module is the top of the DEF fluid pressure line.
Page 67: Figure 4-3: Orientation Of Dosing Module
Section 4 Exhaust & Aftertreatment fIGurE 4-3: Orientation of Dosing Module right hand under dPf and scr with small, medium, or large dEf tanks fIGurE 4-4: RH Under Cab Exhaust with Small, Medium, or Large Tanks. The height differential between the supply module and dosing module can not exceed one meter. The supply module is integrated into the DEF tank assembly, separation of the module from the tank is not allowed.
Page 68: Figure 4-5: Horizontal Exhaust With Small, Medium, Or Large Tanks
Section 4 Exhaust & Aftertreatment horizontal (crossover) dPf and scr with small, medium, or large dEf tanks fIGurE 4-5: Horizontal Exhaust with Small, Medium, or Large Tanks. The height differential between the supply module and dosing module can not exceed one meter. The supply module is integrated into the DEF tank assembly, separation of the module from the tank is not allowed.
Page 69: Figure 4-7: Rh Under Cab Exhaust With Clear Back Of Cab Tank
Section 4 Exhaust & Aftertreatment The height differential between the supply module and dosing module can not exceed one meter. The supply module is integrated into the DEF tank assembly, separation of the module from the tank is not allowed. When relocating the components the maximum pressure DEF hose length, from Supply module to Dosing Module, is 3 meters (118”).
Page 70: Figure 4-8: Vertical With Clear Back Of Cab Tank
Section 4 Exhaust & Aftertreatment Vertical dPf and scr with clear Back of cab dEf tank fIGurE 4-8: Vertical with Clear Back of Cab Tank The installation and design of the Clear Back of Cab (CBOC) tank is highly integrated into the chassis and cooling system. Kenworth does not allow relocation of this tank, only relocation of the supply module.
Page 71: Figure 4-9: Routing Def Lines And Def Trap
Section 4 Exhaust & Aftertreatment Minimum 12” Line Length Below Dosing Module fIGurE 4-9: Routing DEF Lines and DEF Trap clear Back of cab supply module The CBOC Supply Module (or Pump) standard mounting location is inside of the frame rail back of cab. Body builders may need to relocate this component, and should follow the location and length restrictions above.
Page 72 Section 4 Exhaust & Aftertreatment GEnEral Exhaust InformatIon Kenworth will offer three main DPF and SCR exhaust systems on heavy duty chassis in 2010. A Right Hand Under DPF and SCR system, in which both canisters are located underneath the cab access step. A horizontal system with both the DPF and SCR located horizontally with a cross over pipe in the frame, and an Independent DPF and SCR located verti- cally back of cab on stanchion brackets.
Page 73: Figure 4-11: Isometric View Of Right Hand Under Dpf And Scr With Single Soc Tailpipe
Section 4 Exhaust & Aftertreatment right hand under dPf and scr on daycab with single side of cab tailpipe fIGurE 4-11: Isometric View of Right Hand Under DPF and SCR with Single SOC Tailpipe fIGurE 4-12: Top View of Right Hand Under DPF and SCR with Single SOC Tailpipe 08/12 4-11...
Page 74: Figure 4-13: Right View Of Right Hand Under Dpf And Scr With Single
Section 4 Exhaust & Aftertreatment fIGurE 4-13: Right View of Right Hand Under DPF and SCR with Single SOC Tailpipe fIGurE 4-14: Back View of Right Hand Under DPF and SCR with Single SOC Tailpipe 4-12 08/12...
Page 75: Figure 4-15: Isometric View Of Right Hand Under Dpf And Scr With
Section 4 Exhaust & Aftertreatment right hand under dPf and scr on daycab with dual side of cab tailpipes fIGurE 4-15: Isometric View of Right Hand Under DPF and SCR with Dual SOC Tailpipes fIGurE 4-16: Top View of Right Hand Under DPF and SCR with Dual SOC Tailpipes 08/12 4-13...
Page 76: Figure 4-17: Right View Of Right Hand Under Dpf And Scr With Dual
Section 4 Exhaust & Aftertreatment fIGurE 4-17: Right View of Right Hand Under DPF and SCR with Dual SOC Tailpipes fIGurE 4-18: Back View of Right Hand Under DPF and SCR with Dual SOC Tailpipes 4-14 08/12...
Page 77: Figure 4-19: Isometric View Of Right Hand Under Dpf And Scr On
Section 4 Exhaust & Aftertreatment right hand under dPf and scr on aerocabs with single side of cab tailpipe fIGurE 4-19: Isometric View of Right Hand Under DPF and SCR on Aerocab with Single SOC Tailpipe fIGurE 4-20: Top View of Right Hand Under DPF and SCR on Aerocab with Single SOC Tailpipe 08/12 4-15...
Page 78: Figure 4-21: Right View Of Right Hand Under Dpf And Scr On Aerocab
Section 4 Exhaust & Aftertreatment fIGurE 4-21: Right View of Right Hand Under DPF and SCR on Aerocab with Single SOC Tailpipe fIGurE 4-22: Back View of Right Hand Under DPF and SCR on Aerocab with Single SOC Tailpipe 4-16 08/12...
Page 79: Figure 4-23: Isometric View Of Right Hand Under Dpf And Scr On
Section 4 Exhaust & Aftertreatment right hand under dPf and scr on aerocabs with dual side of cab tailpipes fIGurE 4-23: Isometric View of Right Hand Under DPF and SCR on Aerocab with Dual SOC Tailpipes fIGurE 4-24: Top View of Right Hand Under DPF and SCR on Aerocab with Dual SOC Tailpipes 08/12 4-17...
Page 80: Figure 4-25: Right View Of Right Hand Under Dpf And Scr On Aerocab
Section 4 Exhaust & Aftertreatment fIGurE 4-25: Right View of Right Hand Under DPF and SCR on Aerocab with Dual SOC Tailpipes fIGurE 4-26: Back View of Right Hand Under DPF and SCR on Aerocab with Dual SOC Tailpipes 4-18 08/12...
Page 81: Figure 4-27: Isometric View Of Horizontal Dpf And Scr With Horizontal Tailpipe
Section 4 Exhaust & Aftertreatment horizontal dPf and scr with horizontal tailpipe fIGurE 4-27: Isometric View of Horizontal DPF and SCR with Horizontal Tailpipe fIGurE 4-28: Top View of Horizontal DPF and SCR with Horizontal Tailpipe 08/12 4-19...
Page 82: Figure 4-29: Right View Of Horizontal Dpf And Scr With Horizontal Tailpipe
Section 4 Exhaust & Aftertreatment fIGurE 4-29: Right View of Horizontal DPF and SCR with Horizontal Tailpipe fIGurE 4-30: Back View of Horizontal DPF and SCR with Horizontal Tailpipe 4-20 08/12...
Page 83: Figure 4-31: Isometric View Of Vertical Dpf And Scr
Section 4 Exhaust & Aftertreatment Vertical Independent dPf and scr with horizontal tailpipe fIGurE 4-31: Isometric View of Vertical DPF and SCR fIGurE 4-32: Top View of Vertical DPF and SCR 08/12 4-21...
Page 84: Figure 4-33: Right View Of Vertical Dpf And Scr
Section 4 Exhaust & Aftertreatment fIGurE 4-33: Right View of Vertical DPF and SCR fIGurE 4-34: Back View of Vertical DPF and SCR 4-22 08/12...
Page 85 Section 4 Exhaust & Aftertreatment Exhaust InformatIon This section includes information on how to calculate tailpipe heights, and reference information for PTO clearance. Optional equipment is not shown. tailpipe stack height calculation dimension a Tailpipes side of Aerocab, RH 75.0” under DPF Tailpipes independent back of 75.0”...
Page 86 Section 4 Exhaust & Aftertreatment This page intentionally left blank. 4-24 08/12...
Page 87 Section 5 Frame Layouts FRAME LAYOUTS The dimensions in the frame layout section are intended to aid in layout of the chassis, and to help determine the best possible combination of fuel tanks, battery boxes, the diesel particulate filter (DPF), SCR canister, and Diesel Exhaust Fluid (DEF) tank.
Page 88: Table 5-2: Fuel Tank Overall Length (In)
Section 5 Frame Layouts COMMOn OpTIOnAL COMpOnEnTS The frame layouts that follow contain the minimum frame requirements to be operational (fuel tanks, battery box, and after-treatment components). All layouts are shown with standard length battery boxes unless other- wise noted. Dimensions for these components have been provided below to help complete the frame layout for chassis with more fuel tanks, additional tool boxes, etc.
Page 89: Table 5-4: Def Tanks Systems
Section 5 Frame Layouts FIGURE 5-1. DEF Tank Dimensions. TABLE 5-4. DEF Tanks Systems Usable Volume, Fuel Tank Description Gallons Diameter 22” 27.4 15.3 Small DEF Tank 24.5” 27.4 15.8 28.5” 28.6 17.2 22” 27.7 15.0 Medium DEF Tank 24.5” 27.7 15.5 28.5”...
Page 90 Section 5 Frame Layouts FRAME LAYOUT InDEX Day Cab Chassis Layout Options D1 is used with RHUC DPF/SCR, LHUC fuel tank, RH BOC DEF tank, and LH BOC cantilever battery box. Charts located on pages 5-9 through 5-13. D2 is used with RHUC DPF/SCR, LHUC fuel tank, RH BOC cantilever battery box, and LH BOC DEF tank. Charts lo- cated on pages 5-14 through 5-18.
Page 91 Section 5 Frame Layouts D6 is used with RHUC DPF/SCR, LHUC fuel tank, Clear BOC DEF tank, and in cab battery box. Charts located on pages 5-34 through 5-38. D7 is used with horizontal DPF/SCR, RHUC fuel tank, LHUC battery box, and RH BOC DEF tank. Charts located on pages 5-39 through 5-40.
Page 92 Section 5 Frame Layouts D11 is used with Vertical-Vertical DPF/SCR, LH vertical tailpipe, RHUC fuel tank, LHUC battery box, and RH BOC DEF tank. Charts located on pages 5-50 through 5-54. D12 is used with Vertical-Vertical DPF/SCR, LH vertical tailpipe, LHUC & RHUC fuel tanks, RH BOC cantilever battery box, and LH BOC DEF tank.
Page 93 Section 5 Frame Layouts Sleeper Chassis Layout Options S1 is used with 38” AeroCab or 42” Modular sleeper with RHUC DPF/SCR, LHUC fuel tank, RH BOC DEF tank, and LH BOC cantilever battery box. Charts located on pages 5-65 through 5-72. S2 is used with 38”...
Page 94 Section 5 Frame Layouts S6 is used with 38” AeroCab or 42” Modular sleeper with horizontal DPF/SCR, RHUC tool box, LHUC battery box, RH BOC DEF tank, and LH BOC fuel tank. Charts located on pages 5-101 through 5-104. S7 is used with 38” AeroCab or 42” Modular sleeper with Vertical-Vertical DPF/SCR, LH vertical tailpipe, RHUC fuel tank, LHUC battery box, and LH BOC DEF tank.
Page 95 Section 5 Frame Layouts D1A—Use with the following models: T800SH Dimension E (BOC to DPF/SCR)* = 3.1in TABLE 5-5. T8SH Dimension D Fuel Tank Size Dimension F Dimension B BOC to DEF Tank, Daycab* (in) BOC to Fuel Tank, BOC to Battery Box, DEF Tank Size Daycab* (in) Daycab* (in)
Page 96 Section 5 Frame Layouts D1B—Use with the following models: T800B and C500B Dimension E (BOC to DPF/SCR)* = 0.3in TABLE 5-6. T8B & C5B Dimension D Dimension F Dimension B BOC to DEF Tank, Daycab* (in) Fuel Tank Size BOC to Fuel Tank, BOC to Battery DEF Tank Size Daycab* (in)
Page 97 Section 5 Frame Layouts D1C—Use with the following models: W900S Dimension E (BOC to DPF/SCR)* = 0.3in TABLE 5-7. Dimension D Dimension F Dimension B BOC to DEF Tank, Daycab* (in) Fuel Tank Size BOC to Fuel Tank, BOC to Battery DEF Tank Size Daycab* (in) Box, Daycab* (in)
Page 98 Section 5 Frame Layouts D1D—Use with the following models: W900B Dimension E (BOC to DPF/SCR)* = 0.3in TABLE 5-8. Dimension D Dimension F Dimension B BOC to DEF Tank, Daycab* (in) Fuel Tank Size BOC to Fuel Tank, BOC to Battery DEF Tank Size Daycab* (in) Box, Daycab* (in)
Page 99 Section 5 Frame Layouts D1E—Use with the following models: W900L Dimension E (BOC to DPF/SCR)* = 0.3in TABLE 5-9. Dimension D Dimension F Dimension B BOC to DEF Tank, Daycab* (in) Fuel Tank Size BOC to Fuel Tank, BOC to Battery DEF Tank Size Daycab* (in) Box, Daycab* (in)
Page 100 Section 5 Frame Layouts D2A—Use with the following models: T800SH Dimension E (BOC to DPF/SCR)* = 3.1in Dimension B (BOC to Cantilever Battery Box)* = 24.5in TABLE 5-10. T8SH Dimension D Dimension F BOC to DEF Tank* (in) Fuel Tank Size BOC to Fuel Tank, DEF Tank Size Daycab* (in)
Page 101 Section 5 Frame Layouts D2B—Use with the following models: T800B and C500B Dimension E (BOC to DPF/SCR)* = 0.3in Dimension B (BOC to Cantilever Battery Box)* = 21.7in TABLE 5-11. T8B & C5B Dimension D Dimension F BOC to DEF Tank* (in) Fuel Tank Size BOC to Fuel Tank, DEF Tank Size...
Page 102 Section 5 Frame Layouts D2C—Use with the following models: W900S Dimension E (BOC to DPF/SCR)* = 0.3in Dimension B (BOC to Cantilever Battery Box)* = 21.7in TABLE 5-12. Dimension D Dimension F BOC to DEF Tank* (in) Fuel Tank Size BOC to Fuel Tank, DEF Tank Size Daycab* (in)
Page 103 Section 5 Frame Layouts D2D—Use with the following models: W900B Dimension E (BOC to DPF/SCR)* = 0.3in Dimension B (BOC to Cantilever Battery Box)* = 21.7in TABLE 5-13. Dimension D Dimension F BOC to DEF Tank* (in) Fuel Tank Size BOC to Fuel Tank, DEF Tank Size Daycab* (in)
Page 104 Section 5 Frame Layouts D2E—Use with the following models: W900L Dimension E (BOC to DPF/SCR)* = 0.3in Dimension B (BOC to Cantilever Battery Box)* = 21.7in TABLE 5-14. Dimension D Dimension F BOC to DEF Tank* (in) Fuel Tank Size BOC to Fuel Tank, DEF Tank Size Daycab* (in)
Page 105 Section 5 Frame Layouts D3A—Use with the following models: T800SH Dimension E (BOC to DPF/SCR)* = 3.1in Dimension B (BOC to Battery Box)* = -4.5in TABLE 5-15. T8SH Dimension D Dimension F BOC to DEF Tank, Daycab* (in) Fuel Tank Size BOC to Fuel Tank, DEF Tank Size Daycab* (in)
Page 106 Section 5 Frame Layouts D3B— —Use with the following models: T800B and C500B Dimension E (BOC to DPF/SCR)* = 0.3in Dimension B (BOC to Battery Box)* = -4.5in TABLE 5-16. T8B & C5B Dimension D Dimension F BOC to DEF Tank, Daycab* (in) Fuel Tank Size BOC to Fuel Tank, DEF Tank Size...
Page 107 Section 5 Frame Layouts —Use with the following models: W900S Dimension E (BOC to DPF/SCR)* = 0.3in Dimension B (BOC to Battery Box)* = -10.6in TABLE 5-17. Dimension D Dimension F BOC to DEF Tank, Daycab* (in) Fuel Tank Size BOC to Fuel Tank, DEF Tank Size Daycab* (in)
Page 108: Diameter Gallons
Section 5 Frame Layouts —Use with the following models: W900B Dimension E (BOC to DPF/SCR)* = 0.3in Dimension B (BOC to Battery Box)* = -10.6in TABLE 5-18. Dimension D Dimension F BOC to DEF Tank, Daycab* (in) Fuel Tank Size BOC to Fuel Tank, DEF Tank Size Daycab* (in)
Page 109: Dimension D
Section 5 Frame Layouts —Use with the following models: W900L Dimension E (BOC to DPF/SCR)* = 0.3in Dimension B (BOC to Battery Box)* = -10.6in TABLE 5-19. Dimension D Dimension F BOC to DEF Tank, Daycab* (in) Fuel Tank Size BOC to Fuel Tank, DEF Tank Size Daycab* (in)
Page 110 Section 5 Frame Layouts D4A—Use with the following models: T800SH Dimension E (BOC to DPF/SCR)* = 3.1in Dimension B (BOC to Battery Box)* = -4.5in TABLE 5-20. T8SH Dimension D Dimension F BOC to DEF Tank, Daycab* (in) Fuel Tank Size BOC to Fuel Tank, DEF Tank Size Daycab* (in)
Page 111 Section 5 Frame Layouts D4B—Use with the following models: T800B and C500B Dimension E (BOC to DPF/SCR)* = 0.3in Dimension B (BOC to Battery Box)* = -4.5in TABLE 5-21. T8B & C5B Dimension D Dimension F BOC to DEF Tank, Daycab* (in) Fuel Tank Size BOC to Fuel Tank, DEF Tank Size...
Page 112: Small Medium
Section 5 Frame Layouts D4C—Use with the following models: W900S Dimension E (BOC to DPF/SCR)* = 0.3in Dimension B (BOC to Battery Box)* = -10.6in TABLE 5-22. Dimension D Dimension F BOC to DEF Tank, Daycab* (in) Fuel Tank Size BOC to Fuel Tank, DEF Tank Size Daycab* (in)
Page 113 Section 5 Frame Layouts D4D—Use with the following models: W900B Dimension E (BOC to DPF/SCR)* = 0.3in Dimension B (BOC to Battery Box)* = -10.6in TABLE 5-23. Dimension D Dimension F BOC to DEF Tank, Daycab* (in) Fuel Tank Size BOC to Fuel Tank, DEF Tank Size Daycab* (in)
Page 114 Section 5 Frame Layouts D4E—Use with the following models: W900L Dimension E (BOC to DPF/SCR)* = 0.3in Dimension B (BOC to Battery Box)* = -10.6in TABLE 5-24. Dimension D Dimension F BOC to DEF Tank, Daycab* (in) Fuel Tank Size BOC to Fuel Tank, DEF Tank Size Daycab* (in)
Page 115 Section 5 Frame Layouts D5A—Use with the following models: T800SH and In-cab battery box. Dimension E (BOC to DPF/SCR)* = 3.1in TABLE 5-25. T8SH Dimension D Dimension F BOC to DEF Tank, Daycab* (in) Fuel Tank Size BOC to Fuel Tank, DEF Tank Size Daycab* (in) Diameter...
Page 116 Section 5 Frame Layouts D5B—Use with the following models: T800B and C500B and In-cab battery box. Dimension E (BOC to DPF/SCR)* = 0.3in TABLE 5-26. T8B & C5B Dimension D Dimension F BOC to DEF Tank, Daycab* (in) Fuel Tank Size BOC to Fuel Tank, DEF Tank Size Daycab* (in)
Page 117 Section 5 Frame Layouts D5C—Use with the following models: W900S and In-cab battery box. Dimension E (BOC to DPF/SCR)* = 0.3in TABLE 5-27. Dimension D Dimension F BOC to DEF Tank, Daycab* (in) Fuel Tank Size BOC to Fuel Tank, DEF Tank Size Daycab* (in) Diameter...
Page 118 Section 5 Frame Layouts D5D—Use with the following models: W900B and In-cab battery box. Dimension E (BOC to DPF/SCR)* = 0.3in TABLE 5-28. Dimension D Dimension F BOC to DEF Tank, Daycab* (in) Fuel Tank Size BOC to Fuel Tank, DEF Tank Size Daycab* (in) Diameter...
Page 119 Section 5 Frame Layouts D5E—Use with the following models: W900L and In-cab battery box. Dimension E (BOC to DPF/SCR)* = 0.3in TABLE 5-29. Dimension D Dimension F BOC to DEF Tank, Daycab* (in) Fuel Tank Size BOC to Fuel Tank, DEF Tank Size Daycab* (in) Diameter...
Page 120 Section 5 Frame Layouts D6A—Use with the following models: T800SH and In-cab battery box. Dimension E (BOC to DPF/SCR)* = 3.1in Dimension D (BOC to DEF tank)* = 1.0in TABLE 5-30. T8SH Fuel Tank Size Dimension F BOC to Fuel Tank, Diameter Gallons Length (in)
Page 121 Section 5 Frame Layouts D6B—Use with the following models: T800B and C500B and In-cab battery box. Dimension E (BOC to DPF/SCR)* = 0.3in Dimension D (BOC to DEF tank)* = 1.0in TABLE 5-31. T8B & C5B Fuel Tank Size Dimension F BOC to Fuel Tank, Diameter Gallons...
Page 122 Section 5 Frame Layouts D6C—Use with the following models: W900S and In-cab battery box. Dimension E (BOC to DPF/SCR)* = 0.3in Dimension D (BOC to DEF tank)* = 1.0in TABLE 5-32. Fuel Tank Size Dimension F BOC to Fuel Tank, Diameter Gallons Length (in)
Page 123 Section 5 Frame Layouts D6D—Use with the following models: W900B and In-cab battery box. Dimension E (BOC to DPF/SCR)* = 0.3in Dimension D (BOC to DEF tank)* = 1.0in TABLE 5-33. Fuel Tank Size Dimension F BOC to Fuel Tank, Diameter Gallons Length (in)
Page 124 Section 5 Frame Layouts D6E—Use with the following models: W900L and In-cab battery box. Dimension E (BOC to DPF/SCR)* = 0.3in Dimension D (BOC to DEF tank)* = 1.0in TABLE 5-34. Fuel Tank Size Dimension F BOC to Fuel Tank, Diameter Gallons Length (in)
Page 125 Section 5 Frame Layouts D7A—Use with the following models: T800SH Dimension B (BOC to Battery Box)* = -4.5in Dimension E1 (BOC to DPF/SCR)* = 53.6in Dimension E2 (BOC to Diffuser)* = 67.4in TABLE 5-35. T8SH Dimension D Dimension F BOC to DEF Tank,* (in) Fuel Tank Size BOC to Fuel Tank, DEF Tank Size...
Page 126 Section 5 Frame Layouts D7B—Use with the following models: T800B Dimension B (BOC to Battery Box)* = -4.5in Dimension E1 (BOC to DPF/SCR)* = 53.6in Dimension E2 (BOC to Diffuser)* = 67.4in TABLE 5-36. Dimension D Dimension F BOC to DEF Tank,* (in) Fuel Tank Size BOC to Fuel Tank, DEF Tank Size...
Page 127 Section 5 Frame Layouts D8A—Use with the following models: T800SH Dimension B (BOC to Battery Box)* = -4.5in Dimension E1 (BOC to DPF/SCR)* = 53.6in Dimension T (BOC to Tool Box)* = -4.5in Dimension E2 (BOC to Diffuser)* = 67.4in TABLE 5-37.
Page 128 Section 5 Frame Layouts D8B—Use with the following models: T800B Dimension B (BOC to Battery Box)* = -4.5in Dimension E1 (BOC to DPF/SCR)* = 53.6in Dimension T (BOC to Tool Box)* = -4.5in Dimension E2 (BOC to Diffuser)* = 67.4in. TABLE 5-38.
Page 129 Section 5 Frame Layouts D9A—Use with the following models: T800SH and In-cab battery box. Dimension E1 (BOC to DPF/SCR)* = 53.6in Dimension E2 (BOC to Diffuser)* = 67.4in TABLE 5-39. T8SH Dimension D Dimension F1 & BOC to DEF Tank,* (in) Fuel Tank Size F2 BOC to Fuel Tank,...
Page 130 Section 5 Frame Layouts D9B—Use with the following models: T800B and In-cab battery box. Dimension E1 (BOC to DPF/SCR)* = 53.6in Dimension E2 (BOC to Diffuser)* = 67.4in TABLE 5-40. Dimension D Dimension F1 & BOC to DEF Tank,* (in) Fuel Tank Size F2 BOC to Fuel Tank,...
Page 131 Section 5 Frame Layouts D10A—Use with the following models: T800SH Dimension B (BOC to Battery Box)* = -4.5in Dimension E (BOC to DPF/SCR) = 19.6in TABLE 5-41. T8SH Dimension D Dimension D Dimension F Dimension F BOC to DEF Tank, Daycab (in) BOC to DEF Tank, Ext.
Page 132 Section 5 Frame Layouts D10B—Use with the following models: T800B and C500B Dimension B (BOC to Battery Box)* = -4.5in Dimension E (BOC to DPF/SCR) = 19.6in TABLE 5-42. T8B & C5B Dimension D Dimension D Dimension F Dimension F BOC to DEF Tank, Daycab (in) BOC to DEF Tank, Ext.
Page 133 Section 5 Frame Layouts D10C—Use with the following models: W900S Dimension B (BOC to Battery Box)* = -10.6in Dimension E (BOC to DPF/SCR) = 19.6in TABLE 5-43. Dimension D Dimension D Dimension F Dimension F BOC to DEF Tank, Daycab (in) BOC to DEF Tank, Ext.
Page 134 Section 5 Frame Layouts D10D—Use with the following models: W900B Dimension B (BOC to Battery Box)* = -10.6in Dimension E (BOC to DPF/SCR) = 19.6in TABLE 5-44. Dimension D Dimension D Dimension F Dimension F BOC to DEF Tank, Daycab (in) BOC to DEF Tank, Ext.
Page 135 Section 5 Frame Layouts D10E—Use with the following models: W900L Dimension B (BOC to Battery Box)* = -10.6in Dimension E (BOC to DPF/SCR) = 19.6in TABLE 5-45. Dimension D Dimension D Dimension F Dimension F BOC to DEF Tank, Daycab (in) BOC to DEF Tank, Ext.
Page 136 Section 5 Frame Layouts D11A—Use with the following models: T800SH Dimension B (BOC to Battery Box)* = -4.5in Dimension E (BOC to DPF/SCR) = 19.6in TABLE 5-46. T8SH Dimension D Dimension D Dimension F Dimension F BOC to DEF Tank, Daycab (in) BOC to DEF Tank, Ext.
Page 137 Section 5 Frame Layouts D11B—Use with the following models: T800B and C500B Dimension B (BOC to Battery Box)* = -4.5in (T8) Dimension E (BOC to DPF/SCR) = 19.6in TABLE 5-47. T8B & C5B Dimension D Dimension D Dimension F Dimension F BOC to DEF Tank, Daycab (in) BOC to DEF Tank, Ext.
Page 138 Section 5 Frame Layouts D11C—Use with the following models: W900S Dimension B (BOC to Battery Box)* = -10.6in Dimension E (BOC to DPF/SCR) = 19.6in TABLE 5-48. Dimension D Dimension D Dimension F Dimension F BOC to DEF Tank, Daycab (in) BOC to DEF Tank, Ext.
Page 139 Section 5 Frame Layouts D11D—Use with the following models: W900B Dimension B (BOC to Battery Box)* = -10.6in Dimension E (BOC to DPF/SCR) = 19.6in TABLE 5-49. Dimension D Dimension D Dimension F Dimension F BOC to DEF Tank, Daycab (in) BOC to DEF Tank, Ext.
Page 140 Section 5 Frame Layouts D11E—Use with the following models: W900L Dimension B (BOC to Battery Box)* = -10.6in Dimension E (BOC to DPF/SCR) = 19.6in TABLE 5-50. Dimension D Dimension D BOC to DEF Tank, Daycab (in) BOC to DEF Tank, Ext. Daycab (in) Fuel Tank Size Dimension F Dimension F...
Page 141 Section 5 Frame Layouts D12A—Use with the following models: T800SH Dimension E (BOC to DPF/SCR) = 19.6in TABLE 5-51. T8SH Dimension D Dimension Dimension Dimension D Dimension B Dimension B BOC to DEF Tank, F1 & F2 F1 & F2 BOC to DEF Tank, Daycab (in) Fuel Tank Size BOC to...
Page 142 Section 5 Frame Layouts D12B—Use with the following models: T800B and C500B Dimension E (BOC to DPF/SCR) = 19.6in TABLE 5-52. T8B & C5B Dimension D Dimension D Dimension Dimension BOC to DEF Tank, Dimension B Dimension B BOC to DEF Tank, Daycab (in) F1 &...
Page 143 Section 5 Frame Layouts D12C—Use with the following models: W900S Dimension E (BOC to DPF/SCR) = 19.6in TABLE 5-53. Dimension D Dimension D Dimension Dimension Dimension B BOC to DEF Tank, Dimension B BOC to DEF Tank, Daycab (in) F1 & F2 F1 &...
Page 144 Section 5 Frame Layouts D12D—Use with the following models: W900B Dimension E (BOC to DPF/SCR) = 19.6in TABLE 5-54. Dimension D Dimension D Dimension Dimension BOC to DEF Tank, Dimension B Dimension B BOC to DEF Tank, Daycab (in) F1 & F2 F1 &...
Page 145 Section 5 Frame Layouts D12E—Use with the following models: W900L Dimension E (BOC to DPF/SCR) = 19.6in TABLE 5-55. Dimension D Dimension D Dimension Dimension BOC to DEF Tank, Dimension B Dimension B BOC to DEF Tank, Daycab (in) Fuel Tank Size F1 &...
Page 146 Section 5 Frame Layouts D13A—Use with the following models: T800SH Dimension B (BOC To Battery Box)* = -4.5in Dimension E (BOC to DPF/SCR) = 19.6in Dimension D (BOC to DEF tank)* = 1.0in TABLE 5-56. T8SH Fuel Tank Size Dimension F Dimension F BOC to Fuel Tank, BOC to Fuel Tank,...
Page 147 Section 5 Frame Layouts D13B—Use with the following models: T800B and C500B Dimension B (BOC To Battery Box)* = -4.5in Dimension E (BOC to DPF/SCR) = 19.6in Dimension D (BOC to DEF tank)* = 1.0in TABLE 5-57. T8B & C5B Fuel Tank Size Dimension F Dimension F...
Page 148 Section 5 Frame Layouts D13C—Use with the following models: W900S Dimension B (BOC To Battery Box)* = -10.6in Dimension E (BOC to DPF/SCR) = 19.6in Dimension D (BOC to DEF tank)* = 1.0in TABLE 5-58. Fuel Tank Size Dimension F Dimension F BOC to Fuel Tank, BOC to Fuel Tank,...
Page 149 Section 5 Frame Layouts D13D—Use with the following models: W900B Dimension B (BOC To Battery Box)* = -10.6in Dimension E (BOC to DPF/SCR) = 19.6in Dimension D (BOC to DEF tank)* = 1.0in TABLE 5-59. Fuel Tank Size Dimension F Dimension F BOC to Fuel Tank, BOC to Fuel Tank,...
Page 150 Section 5 Frame Layouts D13E—Use with the following models: W900L Dimension B (BOC To Battery Box)* = -10.6in Dimension E (BOC to DPF/SCR) = 19.6in Dimension D (BOC to DEF tank)* = 1.0in TABLE 5-60. Fuel Tank Size Dimension F Dimension F BOC to Fuel Tank, BOC to Fuel Tank,...
Page 151 Section 5 Frame Layouts S1A—Use with the following models: T800SH 38” Dimension E (BOS to DPF/SCR) = -24.9in. TABLE 5-61. T8SH 38” Dimension D Dimension F Dimension B BOS to DEF Tank (in) Fuel Tank Size BOS to BOS to DEF Tank Size Fuel Tank (in) Battery Box (in)
Page 152 Section 5 Frame Layouts S1B—Use with the following models: T800SH 42” Dimension E (BOS to DPF/SCR) = -40.9in TABLE 5-62. T8SH 42” Dimension D Dimension F Dimension B BOS to DEF Tank (in) Fuel Tank Size BOS to BOS to DEF Tank Size Fuel Tank (in) Battery Box (in)
Page 153 Section 5 Frame Layouts S1C—Use with the following models: T800B and C500B 38” Dimension E (BOS to DPF/SCR) = -26.2in TABLE 5-63. T8B & C5B 38” Dimension D Dimension F Dimension B BOS to DEF Tank (in) Fuel Tank Size BOS to BOS to DEF Tank Size...
Page 154 Section 5 Frame Layouts S1D—Use with the following models: T800B and C500B 42” Dimension E (BOS to DPF/SCR) = -43.7in TABLE 5-64. T8B & C5B 42” Dimension D Dimension F Dimension B BOS to DEF Tank (in) Fuel Tank Size BOS to BOS to DEF Tank Size...
Page 155 Section 5 Frame Layouts S1E—Use with the following models: W900B 38” Dimension E (BOS to DPF/SCR) = -27.7in TABLE 5-65. W900B 38” Dimension D Dimension F Dimension B BOS to DEF Tank (in) Fuel Tank Size BOS to BOS to DEF Tank Size Fuel Tank (in) Battery Box (in)
Page 156 Section 5 Frame Layouts S1F—Use with the following models: W900B 42” Dimension E (BOS to DPF/SCR) = -43.7in TABLE 5-56. W900B 42” Dimension D Dimension F Dimension B BOS to DEF Tank (in) Fuel Tank Size BOS to BOS to DEF Tank Size Fuel Tank (in) Battery Box (in)
Page 157 Section 5 Frame Layouts S1G—Use with the following models: W900L 38” Dimension E (BOS to DPF/SCR) = -27.7in TABLE 5-57. W900L 38” Dimension D Dimension F Dimension B BOS to DEF Tank (in) Fuel Tank Size BOS to BOS to DEF Tank Size Fuel Tank (in) Battery Box (in)
Page 158 Section 5 Frame Layouts S1H—Use with the following models: W900L 42” Dimension E (BOS to DPF/SCR) = -43.7in TABLE 5-58. W900L 42” Dimension D Dimension F Dimension B BOS to DEF Tank (in) Fuel Tank Size BOS to BOS to DEF Tank Size Fuel Tank (in) Battery Box (in)
Page 159 Section 5 Frame Layouts S2A—Use with the following models: T800SH 38” Dimension E (BOS to DPF/SCR) = -24.9in Dimension B (BOS to Cantilever Battery Box) = 0.9in TABLE 5-59. T8SH 38” Dimension D BOS to DEF Tank (in) Fuel Tank Size Dimension F BOS to Fuel Tank (in) DEF Tank Size...
Page 160 Section 5 Frame Layouts S2B—Use with the following models: T800SH 42” Dimension E (BOS to DPF/SCR) = -40.9in Dimension B (BOS to Cantilever Battery Box) = -19.5in TABLE 5-60. T8SH 42” Dimension D BOS to DEF Tank (in) Fuel Tank Size Dimension F BOS to Fuel Tank (in) DEF Tank Size...
Page 161 Section 5 Frame Layouts S2C—Use with the following models: T800B and C500B 38” Dimension E (BOS to DPF/SCR) = -26.2in Dimension B (BOS to Cantilever Battery Box) = 0.9in TABLE 5-61. T8B & C5B 38” Dimension D BOS to DEF Tank (in) Fuel Tank Size Dimension F BOS to Fuel Tank (in)
Page 162 Section 5 Frame Layouts S2D—Use with the following models: T800B and C500B 42” Dimension E (BOS to DPF/SCR) = -43.7in Dimension B (BOS to Cantilever Battery Box) = -22.3in TABLE 5-62. T8B & C5B 42” Dimension D BOS to DEF Tank (in) Fuel Tank Size Dimension F BOS to Fuel Tank (in)
Page 163 Section 5 Frame Layouts S2E—Use with the following models: W900B 38” Dimension E (BOS to DPF/SCR) = -27.7in Dimension B (BOS to Cantilever Battery Box) = 0.9in TABLE 5-63. W900B 38” Dimension D BOS to DEF Tank (in) Fuel Tank Size Dimension F BOS to Fuel Tank (in) DEF Tank Size...
Page 164 Section 5 Frame Layouts S2F—Use with the following models: W900B 42” Dimension E (BOS to DPF/SCR) = -43.7in Dimension B (BOS to Cantilever Battery Box) = -22.3in TABLE 5-64. W900B 42” Dimension D BOS to DEF Tank (in) Fuel Tank Size Dimension F BOS to Fuel Tank (in) DEF Tank Size...
Page 165 Section 5 Frame Layouts S2G—Use with the following models: W900L 38” Dimension E (BOS to DPF/SCR) = -27.7in Dimension B (BOS to Cantilever Battery Box) = 0.9in TABLE 5-65. W900L 38” Dimension D BOS to DEF Tank (in) Fuel Tank Size Dimension F BOS to Fuel Tank (in) DEF Tank Size...
Page 166 Section 5 Frame Layouts S2H—Use with the following models: W900L 42” Dimension E (BOS to DPF/SCR) = -43.7in Dimension B (BOS to Cantilever Battery Box) = -22.3in TABLE 5-66. W900L 42” Dimension D BOS to DEF Tank (in) Fuel Tank Size Dimension F BOS to Fuel Tank (in) DEF Tank Size...
Page 167 Section 5 Frame Layouts S3A—Use with the following models: T800SH 38” Dimension E (BOS to DPF/SCR) = -24.9in Dimension B (BOS to Battery Box) = -32.5in TABLE 5-67. T8SH 38” Dimension D BOS to DEF Tank (in) Fuel Tank Size Dimension F BOS to Fuel Tank (in) DEF Tank Size...
Page 168 Section 5 Frame Layouts S3B—Use with the following models: T800SH 42” Dimension E (BOS to DPF/SCR) = -40.9in Dimension B (BOS to Battery Box) = -48.5in TABLE 5-68. T8SH 42” Dimension D BOS to DEF Tank (in) Fuel Tank Size Dimension F BOS to Fuel Tank (in) DEF Tank Size...
Page 169 Section 5 Frame Layouts S3C—Use with the following models: T800B and C500B 38” Dimension E (BOS to DPF/SCR) = -26.2in Dimension B (BOS to Battery Box) = -32.5in TABLE 5-69. T8B & C5B 38” Dimension D BOS to DEF Tank (in) Fuel Tank Size Dimension F BOS to Fuel Tank (in)
Page 170 Section 5 Frame Layouts S3D—Use with the following models: T800B and C500B 42” Dimension E (BOS to DPF/SCR) = -43.7in Dimension B (BOS to Battery Box) = -48.5in TABLE 5-70. T8B & C5B 42” Dimension D BOS to DEF Tank (in) Fuel Tank Size Dimension F BOS to Fuel Tank (in)
Page 171 Section 5 Frame Layouts S3E—Use with the following models: W900B 38” Dimension E (BOS to DPF/SCR) = -27.7in Dimension B (BOS to Battery Box) = -38.6in TABLE 5-71. W9B 38” Dimension D BOS to DEF Tank (in) Fuel Tank Size Dimension F BOS to Fuel Tank (in) DEF Tank Size...
Page 172 Section 5 Frame Layouts S3F—Use with the following models: W900B 42” Dimension E (BOS to DPF/SCR) = -43.7in Dimension B (BOS to Battery Box) = -54.6in TABLE 5-72. W9B 42” Dimension D BOS to DEF Tank (in) Fuel Tank Size Dimension F BOS to Fuel Tank (in) DEF Tank Size...
Page 173 Section 5 Frame Layouts S3G—Use with the following models: W900L 38” Dimension E (BOS to DPF/SCR) = -27.7in Dimension B (BOS to Battery Box) = -38.6in TABLE 5-73. W9L 38” Dimension D BOS to DEF Tank (in) Fuel Tank Size Dimension F BOS to Fuel Tank (in) DEF Tank Size...
Page 174 Section 5 Frame Layouts S3H—Use with the following models: W900L 42” Dimension E (BOS to DPF/SCR) = -43.7in Dimension B (BOS to Battery Box) = -54.6in TABLE 5-74. W9L 42” Dimension D BOS to DEF Tank (in) Fuel Tank Size Dimension F BOS to Fuel Tank (in) DEF Tank Size...
Page 175 Section 5 Frame Layouts S4A—Use with the following models: T800SH 38” Dimension E (BOS to DPF/SCR) = -24.9in Dimension B (BOS to Battery Box) = -32.5in TABLE 5-75. T8SH 38” Dimension D BOS to DEF Tank (in) Fuel Tank Size Dimension F DEF Tank Size BOS to Fuel Tank (in)
Page 176 Section 5 Frame Layouts S4B—Use with the following models: T800SH 42” Dimension E (BOS to DPF/SCR) = -40.9in Dimension B (BOS to Battery Box) = -48.5in TABLE 5-76. T8SH 42” Dimension D BOS to DEF Tank (in) Fuel Tank Size Dimension F DEF Tank Size BOS to Fuel Tank (in)
Page 177 Section 5 Frame Layouts S4C—Use with the following models: T800B and C500B 38” Dimension E (BOS to DPF/SCR) = -26.2in Dimension B (BOS to Battery Box) = -32.5in TABLE 5-77. T8B & C5B 38” Dimension D BOS to DEF Tank (in) Fuel Tank Size Dimension F DEF Tank Size...
Page 178 Section 5 Frame Layouts S4D—Use with the following models: T800B and C500B 42” Dimension E (BOS to DPF/SCR) = -43.7in Dimension B (BOS to Battery Box) = -48.5in TABLE 5-78. T8B & C5B 42” Dimension D BOS to DEF Tank (in) Fuel Tank Size Dimension F DEF Tank Size...
Page 179 Section 5 Frame Layouts S4E—Use with the following models: W900B 38” Dimension E (BOS to DPF/SCR) = -27.7in Dimension B (BOS to Battery Box) = -38.6in TABLE 5-79. W900B 38” Dimension D BOS to DEF Tank (in) Fuel Tank Size Dimension F DEF Tank Size BOS to Fuel Tank (in)
Page 180 Section 5 Frame Layouts S4F—Use with the following models: W900B 42” Dimension E (BOS to DPF/SCR) = -43.7in Dimension B (BOS to Battery Box) = -54.6in TABLE 5-80. W900B 42” Dimension D BOS to DEF Tank (in) Fuel Tank Size Dimension F DEF Tank Size BOS to Fuel Tank (in)
Page 181 Section 5 Frame Layouts S4G—Use with the following models: W900L 38” Dimension E (BOS to DPF/SCR) = -27.7in Dimension B (BOS to Battery Box) = -38.6in TABLE 5-81. W900L 38” Dimension D BOS to DEF Tank (in) Fuel Tank Size Dimension F DEF Tank Size BOS to Fuel Tank (in)
Page 182 Section 5 Frame Layouts S4H—Use with the following models: W900L 42” Dimension E (BOS to DPF/SCR) = -43.7in Dimension B (BOS to Battery Box) = -54.6in TABLE 5-82. W900L 42” Dimension D BOS to DEF Tank (in) Fuel Tank Size Dimension F DEF Tank Size BOS to Fuel Tank (in)
Page 183 Section 5 Frame Layouts S5A—Use with the following models: T800SH 38” Dimension B (BOS to Battery Box) = -32.5in Dimension E1 (BOS to DPF/SCR) = 13.6in Dimension E2 (BOS to Diffuser) = 27.5in TABLE 5-83. T8SH 38” Dimension D BOS to DEF Tank (in) Fuel Tank Size Dimension F BOS to Fuel Tank (in)
Page 184 Section 5 Frame Layouts S5B—Use with the following models: T800SH 42” Dimension B (BOS to Battery Box) = -48.5in Dimension E1 (BOS to DPF/SCR) = 11.4in Dimension E2 (BOS to Diffuser) = 25.2in TABLE 5-84. T8SH 42” Dimension D BOS to DEF Tank (in) Fuel Tank Size Dimension F BOS to Fuel Tank (in)
Page 185 Section 5 Frame Layouts S5C—Use with the following models: T800B 38” Dimension B (BOS to Battery Box) = -32.5in Dimension E1 (BOS to DPF/SCR) = 13.6in Dimension E2 (BOS to Diffuser) = 27.5in TABLE 5-85. T8B 38” Dimension D BOS to DEF Tank (in) Fuel Tank Size Dimension F BOS to Fuel Tank (in)
Page 186 Section 5 Frame Layouts S5D—Use with the following models: T800B 42” Dimension B (BOS to Battery Box) = -48.5in Dimension E1 (BOS to DPF/SCR) = 11.4in Dimension E2 (BOS to Diffuser) = 25.2in TABLE 5-86. T8B 42” Dimension D BOS to DEF Tank (in) Fuel Tank Size Dimension F BOS to Fuel Tank (in)
Page 187 Section 5 Frame Layouts S6A—Use with the following models: T800SH 38” Dimension B (BOS to Battery Box) = -32.5in Dimension E1 (BOS to DPF/SCR) = 13.6in Dimension E2 (BOS to Diffuser) = 27.5in TABLE 5-87. T8SH 38” Dimension D BOS to DEF Tank (in) Fuel Tank Size Dimension F BOS to Fuel Tank (in)
Page 188 Section 5 Frame Layouts S6B—Use with the following models: T800SH 42” Dimension B (BOS to Battery Box) = -48.5in Dimension E1 (BOS to DPF/SCR) = 11.4in Dimension E2 (BOS to Diffuser) = 25.2in TABLE 5-88. T8SH 42” Dimension D BOS to DEF Tank (in) Fuel Tank Size Dimension F BOS to Fuel Tank (in)
Page 189 Section 5 Frame Layouts S6C—Use with the following models: T800B 38” Dimension B (BOS to Battery Box) = -32.5in Dimension E1 (BOS to DPF/SCR) = 13.6in Dimension E2 (BOS to Diffuser) = 27.5in TABLE 5-89. T8B 38” Dimension D BOS to DEF Tank (in) Fuel Tank Size Dimension F BOS to Fuel Tank (in)
Page 190 Section 5 Frame Layouts S6D—Use with the following models: T800B 42” Dimension B (BOS to Battery Box) = -48.5in Dimension E1 (BOS to DPF/SCR) = 11.4in Dimension E2 (BOS to Diffuser) = 25.2in TABLE 5-90. T8B 42” Dimension D BOS to DEF Tank (in) Fuel Tank Size Dimension F BOS to Fuel Tank (in)
Page 191 Section 5 Frame Layouts S7A—Use with the following models: T800SH 38” Dimension B (BOS to Battery Box) = -32.5in Dimension E (BOS to DPF/SCR) = 19.6in TABLE 5-91. T8SH 38” Dimension D BOS to DEF Tank (in) Fuel Tank Size Dimension F BOS to Fuel Tank (in) DEF Tank Size...
Page 192 Section 5 Frame Layouts S7B—Use with the following models: T800SH 42” Dimension B (BOS to Battery Box) = -48.5in Dimension E (BOS to DPF/SCR) = 19.6in TABLE 5-92. T8SH 42” Dimension D BOS to DEF Tank (in) Fuel Tank Size Dimension F BOS to Fuel Tank (in) DEF Tank Size...
Page 193 Section 5 Frame Layouts S7C—Use with the following models: T800B and C500B 38” Dimension B (BOS to Battery Box) = -32.5in Dimension E (BOS to DPF/SCR) = 19.6in TABLE 5-93. T8B and C5B 38” Dimension D BOS to DEF Tank (in) Fuel Tank Size Dimension F BOS to Fuel Tank (in)
Page 194 Section 5 Frame Layouts S7D—Use with the following models: T800B and C500B 42” Dimension B (BOS to Battery Box) = -48.5in Dimension E (BOS to DPF/SCR) = 19.6in TABLE 5-94. T8B and C5B 42” Dimension D BOS to DEF Tank (in) Fuel Tank Size Dimension F BOS to Fuel Tank (in)
Page 195 Section 5 Frame Layouts S8A—Use with the following models: T800SH 38” Dimension B (BOS to Battery Box) = -32.5in Dimension E (BOS to DPF/SCR) = 19.6in TABLE 5-95. T8SH 38” Dimension D BOS to DEF Tank (in) Fuel Tank Size Dimension F BOS to Fuel Tank (in) DEF Tank Size...
Page 196 Section 5 Frame Layouts S8B—Use with the following models: T800SH 42” Dimension B (BOS to Battery Box) = -48.5in Dimension E (BOS to DPF/SCR) = 19.6in TABLE 5-96. T8SH 42” Dimension D BOS to DEF Tank (in) Fuel Tank Size Dimension F BOS to Fuel Tank (in) DEF Tank Size...
Page 197 Section 5 Frame Layouts S8C—Use with the following models: T800B and C500B 38” Dimension B (BOS to Battery Box) = -32.5in Dimension E (BOS to DPF/SCR) = 19.6in TABLE 5-97. T8B & C5B 38” Dimension D BOS to DEF Tank (in) Fuel Tank Size Dimension F BOS to Fuel Tank (in)
Page 198 Section 5 Frame Layouts S8D—Use with the following models: T800B and C500B 42” Dimension B (BOS to Battery Box) = -48.5in Dimension E (BOS to DPF/SCR) = 19.6in TABLE 5-98. T8B & C5B 42” Dimension D BOS to DEF Tank (in) Fuel Tank Size Dimension F BOS to Fuel Tank (in)
Page 199 Section 5 Frame Layouts S9A—Use with the following models: T800SH 38” Dimension E (BOS to DPF/SCR) = 19.6in TABLE 5-99. T8SH 38” Dimension D Dimension F1 & F2 Dimension B BOS to DEF Tank (in) Fuel Tank Size BOS to BOS to DEF Tank Size Fuel Tank (in)
Page 200 Section 5 Frame Layouts S9B—Use with the following models: T800SH 42” Dimension E (BOS to DPF/SCR) = 19.6in TABLE 5-100. T8SH 42” Dimension D Dimension F1 & F2 Dimension B BOS to DEF Tank (in) Fuel Tank Size BOS to BOS to DEF Tank Size Fuel Tank (in)
Page 201 Section 5 Frame Layouts S9C—Use with the following models: T800B and C500B 38” Dimension E (BOS to DPF/SCR) = 19.6in TABLE 5-101. T8B & C5B 38” Dimension D Dimension F1 & F2 Dimension B BOS to DEF Tank (in) Fuel Tank Size BOS to BOS to DEF Tank Size...
Page 202 Section 5 Frame Layouts S9D—Use with the following models: T800B and C500B 42” Dimension E (BOS to DPF/SCR) = 19.6in TABLE 5-102. T8B & C5B 42” Dimension D Dimension F1 & F2 Dimension B BOS to DEF Tank (in) Fuel Tank Size BOS to BOS to DEF Tank Size...
Page 203: Figure 6-1: Isometric View Of T800 Fepto Front End With
Section 6 Body Mounting FRAME INFORMATION Frame information provided is per rail, some specifications are written for RBM requirements per pair of rails. Make sure to know the requirement before deciding on the frame rail. TABLE 6-1. Single Steel Rails Rail Height Flange Width Web Thickness...
Page 204: Figure 6-2: T800 Fepto Front End With 66" Bumper Setting
Section 6 Body Mounting FIGURE 6-2: T800 FEPTO front end with 66” Bumper Setting FIGURE 6-3: Isometric View of T800 FEPTO front end with 73” Bumper Setting FIGURE 6-4: T800 FEPTO front end with 73” Bumper Setting 08/12...
Page 205: Figure 6-5: Minimum Clearance Between Top Of Rear Tires And
Section 6 Body Mounting CRITICAL CLEARANCES Rear Wheels and Cab CAUTION: Insufficient clearance between rear tires and body structure could cause damage to the body during suspension movement. Allow at least 8 inches clearance (See Figure 6–5.) Normal suspension movement could cause contact between the tires and the body. To prevent this, mount the body so that the minimum clearance between the top of the tire and the bottom of the body is 8 inches (203 mm).
Page 206: Figure 6-6: Minimum Back Of Cab Clearance
Section 6 Body Mounting 4” FIGURE 6-6. Minimum Back of Cab Clearance WARNING: If the frame rail flanges are modified or damaged, the rail could fail prematurely and cause an accident. When mounting a body to the chassis, DO NOT drill holes in the upper or lower flange of the frame rail.
Page 207: Figure 6-7: Spacer Between Frame Sill And Body Rail - Rubber Or Plastic
Section 6 Body Mounting Frame Sill If the body is mounted to the frame with brackets, we recommend that the frame sill spacer be made from a strip of rub- ber or plastic (delrin or nylon). These materials will not undergo large dimensional changes during periods of high or low humidity.
Page 208: Figure 6-10: Crossmember-Gusset Hole Pattern Requirements [Inch (Mm)]
Section 6 Body Mounting MOUNTING HOLES When installing the lower bracket on frame rails the mounting holes in the chassis frame bracket and frame rail must com- ply with the general spacing and location guidelines illustrated in Figure 6–10. The hole diameter should not exceed the bolt diameter by more than .060 inches (1.5 mm).
Page 209: Figure 6-11: Acceptable U-Bolt Mounting With Wood And Fabricated Spacers [Inch (Mm)]
Section 6 Body Mounting BODy MOUNTING USING U–BOLTS Spacers If the body is mounted to the frame with U–bolts, use a hardwood sill (minimum 1/2 inch (12 mm) thick) between the frame rail and body frame to protect the top surface of the rail flange. WARNING: Do not allow the frame rails or flanges to deform when tightening the U–bolts.
Page 210: Figure 6-12: Clearance Space For Air Lines And Cables
Section 6 Body Mounting Frame Rail U-Bolt Air Lines and Wiring Frame Rail Spacer Harness (Hardwood or Steel Check Clearance U-Bolt Spacer Space for Air Lines and Wiring FIGURE 6-12. Clearance Space for Air Lines and Cables WARNING: Do not notch frame rail flanges to force a U–bolt fit. Notched or damaged frame flanges could result in premature frame failure.
Page 211: Figure 6-13: Example Of Fishplate Bracket At Rear End Of Body
Section 6 Body Mounting Rear Body Mount When U–bolts are used to mount a body we recommend that the last body attachment be made with a “fishplate” bracket. See Figure 6–13. This provides a firm attaching point and helps prevent any relative fore or aft movement between the body and frame.
Page 212 Section 6 Body Mounting This page intentionally left blank. 6-10 08/12...
Page 213 Section 7 Frame Modifications FRAME MODIFICATIONS Introduction Kenworth offers customer specified wheelbases. So, in most cases frame modifications to produce a certain wheelbase should not be necessary. However, some installations may require slight modifications, while other installations will require extensive modifications. Sometimes an existing dealer stock chassis may need to have the wheelbase changed to better fit a customer’s applica- tion.
Page 214: Figure 7-1: Detail Of Frame Extension And Joint Welding
Section 7 Frame Modifications MODIFYING FRAME LENGTH The frame cutoff after the rear axle can be shortened to match a particular body length. Using a torch is acceptable; however, heat from a torch will affect the material characteristics of the frame rail. The affected material will normally be confined to within 1 to 2 inches (25 to 50 mm) of the flame cut and may not adversely affect the strength of the chassis or body installation.
Page 215: Figure 7-2: Frame Insert
Section 7 Frame Modifications WELDED JOINT 24 Inch Minimum (610 mm) FIGURE 7-2. Frame Insert Where possible, use existing bolt holes to attach the insert to the frame. Bolt holes must not be located closer to the frame flanges than the present bolt pattern. If the insert is placed in a section of the main frame where few bolts are located, additional bolts are required.
Page 216: Figure 7-3: Comparison Of Original, Shortened, And Extended Wheelbases
Section 7 Frame Modifications When reducing the wheelbase, we recommend that the suspension be moved forward and relocated on the original rail. The rail behind the suspension can then be cut to achieve the desired frame cutoff. See Figure 7–3. WARNING! Do not drill new holes any closer than 2 inches (50 mm) to existing holes.
Page 217: Figure 7-4: Crossmember Added When Distance Exceeds 60 Inches (1524 Mm)
Section 7 Frame Modifications CROSSMEMbERS After changing a wheelbase, an additional crossmember may be required to maintain the original frame strength. The maximum allowable distance between adjacent crossmembers is 60 inches (1524 mm). If the distance between adja- cent crossmembers exceeds this dimension, add a crossmember between them. See Figure 7–4. Less Than 60”...
Page 218 Section 7 Frame Modifications WELDING Kenworth DOES NOT recommend frame welding. The high heat of welding nullifies the special heat treatment of the rails, greatly reducing the tensile strength of the frame rail. If a frame member becomes cracked from overloading, fatigue, surface damage or a collision, the only permanent repair is to replace the damaged frame member with a new part.
Page 219: Table 7-1: Customary Grade 8 Unf Or Unc
Section 7 Frame Modifications TORqUE REqUIREMENTS TABLE 7-1. Customary Grade 8 UNF or UNC. Fastener Torque Size Lb.-Ft 5/16 22–30 16–22 41–54 30–40 7/16 75–88 55–65 109–122 80–90 9/16 156–190 115-140 224–265 165–195 394–462 290–340 517–626 380–460 952–1129 800–830 1-1/8 1346–1591 990–1170 1-1/4...
Page 220 Section 7 Frame Modifications This page intentionally left blank. 08/12...
Page 221 Section 8 Electrical ELECTRICAL Information in this section will cover the following topics: • Overview of Kenworth’s 2010 multiplex instrumentation • Access instructions for the dash, gauges, and switches. • Wiring instructions for alarm and telltale (warning lights) • Reconfiguring telltale cards •...
Page 222: Figure 8-1: Kenworth B-Cab Dash
Section 8 Electrical INTERIOR IDENTIFICATION Kenworth began production of this interior in 2005. Chassis with this new interior can be identified by appearance, see Figure 8-1. All dashes that resemble the following picture will utilize multiplex wiring. FIGURE 8-1. Kenworth B-Cab Dash A 2010 Chassis can quickly be identified by the presence of the Diesel Exhaust Fluid “DEF” gauge. See Figure 8-2. FIGURE 8-2. Diesel Exhaust Fluid Gauge Note: The information contained in this manual is specific to chassis with 2010 engines. For pre-2010 engines please work with your local Kenworth dealer. 08/12...
Page 223: Figure 8-3: Multiplexed Instrumentation Block Diagram
Section 8 Electrical Data Bus Communication The multiplexed instrumentation system uses several different data links to transmit input/output data from other systems to the Cab Electronic Control Unit (CECU), and ultimately to the Central Instrument Cluster and CVSG Gauges. See Fig- ure 8-3, Multiplexed Instrumentation Block Diagram on page 8-3.
Page 224: Figure 8-4: Cecu Location
Section 8 Electrical Functional Description Cab Electronic Control Unit (CECU) The heart of the multiplexed instrumentation system is the Cab Electronic Control Unit (CECU). The CECU is located behind the center console. See Figure 8-4. FIGURE 8-4. CECU Location. Vehicle component inputs are sent to the CECU through the J1939 data bus or conventional wiring. The CECU interprets the various inputs and monitors/controls the functions for each input through the CECU software.
Page 225: Figure 8-5: Instrument Cluster Components
Section 8 Electrical FIGURE 8-5. Instrument Cluster Components CVSG Gauges The right and left instrument panel gauges used with the multiplexed instrumentation are commonly referred to as Com- mercial Vehicle Smart Gauges (CVSG). Like the central instrument cluster, the 2-inch gauges also receive input data directly from the CECU.
Page 226: Figure 8-6: Cvsg Gauges
Section 8 Electrical • 4-way jumper harnesses link each 2-inch gauge together. Pin # Color Function Blue Data, backlighting for Electronic Gauges Brown Backlighting for Mechanical Gauges White Ground (Return) Yellow Power • Backlighting for 2-inch electronic gauges is sent from the CECU to the gauges via the data link (blue wire). •...
Page 227: Figure 8-7: Firewall Air Junction Block (View From Inside Of Cab)
Section 8 Electrical Sensors Kenworth’s chassis contain standard connectors in the wiring harnesses for gauges even when they were not specified on a particular chassis. This allows you to easily locate connectors to add gauges. To add an electronic gauge install the sen- sor (available from your local Kenworth dealer) in the noted location, plug in the wiring harness, and then install the gauge in the dash.
Page 228: Figure 8-9: Fuel Filter Restriction Pressure Gauge Sensor Location (Typical)
Section 8 Electrical FIGURE 8-9. Fuel Filter Restriction Pressure Gauge Sensor Location (typical) 08/12...
Page 229 Section 8 Electrical ACCESSING GAUGES AND SWITCHES In order to access and install components described later on in the manual, you will need to know how to correctly remove the dash panels without causing damage. 1. Remove trim bezel by prying upward at one of the four pry points. Carefully pry the remaining clips. SPEEDO AND TACH PANEL 2.
Page 230 Section 8 Electrical 3. Unclip harness and remove Speedo - Tach panel. ACCESSING RIGHT HAND GAUGE & SWITCH PANEL 4. Remove (7) screws to remove right gauge panel. 5. Unclip leads to gauges, effort is required to separate the friction lock. 8-10 08/12...
Page 231 Section 8 Electrical 6. Pinch to unlock connector and remove right gauge panel. 7. Unscrew gauge collar to remove gauge. 8. To remove switches, push both tabs down..and then push switch out of plate on top side... 8-11 08/12...
Page 232 Section 8 Electrical ...then flip over and do the same on the bottom side. 9. Push down to unhook connector from switch. ACCESSING LEFT HAND GAUGE & SWITCH PANEL 10. Remove (4) screws to remove left gauge panel. 8-12 08/12...
Page 233 Section 8 Electrical 11. Pinch to unlock connectors from switches. 12. Unclip harness and remove left gauge panel. 13. Unscrew gauge collar to remove gauge. 14. To remove switches, push both tabs down... 8-13 08/12...
Page 234 Section 8 Electrical ...and then push switch out of plate on top side..then flip over and do the same on the bottom side. 15. Push down to unhook connector from switch. ACCESSING SWITCHES IN THE UPPER DASH 16. Remove (4) screws to remove Upper Switch Cluster. 8-14 08/12...
Page 235 Section 8 Electrical 17. Pinch to unlock connector and remove Upper Switch Cluster 18. To remove switches push both tabs down..and then push switch out of plate on top side..then flip over and do the same on the bottom side. 8-15 08/12...
Page 236 Section 8 Electrical 19. Push down to unhook connector from switch ACCESSING SWITCHES IN THE KEY SWITCH PANEL 20. Insert key into the ignition switch, turn to ACC and pull. The tabs which hold the trim piece to the dash will release. The switches can be serviced by following steps 18 &...
Page 237: Figure 8-10: Telltale Symbol Standard Cards
Section 8 Electrical TELLTALE SYMBOLS Kenworth’s interior allows Body Builders to customize the dash telltale symbols (warning lights). The editable telltale symbols are located on removable cards inside the baseline cluster. This section will describe how to replace and insert editable cards, as well as how to activate the telltale lights.
Page 238: Figure 8-11: Blank Telltale Card
Section 8 Electrical TABLE 8-1. Telltales Position and Color Light Editable or Position Standard Function Color Fixed? Engine Retarder Green Fixed Wait To Start Yellow Fixed Fifth Wheel Slide Fixed King Pin Lock Editable Refrigerator Green Fixed Park Brake Fixed Check Transmission Editable Transmission Temp...
Page 239: Figure 8-12: Telltale Icons
Section 8 Electrical Your local Kenworth dealer will also sell a sheet of telltale light icons to install on the editable card. The symbols that are available are shown in Figure 8-12 below. FIGURE 8-12. Telltale Icons The telltales can then be peeled off of the sheet and applied directly to the card. The color of the telltale is controlled by the light, all of the icons are clear.
Page 240: Figure 8-13: Kenworth Spare Switches
Section 8 Electrical ALARMS There are four spare Alarm female ¼” slide connector breakouts behind the speedo-tach cluster near the speedo-tach connector labeled: • Alarm 1A • Alarm 1B • Alarm 1C • Alarm 2 When these circuits are either grounded or powered an alarm sound in the dash will turn on. Alarm 1 and Alarm 2 have two different tones.
Page 241: Figure 8-14: Spare Switch Harness
Section 8 Electrical FIGURE 8-14. Spare Switch Harness Kenworth also offers flat panel inserts that can be easily modified or removed to add switches or gauges. The small panel is 5” x 5” and the large panel is 7.5” x 5”. To add these to a chassis order work with your local Kenworth dealer. Kenworth offers a variety of pre-labeled switches. See Figure 8-15 below for details of all switches offered, and the switch diagram. Please note, when switching relay coils, only use P27-1123-XXX switches. 8-21 08/12...
Page 242: Figure 8-15: Specialty Switches
Section 8 Electrical FIGURE 8-15. Specialty Switches 8-22 08/12...
Page 243: Figure 8-16: Spare Relay Connectors
Section 8 Electrical SPARE RELAYS BODY BUILDER INSTALLED (For loads exceeding 20 amps) There are two spare relay locations in the central electrical panel. To access these relays there are two spare relay breakouts behind the LH gauge cluster labeled, “SPARE RELAY #1, and SPARE RELAY #2” To connect to these relays you can use one of two harnesses also available from you local Kenworth Part Department. P92-1947-1, -3 for accessing the normally OPEN contact of the relay (87) or P92-1947-2, -4 for accessing the normally closed contact of the relay (87a).
Page 244: Figure 8-17: Spare Relay Harnesses
Section 8 Electrical FIGURE 8-17. Spare Relay Harnesses 8-24 08/12...
Page 245: Figure 8-18: Spare Bullet Connectors
Section 8 Electrical ADDITIONAL SPARE CIRCUITS If you just need spare power wire into one of 18 spare circuits we provide. WARNING! Do not install an electrical circuit that requires more amperage (electrical capacity) than what is available in the specific chassis circuit. An overloaded circuit could cause a fire. Compare the amperage requirements of the new circuit to the electrical current capacity of the existing chassis circuit before adding the body or other equipment.
Page 246: Figure 8-19: Spare Pigtail Connector
Section 8 Electrical 3. Plug one end of a K333-127-2 pigtail harness into the appropriate spare circuit bullet connector. See Figure 8-19. FIGURE 8-19. Spare Pigtail Connector 4. Connect the other end of the pigtail harness to the accessory. 5. Install the correct rated fuse, or circuit breaker for the gauge of wire going to your accessory, into the fuse socket that corresponds to the spare circuit selected in step 2.
Page 247 Follow the engine manufacturer’s guidelines for use of these circuits. See your engine manufacturer to verify that the engine is programmed correctly for the intended applications. Failure to properly program the engine or wire these circuits could cause an accident. TABLE 8-2. 2010 PACCAR MX Corresponding Common Body Builder...
Page 248 Section 8 Electrical FIGURE 8-20. 2010 PACCAR MX Routing Diagram The location of the remote PTO throttle harness pin out connection can be found on the MX engine as noted in the diagrams below. It is from this location that the optional remote throttle chassis harness is installed. If engine specified from the factory does not include the factory installed body builder harness, the remote PTO throttle harness is capped off.
Page 249 Section 8 Electrical REMOTE PTO/THROTTLE HARNESS This option provides a connection from the engine ECU for remote control of engine throttle and PTOs. Options that extend the wiring to the end of frame also exist, however controls are not provided. A 12-pin Deutsch connector (Deutsch P/N DT06-12SA-P012) is included.
Page 250 Section 8 Electrical FIGURE 8-21. 2010 Cummins ISX15 Routing Diagram The location of the optional multi-function engine connector is noted below. The remote PTO throttle harness pin out connection will only be installed if the multi-funtion engine connector is ordered. It can be found on the ISX15 engine as noted in the diagrams below.
Page 251 Section 8 Electrical FIGURE 8-22. 2010 Cummins ISX12 Routing Diagram The location of the remote PTO throttle harness pin out connection can be found on the ISX12 engine as noted in the diagrams below. It is from this location the remote throttle chassis harness is installed. If the engine specified from the factory does not include the factory installed body builder harness, the remote PTO throttle harness is capped off.
Page 252 Section 8 Electrical FIGURE 8-23. 2010 Cummins ISL/PX-8 Routing Diagram The location of the remote PTO throttle harness pin out connection can be found on the ISL/PX-8 engine as noted in the diagrams below. It is from this location the remote throttle chassis harness is installed. If the engine specified from the factory does not include the factory installed body builder harness, the remote PTO throttle harness is capped off.
Page 253 Section 8 Electrical MULTIFUNCTION TURN SIGNAL STALK, CHASSIS NODE & CHASSIS LOAD CENTER Kenworth introduced the chassis node and chassis load center with 2010 emissions. The information that follows covers the functions of the chassis node, along with guidelines for installing additional lights on the chassis. Exterior Lighting Circuit Limits The multifunction turn signal stalk communicates to the CECU inside the cab which sends information to the Chassis Node over the F-CAN bus.
Page 254 Section 8 Electrical FIGURE 8-24. Chassis Power Distribution Center Mounting Above Washer Bottle 8-34 08/12...
Page 255 Section 8 Electrical CHASSIS LOAD CENTER DIMENSIONS The chassis load center is mounted on the firewall near the washer bottle. Do not relocate the chassis load center. See Figure 8-25. FIGURE 8-25. Chassis Power Distribution Center Dimensions 8-35 08/12...
Page 256 Section 8 Electrical 2010 ELECTRICAL HARDWARE Kenworth incorporated new electrical hardware to enhance the truck capabilities and performance. The locations of the hardware are shown here for reference. The chassis node is mounted above the LH frame rail under the cab on Day Cabs or Extended Day Cabs.
Page 257 Section 8 Electrical FIGURE 8-28. Aerocab Alternate Hardware Location. FIGURE 8-29. Chassis Node Dimensions 8-37 08/12...
Page 258 Section 8 Electrical ELECTRICAL WIRE NUMBER AND COLOR GENERAL WIRE LABELS Kenworth introduced a new electrical wire numbering system in 2007. This wire number system uses only 10 different colors and only one striped wire color. These colors determine a circuits FUNCTION as follows: Direct Battery Power Protected Battery Power IGN/ACC/Start Power...
Page 259 Section 8 Electrical DATA BUS WIRE COLORS Data Bus wiring has its own color scheme as follows: • Data-bus high-side wires – VIO – J1587 & J1708 – ORG – J1922 – YEL – J1939 – RED – OEM – GRY – CAN –...
Page 260 Section 8 Electrical TRAILER CABLE CONNECTIONS Kenworth offers many different trailer connection options. The SAE J560 connector is shown in Figure 8-30, the ISO 3731 connector is shown in Figure 8-31. FIGURE 8-30: SAE J560 Trailer Connector FIGURE 8-31: ISO 3731 Trailer Connector There are three basic configurations for trailer connections, they are detailed below. Work with your local Kenworth dealer to identify which setup will be ideal for your intended application.
Page 261: Figure 8-32
Section 8 Electrical – Trailer ABS warning lamp circuit is on pin 3 of the ISO 3731 connector. – Ground is on pin 1 of the SAE J560 & ISO 3731 connectors. 3. J560 Hotline & ISO 3731 with Full Truck &/or Tractor Kit: This option provides two connectors: a SAE J560 and a ISO 3731 connector at the noted location(s) –...
Page 262 Section 8 Electrical BENDIX ELECTRONIC STABILITY PROGRAM Kenworth is offering Bendix Electronic Stability Program (ESP) as a pre-wire option on specific Bendix approved full truck configurations. Work with your local Kenworth dealer to determine if ESP is approved for your application. The Kenworth pre-wire option includes all the Bendix ESP system components installed and tested, but because Kenworth is the incom- plete vehicle manufacturer the ESP system cannot receive final verification until the body is installed. ESP functionality will be disabled when the vehicle leaves the Kenworth manufacturing facility. (The ESP system will be programmed with con- figuration specific information provided to Kenworth on the sales order – this data includes the Body Type, Body Builder, and Body Information.) To demonstrate that the ESP system has been tested and disabled, the ESP/ATC warning lamp will illuminate solidly and remain on after the truck has been driven at speeds greater than 30 miles per hour.
Page 263 Section 8 Electrical FACTORY INSTALLED SNOW PLOW LIGHT WIRING This options provides the ability to switch between operating lights mounted on a snow plow versus the standard lights on the hood. A switch is mounted in the dash to allow the operator to select the mode. See Figure 8-31 for the snow plow switch icon.
Page 264 For aftermarket installation of cameras for display on the NavPlus screen, or replacement parts, you will need to be famil- iar with the pin outs in the back of the head unit. FIGURE 8-35. PACCAR Head Unit Main Wireless Data...
Page 265 Section 8 Electrical FIGURE 8-36. Connector Pin outs Rear Right Speaker + Not Used Fuse Front Right Speaker + Not Used Front Left Speaker + Not Used Rear Left Speaker + Not Used Rear Right Speaker – CAN High Front Right Speaker – Not Used Front Left Speaker –...
Page 266 Section 8 Electrical This page intentionally left blank. 8-46 08/12...
Page 267: Figure 9-1: Clamp And Butterfly Clamp
Section 9 Routing ROUTING Introduction This section specifies the general requirements for securing hoses and electrical wires to present an orderly appearance, facilitate inspection and maintenance, and prevent potential damage to these lines. Definitions Bundle: Two or more air, electrical, fuel, or other lines tied together to form a unitized assembly. Clamp: A cushioned rigid or semi-rigid, anti-chafing device for containing the bundle and securing it to the frame or other structural support.
Page 268: Figure 9-4: Heavy Duty (Hd) Mount
Section 9 Routing Heavy duty tie straps 0.50in (12.7mm) wide (Tyton T255ROHIR or similar) shall be used Note: whenever HD mounts are specified, although 0.25in (6.4mm) tie straps may be used in some specified applications. FIguRe 9-4. Heavy Duty (HD) Mount. excess of material: More than 3 inches of slack for every 14 inch section of hose routing, except for air conditioner hoses.
Page 269 Section 9 Routing Wires Crossing other Components Electrical wires crossing over other components, such as lines, bolt heads, fittings, engine components lifting eyes, engine block, cylinder head, etc., close enough to rub shall be isolated with a covering of convoluted tubing and separated from the component by using butterfly clamps, butterfly ties, or plastic sheathing.
Page 270: Figure 9-5: Definition Of Measurements
Section 9 Routing Routing of Wires and Hoses near exhaust System TaBle 9-1. Exhaust – System Clearance Description Shielded unshielded Coolant hoses, HVAC hoses and tubing, and electrical wires within 15” of the turbo and/or over 15” from the turbo 2”...
Page 271: Figure A-1: Vehicle Identification Number (Vin
Appendix A Vehicle Identification VEHICLE IDENTIFICATION NUMBER A 17–character number (numeral and letter combination) forms the Vehicle Identification Number (VIN) which includes the Chassis Number. It contains among other information, the model year (4), assembly plant (5), and vehicle serial number (6).
Page 272: Figure A-2: Drivers Door And Door Frame Labels
Appendix A Vehicle Identification VEHICLE IDENTIFICATION LABELs Vehicle Identification Labels are located on the driver’s side door edge or on either the driver’s or passenger’s side door frames. See Figure A-2. Labels include Vehicle Certification, Components and Weights, Tire/Rim and Weight Rating Data, Noise Emissions, and Paint Identification.
Page 273: Figure A-3: Front Axle Identification
Appendix A Vehicle Identification Noise Emission Label The Noise Emission Label contains the chassis serial number, date of manufacture, and information regarding US noise emission regulations. This label is not provided on Canadian registered vehicles. Paint Identification Label The Paint Identification Label contains the paint colors used by the factory to paint the truck. It lists frame, wheels, cab in- terior and exterior colors.
Page 274: Figure A-4: Rear Axle Identification
Appendix A Vehicle Identification Rear Axle Identification The rear axle identification numbering system includes two labels or stamps. 1. Axle Housing Number Tag, located on the left forward side of the housing arm. This tag identifies the axle housing. 2. Axle Differential Carrier Identification, located on the top side of the differential carrier. The following information is either stamped, or marked with a metal tag: Model No., Carrier Production Assembly No., Carrier Assembly Serial No., Gear Ratio, Axle Specifications Number and OEM part number and country of origin.
Page 275 Appendix A Vehicle Identification This page intentionally left blank. 08/12...
Page 276 Appendix A Vehicle Identification ® Kenworth Truck Company P.O. Box 1000 Kirkland, WA 98083 (425) 828-5000 08/12...

This manual is also suitable for:

Kenworth t800w 2012 Kenworth t800sh 2012 Kenworth w900s 2012 Kenworth w900b 2012 Kenworth w900l 2012 Kenworth c500 2012

Paccar Kenworth T800 2012 Manual

Quick Links

Related Manuals for Paccar Kenworth T800 2012

Summary of Contents for Paccar Kenworth T800 2012

This manual is also suitable for:

Table of Contents