Paccar Kenworth T680 2019 Manual
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Paccar Kenworth T680 2019 Manual

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Kenworth Heavy Duty
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2019
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Summary of Contents for Paccar Kenworth T680 2019

  • Page 1 Kenworth Heavy Duty Body Builder Manual 2019 ®...
  • Page 2 This page intentionally left blank.
  • Page 3 Kenworth Heavy Duty 2.1m Cab Body Builder Manual ®...

  • Page 4: Table Of Contents

    Body Builder Manual Contents SECTION 1: INTRODUCTION SECTION 2: SAFETY & COMPLIANCE SAFETY SIGNALS FEDERAL MOTOR VEHICLE SAFETY STANDARDS COMPLIANCE SECTION 3: DIMENSIONS DIMENSIONS ABBREVIATIONS TURNING RADIUS OVERALL DIMENSIONS T680 STANDARD HOOD DAYCAB T680 MX (SHORT) HOOD DAYCAB T880 STANDARD HOOD DAYCAB T880S SFFA (SHORT) HOOD DAYCAB T680 STANDARD HOOD 40”...
  • Page 5 4-4 T680/880 TRANSMISSION PTO APPLICATION GUIDE 4-10 4 5 PTO CONTROLS: 4-14 4-6 ELECTRIC OVER AIR SYSTEM INTERLOCKING 4-22 4-7 PACCAR MX ENGINES - PTO PROGRAMMING: 4-25 SECTION 5: EXHAUST & AFTERTREATMENT EXHAUST AND AFTER-TREATMENT INFORMATION GENERAL GUIDELINES FOR DEF SYSTEM GENERAL EXHAUST INFORMATION...
  • Page 6 Figures FIGURE 2-1. Incomplete Vehicle Certification Document FIGURE 2-2. Locations Of Certification Labels - Driver’s Door And Frame FIGURE 2-3: Aerodynamic Mirror Oat Sensor Location FIGURE 2-4: Instrument Cluster For T680/T880 FIGURE 3-1. Prospecter Turn Circle Analysis FIGURE 4-1. Medium Duty Manual Transmission Ptos FIGURE 4-2.
  • Page 7 Figures FIGURE 5-9. Right View Of Right Hand Under Dpf/Scr With Dual Side Of Cab Tailpipe 5-11 FIGURE 5-10. Back View Of Right Hand Under Dpf/Scr With Dual Side Of Cab Tailpipe 5-11 FIGURE 5-11. Isometric View Of Right Hand Under Dpf/Scr With Single Back Of Cab Tailpipe 5-12 FIGURE 5-12.
  • Page 8 Figures Figures FIGURE 9-16. Chassis Harness From Cab Mount To Front Of Frame 9-11 FIGURE 9-17. Chassis Harness From Cab Mount To Boc 9-12 FIGURE 9-18. Connectors Near Front Cab Mount 9-12 FIGURE 9-19. Connector Near Boc 9-13 FIGURE 9-20. Vcan Connectors 9-13 FIGURE 9-21.
  • Page 9 TABLE 4-4. Current single-acting PTOs include: 4-16 TABLE 4-6. Reversible PTO States to Ports 4-20 TABLE 4-7. PACCAR PTO TSC1 Message Requirements 4-26 TABLE 4-8. In cab PTO Control – ESA Settings for T680/T880 4-29 TABLE 4-9. In-Cab PTO Control – PEP Settings 4-31 TABLE 4-10.
  • Page 10 Figures Tables TABLE 6-13. 6-14 TABLE 6-14. 6-15 TABLE 6-15. 6-16 TABLE 6-16. 6-17 TABLE 6-17. 6-18 TABLE 6-18. 6-19 TABLE 6-19. 6-20 TABLE 7-1. Single Steel Rails TABLE 7-2. Inserted Steel Rails TABLE 8-1. Customary Grade 8 UNF or UNC. TABLE 8-2.

  • Page 11: Section 1: Introduction

    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.
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  • Page 13: Section 2: Safety & Compliance

    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: Federal Motor Vehicle Safety Standards Compliance

    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 All diesel engines will be equipped with an On-Board Diagnostics (OBD) system. The OBD system consists of computer program on one or more of the vehicle’s Electronic Control Units (ECUs). This program uses information from the control system and from additional sensors to detect malfunctions.
  • Page 17 Section 2 Safety & Compliance PARTS Replacement nylon fuel line assemblies are available based on individual chassis and fuel system hardware. For other chassis changes, individual parts are listed below. DESCRIPTION PART NO. Supply Tee – All ports open Dual LH and RH fuel tanks K38-1057 Supply Tee –...
  • Page 18 Section 2 Safety & Compliance Exhaust and Exhaust After-treatment System The following are highlights of some of the more common or critical aspects of this system. • The following after-treatment and exhaust system components may not be modified: • DPF assembly •...
  • Page 19 • 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 20: Figure 2-3: Aerodynamic Mirror Oat Sensor Location

    Section 2 Safety & Compliance FIGURE 2-3: Aerodynamic Mirror OAT Sensor Location • Coolant Sensor considerations are given in the Cooling section above • The OBD/Diagnostic connector port is located below the dash to the left of the steering wheel. This connector and its location may not be changed.
  • Page 21 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 •...
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  • Page 23: Dimensions

    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 24 Section 3 Dimensions TABLE 3-2 CONTINUED Rear Wheel Base Turning Model Steering Gear Front Axle Front Wheel Front Tire Suspension (in.) Radius (ft) 26.9 27.4 28.5 30.2 31.2 Meritor 32.9 MFS12 or 34.0 Single Gear MFS13 Accuride 50487 Tandem T680/T880 HD94 or or Alcoa 88367 11R22.5...

  • Page 25: Figure 4-38

    Section 3 Dimensions TABLE 3-2 CONTINUED Rear Wheel Base Turning Model Steering Gear Front Axle Front Wheel Front Tire Suspension (in.) Radius (ft) 28.1 28.6 29.8 31.5 32.5 Meritor 34.2 MFS20 35.4 Dual Gears Standard Track Tandem Alcoa 82362 T880 HD94 or 385/65R22.5 52”...

  • Page 26: 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 27: Overall Dimensions

    Section 3 Dimensions OVERALL DIMENSIONS This section includes drawings and charts of the following Class 8 models: T680 and T880, including 40”, 52”, and 76” sleepers On the pages that follow, detail drawings show particular views of each vehicle, all dimensions are in inches (in). They illustrate important measurements critical to designing bodies of all types.

  • Page 28: T680 Standard Hood Daycab

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

  • Page 29: T680 Mx (Short) Hood Daycab

    Section 3 Dimensions T680 MX (SHORT) HOOD DAYCAB The following drawings are of a standard T680 MX (Short) Hood Daycab, shown with standard chassis components. 2/17...

  • Page 30: T880 Standard Hood Daycab

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

  • Page 31: T880S Sffa (Short) Hood Daycab

    Section 3 Dimensions T880S SFFA (SHORT) HOOD DAYCAB The following drawings are of a standard T880S SFFA (Short) Hood Daycab, shown with standard chassis components. 83.8 77.1 37.3 86.2 61.4 DIMENSIONS T880S MIXER TAPERED 114.4 119.7 DUMP TAPERED 29.5 115.8 BOX BUMPER 119.2 82.7...

  • Page 32: T680 Standard Hood 40" Sleeper

    Section 3 Dimensions T680 STANDARD HOOD 40” SLEEPER The following drawings are of a standard T680 Standard Hood 40” Sleeper, shown with standard chassis components. 3-10 2/17...

  • Page 33: T680 Mx (Short) Hood 40" Sleeper

    Section 3 Dimensions T680 MX (SHORT) HOOD 40” SLEEPER The following drawings are of a standard T680 MX (Short) Hood 40” Sleeper, shown with standard chassis components. 3-11 2/17...

  • Page 34: T880 Standard Hood 40" Sleeper

    Section 3 Dimensions T880 STANDARD HOOD 40” SLEEPER The following drawings are of a standard T880 Standard Hood 40” Sleeper, shown with standard chassis components. 3-12 2/17...

  • Page 35: T880S Sffa (Short) Hood 40" Sleeper

    Section 3 Dimensions T880S SFFA (SHORT) HOOD 40” SLEEPER The following drawings are of a standard T880S SFFA (Short) Hood 40” Sleeper, shown with standard chassis components. 18.2 87.2 77.1 37.2 115.7 61.4 DIMENSIONS T880S MIXER TAPERED DUMP TAPERED 29.5 145.3 94.7 119.7...

  • Page 36: T680 Standard Hood 52" Sleeper

    Section 3 Dimensions T680 STANDARD HOOD 52” SLEEPER The following drawings are of a standard T680 Standard Hood 52” Sleeper, shown with standard chassis components. 3-14 2/17...

  • Page 37: T680 Mx (Short) Hood 52" Sleeper

    Section 3 Dimensions T680 MX (SHORT) HOOD 52” SLEEPER The following drawings are of a standard T880 MX (Short) Hood 52” Sleeper, shown with standard chassis components. 3-15 2/17...

  • Page 38: T880 Standard Hood With 52" Sleeper

    Section 3 Dimensions T880 STANDARD HOOD WITH 52” SLEEPER The following drawings are of a standard T880 Standard Hood with 52” Sleeper, shown with standard chassis components. 3-16 2/17...

  • Page 39: T880 Mx (Short) Hood With 52" Sleeper

    Section 3 Dimensions 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. 3-17 2/17...

  • Page 40: T680 Standard Hood With 76" High-Roof Sleeper

    Section 3 Dimensions 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. 3-18 2/17...

  • Page 41: T680 Mx (Short) Hood With 76" High-Roof Sleeper

    Section 3 Dimensions 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. 3-19 2/17...

  • Page 42: T680 Standard Hood With 76" Mid-Roof Sleeper

    Section 3 Dimensions 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. 3-20 2/17...

  • Page 43: T680 Mx (Short) Hood With 76" Mid-Roof Sleeper

    Section 3 Dimensions 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. 3-21 2/17...

  • Page 44: T880 Standard Hood With 76" Mid-Roof Sleeper

    Section 3 Dimensions 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. 3-22 2/17...

  • Page 45: T880 Mx (Short) Hood With 76" Mid-Roof Sleeper

    Section 3 Dimensions 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. 3-23 2/17...

  • Page 46: 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 47 Section 3 Dimensions 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. Rear Suspension Laden: Unladen: Kenworth AG400L 8.5” 8.5” Kenworth AG400 9” 9” Kenworth AG460 10.5”...

  • Page 48: Rear Suspension Layouts

    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 49: Ag400L Tandem

    Section 3 Dimensions AG400L TANDEM 59.4 58.3 56.9 54.7 53.8 Axle Spacing AG400L Suspensions Note: “54” Axle Spacing dmensions shown TABLE 3-4. Rear Suspension Options Laden Ride Unladen Ride Suspension Type Rating Axle Spacing Height Height AG400L Tandem 52" 8.5" 8.5"...

  • Page 50: Ag400 Or Ag460 Tandem

    Section 3 Dimensions AG400 OR AG460 TANDEM 60.6 48.0 58.5 45.9 Ride Height Axle Spacing 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"...

  • Page 51: Ag460 Tandem

    Section 3 Dimensions AG460 TANDEM 67.7 52.0 65.8 49.9 10.5 60.0 AG460 Suspensions TABLE 3-6. Rear Suspension Options Laden Ride Unladen Ride Suspension Type Rating Axle Spacing Height Height AG460 Tandem 60" Spacing 60" 10.5" 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.

  • Page 52: Ag690 Tridem

    Section 3 Dimensions AG690 TRIDEM 87.6 76.0 85.5 73.9 10.5 54.0 54.0 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") 10.5" 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.

  • Page 53: Reyco 79Kb Single Rear Axle

    Section 3 Dimensions REYCO 79KB SINGLE REAR AXLE 30.2 30.1 28.7 29.0 Ride Height 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”...

  • Page 54: Reyco 102 Tandem Rear Axle

    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 55: Neway Adz 123 Single Rear Axle

    Section 3 Dimensions NEWAY ADZ 123 SINGLE REAR AXLE 30.8 29.8 27.8 18.0 26.4 16.0 24.3 18.8 RIDE HEIGHT Optional Neway ADZ Single Suspensions NEWAY ADZ123 TABLE 3-10. Rear Suspension Options SCALE 1:10 Laden Ride Unladen Ride Suspension Type Rating Axle Spacing Height Height...

  • Page 56: Neway Adz 246 Tandem Suspension

    Section 3 Dimensions NEWAY ADZ 246 TANDEM SUSPENSION Shown with a 54” Axle Spacing 57.7 56.7 54.7 44.9 52.1 42.9 50.7 RIDE HEIGHT AXLE SPACING Optional Neway ADZ Tandem Suspensions TABLE 3-11. Rear Suspension Options NEWAY ADZ246 Laden Ride Unladen Ride SCALE 1:10 Suspension Type Rating...

  • Page 57: Neway Adz 369 Tridem Suspension

    Section 3 Dimensions NEWAY ADZ 369 TRIDEM SUSPENSION Shown with 54” Axle Spacings 84.7 83.7 81.7 79.1 71.9 77.7 69.9 72.9 RIDE HEIGHT AXLE SPACING AXLE SPACING NEWAY ADZ369 Optional Neway ADZ Tridem Suspensions SCALE 1:10 TABLE 3-12. Rear Suspension Options Laden Ride Unladen Ride Suspension Type...

  • Page 58: Hendrickson Primaax Ex Tandem Suspension

    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 59: Hendrickson Primaax Ex Tridem Suspension

    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 60: Hendrickson Umx Tandem Suspension

    Section 3 Dimensions HENDRICKSON UMX 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 ULTIMAAX 460 17.5” Saddle Height 54” 11”...

  • Page 61: Hendrickson Rt Tandem Suspension

    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 62: Chalmers 856-46 Tandem Suspension

    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 63 Section 3 Dimensions TABLE 3-17 CONTINUED Laden Ride Unladen Ride Suspension Type Rating Axle Spacing Height Height Chalmers 854-50-H-HS 54” 10.9” 12.5” Chalmers 854-52-L-HS 54” 9.6” 11.3” Chalmers 854-52-H-HS 54” 10.9” 12.5” Chalmers 860-40-L 60” 8.9” 11.1” Chalmers 860-46-L 60” 8.9”...

  • Page 64: Lift Axles (Pushers And Tags)

    Section 3 Dimensions LIFT AXLES (PUSHERS AND TAGS) 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 65 Section 3 Dimensions Watson & Chalin Tru Track Alumilite 13.5K Steerable (SL1190SSR) Watson & Chalin Tru Track 20K Steerable (SL2065) 3-43 2/17...
  • Page 66 Section 3 Dimensions Watson & Chalin 23K Steerable (SL2200) *Use with Duals Only* Watson & Chalin 23K Non-Steerable (AL2200) 3-44 2/17...

  • Page 67: Axle Track And Tire Width

    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 68: Figure 4-25

    Section 3 Dimensions TABLE 3-18 CONTINUED Brake Drum Track Overall Width Axle - Steer Wheel Tire Type Dim “A” Dim “B: Meritor MFS13 Std Track Alcoa 98363 11R24.5 CAST 80.2" 91.0" 24.5X8.25 Dana Spicer E-1322I 13.2K Meritor MFS13 Wide Track Alcoa 98363 11R24.5 CAST...

  • Page 69: 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 70: 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 Vocational...
  • Page 71 PTO Mode Control Controller Area Network PTO Speed Control Cruise Control Power Take Off CECU Cab Electrical Control Unit PACCAR Vehicle Pro Diesel Exhaust Fluid RP1226 TMS Messaging Standard Diagnostics Trouble Code Standard Control Module Engine Control Module Selective Catalyst Reduction...
  • Page 72 Section 4 PTO Mounting & Programming 4.1. TRANSMISSION MOUNTED PTO MANUAL TRANSMISSIONS This is the most common type of PTO that is used. On a manual transmission there are two locations for PTO’s. On medium duty transmissions there are 6 bolt PTO locations on the right and left. On heavy duty manual transmissions there is a 6 bolt PTO on the right and an 8 bolt PTO on the bottom left.
  • Page 73 Section 4 PTO Mounting & Programming AUTOMATIC TRANSMISSIONS On Allison transmissions there are two locations for PTO’s. The Allison 4000 series has PTO locations at 1 and 8 o’clock viewed from the back of the transmission. The 4000HS transmissions do not have any PTO locations. The 3000 series Al- lison transmissions have PTO locations at 4 and 8 o’clock.
  • Page 74 The Cummins ISL9 and PX-9 REPTO turns at a rate of 1.15:1. The Cummins ISX-12 REPTO turns at a rate of 1.32:1. 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.
  • Page 75 Section 4 PTO Mounting & Programming FIGURE 4-6. PTO Telltale Location The standard telltale card has a GREEN PTO icon in position #2 (shown above). To activate this icon, locate where (6) RED, GREEN and YELLOW labeled 2-way connectors are taped to the instrument panel harness on the left side of the cup holder.
  • Page 76 Section 4 PTO Mounting & Programming 4-3. 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 77 Section 4 PTO Mounting & Programming Allison Transmission: 9/18...
  • Page 78 Section 4 PTO Mounting & Programming 4-4. PTO MOUNTING CLEARANCE This application guide indicates if a PTO has sufficient clearance to truck components in various mounting configurations. A green “ok” indicates that there is sufficient clearance to other truck components. A red “x” indicates that there minimal or no clearance and the application is not recommended.
  • Page 79 Section 4 PTO Mounting & Programming TABLE 4-2. 6 and 8-Bolt PTO’s for Eaton Transmissions NOTE 1. Not available with Front 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.
  • Page 80 Section 4 PTO Mounting & Programming TABLE 4-3. Dual PTO Compatibility for Eaton Transmissions HYDRAULIC CLUTCH 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 Section 4 PTO Mounting & Programming 4.5. MX PTO MODE CONTROL (PMC) MX PTO Mode Control (PMC) includes features, limits, and protections that are active in PTO Mode. It also includes PTO Speed Control (PSC) functionality that includes a variety of useful ways to control engine speed during PTO operation. Reference the VECU Programming Guide for detailed information on PTO Mode Control configuration, functionality and usage.
  • Page 82 Section 4 PTO Mounting & Programming MX PTO MODE FEATURES The following features and configurations are available when PTO Mode is active. • Cab Accelerator Configurations • Disable in PTO Mode • Torque Control (Automotive Style) • Speed Control • Enable in Remote PTO Mode •...
  • Page 83 Section 4 PTO Mounting & Programming MX PTO SPEED CONTROL (PSC) FEATURES PTO Mode must be active prior to using PTO Speed Control (PSC) to control engine speed. PSC is available from both the cab station and remote station (see PTO Mode Control Location Section above). In the cab location, cruise control switches and PSC specific switches are used to control engine speed.
  • Page 84 Section 4 PTO Mounting & Programming MX PTO SPEED CONTROL INTERLOCKS PTO Speed Control Interlocks cancel PSC when active. There is an option to disable the accelerator when a PSC interlock is active. When a PSC interlock is active the engine speed will return to the Minimum Engine Speed in PTO Mode or the engine speed commanded by the accelerator if applicable.
  • Page 85 Section 4 PTO Mounting & Programming Remote PMC Connections There are options to control PTO functionality from the following locations. • Engine Bay – Hardwired option only • RP1226 Connection in the Cab – CAN bus connection only • BOC/BOS – Hardwired and CAN bus connections •...
  • Page 86 Section 4 PTO Mounting & Programming 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 4-16 9/18...
  • Page 87 Section 5 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 2017 emission level engines will utilize Selective Catalyst Reduction (SCR). SCR is a process in which Diesel Exhaust Fluid (DEF) is injected into the exhaust downstream of the engine.
  • Page 88 Section 5 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. It is critical that the system is not compromised in any manner. Below, numbers denote the order of the component in the flow.
  • Page 89 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 shut-down situations. The DEF pump (or Supply Module) cannot be relocated from the DEF tank.
  • Page 90 Section 5 Exhaust & Aftertreatment INSTALLATION REQUIREMENTS AND DIMENSIONS FOR DEF SYSTEM When relocating any DEF system components, the locations must meet the guidelines below. Failure to comply may result in non-conformance to EPA standards and engine shutdown. With all relocating procedures, general clearances and routing guidelines must be followed. See section 9 of this manual for general routing guidelines.

  • Page 91: Figure 5-1. Routing Def And Coolant Lines

    Section 5 Exhaust & Aftertreatment Routing to the Dosing Module (Injector) A DEF pressure line “trap” is no longer required after EPA 2013 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.

  • Page 92: Figure 5-2. Supply Module Allowed Clocking Angle Limit Scribes A 90° Inverted Cone

    Section 5 Exhaust & Aftertreatment DEF Supply Module Mounting Requirements The Supply Module (or Pump) standard mounting location 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°...
  • Page 93 Section 5 Exhaust & Aftertreatment GENERAL EXHAUST INFORMATION Kenworth will offer three main DPF and SCR exhaust systems on heavy duty chassis in 2017. 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 vertically back of cab on stanchion brackets.

  • Page 94: Figure 5-3. Isometric View Of Right Hand Under Dpf/Scr With Single Side Of Cab Tailpipe

    Section 5 Exhaust & Aftertreatment 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 2/17...

  • Page 95: Figure 5-5. Right View Of Right Hand Under Dpf/Scr With Single Side Of Cab Tailpipe

    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 2/17...

  • Page 96: Figure 5-7. Isometric View Of Right Hand Under Dpf/Scr With Dual Side Of Cab Tailpipe

    Section 5 Exhaust & Aftertreatment 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 5-10 2/17...

  • Page 97: Figure 5-9. Right View Of Right Hand Under Dpf/Scr With Dual Side Of Cab Tailpipe

    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 5-11 2/17...

  • Page 98: Figure 5-11. Isometric View Of Right Hand Under Dpf/Scr With Single

    Section 5 Exhaust & Aftertreatment Right Hand Under DPF/SCR on DayCab with Single Back of Cab Tailpipe 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 5-12 2/17...

  • Page 99: Figure 5-13. Right View Of Right Hand Under Dpf/Scr With Single Back Of Cab Tailpipe

    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 5-13 2/17...

  • Page 100: Figure 5-15. Isometric View Of Right Hand Under Dpf/Scr With Ground-Dump Tailpipe

    Section 5 Exhaust & Aftertreatment 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 5-14 2/17...

  • Page 101: Figure 5-17. Right View Of Right Hand Under Dpf/Scr With Ground-Dump Tailpipe

    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 5-15 2/17...

  • Page 102: Figure 5-19. Isometric View Of Independent Back Of Cab Dpf/Scr With

    Section 5 Exhaust & Aftertreatment Independent Back of Cab DPF/SCR on DayCab with Back of Cab Tailpipe 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 5-16 2/17...

  • Page 103: Figure 5-21. Right View Of Independent Back Of Cab Dpf/Scr With Back Of Cab Tailpipe

    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 5-17 2/17...

  • Page 104: Figure 5-23. Isometric View Of Horizontal Dpf/Scr With Ground-Dump Tailpipe

    Section 5 Exhaust & 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 5-18 2/17...

  • Page 105: Figure 5-25. Right View Of Horizontal Dpf/Scr With Ground-Dump Tailpipe

    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 5-19 2/17...
  • Page 106 Section 5 Exhaust & Aftertreatment EXHAUST INFORMATION This section includes information on how to calculate tailpipe heights. FIGURE 5-27. Min. Tailpipe Min. Tailpipe Min. Tailpipe Length Length Length Dimension B Dimension “C” Dimension “C” Dimension “C” (DayCab) (40" Sleeper) (52" Sleeper) Tailpipes Side of Cab 69.2"...

  • Page 107: Figure 5-28. Dimension A = Top Of Rail Frame Height From Prospector - Frame Depth

    Section 5 Exhaust & Aftertreatment When utilizing Prospector, remember that heights shown are calculated to top of frame rail, and frame section height needs to be subtracted from Prospector height to get overall frame height from ground to bottom of frame flange Dimension A).
  • Page 108 Section 5 Exhaust & Aftertreatment This page intentionally left blank. 5-22 2/17...
  • Page 109 Section 6 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 110: Table 6-2. Fuel Tank Overall Length (In)

    Section 6 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 111: Figure 6-1. Def Tank Dimensions

    Section 6 Frame Layouts Small DEF Tank Medium DEF Tank (11-gallon usable volume) (18-gallon usable volume 10.1 27.7” 10.1” 28.0” 18.9 18.9” 15.7” 15.5” Large DEF Tank (31.1-gallon usable volume) 28.2 27.8” 28.2” 15.5” FIGURE 6-1. DEF Tank Dimensions. Acronyms Index Throughout the Frame Layout section you will see these acronyms.
  • Page 112 Section 6 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 6-6 through 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.
  • Page 113 Section 6 Frame Layouts 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. 2/17...
  • Page 114 Section 6 Frame Layouts D1—Use with the following models: T880 (Standard Hood) Dimension E (BOC to DPF/SCR) = 2.7in TABLE 6-5. T880 (SBFA) Standard Hood Daycab Fuel Tank Size Dimension D (in) Dimension F Dimension B BOC to DEF Tank (in) BOC to Fuel Tank BOC to Battery Box* Diameter...
  • Page 115 Section 6 Frame Layouts D1—Use with the following models: T880 (Short Hood) Dimension E (BOC to DPF/SCR) = 2.7in TABLE 6-6. T880 (SBFA) Short Hood Daycab Fuel Tank Size Dimension D (in) Dimension F Dimension B BOC to DEF Tank (in) BOC to Fuel Tank BOC to Battery Diameter...
  • Page 116 Section 6 Frame Layouts D1—Use with the following models: T880S (SFFA) Dimension E (BOC to DPF/SCR) = 2.7in TABLE 6-7. T880S (SFFA) Daycab with Short Hood Fuel Tank Size Dimension D (in) Dimension F Dimension B BOC to DEF Tank (in) BOC to Fuel Tank BOC to Battery Box* Diameter...
  • Page 117 Section 6 Frame Layouts D2—Use with the following models: T880 (Standard Hood) Dimension B (BOC to Cantilever Battery Box) = 25.4in Dimension E (BOC to DPF/SCR) = 2.7in TABLE 6-8. T880 (SBFA) Standard Hood Daycab Fuel Tank Size Dimension D (in) Dimension F BOC to DEF Tank (in) BOC to Fuel Tank...
  • Page 118 Section 6 Frame Layouts D2—Use with the following models: T880 (Short Hood) Dimension B (BOC to Cantilever Battery Box) = 25.4in Dimension E (BOC to DPF/SCR) = 2.7in TABLE 6-9. T880 (SBFA) Short Hood Daycab Fuel Tank Size Dimension D (in) Dimension F BOC to DEF Tank (in) BOC to Fuel Tank...
  • Page 119 Section 6 Frame Layouts D2—Use with the following models: T880S (SFFA) Dimension B (BOC to Cantilever Battery Box) = 23.4in Dimension E (BOC to DPF/SCR) = 0.2in TABLE 6-10. T880S (SFFA) Daycab with Short Hood Fuel Tank Size Dimension D (in) Dimension F BOC to DEF Tank (in) BOC to Fuel Tank...
  • Page 120 Section 6 Frame Layouts D3—Use with the following models: T880 (Standard Hood) Dimension B (BOC to 34” Short Battery Box) = -2.5in Dimension B (BOC to 40” Long Battery Box) = 3.5in Dimension E (BOC to DPF/SCR) = 2.7in TABLE 6-11. T880 (SBFA) Standard Hood Daycab Fuel Tank Size Dimension D (in)
  • Page 121 Section 6 Frame Layouts D3—Use with the following models: T880 (Short Hood) Dimension B (BOC to 34” Short Battery Box) = -2.5in Dimension B (BOC to 40” Long Battery Box) = 3.5in Dimension E (BOC to DPF/SCR) = 2.7in TABLE 6-12. T880 (SBFA) Short Hood Daycab Fuel Tank Size Dimension D (in)
  • Page 122 Section 6 Frame Layouts D3—Use with the following models: T880S (SFFA) Dimension B (BOC to 34” Short Battery Box) = -6.5in Dimension B (BOC to 40” Long Battery Box) = -4.0in Dimension E (BOC to DPF/SCR) = 0.2in TABLE 6-13. T880S (SFFA) Daycab with Short Hood Fuel Tank Size Dimension D (in)
  • Page 123 Section 6 Frame Layouts D4—Use with the following models: T880 (Standard Hood) Dimension B (BOC to 34” Short Battery Box) = -2.5in Dimension B (BOC to 40” Long Battery Box) = 3.5in Dimension E (BOC to DPF/SCR) = 2.7in TABLE 6-14. T880 (SBFA) Standard Hood Daycab Fuel Tank Size Dimension D (in)
  • Page 124 Section 6 Frame Layouts D4—Use with the following models: T880 (Short Hood) Dimension B (BOC to 34” Short Battery Box) = -2.5in Dimension B (BOC to 40” Long Battery Box) = 3.5in Dimension E (BOC to DPF/SCR) = 2.7in TABLE 6-15. T880 (SBFA) Short Hood Daycab Fuel Tank Size Dimension D (in)
  • Page 125 Section 6 Frame Layouts D4—Use with the following models: T880S (SFFA) Dimension B (BOC to 34” Short Battery Box) = -6.5in Dimension B (BOC to 40” Long Battery Box) = -4.0in Dimension E (BOC to DPF/SCR) = 0.2in TABLE 6-16. T880S (SFFA) Daycab with Short Hood Fuel Tank Size Dimension D (in)
  • Page 126 Section 6 Frame Layouts D5—Use with the following models: T880 (Standard Hood) Dimension E (BOC to DPF/SCR) = 2.7in TABLE 6-17. T880 (SBFA) Standard Hood Daycab Fuel Tank Size Dimension D (in) Dimension F BOC to DEF Tank (in) BOC to Fuel Tank Diameter Gallons Length (in)
  • Page 127 Section 6 Frame Layouts D5—Use with the following models: T880 (Short Hood) Dimension E (BOC to DPF/SCR) = 2.7in TABLE 6-18. T880 (SBFA) Short Hood Daycab Fuel Tank Size Dimension D (in) Dimension F BOC to DEF Tank (in) BOC to Fuel Tank Diameter Gallons Length (in)
  • Page 128 Section 6 Frame Layouts D5—Use with the following models: T880S (SFFA) Dimension E (BOC to DPF/SCR) = 0.2 in TABLE 6-19. T880S (SFFA) Daycab with Short Hood Fuel Tank Size Dimension D (in) Dimension F BOC to DEF Tank (in) BOC to Fuel Tank Diameter Gallons...
  • Page 129 Section 7 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 7-1. Single Steel Rails Rail Height Flange Width Web Thickness Section Modulus (in...

  • Page 130: Figure 7-1. Minimum Clearance Between Top Of Rear Tires And Body Structure Overhang

    Section 7 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 131: Figure 7-2. Minimum Back Of Cab Clearance

    Section 7 Body Mounting FIGURE 7-2. 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 132: Figure 7-3. Spacer Between Frame Sill And Body Rail - Rubber Or Plastic

    Section 7 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 133: Figure 7-6. Crossmember-Gusset Hole Pattern Requirements. [Inch (Mm)]

    Section 7 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 6–6. The hole diameter should not exceed the bolt diameter by more than .060 inches (1.5 mm).

  • Page 134: Figure 7-7. Acceptable U-Bolt Mounting With Wood And Fabricated Spacers [Inch (Mm)]

    Section 7 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 135: Figure 7-8. Clearance Space For Air Lines And Cables

    Section 7 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 7-8. Clearance Space for Air Lines and Cables WARNING: Do not notch frame rail flanges to force a U–bolt fit. Notched or damaged frame flanges could result in premature frame failure.

  • Page 136: Figure 7-9. Example Of Fishplate Bracket At Rear End Of Body, Used With U-Bolts

    Section 7 Body Mounting Rear Body Mount When U–bolts are used to mount a body we recommend that the last body attachment be made with a “fishplate” bracket. See Figure 6–9. This provides a firm attaching point and helps prevent any relative fore or aft movement between the body and frame.
  • Page 137 Section 8 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 138: Figure 8-1. Detail Of Frame Extension And Joint Welding

    Section 8 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 139: Figure 8-2. Frame Insert

    Section 8 Frame Modifications WELDED JOINT 24 Inch Minimum (610 mm) FIGURE 8-2. 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 140: Figure 8-3. Comparison Of Original, Shortened, And Extended Wheelbases

    Section 8 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 141: Figure 8-4. Crossmember Added When Distance Exceeds 60 Inches (1524 Mm)

    Section 8 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 142 Section 8 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 143 Section 8 Frame Modifications TORQUE REQUIREMENTS TABLE 8-1. 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 144 Section 8 Frame Modifications This page intentionally left blank. 2/17...
  • Page 145 Section 9 CAN Communications INTRODUCTION Controller Area Network (CAN) is a serial network technology that was originally designed for the automotive industry but has also become popular in the commercial trucking industrial. The CAN bus is primarily used in embedded systems and is a network technology that provides fast communication among controllers up to real-time requirements, eliminating the need for the much more expensive and complex technology.
  • Page 146 Section 9 CAN Communications SAE J1939 The Society of Automotive Engineers (SAE) Truck and Bus Control and Communications Subcommittee have developed a family of standards concerning the design and use of devices that transmit electronic signals and control information among vehicle components. SAE J1939 and its companion documents are the accepted industry standard and the vehicle network of choice for commercial truck applications.
  • Page 147 Section 9 CAN Communications PARAMETER GROUP NUMBER Parameter Groups contain information on parameter assignments within the 8-byte CAN data field of each message as well as repetition rate and priority. Parameters groups are, for instance, engine temperature, which includes coolant tem- perature, fuel temperature, oil temperature, etc.

  • Page 148: Figure 4-37

    Section 9 CAN Communications CAN MESSAGES AVAILABLE ON BODY CONNECTIONS CAN Signal Description CAN BUS 5400 SCR Thermal Management Active 61443, EEC2 SCAN, KCAN, BCAN Accelerator Pedal Position 1 61443, EEC2 SCAN, KCAN, BCAN Engine Percent Load At Current Speed 61443, EEC2 SCAN, KCAN, BCAN 5399...
  • Page 149 Section 9 CAN Communications CAN Signal Description CAN BUS 3363 Aftertreatment 1 Exhaust Fluid Tank Heater 65110, AT1T1I SCAN, KCAN, BCAN 5246 Aftertreatment SCR Operator Inducement Severity 65110, AT1T1I SCAN, KCAN, BCAN 5245 Aftertreatment Exhaust Fluid Tank Low Level Indicator 65110, AT1T1I SCAN, KCAN, BCAN 1639...
  • Page 150 Section 9 CAN Communications CAN Signal Description CAN BUS Transmission Current Gear 61445, ETC2 SCAN, KCAN, BCAN Transmission Requested Range 61445, ETC2 SCAN, KCAN, BCAN Transmission Oil Temperature1 65272, TRF1 SCAN, KCAN, BCAN 3027 Transmission Oil Level1 High/Low 65272, TRF1 SCAN, KCAN, BCAN 3026 Transmission Oil Level 1 Measurement Status...
  • Page 151 Section 9 Electrical INTRODUCTION This section is written to provide information to the body builder when installing equipment into vehicles built with Multi- plexed instrumentation. The new technology presented by VECU level instrumentation integrates J-1939 CAN data com- munications between equipment on the vehicle. This book is intended to address how to work in aftermarket equipment while still maintaining full functionality of the OEM vehicle.
  • Page 152 Each wire has a minimum of seven characters, with the first three characters as the wire color. The remaining four characters are related to the wire services. The colors determine the circuits function as follows: Table 10-1. Electrical Wire Circuit Code Table PACCAR Electrical Circuit Code Insulation Color Color Code Electrical Function...
  • Page 153 Section 10 Electrical FIGURE 10-1. Can Bus System Overview CAN BUS SPEEDS AND CIRCUIT DESIGNATION 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 –...
  • Page 154 Section 10 Electrical ELECTRICAL COMPONENT OVERVIEW Figure 10-2. Overview Diagram of Electrical Component Locations 10-4 9/18...
  • Page 155 Section 10 Electrical Chassis Node Figure 10-3. Electrical Harness Overview 10-5 9/18...
  • Page 156 Section 10 Electrical IN CAB CAN BASED MESSAGING CONNECTOR RP1226 CONNECTOR The RP1226 connector is located on the left hand side 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.
  • Page 157 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 10-7 9/18...
  • Page 158 Section 10 Electrical FIGURE 10-7. Front Portion View FIGURE 10-8. Detail View Of Engine Compartment Body Connectors 10-8 9/18...
  • Page 159 Section 10 Electrical FIGURE 10-9. Rear Portion View FIGURE 10-10. Detail View Of Boc/Bos And Eof Body Connectors 10-9 9/18...
  • Page 160 Section 10 Electrical ELECTRIC ENGAGED EQUIPMENT At the left hand forward cab mount, P198 is available for PTO controls that are electrically engaged via ground. Function VEHICLE GROUND #1 PTO ON/OFF PTO PUMP MODE SIGNAL #2 PTO ON/OFF FIGURE 10-11. OPTIONAL 8 PIN PTO INPUT CONNECTOR Function 12V IGNITION SIGNAL...
  • Page 161 Electrical REMOTE THROTTLE AND REMOTE PTO CONTROLS PACCAR MX ENGINES Chassis must be ordered with the appropriate option to have a 12 pin connector on the chassis harness. All signals will feed into the Chassis Modules, which will have Active Low inputs. Connect pins 3 and 5 for simple PTO ON/OFF signal.
  • Page 162 Section 10 Electrical FIGURE 10-14. MX-11 and MX-13 Connector Location. 10-12 9/18...
  • Page 163 Section 10 Electrical Chassis must be ordered with the appropriate option to have a 12 pin connector on the engine harness. The Body IGN signal was moved off the engine harness connector, so for Cummins, the Chassis Harness will include the PTO layer to insert the Body IGN signal back into the 12-way connector.
  • Page 164 Section 10 Electrical FIGURE 10-16. X15 Connection location FIGURE 10-17. ISX12 Connection location 10-14 9/18...
  • Page 165 Section 10 Electrical FIGURE 10-18. Power Distribution Center 10-15 9/18...
  • Page 166 Section 10 Electrical FIGURE 10-19. Engine Side Fuse Box Full Content Population 10-16 9/18...
  • Page 167 Section 10 Electrical FIGURE 10-20. Dash Side Fuse Box Full Content Population 10-17 9/18...
  • Page 168 Section 10 Electrical CHASSIS MODULE The standard chassis modules are replacing the legacy NAMUX4 chassis node. The standard chassis modules are a slave I/O driver controlled by the VECU. The standard chassis modules have an expanded functionality and option plat- form growth in comparison to the chassis node.
  • Page 169 Section 10 Electrical CHASSIS MODULE FUNCTION DESIGNATION PRIMARY CHASSIS MODULE • Exterior Lighting: Headlamps, Park/Tail, Turn, Brake, DRL, Reverse etc. • Axle Temperature Sensor Inputs Front Rear and Rear • Ammeter Sensor Input • Secondary Kingpin Release Solenoid Control • Primary/Secondary Fuel Level Sensors •...
  • Page 170 Section 10 Electrical ELECTRIC OVER AIR SOLENOIDS Air solenoids are the devices that translate the electrical signal into physical change that controls the air pressure in vari- ous circuits. The air solenoids are mounted to 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.
  • Page 171 Section 10 Electrical FIGURE 10-24. Overview Layout FIGURE 10-25. 10-21 9/18...
  • Page 172 Section 10 Electrical SWITCHES FIGURE 10-26. Overview Layout Multiplexing = shorter wire bundles, improved diagnostics, & greater driver feedback. Safety critical switches use hybrid switch with hardwire for redundancy. Less expensive switches with fewer wires behind dash and on chassis. Self-diagnos- able to improve troubleshooting with DAVIE.
  • Page 173 Section 10 Electrical FIGURE 10-28. Switch Relearn Process Switch replacement installation instructions: 1. Turn off the engine and all switches 2. Remove dash panel 3. Unplug LIN jumpers from the original existing switch 4. Remove original switch 5. Replace the old switch with the new switch 6.
  • Page 174 Section 10 Electrical FIGURE 10-29. DAVIE Switch Relearn Screen View SWITCH LOCATION Switch on the 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.
  • Page 175 Section 10 Electrical GROUNDING Grounding any post-OEM component/device/apparatus/etc. to the metal cab structure or frame is not acceptable. Failure to properly ground add-on components can result in vehicle damage and possibly bodily injury. Ground all post-OEM component/device/apparatus/etc. with combined current draw of less than 30A to the firewall ground buss bar with appropriately sized wire/cable for the load required.
  • Page 176 Spare power connector P096 is located on lower left side of dash behind key switch 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.
  • Page 177 Section 10 Electrical FIGURE 10-36. Spare circuit location on Power Distribution Center (Dash-Side, P001) 10-27 9/18...
  • Page 178 Section 10 Electrical FIGURE 10-37. Spare circuit diagram (P001 and P096) 10-28 9/18...
  • Page 179 Section 10 Electrical JUNCTION BOX The junction box provides access to lighting signals. FIGURE 10-38. Junction Box BOC or EOF 10-29 9/18...
  • Page 180 Section 10 Electrical TRANSMISSION BACK UP SIGNALS The back-up signal can be accessed from pin D of the 6-way tail light connector located at the end of frame. The tail light connector is a 6-way connector located in the chassis harness at the end of frame. It will either be connected to a tail light, a jumper harness, or tied up in the rail if no tail lights are provided.
  • Page 181 Section 10 Electrical TELLTALE ICONS INSTALLATION Removing the first panel will allow the panel covering the instrument cluster to be removed. Removing the cluster is nec- essary to 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.
  • Page 182 Section 10 Electrical FIGURE 10-41. Telltale Installation Diagnostics & Service Tool Connection 10-32 9/18...
  • Page 183 Section 10 Electrical LIFT AXLES All truck lift axles (pushers and tag), are direct wire Electric-Only from the switch to the axle mounted solenoid. This is not from the EoA Solenoid Bank. There are a total of four lift axle controls available; 3 pushers and 1 tag axle. These are con- trolled with separate switches by default.
  • Page 184 Section 10 Electrical GAUGES Gauges and switches are fastened directly to the panel. Once the panel is 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.
  • Page 185 Section 10 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 186 Section 11 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 11-4. 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 187 Section 11 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 188 Section 11 Routing Routing of Wires and Hoses near Exhaust System TABLE 11-1. 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 189 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 190 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 191 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 192 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 193 Appendix A Vehicle Identification This page intentionally left blank. 2/17...
  • Page 194 Appendix A Vehicle Identification ® Kenworth Truck Company P.O. Box 1000 Kirkland, WA 98083 (425) 828-5000 2/17...

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