Kenworth Trucks Body & Equipment Mounting Guide

Body & Equipment Mounting Guide Kenworth Trucks Last revised: February 2009 1 KENWORTH TRUCKS BODY & EQUIPMENT MOUNTING GUIDE

2 Body & Equipment Mounting Guide Kenworth Trucks Last revised: February 2009 Table of Contents Contents Page No. SAFETY ................................................................................................................................ 7 GENERAL ............................................................................................................................ 8 FRAME DON’TS................................................................................................................. 10 SAFETY FIRST .................................................................................................................. 12 BASIC CHASSIS DIMENSIONS ........................................................................................ 13 CHASSIS FRAME .............................................................................................................. 45 GENERAL COMMENTS .................................................................................................... 47 VEHICLE IDENTIFICATION .............................................................................................. 49 LEGAL REQUIREMENTS.................................................................................................. 50 AUSTRALIAN DESIGN RULES (Third Edition) .............................................................. 51 INSTALLATION OF CHASSIS MOUNTED EQUIPMENT ................................................ 53 General Points .............................................................................................................. 53 Critical Clearances........................................................................................................ 53 Chassis Side Members ................................................................................................. 54 Frame Drilling................................................................................................................ 54 Frame Welding.............................................................................................................. 55 Body Mounting Methods ............................................................................................... 56 Weight Distribution........................................................................................................ 56 Lateral stability (dynamic) ............................................................................................. 56 Long Term Storage of Chassis ..................................................................................... 57 Body Structures ............................................................................................................ 58 Semi-trailer Coupling .................................................................................................... 58 MOUNTING SYSTEMS ...................................................................................................... 59 Type ‘A’ - Flat Plate ...................................................................................................... 59 Type 'C' - Vertically Flexible.......................................................................................... 61 BODY ANGLES ............................................................................................................ 62 CUSHIONING MATERIAL ............................................................................................ 63 MOUNTING BRACKET LAYOUT...................................................................................... 64 FLATBED PLATFORM / DROPSIDE........................................................................... 64 TIPPER......................................................................................................................... 65 TAUTLINER.................................................................................................................. 66 SPECIALIST BODY EQUIPMENT..................................................................................... 67 RIGID TIPPER.............................................................................................................. 67 CRANES....................................................................................................................... 68 TANKS.......................................................................................................................... 69 TILT TRAYS.................................................................................................................. 71 BEAVER TAIL TRAY.................................................................................................... 72 CONCRETE AGITATOR .............................................................................................. 73 CRANE TRUCKS ......................................................................................................... 74 LAYOUT OF BOLTS .......................................................................................................... 75 FRAME FASTENERS ........................................................................................................ 77 BODY/STRUCTURE WITH SUB-FRAME ......................................................................... 79 SUB-FRAMES .................................................................................................................... 81 FIFTH WHEEL MOUNTING ............................................................................................... 84 DRAWBAR CROSS MEMBER .......................................................................................... 89 TYRE CLEARANCE........................................................................................................... 91 POWER TAKE-OFFS......................................................................................................... 93

3 Body & Equipment Mounting Guide Kenworth Trucks Last revised: February 2009 WHEELBASE ALTERATIONS .......................................................................................... 95 FRAME RAIL CUTOUTS ................................................................................................... 97 VEHICLE MODIFICATIONS .............................................................................................. 99 Engine Replacement ....................................................................................................... 99 Transmission Replacement ............................................................................................. 99 Steer Axle Replacement ................................................................................................ 100 Rear Drive Axle(s) Replacement ................................................................................... 101 Wheel/Rim Replacement ............................................................................................... 101 Inlet and Exhaust Modifications..................................................................................... 102 Tyre Replacement ......................................................................................................... 102 Suspension Replacement ............................................................................................. 103 Seat Replacement ......................................................................................................... 103 KENWORTH WEIGHT DISTRIBUTION CHECKS.......................................................... 104

4 Body & Equipment Mounting Guide Kenworth Trucks Last revised: February 2009 Table of Figures Figures Page No. Figure 1. Frame Section. ..................................................................................................... 8 Figure 2. DO NOT DRILL FLANGES ................................................................................ 10 Figure 3. K104 6 x 4 .......................................................................................................... 15 Figure 4. K104 8 x 4 .......................................................................................................... 16 Figure 5. K108 6x4............................................................................................................. 17 Figure 6. K108 8x4............................................................................................................. 18 Figure 7. C500 6x4 ............................................................................................................ 19 Figure 8. C501 6x4 ............................................................................................................ 20 Figure 9. C508 6x4 ............................................................................................................ 21 Figure 10. C510 6x4 .......................................................................................................... 22 Figure 11. T604 6x4........................................................................................................... 23 Figure 12. T608 6x4........................................................................................................... 24 Figure 13. T650 6x4........................................................................................................... 25 Figure 14. T658 6x4........................................................................................................... 26 Figure 15. T904 6x4........................................................................................................... 27 Figure 16. T908 6x4........................................................................................................... 28 Figure 17. T950 6x4........................................................................................................... 29 Figure 18. T404 6x4........................................................................................................... 30 Figure 19. T404S 6x4 ........................................................................................................ 31 Figure 20. T404SAR 6x4 ................................................................................................... 33 Figure 21. T408 6x4........................................................................................................... 34 Figure 22. T408 8x4........................................................................................................... 35 Figure 23. T408SAR 6x4 ................................................................................................... 36 Figure 24. T401 6x4........................................................................................................... 37 Figure 25. T300 6x4........................................................................................................... 39 Figure 26. T350 6x4........................................................................................................... 40 Figure 27. T358 6x4........................................................................................................... 41 Figure 28. T358 8x4........................................................................................................... 42 Figure 29. T388 6x4........................................................................................................... 43 Figure 30. Typical Chassis Layout .................................................................................... 44 Figure 31. Chassis Frame Rails and Attachments ............................................................ 45 Figure 32. Kenworth Tyre Placard and Vehicle Plates ...................................................... 49 Figure 33. Cab to Body Minimum Clearance .................................................................... 53 Figure 34. Hole Drilling Dimensions .................................................................................. 54 Figure 35. Double Oscillating Fifth Wheel ......................................................................... 58 Figure 36. Typical 'A' Flat Plate Attachment, to suit Kenworth standard hole pitch .......... 59 Figure 37. Typical Type 'B' Vertical Link Bolt Attachment, to suit Kenworth standard hole pitch............................................................................................................................... 60 Figure 38. Typical type 'C' Flexible Attachment, to suit Kenworth standard hole pitch..... 61 Figure 39. Body Angles ..................................................................................................... 62 Figure 40. Improper frame Fixtures ................................................................................... 63 Figure 41. Flatbed Platform ............................................................................................... 64 Figure 42. Mounting Bracket Layout - Tipper .................................................................... 65 Figure 43. Mounting Bracket Layout - Tautliner ................................................................ 66 Figure 44. Rear Tipper ....................................................................................................... 67 Figure 45. Truck Mounted crane ....................................................................................... 68 Figure 46. 3-Point Body Mount .......................................................................................... 69

5 Body & Equipment Mounting Guide Kenworth Trucks Last revised: February 2009 Figure 47. 4-Point Body Mount.......................................................................................... 69 Figure 48. Front, 3-Point Mount ........................................................................................ 70 Figure 49. Rigid Rear Mount ............................................................................................. 70 Figure 50. Tilt Tray ............................................................................................................ 71 Figure 51. Beaver Tail Tray ............................................................................................... 72 Figure 52. Agitator Front Mount ........................................................................................ 73 Figure 53. Correct frame bolt Installation ........................................................................... 75 Figure 54. Bolt Hole Location Scribe Marks ...................................................................... 75 Figure 55. Scribe Mark Damage to Frame ........................................................................ 75 Figure 56. Kenworth Standard Chassis Hole Drill Pattern ................................................ 76 Figure 57. Location of Applied Load through Sub-Frame ................................................. 79 Figure 58. Forward Sub-Frame End Taper ....................................................................... 81 Figure 59. Sub-Frame ....................................................................................................... 82 Figure 60. Sub-Frame with Cross-Braces ......................................................................... 82 Figure 61. Change of Sub-Frame Section ........................................................................ 83 Figure 62. Typical Fifth Wheel Mounting........................................................................... 85 Figure 63. Double OScillating Fifth Wheel ........................................................................ 85 Figure 64. D-Rating, Single Trailer Prime Mover .............................................................. 86 Figure 65. D-Rating, B-Double Prime Mover .................................................................... 87 Figure 66. Typical Fifth Wheel Angle Mounting ................................................................ 88 Figure 67. D-Rating, Rigid Truck and Single Trailer ......................................................... 89 Figure 68. Wheel Clearance.............................................................................................. 91 Figure 69. PTO Isolating Mounts....................................................................................... 94 Figure 70. Driveline Components ...................................................................................... 96 Figure 71. Centre of Gravity Requirement for Vehicle .................................................... 104 Figure 72. Centre of Gravity Location (point load) .......................................................... 105 Figure 73. Centre of Gravity Locations (multiple loads) .................................................. 105 Note: The information contained in this guide is subject to change without prior notification.

6 Body & Equipment Mounting Guide Kenworth Trucks Last revised: February 2009

7 Body & Equipment Mounting Guide Kenworth Trucks Last revised: February 2009 OVERVIEW This section is an expansion of the Body & Equipment Mounting Guide that is issued to all salespersons as part of the Data Book. The guide has been produced to assist body builders mount bodywork and equipment to Kenworth truck chassis. The functional requirements apply to all truck chassis, however some of the unique design features of Kenworth Trucks will require differences in specific design areas. The Guide is not a Maintenance Manual, nor an Operation Manual, nor a Modification Authorisation. It is important to note that the requirements of the ADR's and Kenworth Trucks’ modification guidelines take precedence over any Code of Practice. Any modifications must comply with Kenworth Trucks recommendations and that the ADR compliance of the vehicle as originally manufactured by Kenworth Trucks, or a Secondary Manufacturer, is not invalidated. Vehicle Standards Bulletin No.6, (Part A, Section A, 4.4) stipulates that the "requirements of the ADR’s and original manufacture's modification guidelines shall take precedence". This manual is intended to detail those aspects of the vehicle design where Kenworth requirements differ. Under no circumstances is a vehicle to be rated higher than its original rating without written approval from Kenworth trucks. To acquire written approval the particular vehicle must be taken to an approved Kenworth dealership for verification of the modifications. Under some circumstances the original vehicle rating may be reassessed, in which case an original ratings letter can be issued stipulating the trucks new rating. In this case a Kenworth dealer is not required to examine the vehicle. SAFETY The safety of vehicle operators and mechanics must always be considered before working on/with a commercial vehicle. Any potential risks of specific processes should be considered and all addressed as part of the normal Occupational Health and Safety regime.

8 Body & Equipment Mounting Guide Kenworth Trucks Last revised: February 2009 GENERAL The Kenworth truck chassis design follows the usual practise for heavy commercial vehicle chassis frames to be a 'ladder` formed from channel section steel, with two main longitudinal rails extending the full length of the vehicle, and bracing crossmembers. These main rails consist of a vertical web, or side member, with top and bottom flanges Figure 1. Figure 1. Frame Section. The flanges support the downward weight of the body; for this reason drilling through the flanges is not approved. The web supports the flanges and increases the lateral and torsional stiffness of the member. Chassis frames are designed to allow a certain amount of flexibility, and thus body structures must be designed and built accordingly. Localised resistance to flexing of the chassis frame can be achieved by adding inserts or outserts (flitch plates) which have the effect of strengthening and stiffening the frame. This reinforcement is generally required around points where maximum stresses (shear force) occur, such as the mounting points for tipper bodies. Bodywork can be designed either to flex with the chassis or to remain as a semi-rigid structure whilst allowing the frame to flex independently. Where the body is allowed to flex with the chassis, it is possible to mount the longitudinal body subframe members directly to the top of the side rails. Further, the ends of the subframe should be tapered to avoid stress concentration where a sudden change in stiffness is present. Mounting the body directly onto the top flanges of the chassis will also produce poor durability, as the flanges have no vertical strength, other than that of the material section.

9 Body & Equipment Mounting Guide Kenworth Trucks Last revised: February 2009 A much more satisfactory method of body mounting to the chassis frame is by using brackets attached to the web of the frame, thus placing the downward thrust of the body weight through them. If the body is raised significantly above the chassis rails then, as well as fitting packers, fore and aft bracing must be added to prevent the sub-frame from lozenging under braking or acceleration. The method of mounting bodies described previously is only suited to situations where a degree of flexibility in both chassis and body is acceptable. There are a number of body designs where body rigidity is of prime importance, tanker bodies being an obvious case. Tank bodies should not leak, and thus must be designed as an integral structure unaffected by any flexibilities in the chassis. It is common practise, in budding tanker bodies; to utilise resilient mounting brackets combined with a transversely mounted trunnion assembly to support the front of the tank. The trunnion bracket will itself be mounted to the chassis through resilient mountings. There will usually be two or four side mountings, depending on tank length, in addition to the trunnion mounting, and these can be attached to the chassis at suitable positions relative to the tank design. Frequently, however, it will be necessary to design special chassis mounting brackets, and these should be of adequate proportions to allow a top flange to locate on the top flange of the chassis and extend vertically down the web of the chassis rail far enough to permit two parallel rows of attaching fasteners. Tipping bodies present a slightly different problem, in that a torsionally rigid body structure must be mounted in such a way as to cater for the stresses imposed during tipping, as well as the normal distribution of load into the chassis rails whilst the body is lowered. To minimise any bending moment being transmitted to the chassis rails, the rear pivot mount brackets should be located as near to, or incorporated in, the rearmost suspension brackets. Forward support brackets are required around the hoist location, plus support brackets forwards of the suspension to prevent the body sagging. In addition, lateral location will be required to ensure that the body locates squarely on the chassis frame when lowered.

10 Body & Equipment Mounting Guide Kenworth Trucks Last revised: February 2009 FRAME DON’TS Before attempting any work involving the frame rails, read the following list of items NOT to do: 1. Do not attach any parts to frame rails by welding. 2. Do not drill holes on web close to flanges. Minimum distance from hole centre is 60mm from outer edge of flange. 3. Do not drill holes in flanges of frame rails. Figure 2. DO NOT DRILL FLANGES 4. Do not drill closely spaced holes in the web of the frame, hole centres of two adjacent holes should be spaced at least three times the distance apart of the largest diameter hole. Closer spacing than this could induce a failure between the holes. 5. Do not use chains or cables wrapped around the frame rails for hoisting or straightening unless protective material is used next to the frame rails, see LIFTING below. 6. Do not leave scribe marks on frame rails. Scribe marks removed by drilling are acceptable. 7. Do not use bolts or screws that have their threaded portion against the side of the hole in the frame. 8. Do not plug weld unused bolt holes. The heat effects of welding generally reduce rail strength by more than the drill hole would. NOTE: If in doubt about any frame repair procedure, contact Kenworth Trucks, Customer Service instructions. Kenworth Trucks does not approve straightening of damaged frame rails . Damaged or distorted frame rails must be replaced.

Kenworth Trucks Body & Equipment Mounting Guide

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