Kenworth C-510 and C-540 Heavy-Haulers

[MikePhua]

Kenworth Brand Background
Kenworth, founded in 1923 in Seattle as a successor to the earlier Gersix truck company, has become a renowned builder of Class 5–8 commercial trucks. Since being acquired by PACCAR in 1945, it has grown into a technology-rich division, producing heavy-duty trucks celebrated for durability and innovation—such as the long-running W900 conventional model.
C-Series Origins and Role
The C-Series models—C-509, C-510, and C-540—represent Kenworth’s off-highway heavy haul trucks, particularly designed for demanding mining and road-train applications in markets like Australia. The C-510 was introduced around 1998 to meet these needs, followed by the larger-capacity C-540 unveiled in the 2000s to accommodate even more extreme workloads.
C-510 Capacity and Design
The Kenworth C-510 is a powerful triple-drive, twin-steer heavy hauler developed for mine-haul and road-train service. It typically pairs a high-torque engine—often a 19-liter Cummins variant—delivering approximately 600 horsepower and 1,950 lb-ft of torque.
C-540 Advancements over C-510
The C-540 builds upon the proven C-510 platform but upgrades its drivetrain with a Cummins QSK19-LTA 19-liter engine delivering around 650 horsepower and follow-on torque near 2,275 lb-ft. When coupled with an Allison H6610 six-speed automatic transmission and heavy-duty steer and drive axles, the C-540 can haul a gross combination mass up to 500 tonnes, climb 6–8 percent gradients, and maintain highway speeds up to 70 km/h over long mine-haul distances.
Key Technical Highlights

• Engine: Cummins QSK19-LTA, ~650 hp, ~2,275 lb-ft torque
  
• Transmission: Allison H6610 6-speed automatic with dedicated cooling and retarder
  
• Steer Axle: Dana EF A24 (~10 ton capacity)
  
• Drive Axle: Axletech SPRC 1937 (up to 50 ton capacity)
  
• Cooling: Dual radiator-type with remote header, hydraulic fan that modulates between ~33%–100% speed for thermal efficiency
  
• Tyres & Rims: Michelin 385/95R25 on Titan 10 × 25
  
  

Terminology Notes

• Off-highway prime mover: Heavy-duty truck designed for non-public roads, such as mine sites and haul roads.
  
• Twin-steer / Tri-drive: Configurations using additional steer and drive axles to distribute weight and power across multiple axles.
  
• Retarder: Device in transmission that helps slow the vehicle using hydraulic resistance—valuable for sustained downhill braking on heavy loads.
  

Small Story from the Field
An Australian mine operator documented a C-540 in full road-train mode, hauling ore for 80 km runs through rugged outback terrain. The truck, custom-configured with maximum axle ratio and heavy-duty suspension, handled loads up to 400 tonnes with ease of control. Crews highlighted how the variable-speed hydraulic fan not only improved cooling under high ambient temperatures but also cut noise and fuel burn during lighter load segments—a fine detail that boosted value in long-hour cycles.
Ownership Insights

• Both models are engineering flexible platforms—assembled at Kenworth’s Bayswater, Victoria facility—meaning individual trucks may vary in vehicle width, axle ratios, and engine specs based on customer duty cycle, route, and haul demands.
  
• The C-series forms part of Kenworth Australia’s heavy-haul line, produced alongside models such as W900, T404SAR, K100E, and others targeted to tough haulage applications.
  

Recommendations and Considerations

• For operations needing sustained heavy-mass pulls over variable terrain, opt for the C-540 to leverage its increased power and torque.
  
• Consider the C-510 if slightly lower haul capacity with simplicity and potential fuel savings is acceptable.
  
• Ensure adequate axle configuration, gearing, and cooling setup is matched to haul distances and ambient conditions—both are often custom-engineered.
  
• Cooling system efficiency is critical; the variable hydraulic fan and dedicated retarder cooling on C-540 reduce overheating risk in high-strain environments.
  
• Operator training for managing gear shifts, retarder use, and thermal strategies is key to maximizing haul cycle efficiency and component lifespan.
  

Summary at a Glance

• Kenworth: American heritage; under PACCAR since 1945; maker of rugged heavy-duty trucks.
  
• C-510: Introduced ~1998 for mining/off-highway; ~600 hp / 1,950 lb-ft torque.
  
• C-540: Upgraded C-510; ~650 hp / ~2,275 lb-ft; 500-ton haul, high cooling efficiency.
  

The C-510 and C-540 exemplify Kenworth’s adaptation to extreme haulage demands—merging power, custom chassis engineering, advanced cooling and braking systems, all backed by decades of brand reputation. These trucks are not just tools—they are precision-built machines optimized for the toughest long-haul missions.