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1. FIGURE 6 10 Clearance zones around Hybrid Power Electronics Carrier PEC HAZARDOUS VOLTAGE To reduce the risk of possible serious injury Shock Burn or Death Components marked with High Voltage should be avoided Service must be performed by qualified personnel only 6 6 12 11 Section 6 Body Mounting Clearances For vehicles equipped with a Hybrid PEC frame mounted components or body installations must allow a minimum clear ance of 10 9 in front of the PEC Zone A 3 above the PEC Zone B and 2 behind the PEC Zone C Refer to Section 9 of this manual for information on the routing requirements of the High Voltage and Low Voltage Hybrid cables and wires Service Access Adequate access must be maintained to allow for service of the air cleaner and easy access to the service switch on the front side of the PEC as well as removal of the PEC unit for service Hybrid Battery Box O O taaa gee lO O Lo T GESA ll o o FIGURE 6 11 Clearance zones around the Hybrid Battery Box located LH Under Cab Clearances For vehicles equipped with a Hybrid Battery Box frame mounted components or body installations must allow a minimum clearance of 4 behind the rear
2. Kenworth T170 T270 T370 and Hybrid 2011 Body Builders Manual A PACCAR COMPANY Kenworth Medium Duty Body Builders Manual Models T170 T270 T370 and Hybrid For 2011 Model Year and Later with 2010 EPA Compliant Engines Body Builder s Manual Contents SECTION 1 INTRODUCTION SCOPRE APA a ee dr 1 1 SECTION 2 SAFETY AND COMPLIANCE DAET SIGNALS sawa 448s edhe eden ma oor ee oe aa AA NANA died PERA ar asien 2 1 Warnings Cautions and Notes aaa 2 1 FEDERAL MOTOR VEHICLE SAFETYSTANDARDS COMPLIANCE 2 2 Incomplete Vehicle Certification 2 2222 eee ee 2 2 Noise and Emissions Requirements a 2 3 EK AGUA een 2 4 Compressed Air System eee nena 2 4 Exhaust and Exhaust After treatment System es 2 4 Cooling System eee ete enna 2 5 ale le 1B NCY 2 6 Air Intake System 0 ee eee ee eee eee eens 2 8 Charge Air Cooler System 1 eee eens 2 8 SECTION 3 DIMENSIONS ABBREVIATIONS AND DEFINITIONS 0 0 aaa 3 1 OVERALL DIMENSIONS 0 0 0 0 aaa 3 3 DETAIL VIEWS we faves Sere bo Sh See Redd ok ae a deo a Gh sed eve GA 3 5 A BRA a x ss olga ties PP AP mae at a ate beads AA 3 6 Back of Cab Flush Mounted Flood Lamps T270 370 3 6 DETAIL VIEWS vn en oes aod pendence we oe eee ees pe hee en Enge 3 7 Crossmember Locations T170
3. TERYINAL IRFGRMAT ON FOR JI25 TERMINAL INFORMATION FOR P125 333 619 1 PLACK CI CAVITIES h333 582 1 CRAY Z LAYI IES SD LABEL JI25 TO ENGINE HARR 2EMCTE PTO CORTROLS LABEL P125 TO CUSTOMER INSTALLED Ng aac a 41 vl iu Mir i4 EIRCUT NG z HE IRCUI zu KISO PAG B STEHEN hj A g H795 P lt 9 osa pi gt LED gt 1 6845 PJ 0 i CHNI228 6 z te J panona pb 1513 0 K333 oi CG 5 ie LB ai 1513 12 i o 684 51 0 MALINS OY EX lo 5344 PK 0 HER ee I J MA ING VIT EFIE P 0 993 BR 9 fh da 813 7 aa ae F m I KOS YO Doz 4 b ERA3143 0 H795 7 i ORY 229 6 4 6845 PL 9 TAS 4ERE 3 WH 5134 ae LO 8 WHI 313 6 nn E 6844 P4 0 6841 Gi 0 SEE 1 PKO FIGURE 8 30 Wiring for Customer Installed Throttle Control at End of Frame Sales Code 1900976 Requires 1900082 Multi function engine connector 8 35 12 11 Section 8 Electrical TABLE 8 11 Remote Throttle Wiring to End of Frame ETO ge te S ge ater e ECM Pin Number Color Gauge Number Color Gauge Remote Throttle Sensor Signal BLU3144 G845 PU PTO On Off GRA3511 K999 GN Engine Ground WHT1519 White 18 8 WHTt61a 9 ear an Green 16 Torque Limit Switch GRA3149 Gray Remote Throttle Sensor Supply 52 VIO3144 Violet 18 10 5V Remote Throttle Sensor Return GRN3144 993 BR Remote Throttle On Off GRA3143 Gray E718 PK Remote Throttle Enable Circu
4. Dimension E BOC to DPF SCR 16 8in Dimension F BOC to RH Fuel Tank 0 2in Dimension H BOC to Hybrid Battery Box 2 8in TABLE 5 17 Hybrid PEC PEC Length DIM P BOC to PEC 56 1 12 11 5 36 Section 5 Frame Layouts H5 Hybrid C E SJ Ng CSE SH erg Yd io BE Dimension E BOC to DPF SCR 16 8in Dimension H BOC to Hybrid Battery Box 2 8in TABLE 5 18 Dimension D Fuel Tank i i uel Tank Size Fuel Tank Dimension F BOC to DEF Tank in i vel Tan Length in RH Fuel Tank in DEF Tank Size Hybrid PEC Wheelbase PEC Length DIM P BOC to PEC 56 1 5 37 12 11 Section 5 Frame Layouts H6 Hybrid IT J WU a i TIKI Dimension E1 BOC to DPF 27 2in Dimension E2 BOC to SCR 83 8in Dimension E3 BOC to Diffuser 103 0in Dimension H BOC to Hybrid Battery Box 2 8in TABLE 5 19 Dimension D Fuel Tank Size Paeit Dimension F BOC to DEF Tank in m RH Fue Tan Length in RH Fuel Tank in DEF Tank Size Hybrid PEC Wheelbase PEC Length DIM P BOC to PEC 56 1 12 11 5 38 Section 5 Frame Layouts H7 Hybrid Dimension E1 BOC to DPF 27 2in Dimension E2 BOC to SCR 83 8in Dimension E3 BOC to Diffuser 103 0in Dimensi
5. 0 a 3 7 BE AVE WS gap hg PAP Ge ecard A oe Gish eae ask Ga a Da em Be Gee Ga ears ack a 3 8 Crossmember Locations T170 0 cc ee eee 3 8 COMPONENTS 0 000 aaa 3 9 Frame Rail Configurations T170 270 370 0 ee 3 9 Battery Box T270 370 2 ee eee eens 3 10 Battery Tool Box T270 370 tenes 3 10 22 inch Fuel Tanks 1270 3870 1 ee eee 3 11 24 5 inch Fuel Tanks T270 370 0 ee eee 3 11 Rectangular Fuel Tank 0 0 0 ccc eee eens 3 12 Battery Box T270 370 1 eee eens 3 13 Battery Access Step T170 eens 3 13 Horizontal Exhaust Muffler 0 0 ee eee 3 14 Step DPF Box Assembly RH Under Cab T270 370 3 15 Horizontal Muffler Vertical Tailpipe on Cab 0 cc nenn 3 15 RH Back of Cab Independent Muffler T270 T370 0 0 eens 3 16 RIDE HEIGHTS 4 na HADE SEER ERR ER REE PAGANDA DA DAGA cane LA as 3 17 REAR SUSPENSION LAYOUTS oa vag che eed 2 00 0 0 nn 0 dy SERRE ar Coe dyes 3 19 KENWORTH AG210L SINGLE REAR AXLE a 3 19 KENWORTH AG400L TANDEM REAR AXLE 0000 c eee ee ee eens 3 20 REYCO 79KB SINGLE REAR AXLE 0 0 ee eee 3 21 Optional Reyco 79KB Suspensions 0 00 0 cee ees 3 21 REYCO 102 TANDEM REAR AXLE 0 0 c cee eee ee eee eee 3 22 Optional Reyco 102 Suspension ees 3 22 HENDRICKSON HAS SINGLE REAR AXLE 0 00 0 cece eee eee 3 23 Opti
6. 0 cece 8 32 FIGURE 8 27 P27 6180 Fuse Holder eee eee een eens 8 33 FIGURE 8 28 Battery Harness Jumper 0 0 eee eee teens 8 33 FIGURE 8 29 PACCAR PX 6 and PX 8 0 a 8 34 FIGURE 8 30 Wiring for Customer Installed Throttle Control at End of Frame 8 35 FIGURE 8 31 Cab Load Center MPDC 0 0 0 0c ee eee eae 8 37 FIGURE 8 32 SAE J560 Trailer Connector 0 0 een eens 8 40 FIGURE 8 33 ISO 3731 Trailer Connector 0 eee eee eae 8 40 FIGURE 8 34 JUNCION BOX 22334421 u HG heed Goto ha NE os lasg sea edd ann 8 41 FIGURE 9 1 Clamp and Butterfly Clamp nnna 0 0 0 0 eee eens 9 1 FIGURE 92 Bu uteriy NG sa es KABILAAN wats er Shenae a AN NPA aes at dod 2 9 1 FIGURE 9 3 Te St ap ar its eae het eee ea han eee Bam 9 1 FIGURE 9 4 Heavy Duty HD Mount 0 0 0 00 ee ee eee teens 9 2 FIGURE 9 5 Definition of measurements 0 a 9 4 FIGURE A 1 Vehicle Identification Number VIN 00 00 00 ee ee ees A 1 FIGURE A 2 Drivers Door and Door Frame Labels 0 0 ce eee A 2 FIGURE A 4 Front Axle Identification 0 0 0 0 0 ee eee eee eens A 4 FIGURE A 5 Rear Axle Identification 0 0 0 0 0 0 eee eee eens A 4 li SCOPE 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 bodie
7. 1t sd 8505719 Battery Hold Down Hook o2 1 0 2700791005 ck 113 1 0 2700428005 Washer Flat5 16 Ca fo 1 Ko4180427560h Boi HexM10X275 15 o 4 K3633 39393 Washer Cupped OL pie o cod laos Button S Note 1 For T270 370 with hydraulic brakes use these to install both item 5 otherwise use the existing fasteners 2 Use this in place of item 2 when liftgate wiring is required Install item 9 Upper Battery Retainer with items 14 15 and 16 T270 T370 Install item 10 with items 11 12 and 13 T170 Install item 5 Lower Battery Retainer with item 6 7 and 8 as needed T270 T370 Replace existing Battery Pad with item 4 T270 T370 FIGURE 8 24 Adding a Third Battery 12 11 8 30 Section 8 Electrical Connect jumper and electrical power harness P92 2068 here used with automatic transmission only Move ground and positive cables to posts of 3rd battery Third Battery a Optional FIGURE 8 25 Adding a Third Battery WIRING FOR A LIFTGATE A CAUTION consult the liftgate manufacturer s installation instructions for details concerning wir ing for their product and specific model A liftgate will usually require current much greater than 10 amperes Typically 100 to 150 amperes is required and some models require more than 150 amperes For a liftgate installation a third battery is required for adequate power Note A liftgate installation must have a dedic
8. Detail A Scale 1 2 DEF Return Line Backflow DEF Draw Line Inlet UU DEF Supply Module Pump DEF Pressure Line Outlet DEF Dosing Module Injector 4 1 12 11 Section 4 Exhaust amp 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 It is critical that the system is not compromised in any manner DEF Tank Small Tank Shown DEF Tank Heating Element 5 8 Coolant Hose Green Draw GC II eh Return Tee Draw Tee ug en 7 Coolant Bulkhead 3 8 Coolant Hose Frame m 2 2 Coolant mounted Blue Return td NA Valve 7 E 3 8 Coolant Hose se Green Draw DEF Dosing Module Draw Port Return Port Injector 5 8 Coolant Hose Blue Return ENGINE 12 11 4 2 Section 4 Exhaust amp Aftertreatment GENERAL GUIDELINES FOR DEF SYSTEM The installation of the DEF tank is a critical component of the SCR system While Kenworth does not recommended relo cating the DEF tank there are applications and body installations that will require it The guidelines below must be strictly followed by any entity relocat
9. in Fuel Tank in 20 Diameter Tank Diameter Tank 12 11 5 20 Dimension D Dimension B BOC to DEF Tank in BOC to Battery Box in Section 5 Frame Layouts D12 aa gt TY ICE E7 gt To N ed T a m ill O m m a 0 Dimension E BOC to DPF SCR 16 8in Dimension A BOC to Air Dryer 7 7in Dimension B BOC to Battery Box 5 4in TABLE 5 10 Dimension D Fuel Tank Size BOC to DEF Tank in DEF Tank Size 5 21 12 11 Section 5 Frame Layouts D13 D UNZ D o TY HAUL i Ta O Li IC cm N N SS Dimension E BOC to DPF SCR 16 8in Dimension A BOC to Air Dryer 7 7in Dimension B BOC to Battery Box 5 4in TABLE 5 11 i Dimension D Fuel Tank Tank i uel Tank Size Fuel Tank Dimension F1 BOC to DEF Tank in in RH Fu a Gallons Length in RH Fuel Tank in DEF Tank Size ss 56 Diameter 7 22 Diameter Tank 75 The DEF tank is moved forward approximately 8 3 with a frame rail mounted air dryer 12 11 5 22 Section 5 Frame Layouts D14 E F ef H AO i L Of AO B a A Dimension A BOC to Air Dryer 7 7in Dimension B BOC to Battery Box 5 4in Dimension E BOC to DPF SCR 16 8in Dimension F BOC
10. 1524 mm If the distance between adjacent crossmembers exceeds this dimension add a crossmember between them See Figure 7 4 Less Than 60 N Before Wheelbase is Lengthened Greater Than 60 gt Ef Additional Crossmember FIGURE 7 4 Crossmember Added when Distance Exceeds 60 inches 1524 mm 12 11 7 4 Section 7 Frame Modifications WELDING The 9 875 and 10 62 rails along with the 9 875 insert are heat treated therefore it is not weldable The 9 875 9 7 8 inch rail 10 62 10 5 8 inch rail and the 9 88 9 7 8 insert for the 10 62 inch rail are heat treated therefore are not weldable Welding can affect frame rail strength leading to a failure resulting in serious injury and or an accident Rail failures resulting from such modifications are not warrantable To determine if the frame rails are heat treated 1 Check for heat treat caution labels on the frame rails See figure 7 5 ACAUTION Heat treated alloy De not weld to rail or drill flanges Cracks may result FIGURE 7 5 Heat Treated Frame Rail Warning Kenworth DOES NOT recommend frame welding The high heat of welding nullifies the special heat treatment of the rails gre
11. COMMON OPTIONAL COMPONENTS 0 000 cece eee ee eee eee 5 2 FRAME LAYOUT INDEX ca pa 0 0 0 00 0 0000000000 eee be Booed EOS na eee ed 5 4 SECTION 6 BODY MOUNTING FRAME INFORMATION 0 00 ee eee ee nern 6 1 CRITICAL CLEARANCES 0 0 0 0 ek ee eee eee ees 6 1 Rear Wheels and Cab 0 ccc eee ee teens 6 1 Body Mounting Using Brackets 0 0 0 0 cc eee 6 2 acl APA eb ed bbe See ee APA 6 2 BISCKElS E asad oe own se eae NANDUON DAAN BTANA oe eee ae eke eases eee 6 2 Mounting Holes SA AA AA 6 3 Hang Hina aah aram beens Dp NEHA NAMA NGH ce eee nea gee aes 6 3 Hole Location Guidelines cc eee eens 6 4 BODY MOUNTING USING U BOLTS 0 0 0 0 0 ccc eee 6 4 SPACES asus nenn een AA AAP 6 4 Rear Body Mount 0 0 00 een 6 6 HYBRID CLEARANCES zu naa a Ka ann ana a a a a a a ao 6 6 PYDNA PEC ve en ae ten mean ee re oe an ee dh 6 6 Hybrid Battery Box se eee ennen nenn nennen nenn 6 7 SECTION 7 FRAME MODIFICATIONS FRAME MODIFICATIONS sussie eee eens 7 1 INMOOQUCION 24 AA sa eekeees gees se bases See AA 7 1 BRIEEING RAIE G 246534 se he tata onda ne ewe RE hee RER RE pee eee ee AG 7 1 Location and Hole Pattern 0 0 cee ernennen nenn 7 1 MODIFYING FRAME LENGTH 0 0 0 ccc eee eee ees 7 2 FAMEN cae kap boston ites ae ANDAM nd 7 2 Changing Wheelbase ccc eee eee ees 7 3 ChOSSINeMDCIS uSaeexnuen ye Gees Rhode Sees sade Ges eee ooo Beet 7 4 WELDING
12. E3 Exhaust Diffuser The layouts are organized by type specifically the arrangement of under cab components The visual index that follows will give you a quick overview of the layouts that are included Using the index locate the layout that you are interested in then turn to the specified pages The charts that follow are then model specific It is important that the correct chart is used for accurate dimensional information Visual Index RHUC DPF SCR Horizontal Crossover DPF SCR In Cab Battery Box Cantilever Battery Box PEC Hybrid Power Electronic Carrier Horizontal In Series DPF SCR Vertical DPF SCR Batt Parallel Battery Box with Air Dryer 9 1 12 11 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 TABLE 5 2 Fuel Tank Overall Length in Fuel Tank Overall Length in PT Fuel Tank Diameter 12 11 5 2 Section 5 Frame Layouts SMALL DEF TANK RECTANGULAR DEF TANK 9 Gallon Usable Volume 6 6 Gallon Usable Volume 9 GALLON USABLE VOLUME A 10 4 PT d D246 Medium DEF TANK 18 Ga
13. Medium Rectangular Fuel Tank is moved rearward approximately 10in when using the Medium DEF tank Hybrid PEC PEC Length DIM P BOC to PEC 56 1 5 33 12 11 Section 5 Frame Layouts H2 Hybrid B a E2 pa H Air or Hydraulic Brakes Air Brakes only Dimension F BOC to RH Fuel Tank 0 2in Dimension E1 BOC to DPF SCR 46 5in Dimension H BOC to Hybrid Battery Box 2 8in Dimension E3 BOC to Diffuser 65 7in Hydraulic Brakes only Dimension E1 BOC to DPF SCR 30in Dimension E3 BOC to Diffuser 49 2in TABLE 5 15 Hybrid PEC PEC Length DIMP BOC to PEC 56 1 12 11 5 34 Section 5 Frame Layouts H3 Hybrid Air or Hydraulic Brakes Air Brakes only Dimension H BOC to Hybrid Battery Box 2 8in Dimension E1 BOC to DPF SCR 46 5in Dimension E3 BOC to Diffuser 65 7in Hydraulic Brakes only Dimension E1 BOC to DPF SCR 30in Dimension E3 BOC to Diffuser 49 2in TABLE 5 16 Dimension D Fuel Tank Size Dimension F BOC to DEF Tank in Fuel Tank BOC to 22 Diameter Tank Add 2 8 with Air Brakes Add 8 3 with Air Brakes Hybrid PEC Wheelbase PEC Length DIM P BOC to PEC 281 315 56 1 5 35 12 11 Section 5 Frame Layouts H4 Hybrid IK II RS A SION C Saps l m Ji Ya 7 lt SA a a
14. So i F 1 a ae i F i a al vi a I Au o 7 To access the fuse box remove the face plate as described in the previous steps Push in the two side tabs and flip the cover open 8 13 12 11 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 Note the numbers 1 12 on Figure 8 11 These are how the positions are identified in Table 8 1 and on the instrument panel harness breakouts for the editable telltales behind the right hand cluster To remove the editable cards follow steps 1 3 in the instructions for accessing gauges and switches page 8 10 The access cards have a positive lock To remove the card push inwards on the lock with your thumb and pull the card out with pliers Figure 8 11 below details the cards To reinstall a card slide it in either by hand or with pliers PARIK LOCK 53 1215 5393 1208 FIGURE 8 11 Telltale Symbol Standard Cards Note The numbers 1 12 on Figure 8 11 These are how the positions are identified in Table 8 1 and on il the instrument panel breakouts for the editable te
15. behind the dash panel This aux power circuit can be used only when the igni tion switch is ON Circuits Wired to Battery The following circuits are wired directly to the battery through a fuse and switch Auxiliary Power optional if there are no trailer connections Brake Lamp Tail Lamp Clearance Lamps Right and Left Turn Signal When the optional body harness is properly connected the similar circuit in the body will also have power If the chassis clearance lamps are activated the body clearance lamps will also be activated Auxiliary Power in Battery Circuit The auxiliary power circuit is a 15 ampere capacity circuit connected directly to the battery Install a 15 ampere fuse in the fuse panel location F36 behind the dash Use this circuit whenever you need power for auxiliary equipment There is continuous power to this circuit when the batteries are charged even when the engine is off For example if the van body has interior lights or floodlights these can be wired to the auxiliary power circuit and switched ON from inside the van Connecting Battery Circuits Battery circuits are tagged as follows Auxiliary Power optional w o TRLR connections The auxiliary power circuit wire is tagged AUX PWR and is blue Brake Lamp The brake lamp wire is tagged STOP LP and is red Tail Lamp The tail lamp wire is tagged TAIL LP and is brown Clearance Lamps The clearance lamp wire is tagged CLEARANCE LP and is black
16. 32 2a 202 4 2 oon s Gare eo bce are eee dosha sn te keen kunne 7 5 TORQUE REQUIREMENTS sicecctnivccciraaestaeae dae ek ood eben bea ee 7 7 SECTION 8 ELECTRICAL ELECTRICAL ce en nahen AA te ea ogden eee 8 1 ACCESSING GAUGES AND SWITCHES eee ennen enn ee 8 10 OPTIONAL SWITCHES AIR VALVES AND GAUGES 2 0020 0 00000 eee 8 20 ADDITIONAL SPARE CIRCUITS 0 0 0 8 23 Additional Spare Circuits for Wiring 2 2 0 000 cee eee 8 23 OPTIONAL BODY BUILDER HARNESS 0 00 ee 8 24 Circuits Wired Through the Ignition a 8 26 Connecting Ignition Circuits ee eens 8 26 Circuits Wired to Battery 0 0 0 0 cc eens 8 26 BODY BUILDER POWER DISTRIBUTION CENTER 000 nenn 8 29 INSTALLING A THIRD BATTERY NOT AVAILABLE ON HYBRID 8 30 I 12 11 Body Builder s Manual Contents WIRING FOR ALIFTGATE 022222 aaa 8 31 Liftgate Power SOUCO snk ohne sheen ara re DP na PUNAN GG KA 8 31 Connecting the Liftgate Power aaaea ees 8 32 270 AMP ALTERNATOR RECOMMENDED HOOKUP 200000 ee 8 33 Engine Connections eee eee nennen 8 33 REMOTE PTO THROTTLE HARNESS 0 00 aaa 8 34 TRAILER CABLE CONNECTIONS 22220 8 40 SECTION 9 ROUTING ROUTING sx wean amn AD oes ANAND NAE AN ee NONA oe DEN bee NAG MG ee oe ee 9 1 ROUTING REQUIREMENTS 2022222 aa 9 2 Routing of Wires and Hoses near Exhaust System 9 4 A
17. 6 Section 2 Safety amp 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 or its location may not be changed Vehicles using EPA 2010 compliant engines must be equipped with a Malfunction Indicator Lamp MIL lamp This lamp is required to be an engine outline symbol as defined by ISO International Standards Organiza tion The figure below shows the instrument cluster and MIL lamp position Note this lamp location is fixed with respect to the controls and its location may not be changed if you are updating the warning lamp cards The MIL lamp will not be used with Medium Duty vehicles until 2013 le 13 ip i r u 1 PTO 5 High Exhaust System 10 Brake Fail Temperature HEST 2 Wait to Start 6 Fasten Seat Belts 11 High Beam 3 Malfunction Indicator 7 RH Turn Signal 12 LH Turn Signal Lamp MIL 4 Engine Brake 8 Park Brake 13 Check Transmission 9 Multi Function Display 14 Check Engine Light FIGURE 2 5 Instrument Cluster for T170 T270 T370 used with EPA2010 Emission compliant engines The Check Engine lamp is symbol 21 and the MIL is symbol 8 In addition to the sensors and lamps above the emission system also depends on signals from the exhaust DPF Diesel Particulate Filter SCR Selective Catalytic Reduction and NOx sensor
18. F BOC to DEF Tank in n RH Fuel Tam Length in RH Fuel Tank in DEF Tank Size Add 2 8 with Air Brakes Add 8 3 with Air Brakes 5 17 12 11 Section 5 Frame Layouts Be A E2 Air or Hydraulic Brakes Air Brakes only Dimension A BOC to Air Dryer 7 7in Dimension E1 BOC to DPF SCR 46 5in Dimension B BOC to Battery Box 5 4in Dimension E3 BOC to Diffuser 65 7in Dimension F BOC to Fuel Tank 0 2in Hydraulic Brakes only Dimension E1 BOC to DPF SCR 30in Dimension E3 BOC to Diffuser 49 2in This configuration is only available with a Rectangular Fuel Tank and Small DEF Tank 12 11 5 18 Section 5 Frame Layouts D10 E2 Air or Hydraulic Brakes Air Brakes only Dimension F1 BOC to RH Fuel Tank 0 2in Dimension E1 BOC to DPF SCR 46 5in Dimension F2 BOC to LH Fuel Tank 6 4in Dimension E3 BOC to Diffuser 49 2in Hydraulic Brakes only Dimension E1 BOC to DPF SCR 30in Dimension E3 BOC to Diffuser 49 2in This configuration is only available with a Rectangular Fuel Tank and Small DEF Tank 5 19 12 11 Section 5 Frame Layouts D11 1 gt HM LO i P a br Y u Dimension E BOC to DPF SCR 16 8in TABLE 5 9 Fuel Tank Size Dimension F1 Dimension F2 ihn BOC to RH BOC to LH g Fuel Tank
19. F28 requires Spare Accessory relay K5 Beacon Lamp Switch is located in dash area 4 and use a lighted rocker switch P27 1127 011 Beacon Lamp Switch is wired to both a 2 way Packard Weatherpack connector in the cab behind dash area 2 LH Gauge Panel and wired to the 6 way Packard connector on LH Frame rail Back of Cab near 9 way Trailer body connector Both switched power and ground is provided in the cab and chassis connectors Fuse F28 will accept an optional Polyswitch for circuit protection Optional Switch Panel Harness P92 4122 1xxxxx is used for Beacon Lamp Switch kk JT6 SS Af Lil kwh FIGURE 8 18 Switch and Wiring for Customer Installed Flood Lamp Chassis Harness Sales Code 9058037 Location LH Rail Approx 400mm Back of Cab TABLE 8 6 Switch and Wiring for Customer Installed Flood Lamp a Switch Connector Chassis Connector Chassis Fuse Description Soe ren Connector Description Description Terminal 2nd Flood Lamp J19 2nd Flood Lamp SW P7641 2nd Flood Lamp B Flood Lamp Switch is located in dash area 4 and use a lighted rocker switch P27 1127 002 Flood Lamp Switch is wired to a 2 way Packard Metripack connector on LH Frame rail Back of Cab near 9 way Trailer body connector Both switched power and ground is provided in the chassis connector 12 11 8 22 Section 8 Electrical ADDITIONAL SPARE CIRCUITS If you just need spare power wire into one of t
20. FIGURE 4 17 Isometric view of Horizontal Series DPF and SCR with Horizontal Tailpipe 4 14 FIGURE 4 18 Top view of Horizontal Series DPF and SCR with Horizontal Tailpipe 4 14 FIGURE 4 19 Right view of Horizontal Series DPF and SCR with Horizontal Tailpipe 4 15 FIGURE 4 20 Back view of Horizontal Series DPF and SCR with Horizontal Tailpipe 4 15 FIGURE 4 21 Isometric view of Vertical Independent DPF and SCR 0 00 02 cee 4 16 FIGURE 4 22 Top view of Vertical Independent DPF and SCR aa 4 16 FIGURE 4 23 Right view of Vertical Independent DPF and SCR naana ce 4 17 FIGURE 4 24 Back view of Vertical Independent DPF and SCR aa 4 17 FIGURE 5 1 DEF Tank Dimensions a 5 3 FIGURE 6 1 Minimum Clearance Between Top of Rear Tires and Body Structure Overhang 6 1 FIGURE 6 2 Minimum Back of Cab Clearance 2 eee ees 6 1 FIGURE 6 3 Spacer Between Frame Sill and Body Rail Rubber or Plastic 6 2 FIGURE 6 4 High Compression Spring ee eee eee eens 6 2 FIGURE 6 5 Rubber Spacer Between Brackets Between the Mounting Bolt and Upper Bracket 6 2 FIGURE 6 6 Crossmember Gusset Hole Pattern Requirements aa 6 3 12 11 FIGURE 6 6 Hole Locations Guidelines for Frame Rail and Bracket 0 0 0 eee eee 6 3 FIGURE 6 7 Acceptable U Bolt Mountin
21. Muffler DPF Behind RH Side of Cab inches mm TABLE 3 11 Vertical Tail Pipe Height Dimensions ee Vertical Tail Pipe RH Side of Cab Independent Vertical DPF SCR Back of Cab Vertical Tail Pipe A Bottom of Rail A Bottom of Rail A Bottom of Rrail A Bottom of Rail BOF to Top of BOF to Top of BOF to Top of BOF to Top of Tail Pipe mm Tail Pipe inch Tail Pipe mm Tail Pipe inch 24 Curved 2220 2520 99 2 30 Curved 93 4 105 2 N A N A N A N A 12 11 3 16 Section 3 Dimensions RIDE HEIGHTS The front FS and rear RS suspension ride heights are provided as a basic tool to determine overall height of the cab height of exhaust components and frame heights The heights are calculated from the centerlines of the axles Please be sure to include the tire radius dimension to determine overall height Note frame rail height itself will not affect the overall height as all components are located from the bottom of the rail 2197 1727 ANA k m 57 WE Bahay AF a 1039 TABLE 3 12 Estimated Front Suspension Ride Heights FS Estimated Front Ride Height Model FrontSspensionr_ __Ladeninch mm Unladen inch mm 7 4 188 T270 370 Non Driving ala nn 8 4 213 9 9 251 on 14 6 371 15 8 401 w PX 6 15 6 396 na os Export ISC 15 6 396 17 2 437 MININ 3 17 12 11 Section 3 Dimensions TABLE 3 13 Estima
22. Oversized holes could result in excessive frame wear around the hole Hole pattern dimensions for crossmember designs are illustrated in Page 6 5 Figure 6 8 Hole diameter should not exceed the bolt diameter by more than 060 inches 1 5 mm 7 1 12 11 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 The frame cutoff can be lengthened by adding frame extenders When extending 10 5 frame rails the additional sections can be welded to the existing rails The joint should be welded and reinforced as illustrated in Figure 7 1 i Note See page 7 5 for more information on welding frames Do not drill new holes any closer than 2 inches 50 mm to existing holes WARNING Frame drilling affects the strength of the rails and if not done properly can cause the frame rails to fail and cause an accident Frame Insert A frame insert must be added after welding a frame rail extension to compensate for lost strength The insert should be of the same material as the frame member or of steel and at least equal to the frame rail in thickness Attachme
23. Rail Ft Suspension CU CC as eK esesnezs ar an Boston me an Use Prospector frame heights for more accurate results Sample Tailpipe height 196 Desired overall stack height 162 0 Prospector frame height 43 5 Frame rail depth 10 6 Dimension A from chart 68 6 Tail pipe length 60 5 12 11 4 18 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 For your application the layouts focus on the under cab area with appropriate dimensional information included for pertinent back of cab components Not all optional equipment is included in this section Additional compo nents may be placed on the rail behind components shown The Back of Cab components are shown primarily for refer ence For more specific requirements please work with your local Kenworth Dealer Please read the instructions carefully The following dimensions are consistent across the entire section to aid in the comparison of one layout option versus another TABLE 5 1 Dimension Index F1 Fuel Tank RHS A Air Dryer F2 Fuel Tank LHS B Battery box D DEF tank H Hybrid PEC E1 Exhaust DPF T Tool Box E2 Exhaust SCR
24. Rectangular Small or Medium DEF Tanks 210m Differential FIGURE 4 7 Horizontal Crossover Exhaust system with Small or Medium 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 When relocating the components the maximum pressure DEF hose length from Supply module to Dosing Module is 3 meters 118 DEF Pressure hose must include a trap in the routing if Dosing Module is below the highest point of the Supply Module See Figure 4 8 on page 4 8 4 7 12 11 Section 4 Exhaust amp Aftertreatment Routing to the Dosing Module Injector It is important for the function of the dosing module to ensure that the dosing module is not routed downstream of DEF lines or components If this is unavoidable for example on RH under exhaust systems or Horizontal Series Exhaust a routing trap must be installed A minimum of 12 of line length must be routed below the dosing module in order to catch any leftover DEF when system is purged An P i pi fg 7 _ _ le gt Lie TE po q a ee th FIGURE 4 8 Routing DEF Lines and DEF Trap 12 11 4 8 Section 4 Exhaust amp Aftertreatment GENERAL EXHAUST INFORMATION Kenworth will offer four main DPF and SCR exhaust systems on Medium Duty chassis in 2010 A Right Hand Unde
25. Tank in DEF Tank Size i Small Medium Rectangular 5 29 Diameter Tank 19 7 N A The DEF tank is moved forward approximately 8 3 with a frame rail mounted air dryer 12 11 5 10 Section 5 Frame Layouts D2 Dimension E BOC to DPF SCR 0 0in Dimension A BOC to Air Dryer 7 7in Dimension B BOC to Battery Box 5 4in TABLE 5 5 i Dimension D Fuel Tank Size En ener Dimension F BOC to DEF Tank in aes Length in BOC to Fuel Tank DEF Tank Size l Small Medium Rectangular Diameter Tank i l ne N A The Fuel tank is moved forward approximately 13 with a frame rail mounted air dryer 5 11 12 11 Section 5 Frame Layouts D3 Dimension E BOC to DPF SCR 0 0in TABLE 5 6 i Dimension D eee Fuel Tank Dimension F Dimension B BOC to DEF Tank in i Tank nanga Diameter Galons rengin in Fuel Tank in Battery Box ad DEF Jang KTA Subtract 5 7 inches for the extended Daycab NOTE DIMENSION B IS CALCULATED USING A CANTILEVER SIZED BATTERY BOX OPTIONAL BOXES WILL AFFECT THIS DIMENSION loto tat 12 11 5 12 Section 5 Frame Layouts D4 i oJ Dimension E BOC to DPF SCR 0 0in Dimension F BOC to Fuel Tank 0 2in Dimension B BOC to Battery Box 26 0in This configuration is only av
26. Type Axle Spacing Height Height 12 11 3 26 Section 3 Dimensions CHALMERS 854 40 TANDEM SUSPENSION i p i gen Pa F 1 i i d7 i 24 RIDE Mi HEIGHT Bi I 1 er AXLE SPACING Optional Chalmers Tandem Suspensions TABLE 3 21 Rear Suspension Options BOF Suspension Tvpe Axle Spacin Laden Ride Unladen Ride p g Height Height 3 27 12 11 Section 3 Dimensions TIRE DATA For dimensions for your particular Bridgestone tire visit the Bridgestone website www bridgestonetrucktires com FRAME AND CAB RELATED HEIGHTS The bottom of the frame rail BOF at the front and rear axle can be used as a reference point to estimate vertical heights Use the following to calculate estimates for frame and cab related heights such as top of frame rail step height top of exhaust pipe etc 1 Tire radius data from the manufacturer 2 Front and rear suspension ride heights in this section 3 Frame rail heights defined in this section if needed 4 Component dimensions from bottom of rail defined in this section if needed Note that there are many factors that will affect heights including but not limited to front and rear axle loading and tire pressure Placement of frame components such as fuel tanks will affect loads on the front axle and rear axle as well as distribution to the left and right side of the vehicle Heights calculated from this information are estimates only GROU
27. body builder power distribution module we have simplified the integration of body related electrical systems to the vehicle batteries The module provides the following e 3 Midi fuse locations with M8 output studs e 6 ATO ATC fuse locations with 8 32 output screws e Ground busbar with 3M8 studs and 6 8 32 screws e 200A maximum load SIT PO EPL STOL IIs SBS we a EN je ee AANO Co LS SS x FIGURE 8 23 Detail of Body Builder Power Distribution Module 8 29 12 11 Section 8 Electrical INSTALLING A THIRD BATTERY NOT AVAILABLE ON HYBRID A third battery is a published option and can be ordered with your vehicle If this was not done use Figure 8 25 and 8 26 as guides for installing a third battery You will need the following additional parts to install the third battery TABLE 8 9 Third Battery Installation Parts for Parallel Battery Box LH Under Cab Item Ti70Qty T270 370 ty PartNumber Description 11 1 tt 27 6100 111 Battery GRP 31 w Threaded Posts 12 1 1 K396 1010008 Jumper Cable Positive 1 3 1 14 K395 1020008 Jumper Cable Negative 0 t4 No3 1002 SS BatteryPad S 0 2 N20 1025 Battery Retainer lower 61 o 4 w341070 060 3S Bolt HexM8X60 70 o 4 K1691628CA Nut HexMetric 81 o 8 K363338 2 312 Washer Flat 1 9 o 1 N2000 i Battery Retainer Upper Pot Oo 15055099 Battery Hold Down
28. can also identify and provide the wiring diagrams for any chassis that has been built For the configurations below the following circuits will be dedicated pin locations TABLE 8 14 SAE J560 Connector TABLE 8 15 ISO 3731 Connector Optional Switched Circuit a Trailer ABS Warning Laamp _ PA Stop Lamp Trailer Gg Optional Switched Circuit o 6 Tail Lamp Trailer 7 Trailer ABS Power 7 Trailer ABS Power Trailer Hotline Below is a description of how the cab ABS and trailer ABS control units interface to turn on the trailer ABS warning lamp When there is no direct connection the Power Line Carrier PLC is used to transmit the signal PLC defines that the trailer and cab ABS controllers are communicating via signals transmitted on their power circuits 1 J560 with Full Truck amp or Tractor Kit standard configuration This option provides a single SAE J560 connector at the noted location s Trailer ABS power is received on pin 7 ofthe SAE J560 connector Trailer ABS signal is on pin 7 of the SAE J560 via PLC for trucks Ground is on pin 1 of the SAE J560 connector 2 J560 amp ISO 3731 with Full Truck amp or Tractor Kit This option provides two connectors a SAE J560 and an ISO 3731 connector at the noted location s Trailer ABS power is on pin 7 of the SAE J560 amp ISO 3731 connectors Trailer ABS signal can be received on pin 7 of the SAE J560 amp ISO 3731 via PLC for trucks 12 11 8 4
29. filter see Figure 8 10 OPENING FOR AIR REAR PRIWARY FRONT RESTRICTION FILTER Pagi Pagg USECONDART balabal nia AIR LINE 18 BRAKE APPLICATION OPTIONAL FIGURE 8 8 Firewall Air Junction Block view from inside of cab FIGURE 8 9 Air Filter Restriction Sensor on Firewall Air Junction Block view from inside of cab 12 11 8 8 Section 8 Electrical FIGURE 8 10 Fuel Filter Restriction Pressure Gauge Sensor Location typical 8 9 12 11 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 Removal of the main panels is accomplished by unscrewing the two top screws in each panel F nf u Ca 5 Xa 1 1 WL Ee e es arr Z A dl oo eS del Pa mil 5 NG m 1 Bi Ak i i 7 i gt E i H i F kg aii m z Ej p i ti i H A 12 11 8 10 2 Then lift the panel out of the dash and unclip the main harness 3 To remove the gauges unscrew the gauge collar 8 11 12 11 4 To remove a switch push in the tabs on both sides of the switch and pull out the top section to disconnect the switch ka 5 Pinch the bottom tabs to release the switch from the panel 12 11 8 12 Section 8 Electrical 6 The fuse box is located behind the far right panel i ai Ca
30. for Battery Box amp DPF SCR 4x4 6x6 Dim A Bottom MENS ONTE Front Rear Rear Component of Rail Down to Suspension i Suspension Tires Lowest Part on Component LH Under Battery Box w air tanks 3rd Cab Access Step for Above Battery Box RH Under DPF SCR 12K Box Taperleaf i HAS230L 54 3rd Cab Access Step For Above DPF SCR Box Transfer Case with PX 6 Engine Transfer Case with PX 8 or Export ISC Engine 12 11 3 32 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 Multiple PTO s are shown for layout purposes only Power equipment i e drive shafts amp power pumps are not included Body builders should select the appropriate PTO for their application and customer requirements NOTE Installations depict multiple PTOs PTO locations shown below are for reference only Some PTOs may interfere with frame rail and or other components In order to ensure the PTO area remains clear of air equipment electrical and emissions equipment Kenworth recom mends always ordering PTO controls even when installing the PTO aftermarket Kenworth does offer a variety of factory installed PTOs Contact your local dealer for assistance Automatic Transmission Allison 2000 Right View Forward gt l Bottom View Forward gt 3 33 12 11 Automatic Transmission Allison 300
31. in m RH FUS Tan Length in RH Fuel Tank in DEF Tank Size 12 11 5 26 Section 5 Frame Layouts D18 i E3 ai E2 A Dimension E1 Dimension E2 Dimension E3 Dimension F1 BOC to DPF 27 2in BOC to SCR 83 8in BOC to Diffuser 103 0in BOC to RH Fuel Tank 0 2in Dimension F2 BOC to LH Fuel Tank 6 4in Dimension B BOC to Battery Box 15 0in ON NS TNS ai This configuration is only available with a Rectangular Fuel Tank and Small DEF Tank 5 27 12 11 Section 5 Frame Layouts D19 _ E3 E2 E1 C Tro A Dimension A BOC to Air Dryer 7 7in Dimension B BOC to Battery Box 5 4in Dimension E1 BOC to DPF 27 2in Dimension E2 BOC to SCR 83 8in Dimension E3 BOC to Diffuser 103 0in Dimension F BOC to Fuel Tank 0 2in This configuration is only available with a Rectangular Fuel Tank and Small DEF Tank 12 11 5 28 Section 5 Frame Layouts D20 E3 E2 gt Jb A H YI O o o my Dimension B BOC to Battery Box 3 8in Dimension E1 BOC to DPF 27 2in Dimension E2 BOC to SCR 83 8in Dimension E3 BOC to Diffuser 103 0in Dimension F BOC to Fuel Tank 0 2in This configuration is only available with a Rectangular Fuel Tank and Small DEF Tank 5 29 12 11 Se
32. not come any closer than 2 inches 50 mm to existing holes in the frame WARNING When relocating a suspension bracket do not mount it on the extended added section of a frame rail The suspension loading could result in premature failure of the added section splice This could cause an accident Use care when planning the wheelbase so that the rear suspension bracket is always mounted on the original rail section See Figure 7 3 If you are extending the wheelbase you may also have to extend the frame length to accommodate a body When you reposition the rear suspension spring hangers do not mount them on the added extended portion of the rail The relocated rear suspension bracket should be located on the original frame rails See Figure 7 3 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 AN WARNING When changing the wheelbase amp frame inserts are used crossmembers require re placement and or adjustment or in order to maintain the original frame rail spacing Fail ure to do so could cause damage to rear suspension components amp lead to an accident AN WARNING When changing the wheelbase amp frame outserts are used the rear suspension requires replacement to compensate for the original frame width caused by the outserts Failure to do so could cause damage to rea
33. on the passenger s door frame COMPONENT IDENTIFICATION Each of the following components has their own identification label Engine Identification The engine serial number is stamped on a plate located on the left front of the engine For further information please refer to the Engine Operation and Maintenance Manual included in the glove compartment of each vehicle Engine Identification Location PX 8 Shown MANUFACTURED Br CUMMINS IC ee ee Bale of Mfg IX IX XI PAUNIMG Injary may resell cad serromly Velee Jest cold I III Jel EIER Cab 1d 15 ro1fed tI fyel t id if fw ale rpa or glliigde exceed published warmem ralat fer Ihis model and opplicalron gt PX 8 LABEL Figure A 3 Engine Identification Location A 3 12 11 Appendix A Vehicle Identification Transmission Identification The transmission identification number is stamped on a tag affixed to the right forward side of the transmission case It includes among other specifications the transmission model serial and part number Front Axle Identification The front axle has a identification tag located on the front axle beam It includes the axle model part number and serial number FIGURE A 4 Front Axle 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 h
34. parallel to tank 2 minimum end of tank 1 minimum aluminum ceramic coated exhaust pipe crossing tank 1 5 minimum Air hose nylon 3 minimum 8 minimum wire braid 2 minimum 3 minimum Electrical wires located at or down line of the DPF Shielded dimension aq Unshielded dimension Component Heatshield or blanket Exhaust system pipe muffler FIGURE 9 5 Definition of measurements 12 11 9 4 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 See Figure A 1 SAMPLE VIN 1 x P P H 7 7 x x rlmlo 1 lole 3 o ES 0 eo Manufacturer Identifier Vehicle Attributes Check Digit Model Year Assembly Plant Serial Number Chassis Number FIGURE A 1 Vehicle Identification Number VIN The model year 4 is designated by an alphanumeric code in the tenth character position in the VIN See Table A 1 and Figure A 1 Year 5 7 BEZ TABLE A 1 Model Year Code Designations VIN Location The VIN is marked on the Incomplete Vehicle Certification Label on trucks It
35. provide maintenance access to the battery box and fuel tank fill neck Signals the location of a high voltage electrical components Example HAZARDOUS VOLTAGE To reduce the risk of possible serious injury Shock Burn or Death Components marked with High Voltage should be avoided Service must be performed by qualified personnel only Please take the time to read these messages when you see them and remember WARNING Indicates a potentially hazardous situation which if not avoided could result in death or serious injury CAUTION Signals a potentially hazardous situation which if not avoided could result in minor injury or damage to the vehicle NOTE Useful information that is related to the topic being discussed 2 1 12 11 Section 2 Safety amp 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 See next section and Appendix A for additional information Incomplete Vehicle Certification An Incomplete Vehicle Document is shipped with the vehicle certifying that the vehicle is not complete See Fig
36. system can only be done with the preapproval of Cummins and or Kenworth Body builders first point of contact concerning emissions systems modifications will be Kenworth It is possible to relocate the DEF tank however the relocation requirements need to be followed Any variance from the relocation requirements may cause the emissions control components systems to operate improperly potentially resulting in engine de rate See page 4 3 for relocation requirements NOTE Some 2010 engine emissions certified vehicles will be equipped with an On Board Diagnostics OBD system The OBD system is designed to detect malfunctions of any engine or vehicle component that may increase exhaust emissions or interfere with the proper performance of the OBD system itself 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 When a malfunction is detected information is stored in the ECU s for diagnostic purposes A Malfunction Indicator Light MIL is illuminated in the dash to alert the driver of the need for service of an emission related component or system 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 modificat
37. to Fuel Tank 0 2in This configuration is only available with a Rectangular Fuel Tank and Small DEF Tank 12 11 Section 5 Frame Layouts D15 ll TU CL i IT GP In E Dimension E BOC to DPF SCR 16 8in Dimension F1 BOC to RH Fuel Tank 0 2in Dimension F2 BOC to LH Fuel Tank 6 4in Dimension B BOC to Battery Box 16 7in T uv This configuration is only available with a Rectangular Fuel Tank and Small DEF Tank 12 11 5 24 Section 5 Frame Layouts D16 D Fi Bu 9 Dimension E1 BOC to DPF 27 2in Dimension E2 BOC to SCR 83 8in Dimension E3 BOC to Diffuser 103 0in TABLE 5 12 Dimension D Fuel Tank Size Fuel Tank Dimension F1 Dimension F2 Dimension B BOC to DEF Tank in BOC to RH BOC to LH BOC to Battery Diameter Gallons Length in Fuel Tank in Fuel Tank in Box in AGAIN Size Ca a a a me a 24 5 5 25 12 11 Section 5 Frame Layouts D17 LI TON CA mA Dimension A BOC to Air Dryer 7 7in Dimension B BOC to Battery Box 5 4in Dimension E1 BOC to DPF 27 2in Dimension E2 BOC to SCR 83 8in Dimension E3 BOC to Diffuser 103 0in TABLE 5 13 Dimension D Fuel Tank Size i i i u IZ Fuel Tank Dimension F BOC to DEF Tank
38. 0 Section 8 Electrical Trailer ABS warning lamp circuit can be received on pin 3 of the ISO 3731 connector Ground is on pin 1 of the SAE J560 amp ISO 3731 connectors 3 J560 Hotline amp ISO 3731 with Full Truck amp or Tractor Kit This option provides two connectors a SAE J560 and a ISO 3731 connector at the noted location s Trailer ABS power is on pin 7 of the ISO 3731 connector Trailer ABS signal is on pin 7 of the ISO 3731 via PLC for trucks Trailer ABS warning lamp circuit is on pin 3 of the ISO 3731 connector Trailer Hotline is provided on pin 7 of the SAE J560 connector This may be either battery powered or switched Ground is on pin 1 of both the SAE J560 amp ISO 3731 connectors Note Kenworth provides option variations within the above combinations This may include up to 2 il spare circuits on pins 2 amp 4 of the ISO 3731 connector which may or may not be switched In addition to these configurations an optional junction box is available mounted either behind the cab or at the end of frame See Figure 8 35 Te Tea NE FIGURE 8 34 Junction Box Circuits provided inside the junction box are e Ground Circuit code WHT1512 8AWG e Tail Lamp Trailer Circuit code YEL2421 12AWG e Marker Lamp Trailer Circuit code YEL9130 12AWG e Left Turn Trailer Circuit code YEL9111 12AWG e Stop Lamp Trailer Circuit code YEL9120 8AWG e Right Turn Trailer Circuit code
39. 0RDS 10 Bolt ka pa pr u Foward gt Forward 3 12 11 2 34 Manual Transmission Right Front View an 6 Bolt Right View Forward gt Bottom View Forward 3 35 12 11 Section 4 Exhaust amp 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 DEF is converted to ammonia by the heat of the exhaust system Inside of the SCR canister a catalyst causes a chemical reaction to occur between the ammonia and NOx turning it into water and nitrogen For more information on the specific details of how SCR works please contact your local Kenworth dealer DEF System Schematic On most Kenworth chassis the DEF Supply Module or pump is integrated into the DEF tank Kenworth does not allow relocation of this pump The following schematic details how the DEF lines route to the after treatment system DEF Tank 10 gallon shown DEF Return Line Backflow from Supply Module DEF Draw Line Inlet to Supply Module See Detail A Coolant Draw from Draw Tee Coolant Return to Coolant Valve
40. 12 11 8 26 Section 8 Electrical Hybrid Utility Connector Hybrid utility trucks come equipped with a utility connector to interface with the body builder s body controller The breakout for the utility connector is 3000mm long and can be located bundled up by the transmission see Figure 8 22 The length of the body builders mating harness must not exceed 2500mm Pins 7 and 8 are J1939 communication lines and must be a twisted shielded jacketed pair of wires Pin 6 is the drain wire for the shield Pins 1 amp 2 Pins 1 amp 2 are part of a Park Brake and Hood Switch interlock circuit A ground signal is applied to pin 1 and with both the hood closed and the park brake applied the circuit will be completed and a signal will appear on pin 2 Pin 3 Pin 3 is Battery Power and is rated for 10 Amps The fuse is located inside the Vehicle Electronics Carrier VEC in position F6 Pin 3 is live at key on Pin 4 Not Used Pin 5 Pin 5 is Ground Pin 6 Pin 6 is the drain wire for the J1939 CAN line The drain wire must only be connected to Pin 6 Do not connect the other end of the drain wire Pin 7 amp 8 Pins 7 amp 8 are J1939 11 Vehicle CAN VCAN lines Pin 7 is LOW and Pin 8 is HIGH 8 27 12 11 Section 8 Electrical Note All VCAN lines must conform to J1939 11 guidelines this includes using a jacketed shield ed twisted pair of wires Keep the VCAN lines away from high current rapidly switching il loads and the wire
41. Air Valves Optional Gauges pa t ulit i La CAR i i BT i ki 5 I E l E k T oc os uo di E i I 4 ER i i ia a ra a 7 T E ih A gs i uF _ Ha r KEE m PHI l IEE aa uf Fi fy l r r PTO F ULI UA j IUNI i ei 2 ml 3 SE E Pa u L I 1 B To s rr m A all ii ki u i E a maa n dh I ULI I FIGURE 8 15 Optional Switches 12 11 8 20 Section 8 Electrical TABLE 8 4 Optional Switches Switch Style Indicator Color Part Number FIGURE 8 16 Switch and Wiring for Customer Installed Beacon Lamp in the chassis Harness Sales Code 9080202 External Location LH Rail Approx 400mm Back of Cab TERMINAL IKFORMATIOK FOR POE K333 390 BLACK 2 CAVITIES Lf LABEL PONG BEACON LAMP F Le TERE CIRCUIT KO A WHT2911 4 B EL 911 7 5 Pi PB L U iM FIGURE 8 17 Switch and Wiring for Customer Installed Beacon Lamp in the IP Harness Same codes and locations as Chassis Harness above Internal Location Behind Speedo Tach Panel 8 21 12 11 Section 8 Electrical TABLE 8 5 Switch and Wiring for Customer Installed Beacon Lamp Fuse emer Cab Connector Chassis Connector na zw Connector en aa DP Connector Description eae Description Description Description Terminal F28 15A Spare ACC Beacon J13 P018 P764 Spare Circuits C Lamp Beacon Lamp SW Beacon Lamp Fuse
42. C battery box Chart located on page 5 21 D13 is used with Vertical Vertical DPF SCR LH vertical tailpipe RHUC cylindrical fuel tank LH BOC cylindrical DEF tank and LHUC battery box Chart located on page 5 22 D14 is used with Vertical Vertical DPF SCR LH vertical tailpipe RHUC rectangular fuel tank RHUC rectangular DEF tank and LHUC battery box Chart located on page 5 23 D15 is used with Vertical Vertical DPF SCR LH vertical tailpipe RHUC amp LHUC rectangular fuel tanks RHUC rectangular DEF tank and LH BOC cantilever battery box Chart located on page 5 24 D16 is used with horizontal In Series DPF SCR RH horizontal tailpipe LHUC and RHUC cylindrical fuel tanks RH BOC cylindrical DEF tank and LH BOC cantilever battery box Chart located on page 5 25 D17 is used with horizontal In Series DPF SCR RH horizontal tailpipe RHUC cylindrical fuel tank RH BOC cylindrical DEF tank and LHUC battery box Chart located on page 5 26 12 11 5 6 Section 5 Frame Layouts 1 D18 is used with horizontal In Series DPF SCR RH horizontal tailpipe RHUC amp LHUC rectangular fuel tanks RHUC rectangular DEF tank and LH BOC cantilever battery box Chart located on page 5 27 D19 is used with horizontal In Series DPF SCR RH horizontal tailpipe RHUC rectangular fuel tank RHUC rectangular DEF tank and LHUC battery box Chart located on page 5 28 M g g g g W i sof D20 is a T170 spe
43. CATOR LANE DEPARTURE A SERVICE RANGE INHIBIT LAMP MIL WARNING LDW LVD TRANSMISSION S53 6060 052 53 6060 048 Soo 6060 0449 953 6060 050 S53 6060 05 BRAKE DIESEL EXHAUST HILL HOLD FUEL PRESSURE BRAKE FAILURE SIDE AIRBAG 253 6060 053 53 6060 054 a 53 6060 056 53 6060 057 FIGURE 8 13 CONTINUED 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 Please see Table 8 1 to determine the position and color of the telltales Positions are shown on Figure 8 12 12 11 8 18 Section 8 Electrical ALARMS There are three spare Alarm female 14 slide connector breakouts behind the speedo tach cluster near the speedo tach connector labeled e Alarm IA e Alarm 1B e 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 SPARE SWITCHES FACTORY INSTALLED Kenworth provides the option of coding for up to 3 spare switches with standard fuse locations in the central electrical panel These switches receive power from the Accessory bus Switches 1 3 are fused by separate 15A circuit protection devices fuse or circuit breaker The location of these circuit protection devices are labeled on the central electrical panel cover For example SPARE ACC SWITCH 1 is the label for spare switch 1
44. CVSG electronic gauges is sent from the CECU to the gauges via the data link blue wire Optional CVSG mechanical gauges i e air suspension are driven mechanically with air pressure hosed to the fitting behind the gauge There is no red warning lamp and the backlighting is powered through the brown wire from the CECU a pulse width modulated signal The 4 way jumper harness is still used to pass all 4 circuits through the gauge to the next gauge in the chain Gauges can be relocated to any 2 inch open gauge position in the dash To relocate a gauge unhook the con nector at the back and move it to the desired position Plug the jumper wire in See Accessing Gauges and Switches section below for instructions on physically moving the gauge The connector will require a firm pull to remove it When reinstalling the connector ensure that it is fully inserted Both connector sockets on the rear of the gauge are the same either one can be used 8 6 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 The following diagram shows the locations of standard connectors in the wiring harnesses This allows you to easily locate connectors to add gauges To add an electronic gauge install the sensor available from your local Kenworth dealer in the noted location plug in the wiring harness and then install the gauge in the das
45. FIGURE 8 1 J1939 Data Link Wiring Data Bus Access Location LH side rear of engine J1939 Data Link Extension P92 3422 available from PACCAR Parts 8 1 12 11 Section 8 Electrical INTERIOR IDENTIFICATION 2010 is the first year that Kenworth has used Multiplex Wiring in our T170 T270 and T370 vehicles Chassis with this new interior can be identified by appearance see Figure 8 2 All dashes that resemble the following picture will utilize multiplex wiring FIGURE 8 2 Kenworth B Cab Dash A 2010 Chassis can quickly be identified by the presence of the Diesel Exhaust Fluid DEF gauge See Figure 8 3 FIGURE 8 3 Diesel Exhaust Fluid Gauge Note The information contained in this manual is specific to chassis with 2010 engines For pre 2010 il engines please work with your local Kenworth dealer 12 11 8 2 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 Figure 8 4 Multiplexed Instrumentation Block Diagram on page 8 3 FIREWALL 6 gt 2 V POWER TRAIN lt gt Bee LG 0 east CSVG BUS FIGURE 8 4 Multiplexed Instrumentation Block Diagram e V CAN Vehicle Controller Area Network The V CAN also referred to as the J1939 is used to
46. FIGURE 8 14 Spare switches wired to Power Sales Codes 8208495 2 spare 8208496 3 spare Location LH Rail Approx 400mm back of cab TABLE 8 2 Chassis Harness BA Switch Connector Chassis Connector Chassis Fuse Description rn a ieee Connector Description Description Terminal Spare ACC Switch 1 J07 Spare ACC SW 1 P764 Spare Circuits D Spare ACC Spare ACC Switch 2 J08 Spare ACC SW 2 P764 Spare Circuits Spare ACC Spare ACC Switch 3 J12 Spare ACC SW 3 P764 Spare Circuits Fuses F32 and F33 require Spare Accessory relay K5 Spare Switches are located in dash area 4 and use a lighted rocker switch P27 1127 031 Spare Switches are wired to 6 way Packard connector on LH Frame rail Back of Cab near 9 way Trailer body connector Fuse F15 F32 and F33 will accept an optional Polyswitch for circuit protection 8 19 12 11 Section 8 Electrical OPTIONAL SWITCHES AIR VALVES AND GAUGES The number of optional switches air valves and gauges has changes for Kenworth Medium Duty vehicles The below chart provides a total count based on model type TABLE 8 3 Optional Switches Air Valves and Gauges Brake Svstem Max Number of Max Number of Max Number of y AA Switches a SSA Air Valves pon Gauges EY TY T270 BEE TE BE Hya DE EEEEEEESEERERRR T370 2 o Ar o GO Model With Hybrid Brake System Transmission Max Number of Max Number of Max Number of Optional Switches Optional
47. ND CLEARANCES To calculate estimates for ground clearance for mounted components using the underside of the bottom of the frame rail as a reference use the following 1 Tire radius data from the manufacturer 2 Front and rear suspension ride heights in this section 3 Component dimensions from bottom of rail defined in this section Ground clearances like height calculations are affected by factors including but not limited to front and rear axle loading and tire pressure Placement of frame components such as fuel tanks will affect loads on the front axle and rear axle as well as distribution to the left and right side of the vehicle Ground clearances calculated from this information are estimates only 12 11 3 28 Section 3 Dimensions GROUND CLEARANCE 4X2 6X4 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 17 and 3 18 For comparison the FS value shown is 11 4 unladen and 10 4 laden Front Suspension 12K Taperleaf 54 Dim A Bottom DIMENSION GB Rear Rear Component of Rail Down to Suspension Tires Lowest Part on Component 45 Gal Rect Fuel Tank Def Tank For Above Rect Fuel Tank 22 Dia Round Alum Fuel Tank l i HAS230L i Def Tank For Above 22 Fuel Tank 24 5 Dia Round Alum Fuel Tank Def Tank For Above 24 5 Fuel
48. PPENDIX A VEHICLE IDENTIFICATION VIN LOC AHORN sri een ne oe a ALNG Goat Ge ees Ee hen nae aoe ae a ee A 1 Chassis Number Locations aaa A 1 VEHICLE IDENTIFICATION LABELS aa A 2 Tire Rim and Weight Rating Data Label 0a A 2 Incomplete Vehicle Certification Label 2222 none nennen A 2 Components and Weights Label aaa A 2 Noise Emission Label a GANANG ee Bee PANAY Go wee ae Bee NGA AGA A 3 Paint Identification Label aaaea A 3 COMPONENT IDENTIFICATION 00202222 A 3 Engine Identification ee eee eens A 3 Transmission Identification 2 aoaaa aoa aaaea ee ee eee A 4 Front Axle Identification nnana naaa ee ee ee eee A 4 Rear Axle Identification 1 0 0 0 aaa A 4 FIGURES FIGURE 2 1 Incomplete Vehicle Certification Document 0 0 ees 2 2 FIGURE 2 2 Locations of Certification Labels Driver s Door and Frame 00 ce eee aes 2 2 FIGURE 2 3 West Coast Mirror OAT sensor located in overmold on mirror harness 2 6 FIGURE 2 4 Aerodynamic Mirror OAT Sensor Location ccc eens 2 7 FIGURE 2 5 Instrument Cluster for T170 T270 T370 used with EPA2010 Emission compliant engines 2 7 FIGURE 3 1 Prospector Turn Circle Analysis 0 00 cc ccc eee eens 3 2 FIGURE 3 2 T170 T270 T370 Overall Height and Length Dimensions 0 000 eee 3 3 FIGURE 3 3 Top of Cab View T270 T370 Roof Mounted O
49. TANGULAR HORN LOCATIONS 13 1 13 1 032 332 SINGLE LH HORN 15 3 389 44 4 1128 221 RADIO ANTENNA 562 LOCATION FIGURE 3 3 Top of Cab View T270 T370 Roof Mounted Options NG HIGHEST ROOF POINT we a ur i FE j FIGURE 3 4 Side of Cab View T270 370 Roof Mounted Options 3 5 12 11 Section 3 Dimensions DETAIL VIEWS Back of Cab Flush Mounted Flood Lamps T270 370 25 635 25 635 High Mount Flood Lamp Elevation Mid Mount Flood Lamp oe 62 4 1585 ee Moun ed 14 4 365 14 4 365 Lamp Location for 43 7 Vertical Tailpipe 1110 Back of Cab 37 2 945 BOF FIGURE 3 5 Flush Mounted Flood Lamp Locations inches mm 12 11 3 6 Section 3 Dimensions DETAIL VIEWS Crossmember Locations T170 WB AF FIGURE 3 6 T170 Crossmember Location TABLE 3 5 T170 Cross member Location measured from front axle centerlines inches mm WB a Bl B CB CUD 206 101 8 2585 Y 121 1 3075 Y 1 For without a square end of frame cross member with an AF range of 80 2032 to 125 3175 a crossmember is installed at E WB 64 4 1636mm 2 For AF range of 126 3200 to 173 4394 a 2nd crossmember is installed at E WB 112 4 2855 mm Y SPL100 Driveline centerbearing CB is mounted on this crossmember 3 7 12 11 Section 3 Dimensions DETAIL VIEWS Crossmember Locations T170 Ka WE e
50. TEN ETHER START KA 553 6060 008 S53 6060 009 553 6060 010 SEAT BELT 53 6060 012 S53 6060 01 OO amp a B kya ER gt ES ENGINE HEATER Dh WHEEL WAIT TO START INTER AXLE LOCK SERVICE Oh BODY UP 53 6060 013 SLIDE S53 6060 015 53 6060 016 553 6060 017 853 6060 018 553 6060 014 PTO io E kx NG amp PTO BRAKESAVER Om BODY UP AUXILIARY 09 SPEED CENTRAL TIRE S 53 6060 019 S53 6060 020 S53 6060 021 TRANSMISSION 3 S53 6060 023 INFLATION 553 6060 022 S53 6060 024 PUMP tr ta KE PUMP MODE EXHAUST BRAKE TRANSMISSION TRANSMISSION 53 6060 025 So3 6060 026 FILTER TEMPERATURE S937 ER S53 6060 028 ED Raw Wa HIGH BEAM LEFT TURN RIGHT TURN TRAILER DUMP TRAILER DUMP TRAILER DUMP ey ARROW ARROW FRONT CENTER REAR S953 6060 030 553 6060 031 spo 6060 032 Dos OUO0 035 os BUG 70 77 S OFF WORN BRAKE DUAL REAR AXLES REMOTE SWITCH S53 6060 035 DIFFERENTIAL LOCK ENGINE OFF SERIE 553 6060 037 FIGURE 8 13 Telltale Icons continued on page 8 18 8 17 12 11 Section 8 Electrical Az GA pn EO He STABILITY T SUSPENSION FRONT REAR AXLE REAR REAR AXLE FILTER CONTROL DUMP DIFFERENTIAL LOCK DIFFERENTIAL LOCK REGENERATION 553 6060 038 53 6060 039 553 6060 040 553 6060 04 53 6060 042 av reset ER 3 CRANE UP OVERSPEED WINCH EMISSION SYSTEM TRACTION WARNING SHUTDOWN 553 6060 045 TEMPERATURE ENHANCEMENT 553 6060 043 553 6060 044 WARN I NG 953 1106 047 S53 1106 046 C IA S RANGE o INHIBIT a au VOLTAGE LFUNETION INDI
51. Tank 3 29 12 11 Section 3 Dimensions ul F a as LT TABLE 3 23 Ground Clearance for Battery Box amp DPF SCR 4x2 6x4 Dim A Bottom DIMensIon a Front Rear Rear of Rail Down to Front Tires i Component Suspension Suspension Tires Lowest Part on Component LH Under Battery 12K Taper M711 Box w air tanks ji HAS230L 11R22 5 Leaf 54 RH Under DPF 14PR SCR Box 12 11 3 30 Section 3 Dimensions GROUND CLEARANCE 4X4 6X6 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 17 and 3 18 For comparison the FS value shown is 15 8 unladen and 14 5 laden TABLE 3 24 Ground Clearance for Fuel and DEF Tanks 4x4 6x6 Dim A Bottom DIMENSIOR E of Rail Down to Lowest Part on Component 45 Gal Rect Fuel Tank Def Tank For Above Rect Fuel Tank 3rd Cab Access Step for Above 22 Fuel Tank Front Rear Suspen Suspen Component sion sion 22 Dia Round Alum Fuel Tank 12K Taperleaf 54 Def Tank For Above 22 Fuel Tank 3rd Cab Access Step for Above 22 Fuel Tank 24 5 Dia Round Alum Fuel Tank Def Tank For Above 24 5 Fuel Tank 3rd Cab Access Step for Above 24 5 Fuel Tank 3 31 12 11 Section 3 Dimensions GROUND CLEARANCE 4X4 6X6 TABLE 3 25 Ground Clearance
52. V LITL Brown YEL2411 Yellow 10A F22 Shared w Lamps Chas Tail LPS White WATTS White S TRLR ABS Hotline T RED9920 15A F36 Dedicated Hotline TRLR Batt Fuse 8 25 12 11 Section 8 Electrical Circuits Wired Through the Ignition The Backup Lamp circuit is powered on when the ignition key is turned to the ON position After the connections are made by splicing into the optional body harness the body components will have power when the similar chassis components receive power For instance when the right hand turn signal is activated and the right hand turn signal light flashes on the cab the right hand turn signal light on the installed body will also flash Connecting Ignition Circuits Ignition circuits are tagged as follows Right Turn Signal The right turn signal wire is tagged RH TURN and is green black Left Turn Signal The left turn signal wire is tagged LH TURN and is yellow black Backup Lamp The backup lamp wire is tagged BACKUP LP and is pink white Ground The ground wire is tagged GND and is white Auxiliary Power Standard config for chassis built after first quarter 1998 The auxiliary power circuit wire is tagged AUX PWR and is blue Used for TRLR ABS if there is a trailer Do not use for other purposes if auxiliary power is used for trailer applications This aux power circuit is a 15 ampere capacity circuit in the ignition circuit Install a 15 ampere fuse in the fuse panel locations F79
53. Wheelbase We do not recommend modifying the wheelbase Occasionally however a chassis wheelbase will need to be reduced or lengthened When this needs to be done there are a few guidelines that should to be considered AN WARNING When changing the wheelbase be sure to follow the driveline manufacturer s recom mendations for driveline length or angle changes Incorrectly modified drivelines can fail prematurely due to excessive vibration and could cause personal injury and or an accident AN WARNING When changing the wheelbase a continuous blank frame insert outsert must be added in the area of the new rear suspension mounting bolts All new mounting holes must pass through the original rail rear suspension crossmembers and the insert outsert Failure to do so could cause excessive stress in the original rail due to additional holes Before changing the wheelbase the driveline angles of the proposed wheelbase need to be examined to ensure that no harmful vibrations are created Consult the driveline manufacturer for appropriate recommendations AN WARNING Do not drill new holes any closer than 2 inches 50 mm to existing holes Frame drilling affects the strength of the rails and if not done properly can cause the frame rails to fail and cause an accident Before the rear suspension is relocated check the new location of the spring hanger brackets The new holes for the spring hanger brackets must not overlap existing holes and should
54. Wiring between these devices the Dosing Control Unit DCU and engine ECM should not be tampered with or altered in any way 2 7 12 11 Section 2 Safety amp Compliance Air Intake System The following are highlights of some of the more common or critical aspects of this system e The air intake screen may not be blocked either fully or partially e Modification to the air intake system may not restrict airflow For example pipe diameter may not be reduced e All sensors must be retained in existing locations e To retain system seal proper clamp torque must be used Refer to service manual for proper clamp torque Charge Air Cooler System The following are highlights of some of the more common or critical aspects of this system e The Charge Air Cooler may not be modified e The installation of engine overspeed shutdown devices must not introduce restriction in the intake system e All plumbing associated with the charge air cooler may not be modified 12 11 2 8 Section 3 Dimensions DIMENSIONS This section is designed to provide enough information to successfully layout chassis in the body planning process Only typical truck layouts and configurations are shown Optional equipment may not be depicted Please contact your local Kenworth dealer if more information is desired ABBREVIATIONS AND DEFINITIONS Throughout this section and in other sections as well abbreviations and specific terminology are used to describe ce
55. YEL9112 12AWG e ABS Power switched Circuit code ORN5100 8AWG These circuits are terminated with ring terminals attached to one side of a terminal strip To connect to the circuits use a ring terminal for a 10 screw 8 41 12 11 Section 8 Electrical Page Intentionally Left Blank 12 11 8 42 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 Standard clamps have a black elastomer lining High temperature clamps e g those used with com pressor discharge hose have a white or red elastomer lining most applications for these are called out in the bills of material An assembly of two clamps fastened together to separate components is referred to as a butterfly clamp Note the metal portion of clamps shall be stainless steel or otherwise made capable through plating or other means of passing a 200 hour salt spray test per ASTM B117 without rusting Tu FIGURE 9 1 Clamp and Butterfly Clamp Butterfly Tie A tough plastic nylon or equivalent locking du
56. able warning light symbols called telltale cards Each telltale card slides into the left and right sides of the Driver Warning and Indicator Module DWIM from the bottom The standard cards cover most warning light requirements editable cards can be used for less common components that also require warning lights The central instrument cluster receives input data from the CECU via the I CAN see Figure 8 3 data bus When the ignition key is first turned ON the cluster will perform a calibration power on self test Power On Self Test e Ignition key turned ON e The speedometer and tachometer gauge pointers move from pointing at zero counter clockwise to their mechanical limit approx 8 stay there for one second and go back to pointing at zero e At the same time all LED indicators and telltales are switched on together except for position 4 and 11 e A Warning sound sequence is also activated five times without break 12 11 8 4 Section 8 Electrical The instrument panel is installed with two screws FIGURE 8 6 Main Instrument Panel CVSG Gauges The 2 gauges located to the left and right of the main instrument panel are commonly referred to as Commercial Vehicle Smart Gauges CVSG Like the central instrument cluster the 2 inch gauges also receive input data directly from the CECU CVSQ s are two types electronic and mechanical The electronic CVSG s receive digital
57. ailable with a Rectangular Fuel Tank and Small DEF Tank 5 13 12 11 Section 5 Frame Layouts Dimension E BOC to DPF SCR 0 0in Dimension F BOC to Fuel Tank 0 2in This configuration is only available with a Rectangular Fuel Tank and Small DEF Tank 12 11 5 14 D6 CAN KA PAA LI o a Dimension E BOC to DPF SCR 0 0in Dimension D BOC to DEF Tank 0 4in Section 5 Frame Layouts This configuration is only available with a Rectangular Fuel Tank and Small DEF Tank 12 11 Section 5 Frame Layouts Hydraulic Brakes Air Brakes Dimension E1 BOC to DPF SCR 30in Dimension E1 BOC to DPF SCR 46 5in Dimension E3 BOC to Diffuser 49 2in Dimension E3 BOC to Diffuser 65 7in TABLE 5 7 i Dimension D Fuel Tank Size Fuel Tank Dimension F1 Dimension F2 BOC to DEF Tank in BOC to RH OC i aa eae Add 2 8 with Air Brakes Add 8 3 with Air Brakes 12 11 9 16 Section 5 Frame Layouts D8 Br m gt m A E2 Air or Hydraulic Brakes Air Brakes only Dimension A BOC to Air Dryer 7 7in Dimension E1 BOC to DPF SCR 46 5in Dimension B BOC to Battery Box 5 4in Dimension E3 BOC to Diffuser 65 7in Hydraulic Brakes only Dimension E1 BOC to DPF SCR 30in Dimension E3 BOC to Diffuser 49 2in TABLE 5 8 Dimension D Fuel Tank Size R i i Fuel Tank Dimension
58. al clamp tie strap used to separate bundles or single lines hoses etc These straps must be UV stable Tyton DCT11 FIGURE 9 2 Buiterfly Tie Tie Strap A tough plastic nylon or equivalent locking strap used to tie the lines in a bundle together between clamps or to otherwise secure hoses and wires as noted below These straps must be UV stable FIGURE 9 3 Tie Strap Heavy Duty HD Mount A black rigid device used for securing a tie strap to the frame or other structural support Mounts are made of impact modified heat stabilized UV resistant nylon capable of continuous operation between tem peratures 220 F 150 and 40 F 40 9 1 12 11 Section 9 Not Heavy duty tie straps 0 50in 12 7mm wide Tyton T255ROHIR or similar shall be used ote 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 See section 4 1 3 for air conditioner hose requirements Shortness of material Less than 1 inch of slack on a 14 inch section of hose routing ROUTING REQUIREMENTS Wiring Electrical ground wire terminals must be securely attached and the complete terminal surface must contact a clean bare metal surface See R414 558 for grounding wire connection practice Apply electrical contact corrosion inhibitor Nyoge
59. are Switches standard and adding e Spare Relays e Remote PTO Throttle harness e Electrical wire number and color e Trailer cable connections e After treatment Control Modules MULTIPLEX INSTRUMENTATION Kenworth utilizes Multiplex instrumentation and wiring to continuously improve our quality and the capability of our trucks Multiplexing utilizes the industry standard Society of Automotive Engineering SAE J1939 data bus to send multiple signals over a single twisted pair of wires instead of individual wires for each function The advantages are fewer wires sensors and connections that provide greater consistency improved reliability and the ability to use ESA to troubleshoot the instrumentation The following information is provided to increase your awareness about the Kenworth product it may be useful in installing telltales warning lights and gauges and coordination with other installed equipment WARNING Don t cut or tap into green yellow twisted pairs Only use T connectors and only add i approved J1939 components with validated software TERMINAL INFORMATION FOR P20 1194 20 BLUE 6 CAVIT LABEL RII4 J1939 V CAN TERM RESISTOR TERM CIRCUIT NO IB GRN0812 0 2B YELO812 0 TERMINAL INFORMATION FOR PIJ4 P20 1193 12026 BLACK 2 CAVITIES EL PI14 J1939 V CAN POWERTRAIN iT pO a Ka AIN TERM CIRCUIT NO Wag GRNO8 12 1 u
60. ated circuit to distribute power to the liftgate il Liftgate Power Source Liftgate motors will typically use DC power A convenient power source is the battery Use Figure 8 27 as a guide Install the circuit breaker inside the battery box on the rear panel WARNING DO NOT use a circuit breaker of lower capacity than the liftgate amperage requirements If you do it could result in an electrical overload or fire Follow the liftgate installation AN instructions and use a circuit breaker with capacity recommended by the liftgate manufacturer 8 31 12 11 Section 8 Electrical Connecting the Liftgate Power Follow these instructions to connect the liftgate to the third battery See Figure 8 26 1 Install the third battery Positive battery jumper cable with ring terminal breakout wire item 17 in Table 8 9 page 8 30 should be installed instead of item 2 3 Install circuit breaker Shorten the ring terminal breakout wire on positive battery jumper cable item 17 to length as needed for rout ing to the circuit breaker Install ring terminal item 18 as needed Route the wire per routing requirements in Section 7 5 Connect the ring terminal breakout wire to the circuit breaker The positive battery jumper cable with ring terminal breakout item 17 and the ring terminal item 18 are in Table 8 9 page 8 30 These are available form PACCAR Parts The remainder of the wiring installation should be in accordance with the l
61. ater Than 2 inches 50 mm Lower Frame Flange FIGURE 6 6 Hole Locations Guidelines for Frame Rail and Bracket 4 HOLES 6 HOLES 5 IN DIA 5 IN DIA 12 7mm 12 7mm RE 5 5 le 5 5 140mm 140mm 11 0 279mm FIGURE 6 6 Crossmember Gusset Hole Pattern Requirements inch mm Frame Drilling When mounting a body to the chassis DO NOT drill holes AN WARNING in the upper or lower flange of the frame rail If the frame rail flanges are modified or damaged the rail could fail prematurely and cause an accident Mount the body using body mounting brackets or U bolts Use care when drilling the frame web so the wires and air lines routed inside the rail are CAUTION not damaged Failure to do so could lead to equipment damage and cause an inoper able electrical or air system circuit Do not drill new holes any closer than 2 inches 50 mm to existing holes AN WARNING Frame drilling affects the strength of the rails and if not done properly can cause the frame rails to fail and cause an accident 6 3 12 11 Section 6 Body Mounting Hole Location Guidelines Holes must be located from the flange as indicated in Figure 6 7 They must be no closer than 2 inches 50 mm to each other Any unused holes must have the correct size bolts installed and torqued CAUTION properly Failure to do so can cause the frame rails to crack around the holes locations
62. atly 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 The following information is provided for temporary emergency repair Prior to welding a cracked frame rail the area should be beveled V d out to allow for a better weld To prevent spreading of the crack a 7 to 9 mm 1 4 in to 3 8 in dia hole should be drilled at the end of the crack Widen the crack along its full length by using two hack saw blades together When welding steel frames use the shielded arc method When welding aluminum frames use either the tungsten inert gas TIG or consumable electrode method Be sure to obtain full weld penetration along the entire length of the crack Precautions CAUTION Before welding disconnect the negative terminal battery cable Failure to comply may A result in equipment damage CAUTION Before welding disconnect the alternator terminals Failure to do so may result in damage to the voltage regulator and or alternator CAUTION To prevent damage to electrical equipment disconnect battery cables before arc welding on a truck and be sure that the welding ground lead is connected to the frame Bearings A and other parts will be damaged if current must pass through them in order to complete the circuit 7 5 12 11 Section 7 Frame Modifications Welding Precauti
63. bolts so they do not chafe on frame rail Failure to do so could result in premature wear of the U bolt or frame rail and cause an accident 12 11 6 4 Section 6 Body Mounting U Bolt Air Lines and Wiring Frame Rail Spacer Harness Hardwood or Steel NN Frame Rail 4 A LES Check Clearance Space for Air 4 Lines and Wiring U Bolt Spacer SSS N N NJ NEE FIGURE 6 8 Clearance Space for Air Lines and Cables N WARNING Do not notch frame rail flanges to force a U bolt fit Notched or damaged frame flanges could result in premature frame failure Use a larger size U bolt Use a hardwood spacer as shown in Figure 6 9 6 5 12 11 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 9 This provides a firm attaching point and helps prevent any relative fore or aft movement between the body and frame Refer to Figure 6 6 for mounting hole location guidelines Body Structure Frame Rail FIGURE 6 9 Example of Fishplate Bracket at Rear End of Body used with U Bolts HYBRID CLEARANCES Hybrid PEC ne C NS I
64. cific configuration used with horizontal In Series DPF SCR RH horizontal tailpipe RHUC rectangular fuel tank RHUC rectangular DEF tank and LHUC battery box Chart located on page 5 29 Fuel D21 is a T170 specific configuration used with horizontal In Series DPF SCR RH horizontal tailpipe RHUC 4 LHUC rectangular fuel tanks RHUC rectangular DEF tank and in cab battery box Chart located on page 5 30 E DPF SCR D22 is a T170 specific configuration used with horizontal Crossover DPF SCR LH horizontal tailpipe RHUC rectangular fuel tank RHUC rectangular DEF tank and LHUC battery box Chart located on page 5 31 i J Fuet pE Gat u DPFISCR D23 is a T170 specific configuration used with horizontal Crossover DPF SCR LH horizontal tailpipe RHUC amp LHUC rectangular fuel tanks RHUC rectangular DEF tank and in cab battery box Chart located on page 5 32 5 12 11 Section 5 Frame Layouts Hybrids H1 Hybrid configuration used with RHUC DPF SCR vertical SOC tailpipe RH BOC DEF tank with RH BOC fuel tank LHUC hybrid battery box and LH BOC Hybrid PEC Chart located on page 5 33 L DPFISCR H2 is a Hybrid configuration used with horizontal Crossover DPF SCR LH horizontal tailpipe RHUC rectangular fuel tank RHUC rectangular DEF tank LHUC hybrid battery box and LH BOC hybrid PEC Chart located on page 5 34 iha 81 L DPFISCR H3 is a Hybrid configuration used with horiz
65. ction 5 Frame Layouts D21 E3 E2 ELS I i o o 0 Dimension E1 BOC to DPF 27 2in Dimension E2 BOC to SCR 83 8in Dimension E3 BOC to Diffuser 103 0in Dimension F1 BOC to RH Fuel Tank 0 2in Dimension F2 BOC to LH Fuel Tank 6 4in This configuration is only available with a Rectangular Fuel Tank and Small DEF Tank 12 11 5 30 Section 5 Frame Layouts D22 Dimension B BOC to Battery Box 3 8in Dimension E1 BOC to DPF SCR 30in Dimension E3 BOC to Diffuser 49 2in Dimension F BOC to Fuel Tank 0 2in This configuration is only available with a Rectangular Fuel Tank and Small DEF Tank 5 31 12 11 Section 5 Frame Layouts D23 Dimension E1 Dimension E3 Dimension F1 Dimension F2 BOC to DPF SCR 30in BOC to Diffuser 49 2in BOC to RH Fuel Tank 0 2in BOC to LH Fuel Tank 6 4in EN A mm aaa O ans This configuration is only available with a Rectangular Fuel Tank and Small DEF Tank 12 11 5 32 Section 5 Frame Layouts H1 Hybrid Dimension E BOC to DPF SCR 0 0in Dimension H BOC to Hybrid Battery Box 2 8in TABLE 5 14 Dimension D Fuel Tank Size Dimension F BOC to DEF Tank in Fuel Tank BOC to Fuel Length in Tank in DEF Tank Size Diameter ank in Smal
66. ctor Turn Circle Analysis Please see Figure 3 1 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 Turing Radius Report Left Turn Radius Curb to Curb 36 1 ft N car wip NM Wi all fo wie all fr A i w i i po E gp Sc as pr j pe N a ee Bill to Wall Curb ich Curb i j WA L Truck T3 Series Conventional FULL TRUCK Wheel Base 26 in Axle Front Ade 10 000 ibs Dana Spicer E 10021 Weight 26000 lbs Tire FR Bridgestone R250F 295 175R22 5 HPR Wheel FR wheel KW Stylized ill 88767 22 5x8 25 Axle Spac ng Din Quote OTPO CO 005199588 FIGURE 3 1 Prospector Turn Circle Analysis Please consult your local Kenworth Dealer for this information as it is chassis specific 12 11 Section 3 Dimensions OVERALL DIMENSIONS This section includes drawings and charts of the following medium duty models T170 T270 and T370 On the pages that follow detail drawings show particular views of each vehicle with dimensions being in inches and mm They illustrate important measurements critical to designing bodies of all types See the Table of Contents at the begin ning of the manual to locate the drawing that you need Kenworth also offers dxf files and frame layouts of ordered chassis four weeks prior to build Please speak to your sales person to requ
67. data from the CECU via the CVSG data bus The mechanical gauges i e Suspension air pressure etc are driven directly from the air pressure Both types of gauges receive backlighting signals from the CECU via a 4 wire daisy chained jumper harness that links one gauge to another When the ignition key is first turned ON all the electronic 2 inch gauges will perform a calibration power on self test Note The mechanical CVSG do not perform a power on self test Power On Self Test e Ignition key turned ON e The gauge pointers move from pointing at zero counter clockwise to their mechanical limit approx 5 stay there for one second and go back to pointing at zero e Atthe same time all telltales in DWIM and main gauges are switched on together and then switched off together Additional CVSG gauge information body builders should be aware of e The CECU sends gauge information to CVSGs over a data link blue wire between the CECU and the gauge calle CVSG bus e CVSG gauges get their power from the CECU e Yellow Power wire 9 16 volts e White Ground return wire 8 5 12 11 12 11 Section 8 Electrical 4 way jumper harnesses link CVSG electronic gauges together by a daisy chain system Pin out is as follows Pin Color Function O O O 1 Bue Data backlighting for Electronic Gauges 2 Brow Backlighting for Mechanical Gauges 3 wie Re 4 Yelow Power Backlighting level for
68. ded test procedure Additionally the maximum voltage differential and the peak peak voltage differential between the engine ECM block ground stud and battery negative terminal may not exceed 500 mV under any combination of loads or operating conditions Installation of aftermarket transfer cases must address the vehicle speed sensor position The standard posi tion of the speed sensor is at the transmission tail shaft When a transfer case is added it is best to relocate the sensor to the axle side output shaft of the transfer case This is typically accomplished by adding a tone wheel into the driveline yoke assembly 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 The OAT sensor is located in the driver s side mirror assembly on Kenworth trucks and is shown in the figures below If the body builder needs to modify the mirror assembly in any way it is im portant the OAT sensor stay positioned on the mirror assembly Running the vehicle without the OAT sensor connected will cause the MIL lamp to illuminate If needed a replacement sensor can be ordered from your Kenworth dealer FIGURE 2 3 West Coast Mirror OAT sensor located in overmold on mirror harness 2
69. e FIGURE 4 13 Isometric view of Horizontal DPF and SCR with Horizontal Tailpipe FIGURE 4 14 Top view of Horizontal DPF and SCR with Horizontal Tailpipe 12 11 4 12 FIGURE 4 16 Back view of Horizontal DPF and SCR with Horizontal Tailpipe 4 13 12 11 Horizontal Series DPF and SCR with Horizontal Tailpipe FIGURE 4 18 Top view of Horizontal Series DPF and SCR with Horizontal Tailpipe 12 11 4 14 FIGURE 4 20 Back view of Horizontal Series DPF and SCR with Horizontal Tailpipe 4 15 12 11 Vertical Independent DPF and SCR FIGURE 4 21 Isometric view of Vertical Independent DPF and SCR FIGURE 4 22 Top view of Vertical Independent DPF and SCR 12 11 4 16 FIGURE 4 23 Right view of Vertical Independent DPF and SCR FIGURE 4 24 Back view of Vertical Independent DPF and SCR 4 17 12 11 Section 4 Exhaust amp 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 TABLE 4 1 Stack Height DPF mounted independent 76 5 back of cab Tailpipes side of cab Mount DPF RH under Tailpipes back of cab Mount DPF RH under DIMENSION B IS THE TAILPIPE LENGTH TABLE 4 2 Unladen Stack Height For approximate unladen stack height 12 000 pound springs use the following frame heights Top of
70. e 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 See Figure 8 30 below for wiring harness connector pin outs Adding Electrical Options WARNING 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 AN applications Failure to properly program the engine or wire these circuits could cause an accident TERMINAL INFORMATION i i bfi i AT la LA It LABEL Pi24 REMOTE PTO THROTTLE CONTR FIGURE 8 29 PACCAR PX 6 and PX 8 12 11 8 34 Section 8 Electrical TABLE 8 10 Multifunction Engine Connector KW mPDC in Cab Number Color Gauge Location Description Rating Nouse nome None None Noo 1 ll Nous nome None None None 2 T common Retun 19 GANG115 Green 8 3 Th aa e pee a je T T Signal PTO On Off 39 GRA3511 Gray 18 5 f o o o Remote Throttle Enable None GRA3143 Gray 18 Jo ocho Engine Ground None WHT1513 white 18 8 Supply 5V 40 GRA3143 Gry 18 12 o Remote Throttle Enable Circuit runs from Pin6 of MF Eng Connector P124 to Firewall 47 way connector pin 11 P103
71. es See Table 8 12 for the general categories TABLE 8 12 Wire Number General Categories To identify similarly labeled wires a suffix can be added For example YEL2950 1 would be a yellow wire indicating it is activated power The 2950 indicates the load in this case fog lamps the 1 is a suffix used to differentiate similarly labeled circuit 12 11 8 38 Section 8 Electrical DATA BUS WIRE COLORS Data Bus wiring has its own color scheme as follows Data bus high side wires VIO J1587 amp J1708 ORG J1922 YEL J1939 RED OEM GRY CAN BLU Single wire bus Data bus low side wires GRN All Data bus low side wires TRAILER BODY BUILDER WIRE COLORS Trailer Wires have their own wiring scheme as follows TABLE 8 13 Trailer Wire Colors Stop lamps Light green Right turn lamps Light blue ABS power Auxiliary To identify specific circuits contact your local Kenworth Dealer 8 39 12 11 Section 8 Electrical TRAILER CABLE CONNECTIONS Kenworth offers may different trailer connection options The SAE J560 connector is shown in Figure 8 33 the ISO 3731 connector is shown in Figure 8 34 FIGURE 8 32 SAE J560 Trailer Connector FIGURE 8 33 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 Your local dealer
72. est this feature when specifying your chassis 107 7 72 2 2735 1834 395 370 111 940 282 H Pa 8 f 76 7 451 ar 1948 Highest Point on Roof 1941 45 8 Highest Point 1164 a in Dip of Roof Bottom of Frame ra Rail Hange Fe ee m aus Bil dl 864 ka 794 n9 2010 ph 93 9 96 2385 2440 Dimensions are typical Measurements will vary with axle brake drum tires and wheel selections FIGURE 3 2 T170 T270 T370 Overall Height and Length Dimensions inches mm 3 3 12 11 Section 3 Dimensions TABLE 3 3 Hydraulic Brake Vehicles T170 Single Rear Axle Overall Fore Aft Dimensions inches mm WB OM Fe A 153 3886 235 9 5992 55 1397 72 1829 162 4115 240 9 6119 55 1397 77 1956 TABLE 3 4 Hydraulic Brake Vehicles T270 370 with Single Rear Axle Overall Fore Aft Dimensions inches mm 153 3886 235 9 5992 55 1397 72 1829 162 4115 240 9 6119 55 1397 77 1956 176 4470 280 9 7135 64 1626 108 2743 236 5994 376 9 9573 100 2540 168 4267 254 6452 186 4724 Air Brake Vehicles T270 T370 wheelbases for Single Rear Axle begin at 140 inches Tandem Rear axles begin at 175 inches Wheelbase on Air Brake vehicles available in 1 inch increments 12 11 3 4 Section 3 Dimensions DETAIL VIEWS Top of Cab Roof Mounted Options T270 370 DUAL 23 REC
73. eters 118 DEF Pressure hose must include a trap in the routing if Dosing Module is below the highest point of the Supply Module See Figure 4 8 on page 4 8 4 5 12 11 Section 4 Exhaust amp Aftertreatment Horizontal Series DPF and SCR with Rectangular Small or Medium DEF Tanks FIGURE 4 5 Horizontal Series Exhaust with Small or Medium Tanks The height differential between the supply module and dosing module cannot exceed one meter The supply module is integrated into the DEF tank assembly separation of the module frm the tank is not allowed When relocating the components the maximum pressure DEF hose length from Supply module to Dosing Module is 3 meters 1187 DEF Pressure hose must include a trap in the routing if Dosing Module is below the highest point of the Supply Module See Figure 4 8 on page 4 8 Vertical DPF and SCR with Rectangular Small or Medium DEF Tanks W 1 0m Height Differential FIGURE 4 6 Vertical Exhaust with Small or Medium Tanks 12 11 4 6 Section 4 Exhaust amp 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 Horizontal Crossover Exhaust System
74. g with Wood and Fabricated Spacers 6 4 FIGURE 6 8 Clearance Space for Air Lines and Cables 0a 6 5 FIGURE 6 9 Example of Fishplate Bracket at Rear End of Body used with U Bolts 6 6 FIGURE 6 10 Clearance zones around Hybrid Power Electronics Carrier PEC 6 6 FIGURE 6 11 Clearance zones around the Hybrid Battery Box located LH Under Cab 6 7 FIGURE 7 1 Detail of Frame Extension and Joint Welding 0 00 eens 7 2 FIGURE 7 2 Frame Insert 22 084 ARA 2 ar es Lee eee eee eee eens ana 7 2 FIGURE 7 3 Comparison of Original Shortened and Extended Wheelbases 7 4 FIGURE 7 4 Crossmember Added when Distance Exceeds 60 inches 1524 mm 7 4 FIGURE 7 5 Heat Treated Frame Rail Warning 0 0 eee eee eens 7 5 FIGURE 8 1 J1939 Data link Wiring 0 0 ee eee ee eee nes 8 1 FIGURE 8 2 Kenworihi6 Cab Dash 22222 doce tees ee eee cet Seed Sancta toa gt a oes 8 2 FIGURE 8 3 Diesel Exhaust Fluid Gauge 2 nnna teen nes 8 2 FIGURE 8 4 Multiplexed Instrumentation Block Diagram a 8 3 FIGURE 8 5 CECU Location n eas ee unseren net 8 4 FIGURE 8 6 Main Instrument Panel a 8 5 FIGURE 8 7 Instrumentation Harness Interface Diagram 22m 0c ce ees 8 7 FIGURE 8 8 Firewall Air Junction Block view from inside of cab 0 0 0 ees 8 8 FIGURE 8 9 Air Fi
75. h The gauge will then need to be activated Your local Kenworth dealer can easily activate the gauge using Kenworth s Electronic Ser vice Analyst ESA Connector Reference Connector Location FIREWALL BEHIND RH CVSG GAUGE PANEL BEHIND RH CVSG GAUGE PANEL BEHIND LH CVSG GAUGE PANEL INSIDE BATTERY BOX BELOW PD BOX ENG SIDE OF FIREWALL Outside Air MAIN TRANSMISSION OIL TEMP SENSOR Temp AUX TRANSMISSION OIL TEMP SENSOR Sensor INSIDE LH FRAME NEAR REAR CAB SUPT C M PRIMARY FUEL TANK FUEL FILTER Primary Air Pressure Sensor Secondary Air Pressure Sensor Brake Application Sensor Sensors Mounted On Air Junction Block inside Dash LH SIDE OF ENGINE NEAR STARTER Air Filter Restriction Fuel Filter Restriction Fuel Level Sensor Sensor amp Denotes Harness Connector e Denotes Firewall Pass Through Grommet FIGURE 8 7 Instrumentation Harness Interface Diagram 8 7 12 11 Section 8 Electrical The following diagrams show the location of sensors on the firewall junction block This is to aid in locating these sensors Primary Air sensor is located on the primary air block the Secondary Air Sensor is located on the secondary air block the Application Air Sensor is located by the brake application block See Figure 8 8 The Air Filter Restriction Sensor is located near the brake application sensor see Figure 8 9 The Fuel Filter Restriction Sensor is located near the fuel
76. hassis See Figure 6 3 Body Subframe Rail Chassis Frame Rail Sill FIGURE 6 3 Spacer Between Frame Sill and Body Rail Rubber or Plastic Brackets When mounting a body to the chassis with brackets we recommend designs that offer limited amount of relative move ment bolted securely but not too rigid Brackets should allow for slight movement between the body and the chassis For instance Figure 6 4 shows a high compression spring between the bolt and the bracket vy n Spring ee Rubber j IT Spacer i nA Hi ki i f N Il Ti FIGURE 6 4 High Compression Spring FIGURE 6 5 Rubber Spacer Between Brackets Between the Mounting Bolt and Upper Bracket Another possibility is mounting a rubber spacer between the brackets See Figure 6 5 These designs will allow relative movement between the body and the chassis during extreme frame racking situations Extreme frame racking with rigid mountings could cause damage to the body This is particularly true with tanker Wastallations 6 2 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 6 The hole diameter should not exceed the bolt diameter by more than 060 inches 1 5 mm Upper Frame A or B Equal to or Flange Gre
77. he 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 AN 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 When adding an electrical circuit you must know the current capacity amperes of each circuit The capacity of the existing system in the chassis must be enough to power the additional circuit The new circuit will re quire a certain amount of power to operate so the existing battery or alternator power source must have the capacity to provide additional power or the new circuit will not function properly Check the current ampere demand of the circuit to be added Compare it to the current capacity of the circuit you are connecting into The current carrying capacity of the wires controls switches and circuit breakers that provide current to the circuit must be equal to or greater than the demand of the added circuit otherwise these components may not work properly See Table 8 7 for relevant circuit information Additional Spare Circuits for Wiring Depending on options ordered for the truck there may be up to five spare circuits with labeled connectors available in the dash harness See Table 8 7 for circuit information circuit CAPACITY connector b
78. heelbase DRILLING RAILS Location and Hole Pattern If holes need to be drilled to attach anything to the rail see SECTION 6 BODY MOUNTING for more information Follow the general spacing and hole location guidelines on Page 6 4 Figure 6 7 WARNING When mounting a body to the chassis DO NOT drill holes in the upper or lower flange of the frame rail If the frame rail flanges are modified or dam aged the rail could fail prematurely and cause an accident Mount the body using body mounting brackets or U bolts AN WARNING Do not drill new holes any closer than 2 inches 50 mm to existing holes Frame drilling affects the strength of the rails and if not done properly can cause the frame rails to fail and cause an accident A CAUTION An appropriately sized bolt and nut must be installed and torqued properly in all unused frame holes Failure to do so could result in frame crack initiation around the hole A CAUTION Use care when drilling the frame web so the wires and air lines routed inside the rail are not damaged Failure to do so could lead to equipment damage and cause an inoperable electrical or air system circuit A CAUTION Never use a torch to make holes in the rail Use the appropriate diameter drill bit Heat from a torch will affect the material properties of the frame rail and could result in frame rail cracks A CAUTION Hole diameter should not exceed the bolt diameter by more than 060 inches 1 5 mm
79. hts either on the standard card or the editable card locate the wiring connections on pigtail connectors behind the right hand side gauge panel The wires will be labeled and tagged with position numbers For example for position 1 the breakout label will be green and have the following text TELLTALE POS 1 The color of the tag corresponds to the color of the light When these circuits are either grounded or powered the light in the dash will turn on All cards come with standard editable telltale lights even if the chassis you have was not ordered with related components 8 15 12 11 Section 8 Electrical The standard trays are shown above in Figure 8 11 Editable trays are also available from your local Kenworth dealer The left and right trays are shown in Figure 8 12 below A u 0 75 _ 0 5bO a a aL 0 ag section AA A N FIGURE 8 12 Blank Telltale Tray 12 11 8 16 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 13 below a DO NOT SHIFT Eg De PARK ENGINE BRAKE PARK BRAKE REFRIGERATOR CHECK FLUIDS DON T SHIFT CHECK TRANSMISSION BLANK 53 6060 001 S53 6060 002 S53 6060 003 553 6060 004 S53 6060 005 S53 6060 006 53 6060 000 ED pi C4 Fa KINGPIN LOCK FUEL HEATER MESSAGE WAITING ALTERNATOR FAS
80. i AF Da l i lan Aa W SE Er BAI I BP cm ame 2 A L MA T L 1 i An A B C D FIGURE 3 7 T170 Crossmember Location TABLE 3 6 T170 Cross member Location measured from front axle centerlines inches mm MB a CB CDE 101 8 2585 YY 1 For without a square end of frame crossmember with an AF 162 101 8 2585 Y range of 80 2032 to 125 3175 a crossmember is installed at 162 101 8 2885 Y E WB4 64 4 1636mm 176 101 8 2585 Y 176 Yi 2 For AF range of 126 3200 to 173 4394 a 2nd crossmember is 101 8 2585 PY gt of installed at E WB 112 4 2855 mm Y SPL100 Driveline center bearing CB is mounted on this cross member 12 11 3 8 Section 3 Dimensions COMPONENTS This section includes detail drawings and charts showing particular vehicle components with dimensions in inches and millimeters They illustrate important measurements critical to designing bodies of all types See the Table of Contents at the beginning of the manual to locate the drawing that you need Frame Rail Configurations T170 270 370 Note Bottom of frame rail is a reference point that you can use to determine estimated heights of components and ground clearances td W Rail Heat Treated Optional Insert Heat Treated Shown FIGURE 3 8 Frame Rail Dimensions and Properties inches mm TABLE 3 7 Frame Rail Properties Frame Rail or Insert KER nect
81. iftgate manufacturer s installation instructions Mount circuit breaker on this panel Connect ring terminal breakout Ps ee on item 17 to circuit breaker Nag Ze oo SEA Shorten breakout to length as required P ci he and install item 18 as needed a ee LY y LX B FIGURE 8 26 Liftgate Circuit Breaker Inside Battery Box 12 11 8 32 Section 8 Electrical 270 AMP ALTERNATOR RECOMMENDED HOOKUP PE O ID Tam a E7 S pa i a i Sam mg ae P ba RR AN NI Paa o AIN KO N Jad AN TA i PALI NN er x i a GAN 2 NAA AD NSS u Al BAL 31 Pa SSO AHAB US UL R Be Da FIGURE 8 27 P27 6180 Fuse Holder FIGURE 8 28 Battery Harness Jumper Part No P92 2683 100000 e Use three batteries e Use P27 6180 150 Mega Fuse Mount in Battery Box to provide Body Power e Use P92 2683 10000 to provide power from batteries to Mega Fuse e Tie Body Ground circuits to additional ground stud located on the lower outboard driver side of firewall at cover plate Engine Connections Electronic engines have the ability to send and receive control and warning signals from the components on the chassis and body Consult the appropriate body builder manual before making connections to the engine electronic control unit ECU or to other electronic engine components 8 33 12 11 Section 8 Electrical REMOTE PTO THROTTLE HARNESS This option provides a connection from the engin
82. in cab battery box Chart located on page 5 14 12 11 5 4 Section 5 Frame Layouts S OPFPFISCR D6 is a Clear BOC configuration used with RHUC DPF SCR vertical SOC tailpipe LHUC 24 5 x 56gal fuel tank with LHUC Small DEF tank and in cab battery box Chart located on page 5 15 DPFISCR D7 is used with horizontal Crossover DPF SCR LH horizontal tailpipe LHUC and RHUC cylindrical fuel tanks RH BOC cylindrical DEF tank and in cab battery box Chart located on page 5 16 DPHSCR D8 is used with horizontal Crossover DPF SCR LH horizontal tailpipe RHUC cylindrical fuel tank RH BOC cylindrical DEF tank and LHUC battery box Chart located on page 5 17 L DPFISCR D9 is used with horizontal Crossover DPF SCR LH horizontal tailpipe RHUC rectangular fuel tank RHUC rectangular DEF tank and LHUC battery box Chart located on page 5 18 DPFISCR D10 is used with horizontal Crossover DPF SCR LH horizontal tailpipe RHUC amp LHUC rectangular fuel tanks RHUC rectangular DEF tank and in cab battery box Chart located on page 5 19 D11 is used with Vertical Vertical DPF SCR LH vertical tailpipe LHUC and RHUC cylindrical fuel tanks RH BOC cylindri cal DEF tank and LH BOC cantilever battery box Chart located on page 5 20 5 5 12 11 Section 5 Frame Layouts D12 is used with Vertical Vertical DPF SCR LH vertical tailpipe RHUC cylindrical fuel tank RH BOC cylindrical DEF tank and LHU
83. ing the tank Failure to follow the guidelines completely and accurately may result in engine shutdown situations Kenworth offers a variety of DEF tank sizes to meet every application The DEF tank volume is regulated by the E PA Kenworth advises against modifying the tank volume after the truck has been delivered from the factory e Total DEF capacity must meet or exceed 6 of the usable fuel capacity on the truck The calcula tion to determine DEF capacity is Minimum DEF Tank Volume Useable Fuel Capacity gal x 0 06 Example For a truck with 100 useable gallons of fuel the equation is DEF required 100 x 0 06 6 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 In addition the Medium Duty Rectangular DEF Tank that is used to meet clear back of cab requirements cannot be relocated 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 DEF piping relative heights In order to ensure proper functionality of DEF system the height differences in the guidelines below must be followed during line routing and component placemen
84. inside of frame flanges where necessary Do not extend the harnesses The DPF the SCR catalyst or their mounting may not be modified The NO sensor may not been relocated or altered in any way Exhaust pipes used for tailpipes stacks must be properly sized and must prevent water from entering the exhaust system Ensure adequate clearance between the exhaust and body panels hoses and wire harnesses The body in the vicinity of the DPF must be able to withstand temperatures up to 400 C 750 F Do not add thermal insulation to the external surface of the DPF The SCR water drain hole may not be blocked Allow adequate clearance 25mm 1 inch for servicing the DPF sensors wiring and clamped joints Drainage may not come in contact with the DPF SCR catalyst sensors or wiring Allow sufficient clearance for removing sensors from DPF Thermistors require four inches Other sensors require one inch Wiring should be routed protected from heat and properly secured to prevent damage from other components The exhaust system from an auxiliary power unit APU must not be connected to any part of the vehicle after treatment system or vehicle tail pipe Cooling System The following are highlights of some of the more common or critical aspects of this system Modifications to the design or locations of fill or vent lines heater or defroster core and surge tank are not recommended With the exception of post thermostat installation addit
85. ion RBM per Rail Weight per Inch Height H Flange Width Thickness T 1 2 a Ibs Inch per Pair Ibs inch mm W inch mm inch mm 9 7 8 Frame Rail T170 T270 1 251 767 9 88 251 3 46 87 8 0 25 6 4 10 5 8 Frame Rail T270 T370 1 776 000 10 63 270 3 46 87 8 0 31 7 9 10 3 4 Frame Rail T270 T370 2 132 000 10 75 273 3 46 87 8 0 38 9 5 73 0 6 4 i 9 7 8 Insert ONLY for 10 518 Frame Rail 2 3 7279 7370 en er ee 10 5 8 Frame Rail with To70 T370 23 4 2 925 000 4 96 10 63 270 3 46 87 8 0 56 14 3 9 7 8 Insert 10 3 4 Frame Rail with To70 T370 27 4 3 281 000 5 50 10 75 273 3 46 87 8 0 63 15 9 9 7 8 Insert Frame rails and inserts are heat treated 1 Yield Strength 120 000 PSI 2 3 Full inserts start ahead of the steering gear and end at the end of frame 4 Partial inserts start 25 inches behind the center line of the front axle and end at the end of the frame 3 9 12 11 Section 3 Dimensions Battery Box T270 370 Parallel Battery Box LH Under Cab for air braked truck or hydraulic braked truck with an accessory air system Rear View FIGURE 3 9 T270 370 Battery Box Measurements inches mm TABLE 3 8 T270 370 Battery Box Measurements inches mm A inch mm B inch mm C inch mm D inch mm Hybrid 33 4 848 6 7 170 9 5 241 15 8 401 Non Hybrid 33 4 848 8 5 215 9 3 236 13 4 354 Battery Tool Box T270 370 Paral
86. ional accessories plumbed into the engine cooling system are not permitted and may void vehicle warranty Coolant level sensor tampering will void warranty When installing auxiliary equipment in front of the vehicle or additional heat exchangers ensure that adequate air flow is available to the vehicle cooling system Refer to engine manufacturer application guide lines for further detail When installing FEPTO drivelines the lower radiator anti recirculation seal must be retained with FEPTO driveline clearance modification only Changes made to cooling fan circuit and controls are not allowed with the exception of AC minimum fan on time parameter See owner s manual for appropriate winter front usage 2 5 12 11 Section 2 Safety amp Compliance Electrical System The following are highlights of some of the more common or critical aspects of this system 12 11 Electrical harnesses providing battery power and electronic control signals to engine and emissions control vehicle OBD components including datalinks may not be spliced These emissions control vehicle OBD components include the following e throttle pedal e vehicle speed sensor e after treatment wiring If the alternator or battery is substituted it must meet the requirements of the engine manufacture s guide lines This includes alternator ground voltage drop and alternator ground cable effectiveness See the engine manufacture s guidelines for recommen
87. ions 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 2 3 12 11 Section 2 Safety amp Compliance Fuel System The following are highlights of some of the more common or critical aspects of this system The overall system restriction may not exceed the restriction limitations set forth by the engine manufacturer for both supply and return Ensure that fuel lines are not pinched or can potentially be damaged when installed between body and frame Fuel lines must be routed and secured without dips or sags There must be easy access to filter s and fill cap The tank vent may not obstructed Added accessories heaters generators cannot introduce air into system Fuel tank must be located so that the full level is not above cylinder head Ultra Low Sulfur Fuel Only labels must be present on the dash and fuel fill Modification of the pressure side secondary filter and plumbing is not allowed without engine manufacturer approval Body installation of fuel tank or routing of lines must not cause significant increase in fuel temperature Fuel hoses shall meet or exceed OEM supplied hose material construction specifications Compressed Air System The following are highlights of some of the more common or critical aspects of this system Air system modification must meet applicable FMVSS regulations C
88. ires shall be butterfly clamped to the air compressor discharge hose and cov ered with convoluted tubing at the clamp point use high temperature clamps on the compressor hose Bundles HD mount and tie strap or clamp shall be located at intervals not to exceed 14 inches 356 mm along the bundle Regular tie straps shall be located at intervals not to exceed 7 inches 178 mm between HD mount or clamps Extra tie straps may be used as needed to contain the hoses and wires in the bundle Routing of Wires and Hoses near Moving Components Wires and Hoses shall be routed away from moving components such as fans shackle links drivelines steering linkages etc so that there is at least 0 5 inches 12 7 mm clearance when the component is operating at its maximum travel limits A minimum clearance of 1 0 inchs 25 4 shall be maintained between steering axle tires and associated rotating parts in all positions and routed components such as hoses oil lines wires pipes etc 9 3 12 11 Section 9 Routing Routing of Wires and Hoses near Exhaust System TABLE 9 1 Exhaust System Clearance Shielded Unshielded Coolant hoses HVAC hoses and tubing and electrical wires within 15 of the turbo and or over 15 from the turbo 2 minimum 3 minimum Fuel hoses within 15 of the turbo n a 4 minimum over 15 from the turbo 2 minimum 3 minimum Fuel tanks and hydraulic tanks crossing tank 2 minimum
89. is located either on the driver s door edge or door frame See Figure A 2 Chassis Number Locations The Chassis Number comprises the last six characters of the VIN The vehicle chassis number is shown in multiple locations Left side of cab lower right corner of door frame stamped plate Tire Rim and Weight Rating Data label Major Components and Weights label Noise Emission label Paint Identification label A 1 12 11 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 Quantity and location of labels may differ based on Complete Incomplete vehicle and Single Dual certification Labels Tire Rim amp Weight Rating Certification Major Components amp Weights Paint Canadian Safety Mark Canadian registry only U S EPA Noise Patent and others Note Final Stage Ay Manufacturer Label to be installed by Final Stage A x Manufacturer on driver s Aq S door edge or driver s door frame Chassis Serial Number FIGURE A 2 Drivers Door and Door Frame Labels Tire Rim and Weight Rating Data Label The Tire Rim and Weight Rating Data Label is used in conjunction with the Inco
90. it runs from Pin 6 of MF Eng Connector P124 to Firewall 47 way connector pin 11 P103 WARNING To prevent emissions functions of the engine from modifying torque or speed during PTO operation be sure to connect the PTO sensor wire to the appropriate engine AN controller input 12 11 8 36 Section 8 Electrical T il D HE Ta FE et ICAUTION REFER TO OPERATORS MANUAL PRIOR TO SERVICING m m an OA KEY SWITCH BATT PWR 0A DRL MODULE BATT 4 WA FLOODLAMP SWITCH 0A RADIO MEMORY BATT WA DIAGNOSTIC PWR 20A AFTERTREAT LINE HTR 25A FLASHER BATT 170A WIPER SWITCH HVAC PWR CECU ACC CB ACC PWR RADIO ACC PWR A SPARE ACC SWITCH 1 TAILPARK LAMP CECU TRLR BETAL 5 A LH HEATED MIRROR Fis 10A RH HEATED MIRROR F20 20A TATION ACC F21 10A MARKER LAMPS FIGURE 8 31 Cab Load Center mPDC 8 37 12 11 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 RED ProiscedBaten Power one laWacosian Power BRN inacatorNumaton Beckghng aN Sensor commen ror connected to GND Each wire has at a minimum a 7 character label the first three characters are the circuits color as listed above the re maining four are numerical which relate to the load the wire servic
91. l 759G grease made by William F Nye Inc New Bedford MA per R414 558 Don t bend wires or use tie straps within 3 inches 75 mm of connected wire connectors or plugs Wires in Bundles Electrical wires other than the exceptions covered below running parallel with air or coolant hose bundles may be in cluded in the bundle if they are isolated from the hoses with a covering of convoluted plastic tubing EXCEPTIONS Battery cables including jump start cables may be bundled with or tied to the charging wire harness They shall not be bundled with or tied directly to any other components including hoses wires or bundles They shall be separated from other routed components using butterfly ties at intervals not exceeding 14 inches 856 mm Battery strap W84 1000 tie down shall be used without exception to secure battery cables to frame mounted or other major component e g engine tmsn etc mounted standoffs at intervals not exceeding 14 inches 356 mm The positive battery cable shall be covered with convoluted plastic tubing from terminal to terminal 110 220 volt wires for engine heaters oil pan heaters transmission oil heaters and battery pad warm ers shall not be included in any hose wire bundle with a fuel hose Individual heater wires not ina bundle shall be separated from other components by using butterfly clamps or butterfly ties at intervals not exceeding 14 inches 856 mm Heater wires with a secondary coveri
92. l spacings please contact your local Kenworth dealer KENWORTH AG210L SINGLE REAR AXLE i 33 4 js 30 1 RIDE HEIGHT 6 5 TABLE 3 14 Optional Kenworth Single Suspension 00000 Rating Axle Spacing Laden Ride Height Unladen Ride Height Kenworth AG210L_ 3 22k TT 3 19 12 11 Section 3 Dimensions KENWORTH AG400L TANDEM REAR AXLE 59 4 di AXLE SPACING TABLE 3 15 Optional Kenworth Tandem Suspension nn Rating Axle Spacing Laden Ride Height Unladen Ride Height Kenworth AG400L 12 11 3 20 Section 3 Dimensions REYCO 79KB SINGLE REAR AXLE 30 2 755 a 30 1 765 28 7 728 _ 29 0 736 BOF RIDE HEIGHT Optional Reyco 79KB Suspensions TABLE 3 16 Rear Suspension Options Suspension Type ot Axle Spacing Laden Ride Height Unladen Ride Height Reyco 79KB single 4x2 13 5K Reyco 79KB nga 4x2 Pej TEKS al 62 ox ln Penn rung me a Peyo 7OKB ange 2K e o Peyo 7oKB single x k AS TE Reoyo 7oKB single a K O o SL ET 3 21 12 11 Section 3 Dimensions REYCO 102 TANDEM REAR AXLE AXLE SPACING e Optional Reyco 102 Suspension TABLE 3 17 Rear Suspension Options Suspension Type Axle S
93. lel Battery Box LH Under Cab for Hydraulic braked Truck without an Accessory Air System or Tool Box Under Cab lt U lt gt FIGURE 3 10 T270 370 Battery Tool Box Measurements inches mm TABLE 3 9 T270 370 Battery Box Toolbox Dimensions inches mm A inch mm B inch mm C inch mm Non Hybrid Battery Box 8 5 215 9 4 239 33 4 848 Hybrid Battery Box 8 5 215 9 5 241 6 33 4 848 9 3 236 9 2 233 33 848 12 11 3 10 Section 3 Dimensions 22 inch Fuel Tanks T270 370 Round Fuel Tank Mounting REAR VIEW REAR VIEW LEFT SIDE BEHIND CAB RIGHT SIDE UNDER CAB FIGURE 3 11 T270 370 22 Fuel Tank Mounting Measurements inches mm 22 Fuel Tank Height A inch mm 16 3 416 Raised 1 Inch 15 3 389 24 5 inch Fuel Tanks T270 370 29 0 790 18 2 T 462 462 32 1 815 NO STEPS WITH STEPS FIGURE 3 12 T270 370 24 5 Fuel Tank Mounting Measurements With and without steps inches mm 3 11 12 11 Section 3 Dimensions Rectangular Fuel Tank Rectangular Fuel Tank Mounting 30 7 780 FIGURE 3 13 Rectangular Fuel Tank Measurements inches mm 12 11 3 12 Section 3 Dimensions Battery Box T270 370 Cantilever Battery B
94. llon Usable Volume 18 GALLON USABLE VOLUME 189 FIGURE 5 1 DEF Tank Dimensions TABLE 5 3 DEF Tanks Systems Beserisilen Usable Volume Fuel Tank p Gallons Diameter Small DEF Tank Medium DEF Tank Rectangular DEF Tank 66 NA see Figure 5 1 see Figure 5 1 Acronyms Index Throughout the Frame Layout section you will see these acronyms They are defined here to help you decode the layouts Back Of Cab CBOC Clear Back Of Cab LHUC Left Hand Under Cab RHUC Right Hand Under Cab Side Of Cab Diesel Exhaust Fluid DSOC Dual Side Of Cab 5 3 12 11 Section 5 Frame Layouts FRAME LAYOUT INDEX D1 is used with RHUC DPF SCR vertical SOC tailpipe RH BOC fuel tank LHUC battery box and LH BOC DEF tank Chart located on page 5 10 Fuel D2 is used with RHUC DPF SCR vertical SOC tailpipe LH BOC fuel tank LHUC battery box and RH BOC DEF tank Chart located on page 5 11 D3 is used with RHUC DPF SCR vertical SOC tailpipe LHUC cylindrical fuel tank LH BOC cantilever battery box and RH BOC cylindrical DEF tank Chart located on page 5 12 D4 is used with RHUC DPF SCR vertical SOC tailpipe LHUC rectangular fuel tank with LHUC rectangular DEF tank and LH BOC cantilever battery box Chart located on page 5 13 D5 is used with RHUC DPF SCR vertical SOC tailpipe LHUC rectangular fuel tank with LHUC rectangular DEF tank and
95. lltales behind the right hand cluster 12 11 8 14 Section 8 Electrical TABLE 8 1 Telltales Position and Color Position Standard Function Use Light Color Editable or Fixed Illuminates to Indicate PTO is Engaged Editable Check Transmission Illuminates During Transmission Fault Editable 3 Left Turn Arrow Iluminates to Indicate Left Trun Signal is Green Fixed Applied 4 Wait To Start Iluminates when Driver needs to Wait Before Yellow Fixed Starting Engine 5 Brake Fail illuminates When the Hydraulic Brake ECU Editable Determines Fault High Beam IIluminates to Indicate High Beam Lights are Blue Fixed Applied 7 Malfunction Indicator Illuminates to Indicate a Malfunction in Yellow Fixed Lamp MIL Emissions System After 2013 8 Fasten Seat Belt Used with Seatbelt Warning Option Red Fied Park Brake Iluminates to Indicate the Park Brake is Fixed Applied Engine Brake illuminates to Indicate Engine Brake Active Regeneration Note Only the positions labeled as editable in the chart above can be changed You must apply the il standard icons on the editable card on all the positions that read fixed The wait to start and malfunction indicator lamp are part of the emission control system They must not be removed or altered If a connector is already connected to the editable Position in the IP harness that Position cannot be used for another function In order to activate the editable lig
96. lter Restriction Sensor on Firewall Air Junction Block view from inside of cab 8 8 FIGURE 8 10 Fuel Filter Restriction Pressure Gauge Sensor Location typical 8 9 FIGURE 8 11 Telltale Symbol Standard Cards cee nes 8 14 FIGURE 8 12 Blank Telltale Tray eee nent eens 8 16 FIGURE 8 13 Telltale Icons continued on page 8 18 sneen nn ken ee 8 17 FIGURE 8 14 Spare switches wired to Power eee eee eae 8 19 FIGURE 8 15 Optional SWIICNES erent osinn es Seabee Segue Her aaa 8 20 FIGURE 8 16 Switch and Wiring for Customer Installed Beacon Lamp in the Chassis Harness 8 21 FIGURE 8 17 Switch and Wiring for Customer Installed Beacon Lamp in the IP Harness 8 21 FIGURE 8 18 Switch and Wiring for Customer Installed Flood Lamp in the Chassis Harness 8 22 FIGURE 8 19 Location of Standard Body Harness Connection 0 0 cece eee ee 8 24 FIGURE 8 20 Body Junction Harness 0c ee eens 8 25 FIGURE 8 21 ePTO Harness Location eee etna 8 28 FIGURE 8 22 Location of Body Builder Distribution Module on Hybrid 0 00 c eee eee 8 29 FIGURE 8 23 Detail of Body Builder Power Distribution Module 0 0 0 eee eee 8 29 FIGURE 8 24 Adding a Third Battery 0 ee eee teens 8 30 FIGURE 8 25 Adding a Third Battery ce eee tenes 8 31 FIGURE 8 26 Liftgate Circuit Breaker Inside Battery Box
97. mplete Vehicle Certification Label on Incomplete Vehicles It contains chassis serial number and the following information e GVWR Gross Vehicle Weight Rating e GAWR FRONT and REAR Gross Axle Weight Ratings for Front and Rear Axle e TIRE RIM SIZES AND INFLATION PRESSURES Tire Rim Sizes and Cold Pressure Minimums HI Note GVWR is the TOTAL WEIGHT the vehicle is designed to carry This includes the weight of the empty vehicle loading platform occupants fuel and any load Incomplete Vehicle Certification Label The Incomplete Vehicle Certification Label contains the chassis VIN date of manufacture and listing of applicable motor vehicle safety standards Components and Weights Label The Major Components and Weights Label includes chassis weight and gross weight information as well as model and serial numbers for the vehicle engine transmission and axles 12 11 A 2 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 This label is located either underneath the dash to the left of the steering column support inside the glovebox or
98. n the rear of the PEC The temperature of the air entering the PEC must be the same temperature as the ambient air temperature thus ducting or otherwise providing intake air that has been heated above ambient temperature is not permitted Service Access Adequate access must be maintained to allow for service of the air cleaner and easy access to the service switch on the front side of the PEC as well as removal of the PEC unit for service Warning The PEC is not to be used or installed in a manner susceptible to being used as a step or seat HAZARDOUS VOLTAGE To reduce the risk of possible serious injury Shock Burn or Death Components marked with High Voltage should be avoided Service must be performed by qualified personnel only 12 11 6 8 Section 6 Body Mounting Page Intentionally Left Blank 6 9 12 11 Section 7 Frame Modifications FRAME MODIFICATIONS Introduction The T170 T270 T370 offers multiple wheelbase configurations from the factory So in most cases frame modifications to produce a particular wheelbase should not be necessary However some installations may require slight modifications while other installations will require extensive modifications For example an existing dealer stock chassis may need to have the wheelbase changed to better fit a customer s applica tion The modifications may be as simple as shortening or lengthening the frame cutoff or they may be as complex as changing the w
99. nd Theft Prevention Standards if applicable in effect in month year 12 11 2 2 Section 2 Safety amp 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 For Canadian final stage manufacturers see http www gazette gc ca archives p2 2002 2002 02 13 html sor dors55 eng html and http www tc gc ca acts regulations regulations crc c 1038 menu htm for the regulations Or contact Transport Canada Tower C Place de Ville 330 Sparks Street Ottawa Ontario KTA ON5 613 990 2309 TTY 1 888 675 6863 Noise and Emissions Requirements NOTE 2010 Automotive engines have been tested and EPA CARB certified with a complex inte grated system This system is comprised of several emissions control devices including il but not limited to a Diesel Particulate filter DPF and a Selective Catalyst Reduction SCR system The body builder must not modify or relocate any devices included in the emissions system Doing so may result in the voiding of all warranties and the occurrence of an emissions noncompliance event that may be considered tampering and punishable by the assessment of penalties by the EPA and ARB as well as the need for remedial measures Modification of the emissions
100. ng shall be covered with con voluted tubing whether they are in bundles or not 12 11 9 2 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 110 220 volt engine heater wiring shall be installed with butterfly ties or butterfly clamps Piping Use no street elbows in air brake water fuel or hydraulic systems unless specified on the piping diagram and the build instructions Use no elbows in the air brake system unless specified on the air piping diagram and the build instructions Hoses Crossing Components Hoses crossing over other components close enough to rub shall be protected with a secured covering of convoluted plas tic tubing KW part number K344 813 another section of hose or plastic sheathing KW part number K213 1312 The usage of butterfly ties or butterfly clamps are also recommended Air Compressor Discharge Hoses Wires or hoses shall not be tied to the high temperature air compressor discharge hose Hoses and wires may be routed across the air compressor discharge hose at a distance of 18 inches 457 mm or greater from the compressor discharge port In this case the crossing hoses and w
101. nt of the insert to the frame should be made with Ream Fit heat treated bolts 5 8 in 16 mm diameter or the next larger size Both the reinforcement and frame holes should be reamed to provide a fit of from 001 in to 003 in 025 to 076 mm clear ance Do not weld reinforcing members The insert should span a distance of at least 24 21 in 615 mm on either side of the crack to ensure an even distribution of stresses Cut the ends of the insert at 45 as shown in Figure 7 2 unless the insert extends to the end of the frame SET ae tains rear ies AA aira HAAN ae TEE EHER NAO Rares tty er ree ne ge wie EN a mi er a V LD FRAME RAILS ON THE OUTSIDE ONLY 24 21 Inch S Minimum ER 615 mm FIGURE 7 1 Detail of Frame Extension and Joint Welding FIGURE 7 2 Frame Insert 8 84 19 6B 250 500 ADD PAIRS OF HOLES EQUALLY SPACED AS NEEDED 8 07 98 25 i 205 97 4 92 30 125 ay INSERT DETAIL WARIABLE LENGTH 1235 INSERT DETAIL MINIMUM LENGTH 12 1 7 2 Section 7 Frame Modifications 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 Use the fol lowing guideline for locating additional bolt holes Changing
102. of 72 inches 1829 mm from the front axle to the leading edge of the body See SECTION 3 DIMENSIONS for further details on dimensions and clearances Also see APPENDIX B WEIGHT DIS TRIBUTION for explanation of back of cab BOC CA calculations 72 RUA 16299 FIGURE 6 2 Minimum Back of Cab Clearance AN WARNING If the frame rail flanges are modified or damaged the rail may 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 Mount the body using body mounting brackets or U bolts Failure to comply may result in personal injury death equipment or property damage 6 1 12 11 Section 6 Body Mounting Body Mounting Using Brackets C AUTION _ Always install a spacer between the body subframe and the top flange of the frame rail Failure to do so could result in corrosion due to dissimilar materials Installation of a spacer between the body subframe and the top flange of the frame rail will help prevent premature wear of the components due to chafing or corrosion Frame Sill If the body is mounted to the frame with brackets we recommend that the frame sill soacer 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 The strip will be less likely to fall out during extreme relative motion between body and c
103. ompressed Air tank may not be modified exception addition or removal of fittings or relocation of the tank Added devices or bodywork may not interfere with or rub air lines Air supply to the engine doser may not be restricted or disconnected Air lines should be routed protected from heat and properly secured to prevent damage from other components Care should be taken so that air lines do not rub against other components Care should be taken to protect the air system from heat sources Exhaust and Exhaust After treatment System The following are highlights of some of the more common or critical aspects of this system 12 11 The following after treatment and exhaust system components may not be modified e DPF assembly e SCR Catalyst assembly e Exhaust pipes between the engine and after treatment devices DPF SCR Catalyst and between after treatment devices e NO Sensor 2 4 Section 2 Safety amp Compliance The following modifications may only be done within the guidelines of the DEF System Relocation Guide e Modifications to Diesel Exhaust Fluid DEF throttle suction or pressure lines e Modification or relocation of the DEF tank e Modification of coolant lines to and from the DEF tank All DEF and coolant lines should be routed protected and properly secured to prevent damage during vehicle operation or other components If relocation of the DCU is necessary use existing frame brackets and mount
104. on F BOC to RH Fuel Tank 0 2in Dimension H BOC to Hybrid Battery Box 2 8in TABLE 5 20 Hybrid PEC Wheelbase PEC Length DIM P BOC to PEC 56 1 281 315 5 39 12 11 Section 5 Frame Layouts Page Intentionally Left Blank 12 11 5 40 Section 6 Body Mounting CRITICAL CLEARANCES Rear Wheels and Cab IN 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 1 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 This should be measured with the body empty See Figure 6 1 Ban 203mm FIGURE 6 1 Minimum Clearance Between Top of Rear Tires and Body Structure Overhang A CAUTION Maintain adequate clearance between back of cab and the front leading edge of mounted body Failure to do so could cause damage to the cab body or both during cab amp body movement See Figure 6 2 HI Note Be sure to provide maintenance access to battery box and fuel tank fill neck The true distance from the centerline of the front axle to the back of the cab is 68 inches 1727 mm It is recommended that the leading edge of the body be mounted a minimum of 4 inches 102 mm behind the cab The result is a minimum back of cab clearance
105. on the vehicle Upon completion of the vehicle installation of the body and any other modifications you should affix your certification label to the vehicle as required by Federal law This tag identifies you as the Intermediate or Final Stage Manufacturer and certifies that the vehicle complies with Federal Motor Vehicle Safety Standards See Figure 2 2 Be advised that regulations affecting the intermediate and final stage manufacturer may change without notice Ensure you are referencing the most updated copy of the regulation during the certification and documentation processes In part if the final stage manufacturer can complete and certify the vehicle within the instruction in the incomplete vehicle document IVD the certification label would need a statement that reads This vehicle has been completed in accordance with the prior manufacturers IVD where applicable This vehicle conforms to all applicable Federal Motor Vehicle Safety Standards and Bumper and Theft Prevention Standards if applicable in effect in month year However if the vehicle can not be completed and certified with in the guidance provided in the IVD the final stage manu facturer must ensure the vehicle conforms to all applicable Federal Motor Vehicle Safety Standards FMVSS The final stage manufactures certification label would need a statement that reads This vehicle conforms to all applicable Federal Motor Vehicle Safety Standards and Bumper a
106. onal Hendrickson HAS Single Suspensions 3 23 HENDRICKSON PRIMAAX SINGLE REAR AXLE 0 00 00 ce eee eee eee 3 24 Optional Hendrickson Promaax Single Suspensions 3 24 HENDRICKSON HAS TANDEM SUSPENSION 2 2 22 nee nennen 3 25 Optional Hendrickson HAS Tandem Suspensions 3 25 HENDRICKSON RT TANDEM SUSPENSION 0 0 0 0 cee eee eee 3 26 Optional Hendrickson RT Tandem Suspensions cence eee 3 26 CHALMERS 854 40 TANDEM SUSPENSION aaa 3 27 Optional Chalmers Tandem Suspensions 00 0c eee ee eens 3 27 TIBETAN en PERA ABA PILA ee PAA ee ce we es GA E hg are 3 28 FRAME AND CAB RELATED HEIGHTS 0 0 a 3 28 12 11 Body Builder s Manual Contents GROUND CLEARANCES aa 5s a 00 oa nn HES OS BRAKE eee Ew me 3 28 PTC CLEARANCES zu a a ee hone hae GLO os eee ead 3 33 SECTION 4 EXHAUST amp AFTERTREATMENT EXHAUST AND AFTER TREATMENT INFORMATION 000 0c eee eee 4 1 GENERAL GUIDELINES FOR DEF SYSTEM 0 0c ce ee 4 3 INSTALLATION REQUIREMENTS AND DIMENSIONS FOR DEF SYSTEM 4 3 MEASUREMENT REFERENCE POINTS 0 000 cee eee ee ees 4 4 GENERAL EXHAUST INFORMATION 0 0 00 cee eee 4 9 EXHAUST INFORMATION 2 424 202 er una een NLA ee ren 4 18 SECTION 5 FRAME LAYOUTS FRAME LAYOUTS 24 02 cc dans Chea Pe ee dhe wee da ee da eed nenn aan 5 1
107. ons All Electronic Engines Before welding on vehicles with electronic engines the following precautions should be observed 1 2 3 4 Note 12 11 Disconnect all electrical connections to the vehicle batteries Disconnect all ECM connectors Do no use the ECM or engine ground stud for the ground of the welding probe Ensure that the ground connection for the welder is as close to the weld point as possible This ensures maxi mum weld current and minimum risk to damage electrical components on the vehicle Turn off key Bendix ABS Bosch ABS and Wabco ABS Disconnect ECU 7 6 Section 7 Frame Modifications TORQUE REQUIREMENTS TABLE 7 1 Customary Grade 8 UNF or UNC Lb Ft 5 16 22 30 16 22 3 8 41 54 30 40 7 16 75 88 55 65 1 2 109 122 80 90 9 16 1596 190 115 140 Torque values apply to fasteners with clean threads lightly lubricated with hardened steel washers and nylon insert nuts TABLE 7 2 U S Customary Grade 8 Metric Class 10 9 a a ggg an U Im DR 7 7 12 11 Section 7 Frame Modifications Page Intentionally Left Blank 12 11 7 8 Section 8 Electrical ELECTRICAL Information in this section will cover the following topics e Overview of Kenworth s 2010 multiplex instrumentation for Medium Duty Trucks e Access instructions for the dash gauges and switches e Wiring instructions for alarm and telltale warning lights e Reconfiguring telltale cards e Sp
108. ontal Crossover DPF SCR LH horizontal tailpipe RHUC cylindrical fuel tank RH BOC cylindrical DEF tank LHUC hybrid battery box and LH BOC hybrid PEC Chart located on page 5 35 We rid Ratt H4 isa Hybrid configuration used with Vertical Vertical DPF SCR LH vertical tailpipe RHUC rectangular fuel tank RHUC rectangular DEF tank LHUC hybrid battery box and LH BOC hybrid PEC Chart located on page 5 36 aj tiytrid Batt E H5 is a Hybrid configuration used with Vertical Vertical DPF SCR LH vertical tailpipe RHUC cylindrical fuel tank RH BOC cylindrical DEF tank LHUC hybrid battery box and LH BOC hybrid PEC Chart located on page 5 37 12 11 5 8 Section 5 Frame Layouts Hytrld Rat amp H6 is a Hybrid configuration used with In Series DPF SCR RH horizontal tailpipe RHUC cylindrical fuel tank RH BOC cylindrical DEF tank LHUC hybrid battery box and LH BOC hybrid PEC Chart located on page 5 38 ay i tytrid Batt 8 H7 is a Hybrid configuration used with horizontal In Series DPF SCR RH horizontal tailpipe RHUC rectangular fuel tank RHUC rectangular DEF tank LHUC hybrid battery box and LH BOC hybrid PEC Chart located on page 5 39 5 9 12 11 Section 5 Frame Layouts ju A Dimension E BOC to DPF SCR 0 0in Dimension A BOC to Air Dryer 7 7in Dimension B BOC to Battery Box 5 4in TABLE 5 4 Dimension D Diamet r Length in BOC to Fuel
109. ousing 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 FIGURE A 5 Rear Axle Identification Note Illustrated identification tag locations are typical Actual locations may vary by axle manu il facturer and with single versus tandem axles 12 11 A 4 KENWORTH A PACCAR COMPANY Kenworth Truck Company P O Box 1000 Kirkland WA 98083 425 828 5000 12 11
110. ox Back of Cab BOF e 31 0 787 gt Rear View FIGURE 3 14 T270 370 Battery Box Measurements inches mm Battery Access Step T170 Parallel Battery Box LH Under Cab or Cab Access RH under Cab 27 7 704 HEE Rear View Battery Box LH under shown Cab Access Step RH under is opposite FIGURE 3 15 T170 Battery Box Cab Access Step Measurements inches mm 3 13 12 11 Section 3 Dimensions Horizontal Exhaust Muffler Horizontal Exhaust Muffler DPF Mounting BOF FIGURE 3 16 Horizontal Exhaust Muffler DPF Measurements inches mm TABLE 3 10 RH Under Frame Horizontal Exhaust Mounting A B C D E F G H Inch mm Inch mm Inch mm Inch mm Inch mm Inch mm Inch mm Inch mm 12 11 3 14 Section 3 Dimensions Step DPF Box Assembly RH Under Cab T270 370 18 459 114 263 282 668 FIGURE 3 17 T270 T370 RH Step DPF Box Assembly for Use with Vertical Tailpipe left or Horizontal Tailpipe right inches mm Horizontal Muffler Vertical Tailpipe on Cab T270 370 10 3 262 13 8 351 ba a 321 815 FIGURE 3 18 T270 370 Vertical Tailpipe on Right Side of Cab inches mm 3 15 12 11 Section 3 Dimensions RH Back of Cab Independent Muffler T270 T370 r 16 9 430 FIGURE 3 19 1270 1370 with Vertical
111. pacing Laden Ride Height ne 12 11 3 22 Section 3 Dimensions HENDRICKSON HAS SINGLE REAR AXLE tg hd 55 x NESE BZ a NG h 5 9 7 BOF Ride 2 4 Optional Hendrickson HAS Single Suspensions TABLE 3 18 Rear Suspension Options Laden Ride Unladen Ride Suspension Type Axle Spacing Height Height 3 23 12 11 Section 3 Dimensions HENDRICKSON PRIMAAX SINGLE REAR AXLE 9 2 Optional Hendrickson Primaax Single Suspensions TABLE 3 18 1 Rear Suspension Options Laden Ride Unladen Ride Suspension Type Axle Spacing Height Height 12 11 3 24 Section 3 Dimensions HENDRICKSON HAS TANDEM SUSPENSION 54 5 52 3 49 5 52 6 42 5 51 1 39 7 46 4 5 8 TB Het HH tea isa AR Ll Er s A g cas a Mm Nd ma Hi Ti thy N ine om Pa ka ba Pr u nn Pa Optional Hendrickson HAS Tandem Suspensions TABLE 3 19 Rear Suspension Options Laden Ride Unladen Ride Suspension Type Axle Spacing Height Height 3 25 12 11 Section 3 Dimensions HENDRICKSON RT TANDEM SUSPENSION Shown with a 54 Axle Spacing Without Track Rods 55 2 H a 53 0 47 4 T e See 1 Ze a hs I zi F ms BT EH Es k et Mic Pa i Jet ee er let 1 Bing Hr BO F a Br a ae fo Fa a ih st Pu a NG AXLE SPACING Optional Hendrickson RT Tandem Suspensions TABLE 3 20 Rear Suspension Options Laden Ride Unladen Ride Suspension
112. ply Module Pump 0 0 0 0 cee eee 4 4 FIGURE 4 2 Measurement Location of DEF Dosing Module Injector 20 0 0 eee eee 4 4 FIGURE 4 3 Orientation of Dosing Module 0 eee ennen nen k ernennen 4 5 FIGURE 4 4 RH Under Cab Exhaust with Small or Medium Tanks a 4 5 FIGURE 4 5 Horizontal Series Exhaust with Small or Medium Tanks 00000 eee ees 4 6 FIGURE 4 6 Vertical Exhaust with Small or Medium Tanks 0 0 0c ees 4 6 FIGURE 4 7 Horizontal Crossover Exhaust system with Small or Medium Tanks 4 7 FIGURE 4 8 Routing DEF Lines and DEF Trap 0 cee ees 4 8 FIGURE 4 9 Isometric View of Right Hand Under DPF and SCR with Single SOC Tailpipe 4 10 FIGURE 4 10 Top View of Right Hand Under DPF and SCR with Single SOC Tailpipe 4 10 FIGURE 4 11 Right View of Right Hand Under DPF and SCR with Single SOC Tailpipe 4 11 FIGURE 4 12 Back View of Right Hand Under DPF and SCR with Single SOC Tailpipe 4 11 FIGURE 4 13 Isometric view of Horizontal DPF and SCR with Horizontal Tailpipe 4 12 FIGURE 4 14 Top view of Horizontal DPF and SCR with Horizontal Tailpipe 4 12 FIGURE 4 15 Right view of Horizontal DPF and SCR with Horizontal Tailpipe 4 13 FIGURE 4 16 Back view of Horizontal DPF and SCR with Horizontal Tailpipe 4 13
113. ptions aa 3 5 FIGURE 3 4 Side of Cab View T270 370 Roof Mounted Options 2 0 0 eee eee es 3 5 FIGURE 3 5 Flush Mounted Flood Lamp Locations a 3 6 FIGURE 3 6 T170 Crossmember Location 0 0 ccc eee eee eas 3 7 FIGURE 3 7 T170 Crossmember Location 0 0 0 eee eens 3 8 FIGURE 3 8 Frame Rail Dimensions and Properties ccc eens 3 8 FIGURE 3 9 T270 370 Battery Box Measurements 0000 eee eee eens 3 10 FIGURE 3 10 T270 370 Battery Tool Box Measurements 0000 cece eee 3 10 FIGURE 3 11 1270 3870 22 Fuel Tank Mounting Measurements a 3 11 FIGURE 3 12 T270 370 24 5 Fuel Tank Mounting Measurements With and without steps 3 11 FIGURE 3 13 Rectangular Fuel Tank Measurements 2 ee eee ee 3 12 FIGURE 3 14 T270 370 Battery Box Measurements 00000 cece eee eens 3 13 FIGURE 3 15 T170 Battery Box Cab Access Step Measurements 0000 cece eee 3 13 FIGURE 3 16 Horizontal Exhaust Muffler DPF Measurements aaa 3 14 FIGURE 3 17 T270 T370 RH Step DPF Box Assembly for Use with Vertical Tailpipe left or Horizontal Tailpipe ee eee ee ete eet eee ene 3 15 FIGURE 3 18 T270 370 Vertical Tailpipe on Right Side of Cab 0 0 0 ce ee 3 15 FIGURE 3 19 T270 T370 with Vertical Muffler DPF Behind RH Side of Cab 3 16 FIGURE 4 1 Measurement Location of DEF Sup
114. r DPF and SCR system in which both canisters are located underneath the cab access step a Horizontal Series system where DPF SCR and tailpipe are installed by the right hand rail and an Independent DPF and SCR located vertically back of cab on stanchion brackets RH Under DPF Horizontal DPF and SCR Horizontal Series DPF and Vertical Independent and SCR with Horizontal Tailpipe SCR with Horizontal Tailpipe DPF and SCR The following images depict the typical exhaust routings for each system and can be used to determine exhaust routing paths for systems you choose Dimensional information can be found in Section 5 of this manual Body Builders must not modify including altering substituting and relocating the DPF and SCR canisters The exhaust piping after it exits the SCR canister may be modified however using smaller diameter piping or piping with numerous bends is not recommend as the backpressure requirements of the system may be exceeded 4 9 12 11 Right Hand Under DPF and SCR on Daycab with Single Side of Cab Tailpipe FIGURE 4 9 Isometric View of Right Hand Under DPF and SCR with Single SOC Tailpipe FIGURE 4 10 Top View of Right Hand Under DPF and SCR with Single SOC Tailpipe 12 11 4 10 FIGURE 4 11 Right View of Right Hand Under DPF and SCR with Single SOC Tailpipe FIGURE 4 12 Back View of Right Hand Under DPF and SCR with Single SOC Tailpipe 4 11 12 11 Horizontal DPF and SCR with Horizontal Tailpip
115. r suspension components amp lead to an accident When inserts longer than the minimum length are required extra pairs of bolt holes shall be added evenly spaced result ing in bolt spacings of not less than 9 8 inches 250mm or more than 19 7 inches 500mm along the length of the insert as shown in Figure 7 2 Insert Detail Variable Length 7 3 12 11 Section 7 Frame Modifications AN WARNING Do not drill new holes any closer than 2 inches 50 mm to existing holes Frame drilling affects the strength of the rails and if not done properly can cause the frame rails to fail and cause an accident Before the rear suspension is relocated check the new location of the spring hanger brackets The new holes for the spring hanger brackets must not overlap existing holes and should not come any closer than 2 inches 50 mm to existing holes Mount the suspension Brackets On the Original Rail See frame insert section amp figures 7 1 amp 7 2 Do Not Mount the Suspension Bracket On the Added Frame Rail Relocated Rear Suspension Mi ED Mie Fl i ik Sin Cut Frame at Rear to Shortened Wheelbase Obtain Desired Cutoff ze FIGURE 7 3 Comparison of Original Shortened and Extended Wheelbases 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
116. re for your protection and information These alerting messages can help you avoid injury to yourself or others and help prevent costly damage to the vehicle Key symbols and signal words are used to indicate what kind of message is going to follow Pay special attention to comments prefaced by WARNING CAUTION and NOTE Please do not ignore any of these alerts Warnings Cautions and Notes When you see this word and symbol the message that follows is especially vital It signals a potentially hazardous situation which if not avoided could result in death or serious injury This message will tell you what the hazard is what can happen if you do not heed the warning and how to avoid it Example AN WARNING WARNING Be sure to use a circuit breaker designed to meet liftgate amperage requirements An incorrectly specified circuit breaker could result in an electrical overload or fire situation Follow the liftgate installation instructions and use a circuit breaker with the recommended capacity Signals a potentially hazardous situation which if not avoided could result in minor or moderate injury or damage to the vehicle CAUTION Enna CAUTION Never use a torch to make a hole in the rail Use the appropriate drill bit Provides general information for example the note could warn you about how to HI NOTE avoid damaging your vehicle or how to drive the vehicle more efficiently Example Lidia e sure to
117. re line See Figure 4 1 FIGURE 4 1 Measurement Location of DEF Supply Module Pump Dosing Module The dosing module is commonly called an injector this injector is located on the SCR mixing pipe which is between the DPF and SCR canister The measurement point on the dosing module is the top of the DEF fluid pressure line See Figure 4 2 FIGURE 4 2 Measurement Location of DEF Dosing Module Injector The following relocation guidelines are dependant on exhaust configuration and DEF tank type and location The Dosing Module should not need to be relocated However if it is removed for any reason it is critical that the module be reinstalled at the correct orientation Figure 4 3 below illustrates the correct installation orientations The angle refer ences the vertical plane 12 11 4 4 Section 4 Exhaust amp Aftertreatment Installation orientation of Dosing Module Between 45 and 85 Between 45 and 85 FIGURE 4 3 Orientation of Dosing Module Right Hand Under DPF and SCR with Rectangular Small or Medium DEF Tanks FIGURE 4 4 RH Under Cab Exhaust with Small or Medium 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 When relocating the components the maximum pressure DEF hose length from Supply module to Dosing Module is 3 m
118. reakout locations and location to install fuses in fuse panel For unused spare circuits since these are separate circuits you will not affect existing circuits in the chassis by connecting to them They include e 3 spare battery circuits e 2 spare ignition circuits Note some Spare circuits may be used with factory installed options For specific chassis questions il please work with your Kenworth Dealer TABLE 8 7 Additional Spare Circuits for Wiring Dash Harness Connector Behind Dash Panel 4 Spare Circuit aT ad Label on Minimum Capacity Amperes Numbered Loca Through Connector Wire Gauge Circuit Wire Color Install a fuse of ap tion on fuse panel propriate rating behind dash 8 23 12 11 Section 8 Electrical OPTIONAL BODY BUILDER HARNESS Through the use of an optional body harness and additional spare circuits we have tried to reduce the complexity associ ated with adding common circuits to a body installation Note The most common circuits that body builders may need are pre connected to this il optional wiring harness The optional body harness can be connected to the chassis harness through a standard connector mounted on the left hand frame rail directly behind the battery box See Figure 8 20 Truck Body Connector to Chassis Harness Left Rail AMAMA FIGURE 8 19 Location of Standard Body Harness Connection For shipping purposes the body harness is coiled and shipped loose in
119. rtain characteristics on your vehicle The charts below list the abbreviated terms used and provide definitions for terminology used TABLE 3 1 Abbreviations Used AF After Frame Frame rail overhang behind rear axle or measured from the centerline of tandem Back of Cab BOF Bottom of Rail Back of cab to centerline of rear axle or centerline of tandems on tandem suspension FS Front suspension height from centerline of axle up to the bottom of the frame rail Overall Vehicle Length Side of Cab RS Rear suspension height from centerline of axle up to the bottom of the frame rail WB Centerline of front axle to centerline of rear axle or centerline of tandems on tandem suspension TABLE 3 2 Definitions The maximum allowable weight each axle assembly is designed to carry as measured at the tires there fore including the weight of the axle assembly itself GAWR is established by considering the rating of each of its components tires wheels springs axle and steering system and rating the axle on its weakest link The GAWR assumes that the load is equal on each side LADEN This is the weight condition of the truck with the front and rear axles loaded to their Gross Axle Weight Rating GAWR UNLADEN This is the weight condition of the truck delivered from the PACCAR factory This is without the following body driver and tools It does include fluids but no fuel 3 1 12 11 Section 3 Dimensions Prospe
120. s connected to these devices For more details about 1939 11 VCAN specifications please refer to SAE J1939 11 PTO Hybrid trucks have the option of two different PTO operation modes they can be outfitted with either an Electronic PTO or a Mechanical PTO ePTO EPTO uses the Hybrid Systems electric motor to turn the PTO gear in the transmission A 3 way connector is provided on the Transmission Harness to interface with the PTO The connector provides the positive and negative signals to engage the PTO and an interlock to insure the PTO is engaged The interlock circuit is a ground signal This is typically done with a ball switch on the PTO One side of the ball switch would be connected to ground and the other to Pin A ePTO 3 way connector Pin A is for PTO interlock negative signal Pin B is for PTO solenoid Neg Pin C is for PTO solenoid Pos FIGURE 8 21 ePTO Harness Location mPTO MPTO operates like a normal PTO with the exception of the use of a PTO interlock circuit The interlock circuit is a ground signal This is typically done with a ball switch on the PTO One side of the ball switch would be connected to ground and the other to terminal P206 located LH side of the transmission on the hybrid transmission harness 12 11 8 28 BODY BUILDER POWER DISTRIBUTION CENTER For 2010 Medium Duty Hybrid vehicles the Hybrid Battery Box will include a Body Builder Power Distribution Center Through the addition of a battery box mounted
121. s or other associated equipment This manual contains appropriate dimensional information guidelines for mounting bodies guidelines for modifying frames electrical wiring information and other information useful in the body installation process This manual is specific to chassis with 2010 engines The intended primary users of this manual are body builders who install bodies and associated equipment on Kenworth T170 T270 T370 Medium Duty vehicles Dealers who sell and service the vehicle will also find this information useful This Body Builders Manual can be very useful when specifying a vehicle particularly when the body builder is involved in the vehicle definition and ordering process Early in the process professional body builders can often contribute valuable information that reduces the ultimate cost of the body installation In the interest of continuing product development Kenworth reserves the right to change specifications or products at any time without prior notice It is the responsibility of the user to ensure that he is working with the latest update The most current update is available through your local Kenworth dealer If you require additional information or reference materials please contact your local Kenworth dealer 1 1 12 11 Page Intentionally Left Blank Section 2 Safety amp Compliance SAFETY SIGNALS There are a number of alerting messages in this book Please read and follow them They are the
122. surface of the box and must not extend below the battery box in any way Remote Installation Hybrid PEC Hybrid vehicles have an option for additional cables to allow for a remote installation of the hybrid system PEC The inten tion of this option is to allow a body builder to control the location of the PEC within the body if desired Requirements that must be met when relocating the PEC are outlined below Eaton Installation Guide Eaton provides guidelines for OEMs and body builders to follow for the integration of their hybrid components All require ments under the Power Electronic Carrier PEC section of the Eaton installation guide must be met The current version of the Installation Guide can be found on the Eaton website at www Roadranger com 6 7 12 11 Section 6 Body Mounting Clearances Minimum clearances as outlined in the PEC Clearances section of this document must be followed Mounting The PEC must be mounted to a rigid platform or structure with all four 4 of the PEC mounting studs secured and prop erly torqued see Eaton Installation Guide for torque specifications The 4 nuts that are installed between the factory provided frame bracket and the PEC housing must be retained on the PEC studs when relocating the PEC as they are integral to the PEC assembly Airflow Requirements The PEC unit is air cooled and requires unrestricted air flow to the air inlet duct on the front of the PEC and the air exhaust duct o
123. t With all relocating procedures general clearances and routing guidelines must be followed See section 9 of this manual for general routing guidelines When relocating the components the maximum pressure DEF hose length from Supply module to Dosing Module is 3 meters 1187 Maintain a minimum of 3 clearance to shielded exhaust components when routing DEF lines to prevent possible melting lf the DEF tank is relocated the coolant lines will need to be modified During this process if the tank is moved forward on the chassis ie closer to the engine it is necessary to remove excess coolant lines and maintain the original routing path If the tank is moved rearward on the chassis the additional length of cooling line required to complete the installation must be installed in a straight section of the existing coolant routing lines This process will minimizes the change in coolant flow by minimizing changes in restrictions Increase in restriction occur with excessive line length and bends Work with your local Kenworth dealer if you are unsure about the coolant line modifications 4 3 12 11 Section 4 Exhaust amp Aftertreatment MEASUREMENT REFERENCE POINTS For all relocation procedures the measurement points will referenced in the guidelines are taken from the following spe cific 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 pressu
124. ted Rear Suspension Ride Heights ___Model___ Rear Suspension Rear Axles Ladeninch mm Unladen inch mm _ 8 1 206 6 6 168 9 0 228 ax2 amp 0x4 Hendrickson RT 403 40K Capacity Tandem 8 6 218 2 3 236 33 236 6 5 165 155 394 KO 155 394 or 15 5 394 17 2 487 NIT O A _ 12 11 3 18 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 The dimensions shown below are the most typical installations in special cases some hole locations will move If you are planning on using the holes shown for your body installation please confirm with your local KW dealer that the drawing below will be the installation used on your specific truck Ensure that proper torque is used to reinstall any suspension components See Table 7 1 and 7 2 on page 7 7 It would be recommended to order the frame layout of your chassis along with your truck order This can be done on any Kenworth truck and will be provided 4 weeks ahead of the build schedule If there are hole locations that are not detailed please work with your local Kenworth Dealer to request that information If you would like details on the frame drilling with optiona
125. the cab The body harness wire ends are tagged with circuit markers identifying the connecting circuit See Figure 8 21 on the next page A CAUTION Body Builder Power and Return Ground All body builder Power and Return lines must be connected directly to battery terminals and be properly fused Using the frame as a Return Ground is not allowed Using the frame as a Return could result in the creation of ground loops and damage electronic devices on the truck 12 11 8 24 Section 8 Electrical FIGURE 8 20 Body Junction Harness Sales Code 9090312 Location LH Rail Approx 500mm Back of Cab TABLE 8 8 Body Junction Harness Harness Body Junction P92 1922 xxxxx Harn Front Chas P92 3997XXXXXXXXX Wire Circuit Wire Circuit Wire CAPACITY FUSE Comments Description Color Color Amperes LOCATION Backup LP TRLR BB X L79BL Pink YEL2960 Yellow 10A F71 Dedicated Back up White Fuse Lamp Alarm RH Turn Right Turn W L34RT Green YEL2312 Yellow 10A F24 Shared w Signal Lamp Black Front Turn LP LH Turn Left Turn Sig L33LT Yellow YEL2311 Yellow 10A F77 Shared w nal Lamp Black Front Turn LP Aux PWR Auxiliary U P4TRC Blue ORN5100 Orange 15A F79 Dedicated Power body Fuse or Trailer IGN Clearance Marker Clear Z L3MLB Black YEL9130 Yellow 10A F17 Dedicated LP ance Lamps Fuse TRLR BB Tail Lamp Stop LP Stop Lamps S L2STC YEL9120 Yellow 25A F52 Shared w Chas Stop LPS Tail LP Tail Park
126. transmit data between the transmission ABS system engine etc to the Cab Electronic Control Unit CECU e CAN Instrumentation Controller Area Network The I CAN provides data link communication from the Cab Electronic Control Unit CECU to the Central Instrument Cluster e CVSG Bus The CVSG bus is a private data bus used to transmit data from the Cab Electronic Control Unit CECU to the individual 2 inch gauges A series of daisy chained jumper harnesses link each gauge to another 8 3 12 11 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 5 Aa AA nn z D r i i po CEP it ae un FIGURE 8 5 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 Output signals from the CECU provide data for the gauges warning lamps audible alarms and displays inside the cluster Central Instrument Panel The central instrument panel includes the speedometer including odometer and trip meter and tachometer including engine hour meter and outside temperature display plus a Driver Warning and Indicator Module DWIM pre installed standard and or edit
127. ure 2 1 In addition affixed to the driver s side door frame or edge is an Incomplete Vehicle Certification label See Figure 2 2 For further information on Vehicle Certification and Identification see APPENDIX A VEHICLE IDENTIFICATION NOTE These documents list the U S or Canadian Federal Motor Vehicle Safety Standard regulations that the vehicle complied with when it left the build plant You should be aware that if you add modify or alter any il of the components or systems covered by these regulations it is your responsibility as the Intermediate or Final Stage Manufacturer to ensure that the complete vehicle is in compliance with the particular regula tions upon completion of the modifications U S EPA Noise Label U S registered vehicles only Final Stage Manufacturer Label to be Installed by Final Stage Manufacturer ae Tire Rim and mia Weight Rating T ca en aan oe Data label Chassis Serial Number Major Components and ee Safety Mark Canadian a Weights Label Registry Only Incomplete Vehicle O i Certification Label ai FIGURE 2 1 Incomplete Vehicle FIGURE 2 2 Locations of Certification Certification Document Labels Driver s Door and Frame As the Intermediate or Final Stage Manufacturer you should retain the Incomplete Vehicle Document for your records In addition you should record and retain the manufacturer and serial number of the tires
128. you can use the crossmember gusset bolt holes for body mount If your design permits placement of body mounting brackets at crossmember il Note ing See Figure 6 8 BODY MOUNTING USING U BOLTS Spacers If the body is mounted to the frame with U bolts use a hardwood sill minimum 0 5 inch 12 mm thick between the frame rail and body frame to protect the top surface of the rail flange Do not allow the frame rails or flanges to deform when tightening the U bolts It will WARNING weaken the frame and could cause an accident Use suitable spacers made of steel or hardwood on the inside of the frame rail to prevent collapse of the frame flanges Use a hardwood spacer between the bottom flange and the U bolt to prevent the U bolt from notching the frame flange See Figure 6 8 Body Structure U Bolt Wood Sill 0 5 12 Minimum Truck Frame U Bolt Spacer Hardwood Frame Rail Spacer Fabricated Steel or Hardwood 01018 FIGURE 6 7 Acceptable U Bolt Mounting with Wood and Fabricated Spacers inch mm Do not allow spacers and other body mounting parts to interfere with brake lines AN WARNING fuel lines or wiring harnesses routed inside the frame rail Crimped or damaged brake lines fuel lines or wiring could result in loss of braking fuel leaks electrical overload or a fire Carefully inspect the installation to ensure adequate clearances for air brake lines fuel lines and wiring See Figure 6 9 A CAUTION Mount U

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