Paccar Kenworth T170 2011 Builder'S Manual Download

Page: 4 / 179

12/11

Body Builder’s Manual

Contents

SECTION 1 — INTRODUCTION

SCOPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

SECTION 2 — SAFETY AND COMPLIANCE

SAFETY SIGNALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Warnings, Cautions, and Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

FEDERAL MOTOR VEHICLE SAFETYSTANDARDS COMPLIANCE . . . . . . . . . . . . . . . . . 2-2

Incomplete Vehicle Certification

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Noise and Emissions Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

Compressed Air System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

Exhaust and Exhaust After-treatment System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

Air Intake System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8

Charge Air Cooler System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8

SECTION 3 — DIMENSIONS

ABBREVIATIONS AND DEFINITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

OVERALL DIMENSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

DETAIL VIEWS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

DETAIL VIEWS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

Back of Cab: Flush Mounted Flood Lamps – T270/370 . . . . . . . . . . . . . . . . . . . . . . 3-6

DETAIL VIEWS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7

Crossmember Locations – T170 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7

DETAIL VIEWS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8

Crossmember Locations – T170 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8

COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9

Frame Rail Configurations - T170/270/370

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9

Battery Box – T270/370 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10

Battery/Tool Box – T270/370 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10

22-inch Fuel Tanks — T270/370 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11

24 .5-inch Fuel Tanks — T270/370 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11

Rectangular Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12

Battery Box – T270/370 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13

Battery/Access Step – T170 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13

Horizontal Exhaust/Muffler

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14

Step/DPF Box Assembly RH Under Cab – T270/370 . . . . . . . . . . . . . . . . . . . . . . . 3-15

Horizontal Muffler-Vertical Tailpipe on Cab

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15

RH Back of Cab Independent Muffler — T270/T370

. . . . . . . . . . . . . . . . . . . . . . . 3-16

RIDE HEIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17

REAR SUSPENSION LAYOUTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19

KENWORTH AG210L SINGLE REAR AxLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19

KENWORTH AG400L TANDEM REAR AxLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20

REYCO 79KB SINGLE REAR AxLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21

Optional Reyco 79KB Suspensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21

REYCO 102 TANDEM REAR AxLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22

Optional Reyco 102 Suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22

HENDRICKSON HAS SINGLE REAR AxLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23

Optional Hendrickson HAS Single Suspensions . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23

HENDRICKSON PRIMAAx SINGLE REAR AxLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24

Optional Hendrickson Promaax Single Suspensions . . . . . . . . . . . . . . . . . . . . . . . 3-24

HENDRICKSON HAS TANDEM SUSPENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25

Optional Hendrickson HAS Tandem Suspensions . . . . . . . . . . . . . . . . . . . . . . . . . 3-25

HENDRICKSON RT TANDEM SUSPENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26

Optional Hendrickson RT Tandem Suspensions . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26

CHALMERS 854-40 TANDEM SUSPENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27

Optional Chalmers Tandem Suspensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27

TIRE DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28

FRAME AND CAB RELATED HEIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28

Summary of Contents for Kenworth T170 2011

Page 1: ...Kenworth T170 T270 T370 and Hybrid 2011 Body Builders Manual...

Page 2: ......

Page 3: ...Kenworth Medium Duty Body Builders Manual Models T170 T270 T370 and Hybrid For 2011 Model Year and Later with 2010 EPA Compliant Engines...

Page 4: ...270 370 3 11 24 5 inch Fuel Tanks T270 370 3 11 Rectangular Fuel Tank 3 12 Battery Box T270 370 3 13 Battery Access Step T170 3 13 Horizontal Exhaust Muffler 3 14 Step DPF Box Assembly RH Under Cab T2...

Page 5: ...ng 6 3 Hole Location Guidelines 6 4 BODY MOUNTING USING U BOLTS 6 4 Spacers 6 4 Rear Body Mount 6 6 Hybrid Clearances 6 6 Hybrid PEC 6 6 Hybrid Battery Box 6 7 SECTION 7 FRAME MODIFICATIONS FRAME MODI...

Page 6: ...IREMENTS 9 2 Routing of Wires and Hoses near Exhaust System 9 4 APPENDIX A VEHICLE IDENTIFICATION VIN Location A 1 Chassis Number Locations A 1 vehicle identification labels A 2 Tire Rim and Weight Ra...

Page 7: ...r Medium Tanks 4 5 Figure 4 5 Horizontal Series Exhaust with Small or Medium Tanks 4 6 Figure 4 6 Vertical Exhaust with Small or Medium Tanks 4 6 Figure 4 7 Horizontal Crossover Exhaust system with Sm...

Page 8: ...Tray 8 16 FIGURE 8 13 Telltale Icons continued on page 8 18 8 17 FIGURE 8 14 Spare switches wired to Power 8 19 Figure 8 15 Optional Switches 8 20 Figure 8 16 Switch and Wiring for Customer Installed...

Page 9: ...m 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 builde...

Page 10: ...12 11 Section 1 Introduction Page Intentionally Left Blank...

Page 11: ...llow 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 inj...

Page 12: ...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 t...

Page 13: ...s 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 b...

Page 14: ...se 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...

Page 15: ...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 shoul...

Page 16: ...market 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 t...

Page 17: ...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 1 PTO 5 High Exhaust System Temperature HEST 10 Brake Fail 2 Wait to St...

Page 18: ...y not be reduced All sensors must be retained in existing locations To retain system seal proper clamp torque must be used Refer to service manual for proper clamp torque Charge Air Cooler System The...

Page 19: ...ms on tandem suspension FS Front suspension height from centerline of axle up to the bottom of the frame rail OAL Overall Vehicle Length SOC Side of Cab RS Rear suspension height from centerline of ax...

Page 20: ...an example of Kenworth s turn circle calculation made in Prospector for your specific chassis Your local Kenworth dealer can provide this information to you Figure 3 1 Prospector Turn Circle Analysis...

Page 21: ...surements 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 or...

Page 22: ...0 370 with Single Rear Axle Overall Fore Aft Dimensions inches mm WB OAL AF CA 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 188 4775 304...

Page 23: ...3 5 Section 3 Dimensions 12 11 Detail Views Top of Cab Roof Mounted Options T270 370 Figure 3 3 Top of Cab View T270 T370 Roof Mounted Options Figure 3 4 Side of Cab View T270 370 Roof Mounted Options...

Page 24: ...ood Lamps T270 370 Figure 3 5 Flush Mounted Flood Lamp Locations inches mm 37 2 945 25 635 62 4 1585 C L 25 635 High Mount Flood Lamp Elevation BOF 43 7 1110 Mid Mount Flood Lamp Elevations Mid Mount...

Page 25: ...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...

Page 26: ...hes mm WB A CB C D E 153 101 8 2585 Y 1 For without a square end of frame crossmember 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...

Page 27: ...lus per Rail cu in RBM per Rail lbs Inch Weight per Inch per Pair lbs Height H inch mm Flange Width W inch mm Thickness T inch mm 9 7 8 Frame Rail T170 T270 9 88 1 251 767 2 10 9 88 251 3 46 87 8 0 25...

Page 28: ...m 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 Parallel Battery Box LH Under Cab for Hydraulic braked Truck without an Accessory Air...

Page 29: ...CAB RIGHT SIDE UNDER CAB Figure 3 11 T270 370 22 Fuel Tank Mounting Measurements inches mm 22 Fuel Tank Height A inch mm Standard 16 3 416 Raised 1 Inch 15 3 389 24 5 inch Fuel Tanks T270 370 29 0 790...

Page 30: ...ection 3 Dimensions 3 12 12 11 Rectangular Fuel Tank Rectangular Fuel Tank Mounting 22 2 564 6 0 152 6 0 152 16 8 427 17 9 455 12 1 307 30 7 780 Figure 3 13 Rectangular Fuel Tank Measurements inches m...

Page 31: ...iew 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 6 1 154 27 7 704 BOF 0 7 17 Rear View Battery Box LH u...

Page 32: ...xhaust Muffler DPF Measurements inches mm Table 3 10 RH Under Frame Horizontal Exhaust Mounting Model A Inch mm B Inch mm C Inch mm D Inch mm E Inch mm F Inch mm G Inch mm H Inch mm T170 5 7 145 5 3 1...

Page 33: ...er Cab T270 370 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 FIGURE 3...

Page 34: ...DPF SCR Back of Cab Vertical Tail Pipe A Bottom of Rail BOF to Top of Tail Pipe mm A Bottom of Rail BOF to Top of Tail Pipe inch A Bottom of Rrail BOF to Top of Tail Pipe mm A Bottom of Rail BOF to To...

Page 35: ...4 8K Taperleaf with 19 5 Wheels 7 4 188 8 4 213 8K Taperleaf with 22 5 Wheels 7 8 198 8 8 224 10K Taperleaf with 19 5 Wheels 7 4 188 8 5 216 10K Taperleaf with 22 5 Wheels 7 8 198 8 9 226 12K Taperlea...

Page 36: ...8 198 Reyco 102 Multileaf 40K Capacity Tandem 8 0 203 9 6 244 Hendrickson HAS 402 Air Tandem 7 8 198 Hendrickson RT 403 40K Capacity Tandem 7 6 193 8 6 218 Chalmers 854 40 XL 40K Capacity Tandem 6 9 1...

Page 37: ...ll 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...

Page 38: ...Section 3 Dimensions 3 20 12 11 Kenworth AG400L tandem Rear Axle Table 3 15 Optional Kenworth Tandem Suspension Rating Axle Spacing Laden Ride Height Unladen Ride Height Kenworth AG400L 40K 52 8 5 8 5...

Page 39: ...on Type Rating Axle Spacing Laden Ride Height Unladen Ride Height Reyco 79KB single 4x2 13 5K 5 9 8 1 Reyco 79KB single 4x2 20K 6 6 9 0 Reyco 79KB single 4x2 21K 6 6 9 0 Reyco 79KB single 4x2 23K 6 6...

Page 40: ...ons 3 22 12 11 Reyco 102 Tandem Rear Axle Optional Reyco 102 Suspension TABLE 3 17 Rear Suspension Options Suspension Type Rating Axle Spacing Laden Ride Height Unladen Ride Height Reyco 102 Tandem 40...

Page 41: ...rickson HAS Single Suspensions TABLE 3 18 Rear Suspension Options Suspension Type Rating Axle Spacing Laden Ride Height Unladen Ride Height Hendrickson HAS 210L 21K 7 8 7 8 Hendrickson HAL 230L 26K 7...

Page 42: ...Single Rear Axle Optional Hendrickson Primaax Single Suspensions TABLE 3 18 1 Rear Suspension Options Suspension Type Rating Axle Spacing Laden Ride Height Unladen Ride Height Hendrickson Primaax 4x4...

Page 43: ...em Suspensions TABLE 3 19 Rear Suspension Options Suspension Type Rating Axle Spacing Laden Ride Height Unladen Ride Height Hendrickson HAS 402 tandem 40K 52 7 8 7 8 54 5 52 3 49 5 42 5 39 7 52 6 51 1...

Page 44: ...n Shown with a 54 Axle Spacing Without Track Rods Optional Hendrickson RT Tandem Suspensions TABLE 3 20 Rear Suspension Options Suspension Type Rating Axle Spacing Laden Ride Height Unladen Ride Heigh...

Page 45: ...ional Chalmers Tandem Suspensions TABLE 3 21 Rear Suspension Options Suspension Type Rating Axle Spacing Laden Ride Height Unladen Ride Height Chalmers 854 40 XL 6x4 40K 54 6 9 9 3 Chalmers 854 40 XL...

Page 46: ...ear 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...

Page 47: ...TABLE 3 22 Ground Clearance for Fuel and DEF Tanks 4x2 6x4 Front Suspension Front Tires Rear Suspension Rear Tires Component Dim A Bottom of Rail Down to Lowest Part on Component Dimension B Unladen...

Page 48: ...Front Suspension Front Tires Rear Suspension Rear Tires Component Dim A Bottom of Rail Down to Lowest Part on Component Dimension B Unladen Laden 12K Taper Leaf 54 R250F 11R22 5 14PR HAS230L M711 11R2...

Page 49: ...r Suspen sion Rear Tires Component Dim A Bottom of Rail Down to Lowest Part on Component Dimension B Unladen Laden 12K Taperleaf 54 R250F 11R22 5 14PR Reyco 79KB M711 11R22 5 14PR 45 Gal Rect Fuel Tan...

Page 50: ...west Part on Component Dimension B Unladen Laden 12K Taperleaf 54 R250F 11R22 5 14PR HAS230L M711 11R22 5 14PR LH Under Battery Box w air tanks 13 9 22 4 20 1 3rd Cab Access Step for Above Battery Box...

Page 51: ...ct 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...

Page 52: ...Section 3 Dimensions 3 34 12 11 Automatic Transmission Allison 3000RDS...

Page 53: ...3 35 Section 3 Dimensions 12 11 Manual Transmission...

Page 54: ...ction 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 Schemat...

Page 55: ...CR 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...

Page 56: ...equirements 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 res...

Page 57: ...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 li...

Page 58: ...een 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 co...

Page 59: ...odule 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 Mod...

Page 60: ...ust System Rectangular Small or Medium DEF Tanks Figure 4 7 Horizontal Crossover Exhaust system with Small or Medium Tanks The height differential between the supply module and dosing module can not e...

Page 61: ...ing 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...

Page 62: ...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...

Page 63: ...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 Unde...

Page 64: ...ection 4 Exhaust Aftertreatment 4 11 12 11 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 Tailpip...

Page 65: ...ertreatment 4 12 12 11 Horizontal DPF and SCR with Horizontal Tailpipe Figure 4 13 Isometric view of Horizontal DPF and SCR with Horizontal Tailpipe Figure 4 14 Top view of Horizontal DPF and SCR with...

Page 66: ...Section 4 Exhaust Aftertreatment 4 13 12 11 Figure 4 15 Right view of Horizontal DPF and SCR with Horizontal Tailpipe Figure 4 16 Back view of Horizontal DPF and SCR with Horizontal Tailpipe...

Page 67: ...t 4 14 12 11 Horizontal Series DPF and SCR with Horizontal Tailpipe Figure 4 17 Isometric view of Horizontal Series DPF and SCR with Horizontal Tailpipe Figure 4 18 Top view of Horizontal Series DPF a...

Page 68: ...ction 4 Exhaust Aftertreatment 4 15 12 11 Figure 4 19 Right view of Horizontal Series DPF and SCR with Horizontal Tailpipe Figure 4 20 Back view of Horizontal Series DPF and SCR with Horizontal Tailpi...

Page 69: ...Section 4 Exhaust Aftertreatment 4 16 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...

Page 70: ...Section 4 Exhaust Aftertreatment 4 17 12 11 Figure 4 23 Right view of Vertical Independent DPF and SCR Figure 4 24 Back view of Vertical Independent DPF and SCR...

Page 71: ...ipes back of cab mount DPF RH under 68 0 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 Tir...

Page 72: ...ng dimensions are consistent across the entire section to aid in the comparison of one layout option versus another TABLE 5 1 Dimension Index A Air Dryer F1 Fuel Tank RHS B Battery box F2 Fuel Tank LH...

Page 73: ...nts 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 fu...

Page 74: ...EF Tank 6 6 N A 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 BOC Back Of Cab LHUC L...

Page 75: ...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 D...

Page 76: ...al tailpipe RHUC cylindrical fuel tank RH BOC cylindrical DEF tank and LHUC battery box Chart located on page 5 17 D9 is used with horizontal Crossover DPF SCR LH horizontal tailpipe RHUC rectangular...

Page 77: ...ngular 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 LHUC rectangular fuel tanks RHUC rectang...

Page 78: ...ular fuel tank RHUC rectangular DEF tank and LHUC battery box Chart located on page 5 29 D21 is a T170 specific configuration used with horizontal In Series DPF SCR RH horizontal tailpipe RHUC LHUC re...

Page 79: ...is a Hybrid configuration used with horizontal 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 locat...

Page 80: ...l fuel tank RH BOC cylindrical DEF tank LHUC hybrid battery box and LH BOC hybrid PEC Chart located on page 5 38 H7 is a Hybrid configuration used with horizontal In Series DPF SCR RH horizontal tailp...

Page 81: ...4 Fuel Tank Size Fuel Tank Length in Dimension F BOC to Fuel Tank in Dimension D BOC to DEF Tank in Diameter Gallons DEF Tank Size Small Medium Rectangular 22 Diameter Tank 56 35 6 37 5 19 7 29 5 N A...

Page 82: ...5 Fuel Tank Size Fuel Tank Length in Dimension F BOC to Fuel Tank in Dimension D BOC to DEF Tank in Diameter Gallons DEF Tank Size Small Medium Rectangular 22 Diameter Tank 56 35 6 44 8 14 2 24 N A 75...

Page 83: ...ion B BOC to Battery Box in Dimension D BOC to DEF Tank in Diameter Gallons DEF Tank Size Small Medium 22 Diameter Tank 56 35 6 0 4 21 1 14 2 24 75 47 3 12 1 32 8 100 62 2 27 0 47 7 120 74 3 39 1 59 8...

Page 84: ...e Layouts 5 13 12 11 D4 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 available with a Rectangular Fuel Tank and...

Page 85: ...Section 5 Frame Layouts 5 14 12 11 D5 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...

Page 86: ...Section 5 Frame Layouts 5 15 12 11 D6 Dimension E BOC to DPF SCR 0 0in Dimension D BOC to DEF Tank 0 4in This configuration is only available with a Rectangular Fuel Tank and Small DEF Tank...

Page 87: ...E 5 7 Fuel Tank Size Fuel Tank Length in Dimension F1 BOC to RH Fuel Tank in Dimension F2 BOC to LH Fuel Tank in Dimension D BOC to DEF Tank in Diameter Gallons DEF Tank Size Small Medium 22 Diameter...

Page 88: ...rakes only Dimension E1 BOC to DPF SCR 30in Dimension E3 BOC to Diffuser 49 2in TABLE 5 8 Fuel Tank Size Fuel Tank Length in Dimension F BOC to RH Fuel Tank in Dimension D BOC to DEF Tank in Diameter...

Page 89: ...ension 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 Dimen...

Page 90: ...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...

Page 91: ...l Tank in Dimension F2 BOC to LH Fuel Tank in Dimension B BOC to Battery Box in Dimension D BOC to DEF Tank in Diameter Gallons DEF Tank Size Small Medium 22 Diameter Tank 56 35 6 0 4 0 4 32 8 30 7 40...

Page 92: ...OC to Battery Box 5 4in TABLE 5 10 Fuel Tank Size Fuel Tank Length in Dimension F1 BOC to RH Fuel Tank in Dimension D BOC to DEF Tank in Diameter Gallons DEF Tank Size Small Medium 22 Diameter Tank 56...

Page 93: ...4in TABLE 5 11 Fuel Tank Size Fuel Tank Length in Dimension F1 BOC to RH Fuel Tank in Dimension D BOC to DEF Tank in Diameter Gallons DEF Tank Size Small 22 Diameter Tank 56 35 6 0 4 25 2 75 47 3 N A...

Page 94: ...11 D14 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 to Fuel Tank 0 2in This configuration is only available with a Rectangu...

Page 95: ...5 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 This configuration is only available with a Rect...

Page 96: ...n Dimension F1 BOC to RH Fuel Tank in Dimension F2 BOC to LH Fuel Tank in Dimension B BOC to Battery Box in Dimension D BOC to DEF Tank in Diameter Gallons DEF Tank Size Small Medium 22 Diameter Tank...

Page 97: ...to SCR 83 8in Dimension E3 BOC to Diffuser 103 0in TABLE 5 13 Fuel Tank Size Fuel Tank Length in Dimension F BOC to RH Fuel Tank in Dimension D BOC to DEF Tank in Diameter Gallons DEF Tank Size Small...

Page 98: ...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 Dimension B BOC to Battery Box 15 0in This configurat...

Page 99: ...er 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 i...

Page 100: ...n 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...

Page 101: ...1 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 availab...

Page 102: ...11 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 Rectangu...

Page 103: ...D23 Dimension E1 BOC to DPF SCR 30in Dimension E3 BOC to Diffuser 49 2in 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 Recta...

Page 104: ...to Fuel Tank in Dimension D BOC to DEF Tank in Diameter Gallons DEF Tank Size Small Medium Rectangular 56 35 6 50 5 14 2 24 N A 75 47 3 62 2 100 62 2 77 1 Rectangular Tank 45 28 0 42 9 N A N A 11 5 F...

Page 105: ...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 4...

Page 106: ...Diffuser 49 2in TABLE 5 16 Fuel Tank Size Fuel Tank Length in Dimension F BOC to RH Fuel Tank in Dimension D BOC to DEF Tank in Diameter Gallons DEF Tank Size Small Medium 22 Diameter Tank 56 35 6 0 4...

Page 107: ...ybrid 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 Wheelbase PEC Length DIM P BOC to PEC 153 185 56 1 63 1...

Page 108: ...th in Dimension F BOC to RH Fuel Tank in Dimension D BOC to DEF Tank in Diameter Gallons DEF Tank Size Small Medium 22 Diameter Tank 56 35 6 0 4 25 2 35 0 75 47 3 N A N A N A 100 62 2 N A N A N A 120...

Page 109: ...uel Tank Size Fuel Tank Length in Dimension F BOC to RH Fuel Tank in Dimension D BOC to DEF Tank in Diameter Gallons DEF Tank Size Small Medium 22 Diameter Tank 56 35 6 0 4 11 4 21 2 75 47 3 12 1 25 2...

Page 110: ...2in Dimension E2 BOC to SCR 83 8in Dimension E3 BOC to Diffuser 103 0in Dimension 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 DI...

Page 111: ...Section 5 Frame Layouts 5 40 12 11 Page Intentionally Left Blank...

Page 112: ...cab body movement See Figure 6 2 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 inche...

Page 113: ...sis See Figure 6 3 Body Subframe Rail Chassis Frame Rail Sill Spacer FIGURE 6 3 Spacer Between Frame Sill and Body Rail Rubber or Plastic Brackets When mounting a body to the chassis with brackets we...

Page 114: ...th of the rails and if not done properly can cause the frame rails to fail 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 I...

Page 115: ...es 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 in...

Page 116: ...ing U Bolt Frame Rail Spacer Hardwood or Steel U Bolt Spacer FIGURE 6 8 Clearance Space for Air Lines and Cables Do not notch frame rail flanges to force a U bolt fit Notched or damaged frame flanges...

Page 117: ...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...

Page 118: ...For vehicles equipped with a Hybrid Battery Box frame mounted components or body installations must allow a minimum clearance of 4 behind the rear surface of the box and must not extend below the batt...

Page 119: ...to the air inlet duct on the front of the PEC and the air exhaust duct on the rear of the PEC The temperature of the air entering the PEC must be the same temperature as the ambient air temperature th...

Page 120: ...Section 6 Body Mounting 6 9 12 11 Page Intentionally Left Blank...

Page 121: ...frame rail and could result in frame rail cracks Hole diameter should not exceed the bolt diameter by more than 060 inches 1 5 mm Oversized holes could result in excessive frame wear around the hole...

Page 122: ...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 ins...

Page 123: ...e 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 in the frame When relocating...

Page 124: ...ear to Obtain Desired Cutoff Do Not Mount the Suspension Bracket On the Added Frame Rail Mount the suspension Brackets On the Original Rail see frame insert section figures 7 1 7 2 Relocated Rear Susp...

Page 125: ...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 spr...

Page 126: ...onnections to the vehicle batteries 2 Disconnect all ECM connectors 3 Do no use the ECM or engine ground stud for the ground of the welding probe 4 Ensure that the ground connection for the welder is...

Page 127: ...5 195 3 4 394 462 290 340 7 8 517 626 380 460 1 952 1129 800 830 1 1 8 1346 1591 990 1170 1 1 4 1877 2217 1380 1630 Torque values apply to fasteners with clean threads lightly lubricated with hardened...

Page 128: ...Section 7 Frame Modifications 7 8 12 11 Page Intentionally Left Blank...

Page 129: ...izes 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 advantage...

Page 130: ...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 F...

Page 131: ...ITCHES SOME CECU 3 FIGURE 8 4 Multiplexed Instrumentation Block Diagram V CAN Vehicle Controller Area Network The V CAN also referred to as the J1939 is used to transmit data between the transmission...

Page 132: ...river Warning and Indicator Module DWIM pre installed standard and or editable warning light symbols called telltale cards Each telltale card slides into the left and right sides of the Driver Warning...

Page 133: ...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 The mechanical CVSG do not perform a power on self t...

Page 134: ...ere 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...

Page 135: ...sses 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...

Page 136: ...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 Restrictio...

Page 137: ...Section 8 Electrical 8 9 12 11 FIGURE 8 10 Fuel Filter Restriction Pressure Gauge Sensor Location typical...

Page 138: ...CHES 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 acc...

Page 139: ...Section 8 Electrical 8 11 12 11 2 Then lift the panel out of the dash and unclip the main harness 3 To remove the gauges unscrew the gauge collar...

Page 140: ...n 8 Electrical 8 12 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 5 Pinch the bottom tabs to release the switch from the...

Page 141: ...8 Electrical 8 13 12 11 6 The fuse box is located behind the far right panel 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 co...

Page 142: ...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 car...

Page 143: ...tment Filter Regeneration Yellow Fixed 12 Right Turn Arrow Illuminates to Indicate Right Turn Signal is Applied Green Fixed Only the positions labeled as editable in the chart above can be changed You...

Page 144: ...al 8 16 12 11 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 FIGURE 8 12 Bl...

Page 145: ...12 11 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 FIGURE 8 13 Telltale Icon...

Page 146: ...he 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...

Page 147: ...ical panel cover For example SPARE ACC SWITCH 1 is the label for spare switch 1 FIGURE 8 14 Spare switches wired to Power Sales Codes 8208495 2 spare 8208496 3 spare Location LH Rail Approx 400mm back...

Page 148: ...witches Air Valves and Gauges Model Brake System Max Number of Optional Switches Max Number of Optional Air Valves Max Number of Optional Gauges T170 Hyd 9 6 5 T270 Hyd 9 6 5 Air 9 6 3 T370 Hyd 9 6 5...

Page 149: ...1 PTO Full Guard Rocker DPST Amber P27 1127 025 Spare Rocker SPST Green P27 1127 031 Figure 8 16 Switch and Wiring for Customer Installed Beacon Lamp in the chassis Harness Sales Code 9080202 External...

Page 150: ...ched 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...

Page 151: ...ual 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...

Page 152: ...y behind the battery box See Figure 8 20 Truck Body Connector to Chassis Harness Left Rail FIGURE 8 19 Location of Standard Body Harness Connection For shipping purposes the body harness is coiled and...

Page 153: ...al Lamp W L34RT Green Black YEL2312 Yellow 10A F24 Shared w Front Turn LP LH Turn Left Turn Sig nal Lamp Y L33LT Yellow Black YEL2311 Yellow 10A F77 Shared w Front Turn LP Aux PWR Auxiliary Power body...

Page 154: ...nel locations F79 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 throu...

Page 155: ...wire for the shield Pins 1 2 Pins 1 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 circui...

Page 156: ...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 typical...

Page 157: ...r power distribution module we have simplified the integration of body related electrical systems to the vehicle batteries The module provides the following 3 Midi fuse locations with M8 output studs...

Page 158: ...20 008 Jumper Cable Negative 4 0 1 N63 1002 Battery Pad 5 0 2 N20 1025 Battery Retainer lower 6 1 0 4 W34 1070 060 Bolt Hex M8 X 60 7 1 0 4 K169 162 8CA Nut Hex Metric 8 1 0 8 K363 338 2 312 Washer Fl...

Page 159: ...is required for adequate power A liftgate installation must have a dedicated circuit to distribute power to the liftgate Liftgate Power Source Liftgate motors will typically use DC power A convenient...

Page 160: ...e 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 t...

Page 161: ...00 to provide power from batteries to Mega Fuse Tie Body Ground circuits to additional ground stud located on the lower outboard driver side of firewall at cover plate Engine Connections Electronic en...

Page 162: ...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 Follow the engine manufacturer s guidelines for...

Page 163: ...n Off 39 GRA3511 Gray 18 5 Remote Throttle Enable None GRA3143 Gray 18 6 Power Ignition None ORN1229 Orange 18 7 F62 Indicator IGN 10A Engine Ground None WHT1513 White 18 8 Torque Limit Switch 26 GRA3...

Page 164: ...mote Throttle Enable None GRA3143 Gray 18 6 GRA3143 Gray 16 Power Ignition None ORN1229 Orange 18 7 ORN1229 Orange 16 Engine Ground None WHT1513 White 18 8 WHT1513 White 16 Torque Limit Switch 26 GRA3...

Page 165: ...Section 8 Electrical 8 37 12 11 FIGURE 8 31 Cab Load Center mPDC...

Page 166: ...Return GRY Control VIO Reference Voltage BLU Sensor Signal GRN Sensor common not connected to GND WHT Ground Each wire has at a minimum a 7 character label the first three characters are the circuits...

Page 167: ...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 Color Circuit White Ground Blac...

Page 168: ...a mp 4 Stop Lamp Trailer 4 Optional Switched Circuit 5 Right Turn Trailer 5 6 Tail Lamp Trailer 6 7 Trailer ABS Power or Trailer Hotline 7 Trailer ABS Power Below is a description of how the cab ABS a...

Page 169: ...3731 connectors Kenworth provides option variations within the above combinations This may include up to 2 spare circuits on pins 2 4 of the ISO 3731 connector which may or may not be switched In addi...

Page 170: ...Section 8 Electrical 8 42 12 11 Page Intentionally Left Blank...

Page 171: ...her 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...

Page 172: ...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 bun...

Page 173: ...charge 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 45...

Page 174: ...15 from the turbo n a 2 minimum 4 minimum 3 minimum Fuel tanks and hydraulic tanks crossing tank parallel to tank end of tank aluminum ceramic coated exhaust pipe crossing tank n a n a n a n a 2 minim...

Page 175: ...er position in the VIN See Table A 1 and Figure A 1 Code Year Code Year 5 2005 A 2010 6 2006 B 2011 7 2007 C 2012 8 2008 D 2013 9 2009 Table A 1 Model Year Code Designations VIN Location The VIN is ma...

Page 176: ...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 Incomplete Vehicle Certification Label on Incomplete Vehicles It c...

Page 177: ...b 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 on the passenger s door frame COMPONENT IDENTIFICATIO...

Page 178: ...ication The rear axle identification numbering system includes two labels or stamps 1 Axle Housing Number Tag located on the left forward side of the housing arm This tag identifies the axle housing 2...

Page 179: ...12 11 Kenworth Truck Company P O Box 1000 Kirkland WA 98083 425 828 5000...

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