Paccar Kenworth T170 Hybrid 2011 Builder's Manual
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Paccar Kenworth T170 Hybrid 2011 Builder's Manual

Paccar Kenworth T170 Hybrid 2011 Builder's Manual

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Kenworth
T170 / T270 / T370 and Hybrid
2011 Body Builders Manual
®

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Summary of Contents for Paccar Kenworth T170 Hybrid 2011

  • Page 1 Kenworth T170 / T270 / T370 and Hybrid 2011 Body Builders Manual ®...

  • Page 3: Body Builders Manual

    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: Table Of Contents

    Body Builder’s Manual Contents SECTION 1 — INTRODUCTION SCOPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 SECTION 2 —...

  • Page 5: Contents

    Body Builder’s Manual Contents GROUND CLEARANCES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28 PTO CLEARANCES .
  • Page 6 Body Builder’s Manual Contents WIRING FOR A LIFTGATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-31 Liftgate Power Source .
  • Page 7 Figures FIGURES FIGURE 2-1. Incomplete Vehicle Certification Document . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 FIGURE 2-2.
  • Page 8 FIGURE 8-29. PACCAR Px-6 and Px-8 . . . . . . . . . . . . . . . . . .

  • Page 9: Section 1 - Introduction

    Section 1 Introduction 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 bodies 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.
  • Page 10 Section 1 Introduction Page Intentionally Left Blank. 12/11...

  • Page 11: Safety Signals

    Section 2 Safety & Compliance SAFETY SIGNALS There are a number of alerting messages in this book . Please read and follow them . They are there for your protection and information. These alerting messages can help you avoid injury to yourself or others and help prevent costly damage to the vehicle.

  • Page 12: Federal Motor Vehicle Safetystandards Compliance

    Section 2 Safety & Compliance FEDERAL MOTOR VEHICLE SAFETY STANDARDS COMPLIANCE As an Original Equipment Manufacturer (OEM), Kenworth Truck Co . ensures that our products comply with all applicable U.S. or Canadian Federal Motor Vehicle Safety Standards. However, the fact that this vehicle has no fifth wheel and that a Body Builder (Intermediate or Final Stage Manufacturer) will be doing additional modifications means that the vehicle was incomplete when it left the build plant .

  • Page 13: Noise And Emissions Requirements

    Section 2 Safety & Compliance These statements are just part of the changes to the new certification regulation. Please refer to the Feb 15, 2005 final rule for all of the details related to this regulation. You can contact NTEA Technical Services Department at 1-800-441-NTEA for a copy of the final rule (DocID 101760).

  • Page 14: Fuel System

    Section 2 Safety & 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 .

  • Page 15: Cooling System

    Section 2 Safety & Compliance • The following modifications may only be done within the guidelines of the “DEF System Relocation Guide.” • Modifications to Diesel Exhaust Fluid (DEF) throttle, suction, or pressure lines • Modification or relocation of the DEF tank •...

  • Page 16: Electrical System

    • Wiring extensions for the after-treatment wiring are available for relocating the DEF tank from your dealer via Paccar Parts . For relocation of DEF tank, refer to the after-treatment section of this manual . • The emission system requires an accurate Outside Air Temperature (OAT) reading in order to properly run its control algorithms.

  • Page 17: Figure 2-4. Aerodynamic Mirror Oat Sensor Location

    Section 2 Safety & 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 .

  • Page 18: Air Intake System

    Section 2 Safety & Compliance Air Intake System The following are highlights of some of the more common or critical aspects of this system . • The air intake screen may not be blocked, either fully or partially • Modification to the air intake system may not restrict airflow. For example, pipe diameter may not be reduced •...

  • Page 19: Section 3 - Dimensions

    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. 12/11...

  • Page 20: Figure 3-1. Prospector Turn Circle Analysis

    Section 3 Dimensions Prospector 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. FIGURE 3-1. Prospector Turn Circle Analysis Please consult your local Kenworth Dealer for this information, as it is chassis specific.

  • Page 21: Overall Dimensions

    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 .
  • Page 22 Section 3 Dimensions TABLE 3-3. Hydraulic Brake Vehicles. T170 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) 188 (4775)

  • Page 23: Detail Views

    Section 3 Dimensions 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 12/11...

  • Page 24: Back Of Cab: Flush Mounted Flood Lamps - T270/370

    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 Elevations 62 .4 (1585) Mid Mount Flood 14 .4 (365) 14 .4 (365) Lamp Location for 43 .7 Vertical Tailpipe...

  • Page 25: Detail Views

    Section 3 Dimensions DETAIL VIEWS Crossmember Locations – T170 FIGURE 3-6. T170 Crossmember Location TABLE 3-5 T170 Cross member. Location: measured from front axle centerlines [inches (mm)] 101 .8 (2585) 121 .1(3075) 1 .) For without a square end of frame cross- member with an AF range of 80 (2032) 101 .8 (2585) 121 .1(3075)

  • Page 26: Detail Views

    Section 3 Dimensions DETAIL VIEWS Crossmember Locations – T170 FIGURE 3-7. T170 Crossmember Location TABLE 3-6 T170 Cross member. Location: measured from front axle centerlines [inches (mm)] 101 .8 (2585) 1 .) For without a square end of frame crossmember with an AF range of 80 (2032)to 125(3175) a crossmember is installed at: 101 .8 (2585) E=WB+64 .4”(1636mm)

  • Page 27: Components

    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 .

  • Page 28: Battery Box - T270/370

    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)] Type A, inch (mm) B, inch (mm)

  • Page 29: 22-Inch Fuel Tanks - T270/370

    Section 3 Dimensions 22-inch Fuel Tanks — T270/370 Round Fuel Tank Mounting 25 .9 (658) 11 .0 6 .7 (169) (279) 10 .4 (265) 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”...

  • Page 30: Rectangular Fuel Tank

    Section 3 Dimensions Rectangular Fuel Tank Rectangular Fuel Tank Mounting 22 .2 6 .0 (564) (152) 16 .8 (427) 17 .9 (455) 6 .0 (152) 12 .1 (307) 30 .7 (780) FIGURE 3-13. Rectangular Fuel Tank Measurements [inches (mm)] 3-12 12/11...

  • Page 31: Battery Box - T270/370

    Section 3 Dimensions Battery Box – T270/370 Cantilever Battery Box Back of Cab. 8 .0 (202) 31 .0 (787) 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) 0 .7 (17) 6 .1 (154)

  • Page 32: Horizontal Exhaust/Muffler

    Section 3 Dimensions Horizontal Exhaust/Muffler Horizontal Exhaust Muffler/DPF Mounting FIGURE 3-16. Horizontal Exhaust Muffler/DPF Measurements [inches (mm)] TABLE 3-10. RH Under Frame Horizontal Exhaust Mounting Model Inch (mm) Inch (mm) Inch (mm) Inch (mm) Inch (mm) Inch (mm) Inch (mm) Inch (mm) T170 5 .7 (145)

  • Page 33: Step/Dpf Box Assembly Rh Under Cab - T270/370

    Section 3 Dimensions Step/DPF Box Assembly RH Under 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 3-18. T270/370 Vertical Tailpipe on Right Side of Cab [inches (mm)] 3-15 12/11...

  • Page 34: Figure 3-19. T270/T370 With Vertical Muffler/Dpf Behind Rh Side Of Cab

    Section 3 Dimensions RH Back of Cab Independent Muffler — T270/T370 FIGURE 3-19. T270/T370 with Vertical Muffler/DPF Behind RH Side of Cab [inches [mm]] TABLE 3-11. Vertical Tail Pipe Height Dimensions . Vertical Tail Pipe RH Side of Cab Independent Vertical DPF/SCR Back of Cab A Bottom of Rail A Bottom of Rail A Bottom of Rrail...

  • Page 35: Ride Heights

    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.
  • Page 36 Section 3 Dimensions TABLE 3-13. Estimated Rear Suspension Ride Heights RS: Estimated Rear Ride Height Model Rear Suspension (# Rear Axles) Laden inch (mm) Unladen, inch (mm) T170 4x2 Reyco 79KB 13 .5K (Single) 5 .9 (150) 8 .1 (206) Reyco 79KB 20K Capacity (Single) 6 .6 (168) 9 .0 (229)

  • Page 37: Rear Suspension Layouts

    Section 3 Dimensions REAR SUSPENSION LAYOUTS The rear suspension layouts are provided as a tool to help layout bodies prior to arrival. The applicable dimensions are shown . Be sure to check the axle spacing that is shown, as alternate spacings may exist and could change some of the dimensions .

  • Page 38: Kenworth Ag400L Tandem Rear Axle

    Section 3 Dimensions KENWORTH AG400L TANDEM REAR AxLE TABLE 3-15. Optional Kenworth Tandem Suspension Rating Axle Spacing Laden Ride Height Unladen Ride Height Kenworth AG400L 52” 8 .5” 8 .5” 3-20 12/11...

  • Page 39: Reyco 79Kb Single Rear Axle

    Section 3 Dimensions REYCO 79KB SINGLE REAR AxLE 30 .2 (755) 30 .1 (765) 28 .7 (728) 29 .0 (736) Optional Reyco 79KB Suspensions TABLE 3-16. Rear Suspension Options Suspension Type Rating Axle Spacing Laden Ride Height Unladen Ride Height Reyco 79KB single (4x2) 13 .5K 5 .9”...

  • Page 40: Reyco 102 Tandem Rear Axle

    Section 3 Dimensions REYCO 102 TANDEM REAR AxLE Optional Reyco 102 Suspension TABLE 3-17. Rear Suspension Options Unladen Ride Suspension Type Rating Axle Spacing Laden Ride Height Height Reyco 102 Tandem 52” 8 .0” 9 .6” 3-22 12/11...

  • Page 41: Hendrickson Has Single Rear Axle

    Section 3 Dimensions HENDRICKSON HAS SINGLE REAR AxLE 26 .1 24 .5 23 .9 16 .1 28 .9 15 .5 21 .7 13 .9 5 .9 5 .5 2 .4 Ride 3 .7 Height Optional Hendrickson HAS Single Suspensions TABLE 3-18. Rear Suspension Options Laden Ride Unladen Ride Suspension Type...

  • Page 42: Hendrickson Primaax Single Rear Axle

    Section 3 Dimensions HENDRICKSON PRIMAAx SINGLE REAR AxLE Optional Hendrickson Primaax Single Suspensions TABLE 3-18-1. Rear Suspension Options Laden Ride Unladen Ride Suspension Type Rating Axle Spacing Height Height Hendrickson Primaax (4x4) 15 .5” 15 .5” Hendrickson Primaax (4x4) 15 .5” 15 .5”...

  • Page 43: Hendrickson Has Tandem Suspension

    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 8 .0 5 .9 2 .4 3 .1 Ride Height Axle Spacing 38 .8 39 .9 41 .5 42 .1 49 .9...

  • Page 44: Hendrickson Rt Tandem Suspension

    Section 3 Dimensions HENDRICKSON RT TANDEM SUSPENSION Shown with a 54” Axle Spacing Without Track Rods 55 .2 53 .0 47 .4 Optional Hendrickson RT Tandem Suspensions TABLE 3-20. Rear Suspension Options Laden Ride Unladen Ride Suspension Type Rating Axle Spacing Height Height Hendrickson RT403 6”...

  • Page 45: Chalmers 854-40 Tandem Suspension

    Section 3 Dimensions CHALMERS 854-40 TANDEM SUSPENSION Optional Chalmers Tandem Suspensions TABLE 3-21. Rear Suspension Options Laden Ride Unladen Ride Suspension Type Rating Axle Spacing Height Height Chalmers 854-40-xL (6x4) 54” 6 .9” 9 .3” Chalmers 854-40-xL-HS (6x4) 54” 7 .6” 9 .3”...

  • Page 46: Tire Data

    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...
  • Page 47 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”...
  • Page 48 Section 3 Dimensions TABLE 3-23. Ground Clearance for Battery Box & DPF/SCR (4x2, 6x4) Dimension “B” Dim “A” (Bottom Front Rear Rear of Rail Down to Front Tires Component Suspension Suspension Tires Lowest Part on Component) Unladen Laden LH Under Battery 13 .9 15 .4 13 .2...
  • Page 49 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”...
  • Page 50 Section 3 Dimensions GROUND CLEARANCE (4x4, 6x6) TABLE 3-25. Ground Clearance for Battery Box & DPF/SCR (4x4, 6x6) Dimension “B” Dim “A” (Bottom Front Front Rear Rear of Rail Down to Component Suspension Tires Suspension Tires Lowest Part on Component) Unladen Laden LH Under Battery Box...

  • Page 51: Pto Clearances

    Section 3 Dimensions 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 & power pumps are not included. Body builders should select the appropriate PTO for their application and customer requirements .
  • Page 52 Section 3 Dimensions Automatic Transmission – Allison 3000RDS: 3-34 12/11...
  • Page 53 Section 3 Dimensions Manual Transmission: 3-35 12/11...

  • Page 54: Section 4 - Exhaust & Aftertreatment

    Section 4 Exhaust & Aftertreatment ExHAUST AND AFTER-TREATMENT INFORMATION The following section is designed to give you information regarding the exhaust and after-treatment systems on Kenworth chassis . All Kenworth’s equipped with 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.
  • Page 55 Section 4 Exhaust & Aftertreatment DEF will freeze at approximately 11° F. In order to keep DEF from freezing all tanks will be heated with engine coolant. The following schematic shows the routing of these lines . 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 .

  • Page 56: General Guidelines For Def System

    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 .

  • Page 57: Measurement Reference Points

    Section 4 Exhaust & 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 pressure line.

  • Page 58: Figure 4-3. Orientation Of Dosing Module

    Section 4 Exhaust & Aftertreatment 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 .

  • Page 59: Figure 4-5. Horizontal Series Exhaust With Small Or Medium Tanks

    Section 4 Exhaust & 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 .

  • Page 60: Figure 4-7. Horizontal Crossover Exhaust System With Small Or Medium Tanks

    Section 4 Exhaust & 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”) .

  • Page 61: Figure 4-8. Routing Def Lines And Def Trap

    Section 4 Exhaust & 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 .

  • Page 62: General Exhaust Information

    Section 4 Exhaust & Aftertreatment GENERAL ExHAUST INFORMATION Kenworth will offer four main DPF and SCR exhaust systems on Medium Duty chassis in 2010 . A Right Hand Under 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 .

  • Page 63: Figure 4-9. Isometric View Of Right Hand Under Dpf And Scr With Single Soc Tailpipe

    Section 4 Exhaust & Aftertreatment 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 4-10 12/11...

  • Page 64: Figure 4-11. Right View Of Right Hand Under Dpf And Scr With Single Soc Tailpipe

    Section 4 Exhaust & Aftertreatment 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...

  • Page 65: Figure 4-13. Isometric View Of Horizontal Dpf And Scr With Horizontal Tailpipe

    Section 4 Exhaust & Aftertreatment 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 Horizontal Tailpipe 4-12 12/11...

  • Page 66: Figure 4-15. Right View Of Horizontal Dpf And Scr With Horizontal Tailpipe

    Section 4 Exhaust & Aftertreatment 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 4-13 12/11...

  • Page 67: Figure 4-17. Isometric View Of Horizontal (Series) Dpf And Scr With Horizontal Tailpipe

    Section 4 Exhaust & Aftertreatment 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 and SCR with Horizontal Tailpipe 4-14 12/11...

  • Page 68: Figure 4-19. Right View Of Horizontal (Series) Dpf And Scr With Horizontal Tailpipe

    Section 4 Exhaust & Aftertreatment 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 Tailpipe 4-15 12/11...

  • Page 69: Figure 4-21. Isometric View Of Vertical Independent Dpf And Scr

    Section 4 Exhaust & Aftertreatment 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 4-16 12/11...

  • Page 70: Figure 4-23. Right View Of Vertical Independent Dpf And Scr

    Section 4 Exhaust & Aftertreatment 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...

  • Page 71: Exhaust Information

    Section 4 Exhaust & 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 Dimension A DPF mounted independent 76 .5”...

  • Page 72: Section 5 - Frame Layouts

    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 .

  • Page 73: Common Optional Components

    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 .

  • Page 74: Figure 5-1. Def Tank Dimensions

    Section 5 Frame Layouts SMALL DEF TANK RECTANGULAR DEF TANK (9-Gallon Usable Volume) (6 .6-Gallon Usable Volume) Medium DEF TANK (18-Gallon Usable Volume) FIGURE 5-1. DEF Tank Dimensions . TABLE 5-3. DEF Tanks Systems Usable Volume, Fuel Tank Description Gallons Diameter 22”...

  • Page 75: Frame Layout Index

    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 . 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 .
  • Page 76 Section 5 Frame Layouts 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 . 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 .
  • Page 77 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 LHUC 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 .
  • Page 78 Section 5 Frame Layouts D18 is used with horizontal In-Series DPF/SCR, RH horizontal tailpipe, RHUC & 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 .
  • Page 79 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 . 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 .
  • Page 80 Section 5 Frame Layouts 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 . 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 .
  • Page 81 Section 5 Frame Layouts 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 Fuel Tank Size BOC to DEF Tank (in)* Fuel Tank Dimension F Length (in)
  • Page 82 Section 5 Frame Layouts 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. Dimension D Fuel Tank Size BOC to DEF Tank (in) Dimension F Fuel Tank BOC to Fuel Tank,...
  • Page 83 Section 5 Frame Layouts Dimension E (BOC to DPF/SCR) = 0 .0in TABLE 5-6. Dimension D Fuel Tank Size Dimension F Dimension B BOC to DEF Tank (in) Fuel Tank BOC to BOC to Length (in) DEF Tank Size Fuel Tank, (in) Battery Box, (in) Diameter Gallons...
  • Page 84 Section 5 Frame Layouts 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 Small DEF Tank. 5-13 12/11...
  • Page 85 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. 5-14 12/11...
  • Page 86 Section 5 Frame Layouts 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. 5-15 12/11...
  • Page 87 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. Dimension D Fuel Tank Size Dimension F1...
  • Page 88 Section 5 Frame Layouts 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...
  • Page 89 Section 5 Frame Layouts 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...
  • Page 90 Section 5 Frame Layouts 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...
  • Page 91 Section 5 Frame Layouts Dimension E (BOC to DPF/SCR) = 16 .8in TABLE 5-9. Dimension D Fuel Tank Size Dimension F1 Dimension F2 Dimension B BOC to DEF Tank (in) Fuel Tank BOC to RH BOC to LH BOC to Battery Length (in) DEF Tank Size Fuel Tank, (in)
  • Page 92 Section 5 Frame Layouts 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 Dimension F1 BOC to DEF Tank (in) Fuel Tank BOC to Length (in)
  • Page 93 Section 5 Frame Layouts 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. Dimension D Fuel Tank Size BOC to DEF Tank (in) Dimension F1 Fuel Tank BOC to...
  • Page 94 Section 5 Frame Layouts 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 Rectangular Fuel Tank and Small DEF Tank.
  • Page 95 Section 5 Frame Layouts 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 Rectangular Fuel Tank and Small DEF Tank.
  • Page 96 Section 5 Frame Layouts 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 Dimension F1 Dimension F2 Dimension B BOC to DEF Tank (in) Fuel Tank BOC to RH...
  • Page 97 Section 5 Frame Layouts 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.
  • Page 98 Section 5 Frame Layouts 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 Dimension B (BOC to Battery Box) = 15 .0in This configuration is only available with a Rectangular Fuel Tank and Small DEF Tank.
  • Page 99 Section 5 Frame Layouts 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.
  • Page 100 Section 5 Frame Layouts 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.
  • Page 101 Section 5 Frame Layouts 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.
  • Page 102 Section 5 Frame Layouts 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.
  • Page 103 Section 5 Frame Layouts 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 Rectangular Fuel Tank and Small DEF Tank.
  • Page 104 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 BOC to DEF Tank (in) Dimension F Fuel Tank BOC to Fuel Length (in) DEF Tank Size...
  • Page 105 Section 5 Frame Layouts H2 Hybrid 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...
  • Page 106 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.
  • Page 107 Section 5 Frame Layouts H4 Hybrid 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 63 .1...
  • Page 108 Section 5 Frame Layouts H5 Hybrid Dimension E (BOC to DPF/SCR) = 16 .8in Dimension H (BOC to Hybrid Battery Box) = -2 .8in TABLE 5-18. Dimension D Fuel Tank Size Dimension F BOC to DEF Tank (in) Fuel Tank BOC to Length (in) DEF Tank Size...
  • Page 109 Section 5 Frame Layouts H6 Hybrid 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.
  • Page 110 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 Dimension F (BOC to RH Fuel Tank) = 0 .2in Dimension H (BOC to Hybrid Battery Box) = -2 .8in TABLE 5-20.
  • Page 111 Section 5 Frame Layouts Page Intentionally Left Blank. 5-40 12/11...

  • Page 112: Section 6 - Body Mounting

    Section 6 Body Mounting CRITICAL CLEARANCES Rear Wheels and Cab CAUTION: Insufficient clearance between rear tires and body structure could cause damage to the body during suspension movement. Allow at least 8 inches clearance (See Figure 6–1.) 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) .

  • Page 113: Figure 6-3. Spacer Between Frame Sill And Body Rail - Rubber Or Plastic

    Section 6 Body Mounting Body Mounting Using Brackets Always install a spacer between the body subframe and the top flange of the frame rail. CAUTION: 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.

  • Page 114: Figure 6-6. Crossmember-Gusset Hole Pattern Requirements

    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) .

  • Page 115: Body Mounting Using U-Bolts

    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.

  • Page 116: Figure 6-8. Clearance Space For Air Lines And Cables

    Section 6 Body Mounting Frame Rail U-Bolt Air Lines and Wiring Frame Rail Spacer Harness (Hardwood or Steel Check Clearance U-Bolt Spacer Space for Air Lines and Wiring FIGURE 6-8. Clearance Space for Air Lines and Cables WARNING: Do not notch frame rail flanges to force a U–bolt fit. Notched or damaged frame flanges could result in premature frame failure.

  • Page 117: Hybrid Clearances

    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 .

  • Page 118: Figure 6-11. Clearance Zones Around The Hybrid Battery Box Located Lh Under Cab

    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 .
  • Page 119 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).
  • Page 120 Section 6 Body Mounting Page Intentionally Left Blank. 12/11...

  • Page 121: Section 7 - Frame Modifications

    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.

  • Page 122: Modifying Frame Length

    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 .
  • Page 123 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 .

  • Page 124: Figure 7-3. Comparison Of Original, Shortened, And Extended Wheelbases

    Section 7 Frame Modifications 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.

  • Page 125: Welding

    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;...
  • Page 126 Section 7 Frame Modifications Welding Precautions: All Electronic Engines Before welding on vehicles with electronic engines, the following precautions should be observed. 1. Disconnect all electrical connections 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 .
  • Page 127 Section 7 Frame Modifications TORqUE REqUIREMENTS TABLE 7-1. Customary Grade 8 UNF or UNC . Fastener Torque Size Lb.-Ft. 5/16 22–30 16–22 41–54 30–40 7/16 75–88 55–65 109–122 80–90 9/16 156–190 115–140 224–265 165–195 394–462 290–340 517–626 380–460 952–1129 800-–830 1-1/8 1346–1591 990–1170...
  • Page 128 Section 7 Frame Modifications Page Intentionally Left Blank. 12//11...

  • Page 129: Section 8 - Electrical

    Don’t cut or tap into green/yellow twisted pairs. Only use “T” connectors, and only add approved J1939 components with validated software. 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 12/11...

  • Page 130: Figure 8-2. Kenworth B-Cab Dash

    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 .

  • Page 131: Figure 8-4. Multiplexed Instrumentation Block Diagram

    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 .

  • Page 132: Figure 8-5. Cecu Location

    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 . CECU FIGURE 8-5. CECU Location . Vehicle component inputs are sent to the CECU through the J1939 data bus or conventional wiring.

  • Page 133: Figure 8-6. Main Instrument Panel

    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).
  • Page 134 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 Blue Data, backlighting for Electronic Gauges Brown Backlighting for Mechanical Gauges White Return Yellow Power •...

  • Page 135: Figure 8-7. Instrumentation Harness Interface Diagram

    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.

  • Page 136: Figure 8-8. Firewall Air Junction Block (View From Inside Of Cab)

    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 .

  • Page 137: Figure 8-10. Fuel Filter Restriction Pressure Gauge Sensor Location (Typical)

    Section 8 Electrical FIGURE 8-10. Fuel Filter Restriction Pressure Gauge Sensor Location (typical) 12/11...

  • Page 138: Accessing Gauges And Switches

    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. 8-10 12/11...
  • Page 139 Section 8 Electrical 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...
  • Page 140 Section 8 Electrical 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 panel . 8-12 12/11...
  • Page 141 Section 8 Electrical 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 cover open.

  • Page 142: Figure 8-11. Telltale Symbol Standard Cards

    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.
  • Page 143 Section 8 Electrical TABLE 8-1. Telltales Position and Color Position Standard Function Light Color Editable or Fixed? Illuminates to Indicate PTO is Engaged Green Editable Check Transmission Illuminates During Transmission Fault Yellow Editable Illuminates to Indicate Left Trun Signal is Left Turn Arrow Green Fixed...

  • Page 144: Figure 8-12. Blank Telltale Tray

    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 . FIGURE 8-12. Blank Telltale Tray 8-16 12/11...

  • Page 145: Figure 8-13. Telltale Icons . (Continued

    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. FIGURE 8-13. Telltale Icons . (continued on page 8-18) . 8-17 12/11...
  • Page 146 Section 8 Electrical 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 .

  • Page 147: Figure 8-14. Spare Switches Wired To Power

    Section 8 Electrical ALARMS There are three spare Alarm female ¼” slide connector breakouts behind the speedo-tach cluster near the speedo-tach connector labeled: • Alarm 1A • Alarm 1B • 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 .

  • Page 148: Optional Switches, Air Valves And Gauges

    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. Max.

  • Page 149: Figure 8-15. Optional Switches

    Section 8 Electrical TABLE 8-4. Optional Switches . Description Switch Style Contacts Indicator Color Part Number Flood Lamps Cab Mounted Rocker DPST Green P27-1127-002 Beacon Lamp Rocker SPST Green P27-1127-011 Full Guard Rocker DPST Amber P27-1127-025 Spare Rocker SPST Green P27-1127-031 FIGURE 8-16.
  • Page 150 Section 8 Electrical TABLE 8-5. Switch and Wiring for Customer Installed Beacon Lamp . Switch Chassis Fuse Fuse Cab Connector Chassis Connector Fuse Buss Connector Connector size Description Description*** Description**** Description** Terminal F28* Spare ACC Beacon J13, P018, P764, Spare Circuits Lamp Beacon Lamp SW Beacon Lamp...

  • Page 151: Additional Spare Circuits

    Section 8 Electrical ADDITIONAL SPARE CIRCUITS If you just need spare power, wire into one of the 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. 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.

  • Page 152: Optional Body Builder Harness

    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 optional wiring harness.

  • Page 153: Figure 8-20. Body Junction Harness

    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 Function Circuit Wire Circuit Wire CAPACITY...

  • Page 154: Circuits Wired Through The Ignition

    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.
  • Page 155 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 builder’s mating harness must not exceed 2500mm.

  • Page 156: Figure 8-21. Epto Harness Location

    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 loads and the wires connected to these devices. For more details about 1939-11 VCAN specifications please refer to SAE J1939-11.

  • Page 157: Figure 8-22. Location Of Body Builder Distribution Module On Hybrid

    Section 8 Electrical 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 body builder power distribution module, we have simplified the integration of body-related electrical systems to the vehicle batteries.

  • Page 158: Figure 8-24. Adding A Third Battery

    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.

  • Page 159: Wiring For A Liftgate

    Section 8 Electrical FIGURE 8-25. Adding a Third Battery WIRING FOR A LIFTGATE 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 .

  • Page 160: Connecting The Liftgate Power

    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 liftgate manufacturer’s installation instructions.

  • Page 161: Amp Alternator (Recommended Hookup)

    Section 8 Electrical 270 AMP ALTERNATOR (RECOMMENDED HOOKUP) FIGURE 8-27: P27-6180 Fuse Holder . FIGURE 8-28: Battery Harness Jumper, Part No . P92-2683-100000 . • Use three batteries • Use P27-6180-150 Mega Fuse (Mount in Battery Box to provide Body Power). •...

  • Page 162: Remote Pto/Throttle Harness

    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 applications. Failure to properly program the engine or wire these circuits could cause an accident. FIGURE 8-29. PACCAR Px-6 and Px-8 . 8-34 12/11...

  • Page 163: Figure 8-30. Wiring For Customer Installed Throttle Control At End Of Frame

    Section 8 Electrical TABLE 8-10. Multifunction Engine Connector Engine Harness – PACCAR Px-6 & Px-8 KW Harn Conn Pin Outs KW mPDC in Cab Engine KW Circuit Wire Wire Fuse Fuse Fuse Circuit Function Name Pin # Number Color Gauge...
  • Page 164 Section 8 Electrical TABLE 8-11: Remote Throttle Wiring to End of Frame Engine Harness – Paccar Px-6 and Px-8 Extension Harness Engine KW Circuit Wire Wire Pin # KW Circuit Wire Wire Circuit Function Name ECM Pin # Number Color...

  • Page 165: Figure 8-31. Cab Load Center (Mpdc)

    Section 8 Electrical FIGURE 8-31. Cab Load Center (mPDC) 8-37 12/11...
  • Page 166 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: Direct Battery Power Protected Battery Power IGN/ACC/Start Power...
  • Page 167 Section 8 Electrical DATA BUS WIRE COLORS Data Bus wiring has its own color scheme as follows: Data-bus high-side wires – VIO – J1587 & J1708 – ORG – J1922 – YEL – J1939 – RED – OEM – GRY – CAN –...

  • Page 168: Trailer Cable Connections

    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.

  • Page 169: Figure 8-34. Junction Box

    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 & ISO 3731 connectors . 3 . J560 Hotline & ISO 3731 with Full Truck &/or Tractor Kit: This option provides two connectors: a SAE J560 and a ISO 3731 connector at the noted location(s) –...
  • Page 170 Section 8 Electrical Page Intentionally Left Blank. 8-42 12/11...

  • Page 171: Section 9 - Routing

    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.

  • Page 172: Routing Requirements

    Section 9 Routing Heavy duty tie straps 0.50in (12.7mm) wide (Tyton T255ROHIR or similar) shall be used Note: whenever HD mounts are specified, although 0.25in (6.4mm) tie straps may be used in some specified applications. FIGURE 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 .
  • Page 173 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.

  • Page 174: Routing Of Wires And Hoses Near Exhaust System

    Section 9 Routing Routing of Wires and Hoses near Exhaust System TABLE 9-1. Exhaust – System Clearance Description Shielded Unshielded Coolant hoses, HVAC hoses and tubing, and electrical wires within 15” of the turbo and/or over 15” from the turbo 2”...

  • Page 175: Appendix A Vehicle Identification

    Appendix A Vehicle Identification VEHICLE IDENTIFICATION NUMBER A 17–character number (numeral and letter combination) forms the Vehicle Identification Number (VIN) which includes the Chassis Number. It contains among other information, the model year (4), assembly plant (5), and vehicle serial number (6) .

  • Page 176: Vehicle Identification Labels

    Appendix A Vehicle Identification VEHICLE IDENTIFICATION LABELS Vehicle Identification Labels are located on the driver’s side door edge or on either the driver’s or passenger’s side door frames. See Figure A-2. Labels include Vehicle Certification, Components and Weights, Tire/Rim and Weight Rating Data, Noise Emissions, and Paint Identification.

  • Page 177: Noise Emission Label

    Appendix A Vehicle Identification Noise Emission Label The Noise Emission Label contains the chassis serial number, date of manufacture, and information regarding US noise emission regulations. This label is not provided on Canadian registered vehicles. Paint Identification Label The Paint Identification Label contains the paint colors used by the factory to paint the truck. It lists frame, wheels, cab in- terior and exterior colors .

  • Page 178: Transmission Identification

    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.
  • Page 179 ® Kenworth Truck Company P .O . Box 1000 Kirkland, WA 98083 (425) 828-5000 12/11...

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