2011+ Kenworth T170/T270/T370/Hybrid Body Builders Trucks OEM Service & Repair Manual

Kenworth T170 / T270 / T370 and Hybrid 2011 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

12/11 Body Builder’s Manual Contents I 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

12/11 Body Builder’s Manual Contents II GROUND CLEARANCES                                                   3-28 PTO CLEARANCES                                                       3-33 SECTION 4 — EXHAUST & AFTERTREATMENT EXHAUST AND AFTER-TREATMENT INFORMATION                            4-1 GENERAL GUIDELINES FOR DEF SYSTEM                                    4-3 INSTALLATION REQUIREMENTS AND DIMENSIONS FOR DEF SYSTEM            4-3 MEASUREMENT REFERENCE POINTS                                        4-4 GENERAL EXHAUST INFORMATION                                          4-9 EXHAUST INFORMATION                                                  4-18 SECTION 5 — FRAME LAYOUTS FRAME LAYOUTS                                                          5-1 COMMON OPTIONAL COMPONENTS                                         5-2 FRAME LAYOUT INDEX                                                    5-4 SECTION 6 — BODY MOUNTING FRAME INFORMATION                                                     6-1 CRITICAL CLEARANCES                                                    6-1 Rear Wheels and Cab                                                6-1 Body Mounting Using Brackets                                         6-2 Frame Sill                                                          6-2 Brackets                                                           6-2 Mounting Holes                                                     6-3 Frame Drilling                                                       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 MODIFICATIONS                                                    7-1 Introduction                                                        7-1 DRILLING RAILS                                                          7-1 Location and Hole Pattern                                             7-1 MODIFYING FRAME LENGTH                                                7-2 Frame Insert                                                        7-2 Changing Wheelbase                                                 7-3 Crossmembers                                                      7-4 WELDING                                                                7-5 TORQUE REQUIREMENTS                                           7-7 SECTION 8 - ELECTRICAL ELECTRICAL                                                             8-1 ACCESSING GAUGES AND SWITCHES                                       8-10 OPTIONAL SWITCHES, AIR VALVES AND GAUGES                            8-20 ADDITIONAL SPARE CIRCUITS                                             8-23 Additional Spare Circuits for Wiring                                     8-23 OPTIONAL BODY BUILDER HARNESS                                       8-24 Circuits Wired Through the Ignition                                     8-26 Connecting Ignition Circuits                                           8-26 Circuits Wired to Battery                                             8-26 BODY BUILDER POWER DISTRIBUTION CENTER                            8-29 INSTALLING A THIRD BATTERY (NOT AVAILABLE ON HYBRID)                  8-30

Body Builder’s Manual Contents III WIRING FOR A LIFTGATE                                                 8-31 Liftgate Power Source                                               8-31 Connecting the Liftgate Power                                         8-32 270 AMP ALTERNATOR (RECOMMENDED HOOKUP)                          8-33 Engine Connections                                                 8-33 REMOTE PTO/THROTTLE HARNESS                                        8-34 TRAILER CABLE CONNECTIONS                                            8-40 SECTION 9 - ROUTING ROUTING                                                                9-1 ROUTING REQUIREMENTS                                                 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 Rating Data Label                                  A-2 Incomplete Vehicle Certification Label A-2 Components and Weights Label                                       A-2 Noise Emission Label  A-3 Paint Identification Label A-3 COMPONENT IDENTIFICATION                                             A-3 Engine Identification A-3 Transmission Identification A-4 Front Axle Identification A-4 Rear Axle Identification A-4

12/11 Figures IV FIGURES FIGURE 2-1. Incomplete Vehicle Certification Document                                         2-2 FIGURE 2-2. Locations of Certification Labels - Driver’s Door and Frame                            2-2 FIGURE 2-3. West Coast Mirror OAT sensor, located in overmold on mirror harness.                  2-6 FIGURE 2-4. Aerodynamic Mirror OAT Sensor Location                                         2-7 FIGURE 2-5. Instrument Cluster for T170/T270/T370 used with EPA2010 Emission compliant engines    2-7 FIGURE 3-1. Prospector Turn Circle Analysis                                                 3-2 FIGURE 3-2. T170/T270/T370 Overall Height, and Length Dimensions                             3-3 FIGURE 3-3. Top of Cab View, T270/T370, Roof Mounted Options                                3-5 FIGURE 3-4. Side of Cab View, T270/370, Roof Mounted Options                                 3-5 FIGURE 3-5. Flush Mounted Flood Lamp Locations                                            3-6 FIGURE 3-6. T170 Crossmember Location                                                   3-7 FIGURE 3-7. T170 Crossmember Location                                                   3-8 FIGURE 3-8. Frame Rail Dimensions and Properties                                           3-8 FIGURE 3-9. T270/370 Battery Box Measurements]                                           3-10 FIGURE 3-10. T270/370 Battery/Tool Box Measurements                                      3-10 FIGURE 3-11. T270/370 22” Fuel Tank Mounting Measurements                                 3-11 FIGURE 3-12. T270/370 245” Fuel Tank Mounting Measurements With and without steps           3-11 FIGURE 3-13. Rectangular Fuel Tank Measurements                                         3-12 FIGURE 3-14. T270/370 Battery Box Measurements                                          3-13 FIGURE 3-15. T170 Battery Box/Cab Access Step Measurements                                3-13 FIGURE 3-16. Horizontal Exhaust Muffler/DPF Measurements                                   3-14 FIGURE 3-17. T270/T370 RH Step/DPF Box Assembly for Use with Vertical Tailpipe (left) or Horizontal Tailpipe                                                                 3-15 FIGURE 3-18. T270/370 Vertical Tailpipe on Right Side of Cab                                  3-15 FIGURE 3-19. T270/T370 with Vertical Muffler/DPF Behind RH Side of Cab                        3-16 FIGURE 4-1. Measurement Location of DEF Supply Module (Pump)                               4-4 FIGURE 4-2. Measurement Location of DEF Dosing Module (Injector)                              4-4 FIGURE 4-3. Orientation of Dosing Module                                                   4-5 FIGURE 4-4. RH Under Cab Exhaust with Small or 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 Small or Medium Tanks.                     4-7 FIGURE 4-8. Routing DEF Lines and DEF Trap                                               4-8 FIGURE 4-9. Isometric View of Right Hand Under DPF and SCR with Single SOC Tailpipe            4-10 FIGURE 4-10. Top View of Right Hand Under DPF and SCR with Single SOC Tailpipe               4-10 FIGURE 4-11. Right View of Right Hand Under DPF and SCR with Single SOC Tailpipe              4-11 FIGURE 4-12. Back View of Right Hand Under DPF and SCR with Single SOC Tailpipe               4-11 FIGURE 4-13. Isometric view of Horizontal DPF and SCR with Horizontal Tailpipe                    4-12 FIGURE 4-14. Top view of Horizontal DPF and SCR with Horizontal Tailpipe                        4-12 FIGURE 4-15. Right view of Horizontal DPF and SCR with Horizontal Tailpipe                       4-13 FIGURE 4-16. Back view of Horizontal DPF and SCR with Horizontal Tailpipe                       4-13 FIGURE 4-17. Isometric view of Horizontal (Series) DPF and SCR with Horizontal Tailpipe             4-14 FIGURE 4-18. Top view of Horizontal (Series) DPF and SCR with Horizontal Tailpipe                 4-14 FIGURE 4-19. Right view of Horizontal (Series) DPF and SCR with Horizontal Tailpipe                4-15 FIGURE 4-20. Back view of Horizontal (Series) DPF and SCR with Horizontal Tailpipe                4-15 FIGURE 4-21. Isometric view of Vertical Independent DPF and SCR                              4-16 FIGURE 4-22. Top view of Vertical Independent DPF and SCR                                  4-16 FIGURE 4-23. Right view of Vertical Independent DPF and SCR                                 4-17 FIGURE 4-24. Back view of Vertical Independent DPF and SCR                                 4-17 FIGURE 5-1. DEF Tank Dimensions                                                        5-3 FIGURE 6-1. Minimum Clearance Between Top of Rear Tires and Body Structure Overhang            6-1 FIGURE 6-2. Minimum Back of Cab Clearance                                                6-1 FIGURE 6-3. Spacer Between Frame Sill and Body Rail - Rubber or Plastic                         6-2 FIGURE 6-4. High Compression Spring                                                      6-2 FIGURE 6-5. Rubber Spacer Between Brackets, Between the Mounting Bolt and Upper Bracket         6-2 FIGURE 6-6. Crossmember-Gusset Hole Pattern Requirements                                  6-3

FIGURE 6-6. Hole Locations Guidelines for Frame Rail and Bracket                               6-3 FIGURE 6-7. Acceptable U-Bolt Mounting with Wood and Fabricated Spacers                        6-4 FIGURE 6-8. Clearance Space for Air Lines and Cables                                         6-5 FIGURE 6-9. Example of Fishplate Bracket at Rear End of Body, used with U-Bolts                   6-6 FIGURE 6-10. Clearance zones around Hybrid Power Electronics Carrier (PEC)                      6-6 FIGURE 6-11. Clearance zones around the Hybrid Battery Box located LH Under Cab                 6-7 FIGURE 7-1. Detail of Frame Extension and Joint Welding                                       7-2 FIGURE 7-2. Frame Insert                                                                7-2 FIGURE 7-3. Comparison of Original, Shortened, and Extended Wheelbases                        7-4 FIGURE 7-4. Crossmember Added when Distance Exceeds 60 inches (1524 mm)                    7-4 FIGURE 7-5. Heat Treated Frame Rail Warning                                               7-5 FIGURE 8-1. J1939 Data link Wiring                                                        8-1 FIGURE 8-2. Kenworth B-Cab Dash                                                        8-2 FIGURE 8-3. Diesel Exhaust Fluid Gauge                                                    8-2 FIGURE 8-4. Multiplexed Instrumentation Block Diagram                                       8-3 FIGURE 8-5. CECU Location                                                             8-4 FIGURE 8-6. Main Instrument Panel                                                        8-5 FIGURE 8-7. Instrumentation Harness Interface Diagram                                        8-7 FIGURE 8-8. Firewall Air Junction Block (view from inside of cab)                                 8-8 FIGURE 8-9. Air Filter Restriction Sensor on Firewall Air Junction Block (view from inside of cab)        8-8 FIGURE 8-10. Fuel Filter Restriction Pressure Gauge Sensor Location (typical)                      8-9 FIGURE 8-11. Telltale Symbol Standard Cards                                               8-14 FIGURE 8-12. Blank Telltale 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 Beacon Lamp in the Chassis Harness        8-21 FIGURE 8-17. Switch and Wiring for Customer Installed Beacon Lamp in the IP Harness             8-21 FIGURE 8-18. Switch and Wiring for Customer Installed Flood Lamp in the Chassis Harness          8-22 FIGURE 8-19. Location of Standard Body Harness Connection                                  8-24 FIGURE 8-20. Body Junction Harness                                                      8-25 FIGURE 8-21. ePTO Harness Location                                                     8-28 FIGURE 8-22. Location of Body Builder Distribution Module on Hybrid                             8-29 FIGURE 8-23. Detail of Body Builder Power Distribution Module                                  8-29 FIGURE 8-24. Adding a Third Battery                                                      8-30 FIGURE 8-25. Adding a Third Battery                                                      8-31 FIGURE 8-26. Liftgate Circuit Breaker Inside Battery Box                                       8-32 FIGURE 8-27. P27-6180 Fuse Holder                                                     8-33 FIGURE 8-28. Battery Harness Jumper                                                     8-33 FIGURE 8-29. PACCAR PX-6 and PX-8                                                   8-34 FIGURE 8-30. Wiring for Customer Installed Throttle Control at End of Frame                      8-35 FIGURE 8-31. Cab Load Center (mPDC)                                                    8-37 FIGURE 8-32. SAE J560 Trailer Connector                                                  8-40 FIGURE 8-33. ISO 3731 Trailer Connector                                                   8-40 FIGURE 8-34. Junction Box                                                              8-41 FIGURE 9-1. Clamp and Butterfly Clamp                                                     9-1 FIGURE 9-2. Butterfly Tie                                                                 9-1 FIGURE 9-3. Tie Strap                                                                   9-1 FIGURE 9-4. Heavy Duty (HD) Mount.                                                       9-2 FIGURE 9-5. Definition of measurements.                                                    9-4 FIGURE A-1. Vehicle Identification Number (VIN).                                             A-1 FIGURE A-2. Drivers Door and Door Frame Labels                                             A-2 FIGURE A-4. Front Axle Identification                                                       A-4 FIGURE A-5. Rear Axle Identification                                                       A-4 V

12/11 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. This manual is specific to chassis with 2010 engines The intended primary users of this manual are body builders who install bodies and associated equipment on Kenworth T170/T270/T370 Medium Duty vehicles. Dealers who sell and service the vehicle will also find this information useful. This Body Builders’ Manual can be very useful when specifying a vehicle, particularly when the body builder is involved in the vehicle definition and ordering process. Early in the process, professional body builders can often contribute valuable information that reduces the ultimate cost of the body installation In the interest of continuing product development, Kenworth reserves the right to change specifications or products at any time without prior notice It is the responsibility of the user to ensure that he is working with the latest update The most current update is available through your local Kenworth dealer. If you require additional information or reference materials, please contact your local Kenworth dealer Section 1 Introduction 1-1

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2011+ Kenworth T170/T270/T370/Hybrid Body Builders Trucks OEM Service & Repair Manual

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