Kenworth Medium Duty 2010 Body Builder Manual

Kenworth T170 / T270 / T370 and Hybrid 2010 Body Builders Manual ®

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Kenworth Medium Duty Body Builders Manual

Models: T170/T270/T370 and Hybrid For 2011 Model Year and Later with 2010 EPA Compliant Engines







































Body Builder’s Manual Contents SECTION 1 — INTRODUCTION

SCOPE                                                                  1-1 SECTION 2 — SAFETY AND COMPLIANCE

SAFETY SIGNALS ..                                                        22-1 Warnings, Cautions, and Notes                                         22-1 FEDE FEDERA RAL. L.MO MOT TOR VEHI VEHICL CLE. E.SA SAFE FETY TYST STAN AND DARDS ARDS.C .COM OMPL PLIA IANC NCE. E.                  2-2 2-2 Incomplete Vehicle Certication                                         22-2 Noise and Emissions Reuirements                                     22-3 Fuel System                                                        22-4 Compressed Air System                                              22-4 Ehaust and Ehaust After-treatment System                              2 -4 -4 Cooling System ..                                                    22-5 Electrical System                                                    22-6 Air Intake System                                                    22-8 Charge.Air.Cooler.System.2-8 SECTION 3 — DIMENSIONS

ABBREVIATIONS AND DEFINITIONS                                          33-1 OVERALL DIMENSIONS ..                                                   33-3 DETAIL VIEWS ..                                                           33-5 DETAIL VIEWS ..                                                           33-6 Back of Cab: Flus lush Mounted Floo lood Lamps – T270/370                       3-6 DETAIL VIEWS ..                                                           33-7 Crossmember Locations – T170 . .                                        33-7 DETAIL VIEWS ..                                                           33-8 Crossmember Locations – T170 . .                                        33-8 COMPONENTS                                                            33-9 Frame.Rail.Congurations.-.T170/270/370.                                3-9 Battery Bo – T270/370                                              33-10 Battery/Tool Bo – T270/370 . .                                         33-10 22-inch Fuel Tanks — T270/370                                        33-11 245-inch Fuel Tanks — T270/370                                      33-11 Rectangular Fuel Tank                                               33-12 Battery Bo – T270/370                                              33-13 Battery/Access Step – T170                                           33-13 Horizontal Ehaust/Mufer                                            33-14 Step/DPF.Bo.Assembly.RH.Under.Cab.–.T270/37 Step/DPF.Bo.Assembly.RH.Under .Cab.–.T270/370...... 0........... ........... ........... ..... 3-15 RH Back of Cab Independent Mufer — T270/T370. 0.                       3-16 RIDE HEIGHTS                                                    33-17 REAR SUSPENSION LAYOUTS                                              33-19 KENWORTH AG210L SINGLE REAR AxLE                                    33-19 KENWORTH AG400L TANDEM REAR AxLE                                    33 -20 REYCO 79KB SINGLE REAR AxLE                                           33-21 Optional Reyco 79KB Suspensions                                     33-21 REYCO 102 TANDEM REAR AxLE . .                                          33-22 Optional Reyco 102 Suspension . .                                      33-22 HENDRICKSON HAS SINGLE REAR AxLE . .                                    33-23 Optional Hendrickson HAS Single Suspensions. s.                         3-2 3-23 HENDRICKSON HAS TANDEM SUSPENSION                                  33 -24 Optional Hendrickson HAS Tandem Suspensions                         3-2 3-24







































Body Builder’s Manual Contents SECTION 4 — ExHAUST & AFTERTREATMENT

ExHAUST AND AFTER-TREATMENT INFORMATION . .                            4 -1 -1 GENERAL GUIDELINES FOR DEF SYSTEM . .                                   44-3 INST INSTALL ALLA ATION. TION.REq REqUI UIRE REMEN MENTS TS.A .AND ND.D .DIM IMEN ENSI SION ONS. S.FO FOR. R.DE DEF. F.SY SYST STEM. EM.            4-3 4-3 MEASUREMENT REFERENCE POINTS                                        44-4 GENERAL ExHAUST INFORMATION . .                                         44-9 ExHAUST INFORMATION . .                                                 44-18 SECTION 5 — FRAME LAYOUTS

FRAME LAYOUTS                                                          55-1 COMMON OPTIONAL COMPONENTS . .                                        55-2 FRAME LAYOUT INDEx                                                     55-4 SECTION 6 — BODY MOUNTING

FRAME INFORMATION . .                                                    66-1 CRITICAL CLEARANCES                                                    66-2 Rear Wheels and Cab . .                                               66-2 Body Mounting Using Brackets . .                                         66-3 Frame Sill                                                          66-3 Brackets                                                           66-3 Mounting Holes ..                                                    66-4 Frame Drilling                                                       66-4 Hole Location Guidelines                                              66-5 BODY MOUNTING USING U–BOLTS                                           66-5 Spacers ..                                                          66-5 Rear Body Mount                                                    66-7 HYBRID CLEARANCES                                                     66-7 Hybrid PEC . .                                                        66-7 Hybrid Battery Bo                                                   66-8 SECTION 7 — FRAME MODIFICATIONS

FRAME MODIFICATIONS                                                    77-1 Introduction......... Introduction............... ............ ............ ............ ........... ........... ............ ........... ..... 7-1 DRILLING RAILS                                                          77-1 Location.and.Hole.Pattern.7-1 MODIFYING FRAME LENGTH                                                77-2 Frame Insert                                                        77-2 Changing Wheelbase                                                 77-3 Crossmembers                                                      77-4 WELDING                                                                7 7--5 TORqUE REqUIREMENTS . .                                          77-7 SECTION 8 - ELECTRICAL

ELECTRICAL . .                                                            88-1 ACCESSING GAUGES AND SWITCHES                                       88-10 OPTIONAL SWITCHES, AIR VALVES AND GAUGES. S.                           8-2 8-20 ADDITIONAL SPARE CIRCUITS . .                                             88-23 Additional Spare Circuits for Wiring . .                                    88 -23 OPTIONAL BODY BUILDER HARNESS                                        88-24 Circuits Wired Through the Ignition .                                     88-26 C ti I iti Ci it  8 26







































Body Builder’s Manual Contents 270 AMP ALTERNATOR (RECOMMENDED HOOKUP)                          8-3 8-33 Engine Connections                                                 88-33 REMOTE PTO/THROTTLE HARNESS                                         88-34 TRAILER CABLE CONNECTIONS                                            88-40 SECTION 9 - ROUTING

ROUTING . .                                                               9 9--1 ROUTING REqUIREMENTS ..                                                99-2 Routing of Wires and Hoses near Ehaust 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                                   AA-2 Incomplete Vehicle Certication Label                                    AA-2 Components and Weights Label                                        A-2 Noise Emission Label                                                 A-3 Paint Identication Label . .                                              A-3 COMPONENT IDENTIFICATION . .                                             A-3 Engine Identication                                                  A-3 Transmission Identication                                             A-4 Front Ale Identication . .                                              A-4 Rear Ale Identication . .                                               A-4









































Figures FIGURES 2 -2 FIGURE 2-1. Incomplete Vehicle Cer tication Document                                        2Certiication Labels - Driv Drive er’s Door and Frame me                           2-2 FIGURE 2-2. Locations of Cert est.Co Coas ast. t.Mi Mirr rror or.O .OA AT.se T.sens nsor or,. ,.lo loca cate ted. d.in in.o .ove vermo rmold ld.o .on. n.mir mirro ror. r.ha harne rness ss.. ..                 2-6 2-6 FIGURE 2-3. West. A e r o d y n a m i c M i r r o r O A T S e n s o r L o c a t i o n . .                                         22 -7 FIGURE 2-4. Instrument.Cluster.for.T170/T270/T370.used.with.EP used.with.EPA2010.Emission.compliant.engines. A2010.Emission.compliant.engines.    2-7 FIGURE 2-5. Instrument.Cluster.for.T170/T270/T370. .                                                33-2 FIGURE 3-1. Prospector Turn Circle Analysis . 3-3 FIGURE 3-2. T170/T270/T370 Overall Height, and Length Dimensions.                           3-3 3-5 FIGURE 3-3. Top of Cab View, T270/T370, Roof Mounted Options                                3-5 s.                               3-5 3-5 FIGURE 3-4. Side of Cab View, T270/370, Roof Mounted Options. 3-6 FIGURE 3-5. Flush Mounted Flood Lamp Locations                                            33-7 FIGURE 3-6. T170 Crossmember Location                                                   33-8 FIGURE 3-7. T170 Crossmember Location                                                   33-9 FIGURE 3-8. Frame Rail Dimensions and Properties                                           33-10 FIGURE 3-9. T270/370 Battery Bo Measurements]                                           33 -10 FIGURE 3-10. T270/370 Battery/Tool Bo Measurements                                       3.                                3 -1 -11 FIGURE 3-11. T270/370 22” Fuel Tank Mounting Measurements . T270/370. 70.24 245” 5”.Fu .Fuel. el.T Tank.Mo ank.Mount unting. ing.Mea Measur sureme ements nts.With .With.an .and.w d.with ithout out.st .steps eps.. ..           3-11 3-11 FIGURE 3-12. T270/3 3-12 FIGURE 3-13. Rectangular Fuel Tank Measurements                                          3T270/370.Battery.Bo.Measurements...... ............ ............ ............ ........... ........... ............ ...... 3-13 FIGURE 3-14. T270/370.Battery.Bo.Measurements 3-13 FIGURE 3-15. T170 Battery Bo/Cab Access Step Measurements                               3-1 -14 FIGURE 3-16. Horizontal Ehaust Mufer/DPF Measurements                                   3 -1 T270/T370.RH.Step/DPF.Bo.Assembly.for.Use.with. Assembly.for.Use.with.V Vertical.Tailpipe.(left). ertical.Tailpipe.(left). FIGURE 3-17. T270/T370.RH.Step/DPF.Bo. or Horizontal Tailpipe                                                                  33-15 rtical Tailpipe on Right Side of Cab                                  3-1 3-15 FIGURE 3-18. T270/370 Verti T270/T /T37 370. 0.wi witth.V h.Vert ertical ical Muf Mufer/ er/DP DPF. F.Be Behi hind nd.R .RH. H.Si Side de.o .off.Cab. .Cab.                       3-16 3-16 FIGURE 3-19. T270 ).                             4-4 4-4 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. O r i e n t a t i o n . o f . D o s i n g . M o d u l e .                                                   4 - 5 .                              4-5 4-5 FIGURE 4-4. RH Under Cab Ehaust with Small or Medium Tanks. 4-6 FIGURE 4-5. Horizontal Series Ehaust with Small or Medium Tanks.                            4-6 .                                     44 -6 FIGURE 4-6. Vertical Ehaust with Small or Medium Tanks . Horiz zonta ontal. l.Cr Cros osso sov ver.E er.Eh hau aust st.s .sys yste tem. m.wi with th.S .Sma mall ll.o .or. r.Me Medi dium um Tanks anks. .                    4-7 4-7 FIGURE 4-7. Hori 4-8 FIGURE 4-8. Routing DEF Lines and DEF Trap                                                4Isometric. ric.Vie View.o w.of.R f.Right ight.Ha .Hand. nd.Und Under. er.DPF. DPF.and and.SC .SCR.w R.with ith.Si .Singl ngle.S e.SOC. OC.T Tailpipe ailpipe             4-10 4-10 FIGURE 4-9. Isomet View.of of.R .Righ ight. t.Ha Hand nd.U .Und nder er.D .DPF PF.a .and nd.S .SCR CR.w .wit ith. h.Sin Singl gle. e.SOC SOC Tailpi ailpipe. pe.               4-10 4-10 FIGURE 4-10. Top View. Right. t.Vie View. w.of of.R .Righ ight. t.Han Hand. d.Un Unde der. r.DPF DPF.a .and nd.S .SCR CR.w .wit ith. h.Sin Singl gle. e.SOC SOC Tailpi ailpipe pe               4-11 4-11 FIGURE 4-11. Righ Back View View.o .of. f.Rig Right ht.H .Han and. d.Und Under er.D .DPF PF.a .and nd.S .SCR CR.w .wit ith. h.Sin Singl gle. e.SO SOC. C.T Tailpi ailpipe. pe.              4-11 4-11 FIGURE 4-12. Back Isomet etri ric. c.vi view ew.o .of. f.Ho Hori riz zonta ontal. l.DP DPF. F.an and. d.SC SCR. R.wi with th.H .Hor oriz izon onta tal. l.T Tailp ailpip ipe. e.                   4-12 4-12 FIGURE 4-13. Isom view.of w.of Hori Horiz zonta ontal. l.DP DPF. F.an and. d.SC SCR. R.wi witth.Ho h.Hori riz zonta ontal. l.T Tailp ailpip ipe. e. 4-12 4-12 FIGURE 4-14. Top vie









































Tables 6-4 FIGURE 6-6. Hole Locations Guidelines for Frame Rail and Bracket                               6-4 Accepta eptab ble U-Bo U-Bolt lt Moun Mountting. ing.wi with th Wood. ood.an and. d.F Fabri abrica catted.S ed.Spa pace cerrs.                       6-5 6-5 FIGURE 6-7. Acc 6 -6 FIGURE 6-8. Clearance Space for Air Lines and Cables                                         6Eampl ple. e.of of.F .Fis ishp hpla late te.B .Bra rac cket. ket.at at.R .Rea ear. r.En End. d.of of.B .Bod ody y,.us ,.used ed.w .wit ith. h.UU-Bo Bolt lts s .                  6-7 6-7 FIGURE 6-9. Eam Clearrance ance zones ones arou around nd Hybr Hybrid id Power Elec Electtroni ronics cs Carr Carrie ierr.(PE .(PEC) C)                      6-7 6-7 FIGURE 6-10. Clea Cleara ranc nce. e.zo zone nes. s.ar arou ound nd.t .the he.H .Hyb ybrid rid.B .Bat atte tery. ry.Bo Bo. .lo loca cate ted. d.LH LH.U .Und nder er.C .Cab ab                 6-8 6-8 FIGURE 6-11. Clea 7 -2 FIGURE 7-1. Detail of Frame Etension and Joint Welding                                       77-2 FIGURE 7-2. Frame Inser t                                                                7Compar aris ison on of Orig Origin inal al,. ,.Sh Shor orttened ened,. ,.an and. d.E Ettende ended. d.Wh Whee eelb lbas ases es                        7-4 7-4 FIGURE 7-3. Comp Crossm smem embe berr.Add .Added ed when when.D .Dis ista tanc nce. e.E Ece ceed eds. s.60 60.i .inc nche hes s.(1 .(1524. 524.mm mm). ).                   7-4 7-4 FIGURE 7-4. Cros 7-5 FIGURE 7-5. Heat Treated Frame Rail Warning                                                7.                                                       88-1 FIGURE 8-1. J1939 Data link Wiring . .                                                       88-2 FIGURE 8-2. Kenwor th B-Cab Dash . 8-2 FIGURE 8-3. Diesel Ehaust Fluid Gauge                                                    88 -3 FIGURE 8-4. Multipleed Instrumentation Block Diagram                                        8CECU.Location........... ........... ............ ............ ............ ............ ........... ........... ............ ........ .. 8-4 FIGURE 8-5. CECU.Location...... .                                                       88-5 FIGURE 8-6. Main Instrument Panel . 8 -7 FIGURE 8-7. Instrumentation Harness Interface Diagram                                        88-8 FIGURE 8-8. Firewall Air Junction Block (view from inside of cab)                                8-8 Air.Filter.Restric Restriction. tion.Sensor Sensor.on.F .on.Firew irewall.Air all.Air.Jun .Junction. ction.Block Block.(vie .(view.fro w.from.insid m.inside.of e.of.cab) .cab)        8-8 FIGURE 8-9. Air.Filter. Fuel Filt Filter er.R .Res esttrict rictio ion. n.Pr Pres essu surre.Ga e.Gaug uge. e.Se Sens nsor or Loca Locattion. ion.(t (typ ypic ical al))                      8-9 8-9 FIGURE 8-10. Fuel 8-14 FIGURE 8-11. Telltale Symbol Standard Cards                                               88-16 FIGURE 8-12. Blank Telltale Tray                                                          8FIGURE 8-13. Telltale.Icons.(continued.on.page.8-18) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-17 8-20 FIGURE 8-14. Spare switches wired to Power                                                88-20 FIGURE 8-15. Optional Switches                                                         8Switch.and.Wiring Wiring.fo .for.Cus r.Customer. tomer.Insta Installed.B lled.Beacon. eacon.Lamp.i Lamp.in.the n.the.Chass .Chassis.Harn is.Harness ess .       8-21 FIGURE 8-16. Switch.and. Switch.an .and. d.Wir Wiring ing.f .for. or.Cus Custom tomer. er.Ins Instal talled led.Be .Beaco acon.L n.Lamp. amp.in. in.the the.IP .IP.Ha .Harnes rness s... ...            8-21 8-21 FIGURE 8-17. Switch Switch.and.Wiring.for.Customer.Installed.Flood.Lamp.in.the.Chassis.Harness..... ......... .... 8-22 FIGURE 8-18. Switch.and.Wiring.for.Customer.Installed.Flood.Lamp.in.the.Chassis.Harness .                                 8 -2 -24 FIGURE 8-19. Location of Standard Body Harness Connection . 8-25 FIGURE 8-20. Body Junction Harness                                                     8ePTO Harness Location                                                     88-28 FIGURE 8-21.. eP lder Distribu ibution Mod Module on Hybrid rid                             8-29 FIGURE 8-22. Location of Body Builde 8-29 FIGURE 8-23. Detail of Body Builder Power Distribution Module                                 8-2 .                                                      88-30 FIGURE 8-24. Adding a Third Battery . .                                                      88-31 FIGURE 8-25. Adding a Third Battery . 8 -32 FIGURE 8-26. Liftgate Circuit Breaker Inside Battery Bo                                       88-33 FIGURE 8-27. P27-6180 Fuse Holder                                                      88-33 FIGURE 8-28. Battery Harness Jumper                                                    8ACCAR.Px-6.and.Px-8....... ............ ............ ............ ............ ........... ........... ............ ......... ... 8-34 FIGURE 8-29. PACCAR.Px-6.and.Px-8. Wiring ng.f .for or.C .Cus usto tome mer. r.In Inst stal alle led. d.Th Thro rott ttle le.C .Con ontr trol ol.a .at. t.En End. d.of of.F .Fra rame me. .                     8-35 8-35 FIGURE 8-30. Wiri









































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.inf and.installation.process .This.information.will.be.helpful.when.installing.bodies.or.other.associated.euipment ormation.will.be.helpful.when.installing.bodies.or.other.associated.euipment









































Section 1 Introduction

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Section 2 Safety & Compliance SAFETY SIGNALS There.are.a.number.of.alerting.messages.in.this.book.Please.read.and.follo There.are.a.number.of.alerting.messages.in.this.book .Please.read.and.follow.them. w.them.They.are.there.f They.are.there.for.your.protection. or.your.protection. and.information.These.alerting.messages.can.help.y and.information.These.alerting.messages.can.help.you.avoid.injury.to.yours ou.avoid.injury.to.yourself.or.others.and.help.pre elf.or.others.and.help.prevent.costly.. vent.costly.. damage.to.the.vehicle Key.symbols.and.“signal.words” Key.symbols.and.“signal.words”.are.used.to.indicate.what.kind.o .are.used.to.indicate.what.kind.of.message.is.going.to.follo f.message.is.going.to.follow w.Pa .Pay.special.attention.to. y.special.attention.to. comments.prefaced.by.“W comments.prefaced.by.“WARNING”,.“CA ARNING”,.“CAUTION”,.and.“NO UTION”,.and.“NOTE TE”.Please.do.not ”.Please.do.not.ignore.any.of.these.alerts .ignore.any.of.these.alerts

Warnings, Cautions, and Notes When you see this word and symbol, the message that follows is especially vital. It signals a potentially hazardous situation which, if not avoided, could result in death or serious injury. This message will tell you what the hazard is, what can happen if you do not heed the warning, and how to avoid it.

WARNING

CAUTION

NOTE

Eample: WARNING! WARNING! Be sure to use a circuit breaker designed to meet liftgate amperage reuirements. An incorrectly specied circuit breaker could result in an electrical overload or re situation. Follow the liftgate installation instructions and use a circuit breaker with the recommended capacity. Signals a potentially hazardous situation which, if not avoided, could result in minor or moderate injury or damage to the vehicle. Eample: CAUTION: CAUTION: Never use a torch to make a hole in the rail. Use the appropriate drill bit.

Provides general information: for for eample, the note could warn you about how to avoid damaging your vehicle or how to drive the vehicle more efciently. Eample: Note: Be sure to provide maintenance access to the battery bo and fuel tank ll neck. Signals the location of a high voltage electrical components Eample: HAZARDOUS VOLTAGE: To reduce the risk of possible serious injury (Shock, Burn or











































Section 2 Safety & Compliance FEDERAL MOTOR VEHICLE SAFETY STANDARDS COMPLIANCE As.an.Original.Euipment.Manufacturer.(OEM),.Kenworth.T As.an.Original.Euipment.Manufacturer.(OEM),.Kenworth. Truck.Co.ensures.that.our.produc ruck.Co.ensures.that.our.products.comply.with.all.applicable. ts.comply.with.all.applicable. US.or.Canadian.Federal.Motor.Vehicle.Safety.Standards.However,.the.fact.that.this.vehicle.has.no.fth.wheel.and.that.a. Body.Builder.(Intermediate.or.Final.Stage.Manufacturer).will.be.doing.additional.modications.means.that. Body.Builder.(Intermediate.or.Final.Stage.Manuf acturer).will.be.doing.additional.modications.means.that.the.vehicle.was. the.vehicle.was. incomplete.when.it.left.the.build.plant.See.net.section. incomplete.when.it.left.the.build.plant .See.net.section.and.Appendi.A.for.additional.inf and.Appendi.A.for.additional.information ormation

Incomplete Vehicle Vehicle Certication An.Incomplete.Vehicle.Document.is.shipped.with.the.vehicle An.Incomplete.Vehicle.Document.is.shipped.with.the.vehicle,.certifying.that.the.vehicle.is.not. ,.certifying.that.the.vehicle.is.not.complete complete.See.Figure.2–1 .See.Figure.2–1 In.addition,.afed.to.the.driver’ In.addition,.afed.to.the.driver’s.side.door.frame.or.edge.is. s.side.door.frame.or.edge.is.an.Incomplete.V an.Incomplete.Vehicle.Certication.label.See.Figure.2–2 ehicle.Certication.label.See.Figure.2–2.For. .For. further.information.on.Vehicle.Certication.and.Identication,.see.APPENDIx.A.“VEHICLE.I further.information.on.V ehicle.Certication.and.Identication,.see.APPENDIx.A.“VEHICLE.IDENTIFICA DENTIFICATION TION””

NOTE

These.documents.list.the.US.or.Canadian.Feder These.documents.list.the.US .or.Canadian.Federal.Motor.V al.Motor.Vehicle.Safety.Standard. ehicle.Safety.Standard.regulations.that.the. regulations.that.the. vehicle.complied.with.when.it.left.the.build.plant. vehicle.complied.with.when.it.left.the.b uild.plant.Y You.should.be.aware.tha ou.should.be.aware.that.if.you.add,.modify.or. t.if.you.add,.modify.or.alter.any. alter.any. of.the.components.or.systems.covered.by. of.the.components.or.systems.co vered.by.these.regulations,.it.is.y these.regulations,.it.is.your.responsibility.as.the.Intermediate.or. our.responsibility.as.the.Intermediate.or. Final.Stage.Manufacturer.to.ensure.that.the.complete.vehicle.is.in.compliance.with.the.particular.regulations.upon.completion.of.the.modications US.EPA.Noise.Label.(US.registered.vehicles.only) Tire,.Rim.and. Weight.Rating. Data.label

Final.Stage.Manufacturer. Label.to.be.Installed.by. Final.Stage.Manufacturer











































Section 2 Safety & Compliance These.statements.are.just.part.of.the.changes.to.the.new.certication.regulation These.statements.are.just.part.of.the. changes.to.the.new.certication.regulation.Please.refer.to. .Please.refer.to.the.Feb.15,.2005.. the.Feb.15,.2005.. nal.rule.for.all.of.the.details.related.to.this.regulation nal.rule.for.all.of.the.details.related.to.this.regulationY You.can.contact.NTEA.T ou.can.contact.NTEA.Technical.Services.Department.at.. 1-800-441-NTEA.for.a.copy.of.the.nal.rule.(DocID.101760) For.Canadian.nal.stage.manufacturers.see: http://wwwgazettegcca/ http://wwwgazettegcca/archives/p2/2002/2002-02-13/ht archives/p2/2002/2002-02-13/html/sor-dors55-enghtml; ml/sor-dors55-enghtml;.and .and http://wwwtcgcca/acts-regulations/r http://wwwtcgcca/acts-regulations/regulations/crc-c1038/menuhtm.f egulations/crc-c1038/menuhtm.for.the.regulations or.the.regulations Or.contact: Transport.Canada. Tower.C,.Place.de.Ville,.330.Sparks.Street. Ottawa,.Ontario.K1A.0N5. (613).990-2309. TTY:.1-888-675-6863

Noise and Emissions Reuirements NOTE

2010 Automotive engines have been tested and EPA/CARB EPA/CARB certied with a complex inte- grated system. This system is comprised of several emissions control devices including, but not limited to, a Diesel Particulate lter (DPF) and a Selective Catalyst Reduction (SCR) system. The body builder must not modify or relocate any devices included in the emissions system. Doing so may result in the voiding of all warranties and the occurrence of an emissions noncompliance event that may be considered tampering and punishable by the











































Section 2 Safety & Compliance Fuel System The.following.are.highlights.of.some.of.the.more.common.or.critical.aspects. The.following.are.highlights.of .some.of.the.more.common.or.critical.aspects.of.this.system of.this.system The.overall.system.restriction.may.not.e The.overall.system.restriction.may.not.eceed.the.restriction.limitations.set.f ceed.the.restriction.limitations.set.forth.by.the.engine.manufact orth.by.the.engine.manufacturer.for.bot urer.for.both.. h.. supply.and.return •.

Ensure.tha Ensure.that.fue t.fuel.line l.lines.are s.are.not. .not.pinche pinched.or. d.or.can.p can.potent otentially. ially.be.dam be.damaged. aged.when.i when.install nstalled.bet ed.between. ween.body. body.and.f and.frame rame

•.

Fuel.lines.m Fuel.lines.must.b ust.be.rou e.routed.a ted.and.se nd.secured cured.witho .without.di ut.dips.or ps.or.sags .sags

•.

There. There.mus must.b t.be.e e.easy asy.ac .acces cess.t s.to. o.lte lter(s r(s).a ).and. nd.ll. ll.cap cap

•.

The.ta The.tank. nk.ve vent. nt.ma may.n y.not. ot.obs obstru tructe cted d

•.

Added.access Added.accessories. ories.(heat (heaters, ers,.gene .generato rators).c rs).cannot. annot.introd introduce.a uce.air.int ir.into.sys o.system tem

•.

Fuel.tank.m Fuel.tank.must.b ust.be.loc e.located. ated.so.th so.that.t at.the.fu he.full.le ll.level. vel.is.no is.not.abo t.above. ve.cylinde cylinder.hea r.head d

•.

“Ultra.Lo “Ultra.Low.Sulf w.Sulfur.Fu ur.Fuel.Only el.Only”.l ”.labels. abels.must. must.be.pr be.present esent.on.t .on.the.da he.dash.an sh.and.fue d.fuel.ll. l.ll... ..

•.

Modication. Modication.of.th of.the.pre e.pressure ssure.side. .side.second secondary.lt ary.lter.an er.and.plum d.plumbing.is bing.is.not. .not.allow allowed.wit ed.without. hout.engine engine.manuf .manufactur acturer. er. approval

•.

Body.instal Body.installation lation.of.f .of.fuel.t uel.tank.or ank.or.rout .routing.of ing.of.lines .lines.must .must.not. .not.cause cause.signi .signicant. cant.increa increase.in se.in.fuel. .fuel.temper temperature ature

•.

Fuel.hoses. Fuel.hoses.shall. shall.meet. meet.or.e or.eceed ceed.OEM.s .OEM.supplied upplied.hose .hose.mate .material.co rial.construc nstruction. tion.speci specicatio cations ns

Compressed Air System The.following.are.highlights.of.some.of.the.more.common.or.critical.aspects. The.following.are.highlights.of .some.of.the.more.common.or.critical.aspects.of.this.system of.this.system











































Section 2 Safety & Compliance •.

The.followin The.following.mod g.modicati ications.ma ons.may.onl y.only.be. y.be.done. done.within. within.the.g the.guidelin uidelines.of es.of.the. .the.“DEF.S “DEF.System ystem.Reloc .Relocation. ation.Guide Guide”” •. •. •.

Modications Modications.to. .to.Diesel. Diesel.Ehaus Ehaust.Flui t.Fluid.(DE d.(DEF).th F).thrott rottle,.s le,.suctio uction,.or n,.or.pres .pressure. sure.lines lines Modic Modicati ation. on.or. or.rel reloca ocatio tion.o n.of.t f.the. he.DEF. DEF.tan tank k Modication. Modication.of.c of.coolant oolant.lines .lines.to.a .to.and.fr nd.from.th om.the.DEF. e.DEF.tank tank

•.

All.DEF.and. All.DEF.and.coolan coolant.line t.lines.sho s.should.be uld.be.rout .routed,.p ed,.protec rotected,. ted,.and.p and.properl roperly.sec y.secured. ured.to.pr to.prev event. ent.damage. damage.during. during.vehi vehicle. cle. operation.or.other.components

•.

If.relocat If.relocation.of ion.of.the. .the.DCU.is DCU.is.neces .necessary sary,.use ,.use.e .eisting isting.fra .frame.br me.brack ackets.a ets.and.mou nd.mount.in nt.inside.o side.of.fr f.frame.a ame.anges. nges.where. where. necessary.Do.not necessary.Do.not.etend.the.harnesses .etend.the.harnesses

•.

The.DPF The.DPF,.th ,.the.SCR. e.SCR.cataly catalyst,. st,.or.th or.their.m eir.mountin ounting.ma g.may.not y.not.be.m .be.modied odied

•

The NO.sensor.may.not.been.relocated.or.altered.in.any.way

•.

Ehaust.pipe Ehaust.pipes.use s.used.f d.for.t or.tailpipe ailpipes/sta s/stacks. cks.must. must.be.pr be.properly operly.size .sized,.an d,.and.mus d.must.pr t.prev event.w ent.water. ater.from. from.enterin entering.the g.the ehaust.system

•.

Ensure.ade Ensure.adeuate. uate.clear clearance.b ance.betwee etween.th n.the.e e.ehaust. haust.and.bo and.body.pa dy.panels, nels,.hoses .hoses,.and ,.and.wire. .wire.harness harnesses es

•.

The.body.in The.body.in.the. .the.vicinit vicinity.of. y.of.the.D the.DPF.mu PF.must.be st.be.abl .able.to. e.to.withs withstand. tand.temper temperature atures.up. s.up.to.40 to.400°C.( 0°C.(750°F) 750°F)

•.

Do.not.add Do.not.add.therma .thermal.insu l.insulation lation.to. .to.the.e the.eternal ternal.surf .surface.o ace.of.the f.the.DPF .DPF

•.

The.SC The.SCR.w R.wate ater.d r.drai rain.h n.hole. ole.ma may.n y.not. ot.be. be.blo block cked ed

•.

Allow.adeua Allow.adeuate.cl te.clearan earance.(2 ce.(25mm.( 5mm.(1.inch 1.inch)).f )).for.se or.servicing. rvicing.the.D the.DPF.sen PF.sensors sors,.wirin ,.wiring,.a g,.and.cla nd.clamped.j mped.joints oints

•.

Drainage.ma Drainage.may.not y.not.come. .come.in.co in.contact ntact.with .with.the. .the.DPF DPF,.SCR. ,.SCR.cataly catalyst,. st,.sensor sensors.or. s.or.wiring wiring

•.

Allow.sufcient.clearance.for.removing.sensors.from.DPF Allow.sufcient.clearance.f or.removing.sensors.from.DPF Thermistors.reuire.four.inches Thermistors.reuire.four.inches.Ot .Other.sensors. her.sensors.











































Section 2 Safety & Compliance Electrical System The.following.are.highlights.of.some.of.the.more.common.or.critical.aspects. The.following.are.highlights.of .some.of.the.more.common.or.critical.aspects.of.this.system of.this.system •.

Electrical.h Electrical.harnesse arnesses.pro s.providing viding.batt .battery.po ery.power. wer.and.el and.electro ectronic.c nic.contro ontrol.sign l.signals.t als.to.engi o.engine.an ne.and.emis d.emissions. sions.contr control/ ol/ vehicle.OBD.components.including.datalinks.may.not.be.spliced vehicle.OBD.components.including.datalinks.ma y.not.be.spliced.These.emissions.con .These.emissions.control/vehicle.OBD.. trol/vehicle.OBD.. components.include.the.following: •. •. •.

throt hrottl tle. e.pe peda dall vehic ehicle le.s .spe peed ed.s .sen enso sorr afte afterr-tr trea eatm tmen ent. t.wi wirin ring g

•.

If.the.al If.the.alternato ternator.or r.or.batt .battery.is. ery.is.substi substituted tuted,.it. ,.it.must. must.meet. meet.the.r the.reuire euirements. ments.of.th of.the.eng e.engine.ma ine.manuf nufactur acture’s e’s.guide .guide-lines.This.includes.alternator.g lines.This.includes.alternator.ground.voltage.drop.and.alternator. round.voltage.drop.and.alternator.ground.cable.eff ground.cable.effectiveness ectiveness.See.the.engine. .See.the.engine. manufacture’s.guidelines.for.recommended.test manufacture’s.guidelines.for.recommended.test.procedure .procedure.Additionally.the.maimum.voltage.diff .Additionally.the.maimum.voltage.differential.and. erential.and. the.peak-peak.voltage.differential.between.t the.peak-peak.voltage. differential.between.the.engine.ECM.block.ground.s he.engine.ECM.block.ground.stud.and.battery.negative.terminal. tud.and.battery.negative.terminal. may.not.eceed.500.mV.under.any.combination.of. may.not.eceed.500.mV.under.any.combination.of.loads.or.operating.conditions loads.or.operating.conditions

•.

Installatio Installation.of. n.of.afterma aftermarket. rket.tran transfe sfer-cas r-cases.mu es.must.ad st.address dress.the. .the.vehic vehicle.sp le.speed.s eed.sensor. ensor.positi position on.T .The.st he.standar andard.posi d.posi-tion.of.the.speed.sensor.is.at.the.transmission.tail.shaft tion.of.the.speed.sensor.is. at.the.transmission.tail.shaft.When.a.tr .When.a.transfer-case.is.added.it. ansfer-case.is.added.it.is.best.to.relocate. is.best.to.relocate. the.sensor.to.the.ale.side.output.shaft.of.the.t the.sensor.to.the.ale.side. output.shaft.of.the.transfer-case ransfer-case. .This.is.typically.accomplished.by.adding.a.tone. This.is.typically.accomplished.by.adding.a.tone. wheel.into.the.driveline.yoke.assembly.

•.

Wiring.et Wiring.etension ensions.f s.for.t or.the.af he.after-t ter-treatme reatment.wi nt.wiring.ar ring.are.av e.availab ailable.f le.for.re or.relocat locating.th ing.the.DEF. e.DEF.tank. tank.from. from.your your.deal .dealer.via er.via Paccar.Parts.F Paccar.Parts.For.relocation.of.DEF.tank,.r or.relocation.of.DEF.tank,.refer.to.the.af efer.to.the.after-treatment.section.of. ter-treatment.section.of.this.manual this.manual

•.

The.emission.system.reuires.an.accurate.Outside.Air.Temperature.(OA The.emission.system.reuires.an.accurate.Outside.Air.T emperature.(OAT).reading.in.order.to.properly.run.. T).reading.in.order.to.properly.run.. its.control.algorithms.The.OA its.control.algorithms.The.OAT.sensor.is.located.in.the.driver T.sensor.is.located.in.the.driver’s.side.mirror.as ’s.side.mirror.assembly.on.Kenworth.trucks sembly.on.Kenworth.trucks.and. .and. is.shown.in.the.gures.below is.shown.in.the.gures.belo w.If.the.body.builder. .If.the.body.builder.needs.to.modify.the.mirror.assemb needs.to.modify.the.mirror.assembly.in.any.way ly.in.any.way,.it.is.im,.it.is.im-













































Section 2 Safety & Compliance

FIGURE 2-4: Aerodynamic.Mirror.OAT.Sensor.Location •.

Coolant.Sen Coolant.Sensor.c sor.conside onsideratio rations.ar ns.are.giv e.given.in. en.in.the. the.Cooling Cooling.sect .section.ab ion.above ove













































Section 2 Safety & Compliance

Air Intake System The.following.are.highlights.of.some.of.the.more.common.or.critical.aspects. The.following.are.highlights.of .some.of.the.more.common.or.critical.aspects.of.this.system of.this.system •.

The.air.int The.air.intake. ake.scree screen.ma n.may.not y.not.be.b .be.block locked,.e ed,.either ither.fully .fully.or. .or.partially partially

•.

Modication.to.the.air.intake.system.may.not.restrict.airo Modication.to.the.air.intake.syst em.may.not.restrict.airow w.For.e .For.eample,.pipe.diameter.may.not. ample,.pipe.diameter.may.not.be.reduced be.reduced

•.

All.sen All.sensor sors.m s.must ust.be .be.re .retai tained ned.in .in.e .eis istin ting.l g.loca ocatio tions ns

•.

To.retain.system.seal,.proper. o.retain.system.seal,.proper.clamp.torue.must.be.used clamp.torue.must.be.used.Refer.to. .Refer.to.service.manual.for.proper.clamp.torue service.manual.for.proper.clamp.torue

Charge Air Cooler System The.following.are.highlights.of.some.of.the.more.common.or.critical.aspects. The.following.are.highlights.of .some.of.the.more.common.or.critical.aspects.of.this.system of.this.system













































Section 3 Dimensions DIMENSIONS This.section.is.designed.to.provide.enough.information.to.successfully.la This.section.is.designed.to.provide.enoug h.information.to.successfully.layout.chassis.in.the.body.planning.pr yout.chassis.in.the.body.planning.process ocess.Only. .Only. typical.truck.layouts.and.congurations.are.sho typical.truck.layouts.and.congurations.are.shown. wn.Optional.euipment.may.not.be.depicted Optional.euipment.may.not.be.depicted.Please.contact.your.local. .Please.contact.your.local. Kenworth.dealer.if.more.information.is.desired.

ABBREVIATIONS AND DEFINITIONS Throughout.this.section,.and.in.other.sections.as.well,.abbreviations.and.specic.terminology.are.used.to.describe.certain. characteristics.on.your.vehicle characteristics.on.your. vehicle.The.charts.below.list.t .The.charts.below.list.the.abbreviated.terms.used.and. he.abbreviated.terms.used.and.provide.denitions.for provide.denitions.for.terminology. .terminology. used.

TABLE 3-1...Abbreviations.Used.













































Section 3 Dimensions Prospector Turn Turn Circle Analysis: Analys is: Please.see.Figure.3-1.as.an.eample.of.Kenworth’s.turn.circle.calculation.made.in.Prospector.f Please.see.Figure.3-1.as.an.eample.of.Kenworth’ s.turn.circle.calculation.made.in.Prospector.for.your.specic.chassis or.your.specic.chassis. . Your.local.Kenworth.dealer.can.pro our.local.Kenworth.dealer.can.provide.this.information.to.y vide.this.information.to.you ou













































Section 3 Dimensions OVERALL DIMENSIONS

..........

This.section.includes.drawings.and.charts.of.the.following.medium.duty.models: This.section.includes.drawings.and.charts.of.t he.following.medium.duty.models:.T170,. .T170,.T270.and.T370 T270.and.T370 On.the.pages.that.follow,.det On.the.pages.that.follow,.detail.drawings.show.particular.views.of. ail.drawings.show.particular.views.of.each.vehicle.with.dimensions.being.in.inches.and.(mm) each.vehicle.with.dimensions.being.in.inches.and.(mm) They.illustrate.important.measurements.critical.to.designing.bodies.of.all.types They.illustrate.important.measurements.critical.to.designing.bodies.of .all.types.See.the.“T .See.the.“Table.of.Contents” able.of.Contents”.at.the.begin.at.the.beginning.of.the.manual.to.locate.the.drawing.that.you.need Kenworth.also.offers.df.les.and.frame. Kenworth.also.offers.df.les.and.frame.layouts.of.or layouts.of.ordered.chassis.four. dered.chassis.four.weeks.prior.to.build weeks.prior.to.build.Please.speak.to.your.sales. .Please.speak.to.your.sales. person.to.reuest.this.feature.when.specifying.your.chassis















































Section 3 Dimensions .T170.Sin .Single. gle.Rea Rear.Al r.Ale: e:.Ov .Overa erall.F ll.Foreore-Aft. Aft.Dime Dimensio nsions.[ ns.[inch inches.( es.(mm)]. mm)]. TABLE 3-3...Hydraulic Brake Vehicles.T170 WB

OAL

AF

CA

153 (3886)

2359 (5992)

55 (1397)

72 (1829)















































Section 3 Dimensions DETAIL DETAIL VIEWS V IEWS Top of Cab: Roof Mounted Options – T270/370















































Section 3 Dimensions DETAIL DETAIL VIEWS V IEWS Back of Cab: Flush Mounted Flood Lamps – T270/370















































Section 3 Dimensions DETAIL DETAIL VIEWS V IEWS Crossmember Locations – T170















































Section 3 Dimensions DETAIL DETAIL VIEWS V IEWS Crossmember Locations – T170































































































































































































































































































































































































































































































































































































































































































































































































































































































































































































































































































































































































































































































































































Section 4 Exhaust & Aftertreatment Horizontal DPF and SCR with Horizontal Tailpipe Tailpipe

FIGURE 4-13: Isometric.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







































Section 4 Exhaust & Aftertreatment Horizontal (Series) DPF and SCR with Horizontal Tailpipe Tailpipe

FIGURE 4-17: Isometric.view.of.Horizontal.(Series).DPF.and.SCR.with.Horizontal.Tailpipe








































FIGURE 4-19: Right.view.of.Horizontal.(Series).DPF.and.SCR.with.Horizontal.Tailpipe







































Section 4 Exhaust & Aftertreatment Vertical Independent DPF and SCR

FIGURE 4-21:.Isometric.view.of.Vertical.Independent.DPF.and.SCR










































FIGURE 4-23: Right.view.of.Vertical.Independent.DPF.and.SCR









































Section 4 Exhaust & Aftertreatment ExHAUST INFORMA INF ORMATION TION This.section.includes.information.on.how.to.calculate.tailpipe.heights,.and.reference.information.f This.section.includes.information.on.how.to.calculate.tailpipe.heights,.and.ref erence.information.for.PTO.clearance or.PTO.clearance. . Optional.euipment.is.not.shown.

Tailpipe Stack Height Calculation TABLE 4-1..Stack.Height Dimension A

DPF.mounted.independent. back.of.cab

Tailpipes.side.of.cab.mount,.. DPF.RH.under Tailpipes.back.of.cab.mount,.. DPF.RH.under

765”

680”

DIMENSION.“B”.IS.THE.TAILPIPE.LENGTH

TABLE 4-2..Unladen.Stack.Height For.approimate.unladen.stack.height.(12, For.approimate.unladen.stack.height.(12,000.pound.springs).use.the.f 000.pound.springs).use.the.following.frame.heights: ollowing.frame.heights: Tire Size

Top of Rail

Ft. Suspension

11R245

435”

1 2K

11R225

425”

1 2K

285/75R245

42”

1 2K

295/75R225

415”

1 2K

425/65R225

43 2”

2 0K









































Section 5 Frame Layouts FRAME LAYOUTS The.dimensions.in.the.frame.layout.section.are.intended.to.aid.in.layout.of The.dimensions.in.the.frame.layout.section.are.intended.t o.aid.in.layout.of.the.chassis,.and.to.h .the.chassis,.and.to.help.determine.the.best. elp.determine.the.best. possible.combination.of.fuel.tanks,.battery.bo possible.combination.of.fuel.tanks ,.battery.boes,.the.diesel.particulate.lter.(DPF),.SCR.canister es,.the.diesel.particulate.lter.(DPF),.SCR.canister,.and.Diesel.Ehaust. ,.and.Diesel.Ehaust. Fluid.(DEF).tank.For.your Fluid.(DEF).tank.For.your.application,.the.layout .application,.the.layouts.focus.on.the. s.focus.on.the.under.cab.area,.with.appropriate.dimensional.inf under.cab.area,.with.appropriate.dimensional.information. ormation. included.for.pertinent.back.of.cab.components included.for.pertinent.back.of .cab.components.Not.all.optional.euipment.is.included.in.this.section .Not.all.optional.euipment.is.included.in.this.section.Additional.compo.Additional.components.may.be.placed.on.the.rail.behind.components.shown nents.may.be.placed.on. the.rail.behind.components.shown.The.Bac .The.Back.of.Cab.components.are.sho k.of.Cab.components.are.shown.primarily.for.refer wn.primarily.for.refer-ence.For.more.specic. ence.For.more.specic.reuirements.please.work.with.your.local.K reuirements.please.work.with.your.local.Kenworth.Dealer enworth.Dealer.Please.read.the.instructions.carefully .Please.read.the.instructions.carefully The.following.dimensions.are.consistent.across.the.entire.section.to.aid.in.the.comparison.of.one.lay The.following.dimensions.are.consistent.across.the.entire.section.t o.aid.in.the.comparison.of.one.layout.option.versus. out.option.versus. another

TABLE 5-1..Dimension.Inde A = Air Dryer

F1 = Fuel Tank RHS

B = Battery bo

F2 = Fuel Tank LHS

D = DEF tank

H = Hybrid PEC

E1 = Ehaust, DPF

T = Tool Bo

E2.=.Ehaust,.SCR E3.=.Ehaust,.Diffuser The.layouts.are.organized.by.type The.layouts.are.organized.by.type,.specically.the.arrangement.of.un ,.specically.the.arrangement.of.under.cab.components der.cab.components.The.visual.inde .The.visual.inde.that.follows. .that.follows. will.give.you.a.uick.overview.of.the.la will.give.you.a.uick.overview.of.the.layouts.that.are. youts.that.are.included.Using.t included.Using.the.inde.locate.the.la he.inde.locate.the.layout.that.yo yout.that.you.are.interested.in,. u.are.interested.in,. then.turn.to.the.specied.pages.The.charts.that.f then.turn.to.the.specied.pages .The.charts.that.follow.are.then.model.specic ollow.are.then.model.specic.It.is.important.that.the.correct. .It.is.important.that.the.correct.chart.is.used. chart.is.used. for.accurate.dimensional.information

Visual Inde Symbol

Description

RHUC DPF/SCR

Symbol

Description

I C bB

B









































Section 5 Frame Layouts COMMON OPTIONAL COMPONENTS The.frame.layouts.that.follow.contain.the.minimum.frame.reuirements.to.be.operational.(fuel.tanks,.battery. bo,.and.after-treatment.components)..All.layouts.are.shown.with.standard.length.battery.boes.unless.otherwise.noted..Dimensions.for.these.components.have.been.provided.below.to.help.complete.the.frame.layout.for. chassis.with.more.fuel.tanks,.additional.tool.boes,.etc. TABLE 5-2..Fuel.Tank.Overall.Length.(in) Fuel Tank Tank Overall Length (in) Fuel Tank Diameter Gallons

22”

24.5”

45

N/A

N/A

56

356

281

75

473

N/A

100

622

N/A

120

743

N/A









































Section 5 Frame Layouts SMALL.DEF.TANK. (9-Gallon.Usable.Volume)

RECTANGULAR.DEF.TANK. (66-Gallon.Usable.Volume)

Medium.DEF.TANK. (18-Gallon.Usable.Volume)

FIGURE 5-1..DEF.Tank.Dimensions TABLE 5-3. DEF Tanks Systems Description

Usable Volume, Gallons

Small DEF Tank

9

Medium DEF Tank

18

Rectangular DEF Tank

66

Fuel Tank Diameter

A

B

22”

2 7 4

153

245”

274

1 5 8

22”

2 7 7

150

245”

277

1 5 5

N/A

see Figure 5-1

see Figure 5-1

Acronyms Inde Throughout.the.Frame.Layout.section.you.will.see.these.acronyms..They.are.dened.here.to.help.you.decode.











































Section 5 Frame Layouts FRAME LAYOUT INDEx

D1 is.used.with.RHUC.DPF/SCR,.vertical.SOC.tailpipe,.RH.BOC.fuel.tank,.LHUC.battery.bo,.and.LH.BOC.DEF.tank. Chart.located.on.page.5-10

.is.used.with.RHUC.DPF/SCR,.vertical.SOC.tailpipe,.LH.BOC.fuel.tank,.LHUC.battery.bo,.and.RH.BOC.DEF.tank .LHUC.battery.bo,.and.RH.BOC.DEF.tank D2.is.used.with.RHUC.DPF/SCR,.vertical.SOC.tailpipe,.LH.BOC.fuel.tank, Chart.located.on.page.5-11

D3.is.used.with.RHUC.DPF/SCR,.vertical.SOC.tailpipe,.LHUC.cylindrical.fuel.tank,.LH.BOC.cantilever.battery.bo,.and.











































Section 5 Frame Layouts

D6.is.a.Clear.BOC.conguration.used.with.RHUC.DPF/SCR,.vertical.SOC.tailpipe,.LHUC.245”..56gal.fuel.tank.with. LHUC.Small.DEF.tank,.and.in.cab.battery.bo.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.bo.Chart.located.on.page.5-16

D8 is.used.with.horizontal.Crossover.DPF/SCR,.LH.horizontal.tailpipe,.RHUC.cylindrical.fuel.tank,.RH.BOC.cylindrical. DEF.tank,.and.LHUC.battery.bo.Chart.located.on.page.5-17












































.is.used.with.Vertical-Vertical.DPF/SCR,.LH.vertical.tailpipe,.RHUC.cylindrical.fuel.tank,.RH.BOC.cylindrical.DEF.tank,. D12.is.used.with.V and.LHUC.battery.bo.Chart.located.on.page.5-21

.is.used.with.Vertical-Vertical.DPF/SCR,.LH.vertical.tailpipe,.RHUC.cylindrical.fuel.tank,.LH.BOC.cylindrical.DEF.tank, D13.is.used.with.V and.LHUC.battery.bo.Chart.located.on.page.5-22

.is.used.with.Vertical-Vertical.DPF/SCR,.LH.vertical.tailpipe,.RHUC.rectangular.f ertical-Vertical.DPF/SCR,.LH.vertical.tailpipe,.RHUC.rectangular.fuel.tank,.RHUC.rectangular.DEF. uel.tank,.RHUC.rectangular.DEF. D14.is.used.with.V tank,.and.LHUC.battery.bo.Chart.located.on.page.5-23












































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.bo rectangular.DEF.tank,.and.LH.BOC.cantile ver.battery.bo.Chart.located.on.page.5-27 .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.bo.Chart.located.on.page.5-28

.is.a.T170.specic.conguration.used.with.horizontal.In-Series.DPF/SCR,.RH.horizontal.tailpipe,.RHUC.rectangular. n-Series.DPF/SCR,.RH.horizontal.tailpipe,.RHUC.rectangular. D20.is.a.T170.specic.conguration.used.with.horizontal.I fuel.tank,.RHUC.rectangular.DEF.tank,.and.LHUC.battery.bo fuel.tank,.RHUC.rectangular.DEF.tank, .and.LHUC.battery.bo.Chart.located.on.page.5-29 .Chart.located.on.page.5-29











































Section 5 Frame Layouts Hybrids

H1.Hybrid.conguration.used.with.RHUC.DPF/SCR,.vertical.SOC.tailpipe,.RH.BOC.DEF.tank.with.RH.BOC.fuel.tank,. LHUC.hybrid.battery.bo,.and.LH.BOC.Hybrid.PEC.Chart.located.on.page.5-33

.is.a.Hybrid.conguration.used.with.horizontal.Crossover.DPF/SCR,.LH.horizo Crossover.DPF/SCR,.LH.horizontal.tailpipe,.RHUC.rectangular.fuel.tank,. ntal.tailpipe,.RHUC.rectangular.fuel.tank,. H2.is.a.Hybrid.conguration.used.with.horizontal. RHUC.rectangular.DEF.tank,.LHUC.hybrid.battery.bo,.and.LH.BOC.h RHUC.rectangular.DEF.tank,.LHUC.h ybrid.battery.bo,.and.LH.BOC.hybrid.PEC ybrid.PEC.Chart.located.on.page.5-34 .Chart.located.on.page.5-34














































H6.is.a.Hybrid.conguration.used.with.In-Series.DPF/SCR,.RH.horizontal.tailpipe,.RHUC.cylindrical.fuel.tank,.RH.BOC. cylindrical.DEF.tank,.LHUC.hybrid.battery.bo,.and.LH.BOC.hybrid.PEC cylindrical.DEF.tank,.LHUC.hybrid.battery.bo, .and.LH.BOC.hybrid.PEC.Chart.located.on.page.5-38 .Chart.located.on.page.5-38

H7.is.a.Hybrid.conguration.used.with.horizontal.In-Series.DPF/SCR,.RH.horizontal.tailpipe,.RHUC.rectangular.fuel.tank,.













































Section 5 Frame Layouts D1



































































































































































































































































































































































































































Section 5





































Section 5





































Section 5





































Section 5





































Section 5































































































































































































































































































































































































































































































































































































































































































































































































































































































































































































































































































































































Section 7 Frame Modications WARNING:

Do not drill new holes any closer than 2 inches (50 mm) to eisting holes. Frame drilling affects the strength of the rails and if not done properly can cause the frame rails to fail and cause an accident.

Before.the.rear.suspension.is.relocated,.check.the.new.location.of.the.spring.hanger.brackets.The.new.holes.for.the.spring. hanger.brackets.must.not.overlap.eisting.holes.and.should.not.come.any.closer.than.2.inches.(50.mm).to.eisting.holes. Mount.the.suspension.Brackets.On.the. Original.Rail.(see.frame.insert.section.&. gures.7-1.&.7-2)

Etended.Wheelbase

Do.Not.Mount.the. Suspension.Bracket. On.the.Added. Frame.Rail

Original.Wheelbase

Relocated.Rear. Suspension

Shortened.Wheelbase

Cut.Frame.at.Rear.to. Obtain.Desired.Cutoff

FIGURE 7-3..Comparison.of.Original,.Shortened,.and.Etended.Wheelbases

Crossmembers After.changing.a.wheelbase,.an.additional.crossmember.may.be.reuired.to.maintain.the.original.frame.strength After.changing.a.wheelbase,.an.additional.crossmember.may.be.reuired.t o.maintain.the.original.frame.strength.. .. The.maimum.allowable.distance.between.adjacent.crossmembers.is.60.inches.(1524.mm) The.maimum.allowable.distance.betw een.adjacent.crossmembers.is.60.inches.(1524.mm).If.the.distance.between. .If.the.distance.between. adjacent.crossmembers.eceeds.this.dimension,.add.a.crossmember.between.the adjacent.crossmembers.eceeds. this.dimension,.add.a.crossmember.between.them.See.Figure. m.See.Figure.7–4 7–4

Less.Than.60”

Before.Wheelbase.is.Lengthened Greater.Than.60”







































Section 7 Frame Modications WELDING The.9875”.and.1062”.r The.9875”.and.1062”.rails.along.with.the.9875”. ails.along.with.the.9875”.insert.are.heat.treated; insert.are.heat.treated;.therefore .therefore,.it.is.not.weldable ,.it.is.not.weldable The 9.875 (9-7/8) inch rail, 10.62 (10-5/8) inch rail and the 9.88 (9-7/8) insert for the 10.62 inch rail are heat treated; therefore are not weldable. Welding can affect frame rail strength leading to a failure resulting in serious injury and /or an accident. Rail failures resulting from such modications are not warrantable.

To.determine.if.the.frame.rails.are.heat o.determine.if.the.frame.rails.are.heat.treated: .treated: 1 Check.f Check.for.he or.heat.t at.treat. reat.cautio caution.lab n.labels.on els.on.the. .the.frame frame.rail .rails s.See. .See.gure gure.7-5 .7-5

FIGURE 7-5. Heat.Treated.Frame.Rail.Warning Kenworth.DOES.NOT.recommend.frame.welding Kenworth.DOES.NOT.recommend.f rame.welding.The.high.heat .The.high.heat.of.welding.nullies.the.special.heat.treat .of.welding.nullies.the.special.heat.treatment.of.the.. ment.of.the.. rails,.greatly.reducing.the.tensile.strength.of.the. rails,.greatly.reducing.the.tensile.strength.of.the.frame.rail frame.rail.If.a.frame.member.becomes. .If.a.frame.member.becomes.cracked.fr cracked.from.overloading,.f om.overloading,.fatigue,. atigue,. surface.damage.or.a.collision,.the.only.permanent.repair.is.to.replace.the.damaged. surface.damage.or.a.collision,.the.only.permanent.repair.is.to.replace.the.damaged.frame.member.with.a.new.part frame.member.with.a.new.part The.following.information.is.provided.(for. The.following.information.is.provided.(for.temporary.emergency.repair) temporary.emergency.repair).Prior.to.welding.a.crac .Prior.to.welding.a.cracked.frame.rail,.t ked.frame.rail,.the.area. he.area. should.be.beveled.(V’d.out).to.allow.for.a.better.weld.To.prevent.spreading.of.the.crack,.a.7.to.9.mm.(1/4.in.to.3/8.in).dia. hole.should.be.drilled.at.the.end.of.the.crack hole.should.be.drilled.at.the.end.of.the.cr ack.Widen.the.c .Widen.the.crack.along.its.full.length.b rack.along.its.full.length.by.using.two.hack.sa y.using.two.hack.saw.blades.together w.blades.together. . When.welding.steel.frames.use.the.shielded.arc.method When.welding.steel.frames.use.t he.shielded.arc.method.When.welding.aluminum.fr .When.welding.aluminum.frames.use.either.the.tungsten.inert. ames.use.either.the.tungsten.inert. gas.(TIG).or.consumable.electrode.method gas.(TIG).or.consumable.elect rode.method.Be.sure.to.obtain.full.weld.penetr .Be.sure.to.obtain.full.weld.penetration.along.the.entire.length.of.the. ation.along.the.entire.length.of.the.crack crack

Precautions CAUTION:

CAUTION:

CAUTION:

Before welding, disconnect the negative terminal battery cable. Failure to comply may may result in euipment damage.

Before welding, disconnect the alternator terminals. Failure to do so may result in damage to the voltage regulator and/or alternator.







































Section 7 Frame Modications Welding Wel ding Precautions: All Electronic Engines Before.welding.on.vehicles.with.electronic.engines,.the.f Before.welding.on.vehicles.with.electronic.engines,.the.following.precautions.should.be.observed ollowing.precautions.should.be.observed 1 Disconnect. Disconnect.all.el all.electric ectrical.con al.connectio nections.t ns.to.the o.the.veh .vehicle.b icle.batter atteries ies 2 Disconnect. Disconnect.all.EC all.ECM.conn M.connector ectors s 3. Do.no.use.the.ECM.or.engine.ground. Do.no.use.the.ECM.or.engine.ground.stud.for.the. stud.for.the.ground.of.the.welding.probe ground.of.the.welding.probe 4. Ensure.that.the.ground.connection.for.the. Ensure.that.the.ground.connection.for.the.welder.is.as.close.to.the.weld.point welder.is.as.close.to.the.weld.point.as.possible .as.possible.This.ensures. .This.ensures.maimaimum.weld.current.and.minimum.risk.to.damage.electrical.components.on.the.vehicle 5 Turn.off urn.off.k .key ey

Note:

Bendi.ABS,.Bosch.ABS.and.Wabco.ABS: Bendi.ABS,.Bosch.ABS.and. Wabco.ABS:.Disconnect.ECU .Disconnect.ECU







































Section 7 Frame Modications TORqUE REqUIREMENTS TABLE 7-1. Customary.Grade.8.UNF.or.UNC Fastener

Torue

Size

Nm

Lb.-Ft.

5/16

2 2 – 30

16–22

3 /8

41–54

30 – 4 0

7/16

75–88

55– 65

1/2

109–122

80– 90

9/16

156–190

115– 14 0

5/8

224–265

165– 19 5

3 /4

39 4 – 4 6 2

2 9 0 – 34 0

7/8

517–626

38 0 – 4 6 0

1

952–1129

800-–830

1-1/8

1 34 6 – 1 5 9 1

990–1170

1-1/4

1 87 7–2 21 7

1 38 0 – 1 6 30

Torue.values.apply.to.f orue.values.apply.to.fasteners.with.clean.threads,. asteners.with.clean.threads,.lightly.lubricated,.with.hardened.steel.washers lightly.lubricated,.with.hardened.steel.washers,.and.nylon-insert.nuts ,.and.nylon-insert.nuts

TABLE 7-2. US.Customary.—Grade.8,.Metric.Class.109. Torue Fastener

Nm

Lb-Ft

M6

9–15

7–11

M8

2 3– 31

17–23

M10

33–4 3

2 4 – 32

M12

75–101

55–75

M 14

1 34 – 1 6 4

99–121

M 16

1 6 3– 2 1 7

120–160

M 20

35 2 – 4 6 0

260–340







































Section 7 Frame Modications

Page Intentionally Left Blank.









































Section 8 Electrical ELECTRICAL Information.in.this.section.will.cover.the.following.topics: •.

Overview.o Overview.of.K f.Kenworth’ enworth’s.2010 s.2010.mult .multiple iple.inst .instrument rumentation. ation.for for.Medium .Medium.Duty .Duty.T .Trucks rucks

•.

Access.inst Access.instruction ructions.f s.for.th or.the.das e.dash,.ga h,.gauges, uges,.and. .and.swit switches ches

•.

Wiring.instru Wiring.instructions ctions.fo .for.ala r.alarm.and. rm.and.tellt telltale.(w ale.(warning. arning.lights lights))

•.

Reco Recon ngu gurin ring. g.te tellt lltal ale. e.ca card rds s

•.

Spare. Spare.Swit Switche ches.( s.(sta standa ndard. rd.and and.ad .adding ding))

•

Spare Relays

•.

Remo Remote te.P .PT TO/Th O/Thro rott ttle le.h .harn arnes ess s

•.

Elec Electr tric ical. al.wir wire. e.nu numb mber er.a .and nd.c .col olor or

•.

Trail railer er.c .cab able le.c .con onne nect ctio ions ns

•.

Afte Afterr-tr trea eatm tmen ent. t.Co Cont ntro rol. l.Mo Modu dule les s

MULTIPLEx INSTRUMENTATION Kenworth.utilizes.Multiple.instrumentation.and.wiring.to.continuously.improve.our.uality.and.the.capability.of.our. Kenworth.utilizes.Multiple.instrumentation.and.wiring.to.continuously.improve. our.uality.and.the.capability.of.our.trucks trucks Multipleing.utilizes.the.industry.standard.Society.of.Automotiv Multipleing.utilizes.the.industry.standard.Soc iety.of.Automotive.Engineering.(SAE).J1939.data.bus.to. e.Engineering.(SAE).J1939.data.bus.to.send.multiple. send.multiple. signals.over.a.single.twisted.pair.of.wires.instead.of.individual.wires.f signals.over.a.single.twisted.pair.of.wires.instead.of.individual.wires.for.each.function or.each.function.The.adv .The.advantages.are.fe antages.are.fewer.wires,. wer.wires,. sensors,.and.connections.that.provide.greater. sensors,.and.connections.t hat.provide.greater.consistency consistency,.improved.reliability.and.th ,.improved.reliability.and.the.ability.to.use.ESA.to.troub e.ability.to.use.ESA.to.troubleshoot. leshoot. the.instrumentation.The.f the.instrumentation.The.following.information.is.provided.to.increas ollowing.information.is.provided.to.increase.your.awar e.your.awareness.about.the.Ke eness.about.the.Kenworth.product,.it.may. nworth.product,.it.may. be.useful.in.installing.telltales.(warning.lights).and.gauges.and.coordination.with.other.installed.euipment

WARNING!

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









































Section 8 Electrical INTERIOR IDENTIFICATION 2010.is.the.rst.year.that.Kenw 2010.is.the.rst.year.that.Kenworth.has.used.Multiple.Wiring.in.our. orth.has.used.Multiple.Wiring.in.our.T170,.T270. T170,.T270.and.T370.v and.T370.vehicles ehicles.Chassis.with.this.new. .Chassis.with.this.new. interior.can.be.identied.by.appearance,.see.Figure.8-2 interior.can.be.identied.by.appear ance,.see.Figure.8-2.All.dashes.that.resemble.the. .All.dashes.that.resemble.the.following.picture.will.utilize.multiple following.picture.will.utilize.multiple. . wiring

FIGURE 8-2..Kenworth.B-Cab.Dash A.2010.Chassis.can.uickly.be.identied.by.the.presence.of.the.Diesel.Ehaust A.2010.Chassis.can.uickly.be.identied.b y.the.presence.of.the.Diesel.Ehaust.Fluid.“DEF” .Fluid.“DEF”.gauge .gauge.See.Figure.8-3 .See.Figure.8-3









































Section 8 Electrical Data Bus Communication Communication The.multipleed.instrumentation.system.uses.sev The.multipleed.instrumentation.system.uses.several.different. eral.different.data.links.to.transmit.input/outpu data.links.to.transmit.input/output.data.from.other.systems. t.data.from.other.systems. to.the.Cab.Electronic.Control.Unit.(CECU),.and.ultimately.to.the.Central.I to.the.Cab.Electronic.Control.Unit.( CECU),.and.ultimately.to.the.Central.Instrument.Cluster.and.CVSG.Gauges nstrument.Cluster.and.CVSG.Gauges.See.. .See.. Figure.8-4,.Multipleed.Instrumentation.Block.Diagram.on.page.8-3 FIREWALL V-CAN I-CAN DWIM

POWER TRAIN CONTROLLERS

CECU 3 CSVG BUS

ELECTRONIC CVSGs

ELECTRIC SWITCHES (SOME)

FIGURE 8-4. Multipleed.Instrumentation.Block.Diagram •.

V-CAN.= -CAN.= Vehicle ehicle.Co .Contr ntrolle oller.A r.Area rea.Ne .Netwo twork. rk. The.V-CAN,.also.referr The.V-CAN,.also.referred.to.as.the.J1939,.is.used.t ed.to.as.the.J1939,.is.used.to.transmit.data.between.t o.transmit.data.between.the.transmission,.ABS.system,. he.transmission,.ABS.system,. engine,.etc.to.the.Cab.Electronic.Control.Unit.(CECU)

•.

I-CAN. I-CAN.=.I =.Inst nstrume rumenta ntatio tion.C n.Cont ontrol roller ler.Ar .Area. ea.Net Network work The.I-CAN.provides.data.link.communication.from.the.Cab.Electronic.Control.Unit.(CECU).to.the.Central. Instrument.Cluster

•

CVSG Bus The.CVSG.bus.is.a.private.data.bus.used.to.tr The.CVSG.bus.is.a.private. data.bus.used.to.transmit.data.from.the.Cab.Electronic. ansmit.data.from.the.Cab.Electronic.Control.Unit.(CECU).to.the. Control.Unit.(CECU).to.the. individual.2-inch.gauges.A.series.of.“daisy.chained” individual.2-inch.gauges .A.series.of.“daisy.chained”.jumper.harnesses.link.each.gauge.to.another .jumper.harnesses.link.each.gauge.to.another









































Section 8 Electrical Functional Description Cab Electronic Control Unit (CECU) The.heart.of.the.multipleed.instrumentation.system.is.the.Cab.Electronic.Control.Unit.(CECU) The.heart.of.the.multipleed.instrumentation.system.is.the.Cab.Electronic.Contr ol.Unit.(CECU).The.CECU.is.located. .The.CECU.is.located. behind.the.center.console.See.Figure.8-5 behind.the.center.console .See.Figure.8-5

CECU

FIGURE 8-5. CECU.Location Vehicle.component.inputs.are.sent.to.t ehicle.component.inputs.are.sent.to.the.CECU.through.the.J1939.data.b he.CECU.through.the.J1939.data.bus.or.convent us.or.conventional.wiring. ional.wiring.The.CECU.interprets. The.CECU.interprets. the.various.inputs.and.monitors/controls.the.functions.f the.various.inputs.and.monitors/c ontrols.the.functions.for.each.input.through.the. or.each.input.through.the.CECU.software CECU.software.Output.signals.from.the. .Output.signals.from.the. CECU.provide.data.for.the.gauges,.warning.lamps,. CECU.provide.data.for.the.gauges,.warning.lamps,.audible.alarms,.and.displays.inside.the.c audible.alarms,.and.displays.inside.the.cluster luster

Central Instrument Panel The.central.instrument.panel.includes.the.speedometer.(including.odometer.and.trip.meter).and.tachometer.(including. engine.hour.meter.and.outside.temperature.display),.plus.a.Driv engine.hour.meter.and.outside.temper ature.display),.plus.a.Driver.W er.Warning.and.Indicator.Module.(DWIM). arning.and.Indicator.Module.(DWIM).pre-installed. pre-installed. standard.and/or.editable.warning.light.symbols.called.“telltale”.cards Each.“telltale”.card.slides.into.the.left.and.right.s Each.“telltale”.card.slides.into.the.left.and.right.sides.of.the.Driver. ides.of.the.Driver.Warning.and.Indicator.Module.(D Warning.and.Indicator.Module.(DWIM).from.the.bottom WIM).from.the.bottom









































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.t The.2”.gauges.located.to.the.left.and.right.of.the.main.instrument.panel.are.commonly.refer he.main.instrument.panel.are.commonly.referred.to.as.Commercial. red.to.as.Commercial.Vehicle. Vehicle. Smart.Gauges.(CVSG).Like.the.central.instrument.cluster Smart.Gauges.(CVSG).Like .the.central.instrument.cluster,.the.2-inch.gauges.also.receiv ,.the.2-inch.gauges.also.receive.input.data.directly.from.the. e.input.data.directly.from.the. CECU.CVSG’s.are.t CECU.CVSG’s.are.two.types,.electronic.and.mechanical wo.types,.electronic.and.mechanical.The.electronic. .The.electronic.CVSG’s.receive. CVSG’s.receive.digital.data.from.the.CECU.via. digital.data.from.the.CECU.via. the.CVSG.data.bus.The.mechanical.gauges.( the.CVSG.data.bus.The.mechanical.gauges.(ie ie.suspension.air.pressure,.et .suspension.air.pressure,.etc).are.driven.directly.f c).are.driven.directly.from.the.air.pressure rom.the.air.pressure Both.types.of.gauges.receive.backlighting.signals.from.the.CECU.via.a.4Both.types.of.gauges.receiv e.backlighting.signals.from.the.CECU.via.a.4-wire.“daisy.chained” wire.“daisy.chained”.jumper.harness.that.links. .jumper.harness.that.links. one.gauge.to.another When.the.ignition.key.is.rst.turned.ON,.all.the.electronic.2-inch.gau When.the.ignition.key.is.rst.turned.ON,.all.the.electronic.2-inch.gauges.will.perform.a.calibration. ges.will.perform.a.calibration.“power.on.self-test” “power.on.self-test”

Note:

The.mechanical.CVSG.do.not.perform.a.power.on.self-test

Power On Self-Test •.

Igni Igniti tion on.k .key ey.t .tur urne ned. d.ON ON











































Section 8 Electrical •.

4-way.jump 4-way.jumper.ha er.harnesses rnesses.link. .link.CVSG.el CVSG.electro ectronic.ga nic.gauges. uges.toget together her,.by ,.by.a.da .a.daisy.c isy.chain.s hain.system ystem.Pin.out.is .Pin.out.is.as.f .as.follows ollows:: Pin #

Color

Function

1

Blue

Data,.backlighting.for.Electronic.Gauges

2

Brown

Backlighting.for.Mechanical.Gauges

3

White

Return

4

Yellow

Power

•.

Backlightin Backlighting.le g.level. vel.for for.CVSG. .CVSG.elect electronic. ronic.gauges gauges.is.s .is.sent.f ent.from.t rom.the.CEC he.CECU.to. U.to.the.g the.gauges. auges.via.t via.the.dat he.data.link a.link.(bl .(blue. ue. wire)

•.

Optional.CVS Optional.CVSG.mech G.mechanical. anical.gauges gauges.(ie .(ie.air.suspen .air.suspension). sion).are.d are.driven riven.mecha .mechanically nically.with. .with.air.pr air.pressure essure.hosed .hosed.to. .to. the.tting.behind.the.gauge.There. the.tting.behind.the.gauge .There.is.no.red.warning.lamp.and.the.backlighting.is.po is.no.red.warning.lamp.and.the.backlighting.is.powered.through.the.bro wered.through.the.brown. wn. wire.from.the.CECU.(a.pulse-width.modulated.signal).The.4-w wire.from.the.CECU.(a.pulse-width.modulated.signal) .The.4-way.jumper.harness.is.still.used.to.pass. ay.jumper.harness.is.still.used.to.pass.all.4. all.4. circuits.through.the.gauge.to.the.net.gauge.in.the.chain

•.

Gauges.can.be.relocated.to.any.2-inch.open.gauge.position.in.the.dash.T Gauges.can.be.relocated.to.any.2-inch.open.gauge.position.in.the.dash .To.relocate.a.gauge.unhook.the.c o.relocate.a.gauge.unhook.the.cononnector.at.the.back.and.move.it.t nector.at.the.back.and.move.it.to.the.desired.position o.the.desired.position.Plug.the.jumper.wire.in .Plug.the.jumper.wire.in.(See.“Accessing.Gauges.and. .(See.“Accessing.Gauges.and. Switches.section.below.for.instructions.on.physically.moving. Switches.section.below.f or.instructions.on.physically.moving.the.gauge) the.gauge).The.connect .The.connector.will.reuire.a.rm.pull. or.will.reuire.a.rm.pull. to.remove.it.When.reinst to.remove.it.When.reinstalling.the.connector.ensure.that.it. alling.the.connector.ensure.that.it.is.fully.inserted.Both.connect is.fully.inserted.Both.connector.sockets.on. or.sockets.on.the.rear. the.rear. of.the.gauge.are.the.same,.either.one.can.be.used











































Section 8 Electrical Sensors Kenworth’s.chassis.contain.standard.connectors.in.t Kenworth’s.chassis.contain.standard.connectors.in.the.wiring.harnesses.for.gauges.e he.wiring.harnesses.for.gauges.even.when.they. ven.when.they.were.not.specied. were.not.specied. on.a.particular.chassis.The.f on.a.particular.chassis .The.following.diagram.shows.the.locations.o ollowing.diagram.shows.the.locations.of.standard.connectors.in.the. f.standard.connectors.in.the.wiring.harnesses. wiring.harnesses.This. This. allows.you.to.easily.locate.connectors.to.add.gauges allows.you.to.easily.locate.c onnectors.to.add.gauges.T .To.add.an.electronic.gauge.install.the.sens o.add.an.electronic.gauge.install.the.sensor.(available. or.(available.from.your. from.your. local.Kenworth.dealer).in.the.noted.location,.plug.in.the.wiring.harness,.and.then.install.the.gau local.Kenworth.dealer).in.the.noted. location,.plug.in.the.wiring.harness,.and.then.install.the.gauge.in.the.dash ge.in.the.dash.The.gauge. .The.gauge. will.then.need.to.be.activated. will.then.need.to.be.activat ed.Y Your.local.Kenworth.dealer.can.easily.activ our.local.Kenworth.dealer.can.easily.activate.the.gauge.using.K ate.the.gauge.using.Kenworth’s.Electronic.Serenworth’s.Electronic.Service.Analyst.(ESA)

Brake Application Sensor











































Section 8 Electrical The.following.diagrams.show.the.location.of.sensors. The.following.diagrams.show.the.location.of.sensors.on.the.rewall.junction.b on.the.rewall.junction.block lock.This.is.to. .This.is.to.aid.in.locating.these.sensors 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.bloc Application.Air.Sensor.is.located.by.t he.brake.application.block.See. k.See.Figure.8-8 Figure.8-8 The.Air.Filter.Restriction.Sensor.is.located.near.the.brake.application.sensor The.Air.Filter.Restriction.Sensor.is.located.near. the.brake.application.sensor,.see.Figure.8-9 ,.see.Figure.8-9 The.Fuel.Filter.Restriction.Sensor.is.located.near.the.fuel.lter,.see.Figure.8-10 OPENING.FOR.AIR. RESTRICTION.FILTER

BRAKE.APPLICATION. (OPTIONAL)






















































































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.cor In.order.to.access.and.install.components.described.later.on.in.the.manual,.y ou.will.need.to.know.how.to.correctly.remove. rectly.remove. the.dash.panels.without.causing.damage.

1. Removal.of.the.main.panels.is.accomplished.b Removal.of.the.main.panels.is.accomplished.by.unscrewing.the.two.t y.unscrewing.the.two.top.screws.in.each.panel op.screws.in.each.panel













































Section 8 Electrical 2 Then.lift.t Then.lift.the.pa he.panel.ou nel.out.of t.of.the. .the.dash.a dash.and.un nd.unclip.t clip.the.ma he.main.harne in.harness ss













































Section 8 Electrical 4. To.remove.a.switch.push.in.the.tabs.on.both.sides. o.remove.a.switch.push.in.the.tabs.on.both.sides.of.the.switch.and.pull.out of.the.switch.and.pull.out.the.top.section.to.disconnect. .the.top.section.to.disconnect.the.switch the.switch













































Section 8 Electrical 6 The.fuse.bo The.fuse.bo.is. .is.locate located.beh d.behind.th ind.the.f e.far.rig ar.right.pa ht.panel nel













































Section 8 Electrical TELLTALE SYMBOLS Kenworth’s.interior.allows.Body.Builders.to.customize.the. Kenworth’s.interior.allows.Body.Builders.to.customize.the.dash.telltale.symbols.(warning.lights) dash.telltale.symbols.(warning.lights).The.editab .The.editable.telltale. le.telltale. symbols.are.located.on.removable.cards.inside.the.baseline.cluster symbols.are.located.on.remov able.cards.inside.the.baseline.cluster. .This.section.will.describe.how.to.replace.and.insert. This.section.will.describe.how.to.replace.and.insert. editable.cards,.as.well.as.how.to.activ editable.cards,.as.well.as.how.to.activate.the.telltale.lights ate.the.telltale.lights Note.the.numbers.1.–.12.on.Figure.8-11.These.ar Note.the.numbers.1.–.12.on.Figure.8-11 .These.are.how.the.positions.are.identied.in. e.how.the.positions.are.identied.in.T Table.8-1.and.on.the.instrument. panel.harness.breakouts.for.the.“editab panel.harness.breakouts.f or.the.“editable”.telltales.behind.the.right.hand. le”.telltales.behind.the.right.hand.cluster cluster To.remove.the.editable.cards.follo o.remove.the.editable.cards.follow.steps.1-3.in.the.instructions.f w.steps.1-3.in.the.instructions.for.accessing.gauges.and.s or.accessing.gauges.and.switches.(page.8-10) witches.(page.8-10).The.. .The.. access.cards.have.a.positive.lock access.cards.have.a.positive.lock.T .To.remove.the. o.remove.the.card.push.inwards.on.the.loc card.push.inwards.on.the.lock.with.your.thumb.and.pull.t k.with.your.thumb.and.pull.the.card.out.with. he.card.out.with. pliers.Figure.8-11.below.details.the.car pliers.Figure.8-11.below.details.the.cards ds.T .To.reinstall.a.card.slide.it.in.either.b o.reinstall.a.card.slide.it.in.either.by.hand.or.with.pliers y.hand.or.with.pliers ......













































Section 8 Electrical TABLE 8-1. Telltales.Position.and.Color Position

Standard Function

1

PTO

2

Check Transmission

3

Left Turn Arrow

4

Wait To Start

5

Brake Fail

6

High Beam

7

Use

Light Color

Editable or Fied?

Illuminates to Indicate PTO is Engaged

Green

Editable

Illuminates During Transmission Fault

Yellow

Editable

Illuminates.to.Indicate.Left.T Illuminates.to.Indicate.Left. Trun.Signal.is. Applied

Green

Fied

Illuminates.when.Driver.needs.to.Wait.Before. Starting.Engine

Yellow

Fied

Illuminates.When.the.Hydraulic.Brake.ECU. Determines.Fault

Re d

Editable

Illuminates.to.Indicate.High.Beam.Lights.are. Applied

Blue

Fied

Yellow

Fied

Malfunction.Indicator. Illuminates.to.Indicate.a.Malfunction.in.. Lamp.(MIL) Emissions.System.(After.2013)















































Section 8 Electrical The.standard.trays.are.shown.abov The.standard.trays.are.shown.above.(in.Figure.8-11) e.(in.Figure.8-11).Editable.tra .Editable.trays.are.also.av ys.are.also.available.from.your.local.K ailable.from.your.local.Kenworth.dealer enworth.dealer The.left.and.right.trays.are.shown.in.Figure.8-12.belo The.left.and.right.trays.are.shown.in.Figure.8-12.below w















































Section 8 Electrical Your.local.Kenworth.dealer.will.also.sell.a.sheet.of our.local.Kenworth.dealer.will.also.sell.a.sheet.of.telltale.light.icons.to.install.on.the.editab .telltale.light.icons.to.install.on.the.editable.card. le.card.The.symbols.that.are. The.symbols.that.are. available.are.shown.in.Figure.8-13.below






























































































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

Alarm 1A















































Section 8 Electrical OPTIONAL OPTIONA L SWITCHES, SWI TCHES, AIR VAL VALVES VES AND A ND GAUGES The.number.of.optional.switches,.air.valves.and.gauges.has.changes.f The.number.of.optional.switches,.air.valv es.and.gauges.has.changes.for.Kenworth.Medium.Duty.v or.Kenworth.Medium.Duty.vehicles. ehicles..The.below. .The.below. chart.provides.a.total.count.based.on.model.type

TABLE 8-3. Optional.Switches,.Air.Valves.and.Gauges

















































Section 8





































Section 8





































Section 8





































Section 8





































Section 8









































































































































































































































































































































































































































































































































































































































































































































































































































































































































































Kenworth Medium Duty 2010 Body Builder Manual

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