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Kenworth K270, Body Builder'S Manual

The Kenworth K270 Body Builder's Manual is a comprehensive guide for builders and enthusiasts who desire to customize their trucks. This manual is available to download for free on our website, providing step-by-step instructions, diagrams, and specifications to assist in constructing the perfect build. Download it now from manualshive.com!

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  Body Builder’s Manual 

Contents 

 

 
FIGURES  ................................................................................................................................................................. III

 

TABLES   .................................................................................................................................................................. V

 

SECTION 1 INTRODUCTION .............................................................................................................................. 1-1

 

SECTION 2 SAFETY & COMPLIANCE

 

SAFETY SIGNALS 

2-1

 

SECTION 2 SAFETY & COMPLIANCE .............................................................................................................. 2-2

 

FEDERAL MOTOR VEHICLE SAFETY STANDARDS COMPLIANCE 

 

Incomplete Vehicle Certification .................................................................................................... 2-2

 

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

 

SECTION 3 DIMENSIONS

 

ABBREVIATIONS 

3-1

 

TURNING RADIUS 

3-2

 

CAB TILT 

 

K270 W/19.5 Tires .......................................................................................................................... 3-3

 

K370 W/19.5 Tires .......................................................................................................................... 3-3

 

K370 W/22.5 Tires .......................................................................................................................... 3-4

 

OVERALL DIMENSIONS 

 

Side View - K270 ............................................................................................................................ 3-5

 

Side View - K370 ............................................................................................................................ 3-7

 

Front and Rear Views — K270/K370 ............................................................................................. 3-9

 

DETAIL VIEWS 

 

Left side: Chassis Heights –K270 W/19.5 Tires ........................................................................... 3-12

 

Left side: Chassis Heights – K370 ................................................................................................ 3-13

 

Components Locations –K270 W/19.5 Tires ................................................................................ 3-15

 

Components Locations –K370 ...................................................................................................... 3-16

 

Crossmember Locations –K270 W/19.5 Tires .............................................................................. 3-19

 

Frame Rail Configurations ............................................................................................................ 3-21

 

Battery Box, Fuel Tanks and Air Tanks — K270/K370 ............................................................... 3-22

 

DPF & SCR Locations – K270/K370 ........................................................................................... 3-23

 

Reyco 79KB Single Rear Axle

 

Hendrickson HAS Single Rear Axle ........................................ 3-24

 

TIRE DATA .................................................................................................................................. 3-24

 

FRAME AND CAB RELATED HEIGHTS ................................................................................. 3-24

 

GROUND CLEARANCES .......................................................................................................... 3-24

 

PTO Clearances............................................................................................................................. 3-25

 

SECTION 4 EXHAUST & AFTERTREATMENT

 

EXHAUST AND AFTERTREATMENT INFORMATION

 

General Guidelines for DEF System ............................................................................................... 4-3

 

Installation Requirements and Dimensions for DEF System .......................................................... 4-3

 

Measurement Reference Points ....................................................................................................... 4-4

 

GENERAL EXHAUST INFORMATION 

4-6

 

SECTION 5 FRAME LAYOUTS AND BODY MOUNTING

 

FRAME LAYOUTS 

5-1

 

Visual Index .................................................................................................................................... 5-1

 

Acronyms Index .............................................................................................................................. 5-2

 

CRITICAL CLEARANCES 

 

Rear Wheels and Cab ...................................................................................................................... 5-3

 

Body Mounting Using Brackets ...................................................................................................... 5-4

 

Frame Sill ........................................................................................................................................ 5-4

 

Brackets ........................................................................................................................................... 5-5

 

Mounting Holes............................................................................................................................... 5-5

 

Frame Drilling ................................................................................................................................. 5-6

 

Hole Location Guidelines ............................................................................................................... 5-6 

Summary of Contents for K270

Page 1: ......

Page 2: ...Medium Duty Body Builder s Manual Model K270 K370 ...

Page 3: ...omponents Locations K370 3 16 Crossmember Locations K270 W 19 5 Tires 3 19 Frame Rail Configurations 3 21 Battery Box Fuel Tanks and Air Tanks K270 K370 3 22 DPF SCR Locations K270 K370 3 23 Reyco 79KB Single Rear Axle Hendrickson HAS Single Rear Axle 3 24 TIRE DATA 3 24 FRAME AND CAB RELATED HEIGHTS 3 24 GROUND CLEARANCES 3 24 PTO Clearances 3 25 SECTION 4 EXHAUST AFTERTREATMENT EXHAUST AND AFTER...

Page 4: ... 4 Removal and Installation Dashboard Panels 7 4 APPENDIX A VEHICLE IDENTIfiCATION VEHICLE IDENTIFICATION NUMBER VIN Location A 1 Chassis Number Locations A 1 CERTIFICATION LABELS Components and Weights Label A 2 Tire Rim and Weight Rating Data Label A 2 Incomplete Vehicle Certification Label A 2 COMPONENT IDENTIFICATION A 3 Engine Identification A 3 Transmission Identification A 4 Front Axle Identific...

Page 5: ...ront Axle inches mm 3 17 Figure 3 8 2 5 K370 22 5 Tires Short Wheelbase Air Tanks on the RH Side Battery Box DEF Tank and Crossmember Location Measured From Front Axle inches mm 3 18 Figure 3 9 1 K270 Crossmember Location 3 19 Figure 3 9 2 K370 Crossmember Locations 3 20 Figure 3 10 K270 K370 Rail Measurements 3 21 Figure 3 11 K270 K370 Battery Box Fuel Tank and Air Tanks Measurement mm in 3 22 Fi...

Page 6: ...3 Comparison of Original Shortened and Extended Wheelbases 6 4 Figure 6 4 Crossmember Added When Distance Exceeds 60 Inches 1524 mm 6 4 Figure 7 1 Instrument Layout 7 2 Figure 7 2 Data Bus Communication Architecture 7 3 Figure 7 2 Data Bus Communication Architecture 7 3 Figure A 2 Drivers Door and Door Frame Label A 2 Figure A 3 Engine Identification Location A 3 Figure A 4 Front Axle Identification...

Page 7: ...smember Location Measured from the Front of the Frame inches mm 3 19 Table3 9 2 K370 Crossmember Location Measured From Front Axle Centerline inches mm 3 20 Table 3 10 Frame Rail Strength Characteristics 3 21 Table 3 12 K270 K370 Exhaust Location Measured From BOC inches mm 3 23 Table 3 13 K270 K370 Exhaust Location Measured From BOC inches mm 3 23 Table 5 1 Symbols 5 1 Table 7 1 Additional Spare ...

Page 8: ...o sell and service the vehicle will also find this information useful This Body Builder s Manual can be very useful when specifying a vehicle particularly when the body builder is in volved in the vehicle definition and ordering process Early in the process professional body builders can often con tribute valuable information that reduces the ultimate cost of the body installation This manual is not...

Page 9: ...et liftgate amperage requirements An in correctly specified circuit breaker could result in an electrical overload or fire situation Follow the liftgate installation instructions and use a circuit breaker with the recommended capacity CAUTION Signals a potentially hazardous situation which if not avoided could result in minor or moderate injury or damage to the vehicle Example CAUTION Never use a to...

Page 10: ...lity as the Inter mediate or Final Stage Manufacturer to ensure that the complete vehicle is in compliance with the particular regulations upon completion of the modifications Figure 2 1 Incomplete Vehicle Certification Document Tire Rim and Weight Rating Data label Safety Mark Canadian Registry Only Incomplete Vehicle Certification Label U S EPA Noise Label U S registered vehicles only Final Stage M...

Page 11: ...inst the rules that are established by the U S Code of Federal Regu lations and Environment Canada Regulations The converter muffler may only be replaced with an approved part Relocation of converter muffler will affect noise and emission performance Contact the engine manu facturer for any requirements and restrictions prior to any modifications In particular there are re quirements and restrictions...

Page 12: ...n your vehi cle The chart below lists the abbreviated terms used Table 3 1 Abbreviations Used A OVERALLVEHICLE LENGTH AF FRAME RAILOVERHANG LENGTH BEHIND REAR B FRONT BUMPER TO FRONT AXLE LENGTH CA BACK OF CAB TO REAR AXLE LENGTH D CAB HEIGHT WB WHEELBASE LENGTH HA HEIGHT AXLE FAX FRONT AXLE EOF END OF FRAME CA CAB TO AXLE AE AXLE TO END TL TOTAL LENGTH ...

Page 13: ...4 25 7 4 30 25 9 2 202 5130 8 25 57 7 8 31 57 9 6 214 5435 6 26 89 8 2 32 89 10 0 226 5740 4 28 21 8 6 34 21 10 4 238 6045 2 29 53 9 0 35 53 10 8 K370 W 19 5 Tires Single R250F 285 70R19 5 146 3708 4 19 40 5 9 25 40 7 7 158 4013 2 20 72 6 3 26 72 8 1 170 4318 22 04 6 7 28 04 8 5 182 4622 8 23 36 7 1 29 36 8 9 194 4927 6 24 69 7 5 30 69 9 4 206 5232 4 26 01 7 9 32 01 9 8 218 5537 2 27 33 8 3 33 33 ...

Page 14: ...ion 3 Dimensions CAB TILT K270 W 19 5 Tires K370 W 19 5 Tires Table 3 3 Cab Tilt Height CAB Tilt Highest point inches mm K270 W 19 5 Tires 126 5 3217 5 K370 W 19 5 Tires 128 3260 5 K370 W 22 5 Tires 131 3336 9 ...

Page 15: ...3 4 Section 3 Dimensions K370 W 22 5 Tires ...

Page 16: ...nt R250F 245 70R19 5 Rear M729F 245 70R19 5 4 On the K370 w 22 5 Full tires Front R250F 11R22 5 14PR Rear M711 11R22 5 14PR On the pages that follow detail drawings show particular views of each component of the vehicle They illustrate important measurements critical to designing bodies of all types See the Contents at the beginning of the manual to locate the draw ing you need Side View K270 Figu...

Page 17: ...6 7015 4 132 3346 6 17 166 4216 4 13 3 338 8 17 431 8 72 1828 8 285 7240 2 288 7320 2 144 3651 4 18 178 4521 13 3 338 8 17 431 8 84 2133 6 309 7849 8 312 7929 8 156 3956 2 20 190 4826 13 3 338 8 17 431 8 96 2438 4 333 8459 4 336 8539 4 168 4261 22 202 5130 8 13 3 338 8 17 431 8 108 2743 2 357 9069 360 9149 180 4565 8 24 214 5435 6 13 3 338 8 17 431 8 120 3048 381 9678 6 384 9758 6 192 4870 6 26 22...

Page 18: ...Length inches mm CA inches mm Recom mended Body Length ft 166 4216 4 11 4 288 8 15 381 72 1828 8 287 7290 2 290 7370 2 144 7 3676 4 18 178 4521 11 4 288 8 15 381 84 2133 6 311 7899 8 314 7979 8 156 7 3981 2 20 190 4826 11 4 288 8 15 381 96 2438 4 335 8509 4 338 8589 4 168 7 4286 22 202 5130 8 11 4 288 8 15 381 108 2743 2 359 9119 362 9199 180 7 4590 8 24 214 5435 6 11 4 288 8 15 381 120 3048 383 9...

Page 19: ... 279 7087 282 2 7167 146 7 3726 2 17 170 4318 11 4 288 8 40 9 1039 9 72 1828 8 291 7391 8 294 7471 8 158 7 4031 18 182 4622 8 11 4 288 8 40 9 1039 9 84 2133 6 315 8001 4 318 8081 4 170 7 4335 8 20 194 4927 6 11 4 288 8 40 9 1039 9 96 2438 4 339 8611 342 8691 182 7 4640 6 22 206 5232 4 11 4 288 8 40 9 1039 9 108 2743 2 363 9220 6 366 9300 6 194 7 4945 4 24 218 5537 2 11 4 288 8 40 9 1039 9 120 3048...

Page 20: ...3 9 Front and Rear Views K270 K370 inches mm Section 3 Dimensions ...

Page 21: ...ont and Rear Views K270 K370 K270 K370 Figure 3 4 K270 K370 W 19 5 Tires Front View Width and Ground Clearance Measurements inches mm Figure 3 4 1 K270 K370 W 22 5 Tires Front View Width and Ground Clearance Measurements inches mm ...

Page 22: ...19 5 and 22 5 Tires Figure 3 5 K270 W 19 5 Tires Rear View Width and Ground Clearance Measurements inches mm Figure 3 5 1 K370 W 19 5 Tires Rear View Width and Ground Clearance Measurements inches mm Note 11R22 5 is 10 3 261 6mm and 295 75R22 5 is 9 8 248 9mm ...

Page 23: ...Tires Figure 3 6 Cab Floor Side View Left Side Table 3 6 K270 W19 5 Tires Battery Box Step and Cab Floor Measurements Position K270 19 5 Tires Unladen Laden In mm In mm A FUEL SUPPORT STEP 10 1 258 8 205 2 B FIRST STEP 21 4 546 19 483 6 C SECOND STEP FLOOR 33 6 854 3 31 2 793 4 ...

Page 24: ...de View Left Side w 19 5 Tires Table 3 7 1 Battery Box Step and Cab Floor Measurements w 19 5 Tires Position K370 19 5 Tires Unladen Laden In mm In mm A FUEL SUPPORT STEP 10 5 269 7 5 191 2 B FIRST STEP 14 5 369 4 11 1 281 9 C SECOND STEP FLOOR 26 5 673 7 23 585 9 D CABFLOOR 34 3 872 6 30 8 784 ...

Page 25: ...5 266 7 B FIRST STEP 17 5 444 4 14 1 358 1 C SECOND STEP FLOOR 29 5 749 3 26 660 4 D CABFLOOR 37 3 947 4 33 8 858 5 Table 3 8 Floor to Frame Measurements Frame Heights LOADED inches mm UNLOADED inches mm Front Axle Rear Axle Front Axle Rear Axle K270 W 19 5 Tires 32 11 815 3 32 2 817 3 34 47 875 5 34 5 876 1 K370 W 19 5 Tires 32 65 829 3 33 3 846 3 36 08 916 4 35 6 905 4 K370 W 22 5 Tires 35 65 90...

Page 26: ... K270 W Air to Oil Transmission Cooler Battery Box Fuel Tank Air Tank DEF Tank and Cross member Location Measured From Front Axle inches mm Figure 3 8 1 2 K270 W Oil to Water Transmission Cooler Battery Box Fuel Tank Air Tank DEF Tank and Crossmember Location Measured From Front Axle inches mm ...

Page 27: ...ansmission Cooler 19 5 tires Battery Box Fuel Tank Air Tank DEF Tank and Crossmember Location Measured From Front Axle inches mm Figure 3 8 2 2 K370 W Oil to Water Transmission Oil Cooler and 19 5 Tires Battery Box Fuel Tank Air Tank DEF Tank and Crossmember Location Measured From Front Axle inches mm ...

Page 28: ...22 5 Tires Battery Box Fuel Tank Air Tank DEF Tank and Crossmember Location Meas ured From Front Axle inches mm Figure 3 8 2 4 K370 22 5 Tires Battery Box Dual Fuel Tanks Air Tank DEF Tank and Crossmember Location Measured From Front Axle inches mm ...

Page 29: ...3 18 Section 3 Dimensions Figure 3 8 2 5 K370 22 5 Tires Short Wheelbase Air Tanks on the RH Side Battery Box DEF Tank and Crossmember Location Measured From Front Axle inches mm ...

Page 30: ...2 3603 4 Does Not Apply Does Not Apply 172 4378 5 223 5658 Does Not Apply 166 4216 4 81 3 2064 4 125 3183 4 142 3603 4 Does Not Apply Does Not Apply 184 4683 3 235 5962 8 Does Not Apply 178 4521 81 3 2064 4 125 3183 4 142 3603 4 Does Not Apply Does Not Apply 153 3894 7 202 5132 Does Not Apply 190 4826 81 3 2064 4 125 3183 4 142 3603 4 173 4397 Does Not Apply 165 4199 5 214 5436 8 294 7468 202 5130...

Page 31: ...Ap ply 157 3 3996 3 206 5233 6 282 5 7180 4 194 4927 6 46 6 1185 Does Not Apply 136 3463 4 Does Not Apply 167 5 4257 169 3 4301 1 218 5538 4 295 9 7518 206 5232 4 46 6 1185 Does Not Apply 136 3463 4 Does Not Apply 167 5 4257 181 3 4605 9 230 5843 2 313 9 7975 2 218 5537 2 46 6 1185 Does Not Apply 136 3463 4 Does Not Apply 183 5 4663 193 3 4910 7 242 6148 331 8 8432 4 230 5842 46 6 1185 216 5 5503 ...

Page 32: ...re 3 10 K270 K370 Rail Measurements Table 3 10 Frame Rail Strength Characteristics RAIL STRENGTH 10 25 Rail K370 W19 5 and 22 5 tires 9 875 Rail K270 W19 5 tires Yield Strength PSI 120 000 120 000 Section Modulus in3 11 65 10 45 RBM Lbs Inch 1 398 664 1 254 404 Section 3 Dimensions ...

Page 33: ...3 22 Battery Box Fuel Tanks and Air Tanks K270 K370 Figure 3 11 K270 K370 Battery Box Fuel Tank and Air Tanks Measurement mm in Section 3 Dimensions ...

Page 34: ...29 6 751 4 64 8 1645 3 30 7 780 7 78 8 2002 16 5 420 14 6 370 4 K370 40 8 1036 4 76 1930 3 42 1065 7 90 1 2287 3 16 5 420 14 6 370 4 Table 3 13 K270 K370 Exhaust Location Measured From BOC inches mm Model A B C D E F G K270 5 7 145 5 3 134 9 9 250 8 12 6 320 4 16 5 420 2 12 304 2 14 354 2 K370 5 7 145 5 3 134 10 2 260 12 6 320 4 16 5 420 2 12 304 2 14 354 2 Section 3 Dimensions ...

Page 35: ...rs that will affect heights including but not limited to front and rear axle loading and tire pressure Placement of frame components such as fuel tanks will affect loads on the front axle and rear axle as well as distribution to the left and right sides of the vehicle Heights calculated from this information are estimates only GROUND CLEARANCES To calculate estimates for ground clearance for mount...

Page 36: ...or Muncie 24V electric over air PTO s for their applica tion and customer requirements NOTE All installations are only RH side PTO locations shown below are for reference only In order to ensure the PTO area remains clear of air equipment electrical and emissions equipment Kenworth recommends always ordering PTO controls even when installing the PTO aftermarket Contact your local dealer for assist...

Page 37: ...3 26 Figure 3 14 1 K370 PTO Clearances 1 of 2 Figure 3 14 2 K370 PTO Clearances 2 of 2 Section 3 Dimensions ...

Page 38: ...3 27 Figure 3 15 K270 PTO Clearances Section 3 Dimensions ...

Page 39: ...am of the engine DEF is converted to ammonia by the heat of the exhaust system Inside of the SCR canister a catalyst causes a chemical reaction between the ammonia and NOx turning it into water and nitrogen For more information on the specific details of how SCR works please contact your local Kenworth dealer On most Kenworth chassis the DEF Supply Module or pump is integrated into the DEF tank Ke...

Page 40: ...tanks will be heated with engine coolant The following schematic shows the routing of these lines The coolant lines that run to and from the SCR system must not be tampered with or used for a source of heat and or cooling for other components on the chassis It is critical that the system is not compromised in any manner ...

Page 41: ... used to meet clear back of cab requirements cannot be relocated Installation Requirements and Dimensions for DEF System When relocating any DEF system components the locations must meet the guidelines below Failure to comply may result in non conformance to EPA standards and engine shutdown DEF piping relative heights In order to ensure proper functionality of DEF system the height differences in...

Page 42: ... is located on the SCR mixing pipe which is between the DPF and SCR canister The measurement point on the dosing module is the top of the DEF fluid pressure line See Figure 4 2 Figure 4 2 Measurement Location of DEF Dosing Module Injector The following relocation guidelines are dependent on exhaust configuration and DEF tank type and location The Dosing Module should not need to be relocated howev...

Page 43: ... is not routed downstream of DEF lines or components If this is unavoidable for example on RH under exhaust systems or Horizontal Series Exhaust a routing trap must be installed A minimum of 12 of line length must be routed below the dosing module to catch any leftover DEF when system is purged Figure 4 4 Routing DEF Lines and DEF Trap Section 4 Exhaust Aftertreatment ...

Page 44: ... is a Horizontal Crosso ver system for K270 K370 models where DPF SCR and tailpipe are installed side by side with LH horizontal tailpipe Figure 4 5 Horizontal Crossover DPF and SCR with Horizontal Tailpipe Figure 4 5 1 Top view of Horizontal Crossover DPF and SCR with Horizontal Tailpipe Section 4 Exhaust Aftertreatment ...

Page 45: ...7 Figure 4 5 2 Right view of Horizontal Crossover DPF and SCR with Horizontal Tailpipe Figure 4 5 3 Back view of Horizontal Crossover DPF and SCR with Horizontal Tailpipe Section 4 Exhaust Aftertreatment ...

Page 46: ...nts Not all optional equipment is included in this section additional components may be placed on the rail behind components shown The Back of Cab components are shown primarily for reference For more specific requirements work with your local Kenworth Dealer Please read the instructions carefully The following dimensions are consistent across the entire section to aid in the comparison of one lay...

Page 47: ... Clear Back of Cab RHUC Right Hand under Cab DEF Diesel Exhaust Fluid SOC Side Of Cab DSOC Dual Side Of Cab Figure 5 1 Horizontal Crossover DPF SCR LH horizontal tailpipe RH BOC rectangular fuel tank RH BOC rec tangular DEF tank and LH BOC battery box Figure 5 2 Horizontal Crossover DPF SCR LH horizontal tailpipe RH BOC rectangular fuel tank RH BOC rec tangular fuel tank RH BOC rectangular DEF tan...

Page 48: ... Overhang CAUTION Maintain adequate clearance between back of cab and the front leading edge of mounted body See Figure 5 2 Note Be sure to provide maintenance access to battery box and fuel tank fill neck The true distance from the centerline of the front axle to the back of the cab is 13 3 inches 337 8mm for K270 and 11 inches for K370 279 4 mm It is recommended that the leading edge of the body ...

Page 49: ... the frame rail Failure to do so could result in corrosion due to dissimilar materials Installation of a spacer between the body subframe and the top flange of the frame rail will help prevent premature wear of the components due to chafing or corrosion Frame Sill If the body is mounted to the frame with brackets we recommend that the frame sill spacer be made from a strip of rubber or plastic delri...

Page 50: ...een Brackets Another possibility is mounting a rubber spacer between the brackets See Figure 5 6 These designs will allow relative movement between the body and the chassis during extreme frame racking situations Extreme frame racking and mountings that are too rigid could cause damage to the body This is particularly true with tanker installations Mounting Holes When installing the lower bracket ...

Page 51: ...so could cause an inoperable electrical or air sys tem circuit WARNING Do not drill new holes any closer than 2 inches 50 mm to existing holes Frame drilling affects the strength of the rails Hole Location Guidelines Holes must be located from the flange as indicated in Figure 5 7 They must be no closer than 2 inches 50 mm to each other Note If your design permits placement of body mounting bracket...

Page 52: ...able U Bolt Mounting with Wood and Fabricated Spacers WARNING CAUTION Do not allow spacers and other body mounting parts to interfere with brake lines fuel lines or wiring harnesses routed inside the frame rail Crimped or damaged brake lines fuel lines or wir ing could result in loss of braking fuel leaks electrical overload or a fire Carefully inspect the in stallation to ensure adequate clearance...

Page 53: ...9 REAR BODY MOUNT When U bolts are used to mount a body we recommend that the last body attachment be made with a fishplate bracket See Figure 5 11 This provides a firm attaching point and helps prevent any relative fore or aft movement between the body and frame Body Structure Frame Rail Figure 5 11 Example of Fishplate Bracket at Rear End of Body used with U Bolts Section 5 Frame Layouts and Body ...

Page 54: ...drill holes in the upper or lower flange of the frame rail If the frame rail flanges are modified or damaged the rail could fail prematurely and cause an accident Mount the body using body mounting brackets or U bolts Do not drill new holes any closer than 2 inches 50 mm to existing holes Frame drilling af fects the strength of the rails An appropriately sized bolt and nut must be installed and torqu...

Page 55: ...rame Insert A frame insert must be added after welding a frame rail extension to compensate for lost strength The insert should be of the same material as the frame member or of steel and at least equal to the frame rail in thickness Attachment of the insert to the frame should be made with Ream Fit heat treated bolts 5 8 in 16 mm dia or the next larger size Both the reinforcement and frame holes ...

Page 56: ...oposed wheelbase need to be examined to ensure that no harmful vibrations are created Consult the driveline manufacturer for appropriate recommendations WARNING Do not drill new holes any closer than 2 inches 50 mm to existing holes Frame drilling affects the strength of the rails Before the rear suspension is relocated check the new location of the spring hanger brackets The new holes for the spr...

Page 57: ...base Do Not Mount the Suspension Bracket On the Added Frame Rail Original Wheelbase Relocated Rear Suspension Shortened Wheelbase Figure 6 3 Comparison of Original Shortened and Extended Wheelbases Crossmembers Cut Frame at Rear to Obtain Desired Cutoff After changing a wheelbase an additional crossmember may be required to maintain the original frame strength The maximum allowable distance betwee...

Page 58: ...ge requirements of the new circuit to the electrical current capacity of the existing chassis circuit before adding the body or other equipment When adding an electrical circuit you must know the current capacity amperes of each circuit The capacity of the existing system in the chassis must be enough to power the additional circuit The new circuit will require a certain amount of power to operate...

Page 59: ...on 6 Menu selection switch 19 Heater fan speed selector switch in fresh air position or recirculation position 7 Ashtray with 12V auxiliary socket 20 Heater temperature control 8 Hazard warning lights 21 Heater air distribution selector switch 9 unused 22 unused 10 Dump Valve w optional air susp 23 Lighting switch 11 unused 24 ISO diagnostic plug powertrain 12 unused 25 OBD diagnostic plug cab 13 ...

Page 60: ...tion from the Cab Electronic Control Unit CECU to the Central Instrument Cluster Figure 7 2 Data Bus Communication Architecture Abbreviation List ABS E Antilock Braking System TCM Transmission Control Module DIP 4 Digital Instrument Pack MTCO Digital Tachograph ECM Engine Control Module SWS Steering Wheel Switches VIC3 Lite Vehicle Intelligence Center 3 V CAN Vehicle Controller Area Network I CAN ...

Page 61: ...nd the panel causing the con nector to fall behind the panel If necessary remove the switch from the connector Installing switches 1 Connect the connector 2 Insert the switch into the opening in the panel and press until you can feel it locked Removal and Installation Dashboard Panels Note Removal and installation of the dashboard panels have indicated in the proper sequence In order to remove eac...

Page 62: ...ide 1 Remove the attachment bolts from the lower dashboard panel on the co driver s side Remove the lower dashboard panel on the co driver s side Removing engine tunnel dashboard panel 1 Remove the attachment bolts 1 and panel plugs 2 Remove the engine tunnel cover panel 2 Disconnect the 12 V power supply connector at the rear Section 7 Electrical ...

Page 63: ...rument panel 3 5 Remove the connector from the instrument panel 3 Removing lower dashboard panel driver s side 1 Remove the attachment bolts 1 Remove the dashboard panel 2 Disconnect the headlamp height adjustment unit connector at the rear 3 Remove the attachment bolts from the connector block at the rear of the dashboard panel 4 Remove the connector block Removing surrounding frame cover panel 1...

Page 64: ...le control panel 5 2 Remove the ashtray 2 from the central console control panel 5 3 Remove the attachment bolts 1 from the central console control panel 5 4 Remove the central console control panel 5 5 Disconnect the cigarette lighter 4 connector Removing dashboard panel on right hand side 1 Remove the attachment bolts from the dashboard panel 2 Remove the connector of the stepwell lighting door ...

Page 65: ...per dashboard panel driver s side 1 Fit the connectors of the light switch 4 and the stepwell lighting door switch 2 Fit the dashboard panel Hook the radio panel 2 into the dashboard panel 3 Attach any removed cable harnesses to the dashboard panel using cable ties 4 Fit the attachment bolts 3 for the dashboard panel 5 Fit the attachment bolts 1 of the radio panel 2 into the dashboard panel Instal...

Page 66: ...connectors Fit the switches 3 to the central console control pan el 5 4 Attach the central console control panel 5 using the attachment bolts 1 5 Fit the ashtray 2 into the central console control panel 5 Installing upper cover 1 Hook the cover into the cover panel Attach the cover to the cover panel using the attachment bolts Installing surrounding frame cover panel 1 Fit the cover panel into the...

Page 67: ...instrument panel 3 connector 2 Fit the instrument panel 3 to the dashboard panel using the attachment bolts 3 Push the decorative strip 2 back onto the dashboard panel using the fixing clamps Fix the decorative strip 2 to the dashboard panel using the attachment bolts 1 Installing engine tunnel dashboard panel 1 Fit the 12 V power supply connector to the rear of the engine tunnel dashboard panel 2...

Page 68: ...ard panel on the co driver s side using the attachment bolts Installing steering column dashboard panel 1 Fit the steering column dashboard panel using the attachment bolts 1 and the panel plug 2 REMOVAL AND INSTALLATION COMPLETE DASHBOARD Removing dashboard Section 7 Electrical ...

Page 69: ...lugs 5 and remove the engine tunnel cover panel Remove the12 V power supply con nector 5 Remove the attachment bolts 7 and remove the upper cover panel 6 Open the grille 7 Remove the attachment bolt 1 8 Remove the protective cover by pressing the retainer 2 to one side 9 Detach the connectors 1 from the connecting block 10 Press the connecting block retainer 2 inside and push the whole connecting ...

Page 70: ...ners 1 to one side and push the connector plate inside 14 Remove the attachment bolts 1 from the filter casing and remove the filter casing 2 15 Remove the attachment bolts 1 16 Remove the heater hoses 2 and seal the heater tubes Section 7 Electrical ...

Page 71: ...3 Remove the floor pan above the wiring 24 Remove the wiring in front of the seat 25 Remove the attachment bolts in the surrounding frame 26 Remove the attachment bolts on the underside and remove the complete dashboard Installing dashboard 1 Fit the dashboard and secure it in the surrounding frame with a few attachment bolts 2 Fit the seat wiring 3 Replace the floor pan above the wiring 4 Fit the...

Page 72: ...ers 2 13 Fit the connectors 1 14 Fit the cover plate 15 Fit the connecting block via the inside and press it firmly into the retainers 2 16 Fit the connectors 1 to the connecting block Pay attention to the markings on the components 17 Fit the protective cover to the cab feed through and secure it with the attachment bolt 1 18 Close the grille Section 7 Electrical ...

Page 73: ...22 Fit the steering column dashboard panels 23 Fit the 12 V connector to the engine tunnel dashboard panel 24 Fit the cover panel to the engine tunnel 25 Fit the earth lead to the battery terminal A Canadian option is available The speedometer will have primary units in metric For models K270 K370 additional gauges will need to be hard wired and remotely mounted Section 7 Electrical ...

Page 74: ... 4 FLA LOAD Flash Loader Call 5 I CAN L I CAN Low 6 I CAN L I CAN Low 7 I CAN H I CAN High 8 I CAN H I CAN High 9 V CAN SHLD Res V CAN Shield 10 I CAN SHLD Res I CAN Shield 11 V CAN L Vehicle CAN Low 12 V CAN L Vehicle CAN Low 13 V CAN H Vehicle CAN High 14 V CAN H Vehicle CAN High Section 7 Electrical ...

Page 75: ... telltale cards The digital instrument pack receives input data from the VIC via the I CAN and V CAN data bus When the ignition key is first turned ON the DIP 4 will perform a calibration power on self test A Speedometer E Tachometer I Diesel exhaust fluid B Fuel gauge F Reset button trip odometer J Air pressure gauge C Master display G Odometer and trip meter K Outside temperature and clock D Coo...

Page 76: ... Converter Ignition D ORN_BLK1229 2 Ignition Signal 24V E ORN1256 0 NOX up 12V F ORN1256 1 NOX down 12V G YEL_BLK2155 1 Body Lamp 24V H YEL2155 0 Body Lamp 12V Red Green C YEL2601 0 Stop Lamp 12V A RED3215 0 DCU Power 12V D YEL_BLK2601 1 Stop Lamp 24V B RED3237 0 Line heat 12V E YEL_BLK2169 1 Clearance 24V C ORN3912 0 Starter sol 12V F YEL2169 0 Clearance 12V D ORN_BLK3912 1 Start Signal 24V E ORN...

Page 77: ...ctor B068 7099 F Spare 3 20 RC8 RD8 3H F21 5Amp Black Connector B068 7099 A Spare 4 12 RE7 RF7 3A F22 25Amp Black Connector B068 7099 A Spare 5 14 RE8 RF8 3B F23 20Amp Black Connector B068 7099 A Spare 6 N A RG8 RH8 3C Empty Black Connector B068 7099 A Spare 7 N A RG8 RH8 3D Empty Black Connector B068 7099 A Spare 8 N A RG8 RH8 3E Empty Black Connector B068 7099 A this connector available w o fuse...

Page 78: ...ected Not Connected U Not Connected Tails Marker LP Tails markers lamps V YEL2422 2 Yellow F19 20A 12 Turn RH rear Turn signal right hand rear W YEL2007 2 Yellow F15 15A 12 Backup LP Backup lamp X YEL2960 2 Yellow TCU Relay 12 Turn LH rear Turn signal left hand rear Y YEL2006 2 Yellow F14 15A 12 Markers LP Markers lamps Z YEL2412 6 Yellow F19 20A 12 Body Builder 9 pin connector Section 7 Electrica...

Page 79: ...ck has a PTO installed Harness P92 3117 0000 has the necessary connectors to install a PTO Instructions are shown below Connector to Engine Harness Connector to PTO Valve Connector to PTO Pressure Switch Section 7 Electrical ...

Page 80: ...hese circuits See your engine manufacturer to verify that the engine is programmed correctly for the intended applications Failure to properly program the engine or wire these circuits could cause an accident TERMINAL CIRCUIT DESCRIPTION 1 BLU3878 0 CVSG DATA 2 BLU3848 0 Remote Engine STOP 3 GRA5280 0 Remote Engine START 4 BLU3412 0 CAB Lock 5 WHT3100 0 Ground 6 BLU3146 0 ESC N3 SET 7 BLU3145 7 ES...

Page 81: ...IN See Table A 1 and Figure A 1 Code Year C 2012 D 2013 E 2014 F 2015 G 2016 Table A 1 Model Year Code Designations VIN Location The VIN is marked on the Incomplete Vehicle Certification Label on trucks It is located either on the driver s door edge or door frame See Figure A 2 Chassis Number Locations The Chassis Number comprises the last six characters of the VIN The K270 K370 chassis number is s...

Page 82: ...ing Data Label The Tire Rim and Weight Rating Data Label is located on the driver s side door edge above the door latch See Figure A 2 It contains the following information Note GVWR Gross Vehicle Weight Rating GAWR FRONT and REAR Gross Axle Weight Ratings for Front and Rear Axle TIRE RIM SIZES AND INFLATION PRESSURES Tire Rim Sizes and Cold Pressure Minimums Chassis Serial Number GVWR is the TOTA...

Page 83: ...roved by PACCAR Inc The dataplate is located on rocker lever cover as illustrated Have the following engine data available when communicating with a PACCAR Authorized Repair Location 1 Engine Serial Number ESN 2 Engine model information 3 Control Parts List CPL 4 Valve Lash 5 Horsepower and rpm rating 1 Dataplate 2 ESN Figure A 3 Engine Identification Location If the engine dataplate 1 is not reada...

Page 84: ...he rear axle identification numbering system includes two labels or stamps 1 Axle Housing Number Tag located on the left forward side of the housing arm This tag identifies the ax le housing 2 Axle Differential Carrier Identification located on the top side of the differential carrier The following in formation is either stamped or marked with a metal tag Model No Carrier Production Assembly No Carri...

Page 85: ...A Back of cab to centerline of rear axle Note The K270 K370 CA figures are measured from the true back of cab to the centerline of the rear axle To obtain a usable CA the body builder must subtract any required space behind the cab which may be needed for other equipment CG Center of gravity the balance point or center of a load It is usually identified by a circle with alternating black and white q...

Page 86: ... tank 100 lbs Front Axle 100 In 214 In Figure B 1 Balanced Load CGf 100 in from front axle Step 1 Figures B 1 and B 2 show a representation of a 202 inch 5130 8 mm wheelbase WB truck de signed to carry a 100 lb 45 3 kg load Figure B 1 represents a truck with the load placed an equal distance between the two axles a For our balanced load example we need to establish the center of gravity location C...

Page 87: ...6 kg The rear axle now carries a greater proportion of the load than the front axle Although it is usually not important to know the CG of the chassis it is important to know the CG location of truck bodies accessories or loads that may be placed on the chassis This example shows that the location of the CG of an object relative to the front and rear axles FA and RA affects the load carried by eac...

Page 88: ...lled Listed in Tables B 1 and B 2 are the chassis tare weights for the standard single rear axle K270 vehicles and each wheelbase configuration We see that the 214 inch wheelbase 2 axle K270 has the following tare weights FA 6263 4 RA 9628 7 K270 K370 with nominal weights and CGs See your Kenworth Dealer for more exact weights and CGs It also lists their added weight when installed on the chassis a...

Page 89: ...is located 72 inches plus half the body length from the front axle Use Equations 1 and 2 to calculate the distributed additional weight of the body Lr CGf WB X L 184 7 214 4825 4164 4 lbs 1888 9 kg Lf L Lr 4825 4164 4 660 5 lbs 299 6 kg Adding a liftgate to the van body will present some interesting weight distribution results We will add a 1455 pound 659 9 kg liftgate to the end of the van body T...

Page 90: ... amount of this front axle load reduction is equal to the extra weight added to the rear axle By positioning equipment behind the rear axle the effective load on the rear axle is more than the weight of the equipment The farther behind the rear axle the load is mounted the greater the load on the rear axle However the combined weight distributed to the front and rear axles Lf plus Lr does not exce...

Page 91: ...831 lbs 2644 kg Lf L Lr 8 000 5 831 2 169 lbs 983 kg Item Front Axle Rear Axle Total lb kg FA lb kg RA lb kg Chassis 6338 3 2875 3273 8 1484 9 9612 1 4359 9 Fuel 45 Gal Std Tank 206 2 93 5 108 7 49 30 314 9 142 8 Tare Weight 6544 5 2968 5 3382 5 1534 2 9927 4502 8 Liftgate 735 6 333 6 2490 6 1129 7 1755 796 0 Van Body 660 7 299 6 4164 3 1888 8 4825 2188 5 Driver 190 6 86 4 9 34 4 23 199 9 90 71 Cu...

Page 92: ...ssis Rating Calculation sample Item Front Axle Rear Axle Total lb kg FA lb kg RA lb kg Chassis 6845 3 3104 98 3439 2 1559 995 10284 5 4664 971 Fuel 45 Gal Std Tank 206 2 93 5307 108 7 49 30549 314 9 142 8362 Tare Weight 7051 5 3198 51 3547 9 1609 3 10599 4 4807 807 Liftgate 735 6 333 66 2490 6 1129 717 1755 796 0546 Van Body 660 7 299 688 4164 3 1888 895 4825 2188 583 Driver 190 65 86 4774 9 34 4 ...

Page 93: ...erence Body Length Step 6 Your analysis may produce results that indicate an overloaded axle with a total loaded chassis weight less than the GVW This shows that you need to use a different body length for the truck Each wheelbase can accommodate several different body lengths However for each wheelbase and GVW one particular body length will provide close to optimum weight distribution on both ax...

Page 94: ...842 27 238 6045 2 28 242 6146 8 28 For trucks built before and including 6 22 2012 Remember that water level loading assumes that the load is arranged evenly in the body as water would be in a tank If uneven load distribution is part of the vehicle layout your weight distribution analysis may indicate that a different body length deviating from the recommended length will provide the best weight d...

Page 95: ...Safety Standards 2 2 Final stage manufacturer 2 2 Fishplate bracket 5 8 Frame drilling 5 6 Frame welding 6 2 Front axle serial number A 4 Front View 3 9 Fuel tank locations 3 22 G Ground clearance 3 23 I Incomplete vehicle certification 2 2 Incomplete Vehicle Certification Label A 2 M Mounting holes frame 5 5 N Noise Requirements 2 3 Notes 2 1 O Operating information 1 1 Options weights B 4 R Rear a...

Page 96: ... A DIVISION OF PACCAR Kenworth Truck Company P O Box 1000 Kirkland WA 98083 425 828 5000e ...

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