Kenworth T270 (2017) Body Builder Manual and Later with Current EPA Compliant Engines

Kenworth

T170 / T270 / T370

2019 Body Builders Manual

®

Kenworth Medium Duty
Body Builders Manual

Models: T170/T270/T370

For 2017 Model Year and Later with Current EPA Compliant Engines

Contents

CONTENTS

SECTION 1 — INTRODUCTION ........................................................... 9

SECTION 2 — SAFETY & COMPLIANCE ...................................................2-1

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

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

FEDERAL MOTOR VEHICLE SAFETY STANDARDS COMPLIANCE ................2-2

SECTION 3 — DIMENSIONS .............................................................3-1

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

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

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

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

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

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

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

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

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

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

Frame Rail Congurations - T170/270/370 ................................3-9

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

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

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

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

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

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

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

Under Frame Exhuast/Mufe .........................................3-14

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

RIDE HEIGHTS ..........................................................3-16

REAR SUSPENSION LAYOUTS .............................................3-18

KENWORTH AG210L SINGLE REAR AXLE ...................................3-18

KENWORTH AG400L TANDEM REAR AXLE ...................................3-19

REYCO 79KB SINGLE REAR AXLE ..........................................3-20

Optional Reyco 79KB Suspensions ....................................3-20

REYCO 102 TANDEM REAR AXLE ..........................................3-21

Optional Reyco 102 Suspension ......................................3-21

HENDRICKSON HAS SINGLE REAR AXLE ...................................3-22

Optional Hendrickson HAS Single Suspensions ..........................3-22

HENDRICKSON PRIMAAX SINGLE REAR AXLE ...............................3-23

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

HENDRICKSON HAS TANDEM SUSPENSION .................................3-24

Optional Hendrickson HAS Tandem Suspensions .........................3-24

HENDRICKSON RT TANDEM SUSPENSION ..................................3-25

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

CHALMERS 854-40 TANDEM SUSPENSION ..................................3-26

Optional Chalmers Tandem Suspensions ...............................3-26

HENDRICKSON PRIMAAX EX TANDEM SUSPENSION ..........................3-27

Primaax EX Tandem Suspension ......................................3-27

HENDRICKSON HMX TANDEM SUSPENSION .................................3-28

Hendrickson Haulmaax Suspension ...................................3-28

TIRE DATA ..............................................................3-29

FRAME AND CAB RELATED HEIGHTS .......................................3-29

GROUND CLEARANCES ..................................................3-29

GROUND CLEARANCE (4X2, 6X4) ..........................................3-30

GROUND CLEARANCE (4X4, 6X6) ..........................................3-32

GROUND CLEARANCE (4X4, 6X6) ..........................................3-33

PTO CLEARANCES ......................................................3-34

09/19

I

Contents

SECTION 4 — EXHAUST & AFTERTREATMENT .............................................4-1

GENERAL GUIDELINES FOR DEF SYSTEM ...................................4-3

INSTALLATION REQUIREMENTS AND DIMENSIONS FOR DEF SYSTEM ............4-3

MEASUREMENT REFERENCE POINTS .......................................4-4

GENERAL EXHAUST INFORMATION .........................................4-7

EXHAUST INFORMATION .................................................4-12

SECTION 5— FRAME LAYOUTS ..........................................................5-1

COMMON OPTIONAL COMPONENTS ........................................5-2

FRAME LAYOUT INDEX ....................................................5-4

DIMENSION REFERENCE BOC AS ORIGIN ....................................5-7

SECTION 6 — BODY MOUNTING .........................................................6-1

CRITICAL CLEARANCES ...................................................6-1

Rear Wheels and Cab ...............................................6-1

Body Mounting Using Brackets ........................................6-2

Frame Sill .........................................................6-2

Brackets ..........................................................6-2

Mounting Holes ....................................................6-3

Frame Drilling ......................................................6-3

Hole Location Guidelines .............................................6-4

BODY MOUNTING USING U–BOLTS ..........................................6-4

Spacers ..........................................................6-4

Note: .............................................................6-4

Rear Body Mount ...................................................6-6

SECTION 7 — FRAME MODIFICATIONS ...................................................7-1

Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

DRILLING RAILS ..........................................................7-1

Location and Hole Pattern ............................................7-1

MODIFYING FRAME LENGTH ...............................................7-2

Frame Insert .......................................................7-2

Changing Wheelbase ................................................7-3

Crossmembers .....................................................7-4

WELDING ...............................................................7-5

TORQUE REQUIREMENTS ..........................................7-7

SECTION 8 — ELECTRICAL .............................................................8-1

ACCESSING GAUGES AND SWITCHES ......................................8-10

OPTIONAL SWITCHES, AIR VALVES AND GAUGES ............................8-20

ADDITIONAL SPARE CIRCUITS ............................................8-23

Additional Spare Circuits for Wiring ....................................8-23

OPTIONAL BODY BUILDER HARNESS .......................................8-24

Circuits Wired Through the Ignition ....................................8-26

Connecting Ignition Circuits ..........................................8-26

Circuits Wired to Battery .............................................8-26

INSTALLING A THIRD BATTERY ............................................8-27

WIRING FOR A LIFTGATE .................................................8-28

Liftgate Power Source ..............................................8-28

Connecting the Liftgate Power ........................................8-29

GREATER THAN 270 AMP ALTERNATOR (RECOMMENDED HOOKUP) ............8-30

Engine Connections ................................................8-30

REMOTE PTO/THROTTLE HARNESS ........................................8-31

TRAILER CABLE CONNECTIONS ...........................................8-37

II

09/19

Contents

SECTION 9 — ROUTING ................................................................9-1

ROUTING REQUIREMENTS ................................................9-2

Routing of Wires and Hoses near Exhaust System .........................9-4

VIN Location .......................................................A-1

Chassis Number Locations ...........................................A-1

APPENDIX A — VEHICLE IDENTIFICATION ................................................A-1

VEHICLE IDENTIFICATION LABELS ..........................................A-2

Tire/Rim and Weight Rating Data Label ..................................A-2

Incomplete Vehicle Certication Label ...................................A-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 Axle Identication ..............................................A-4

Rear Axle Identication ..............................................A-4

III

Figures

CONTENTS
CONTENTS

FIGURE 2-1. Incomplete Vehicle Certication Document ........................................2-2

FIGURE 2-2. Locations of Certication Labels - Driver’s Door and Frame ...........................2-2

FIGURE 2-3: West Coast Mirror OAT sensor, located in overmold on mirror harness. .................2-6

FIGURE 2-4: Aerodynamic Mirror OAT Sensor Location ........................................2-7

FIGURE 2-5: Instrument Cluster for T170/T270/T370 used with EPA compliant engines. ...............2-7

FIGURE 3-1. PremierSpec Turn Circle Analysis ...............................................3-2

FIGURE 3-2. T170/T270/T370 Overall Height, and Length Dimensions [inches (mm)] .................3-3

FIGURE 3-3. Top of Cab View, T270/T370, Roof Mounted Options ................................3-5

FIGURE 3-4. Side of Cab View, T270/370, Roof Mounted Options .................................3-5

FIGURE 3-5. Flush Mounted Flood Lamp Locations [inches (mm)] ................................3-6

FIGURE 3-6. T170 Crossmember Location ..................................................3-7

FIGURE 3-7. T170 Crossmember Location ..................................................3-8

FIGURE 3-8. Frame Rail Dimensions and Properties [inches (mm)] ...............................3-9

FIGURE 3-9. T270/370 Battery Box Measurements [inches (mm)] ................................3-10

FIGURE 3-10. T270/370 Battery/Tool Box Measurements [inches (mm)] ...........................3-10

FIGURE 3-11. T270/370 22” Fuel Tank Mounting Measurements [inches (mm)] .....................3-11

FIGURE 3-13. Rectangular Fuel Tank Measurements [inches (mm)] ..............................3-12

FIGURE 3-14. T270/370 Battery Box Measurements [inches (mm)] ...............................3-13

FIGURE 3-15. T170 Battery Box/Cab Access Step Measurements [inches (mm)] ....................3-13

FIGURE 3-16. Horizontal Exhaust Mufer/DPF and SCR Canister Mounting [inches (mm)] ............3-14

FIGURE 3-17. T270/T370 RH Step/DPF Box Assembly for Use with Vertical Tailpipe (left) or

Horizontal Tailpipe (right) [inches (mm)] ...................................................3-15

FIGURE 3-18. T270/370 Vertical Tailpipe on Right Side of Cab [inches (mm)] .......................3-15

FIGURE 4-1: Measurement Location of DEF Supply Module (Pump) ..............................4-4

FIGURE 4-2: Measurement Location of DEF Dosing Module (Injector) .............................4-4

FIGURE 4-3: Orientation of Dosing Module ..................................................4-5

FIGURE 4-4: RH Under Cab Exhaust with Small or Medium Tanks. ................................4-5

FIGURE 4-5: Routing DEF Lines and DEF Trap ...............................................4-6

FIGURE 4-6: Isometric View of Right Hand Under DPF/SCR with Single SOC Tailpipe .................4-8

FIGURE 4-7: Top View of Right Hand Under DPF/SCR with Single SOC Tailpipe .....................4-8

FIGURE 4-8: Right View of Right Hand Under DPF/SCR with Single SOC Tailpipe ....................4-9

FIGURE 4-9: Back View of Right Hand Under DPF/SCR with Single SOC Tailpipe ....................4-9

FIGURE 4-10: Isometric view of Horizontal Under RH Rail DPF/SCR .............................4-10

FIGURE 4-11: Top view of Horizontal Under RH Rail DPF/SCR ..................................4-10

FIGURE 4-12: Right view of Horizontal Under RH Rail DPF/SCR ................................4-11

FIGURE 4-13: Back view of Horizontal Under RH Rail DPF/SCR ................................4-11

FIGURE 5-1. DEF Tank Dimensions. ........................................................5-3

FIGURE 6-1. Minimum Clearance Between Top of Rear Tires and Body Structure Overhang ............6-1

FIGURE 6-2. Minimum Back of Cab Clearance ...............................................6-1

FIGURE 6-3. Spacer Between Frame Sill and Body Rail - Rubber or Plastic .........................6-2

FIGURE 6-4. High Compression Spring .....................................................6-2

FIGURE 6-5. Rubber Spacer Between Brackets ...............................................6-2

FIGURE 6-7. Crossmember-Gusset Hole Pattern Requirements [inch (mm)] ........................6-3

FIGURE 6-6. Hole Locations Guidelines for Frame Rail and Bracket ...............................6-3

FIGURE 6-8. Acceptable U-Bolt Mounting with Wood and Fabricated Spacers [inch mm)] ..............6-4

FIGURE 6-9. Clearance Space for Air Lines and Cables ........................................6-5

FIGURE 6-10. Example of Fishplate Bracket at Rear End of Body, used with U-Bolts ..................6-6

FIGURE 7-1. Detail of Frame Extension and Joint Welding ......................................7-2

FIGURE 7-2. Frame Insert ...............................................................7-2

FIGURE 7-3. Comparison of Original, Shortened, and Extended Wheelbases .......................7-4

FIGURE 7- 4. Crossmember Added when Distance Exceeds 60 inches (1524 mm) ...................7-4

FIGURE 7-5. Heat Treated Frame Rail Warning ...............................................7-5

FIGURE 8-2. Kenworth B-Cab Dash ........................................................8-2

FIGURE 8-3. Diesel Exhaust Fluid Gauge ...................................................8-2

FIGURE 8-4. Multiplexed Instrumentation Block Diagram. .......................................8-3

FIGURE 8-5. CECU Location. .............................................................8-4

FIGURE 8-6. Main Instrument Panel ........................................................8-5

FIGURE 8-7. Instrumentation Harness Interface Diagram .......................................8-7

FIGURE 8-8. Firewall Air Junction Block (view from inside of cab) .................................8-8

IV

06/18

Tables

FIGURE 8-9. Air Filter Restriction Sensor on Firewall Air Junction Block (view from inside of cab) ........8-8

FIGURE 8-10. Fuel Filter Restriction Pressure Gauge Sensor Location (typical) ......................8-9

FIGURE 8-11. Telltale Symbol Standard Cards ...............................................8-14

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

FIGURE 8-13. Telltale Icons. .............................................................8-17

FIGURE 8-13 Telltale Icons ..............................................................8-18

FIGURE 8-14. Spare switches wired to Power. ..............................................8-19

FIGURE 8-15. Optional Switches. .........................................................8-20

FIGURE 8-16. Switch and Wiring for Customer Installed Beacon Lamp ............................8-21

FIGURE 8-17. Switch and Wiring for Customer Installed Beacon Lamp . ..........................8-21

FIGURE 8-18. Switch and Wiring for Customer Installed Flood Lamp. ............................8-22

FIGURE 8-20. Body Junction Harness. . ....................................................8-25

FIGURE 8-21. Adding a Third Battery ......................................................8-27

FIGURE 8-22. Adding a Third Battery ......................................................8-28

FIGURE 8-23. Liftgate Circuit Breaker Inside Battery Box ......................................8-29

FIGURE 8-24: P27-6180 Fuse Holder. .....................................................8-30

FIGURE 8-25: Battery Harness Jumper. ....................................................8-30

FIGURE 8-26. PACCAR PX-7 and PX-9.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-31

FIGURE 8-27: Wiring for Customer Installed Throttle Control at End of Frame. .....................8-32

FIGURE 8-28. Cab Load Center (mPDC) ...................................................8-34

FIGURE 8-29: SAE J560 Trailer Connector ..................................................8-37

FIGURE 8-30: ISO 3731 Trailer Connector ..................................................8-37

FIGURE 8-31. Junction Box .............................................................8-38

FIGURE 9-1. Clamp and Buttery Clamp ....................................................9-1

FIGURE 9-2. Buttery Tie ................................................................9-1

FIGURE 9-3. Tie Strap ..................................................................9-1

FIGURE 9-4. Heavy Duty (HD) Mount. ......................................................9-2

FIGURE 9-5. Denition of measurements. ...................................................9-4

FIGURE A-1. Vehicle Identication Number (VIN). .............................................A-1

FIGURE A-2. Drivers Door and Door Frame Labels ............................................A-2

FIGURE A-4. Front Axle Identication .......................................................A-4

FIGURE A-5. Rear Axle Identication .......................................................A-4

V

V

Introduction

SCOPE

This manual was created to provide body builders with appropriate information and guidelines useful in the body planning

and installation process. This information will be helpful when installing bodies or other associated equipment.

This manual contains appropriate dimensional information, guidelines for mounting bodies, guidelines for modifying

frames, electrical wiring information, and other information useful in the body installation process. This manual is specic

to chassis with Current Emissions engines.

The intended primary users of this manual are body builders who install bodies and associated equipment on Kenworth

T170/T270/T370 Medium Duty vehicles. Dealers who sell and service the vehicle will also nd this information useful.

This Body Builders’ Manual can be very useful when specifying a vehicle, particularly when the body builder is involved in
the vehicle denition and ordering process. Early in the process, professional body builders can often contribute valuable

information that reduces the ultimate cost of the body installation.

In the interest of continuing product development, Kenworth reserves the right to change specications or products at any

time without prior notice. It is the responsibility of the user to ensure that he is working with the latest update. The most

current update is available through your local Kenworth dealer.

If you require additional information or reference materials, please contact your local Kenworth dealer.

1-1

09/19

Introduction

Page Intentionally Left Blank.

09/19

Safety & Compliance

SAFETY SIGNALS

There are a number of alerting messages in this book. Please read and follow them. They are there for your protection

and information. These alerting messages can help you avoid injury to yourself or others and help prevent costly
damage to the vehicle.

Key symbols and “signal words” are used to indicate what kind of message is going to follow. Pay special attention to
comments prefaced by “WARNING”, “CAUTION”, and “NOTE.” Please do not 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

Example:
WARNING! Be sure to use a circuit breaker designed to meet liftgate amperage

requirements. 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.

Example:
CAUTION: Never use a torch to make a hole in the rail. Use the appropriate drill bit.

Provides general information: for example, the note could warn you about how to

avoid damaging your vehicle or how to drive the vehicle more efciently.

Example:

Note: Be sure to provide maintenance access to the battery box and fuel tank ll

neck.

Signals the location of a high voltage electrical components

Example:
HAZARDOUS VOLTAGE: To reduce the risk of possible serious injury (Shock, Burn or
Death): Components marked with High Voltage should be avoided. Service must be

performed by qualied personnel only.

Please take the time to read these messages when you see them, and remember:

WARNING!

Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.

CAUTION:

Signals a potentially hazardous situation which, if not avoided, could result in minor injury or
damage to the vehicle.

NOTE:

Useful information that is related to the topic being discussed.

2-1

09/19

Safety & Compliance

FEDERAL MOTOR VEHICLE SAFETY
STANDARDS COMPLIANCE

As an Original Equipment Manufacturer (OEM), Kenworth Truck Co. ensures that our products comply with all applicable

U.S. or Canadian Federal Motor Vehicle Safety Standards. However, the fact that this vehicle has no fth wheel and that a
Body Builder (Intermediate or Final Stage Manufacturer) will be doing additional modications means that the vehicle was

incomplete when it left the build plant. See next section and Appendix A for additional information.

Incomplete Vehicle Certication

An Incomplete Vehicle Document is shipped with the vehicle, certifying that the vehicle is not complete. See Figure 2–1.
In addition, afxed to the driver’s side door frame or edge is an Incomplete Vehicle Certication label. See Figure 2–2. For
further information on Vehicle Certication and Identication, see APPENDIX A “VEHICLE IDENTIFICATION.”

NOTE

These documents list the U.S. or Canadian Federal Motor Vehicle Safety Standard regulations that the

vehicle complied with when it left the build plant. You should be aware that if you add, modify or alter any
of the components or systems covered by these regulations, it is your 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)

Final Stage Manufacturer
Label to be Installed by
Final Stage Manufacturer

Chassis Serial
Number

FIGURE 2-1. Incomplete Vehicle

Certication Document

Tire, Rim and
Weight Rating
Data label

Safety Mark (Canadian
Registry Only)

Incomplete Vehicle

Certication Label

Major Components and
Weights Label

FIGURE 2-2. Locations of Certication
Labels - Driver’s Door and Frame

As the Intermediate or Final Stage Manufacturer, you should retain the Incomplete Vehicle Document for your records. In

addition, you should record and retain the manufacturer and serial number of the tires on the vehicle. Upon completion
of the vehicle (installation of the body and any other modications), you should afx your certication label to the vehicle
as required by Federal law. This tag identies you as the “Intermediate or Final Stage Manufacturer” and certies that the
vehicle complies with Federal Motor Vehicle Safety Standards. (See Figure 2–2.) Be advised that regulations affecting the
intermediate and nal stage manufacturer may change without notice. Ensure you are referencing the most updated copy
of the regulation during the certication and documentation processes.

In part, if the nal stage manufacturer can complete and certify the vehicle within the instruction in the incomplete vehicle
document (IVD) the certication label would need a statement that reads, “This vehicle has been completed in accordance
with the prior manufacturers‚ IVD where applicable. This vehicle conforms to all applicable Federal Motor Vehicle Safety
Standards [and Bumper and Theft Prevention Standards if applicable] in effect in (month, year).”

However, if the vehicle can not be completed and certied with in the guidance provided in the IVD, the nal stage manu­facturer must ensure the vehicle conforms to all applicable Federal Motor Vehicle Safety Standards (FMVSS). The nal
stage manufactures certication label would need a statement that reads, “This vehicle conforms to all applicable Federal
Motor Vehicle Safety Standards [and Bumper and Theft Prevention Standards if applicable] in effect in (month, year).”

09/19

2-2

Safety & Compliance

These statements are just part of the changes to the new certication regulation. Please refer to the Feb 15, 2005
nal rule for all of the details related to this regulation. You can contact NTEA Technical Services Department at
1-800-441-NTEA for a copy of the nal rule (DocID 101760).

For Canadian nal stage manufacturers see:

http://laws-lois.justice.gc.ca/eng/regulations/C.R.C.,_c._1038/FullText.html.

Or contact:

Transport Canada
Tower C, Place de Ville, 330 Sparks Street
Ottawa, ON
K1A 0N5
613-990-2309
1-866-995-9737

Noise and Emissions Requirements

NOTE

It is possible to relocate the DEF tank, however the relocation requirements need to be followed. Any variance from the

relocation requirements may cause the emissions control components/systems to operate improperly potentially resulting
in engine de-rate. See page 4-3 for relocation requirements.

NOTE

Current Emissions engines have been tested and EPA/CARB certied with a complex inte­grated 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
assessment of penalties by the EPA and ARB as well as the need for remedial measures.
Modication of the emissions system can only be done with the preapproval of Cummins
and/or Kenworth. Body builders’ rst point of contact concerning emissions systems
modications will be Kenworth.

All engines will be equipped with an On-Board Diagnostics (OBD) system. The OBD system is

designed to detect malfunctions of any engine or vehicle component that may increase exhaust

emissions or interfere with the proper performance of the OBD system itself.

The OBD system consists of computer program on one or more of the vehicle’s Electronic Control

Units (ECUs). This program uses information from the control system and from additional sensors
to detect malfunctions. When a malfunction is detected, information is stored in the ECU(s) for
diagnostic purposes. A Malfunction Indicator Light (MIL) is illuminated in the dash to alert the

driver of the need for service of an emission-related component or system.

To ensure compliance to emissions regulations, the nal conguration of certain features of the completed vehicle
must meet specic requirements. This section describes requirements relevant for only the most common or critical
modications done by body builders. For a complete description of acceptable modications, see the application
guidance available from the manufacturer of the engine installed in the chassis.

2-3

09/19

Safety & Compliance

Fuel System

The following are highlights of some of the more common or critical aspects of this system.

The overall system restriction may not exceed the restriction limitations set forth by the engine manufacturer for both
supply and return.

• Ensure that fuel lines are not pinched or can potentially be damaged when installed between body and frame

• Fuel lines must be routed and secured without dips or sags

• There must be easy access to lter(s) and ll cap

• The tank vent may not obstructed

• Added accessories (heaters, generators) cannot introduce air into system

• Fuel tank must be located so that the full level is not above cylinder head

• “Ultra Low Sulfur Fuel Only” labels must be present on the dash and fuel ll

• Modication of the pressure side secondary lter and plumbing is not allowed without engine manufacturer

approval

• Body installation of fuel tank or routing of lines must not cause signicant increase in fuel temperature

• Fuel hoses shall meet or exceed OEM supplied hose material construction specications

Compressed Air System

The following are highlights of some of the more common or critical aspects of this system.

• Air system modication must meet applicable FMVSS regulations

• Compressed Air tank may not be modied (exception – addition or removal of ttings or relocation of the tank)

• Added devices or bodywork may not interfere with or rub air lines

• Air supply to the engine doser may not be restricted or disconnected

• Air lines should be routed, protected from heat, and properly secured to prevent damage from other
components

• Care should be taken so that air lines do not rub against other components

• Care should be taken to protect the air system from heat sources.

Exhaust and Exhaust After-treatment System

The following are highlights of some of the more common or critical aspects of this system.

• The following after-treatment and exhaust system components may not be modied:

09/19

• DPF/SCR assembly

• Exhaust pipes between the engine and after-treatment devices (DPF, SCR Catalyst)

• NOx Sensors

• PM Sensor

2-4

Safety & Compliance

• The following modications may only be done within the guidelines of the “DEF System Relocation Guide.”

• Modications to Diesel Exhaust Fluid (DEF) throttle, suction, or pressure lines

• Modication or relocation of the DEF tank

• Modication of coolant lines to and from the DEF tank

• All DEF and coolant lines should be routed, protected, and properly secured to prevent damage during vehicle
operation or other components

• If relocation of the DCU is necessary, use existing frame brackets and mount inside of frame anges where
necessary. Do not extend the harnesses

• The DPF, the SCR catalyst, or their mounting may not be modied

• The NOx sensor may not been relocated or altered in any way

• Exhaust pipes used for tailpipes/stacks must be properly sized, and must prevent water from entering the
exhaust system

• Ensure adequate clearance between the exhaust and body panels, hoses, and wire harnesses

• The body in the vicinity of the DPF must be able to withstand temperatures up to 400°C (750°F)

• Do not add thermal insulation to the external surface of the DPF

• The SCR water drain hole may not be blocked

• Allow adequate clearance (25mm (1 inch)) for servicing the DPF sensors, wiring, and clamped joints

• Drainage may not come in contact with the DPF, SCR catalyst, sensors or wiring

• Allow sufcient clearance for removing sensors from DPF. Thermistors require four inches. Other sensors
require one inch

• Wiring should be routed, protected from heat, and properly secured to prevent damage from
other components

• The exhaust system from an auxiliary power unit (APU) must not be connected to any part of the vehicle

after-treatment system or vehicle tail pipe.

Cooling System

The following are highlights of some of the more common or critical aspects of this system.

• Modications to the design or locations of ll or vent lines, heater or defroster core, and surge tank are not
recommended

• With the exception of post-thermostat installation, additional accessories plumbed into the engine cooling

system are not permitted, and may void vehicle warranty

• Coolant level sensor tampering will void warranty

• When installing auxiliary equipment in front of the vehicle, or additional heat exchangers, ensure that
adequate air ow is available to the vehicle cooling system. Refer to engine manufacturer application guide­lines for further detail

• When installing FEPTO drivelines, the lower radiator anti-recirculation seal must be retained with FEPTO

driveline clearance modication only

• Changes made to cooling fan circuit and controls are not allowed, with the exception of AC minimum fan on
time parameter

• See owner’s manual for appropriate winter front usage

2-5

09/19

Safety & Compliance

Electrical System

The following are highlights of some of the more common or critical aspects of this system.

• Only an OBD compliant battery disconnect switch may be installed on vehicles equipped EPA 2013 and beyond

compliant diesel engines. An OBD compliant switch and harness, even in the off position, supply a small amount

of power to the engine controller and enable certain emissions critical functions (e.g. DEF line purge). Any modi-

cations to the electrical system which interrupt this power supply will cause OBD fault codes and illumination of
the MIL. In addition, such a modication will render the engine non-compliant with certain emission regulations.
As a general rule of thumb, you can remove and replace a battery disconnect switch on a truck equipped with a
battery disconnect switch at the factory. However, if a battery disconnect switch was not installed in the factory a
signicant harness modication is required before a battery disconnect switch can be added.

• Electrical harnesses providing battery power and electronic control signals to engine and emissions control/
vehicle OBD components including datalinks may not be spliced. These emissions control/vehicle OBD

components include the following:

• throttle pedal

• vehicle speed sensor

• after-treatment wiring

• If the alternator or battery is substituted, it must meet the requirements of the engine manufacture’s guide-

lines. This includes alternator ground voltage drop and alternator ground cable effectiveness. See the engine
manufacture’s guidelines for recommended test procedure. Additionally the maximum voltage differential and
the peak-peak voltage differential between the engine ECM block ground stud and battery negative terminal

may not exceed 500 mV under any combination of loads or operating conditions.

• Installation of aftermarket transfer-cases must address the vehicle speed sensor position. The standard posi-
tion of the speed sensor is at the transmission tail shaft. When a transfer-case is added it is best to relocate
the sensor to the axle side output shaft of the transfer-case. This is typically accomplished by adding a tone

wheel into the driveline yoke assembly.

• Wiring extensions for the after-treatment wiring are available for relocating the DEF tank from your dealer via
Paccar Parts. For relocation of DEF tank, refer to the after-treatment section of this manual.

• The emission system requires an accurate Outside Air Temperature (OAT) reading in order to properly run

its control algorithms. The OAT sensor is located in the driver’s side mirror assembly on Kenworth trucks and
is shown in the gures below. If the body builder needs to modify the mirror assembly in any way, it is im­portant the OAT sensor stay positioned on the mirror assembly. Running the vehicle without the OAT sensor

connected will cause the MIL lamp to illuminate. If needed, a replacement sensor can be ordered from your
Kenworth dealer.

FIGURE 2-3: West Coast Mirror OAT sensor, located in overmold on mirror harness.

09/19

2-6

FIGURE 2-4: Aerodynamic Mirror OAT Sensor Location

• Coolant Sensor considerations are given in the Cooling section above

• The OBD/Diagnostic connector port is located below the dash to the left of the steering wheel. This connector
or its location may not be changed.

• Vehicles using EPA compliant engines must be equipped with a Malfunction Indicator Lamp (MIL) lamp. This

lamp is required to be an engine outline symbol as dened by ISO (International Standards Organization). The
gure below shows the instrument cluster and MIL lamp position. Note this lamp location is xed with respect

to the controls and its location may not be changed if you are updating the warning lamp cards.

Safety & Compliance

1 PTO 5 High Exhaust System

Temperature (HEST)

2 Wait to Start 6 Fasten Seat Belts 11 High Beam

3 Malfunction Indicator

Lamp (MIL)

4 Engine Brake 8 Park Brake 13 Check Transmission

7 RH Turn Signal 12 LH Turn Signal

9 Multi-Function Display 14 Check Engine Light

10 Brake Fail

FIGURE 2-5: Instrument Cluster for T170/T270/T370 used with EPA compliant engines. The Check
Engine lamp is symbol 21 and the MIL is symbol 8.

• In addition to the sensors and lamps above, the emission system also depends on signals from the exhaust

DPF (Diesel Particulate Filter), SCR (Selective Catalytic Reduction), and NOx sensor. Wiring between these
devices, the Dosing Control Unit (DCU) and engine ECM should not be tampered with or altered in any way.

2-7

09/19

Safety & Compliance

Air Intake System

The following are highlights of some of the more common or critical aspects of this system.

• The air intake screen may not be blocked, either fully or partially

• Modication to the air intake system may not restrict airow. For example, pipe diameter may not be reduced

• All sensors must be retained in existing locations

• To retain system seal, proper clamp torque must be used. Refer to service manual for proper clamp torque

Charge Air Cooler System

The following are highlights of some of the more common or critical aspects of this system.

• The Charge Air Cooler may not be modied

• The installation of engine overspeed shutdown devices must not introduce restriction in the intake system

• All plumbing associated with the charge air cooler may not be modied

09/19

2-8

Dimensions

DIMENSIONS

This section is designed to provide enough information to successfully layout chassis in the body planning process. Only
typical truck layouts and congurations are shown. Optional equipment may not be depicted. 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. The charts below list the abbreviated terms used and provide denitions for terminology

used.

TABLE 3-1. Abbreviations Used

AF After Frame – Frame rail overhang behind rear axle or measured from the centerline of tandem

BOC Back of Cab

BOF Bottom of Rail

CA Back of cab to centerline of rear axle or centerline of tandems on tandem suspension

FS Front suspension height from centerline of axle up to the bottom of the frame rail

OAL Overall Vehicle Length

SOC Side of Cab

RS Rear suspension height from centerline of axle up to the bottom of the frame rail

WB Centerline of front axle to centerline of rear axle or centerline of tandems on tandem suspension

TABLE 3-2. Denitions

GAWR The maximum allowable weight each axle assembly is designed to carry, as measured at the tires, there-

fore including the weight of the axle assembly itself. GAWR is established by considering the rating of each
of its components (tires, wheels, springs, axle and steering system), and rating the axle on its weakest link.
The GAWR assumes that the load is equal on each side.

LADEN This is the weight condition of the truck with the front and rear axles loaded to their Gross Axle Weight

Rating, GAWR.

UNLADEN This is the weight condition of the truck delivered from the PACCAR factory. This is without the following:

body, driver, and tools. It does include uids, but no fuel.

3-1

09/19

Dimensions

PremierSpec Turn Circle Analysis:

Please see Figure 3-1 as an example of Kenworth’s turn circle calculation made in PremierSpec for your specic chassis.
Your local Kenworth dealer can provide this information to you.

Left Turn Radius Right Turn Radius

Curb to Curb 34.1 Curb to Curb 39.7

Wall to Wall 36.1 Wall to Wall 41.4

Vehicle Summary

Tr u ck T270 Series Conventional/FULL TRUCK

Axle Dana Spicer E-1002IL Front Axle rated 10K

Wheelbase 245

Weight 9,751

Tire Front Tires: Michelin X Works Z 11R22.5PR

Wheel Front Wheel: Alcoa Ultra 22.5x8.25 MagnaForce

FIGURE 3-1. PremierSpec Turn Circle Analysis

Please consult your local Kenworth Dealer for this information, as it is chassis specic.

09/19

3-2

Dimensions

OVERALL DIMENSIONS

This section includes drawings and charts of the following medium duty models: T170, T270 and T370.

On the pages that follow, detail drawings show particular views of each vehicle with dimensions being in inches and (mm).

They illustrate important measurements critical to designing bodies of all types. See the “Table of Contents” at the begin­ning of the manual to locate the drawing that you need.

Kenworth also offers .dxf les and frame layouts of ordered chassis four weeks prior to build. Please speak to your sales

person to request this feature when specifying your chassis.

*

*

* Dimensions are typical. Measurements will vary with axle, brake

drum, tires and wheel selections

*

*

FIGURE 3-2. T170/T270/T370 Overall Height, and Length Dimensions [inches (mm)]

3-3

09/19

Dimensions

TABLE 3-3. Hydraulic Brake Vehicles. T170 Single Rear Axle: Overall Fore-Aft Dimensions [inches (mm)]

WB OAL AF CA

153 (3886) 235.9 (5992) 55 (1397) 72 (1829)

162 (4115) 240.9 (6119) 55 (1397) 77 (1956)

176 (4470) 280.9 (7135) 64 (1626) 108 (2743)

188 (4775) 304.9 (7745) 76 (1930) 120 (3048)

206 (5232) 328.9 (8354) 82 (2083) 138 (3505)

218 (5537) 352.9 (8964) 94 (2388) 150 (3810)

236 (5994) 376.9 (9573) 100(2540) 168 (4267)

245 (6223) 384.9 (9777) 99 (2515) 177 (4496)

TABLE 3-4. Hydraulic Brake Vehicles. T270/370 with Single Rear Axle: Overall Fore-Aft Dimensions [inches
(mm)]

WB* OAL AF CA

153 (3886) 235.9 (5992) 55 (1397) 72 (1829)

162 (4115) 240.9 (6119) 55 (1397) 77 (1956)

176 (4470) 280.9 (7135) 64 (1626) 108 (2743)

188 (4775) 304.9 (7745) 76 (1930) 120 (3048)

206 (5232) 328.9 (8354) 82 (2083) 138 (3505)

218 (5537) 352.9 (8964) 94 (2388) 150 (3810)

236 (5994) 376.9 (9573) 100 (2540) 168 (4267)

245 (6223) 384.9 (9777) 99 (2515) 177 (4496)

254 (6452) 424.9 (10793) 130 (3302) 186 (4724)

260 (6604) 448.9 (11402) 148 (3759) 192 (4877)

272 (6909) 462.9 (11758) 150 (3810) 204 (5182)

* Air Brake Vehicles. T270/T370 wheelbases for Single Rear Axle begin at 140 inches. Tandem Rear axles begin at 175

inches. Wheelbase on Air Brake vehicles available in 1-inch increments.

09/19

3-4

DETAIL VIEWS

Top of Cab: Roof Mounted Options – T270/370

Dimensions

FIGURE 3-3. Top of Cab View, T270/T370, Roof Mounted Options

FIGURE 3-4. Side of Cab View, T270/370, Roof Mounted Options

3-5

09/19

Dimensions

DETAIL VIEWS

Back of Cab: Flush Mounted Flood Lamps – T270/370

Mid Mount Flood

Lamp Elevations

Mid Mount Flood
Lamp Location for
Vertical Tailpipe
Back of Cab

25 (635)

14.4 (365) 14.4 (365)

C/L

25 (635)

High Mount Flood

Lamp Elevation

62.4

(1585)

43.7

(1110)

37.2

(945)

FIGURE 3-5. Flush Mounted Flood Lamp Locations [inches (mm)]

09/19

3-6

BOF

DETAIL VIEWS

Crossmember Locations – T170

FIGURE 3-6. T170 Crossmember Location

Dimensions

TABLE 3-5 T170 Cross member. Location: measured from front axle centerlines [inches (mm)]

WB A CB B CB C D E

206 101.8 (2585) Y 134.8 (3425) Y 1.) For without a square end of frame

218 101.8 (2585) Y 134.8 (3425) Y

236 101.8 (2585) Y 134.8 (3425) Y

245 101.8 (2585) Y 162 (4125) Y

254 101.8 (2585) Y 162 (4125) Y

260 101.8 (2585) Y 162 (4125) Y

272 101.8 (2585)

CROSSOVER EXHAUST IS NOT OFFERED FOR T170

Y

162 (4125)

Y

crossmember with an AF range of 80 (2032)
to 125 (3175) a crossmember is installed at:
E=WB+64.4” (1636mm)

2.) For AF range of 126 (3200) to 173 (4394)
a 2nd crossmember is installed at:
E=WB+112.4” (2855 mm)

3-7

09/19

Dimensions

DETAIL VIEWS

Crossmember Locations – T170

FIGURE 3-7. T170 Crossmember Location

TABLE 3-6 T170 Cross member. Location: measured from front axle centerlines [inches (mm)]

WB A CB C D E

153 101.8 (2585) Y 1.) For without a square end of frame crossmember with an AF

162 101.8 (2585) Y

176 101.8 (2585) Y

188 101.8 (2585) Y

Y SPL100 Driveline center bearing (CB) is mounted on this cross member

range of 80 (2032)to 125(3175) a crossmember is installed at:
E=WB+64.4”(1636mm)

2.) For AF range of 126 (3200) to 173(4394) a 2nd crossmember is
installed at: E=WB+112.4”(2855 mm)

09/19

3-8

Dimensions

COMPONENTS

This section includes detail drawings and charts showing particular vehicle components with dimensions in inches and

(millimeters). They illustrate important measurements critical to designing bodies of all types. See the “Table of Contents”
at the beginning of the manual to locate the drawing that you need.

Frame Rail Congurations - T170/270/370

Note: Bottom of frame rail is a reference point that you can use to determine estimated heights of components and ground
clearances.

W

T

Rail Heat

Treated

H

Optional

Insert, Heat

Treated

Shown

FIGURE 3-8. Frame Rail Dimensions and Properties [inches (mm)]

TABLE 3-7. Frame Rail Properties

Frame Rail or Insert

(1)(2)

9-7/8 Frame Rail T170/T270 9.88 1,251,767 2.10 9.88 (251) 3.46 (87.8) 0.25 (6.4)

10-5/8 Frame Rail T270/T370 14.8 1,776,000 2.90 10.63 (270) 3.46 (87.8) 0.31 (7.9)

10-3/4 Frame Rail T270/T370 17.8 2,132,000 3.50 10.75 (273) 3.46 (87.8) 0.38 (9.5)

9-7/8 Insert ONLY for
10-5/8 Frame Rail (2)(3)

10-5/8 Frame Rail with
9-7/8 Insert

10-3/4 Frame Rail with
9-7/8 Insert

(1) Yield Strength: 120,000 PSI
(2) Frame rails and inserts are heat treated.
(3) Full inserts start ahead of the steering gear and end at the end of frame.
(4) Partial inserts start 25 inches behind the center line of the front axle and end at the end of the frame.
(5) T370s with front axle weight rating of 16k or greater utilize 16mm frame fasteners to replace the standard 12mm fasteners used on medium duty.

(6) The T370 requires bolted frame crossmembers when front axle weight rating is 13k or above.

Model

T270/T370 9.57 1,149,000 2.00 9.88 (251) 2.88 (73.0) 0.25 (6.4)

T270/T370 23.4 2,925,000 4.96 10.63 (270) 3.46 (87.8) 0.56 (14.3)

T270/T370 27.4 3,281,000 5.50 10.75 (273) 3.46 (87.8) 0.63 (15.9)

Section

Modulus per

Rail, cu.in.

RBM per Rail

lbs-Inch

Weight per Inch

per Pair, lbs

Height H,

inch (mm)

Flange Width
W, inch (mm)

Thickness T,

inch (mm)

3-9

09/19

Dimensions

Battery Box – T270/370

Parallel Battery Box LH Under Cab for air braked truck or hydraulic braked truck with an accessory air system.

A

B

BOF

C

D

Rear View

FIGURE 3-9. T270/370 Battery Box Measurements [inches (mm)]

TABLE 3-8. T270/370 Battery Box Measurements [inches (mm)]

Type A, inch (mm) B, inch (mm) C, inch (mm) D, inch (mm)

Standard 33.4 (848) 8.5 (215) 9.3 (236) 13.4 (354)

Front-raised 1” or more 33.4 (848) 8.5 (215) 10.4 (264) 13.4 (354)

Battery/Tool Box – T270/370

Parallel Battery Box LH Under Cab for Hydraulic braked Truck without an Accessory Air System or Tool Box Under Cab.

C

A

BOF

B

Rear View

2.8 (70)

FIGURE 3-10. T270/370 Battery/Tool Box Measurements [inches (mm)]

TABLE 3-9. T270/370 Battery Box/Toolbox Dimensions [inches (mm)]

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

Standard Battery Box 8.5 (215) 9.4 (239) 33.4 (848)

Toolbox 9.3 (236) 9.2 (233) 33 (848)

09/19

3-10

22-inch Fuel Tanks — T270/370

Round Fuel Tank Mounting

Dimensions

25.9

(658)

11.0

(279)

BOF

A

REAR VIEW REAR VIEW
LEFT SIDE BEHIND CAB RIGHT SIDE UNDER CAB

FIGURE 3-11. T270/370 22” Fuel Tank Mounting Measurements [inches (mm)]

22” Fuel Tank Height A, inch (mm)

Standard 16.3 (416)

Raised 1 Inch 15.3 (389)

24.5-inch Fuel Tanks — T270/370

29

(737)

6.7 (169)

10.4 (265)

4.8

(121)

14.2

(361.2)

12.2

(309.87)

32.1

(815.8)

WITH STEPS

NO STEPS

18.2

(462.4)

18.2

(462.4)

Figure 3-12. T270/370 24.5” Fuel Tank Mounting Measurements. With and without steps. [inches (mm)]

3-11

20.4

(517.8)

4.8

(121)

09/19

Dimensions

Rectangular Fuel Tank

Rectangular Fuel Tank Mounting

6

(152.3)

8.6

(219.3)

12

(307)

25.8

(565)

(774.8)

6

(152)

16.8

(425.9)

18.2

(461.4)

6

(152)

30.5

FIGURE 3-13. Rectangular Fuel Tank Measurements [inches (mm)]

09/19

3-12

Battery Box – T270/370

Cantilever Battery Box Back of Cab.

31.0 (787)

Rear View

FIGURE 3-14. T270/370 Battery Box Measurements [inches (mm)]

Dimensions

BOF

8.0 (202)

Battery/Access Step – T170

Parallel Battery Box LH Under Cab or Cab Access RH under Cab.

27.7 (704)

0.7 (17)

6.1 (154)

Rear View – Battery Box LH under shown, Cab Access Step RH under is opposite.

FIGURE 3-15. T170 Battery Box/Cab Access Step Measurements [inches (mm)]

BOF

3-13

09/19

Dimensions

Under Frame Exhuast/Mufe

Horizontal Exhaust Mufer/DPF and SCR Canister Mounting

FIGURE 3-16. Horizontal Exhaust Mufer/DPF and SCR Canister Mounting [inches (mm)]

TABLE 3-10. RH Under Frame Horizontal Exhaust Mounting

Model A

Inch (mm)

T170/270/370 6.6 (167.3) 11.2 (285.5) 14.5 (369.1) 12 (304)

B

Inch (mm)

C

Inch (mm)

D

Inch (mm)

09/19

3-14

Dimensions

Step/DPF and SCR Box Assembly RH Under Cab – T270/370

FIGURE 3-17. T270/T370 RH Step/DPF Box Assembly for Use with Vertical Tailpipe (left) or Horizontal Tailpipe

(right) [inches (mm)]

Horizontal Mufer-Vertical Tailpipe on Cab – T270/370

FIGURE 3-18. T270/370 Vertical Tailpipe on Right Side of Cab [inches (mm)]

3-15

09/19

Dimensions

RIDE HEIGHTS

The front (FS) and rear (RS) suspension ride heights are provided as a basic tool to determine overall height of the cab,

height of exhaust components, and frame heights. The heights are calculated from the centerlines of the axles. Please be

sure to include the tire radius dimension to determine overall height. Note: frame rail height itself will not affect the overall

height as all components are located from the bottom of the rail.

TABLE 3-11. Estimated Front Suspension Ride Heights

Model Front Brakes Type Front Suspension Laden inch (mm) Unladen inch

T170 8K Taper Leaf 7.6 (193) 8.6 (218)

Non RSD Drum or Hydraulic Disc 8K Taperleaf with 19.5” Wheels 7.4 (188) 8.4 (213)
Non RSD Drum or Hydraulic Disc 8K Taperleaf with 22.5” Wheels 7.8 (198) 8.8 (224)
Non RSD Drum or Hydraulic Disc 10K Taperleaf with 19.5” Wheels 7.4 (188) 8.5 (216)
Non RSD Drum or Hydraulic Disc 10K Taperleaf with 22.5” Wheels 7.8 (198) 8.9 (226)

Air Disc or RSD 10K Taperleaf with 22.5” Wheels 8.3 (211) 9.0 (229)

Non RSD Drum or Hydraulic Disc 12K Taperleaf 7.8 (198) 9.2 (234)

T270/T370

With Non

-Front

Driving Axle

T270/T370

with Front

Drive Axle

PX-7

T270/T370

With Front
Drive Axle

PX-9/

Export ISC

Air Disc or RSD 12K Taperleaf 7.8 (198) 9.0 (229)
Non RSD Drum 13.2K Taperleaf 8.6 (218) 10.0 (254)
Air Disc or RSD 13.2K Taperleaf 8.6 (218) 9.7 (246)

Non RåSD Drum 14.6K Taperleaf 8.3 (211) 10.0 (254)

Air Disc or RSD 14.6K Taperleaf 8.3 (211) 9.7 (246)

Non RSD Drum 16K 2-Stage Taperleaf 8.5 (216) 10.3 (262)
Air Disc or RSD 16K Taperlead 8.8 (224) 9.4 (239)
Non RSD Drum 18K 2-Stage Taperleaf* 8.4 (213) 10.8 (274)
Non RSD Drum 20K 2-Stage Taperleaf* 7.9 (201) 10.8 (274)

10K Taperleaf 14.8 (376) 15.6 (396)
12K Taperleaf 14.6 (371) 15.8 (401)
13K Taperleaf 15.8 (401) 17.2 (437)
14K Taperleaf 15.6 (396) 17.2 (437)

10K Taperleaf 15.6 (396) 16.4 (417)
12K Taperleaf 15.4 (391) 16.6 (422)
13K Taperleaf 15.8 (104) 17.2 (437)
14K Taperleaf 15.6 (396) 17.2 (437)
16K Taperleaf 15.1 (384) 16.8 (427)

18K-20K 2-Stage Taperleaf 16.2 (412) 17.8 (452)

Estimated Front Ride Height

Without front frame raised”

(mm)

*16k-20k Suspension with 385 Tires Requires Front Raised 1.5” (Add 1.5” to Ride Height)

09/19

3-16

TABLE 3-12. Estimated Rear Suspension Ride Height

Dimensions

Model Rear Brake Type Rear Suspension (# Rear Axles) Laden

inch (mm)

T170 Hydraulic Only Reyco 79KB 13.5K (Single) 6.2(157) 7.8(198)

Drum or Hydraulic Reyco 79KB 20K Capacity (Single) 7.6 (193) 9.0 (229)

Drum or Hydraulic Reyco 79KB 21K Capacity (Single) 7.5 (191) 9.0 (229)

Drum or Hydraulic Reyco 79KB with Helper 23K Capacity (Single) 7.3 (185) 9.0 (229)

Drum Only Reyco 79KB with Helper 26K Capacity (Single) 8.1(206) 10.8(274)

Drum Only Reyco 79KB with Helper 31K Capacity (Single) 9.5 (241) 11.8 (300)

Air Disc Reyco 79KB 20K Capacity (Single) 7.9(201) 9.3(236)

Air Disc Reyco 79KB 21K Capacity (Single) 7.8(198) 9.3(236)

Air Disc Reyco 79KB with Helper 23K Capacity (Single) 8(203) 9.7(246)

Air Disc Reyco 79KB 23K Capacity For Fire Tankers (Single) 9.3(236) 11(279)

Drum or Hydraulic Hendrickson HAS 21K/23K Air (Single) 8.3 (211) 8.5 (216)

Air Disc Hendrickson HAS 21K/23K Air (Single) 8.8 (224) 8.9 (226)

All Kenworth AG210L 21 K Air (Single) 6.5 (165) 6.7 (170)

Air Disc or Drum Primaax EX232 23K (Single) 8.5(216) 8.5(216)

Air Disc or Drum Primaax EX262 26K (Single) 8.5(216) 8.5(216)

T270/T370

Non Front Drive”

Drum Reyco 102 Multileaf 40K Capacity (Tandem) 8(203) 9.6(244)

Drum Hendrickson HAS 402 Air (Tandem) 52” Axle Spacing 7.9(201) 8.0(203.2)

Air Disc Hendrickson HAS 402 Air (Tandem) 52” Axle Spacing 8.8(224) 8.9(226)

Drum Hendrickson HAS 402 Air (Tandem) 54” Axle Spacing 10.0(254) 10.0(254)

Air Disc or Drum Hendrickson RT-403 6” Saddle Height 40K Capacity

(Tandem)

Air Disc or Drum Hendrickson RT-403 7.19” Saddle Height 40K

Capacity (Tandem)

Drum Hendrickson Primaax 462 (Tandem) 10.0(254) 10.0(254)

Drum Hendrickson HMX 46K Capacity (Tandem) 9.5(241) 10.6(269)

Drum Hendrickson RT463 Capacity (Tandem) 10.0(254) 11.1(282)

Drum Chalmers 854-40-XL 40K Capacity (Tandem) 6.9(175) 9.3(236)

Drum Chalmers 854-40-XL-HS 40K Capacity (Tandem) 7.6(193) 9.3(236)

Air Disc or Drum Chalmers 854-40-L 40K Capacity (Tandem) 8.9(226) 11.1(287)

Drum Chalmers 854-46-L 46K Capacity (Tandem) 8.9(226) 11.3(287)

Drum Chalmers 854-46-L-HS 46K Capacity (Tandem) 9.6(244) 11.3(287)

Air Disc or Drum Kenworth AG400L 40K(Tandem) 52” Axle Spacing 8.5(216) 8.8(224)

7.6(193) 8.6(218)

9.7(246) 10.7(272)

Unladen,

inch (mm)

T270/T370 with

Front Drive Axle”

Drum Only Reyco 79KB 20K (Single) 14.7 (373) 16.5 (419)

Drum Only Reyco 79KB 21K (Single) 14.6 (371) 16.5 (419)

Drum Only Reyco 79KB 23K (Single) 14.4 (366) 16.5 (419)

Drum Only Reyco 79KB 26K (Single) 14.1 (358) 16.5 (419)

Drum Only Reyco 79KB 31K 16-Leaf (Single) 14.5(368) 17.3(439)

Drum Only Primaax EX232 23K (Single) 15.5 (394) 15.5 (394)

Drum Only Primaax EX262 26K (Single) 15.5 (394) 15.5 (394)

Drum Only Chalmers 854-40-XXH-HS 15.5 (394) 17.2 (437) 15.6(396) 17.3(439)

3-17

09/19

Dimensions

REAR SUSPENSION LAYOUTS

The rear suspension layouts are provided as a tool to help layout bodies prior to arrival. The applicable dimensions are

shown. Be sure to check the axle spacing that is shown, as alternate spacings may exist and could change some of the
dimensions. The dimensions shown below are the most typical installations, in special cases some hole locations will

move. If you are planning on using the holes shown for your body installation, please conrm with your local KW dealer
that the drawing below will be the installation used on your specic truck. Ensure that proper torque is used to reinstall any

suspension components. See Table 7-1 and 7-2 on page 7-7.

It would be recommended to order the frame layout of your chassis along with your truck order. This can be done on any

Kenworth truck, and will be provided 4 weeks ahead of the build schedule.

If there are hole locations that are not detailed please work with your local Kenworth Dealer to request that information.

If you would like details on the frame drilling with optional spacings, please contact your local Kenworth dealer.

KENWORTH AG210L SINGLE REAR AXLE

TABLE 3-13. Optional Kenworth Single Suspension

Rating Axle Spacing Laden Ride Height Unladen Ride Height

Kenworth AG210L 21K – 6.5” 6.5”

09/19

3-18

KENWORTH AG400L TANDEM REAR AXLE

Dimensions

TABLE 3-14. Optional Kenworth Tandem Suspension

Rating Axle Spacing Laden Ride Height Unladen Ride Height

Kenworth AG400L 40K 52” 8.5” 8.5”

3-19

09/19

Dimensions

REYCO 79KB SINGLE REAR AXLE

30.2 (755)

28.7 (728)

Optional Reyco 79KB Suspensions

TABLE 3-15. Rear Suspension Options

30.1 (765)

29.0 (736)

BOF

Suspension Type Rating Axle Spacing Laden Ride Height Unladen Ride Height

Reyco 79KB single (4x2) 13.5K - 5.9” 8.1”

Reyco 79KB single (4x2) 20K - 6.6” 9.0”

Reyco 79KB single (4x2) 21K - 6.6” 9.0”

Reyco 79KB single (4x2) 23K - 6.6” 9.0”

Reyco 79KB single (4x2) 26K - 8.2” 11.3”

Reyco 79KB single (4x4) 20K - 14.5” 16”

Reyco 79KB single (4x4) 21K - 14.5” 16”

Reyco 79KB single (4x4) 23K - 14.5” 16”

Reyco 79KB single (4x4) 26K - 14.5” 16”

09/19

3-20

REYCO 102 TANDEM REAR AXLE

Dimensions

BOF

Optional Reyco 102 Suspension

TABLE 3-16. Rear Suspension Options

Suspension Type Rating Axle Spacing Laden Ride Height

Reyco 102 Tandem 40K 52” 8.0” 9.6”

Unladen Ride

Height

3-21

09/19

Dimensions

HENDRICKSON HAS SINGLE REAR AXLE

26.1

24.5

23.9

16.1

15.5

28.9

13.9

5.5

3.7

21.7

Optional Hendrickson HAS Single Suspensions

Ride

Height

5.9

BOF

2.4

TABLE 3-17. Rear Suspension Options

Suspension Type Rating Axle Spacing

Hendrickson HAS 210L 21K - 8.3” 8.5”

Hendrickson HAL 230L 26K - 8.3” 8.5”

09/19

3-22

Laden Ride

Height

Unladen Ride

Height

HENDRICKSON PRIMAAX SINGLE REAR AXLE

Dimensions

Optional Hendrickson Primaax Single Suspensions

TABLE 3-17-1. Rear Suspension Options

Suspension Type Rating Axle Spacing

Hendrickson Primaax (4x4) 23K - 15.5” 15.5”

Hendrickson Primaax (4x4) 26K - 15.5” 15.5”

Laden Ride

Height

Unladen Ride

Height

3-23

09/19

Dimensions

HENDRICKSON HAS TANDEM SUSPENSION

54.5

52.3

8.0

5.8

3.1

49.5

39.7

49.9

50.5

39.9

42.1

42.5

52.6

51.1

46.4

5.9
BOF

2.4

Ride Height

Axle Spacing

38.8

41.5

52.1

53.2

Optional Hendrickson HAS Tandem Suspensions

TABLE 3-18. Rear Suspension Options

Suspension Type Rating Axle Spacing

Hendrickson HAS 402 tandem 40K 52” 7.8” 7.8”

Laden Ride

Height

Unladen Ride

Height

09/19

3-24

HENDRICKSON RT TANDEM SUSPENSION

Shown with a 54” Axle Spacing Without Track Rods

55.2

53.0

47.4

Dimensions

BOF

Optional Hendrickson RT Tandem Suspensions

TABLE 3-19. Rear Suspension Options

Suspension Type Rating Axle Spacing

Hendrickson RT403 6” Saddle Height 40K 52” 7.6” 8.6”

Hendrickson RT403 7.19” Saddle Height 40K 52” 9.7” 10.7”

Hendrickson RT463 6” Saddle Height 46K 54” 10.0” 11.1”

Laden Ride

Height

Unladen Ride

Height

3-25

09/19

Dimensions

CHALMERS 854-40 TANDEM SUSPENSION

Optional Chalmers Tandem Suspensions

TABLE 3-20. Rear Suspension Options

Suspension Type Rating Axle Spacing

Chalmers 854-40-XL (6x4) 40K 54” 6.9” 9.3”

Chalmers 854-40-XL-HS (6x4) 40K 54” 7.6” 9.3”

Chalmers 854-40-XXH-HS (6x6) 40K 54” 15.5” 17.2”

Chalmers 854-46-L (6x4) 46K 54” 8.9” 11.3”

Chalmers 854-46-L-HS (6x4) 46K 54” 9.6” 11.3”

Laden Ride

Height

Unladen Ride

Height

09/19

3-26

Dimensions

HENDRICKSON PRIMAAX EX TANDEM SUSPENSION

Shown with 54” Axle Spacings

Primaax EX Tandem Suspension

TABLE 3-21. Rear Suspension Options

Suspension Type Rating Axle Spacing

Hendrickson Primaax-EX 462 46K 54" 10" 10"

Laden Ride

Height

Unladen Ride

Height

3-27

09/19

Dimensions

HENDRICKSON HMX TANDEM SUSPENSION

Shown with 54” Axle Spacing

Hendrickson Haulmaax Suspension

TABLE 3-22. Rear Suspension Options

Suspension Type Rating Axle Spacing

Hendrickson Haulmaax 16.5"
Saddle Height

46K 54" 9.5" 10.6"

Laden Ride

Height

Unladen Ride

Height

09/19

3-28

Dimensions

TIRE DATA

For dimensions for your particular Bridgestone tire, visit the Bridgestone website, www.bridgestonetrucktires.com.

FRAME AND CAB RELATED HEIGHTS

The bottom of the frame rail (BOF) at the front and rear axle can be used as a reference point to estimate vertical heights.

Use the following to calculate estimates for frame and cab related heights, such as top of frame rail, step height, top of
exhaust pipe, etc.:

1.) Tire radius data from the manufacturer

2.) Front and rear suspension ride heights in this section

3.) Frame rail heights dened in this section if needed

4.) Component dimensions from bottom of rail dened in this section if needed

Note that there are many factors 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 side of the vehicle. Heights calculated from this information are estimates only.

GROUND CLEARANCES

To calculate estimates for ground clearance for mounted components using the underside of the bottom of the frame rail
as a reference use the following:

1.) Tire radius data from the manufacturer

2.) Front and rear suspension ride heights in this section

3.) Component dimensions from bottom of rail dened in this section

Ground clearances, like height calculations, are affected by factors 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 side of the vehicle. Ground clearances calculated from this information are
estimates only.

3-29

09/19

Dimensions

GROUND CLEARANCE (4X2, 6X4)

This information is provided as a reference, not all optional equipment is included. In order to calculate the height on your
specic chassis, please use the ride height information provided on page 3-17 and 3-18. For comparison the FS value

shown is 11.4” unladen and 10.4” laden.

TABLE 3-23. Ground Clearance for Fuel and DEF Tanks (4x2, 6x4)

Dim “A” (Bottom

Component

45 Gal Rect Fuel Tank 11.8

Def Tank For Above Rect Fuel Tank 12.1

22” Dia Round Alum Fuel Tank 16.3

Def Tank For Above 22” Fuel Tank 15.6

24.5” Dia Round Alum Fuel Tank 18.3

Def Tank For Above 24.5” Fuel Tank 15.6

NOTE: To calculate ground clearance, subtract dimension “A” from the distance between the ground and bottom of the frame rail. To nd bottom of the

frame rail height, add tire static loaded radius (SLR) and suspension height (laden or unladed).

of Rail Down to
Lowest Part on

Component)

09/19

3-30

TABLE 3-24. Ground Clearance for Battery Box & DPF/SCR (4x2, 6x4)

Dimensions

Dim “A” (Bottom

Component

LH Under Battery Box (w/air tanks) 14.5

RH Under DPF/SCR Box 15.2

NOTE: To calculate ground clearance, subtract dimension “A” from the distance between the ground and bottom of the frame rail. To nd bottom of the

frame rail height, add tire static loaded radius (SLR) and suspension height (laden or unladed).”

of Rail Down to
Lowest Part on

Component)

3-31

09/19

Dimensions

GROUND CLEARANCE (4X4, 6X6)

This information is provided as a reference, not all optional equipment is included. In order to calculate the height on your
specic chassis, please use the ride height information provided on page 3-17 and 3-18. For comparison the FS value

shown is 15.8” unladen and 14.5” laden.

TABLE 3-25. Ground Clearance for Fuel and DEF Tanks (4x4, 6x6)

Dim “A” (Bottom

Component

45 Gal Rect Fuel Tank 12.1

Def Tank For Above Rect Fuel Tank 12.1

3rd Cab Access Step for Above 22” Fuel Tank 22.0

22” Dia Round Alum Fuel Tank 16.3

Def Tank For Above 22” Fuel Tank 15.3

3rd Cab Access Step for Above 22” Fuel Tank 23.0

24.5” Dia Round Alum Fuel Tank 18.2

Def Tank For Above 24.5”Fuel Tank 15.8

3rd Cab Access Step for Above 24.5” Fuel Tank 24.2

NOTE: To calculate ground clearance, subtract dimension “A” from the distance between the ground and bottom of the frame rail. To nd bottom of the

frame rail height, add tire static loaded radius (SLR) and suspension height (laden or unladed).

of Rail Down to
Lowest Part on

Component)

09/19

3-32

GROUND CLEARANCE (4X4, 6X6)

Dimensions

TABLE 3-26. Ground Clearance for Battery Box & DPF/SCR (4x4, 6x6)

Dim “A” (Bottom

Component

LH Under Battery Box (w/air tanks) 14.5

3rd Cab Access Step for Above Battery Box 15.3

RH Under DPF/SCR Box 11.4

3rd Cab Access Step For Above DPF/SCR Box 22.4

Transfer Case with PX-7 Engine 18.5

Transfer Case with PX-9 or Export ISC Engine 19.2

of Rail Down to
Lowest Part on

Component)

NOTE: To calculate ground clearance, subtract dimension “A” from the distance between the ground and bottom of the frame rail. To nd bottom of the

frame rail height, add tire static loaded radius (SLR) and suspension height (laden or unladed).

3-33

09/19

Dimensions

PTO CLEARANCES

The following visuals are provided to help aid in determining PTO locations and clearances. For specic dimensions
please work through your local Kenworth dealer. Multiple PTO’s are shown for layout purposes only. Power equipment,
i.e., drive shafts & power pumps are not included. Body builders should select the appropriate PTO for their application

and customer requirements. NOTE: Installations depict multiple PTOs. PTO locations shown below are for reference only.
Some PTOs may interfere with frame rail and/or other components.

In order to ensure the PTO area remains clear of air equipment, electrical and emissions equipment, Kenworth recom-

mends always ordering PTO controls, even when installing the PTO aftermarket. Kenworth does offer a variety of factory

installed PTOs. Contact your local dealer for assistance.

Automatic Transmission – Allison 1000RDS/2000RDS:

NOTE: PX-9 shown. No RH PTO clearance is available with PX-7 engines due to exhaust interference.

09/19

3-34

Automatic Transmission – Allison 3000RDS:

Dimensions

3-35

09/19

Dimensions

Manual Transmission:

09/19

3-36

Exhaust & Aftertreatment

EXHAUST AND AFTER-TREATMENT INFORMATION

The following section is designed to give you information regarding the exhaust and after-treatment systems on Kenworth

chassis.

All Kenworth’s equipped with Current emission level engines will utilize Selective Catalyst Reduction (SCR). SCR is a
process in which Diesel Exhaust Fluid (DEF) is injected into the exhaust down stream of the engine. DEF is converted to

ammonia by the heat of the exhaust system. Inside of the SCR canister a catalyst causes a chemical reaction to occur

between the ammonia and NOx, turning it into water and nitrogen. For more information on the specic details of how

SCR works, please contact your local Kenworth dealer.

DEF System Schematic:

On most Kenworth chassis the DEF Supply Module (or pump) is integrated into the DEF tank. Kenworth does not allow
relocation of this pump. The following schematic details how the DEF lines route to the after-treatment system.

DEF Tank

(10-gallon shown)

DEF Return Line

(Backow from

Supply Module)

Coolant Draw

(from Draw Tee)

Detail A

Scale 1:2

DEF Draw Line
(Inlet to Supply
Module)

Coolant Return

(to Coolant Valve)

DEF Draw Line (Inlet)

DEF Supply Module

(Pump)

See Detail A

DEF Return Line (Backow)

DEF Pressure Line

(Outlet)

DEF Dosing Module
(Injector)

4-1

09/19

Exhaust & Aftertreatment

DEF will freeze at approximately 11° F. In order to keep DEF from freezing all tanks will be heated with engine coolant.

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

DEF Tank

(Small Tank Shown)

DEF Tank
Heating
Element

Coolant Hose
(Green – Draw)

Coolant Hose

(Blue – Return)

DEF Supply Module
(Pump)

Coolant Control

Valve

Coolant Hose
(Blue – Return)

09/19

4-2

Exhaust & Aftertreatment

GENERAL GUIDELINES FOR DEF SYSTEM

The installation of the DEF tank is a critical component of the SCR system. While Kenworth does not recommended relo­cating the DEF tank, there are applications and body installations that will require it. The guidelines below must be strictly
followed by any entity relocating the tank. Failure to follow the guidelines completely and accurately may result in engine
shutdown situations.

Kenworth offers a variety of DEF tank sizes to meet every application. The DEF tank volume is regulated by the E.P.A.
Kenworth advises against modifying the tank volume after the truck has been delivered from the factory.

• Total DEF capacity must meet or exceed 6% of the usable fuel capacity on the truck. The calcula­tion to determine DEF capacity is:

Minimum DEF Tank Volume = Useable Fuel Capacity (gal) x 0.06

Example: For a truck with 100 useable gallons of fuel, the equation is
DEF required = 100 x 0.06 = 6 gallons or more of DEF.

PACCAR-approved DEF hoses are required when retrotting for system to function properly. The use of unapproved hoses
for DEF lines will void warranty and may cause engine shutdown situations. The DEF pump (or Supply Module) can not be

relocated from the DEF tank. In addition, the Medium Duty Rectangular DEF Tank, that is 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 the guidelines

below must be followed during line routing and component placement.

With all relocating procedures, general clearances and routing guidelines must be followed. See section 9 of this manual
for general routing guidelines.

When relocating the components the maximum pressure DEF hose length, from Supply module to Dosing Module, is 3
meters (118”).

Maintain a minimum of 3” clearance to shielded exhaust components when routing DEF lines to prevent possible melting.

If the DEF tank is relocated the coolant lines will need to be modied. During this process if the tank is moved forward on
the chassis (ie closer to the engine) it is necessary to remove excess coolant lines and maintain the original routing path.
If the tank is moved rearward on the chassis the additional length of cooling line required to complete the installation must
be installed in a straight section of the existing coolant routing lines. This process will minimizes the change in coolant ow
by minimizing changes in restrictions. Increase in restriction occur with excessive line length and bends. Work with your
local Kenworth dealer if you are unsure about the coolant line modications.

4-3

09/19

Exhaust & Aftertreatment

MEASUREMENT REFERENCE POINTS

For all relocation procedures, the measurement points will referenced in the guidelines are taken from the following spe-

cic points:

Supply Module: The supply module is commonly called a pump. The measurement point on the supply module is the top

of the DEF uid pressure line. See Figure 4-1.

FIGURE 4-1: Measurement Location of DEF Supply Module (Pump)

Dosing Module: The dosing module is commonly called an injector, this injector is located on the SCR mixing pipe which

is between the DPF and SCR canister. The measurement point on the dosing module is the top of the DEF uid pressure

line. See Figure 4-2.

FIGURE 4-2: Measurement Location of DEF Dosing Module (Injector)

The following relocation guidelines are dependant on exhaust conguration and DEF tank type and location.

The Dosing Module should not need to be relocated. However if it is removed for any reason, it is critical that the module

be reinstalled at the correct orientation. Figure 4-3 below illustrates the correct installation orientations. The angle refer-

ences the vertical plane.

09/19

4-4

Exhaust & Aftertreatment

FIGURE 4-3: Orientation of Dosing Module

DEF Tank Location with Rectangular, Small, or Medium DEF Tanks

FIGURE 4-4: RH Under Cab Exhaust with Small or Medium Tanks.

The height differential between the supply module and dosing module can not exceed one meter. The supply module is
integrated into the DEF tank assembly, separation of the module from the tank is not allowed.

When relocating the components the maximum pressure DEF hose length, from Supply module to Dosing Module, is
3 meters (118”).

DEF Pressure hose must include a “trap” in the routing if Dosing Module is below the highest point of the Supply Module
(See Figure 4-8 on page 4-8).

4-5

09/19

Exhaust & Aftertreatment



Routing to the Dosing Module (Injector)

It is important for the function of the dosing module to ensure that the dosing module is not routed downstream of DEF

lines or components. If this is unavoidable (for example on RH under exhaust systems) or Horizontal (Series) Exhaust a

routing trap must be installed. A minimum of 12” of line length must be routed below the dosing module, in order to catch

any leftover DEF when system is purged.

FIGURE 4-5: Routing DEF Lines and DEF Trap

09/19

4-6

Exhaust & Aftertreatment

GENERAL EXHAUST INFORMATION

Kenworth offers two main DPF/SCR exhaust systems on Medium Duty chassis. A Right Hand Under DPF/SCR Single
Canister system, which is located underneath the cab access step, a Horizontal system where DPF/SCR canister and
tailpipe are installed under the right hand rail,.

RH Under DPF/SCR with Horizontal Tailpipe

The following images depict the typical exhaust routings for each system, and can be used to determine exhaust routing
paths for systems you choose. Dimensional information can be found in Section 5 of this manual.

Body Builders must not modify (including altering, substituting, and relocating) the DPF/SCR Canister. The exhaust
piping after it exits the DPF/SCR canister may be modied, however using smaller diameter piping or piping with
numerous bends is not recommend as the backpressure requirements of the system may be exceeded.

4-7

09/19

Exhaust & Aftertreatment

Right Hand Under DPF and SCR on Daycab with Single Side of
Cab Tailpipe

FIGURE 4-6: Isometric View of Right Hand Under DPF/SCR with Single SOC Tailpipe

FIGURE 4-7: Top View of Right Hand Under DPF/SCR with Single SOC Tailpipe

09/19

4-8

Exhaust & Aftertreatment

FIGURE 4-8: Right View of Right Hand Under DPF/SCR with Single SOC Tailpipe

FIGURE 4-9: Back View of Right Hand Under DPF/SCR with Single SOC Tailpipe

4-9

09/19

Exhaust & Aftertreatment

Horizontal Under RH Rail DPF/SC

FIGURE 4-10: Isometric view of Horizontal Under RH Rail DPF/SCR

FIGURE 4-11: Top view of Horizontal Under RH Rail DPF/SCR

09/19

4-10

Exhaust & Aftertreatment

FIGURE 4-12: Right view of Horizontal Under RH Rail DPF/SCR

FIGURE 4-13: Back view of Horizontal Under RH Rail DPF/SCR

4-11

09/19

Exhaust & Aftertreatment

EXHAUST INFORMATION

This section includes information on how to calculate tailpipe heights, and reference information for PTO clearance.
Optional equipment is not shown.

Tailpipe Stack Height Calculation

TABLE 4-1. Stack Height

Dimension A

Tailpipes side of cab mount,

DPF RH under

Tailpipes back of cab mount,

DPF RH under

68.0”

DIMENSION “B” IS THE TAILPIPE LENGTH.

TABLE 4-2. Unladen Stack Height

For approximate unladen stack height use the following frame heights:

Tire Size Top of Rail Ft. Suspension

11R22.5

295/75R22.5

385/65R22.5

*Use PremierSpec frame heights for more accurate results.

Sample: Tailpipe height 13’6” = Desired overall stack height = 162.0”

(–) PremierSpec frame height (–) 43.5”
(+) Frame rail depth (+) 10.6”

(–) Dimension ‘A’ from chart (–) 68.6”

= Tail pipe length = 60.5”

42.5” 12K

41.5” 12K

44.3” 20K

09/19

4-12

Frame Layouts

Symbol Description

ParallelBatteryBoxwithAirDryer

CantileverBatteryBox

InCabBatteryBox

DEFTank

FuelTank

RHUCDPF/SCR

BAT T

D
E
F

BB

FUEL

BATT

ParallelBatteryBoxwithAirDryer

CantileverBatteryBox

BAT T

Symbol Description

ParallelBatteryBoxwithAirDryer

CantileverBatteryBox

InCabBatteryBox

DEFTank

FuelTank

RHUCDPF/SCR

HorizontalDPF/SCR

BAT T

DPF/SC R

D
E
F

BB

FUEL

BATT

ParallelBatteryBoxwithAirDryer

CantileverBatteryBox

InCabBatteryBox

DEFTank

BAT T

BB

BATT

Symbol Description

ParallelBatteryBoxwithAirDryer

ParallelBatteryBoxwithAirDryer

CantileverBatteryBox

InCabBatteryBox

DEFTank

FuelTank

BAT T

D
E
F

BB

BATT

ParallelBatteryBoxwithAirDryer

CantileverBatteryBox

InCabBatteryBox

BAT T

BB

FRAME LAYOUTS

The dimensions in the frame layout section are intended to aid in layout of the chassis, and to help determine the best

possible combination of fuel tanks, battery boxes, the diesel particulate lter (DPF), SCR canister, and Diesel Exhaust

Fluid (DEF) tank. For your application, the layouts focus on the under cab area, with appropriate dimensional information
included for pertinent back of cab components. 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 refer-

ence. For more specic requirements please 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 layout option versus

another.

TABLE 5-1. Dimension Index.

A = Air Dryer F1 = Fuel Tank RHS

B = Battery box F2 = Fuel Tank LHS

D = DEF tank T = Tool Box

E1 = Exhaust DPF/SCR

E2 = Exhaust, Diffuser

The layouts are organized by type, specically the arrangement of under cab components. The visual index that follows
will give you a quick overview of the layouts that are included. Using the index locate the layout that you are interested in,
then turn to the specied pages. The charts that follow are then model specic. It is important that the correct chart is used

for accurate dimensional information.

Visual Index

Symbol Description Symbol Description

DPF/SC R

BAT T

BATT

RHUC DPF/SCR

Horizontal Under RH Rail DPF/SCR

Parallel Battery Box with Air Dryer

In Cab Battery Box

BB

D
E
F

FUEL

Cantilever Battery Box

DEF Tank

Fuel Tank

5-1

09/19

Frame Layouts

COMMON OPTIONAL COMPONENTS

The frame layouts that follow contain the minimum frame requirements to be operational (fuel tanks, battery
box, and after-treatment components). All layouts are shown with standard length battery boxes unless other-

wise noted. Dimensions for these components have been provided below to help complete the frame layout for

chassis with more fuel tanks, additional tool boxes, etc.

TABLE 5-2. Fuel Tank Overall Length (in)

Fuel Tank Overall Length (in)

Fuel Tank Diameter

Gallons 22” 24.5”

45 27.9 N/A

56 35.6 28.1

75 47.2 38.5

90 N/A 45.5

100 62.2 50.0

120 74.3 N/A

09/19

5-2

Frame Layouts

SMALL DEF TANK

(9-Gallon Usable Volume)

Medium DEF TANK

(18-Gallon Usable Volume)

FIGURE 5-1. DEF Tank Dimensions.

TABLE 5-3. DEF Tanks Systems

RECTANGULAR DEF TANK

(6.6-Gallon Usable Volume)

Description

Small DEF Tank 9

Medium DEF Tank 18

Rectangular DEF Tank 6.6 N/A see Figure 5-1 see Figure 5-1

Usable Volume,

Gallons

Fuel Tank

Diameter

22” 27.4 15.3

24.5” 27.4 15.8

22” 27.7 15.0

24.5” 27.7 15.5

A B

Acronyms Index

Throughout the Frame Layout section you will see these acronyms. They are dened here to help you decode

the layouts.

BOC Back Of Cab

CBOC Clear Back Of Cab

DEF Diesel Exhaust Fluid

DSOC Dual Side Of Cab

HHP High Horsepower = PX-9, 370-450 HP

LHP Low Horsepower = PX-7, 200-260 HP

LHUC Left Hand Under Cab

MHP Mid-Horsepower = PX-7, 280-360 HP or PX-9, 260-350 HP

RHUC Right Hand Under Cab

SOC Side Of Cab

5-3

09/19

Frame Layouts

1A1

1A2

1B

2A

2B

FRAME LAYOUT INDEX

1A1 is used with PARALLEL LH UNDER CAB Battery box, RH UNDER CAB DPF/SCR, Vertical SOC tailpipe, RH BACK OF

CAB Fuel tank, Air dryer mounted to rear of LH UNDER CAB battery box and RH DEF tank. Chart located on page 5-8.

1A2 is used with PARALLEL LH UNDER CAB Battery box, RH UNDER CAB DPF/SCR, LH BACK OF CAB Fuel tank, Air
dryer mounted to rear of LH UNDER CAB battery box and LH DEF tank. Chart located on page 5-9.

1B is used with PARALLEL LH UNDER CAB Battery box, HORIZONTAL UNDER RH RAIL DPF/SCR, RH UNDER CAB
Fuel tank, Air dryer mounted to rear of LH UNDER CAB battery box and LH DEF tank. Chart located on page 5-10.

2A is used with NARROW PARALLEL LH UNDER CAB Battery box, RH UNDER CAB DPF/SCR, RECTANGULAR IN
FRAME BEHIND REAR AXLE Fuel tank, and LH DEF tank. Chart located on page 5-11.

2B is used with NARROW PARALLEL LH UNDER CAB Battery box, HORIZONTAL UNDER RH RAIL DPF/SCR, RH
UNDER CAB Fuel tank, and LH DEF tank. Chart located on page 5-12.

09/19

5-4

Frame Layouts

3A1

3A2

3B1

3B2

4A1

3A1 is used with CANTILEVER, RH BACK OF CAB Battery box, RH UNDER CAB DPF/SCR, LH UNDER CAB Round
Fuel tank, and LH Round DEF tank. Chart located on page 5-13.

3A2 is used with CANTILEVER, LH BACK OF CAB Battery box, RH UNDER CAB DPF/SCR, LH UNDER CAB Round
Fuel tank, and RH Round DEF tank. Chart located on page 5-14.

3B1 is used with CANTILEVER, LH BACK OF CAB Battery box, HORIZONTAL UNDER RH RAIL DPF/SCR, LH UNDER
CAB Round Fuel tank, and LH Round DEF tank, RH UNDER CAB TOOLBOX. Chart located on page 5-15.

3B2 is used with CANTILEVER, LH BACK OF CAB Battery box, HORIZONTAL UNDER RH RAIL DPF/SCR, LH and RH
UNDER CAB Round Fuel tank, and LH Round DEF tank. Chart located on page 5-16.

4A1 is used with IN CAB UNDER RIDER SEAT Battery box, RH UNDER CAB DPF/SCR, LH UNDER CAB Round Fuel
tank, and LH Round DEF tank. Chart located on page 5-17.

5-5

09/19

Frame Layouts

4A2

4B1

4B2

5A1

5B

4A2 is used with IN CAB UNDER RIDER SEAT Battery box, RH UNDER CAB DPF/SCR, LH UNDER CAB Rectangular
Fuel tank, and LH Rectangular DEF tank. Chart located on page 5-18.

4B1 is used with IN CAB UNDER RIDER SEAT Battery box, HORIZONTAL UNDER RH RAIL DPF/SCR, LH UNDER CAB
Round Fuel tank, and LH Round DEF tank, RH UNDER CAB TOOLBOX. Chart located on page 5-19.

4B2 is used with IN CAB UNDER RIDER SEAT Battery box, HORIZONTAL UNDER RH RAIL DPF/SCR, LH and RH UN­DER CAB Round Fuel tank, and LH Round DEF tank. Chart located on page 5-20.

5A is used with Temporary Battery Box Across the Rails, RH UNDER CAB DPF/SCR, LH UNDER CAB Round Fuel tank,
and LH Round DEF tank. Chart located on page 5-21.

5B is used with Temporary Battery Box Across the Rails, HORIZONTAL UNDER RH RAIL DPF/SCR, LH UNDER CAB
Round Fuel tank, and LH Round DEF tank, RH UNDER CAB TOOLBOX. Chart located on page 5-22.

09/19

5-6

DIMENSION REFERENCE BOC AS ORIGIN

Frame Layouts

5-7

09/19

1A1

Frame Layouts

Dimension A (BOC to Air Dryer) = 5.3 in
Dimension B (BOC to Battery Box) = -5.2 in

TABLE 5-4.

Fuel Tank Size

Diameter Gallons

56 35.6 55.4

22"

Diameter

Tank

24.5"

Diameter

Tank

75 47.3 67.1

100 62.2 81.9

120 74.3 94

56 28.1 47.9

60 30.6 50.3

75 38.5 58.3

90 45.5 65.3

100 50 69.8

110 55 74.7

120 60.6 80.3

Fuel Tank

Length (in)

Dimension F
(BOC to Fuel

Tank) (in)”

Dimension D

(BOC to DEF Tank) (in)*

Small Medium Rectangular LHP MHP HHP

18.3 27.5 N/A

18.3 27.5 N/A

Dimension E

(BOC to DPF/SCR)

(in)

2.1 3.8 7.6

135 67.2 87

150 74.5 94.3

Rectangular

Tank

NOTE :

*The Def Tank is moved backward approximately 1.7” with MHP and 5.5” with HHP Exhaust conguration.

09/19

45 28 50.1 N/A N/A 19.8

5-8

1A2

Frame Layouts

Dimension A (BOC to Air Dryer) = 5.3 in
Dimension B (BOC to Battery Box) = -5.2 in

TABLE 5-5.

Fuel Tank Size

Diameter Gallons

22" Diameter

Tank

24.5" Diameter
Tank

56 35.6 55.4

75 47.3 67.1

100 62.2 81.9

120 74.3 94

56 28.1 47.9

60 30.6 50.3

75 38.5 58.3

90 45.5 65.3

100 50 69.8

110 55 74.7

120 60.6 80.3

Fuel

Tank

Length

(in)

Dimension F
(BOC to Fuel

Tank) (in)

Dimension D

(BOC to DEF Tank) (in)*

Small Medium Rectangular LHP MHP HHP

18.3 27.5 N/A

18.3 27.5 N/A

Dimension E

(BOC to DPF/SCR)(in)

2.1 3.8 7.6

135 67.2 87

150 74.5 94.3

Rectangular

Tank

NOTE :

*The DEF tank is moved forward approximately 8.3” with a frame rail mounted air dryer.

45 28 48.1 N/A N/A 18.5

5-9

09/19

1B

Frame Layouts

Dimension A (BOC to Air Dryer) = 5.3 in
Dimension B (BOC to Battery Box) = -5.2 in

TABLE 5-6.

Dimension E1 Dimension E2

LHP MHP HHP LHP MHP HHP

31.5 34.3 38 58.3 60.2 64.8

Fuel Tank Size

Diameter Gallons

56 35.6 0.3

22" Diameter Tank

24.5" Diameter Tank

Rectangular Tank 45 28 -6.5 N/A N/A 18.5

NOTE :

*The DEF tank is moved forward approximately 8.3” with a frame rail mounted air dryer.

09/19

75 47.3 12

100 62.2 26.9

120 74.3 39

56 28.1 -11.1

60 30.6 -8.5

75 38.5 -0.6

90 45.5 6.3

100 50 10.8

110 55 15.8

120 60.6 21.4

135 67.2 28.1

150 74.5 35.4

Fuel Tank

Length (in)

Dimension F

(BOC to Fuel Tank) (in)

Small Medium Rectangular

18.3 27.5 N/A

18.3 27.5 N/A

5-10

Dimension D

(BOC to DEF Tank) (in)*

2A

Frame Layouts

Dimension B (BOC to Battery Box) = -13.7in

TABLE 5-7.

Fuel Tank

Size

Gallons Small Medium Rectangular LHP MHP HHP

45 28 39.7

70 43.5 55.3

NOTE :
*For CBOC use 45 or 70 Gal tank with a small DEF Tank and LHP DPF/SCR

Fuel Tank

Length

(in)

Dimension F

(Rear Axle to

Fuel Tank) (in)

Dimension D

(BOC to DEF Tank) (in)

0.1* 13.8 -0.1* 2.1* 3.8 7.6

Dimension E

(BOC to DPF/SCR) (in)

5-11

09/19

2B

Frame Layouts

Dimension B (BOC to Battery Box) = -13.7in

TABLE 5-8.

Dimension E1 Dimension E2

LHP MHP HHP LHP MHP HHP

31.5 34.3 38 58.3 60.2 64.8

Fuel Tank Size

Diameter Gallons

22" Diameter Tank

24.5" Diameter tank

56 35.6 0.3*

75 47.3 12

100 62.2 26.9

120 74.3 39

56 28.1 -11.1*

60 30.6 -8.5*

75 38.5 -0.6*

90 45.5 6.3

100 50 10.8

Fuel Tank

Length (in)

Dimension F

(BOC to Fuel Tank) (in)

Dimension D

(BOC to DEF Tank) (in)

Small Medium Rectangular

0.1* 13.8 N/A

0.1* 13.8 N/A

110 55 15.8

120 60.6 21.4

135 67.2 28.1

150 74.5 35.4

NOTE :
*For CBOC use 56, 60 or 75 (24.5”) Gal Fuel tank with Small DEF tank .

09/19

5-12

3A1

Frame Layouts

TABLE 5-9.

Fuel Tank Size

Diameter Gallons Small Medium LHP MHP HHP

56 35.6 0.3 14.2 21.6

22" Diameter

Tank

24.5"

Diameter

Tank

75 47.3 12 26 33.4

100 62.2 26.9 39.8 51.2

120 74.3 39 51.6 60.9

56 28.1 -11.1 1.2 13.8

60 30.6 -8.5 6.4 13.8

75 38.5 -0.6 12.3 21.6

90 45.5 6.3 20.2 27.5

100 50 10.8 24.1 33.4

110 55 15.8 28.1 37.4

120 60.6 21.4 33.9 43.3

135 67.2 28.1 41.8 51.2

150 74.5 35.4 47.7 57.1

Fuel Tank

Length (in)

Dimension F
(BOC to Fuel

Tank) (in)

Dimension D

(BOC to DEF Tank) (in)

Dimension E

(BOC to DPF/SCR)

2.1 3.8 7.6

5-13

09/19

3A2

Frame Layouts

Dimension A (BOC to Air Dryer) = 5.28in

TABLE 5-10.

Fuel Tank Size

Diameter Gallons

56 35.6 0.3

22" Diameter

Tank

24.5"

Diameter

Tank

75 47.3 12 35.8

100 62.2 26.9 50.6

120 74.3 39 62.4

56 28.1 -11.1

60 30.6 -8.5 15.1

75 38.5 -0.6 23

90 45.5 6.3 30.9

100 50 10.8 34.8

110 55 15.8 40.7

120 60.6 21.4 44.6

Fuel
Tank

Length

(in)

Dimension F
(BOC to Fuel

Tank) (in)

Dimension D
(BOC to DEF

Tank) (in)*

Small Medium LHP MHP HHP

18.3 27.5

18.3 27.5

Dimension E

(BOC to DPF/SCR)(in)

2.1 3.8 7.6

Dimension B

(BOC to Battery

Box)

24.9

13.2

135 67.2 28.1 52.5

150 74.5 35.4 58.4

NOTE :

*The Def Tank is moved backward approximately 1.7” with MHP and 5.5” with HHP Exhaust conguration

09/19

5-14

3B1

Frame Layouts

TABLE 5-11.

LHP MHP HHP LHP MHP HHP

31.5 34.3 38 58.3 60.2 64.8

Fuel Tank Size

Diameter Gallons

22" Diameter

Tank

24.5" Diameter
Tank

Dimension E1 Dimension E2

Fuel Tank

Length (in)

56 35.6 0.3 14.2 21.6 38.7

75 47.3 12 26 33.4 50.5

100 62.2 26.9 39.8 51.2 64.3

120 74.3 39 51.6 60.9 76.1

56 28.1 -11.1 1.2 13.8 25

60 30.6 -8.5 6.4 13.8 30.9

75 38.5 -0.6 12.3 21.6 36.8

90 45.5 6.3 20.2 27.5 44.6

100 50 10.8 24.1 33.4 47.6

110 55 15.8 28.1 37.4 52.5

Dimension F
(BOC to Fuel

Tank) (in)

Dimension D

(BOC to DEF Tank) (in)

Small Medium

Dimension B

(BOC to Battery Box)

120 60.6 21.4 33.9 43.3 58.4

135 67.2 28.1 41.8 51.2 66.3

150 74.5 35.4 47.7 57.1 72.2

5-15

09/19

3B2

Frame Layouts

TABLE 5-12.

Dimension E1 Dimension E2

LHP MHP HHP LHP MHP HHP

31.5 34.3 38 58.3 60.2 64.8

Fuel Tank Size

Diameter Gallons Dimension F1 Dimension F2

56 35.6 0.3 0.3 14.2 21.6 38.7

22"

Diameter

Tank

24.5"

Diameter

Tank

75 47.3 12 12 26 33.4 50.5

100 62.2 26.9 26.9 39.8 51.2 64.3

120 74.3 39 39 51.6 60.9 76.1

56 28.1 -11.1 -11.1 1.2 13.8 25

60 30.6 -8.5 -8.5 3.5 13.8 30.9

75 38.5 -0.6 -0.6 12.3 21.6 36.8

90 45.5 6.3 6.3 20.2 27.5 44.6

100 50 10.8 10.8 24.1 33.4 47.6

110 55 15.8 15.8 28.1 37.4 52.5

Fuel Tank

Length (in)

(BOC to Fuel Tank) (in)

Dimension D

(BOC to DEF Tank) (in)

Small Medium

Dimension B

(BOC to

Battery Box)

09/19

120 60.6 21.4 21.4 33.9 43.3 58.4

135 67.2 28.1 28.1 41.8 51.2 66.3

150 74.5 35.4 35.4 47.7 57.1 72.2

5-16

4A1

Frame Layouts

Dimension B (BOC to Battery Box) = -2.9 in

TABLE 5-13.

Fuel Tank Size

Diameter Gallons Small Medium LHP MHP HHP

56 35.6 0.3 14.2 21.6

22"

Diameter

Tank

24.5"

Diameter

Tank

NOTE :
*For CBOC use 24.5” diameter, 56 Gal tank with small DEF Tank and LHP DPF/SCR

75 47.3 12 26 33.4

100 62.2 26.9 39.8 51.2

120 74.3 39 51.6 60.9

56 28.1 -11.1* 0.7* 13.8

60 30.6 -8.5 6.4 13.8

75 38.5 -0.6 12.3 21.6

90 45.5 6.3 20.2 27.5

100 50 10.8 24.1 33.4

110 55 15.8 28.1 37.4

120 60.6 21.4 33.9 43.3

135 67.2 28.1 41.8 51.2

150 74.5 35.4 47.7 57.1

Fuel Tank

Length (in)

Dimension F
(BOC to Fuel

Tank) (in)

Dimension D

(BOC to DEF Tank) (in)

Dimension E

(BOC to DPF/SCR)

2.1* 3.8 7.6

5-17

09/19

4A2

Frame Layouts

Dimension B (BOC to Battery Box) = -2.9 in

TABLE 5-14.

Fuel Tank Size

Diameter Gallons

Rectangular

Tank

NOTE :
*For CBOC use with Rectangular 45 Gal tank with Rectangular DEF Tank and LHP DPF/SCR

45 28 0.9* N/A N/A -28.4* 2.1* 3.8

Fuel

Tank

Length

(in)

Dimension F
(BOC to Fuel

Tank) (in)

Small* Medium Rectangular* LHP MHP HHP

Dimension D

(BOC to DEF Tank) (in)

Dimension E

(BOC to DPF/SCR)(in)

7.6

09/19

5-18

4B1

Frame Layouts

Dimension B (BOC to Battery Box) = -2.9 in
Dimension T (BOC to Tool Box) = -5.5 in

TABLE 5-15.

Dimension E1 Dimension E2

LHP MHP HHP LHP MHP HHP

31.5 34.3 38 58.3 60.2 64.8

Fuel Tank Size

Diameter Gallons

22" Diameter Tank

24.5" Diameter tank

56 35.6 0.3 14.2 21.6

75 47.3 12 26 33.4

100 62.2 26.9 39.8 51.2

120 74.3 39 51.6 60.9

56 28.1 -11.1* 0.7* 13.8

60 30.6 -8.5* 6.4 13.8

75 38.5 -0.6* 12.3 21.6

90 45.5 6.3 20.2 27.5

100 50 10.8 24.1 33.4

Length (in)

Fuel Tank

Dimension F

(BOC to Fuel Tank) (in)

Dimension D

(BOC to DEF Tank) (in)

Small Medium

110 55 15.8 28.1 37.4

120 60.6 21.4 33.9 43.3

135 67.2 28.1 41.8 51.2

150 74.5 35.4 47.7 57.1

NOTE :

*For CBOC use 24.5” diameter tank (56, 60 or 75 Gal) with small DEF Tank.

5-19

09/19

4B2

Frame Layouts

Dimension B (BOC to Battery Box) = -2.9 in

TABLE 5-16.

Dimension E1 Dimension E2

LHP MHP HHP LHP MHP HHP

31.5 34.3 38 58.3 60.2 64.8

Fuel Tank Size

Diameter Gallons Dimension F1 Dimension F2

56 35.6 0.3 0.3 14.2 21.6

22" Diameter

Tank

24.5" Diameter
Tank

75 47.3 12 12 26 33.4

100 62.2 26.9 26.9 39.8 51.2

120 74.3 39 39 51.6 60.9

56 28.1 -11.1* -11.1* 0.7* 13.8

60 30.6 -8.5* -8.5* 6.4 13.8

75 38.5 -0.6* -0.6* 12.3 21.6

90 45.5 6.3 6.3 20.2 27.5

100 50 10.8 10.8 24.1 33.4

110 55 15.8 15.8 28.1 37.4

120 60.6 21.4 21.4 33.9 43.3

135 67.2 28.1 28.1 41.8 51.2

150 74.5 35.4 35.4 47.7 57.1

Fuel Tank

Length (in)

(BOC to Fuel Tank) (in)

Dimension D

(BOC to DEF Tank) (in)

Small Medium

NOTE :

*For CBOC use 24.5” diameter tank (56, 60 or 75 Gal) with small DEF Tank

09/19

5-20

5A

Frame Layouts

Dimension B (BOC to Battery Box) = 20.8 in

TABLE 5-17.

Fuel Tank Size

Diameter Gallons Small Medium LHP MHP HHP

56 35.6 0.3 14.2 21.6

22" Diameter

Tank

24.5" Diam­eter tank

NOTE :
*For CBOC use 24.5” diameter tank (56, 60 or 75 Gal) with small DEF Tank and LHP DPF/SCR (See 4A2 for rectangular tanks)

75 47.3 12 26 33.4

100 62.2 26.9 39.8 51.2

120 74.3 39 51.6 60.9

56 28.1 -11.1* 0.7* 13.8

60 30.6 -8.5* 6.4 13.8

75 38.5 -0.6* 12.3 21.6

90 45.5 6.3 20.2 27.5

100 50 10.8 24.1 33.4

110 55 15.8 28.1 37.4

120 60.6 21.4 33.9 43.3

135 67.2 28.1 41.8 51.2

150 74.5 35.4 47.7 57.1

Fuel Tank

Length (in)

Dimension F
(BOC to Fuel

Tank) (in)

Dimension D

(BOC to DEF Tank) (in)

Dimension E

(BOC to DPF/SCR)

2.1* 3.8 7.6

5-21

09/19

5B

Frame Layouts

Dimension B (BOC to Battery Box) = 20.8 in

TABLE 5-18.

Dimension E1 Dimension E2

LHP MHP HHP LHP MHP HHP

31.5 34.3 38 58.3 60.2 64.8

Fuel Tank Size

Diameter Gallons

22" Diameter Tank

24.5" Diameter Tank

56 35.6 0.3 14.2 21.6

75 47.3 12 26 33.4

100 62.2 26.9 39.8 51.2

120 74.3 39 51.6 60.9

56 28.1 -11.1* 0.7* 13.8

60 30.6 -8.5* 6.4 13.8

75 38.5 -0.6* 12.3 21.6

90 45.5 6.3 20.2 27.5

100 50 10.8 24.1 33.4

Fuel Tank

Length (in)

Dimension F
(BOC to Fuel

Tank) (in)

Dimension D

(BOC to DEF Tank) (in)

Small Medium

110 55 15.8 28.1 37.4

120 60.6 21.4 33.9 43.3

135 67.2 28.1 41.8 51.2

150 74.5 35.4 47.7 57.1

NOTE :
*For CBOC use 24.5” diameter tank (56, 60 or 75 Gal) with small DEF Tank (See 4A2 for rectangular tanks)

09/19

5-22

CRITICAL CLEARANCES

Rear Wheels and Cab

Body Mounting

CAUTION:

Normal suspension movement could cause contact between the tires and the body. To prevent this, mount the body so

that the minimum clearance between the top of the tire and the bottom of the body is 8 inches (203 mm). This should be
measured with the body empty. See Figure 6–1.

FIGURE 6-1. Minimum Clearance Between Top of Rear Tires and Body Structure Overhang

CAUTION:

Note:

Insufcient clearance between rear tires and body structure could cause damage to the

body during suspension movement. Allow at least 8 inches clearance (See Figure 6–1.)

Maintain adequate clearance between back of cab and the front (leading edge) of
mounted body. Failure to do so could cause damage to the cab, body or both during cab
& body movement. See Figure 6–2.

Be sure to provide maintenance access to battery box and fuel tank ll neck.

The true distance from the centerline of the front axle to the back of the cab is 68 inches (1727 mm). It is recommended
that the leading edge of the body be mounted a minimum of 4 inches (102 mm) behind the cab. The result is a minimum
back–of–cab clearance of 72 inches (1829 mm) from the front axle to the leading edge of the body.

See SECTION 3 “DIMENSIONS” for further details on dimensions and clearances. Also, see APPENDIX B “WEIGHT DIS­TRIBUTION” for explanation of back–of–cab (BOC) / CA calculations.

FIGURE 6-2. Minimum Back of Cab Clearance

WARNING:

If the frame rail anges are modied or damaged, the rail may fail prematurely and cause

an accident. When mounting a body to the chassis, DO NOT drill holes in the upper or

lower ange of the frame rail. Mount the body using body mounting brackets or U-bolts.

Failure to comply may result in personal injury, death, equipment or property damage.

6-1

09/19

Body Mounting

Body Mounting Using Brackets

CAUTION:

Installation of a spacer between the body subframe and the top ange of the frame rail will help prevent premature wear
of the components due to chang or corrosion.

Always install a spacer between the body subframe and the top ange of the frame rail.

Failure to do so could result in corrosion due to dissimilar materials.

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 (delrin or nylon). These materials will not undergo large dimensional changes during periods of high or low

humidity. The strip will be less likely to fall out during extreme relative motion between body and chassis. See Figure 6–3.

Body Subframe
(Rail)

Spacer

Chassis Frame
(Rail) Sill

FIGURE 6-3. Spacer Between Frame Sill and Body Rail - Rubber or Plastic

Brackets

When mounting a body to the chassis with brackets, we recommend designs that offer limited amount of relative move­ment, bolted securely but not too rigid. Brackets should allow for slight movement between the body and the chassis. For

instance, Figure 6–4 shows a high compression spring between the bolt and the bracket.

Spring

FIGURE 6-4. High Compression Spring FIGURE 6-5. Rubber Spacer Between Brackets
Between the Mounting Bolt and Upper Bracket

Rubber
Spacer

Another possibility is mounting a rubber spacer between the brackets. See Figure 6–5.

These designs will allow relative movement between the body and the chassis during extreme frame racking situations.

Extreme frame racking, with rigid mountings, could cause damage to the body. This is particularly true with tanker
installations.

09/19

6-2

Body Mounting

Mounting Holes

When installing the lower bracket on frame rails the mounting holes in the chassis frame bracket and frame rail must com­ply with the general spacing and location guidelines illustrated in Figure 6–6. The hole diameter should not exceed the bolt
diameter by more than .060 inches (1.5 mm).

5.63

(143mm)

2.0

(50mm)

Upper
Frame
Flange

Lower Frame
Flange

4 HOLES

.5 IN. DIA.

(12.7mm)

5.5

(140mm)

A or B Equal to or
Greater Than 2 inches
(50 mm)

FIGURE 6-6. Hole Locations Guidelines
for Frame Rail and Bracket

6 HOLES

.5 IN. DIA.

(12.7mm)

5.63

(143mm)

2.0

(50mm)

5.5

(140mm)

11.0

(279mm)

FIGURE 6-7. Crossmember-Gusset Hole Pattern Requirements [inch (mm)]

Frame Drilling

WARNING:

CAUTION:

WARNING:

When mounting a body to the chassis, DO NOT drill holes

in the upper or lower ange of the frame rail. If the frame
rail anges are modied or damaged, the rail could fail

prematurely and cause an accident. Mount the body using
body mounting brackets or U–bolts.

Use care when drilling the frame web so the wires and air lines routed inside the rail are
not damaged. Failure to do so could lead to equipment damage and cause an inoper­able electrical or air system circuit.

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

6-3

09/19

Body Mounting

Hole Location Guidelines

Holes must be located from the ange as indicated in Figure 6–7. They must be no closer than 2 inches (50 mm) to

each other.

Any unused holes must have the correct size bolts installed and torqued

CAUTION:

Note:

BODY MOUNTING USING U–BOLTS

Spacers

If the body is mounted to the frame with U–bolts, use a hardwood sill (minimum 0.5 inch (12 mm) thick)

between the frame rail and body frame to protect the top surface of the rail ange.

properly. Failure to do so can cause the frame rails to crack around the holes.

If your design permits placement of body mounting brackets at crossmember
locations, you can use the crossmember gusset bolt holes for body mount­ing. See Figure 6-8

Do not allow the frame rails or anges to deform when tightening the U–bolts. It will

WARNING:

Use a hardwood spacer between the bottom ange and the U–bolt to prevent the U–bolt from notching the frame ange.

See Figure 6–8.

Body Structure

Wood Sill 0.5 (12) Minimum

Frame Rail Spacer

(Fabricated Steel or

FIGURE 6-8. Acceptable U-Bolt Mounting with Wood and Fabricated Spacers [inch mm)]

WARNING:

weaken the frame and could cause an accident. Use suitable spacers made of steel

or hardwood on the inside of the frame rail to prevent collapse of the frame anges.

U-Bolt

Truck Frame

U-Bolt Spacer (Hardwood)

Hardwood)

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 wiring could result in loss of braking, fuel leaks, electrical

overload or a re. Carefully inspect the installation to ensure adequate clearances

for air brake lines, fuel lines, and wiring. See Figure 6–9.

09/19

CAUTION:

Mount U–bolts so they do not chafe on frame rail. Failure to do so could result in
premature wear of the U-bolt or frame rail and cause an accident.

6-4

Body Mounting

Frame Rail

Air Lines and Wiring

Harness

Check Clearance

Space for Air

Lines and Wiring

FIGURE 6-9. Clearance Space for Air Lines and Cables

WARNING:

Do not notch frame rail anges to force a U–bolt t. Notched or damaged frame anges

could result in premature frame failure. Use a larger size U–bolt. Use a hardwood
spacer as shown in Figure 6-9.

U-Bolt

Frame Rail Spacer
(Hardwood or Steel

U-Bolt Spacer

6-5

09/19

Body Mounting

Rear Body Mount

When U–bolts are used to mount a body we recommend that the last body attachment be made with a “shplate” bracket.
See Figure 6–9. This provides a rm attaching point and helps prevent any relative fore or aft movement between the body

and frame. Refer to Figure 6-6 for mounting hole location guidelines.

Body Structure

Frame Rail

FIGURE 6-10. Example of Fishplate Bracket at Rear End of Body, used with U-Bolts

09/19

6-6

Frame Modications

FRAME MODIFICATIONS
Introduction

The T170/T270/T370 offers multiple wheelbase congurations from the factory. So, in most cases frame modications to

produce a particular wheelbase should not be necessary.

However, some installations may require slight modications, while other installations will require extensive modications.

.

For example an existing dealer stock chassis may need to have the wheelbase changed to better t a customer’s applica­tion. The modications may be as simple as shortening or lengthening the frame cutoff, or they may be as complex as

changing the wheelbase.

DRILLING RAILS
Location and Hole Pattern

If holes need to be drilled to attach anything to the rail, see SECTION 6 “BODY MOUNTING” for more information. Follow
the general spacing and hole location guidelines on Page 6–4, Figure 6–7.

WARNING:

WARNING:

CAUTION:

CAUTION:

CAUTION:

When mounting a body to the chassis, DO NOT drill holes in the upper or
lower ange of the frame rail. If the frame rail anges are modied 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 affects the strength of the rails and if not done properly can
cause the frame rails to fail and cause an accident.

An appropriately sized bolt and nut must be installed and torqued properly in
all unused frame holes. Failure to do so could result in frame crack initiation
around the hole.

Use care when drilling the frame web so the wires and air lines routed inside
the rail are not damaged. Failure to do so could lead to equipment damage
and cause an inoperable electrical or air system circuit.

Never use a torch to make holes in the rail. Use the appropriate diameter drill
bit. Heat from a torch will affect the material properties of the frame rail and
could result in frame rail cracks.

CAUTION:

Hole pattern dimensions for crossmember designs are illustrated in Page 6–5, Figure 6–8.

Hole diameter should not exceed the bolt diameter by more than .060 inches (1.5 mm).

Hole diameter should not exceed the bolt diameter by more than .060 inches
(1.5 mm). Oversized holes could result in excessive frame wear around the hole.

7-1

09/19

Frame Modications

MODIFYING FRAME LENGTH

The frame cutoff after the rear axle can be shortened to match a particular body length. Using a torch is acceptable;

however, heat from a torch will affect the material characteristics of the frame rail. The affected material will normally be
conned to within 1 to 2 inches (25 to 50 mm) of the ame cut and may not adversely affect the strength of the chassis or

body installation.

The frame cutoff can be lengthened by adding frame extenders.

When extending 10.5” frame rails, the additional sections can be welded to the existing rails. The joint should be welded
and reinforced as illustrated in Figure 7–1.

Note:

WARNING:

See page 7-5 for more information on welding frames.

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

Frame 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) diameter or the next larger size. Both
the reinforcement and frame holes should be reamed to provide a t of from .001 in. to .003 in. (.025 to .076 mm) clear­ance. Do not weld reinforcing members. The insert should span a distance of at least 24.21 in. (615 mm) on either side of

the crack to ensure an even distribution of stresses. Cut the ends of the insert at 45° as shown in Figure 7–2 unless the

insert extends to the end of the frame.

FIGURE 7-1. Detail of Frame
Extension and Joint Welding

09/19

WELDED
JOINT

24.21 Inch
Minimum

(615 mm)

FIGURE 7-2. Frame Insert

7-2

Frame Modications

Where possible, use existing bolt holes to attach the insert to the frame. Bolt holes must not be located closer to the frame

anges than the present bolt pattern.

If the insert is placed in a section of the main frame where few bolts are located, additional bolts are required. Use the fol­lowing guideline for locating additional bolt holes.

Changing Wheelbase

We do not recommend modifying the wheelbase. Occasionally, however, a chassis wheelbase will need to be reduced or

lengthened. When this needs to be done there are a few guidelines that should to be considered.

WARNING:

WARNING:

Before changing the wheelbase the driveline angles of the proposed wheelbase need to be examined to ensure that no
harmful vibrations are created. Consult the driveline manufacturer for appropriate recommendations.

WARNING:

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 existing holes and should not come any closer than 2 inches (50 mm) to existing

holes in the frame.

WARNING:

If you are extending the wheelbase, you may also have to extend the frame length to accommodate a body. When you

reposition the rear suspension spring hangers, do not mount them on the added extended portion of the rail. The relocated
rear suspension bracket should be located on the original frame rails. See Figure 7–3.

When changing the wheelbase, be sure to follow the driveline manufacturer’s recom-

mendations for driveline length or angle changes. Incorrectly modied drivelines can

fail prematurely due to excessive vibration and could cause personal injury and/or an
accident.

When changing the wheelbase, a continuous blank frame insert/outsert must be added
in the area of the new rear suspension mounting bolts. All new mounting holes must
pass through the original rail, rear suspension crossmembers and the insert/outsert.
Failure to do so could cause excessive stress in the original rail due to additional holes.

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

When relocating a suspension bracket, do not mount it on the extended (added) section
of a frame rail. The suspension loading could result in premature failure of the added
section splice. This could cause an accident. Use care when planning the wheelbase
so that the rear suspension bracket is always mounted on the original rail section. See
Figure 7–3.

When reducing the wheelbase, we recommend that the suspension be moved forward and relocated on the original rail.
The rail behind the suspension can then be cut to achieve the desired frame cutoff. See Figure 7–3.

WARNING:

WARNING:

When inserts longer than the minimum length are required, extra pairs of bolt holes shall be added, evenly spaced, result­ing in bolt spacings of not less than 9.8 inches (250mm) or more than 19.7 inches (500mm) along the length of the insert,
as shown in Figure 7-2: Insert Detail, Variable Length.

When changing the wheelbase & frame inserts are used, crossmembers require re­placement and/or adjustment or in order to maintain the original frame rail spacing. Fail­ure to do so could cause damage to rear suspension components & lead to an accident

When changing the wheelbase & frame outserts are used, the rear suspension requires
replacement to compensate for the original frame width caused by the outserts. Failure
to do so could cause damage to rear suspension components & lead to an accident.

7-3

09/19

Frame Modications

WARNING:

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 existing holes and should not come any closer than 2 inches (50 mm) to existing holes.

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

Mount the suspension Brackets On the
Original Rail (see frame insert section &

gures 7-1 & 7-2)

Extended Wheelbase

Original Wheelbase

Do Not Mount the
Suspension Bracket
On the Added
Frame Rail

Relocated Rear

Suspension

Shortened Wheelbase

FIGURE 7-3. Comparison of Original, Shortened, and Extended Wheelbases

Cut Frame at Rear to
Obtain Desired Cutoff

Crossmembers

After changing a wheelbase, an additional crossmember may be required to maintain the original frame strength.
The maximum allowable distance between adjacent crossmembers is 60 inches (1524 mm). If the distance between
adjacent crossmembers exceeds this dimension, add a crossmember between them. See Figure 7–4.

Less Than 60”

Before Wheelbase is Lengthened

Greater Than 60”

Additional Crossmember

FIGURE 7- 4. Crossmember Added when Distance Exceeds 60 inches (1524 mm)

09/19

7-4

Frame Modications

WELDING

The 9.875”, 10.625”, and 10.75” rails along with the 9.875” insert are heat treated; therefore, it is not weldable.

The 9.875 (9-7/8) inch rail, 10.625 (10-5/8) inch, and 10.75 (10-3/4) 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 treated:

1. Check for heat treat caution labels on the frame rails. See gure 7-5.

FIGURE 7-5. Heat Treated Frame Rail Warning

Kenworth DOES NOT recommend frame welding. The high heat of welding nullies the special heat treatment of the
rails, greatly reducing the tensile strength of the frame rail. If a frame member becomes cracked from overloading, fatigue,

surface damage or a collision, the only permanent repair is to replace the damaged frame member with a new part.

The following information is provided (for temporary emergency repair). Prior to welding a cracked frame rail, the area
should be beveled (V’d out) to allow for a better weld. To prevent 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. Widen the crack along its full length by using two hack saw blades together.
When welding steel frames use the shielded arc method. When welding aluminum frames use either the tungsten inert
gas (TIG) or consumable electrode method. Be sure to obtain full weld penetration along the entire length of the crack.

Precautions

CAUTION:

CAUTION:

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

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

CAUTION:

To prevent damage to electrical equipment, disconnect battery cables before arc-welding
on a truck, and be sure that the welding ground lead is connected to the frame. Bearings
and other parts will be damaged if current must pass through them in order to complete
the circuit.

7-5

09/19

Frame Modications

Welding Precautions: All Electronic Engines and other Components

Before welding on vehicles with electronic engines, the following precautions should be observed.

1. Disconnect all electrical connections to the vehicle batteries.

2. Disconnect all ECM connectors.

3. Do no use the ECM or engine ground stud for the ground of the welding probe.

4. Ensure that the ground connection for the welder is as close to the weld point as possible. This ensures maxi-

mum weld current and minimum risk to damage electrical components on the vehicle.

5. Turn off key.

Note:

Bendix ABS, Bosch ABS and Wabco ABS: Disconnect ECU.

09/19

7-6