k270 k370 body builder manual 2012

7/22/2019 k270 k370 Body Builder Manual 2012

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Medium Duty

BodyBuildersManual

Model: K270/K370For Trucks Produced After March 2012


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i

Body Builders ManualContents

FIGURES .................................................................................................................................................................. i

TABLES .................................................................................................................................................................. i

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

SECTION 2 SAFETY & COMPLIANCESAFETY SIGNALS 2

FEDERAL MOTOR VEHICLE SAFETY STANDARDS COMPLIANCE 2

Incomplete Vehicle Certification .................................................................................................... 2Noise and Emissions Requirements ................................................................................................ 2

SECTION 3 DIMENSIONSABBREVIATIONS 3

TURNING RADIUS 3

CAB TILT 3

OVERALL DIMENSIONS 3

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

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

Front and Rear ViewsK270/K370 ............................................................................................. 3

DETAIL VIEWS 3-1

Left side: Chassis HeightsK270 ................................................................................................. 3-1

Right side: Chassis HeightsK370 ............................................................................................... 3-1Components LocationsK270 ...................................................................................................... 3-1

Components LocationsK370 ...................................................................................................... 3-1

Crossmember LocationsK270 .................................................................................................... 3-1

Frame Rail Configurations ............................................................................................................ 3-2

Battery Box, Fuel Tanks and Air TanksK270/K370 ............................................................... 3-2

DPF & SCR LocationsK270/K370 ........................................................................................... 3-2

Reyco 79KB Single Rear Axle ..................................................................................................... 3-2

TIRE DATA .................................................................................................................................. 3-2

FRAME AND CAB RELATED HEIGHTS ................................................................................. 3-2

GROUND CLEARANCES .......................................................................................................... 3-2

PTO Clearances............................................................................................................................. 3-2

SECTION 4 EXHAUST & AFTERTREATMENTEXHAUST AND AFTERTREATMENT INFORMATION 4General Guidelines for DEF System ............................................................................................... 4

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

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

GENERAL EXHAUST INFORMATION 4

SECTION 5 FRAME LAYOUTS AND BODY MOUNTINGFRAME LAYOUTS

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

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

CRITICAL CLEARANCES 5

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

Body Mounting Using Brackets ...................................................................................................... 5-Frame Sill ........................................................................................................................................ 5-

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

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

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

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

BODY MOUNTING USING UBOLTS 5

Spacers ............................................................................................................................................ 5-

REAR BODY MOUNT 5


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Body Builder Manual

Contents

SECTION 6 FRAME MODIFICATIONSFRAME MODIFICATIONS 6

Introduction ..................................................................................................................................... 6-

DRILLING RAILS ......................................................................................................................... 6-

Location and Hole Pattern ............................................................................................................... 6-

MODIFYING FRAME LENGTH 6

Frame Insert .................................................................................................................................... 6Changing Wheelbase ....................................................................................................................... 6Crossmembers ................................................................................................................................. 6

SECTION 7 ELECTRICALELECTRICAL

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

ELECTRICAL CIRCUITS

Capacity .......................................................................................................................................... 7

Dashboard Identification. ................................................................................................................ 7-

Data Bus Communication ............................................................................................................... 7-

REMOVAL AND INSTALLATION

Removal and Installation, Switches ................................................................................................ 7-

Removal and Installation, Dashboard Panels .................................................................................. 7

APPENDIX A VEHICLE IDENTIFICATIONVEHICLE IDENTIFICATION NUMBER A

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

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

CERTIFICATION LABELS A

Components and Weights Label .................................................................................................... A-

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

Incomplete Vehicle Certification Label ......................................................................................... A

COMPONENT IDENTIFICATION A

Engine Identification ...................................................................................................................... A

Transmission Identification............................................................................................................ A

Front Axle Identification................................................................................................................ ARear Axle Identification ................................................................................................................. A

APPENDIX B WEIGHT DISTRIBUTIONINTRODUCTION

Abbreviations ................................................................................................................................. B-

CALCULATIONS B

Weight Distribution without Body ................................................................................................. B-

Weight Distribution with Body ...................................................................................................... B-Chassis Weights ............................................................................................................................. B

COMPLETE (LOADED) VEHICLE B

Weight Distribution Analysis ......................................................................................................... B-

Body Length ................................................................................................................................... B


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Figures

Figure 3-1. Side ViewK270 W/19.5 Tires Height and Length Measurement .................................................................................... 3

Figure 3-2. Side ViewK370 W/19.5 Tires Height and Length Measurement................................................................................... 3Figure 3-3. Side ViewK270/K370 W/22.5 Tires Height and Length Measurement ........................................................................ 3

Figure 3-4. K270/K370 W/19.5 Tires Front View: Width and Ground Clearance Measurements: inches (mm). .................................... 3-

Figure 3-4.1. K270/K370 W/22.5 Tires Front View: Width and Ground Clearance Measurements: inches (mm). ................................. 3-Figure 3-5. K270 W/19.5 Tires Rear View: Width and Ground Clearance Measurements: inches(mm)...................................... 3-

Figure 3-5.1 K370 W/19.5 Tires Rear View: Width and Ground Clearance Measurements: inches (mm). ............................................. 3-

Figure 3-6. Cab Floor: Side View, Left Side ......................................................................................................................................... 3-

Figure 3-7. Cab Floor: Side View, Left Side......................................................................................................................................... 3-Figure 3 -7.1.1 K270 W/ Air to Oil Transmission Cooler, Battery Box, Fuel Tank, Air Tank, DEF Tank, and Crossmember

Location Measured From Front Axle: inches (mm). ............................................................................................................ 3-1

Figure 3-7.1.2 K270 W/ Oil to Water Transmission Cooler, Battery Box, Fuel Tank, Air Tank, DEF Tank, and Crossmember

Location Measured From Front Axle: inches (mm). ............................................................................................................ 3-1

Figure 3-7.2.2 K370 W/Oil to Water Cooler and 19.5 Tires, Battery Box, Fuel Tank, Air Tank, DEF Tank, and CrossmemberLocation Measured From Front Axle: inches (mm). ............................................................................................................ 3-1

Figure 3-7.2.3 K270/K370 22.5 Tires Battery Box, Fuel Tank, Air Tank, DEF Tank, and Crossmember Location Measured

From Front Axle: inches (mm). ............................................................................................................................................ 3-Figure 3-8.3. K270 Crossmember Location ............................................................................................................................................. 3-

Figure 3-8.4. K370 Crossmember Locations....................................................................................................................................... 3-

Figure 3-9. K270/K370 Rail Measurements....................................................................................................................................... 3-2

Figure 3-10. K270/K370 Battery Box, Fuel Tank and Air Tanks Measurement mm (in)................................................................... 3-2

Figure 3-11. K270/K370 Exhaust Measurements ..................................................................................................................................... 3-2Figure 4-1: Measurement Location of DEF Supply Module (Pump) ......................................................................................................... 4

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

Figure 4-3: Orientation of Dosing Module ................................................................................................................................................. 4Figure 4-4: Routing DEF Lines and DEF Trap........................................................................................................................................... 4

Figure 4-5: Horizontal Crossover DPF and SCR with Horizontal Tailpipe................................................................................................ 4

Figure 4-5.1: Top view of Horizontal Crossover DPF and SCR with Horizontal Tailpipe ........................................................................ 4Figure 4-5.2: Right view of Horizontal Crossover DPF and SCR with Horizontal Tailpipe ...................................................................... 4

Figure 4-5.3: Back view of Horizontal Crossover DPF and SCR with Horizontal Tailpipe ...................................................................... 4

Figure 5-1: Horizontal Crossover DPF/SCR, LH horizontal tailpipe, RH BOC rectangular fuel tank, RH BOC rectangular

DEF tank and LH BOC battery box ........................................................................................................................................ 5

Figure 5-2. Minimum Clearance Between Top Of Rear Tires And Body Structure Overhang. ................................................................. 5

Figure 5-3. Minimum Back of Cab Clearance ....................................................................................................................................... 5

Figure 5-4. Spacer Between Frame Sill and Body Rail - Rubber orPlastic ....................................................................................... 5Figure 5-5. High Compression Spring Between the Mounting Bolt and UpperBracket.................................................................. 5

Figure 5-6. Rubber SpacerBetween Brackets ....................................................................................................................................... 5Figure 5-7. Hole Locations Guidelines forFrame Rail and Bracket ................................................................................................... 5

Figure 5-8. Crossmember-Gusset Hole Pattern Requirements. [inch(mm)] .................................................................................... 5

Figure 5-9. Acceptable U-Bolt Mounting with Wood and Fabricated Spacers ................................................................................... 5

Figure 5-10. Clearance Space forAir Lines and Cables ..................................................................................................................... 5Figure 5-11 Example ofFishplate Bracket at Rear End of Body, used with U-Bolts......................................................................... 5

Figure 6-1. Detail of Frame ........................................................................................................................................................................ 6

Figure 6-2. Frame Insert Extension and Joint Welding .............................................................................................................................. 6

Figure 6-3 Comparison of Original, Shortened, and Extended Wheelbases............................................................................................... 6Figure 6-4. CrossmemberAdded When Distance Exceeds 60 Inches (1524 mm) ......................................................................... 6

Figure 7-1. Instrument Layout .................................................................................................................................................................... 7

Figure 7-2. Data Bus Communication Architecture ................................................................................................................................... 7Figure A-2. Drivers Door and Door Frame Label ................................................................................................................................ AFigure A-3. Engine IdentificationLocation ......................................................................................................................................... A

Figure A-4. Front Axle Identification.................................................................................................................................................... A

Figure A-5. Rear Axle Identification ..................................................................................................................................................... AFigure B-1. Balanced Load: CGf 100 in. from front axle ....................................................................................................................B

Figure B-2. Unbalanced Load: CGf 133 In. From Front Axle ............................................................................................................B

Figure B-3. Balanced Body Unloaded: CGf 184.7 in. (4691.45 mm) from front axle. .....................................................................B

Figure B-4. Liftgate Example: CGf 322.2 in (8183.9 mm) from front axle. .......................................................................................B
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Tables

Table 3-1. Abbreviations Used............................................................................................................................................................... Table 3-2 Turning Radius ...........................................................................................................................................................................

Table 3-3 Cab Tilt Height ........................................................................................................................................................................... Table 3-4. Overall K270 W/19.5 Tires Dimensions inches (mm) ..............................................................................................................

Table 3-5.1. Overall K370 W/19.5 Tires Dimensions ..................................................................................................................................

Table 3-5.2. K270/K370W/22.5 Tires Overall Dimensions ...................................................................................................................... Table 3-6 K270 W19.5 Tires Battery Box Step and Cab Floor Measurements ........................................................................................ 3

Table 3-7 Battery Box Step and Cab Floor Measurements ..................................................................................................................... 3

Table 3-8 Floor to Frame Measurements .................................................................................................................................................. 3

Table 3-9.1.K270 Crossmember LocationMeasured From the Front of the Frame inches (mm) ......................................................... 3

Table 3-9.2K370 Crossmember LocationMeasured From Front Axle Centerline inches (mm) ........................................................ 3

Table 3-10. Frame Rail Strength Characteristics ...................................................................................................................................... 3Table 3-11. K270/K370 Exhaust Location Measured From BOC inches (mm) ....................................................................................... 3

Table 3-12. K270 / K370 Exhaust Location Measured From BOC inches (mm) ..................................................................................... 3

Table 5-1 Symbols ......................................................................................................................................................................................

Table 7-1. Additional Spare Circuits for Wiring ...................................................................................................................................... 7Table A-1. Model Year (Code) Designations. ...................................................................................................................................... A

Table B-1. K270/K370 Single Rear Axle BareChassis Tare Weights (no driver, no fuel) ................................................................. B

Table B-2. K270 Weight Distribution and Chassis Rating Calculation (sample ........................................................................................BTable B-2.1. K370 Weight Distribution and Chassis Rating Calculation (sample) .................................................................................... B

Table B-3. Available K270/K370 Body Lengths ............................................................................................................................. B


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Section 1Introduction

This manual provides body builders with appropriate information and guidelines useful in thebody planning

and installationprocess. This information willbe helpful when installing bodies or other associated equipment.

This manual contains appropriate dimensional information, guidelines formounting bodies, guidelines formodi-

fying frames,

electrical wiring information, and other information useful in the body installationprocess.

The intendedprimary users of this manual are body builders who install bodies and associated equipment

on K270/K370 Medium Duty vehicles. Dealers who sell and service the vehicle will also find this information

useful.

This Body Builders Manual can be very useful when specifying a vehicle, particularly when the body builderis

involved in the vehicle definition and orderingprocess. Early in the process, professionalbody builders can of-

ten contribute valuable information that reduces the ultimate cost of the body installation.

This manual is not a maintenance manual or an operation manual.

Forchassis maintenance and repair information consult the PACCARServiceNet available in the Service

Department of the selling dealeror order a custom shop manual or parts catalog foryour vehicle through

your local dealer.

Forchassis operating information consult the Operators Manual, included with each vehicle. It can also

be ordered from your local dealer.


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Section 2Safety & Compliance

SAFETY SIGNALSWe have put a number of alerting messages in this book. Please read and follow them. They are there for your protection and infor-mation. 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 ofmessage is going to follow. Pay special attention to

comments prefacedby WARNING, CAUTION,and NOTE.Please do not ignore any ofthese alerts.

Warnings, Cautions, and Notes

WARNING:When you see this word and symbol, the message that follows is especially vital. It signalsa potentially hazardous situation which, ifnot avoided, could result in death orserious

injury. This message will tell you what the hazard is, what can happen ifyou dontheed the

warning, and how to avoid it.

Example:

WARNING! Be sure to use a circuit breaker designed to meet liftgate amperage requirements. An in-correctly specified circuit breaker could result in an electrical overload or fire situation. Follow the

liftgate installation instructions and use a circuit breaker with the recommended capacity.

CAUTION: Signals a potentially hazardous situation which, ifnot avoided, could result in minorormoderate injury ordamage to the vehicle.

Example:

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

NOTE:

Provides general information. F orexample, the note could warn you on how to avoid damaging your vehicle or how todrive the vehicle more efficiently.

Example:

Note: Be sure to provide maintenance access to the battery box and fuel tankfillneck.

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

WARNING

Indicates a potentially hazardous situation which, ifnot avoided, could result in death orserious injury.

CAUTION

Signals a potentially hazardous situation which, ifnot avoided, could result in minor ormoderate

injury ordamage to the vehicle.

NOTE

Useful information that is related to the topic being discussed.


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FEDERAL MOTOR VEHICLE SAFETY

STANDARDS COMPLIANCE

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

U.S. orCanadian Federal Motor Vehicle Safety Standards. However, the fact that this vehicle has no fifth wheel and that a

Body Builder (Intermediate or Final Stage Manufacturer)will

be doing additional modifications means that the vehicle wasincomplete when it left the build plant. See next section and Appendix A foradditional information.

Incomplete Vehicle CertificationAn Incomplete Vehicle Document is shipped with the vehicle, certifying that the vehicle is not complete. See Figure 21.

In addition, affixed to the drivers side door frame or edge is an Incomplete Vehicle Certification label. See Figure 22. For further in-

formation on Vehicle Certificationand Identification, see APPENDIX A VEHICLE IDENTIFICATION.

NOTE:These documents list the U.S. orCanadian Federal Motor Vehicle Safety Standard regulations that thevehicle complied with when it left the build plant. You should be aware that ifyou add, modify or alter

any of the components orsystems coveredby these regulations, it is your responsibility as the Inter-

mediate or Final Stage Manufacturerto ensure that the complete vehicle is in compliance with the

particularregulations upon completion of the modifications.

Figure 2-1. IncompleteVehicle

Certification Document

Tire, Rim and

Weight Rating

Datalabel

Safety Mark(Canadian

Registry Only)

IncompleteVehicle

CertificationLabel

U.S. EPA Noise Label (U.S. registeredvehicles only)

Final StageManufacturer

Label to be Installedby

Final StageManufacturer

Chassis Serial

Number

MajorComponents and

WeightsLabel

Figure 2-2. Locations of Certification Labels

- Drivers 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 (instal-

lation of the body and any other modifications), you shouldaffix your certification label to the vehicle as required by Federal law.

This tag identifiesyou as the Intermediate or Final Stage Manufacturer and certifies that the vehicle complies with Federal Motor

Vehicle Safety Standards. (See Figure 22.) For Canadian final stage manufacturers see:

http://www.gazette.gc.ca/index-eng.htmlandhttp://www.tc.gc.ca/eng/acts-regulations/menu.htmfor the regulations.

Orcontact:

Transport Canada

Tower C, Place de Ville, 330 Sparks Street

Ottawa, Ontario K1A 0N5

(613) 990-2309

TTY: 1-888-675-6863
http://www.gazette.gc.ca/index-eng.htmlhttp://www.gazette.gc.ca/index-eng.htmlhttp://www.tc.gc.ca/eng/acts-regulations/menu.htmhttp://www.tc.gc.ca/eng/acts-regulations/menu.htmhttp://www.tc.gc.ca/eng/acts-regulations/menu.htmhttp://www.tc.gc.ca/eng/acts-regulations/menu.htmhttp://www.gazette.gc.ca/index-eng.html


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Noise and Emissions Requirements

NOTE:

NOTE:

This truck may be equipped with a converter mufflerunit in order to meetboth noise and exhaust

emissions requirements. Removal ortampering with the converter mufflerwill not improve engine per-

formance. Also tampering is against the rules that are establishedby the U.S. Code ofFederal Regu-

lations and Environment Canada Regulations. The converter mufflermay only be replaced with anapprovedpart.

Relocation of converter muffler will affect noise and emission performance. Contact the engine manu-

facturerforany requirements and restrictionsprior to any modifications. In particular, there are re-quirements and restrictions forexhaustpipe materials and formaximum exhaust system lengths fromturbo outlet to muffler inlet.


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Section 3Dimensions

ABBREVIATIONSThroughout this section and in othersections as well, abbreviations are used to describe certain characteristics on yourvehicle. The chart below lists the abbreviated terms used.

Table 3-1. Abbreviations Used

A OVERALL VEHICLE LENGTH

AF FRAME RAIL OVERHANG LENGTH BEHIND REAR

B FRONT BUMPER TO FRONT AXLE LENGTH

CA BACK OF CAB TO REAR AXLE LENGTH

D CAB HEIGHT

WB WHEELBASE LENGTH

HA HEIGHT AXLE

FAX FRONT AXLE

EOF END OF FRAME

CA CAB TO AXLE

AE AXLE TO END

TL TOTAL LENGTH


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Section 3Dimensions

TURNING RADIUSApproximate turning radius specifications for the K270/K370 are listed (by wheelbase) in the following tables. Tables 3-2 and 3-3 listturn radius information for chassis with standard components. Optional components may give different results.

Table 3-2 Turning Radius

ModelRear

Axles

Tires, Bridge-

stone

Wheelbase Range Curb to Curb Est. Radius Wall to Wall Radius Est

mm Inch ft m ft m

K270

W/19.5 TiresSingle

R250F

245/70R19.5

3606.8 142 15.12 4.6 19.12 5.8

3911.6 154 16.40 5.0 20.40 6.2

4216.4 166 17.68 5.4 21.68 6.6

4521.2 178 18.95 5.8 22.95 7.0

4826 190 20.23 6.2 24.23 7.4

5130.8 202 21.51 6.6 25.51 7.8

5435.6 214 22.79 6.9 26.79 8.2

5740.4 226 24.07 7.3 28.07 8.6

6045.2 238 25.34 7.7 29.34 8.9

K370

W/19.5 TiresSingle

R250F

285/70R19.5

4216.4 166 18.06 5.5 22.06 6.7

4521.2 178 19.36 5.9 23.36 7.1

4826 190 20.67 6.3 24.67 7.5

5130.8 202 21.98 6.7 25.98 7.9

5435.6 214 23.28 7.1 27.28 8.3

K270/K370

W/22.5 tiresSingle

R250F11R22.5

14PR or

R250ED275/70R22.5

18PLY

3708.4 146 15.88 4.8 19.88 6.1

4013.2 158 17.19 5.2 21.19 6.5

4318 170 18.49 5.6 22.49 6.9

4622.8 182 19.80 6.0 23.80 7.3

4927.6 194 21.11 6.4 25.11 7.7

5232.4 206 22.41 6.8 26.41 8.1

5537.2 218 23.72 7.2 27.72 8.4

5842 230 25.02 7.6 29.02 8.8

6146.8 242 26.33 8.0 30.33 9.2


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Section 3Dimensions

CAB TILT

K270 W/19.5 Tires

K370 W/19.5 Tires

Table 3-3 Cab Tilt Height

CAB Tilt Highest point mm (in)

K270

W/19.5

Tires3217.5 (126.5)

K370W/19.5

Tires3260.5 (128)

K270/K370

W/22.5

Tires3336.9 (131)


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Section 3Dimensions

K270/K370 W/22.5 Tires


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3-5

Section 3Dimensions

OVERALL DIMENSIONS

This section includes drawings and charts of the base model K270/K370 vehicle, which includes K370 rear and front suspension

R250F 245/70R19.5, M729F 245/70R19.5 K270, 14PLY 295/75R22.5 M725 and M711 11R22.5 14PR 41.9 tires, a R227F285/70R19.5 and M729F 285/70R19.5 K370 tires. Use these drawings to plan overall vehicle configurations.

On the pages that follow, detail drawings show particular views of each component of the vehicle. They illustrate importan

measurements critical to designing bodies of all types. See the Contents at the beginning of the manual to locate the draw

ing you need.

Side View - K270

Figure 3-1. Side ViewK270W/19.5 Tires Height and Length Measurement


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Section 3Dimensions

Table 3-4. Overall K270 W/19.5 Tires Dimensions inches (mm)

Model WB mm (in)

FAX to

BOCmm (in)

FAX to Back

of Intakemm (in)

Overhangmm(in)

Frame Lengthmm(in)

Overall

Lengthmm(in)

*CA mm(in)RecommendBody Length

K270

W/19.5Tires

3606.8 (142) 338.8 (13.3) 431.8 (17) 1828.8 (72) 6630.6 (261) 6710.6 (264) 3041.8 (120) 16

3911.6 (154) 338.8 (13.3) 431.8 (17) 1828.8 (72) 6935.4 (273) 7015.4 (276) 3346.6 (132) 17

4216.4 (166) 338.8 (13.3) 431.8 (17) 1828.8 (72) 7240.2 (285) 7320.2 (288) 3651.4 (144) 18

4521 (178) 338.8 (13.3) 431.8 (17) 2133.6 (84) 7849.8 (309) 7929.8 (312) 3956.2 (156) 20

4826 (190) 338.8 (13.3) 431.8 (17) 2438.4 (96) 8459.4 (333) 8539.4 (336) 4261 (168) 22

5130.8 (202) 338.8 (13.3) 431.8 (17) 2743.2 (108) 9069 (357) 9149 (360) 4565.8 (180) 24

5435.6 (214) 338.8 (13.3) 431.8 (17) 3048 (120) 9678.6 (381) 9758.6 (384) 4870.6 (192) 26

5740.4 (226) 338.8 (13.3) 431.8 (17) 3048 (120) 9983.4 (393) 10063.4 (396) 5175.4 (204) 27

6045.2 (238) 338.8 (13.3) 431.8 (17) 3048 (120) 10288.2 (405) 10368.2 (408) 5480.2 (216) 28

*Consider a usable CA= CA Dimension - 6 High air intake 4 Clearance.


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Section 3Dimensions

Side View - K370

Figure 3-2. Side ViewK370 W/19.5 Tires Height and Length Measurement

Table 3-5.1. Overall K370 W/19.5 Tires Dimensions

K370W/19.5Tires

WB mm (in)

FAX to

BOC

mm (in)

FAX toBack of

Intake mm

(in)

Overhang

mm(in)

Frame Length

mm(in)

Overall Length

mm(in)*CA mm(in)

Recomend

Bod

Lengt

4216.4 (166) 288.8 (11.4) 381.0 (15) 1828.8 (72) 7290.2 (287) 7370.2 (290) 3676.4 (144.7) 18

4521 (178) 288.8 (11.4) 381.0 (15) 2133.6 (84) 7899.8 (311) 7979.8 (314) 3981.2 (156.7) 20

4826 (190) 288.8 (11.4) 381.0 (15) 2438.4 (96) 8509.4 (335) 8589.4 (338) 4286 (168.7) 22

5130.8 (202) 288.8 (11.4) 381.0 (15) 2743.2 (108) 9119 (359) 9199 (362) 4590.8 (180.7) 24

5435.6 (214) 288.8 (11.4) 381.0 (15) 3048 (120) 9728.6 (383) 9808.6 (386) 4895.6 (192.7) 26

*Consider a usable CA= CA Dimension - 6 High air intake 4 Clearance.


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Section 3Dimensions

Figure 3-3. Side ViewK270/K370 W/22.5 Tires Height and Length Measurement

Table 3-5.2. K270/K370W/22.5 Tires Overall Dimensions

ModelWB mm

(in)

FAX toBOC

mm (in)

FAX to Backof Intake

mm (in)

Overhang

mm(in)

FrameLength

mm(in)

OverallLength

mm(in)

*CA mm(in)RecommeBody Len

ft

K270/K370

W/22.5Tires

3708.4(146)

288.8 (11.4)1039.9(40.9)

1828.8 (72) 6782.2 (267) 6862.2 (270)3421.38(134.7)

16

4013.2(158)

288.8 (11.4)1039.9(40.9)

1828.8 (72) 7087 (279) 7167 (282.2)3726.18(146.7)

17

4318 (170) 288.8 (11.4)1039.9

(40.9)1828.8 (72) 7391.8 (291) 7471.8 (294)

4030.98

(158.7)18

4622.8(182)

288.8 (11.4) 1039.9(40.9)

2133.6 (84) 8001.4 (315) 8081.4 (318) 4335.78(170.7)

20

4927.6(194)

288.8 (11.4)1039.9(40.9)

2438.4 (96) 8611 (339) 8691 (342)4640.58(182.7)

22

5232.4

(206)288.8 (11.4)

1039.9

(40.9)

2743.2

(108)9220.6 (363) 9300.6 (366)

4945.38

(194.7)24

5537.2

(218)288.8 (11.4)

1039.9

(40.9)3048 (120) 9830 (387) 9910.2 (390)

5250.18

(206.7)26

5842 (230) 288.8 (11.4)1039.9

(40.9)3048 (120) 10135 (399) 10215 (402)

5554.98

(218.7)27

6146.8

(242)288.8 (11.4)

1039.9

(40.9)3048 (120)

10439.9

(411)

10519.8

(414)

5859.78

(230.7)28

*Consider a usable CA= CA Dimension -6 High air intake 4 Clearance 4 Interface duct.


19/95

3-9

Front and Rear Views

K270/K370inches (mm)

Section 3Dimensions


20/95

3-10

Section 3

Dimensions

Front and Rear ViewsK270/K370

K270 K370

Figure 3-4. K270/K370 W/19.5 Tires Front View: Width and Ground Clearance Measurements: inches (mm).

Figure 3-4.1. K270/K370 W/22.5 Tires Front View: Width and Ground Clearance Measurements: inches (mm).


21/95

3-11

Section 3Dimensions

Front and Rear ViewsK270/K370W/19.5 and 22.5 Tires

Figure 3-5. K270 W/19.5 Tires Rear View: Width and Ground Clearance Measurements: inches(mm).

Figure 3-5.1 K370 W/19.5 Tires Rear View: Width and Ground Clearance Measurements: inches (mm).

Note: 11R22.5 is 10.3" (261.6mm) and 295/75R22.5 is 9.8" (248.9mm)


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3-12

.Section 3

Dimensions

DETAIL VIEWS

Left side: Chassis Heights K270 W/19.5 Tires

Figure 3-6. Cab Floor: Side View, Left Side

Table 3-6 K270 W19.5 Tires Battery Box Step and Cab Floor Measurements

PositionK270 19.5 Tires

Unladen Laden

In mm In mm

AFUEL SUPPORT STEP 10.1 258 8 205.2

B FIRST STEP 21.4 546 19 483.6

C SECOND STEP FLOOR 33.6 854.3 31.2 793.4


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3-13

Section 3Dimensions

Detail Views

Right side: Chassis Heights K270/K370W/22.5 Tires

Figure 3-7. Cab Floor: Side View, Left Side

Table 3-7 Battery Box Step and Cab Floor Measurements

PositionK370 19.5 Tires K270/K370 22.5 Tires

Unladen Laden Unladen Laden

In mm In mm In mm In mm

A FUEL SUPPORTSTEP

10.5 269 7.5 191.2 13.5 342.9 10.5 266.7

B FIRST STEP 14.5 369.4 11.1 281.9 17.5 444.4 14.1 358.1

C SECOND STEPFLOOR

26.5 673.7 23 585.9 29.5 749.3 26 660.4

D CABFLOOR 34.3 872.6 30.8 784 37.3 947.4 33.8 858.5


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3-14

Section 3

Dimensions

Table 3-8 Floor to Frame Measurements.

Frame Heights LOADED inches (mm) UNLOADED inches (mm)Front Axle Rear Axle Front Axle Rear Axle

K270 W/19.5

Tires 32.11 (815.3) 32.2 (817.3) 34.47 (875.5) 34.5 (876.1)

K370W/19.5

Tires 32.65 (829.3) 33.3 (846.3) 36.08 (916.4) 35.6 (905.4)

K270/K370

W/22.5 Tires 35.65 (905.5) 36.3 (922.0) 39.08 (992.6) 38.6 (980.4)


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3-15

Section 3Dimensions

Detail Views

Components Locations K270 W/19.5 Tires

Figure 3 -7.1.1 K270 W/ Air to Oil Transmission Cooler, Battery Box, Fuel Tank, Air Tank, DEF Tank, and Cross

member Location Measured From Front Axle: inches (mm).

Figure 3-7.1.2 K270 W/ Oil to Water Transmission Cooler, Battery Box, Fuel Tank, Air Tank, DEF Tank, and

Crossmember Location Measured From Front Axle: inches (mm).


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3-16

Section 3

Dimensions

Detail Views

Components Locations K370

Figure 3-7.2.1 K370 W/Air to Oil Transmission Cooler, 19.5 tires Battery Box, Fuel Tank, Air Tank, DEF Tank and

Crossmember Location Measured From Front Axle: inches (mm).

Figure 3-7.2.2 K370 W/Oil to Water Transmission Oil Cooler and 19.5 Tires, Battery Box, Fuel Tank, Air Tank,

DEF Tank, and Crossmember Location Measured From Front Axle: inches (mm).

*


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3-17

Section 3Dimensions

Figure 3-7.2.3 K270/K370 22.5 Tires, Battery Box, Fuel Tank, Air Tank, DEF Tank, and Crossmember Location

Measured From Front Axle: inches (mm).

*


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3-18

Section 3

Dimensions

Detail Views

Crossmember Locations K270 W/19.5 Tires

Figure 3-8.3. K270 Crossmember Location

Table 3-9.1.K270 Crossmember LocationMeasured From the Front of the Frame inches (mm)

ModelWB mm

(in)

BOC C/M

mm(in)

1st Inter-

mediate

C/M

mm(in)

1st Mid-

ship C/M

mm(in)

2nd Interme-

diate C/M

mm(in)

2nd Midship

C/M mm(in)

Front susp

C/M

mm(in)

Rear susp

C/M

mm(in)

2nd Fill

C/M mm

K270

W/19.5

Tires

3606.8 (142) 2064.4 (81.3) 3183.4 (125) 3603.4 (142) Does Not Apply Does Not Apply 4073.7 (160) 5353.2 (211) Does Not A

3911.6 (154) 2064.4 (81.3) 3183.4 (125) 3603.4 (142) Does Not Apply Does Not Apply 4378.5 (172) 5658 (223) Does Not A

4216.4 (166) 2064.4 (81.3) 3183.4 (125) 3603.4 (142) Does Not Apply Does Not Apply 4683.3 (184) 5962.8 (235) Does Not A

4521 (178) 2064.4 (81.3) 3183.4 (125) 3603.4 (142) Does Not Apply Does Not Apply 3894.7 (153) 5132 (202) Does Not A

4826 (190) 2064.4 (81.3) 3183.4 (125) 3603.4 (142) 4397 (173) Does Not Apply 4199.5 (165) 5436.8 (214) 7468 (29

5130.8 (202) 2064.4 (81.3) 3183.4 (125) 3603.4 (142) Does Not Apply 4663 (183.5) 5597.7 (220) 6877.2 (271) 7925.2 (3

5435.6 (214) 2064.4 (81.3) 3183.4 (125) 3603.4 (142) Does Not Apply 4700 (185) 5902.5 (232) 7182 (283) 8382.4 (3

5740.4 (226) 2064.4 (81.3) 3183.4 (125) 3603.4 (142) Does Not Apply 4700 (185) 6207.3 (244) 7486.8 (295) 8687.2 (3

6045.2 (238) 2064.4 (81.3) 3183.4 (125) 3603.4 (142) Does Not Apply 5025 (198) 6512.1 (156) 7791.6 (307) 8992 (35


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3-19

Section 3Dimensions

Detail Views

Crossmember Locations K370

Figure 3-8.4. K370 Crossmember Locations

Table 3-9.2K370 Crossmember LocationMeasured From Front Axle Centerline inches (mm)

ModelWB mm

(in)

BOC

C/M

mm(in)

1st Intermedi-

ate C/M

mm(in)

1st Mid-

ship C/M

mm(in)

2nd Interme-

diate C/M

mm(in)

2nd Midship

C/M mm(in)

Front

susp

C/M

mm(in)

Rear

susp

C/M

mm(in)

2nd Fill in

C/M

K270/K370

W/22.5Tires

3708.4 (146) 1185 (46.6) Does Not Apply 3463.4 (136) Does Not Apply Does Not Apply 3081.9 4319.2 Does Not Apply

4013.2 (158) 1185 (46.6) Does Not Apply 3463.4 (136) Does Not Apply Does Not Apply 3386.7 4624 Does Not Apply

4318 (170) 1185 (46.6) Does Not Apply 3463.4 (136) Does Not Apply Does Not Apply 3691.5 4928.8 Does Not Apply

4622.8 (182) 1185 (46.6) 4257 (167.5) 3463.4 (136) Does Not Apply Does Not Apply 3996.3 5233.6 7180.4 (282.5)

4927.6 (194) 1185 (46.6) Does Not Apply 3463.4 (136) Does Not Apply 4257 (167.5) 4301.1 5538.4 7619.6 (300)

5232.4 (206) 1185 (46.6) Does Not Apply 3463.4 (136) Does Not Apply 4257 (167.5) 4605.9 5843.2 8076.8 (318)

5537.2 (218) 1185 (46.6) Does Not Apply 3463.4 (136) Does Not Apply 4663 (183.5) 4910.7 6148 8483.2 (334)

5842 (230) 1185 (46.6) 5503 (216.5) 3463.4 (136) Does Not Apply 4663 (183.5) 5215.5 6452.8 8781 (346)

6146.8 (242) 1185 (46.6) 5815 (229) 3463.4 (136) Does Not Apply 4875 (192) 5520.3 6757.6 9085.8 (358)

K370

W/19.5

Tires

BOC C/M 1st C/M 2nd C/M Front susp C/M Rear susp C/M 1st Rear C/M

WB 166 46.6 (1185) 92.9 (2358.4) Does Not Apply 141.3 (3589.9) 190 (4827.2) Does Not Apply

WB 178 46.6 (1185) 92.9 (2358.4) 173.1 (4397) 153.3 (3894.7) 202 (5132) Does Not Apply

WB 190 46.6 (1185) 92.9 (2358.4) 173.1 (4397) 165.3 (4199.5) 214 (5436.8) 252.5 (6413)

WB 202 46.6 (1185) 92.9 (2358.4) 173.1 (4397) 177.3 (4504.3) 226 (5741.6) 270.5 (6870.2)

WB 214 46.6 (1185) 92.9 (2358.4) 140.1 (3558) 189.3 (4809.1) 238 (6046.5) 288.5 (7327.4)


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3-20

Frame Rail Configurations

K270 K370

9-7/8 STEEL RAIL 10-1/4 STEEL RAIL

Figure 3-9. K270/K370 Rail Measurements

Table 3-10. Frame Rail Strength Characteristics

RAIL STRENGTH 10.25 Rail

(K270 W22.5 tires and

K370 W19.5 and 22.5 tires)

9.875 Rail

(K270 W19.5 tires)

Yield Strength, PSI 120,000 120,000

Section Modulus, in3 11.65 10.45

RBM, Lbs-Inch 1,398,664 1,254,404

Section 3Dimensions


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3-21

Battery Box, Fuel Tanks and Air Tanks K270/K370

Figure 3-10. K270/K370 Battery Box, Fuel Tank and Air Tanks Measurement mm (in)

Section 3Dimensions


32/95

3-22

Detail ViewsDPF & SCR Locations K270/K370

Figure 3-11. K270/K370 Exhaust Measurements

Table 3-11. K270/K370 Exhaust Location Measured From BOC inches (mm)

Model A B C D E F

K270 29.6 (751.4) 64.8 (1645.3) 30.7 (780.7) 78.8 (2002) 16.5 (420) 14.6 (370.4)

K370 40.8 (1036.4) 76 (1930.3) 42 (1065.7) 90.1 (2287.3) 16.5 (420) 14.6 (370.4)

Table 3-12. K270 / K370 Exhaust Location Measured From BOC inches (mm)

Model A B C D E F G

K270 5.7 (145) 5.3 (134) 9.9 (250.8) 12.6 (320.4) 16.5 (420.2) 12 (304.2) 14 (354.2)

K370 5.7 (145) 5.3 (134) 10.2 (260) 12.6 (320.4) 16.5 (420.2) 12 (304.2) 14 (354.2)

Section 3Dimensions


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3-23

Reyco 79KB Single Rear Axle Hendrickson HAS Single Rear Axle

Suspension Rating Laden Ride Height Unladen Ride HeightReyco 79KB Single 21K 6.6" 9.0"

Hendrickson HAS

210L 23K 8.3" 8.5"

TIRE DATAFor dimensions of your particular Bridgestone tire, visit the Bridgestone website, www.bridgestonetrucktires.com

FRAME AND CAB RELATED HEIGHTSThe 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 defined in this section if needed

4.) Component dimensions from bottom of rail defined 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 sides 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 railas 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 defined 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.

Section 3Dimensions


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3-24

PTO ClearancesThe following visuals are provided to help or aid in determining PTO locations and clearances. For specific dimensions please work

through your local Kenworth dealer. Multiple PTOs are shown for layout purposes only. Power equipment, i.e., drive shafts & power

pumps are not included. Body builders should select the appropriate Chelsea or Muncie 24V electric over air PTOs for their applica-

tion and customer requirements.

NOTE: All installations are only RH side PTO locations shown below are for reference only.

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

ordering PTO controls, even when installing the PTO aftermarket. Contact your local dealer for assistance.

Automatic TransmissionAllison 2000:

Section 3Dimensions


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4-1

EXHAUST AND AFTERTREATMENT INFORMATION

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

chassis. All Kenworths equipped with 2010 emission level engines will utilize Selective Catalyst Reduction (SCR). SCR

is a process in which Diesel Exhaust Fluid (DEF) is injected into the exhaust down stream of the engine. DEF is converted

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

the ammonia and NOx, turning it into water and nitrogen. For more information on the specific details of how

SCR works, please contact your local Kenworth dealer.

On most Kenworth chassis, the DEF Supply Module (or pump) is integrated into the DEF tank. Kenworth does not allow

relocation of this pump. The following schematic details how the DEF lines route to the after-treatment system.

Section 4Exhaust & Aftertreatment


36/95

4-2

Section 4

Exhaust & Aftertreatmen

DEF will freeze at approximately 11 F (-12 C). 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.


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4-3

General Guidelines for DEF SystemThe installation of the DEF tank is a critical component of the SCR system. While Kenworth does not recommend relocat-

ing 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 useable fuel capacity on the truck. The calculation to determineDEF capacity is:

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

Example: For a truck with 45 useable gallons of fuel, the equation is:

DEF required = 45 x 0.06 = 2.7 gallons or more of DEF.

PACCAR-approved DEF hoses are required when retrofitting for system to function properly. The use of unapproved

hoses for DEF lines will void warranty and may cause engine shutdown situations. The DEF pump (or Supply Module)

cannot be relocated from the DEF tank. In addition, the Medium Duty Rectangular DEF Tank that is used to meet clearback of cab requirements, cannot be relocated.

Installation Requirements and Dimensions for DEF SystemWhen 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 guide-

lines below must be followed during line routing and component placement.

When relocating the components the maximum pressure DEF hose length from Supply module to Dosing Module is 3 me-

ters (118).

Maintain a minimum of 3 (76mm) clearance to shielded exhaust components when routing DEF lines to prevent possiblemelting. If the DEF tank is relocated, the coolant lines will need to be modified. During this process, if the tank is movedforward 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 the cooling line required to complete

the installation must be installed in a straight section of the existing coolant routing lines. This process will minimize the

change in coolant flow by minimizing changes in restrictions. Increase in restriction occurs with excessive line length and

bends. Work with your local Kenworth dealer if you are unsure about the coolant line modifications.



38/95

4-4

Measurement Reference PointsFor all relocation procedures, the measurement points referenced in the guidelines are taken from the following specific

points:

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

of the DEF fluid pressure line. 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 fluid pressureline. See Figure 4-2.

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

The following relocation guidelines are dependent on exhaust configuration and DEF tank type and location.

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

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

references the vertical plane.



39/95

4-5

Figure 4-3: Orientation of Dosing Module

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 to catch

any leftover DEF when system is purged.

Figure 4-4: Routing DEF Lines and DEF Trap



40/95

4-6

Section 4

Exhaust & Aftertreatment

GENERAL EXHAUST INFORMATION

Kenworth will offer a DPF and SCR exhaust system on K270/K370 chassis in 2012, which is a Horizontal Crossover sys-

tem for K270/K370 models where DPF, SCR and tailpipe are installed side by side with LH horizontal tailpipe.

Figure 4-5: Horizontal Crossover DPF and SCR with Horizontal Tailpipe

Figure 4-5.1: Top view of Horizontal CrossoverDPF and SCR with Horizontal Tailpipe


41/95

4-7

Figure 4-5.2: Right view of HorizontalCrossover DPF and SCR with Horizontal Tailpipe

Figure 4-5.3: Back view of Horizontal CrossoverDPF and SCR with Horizontal Tailpipe



42/95

5-1

Section 5Frame Layouts and

Body Mounting

FRAME LAYOUTSThe dimensions in the frame layout section are intended to aid in layout of the chassis, and to help determine the best pos-

sible combination of fuel tanks, battery boxes, diesel particulate filter (DPF), SCR canister, and Diesel Exhaust Fluid

(DEF) tank. For your application, the layouts focus on the under cab area, with appropriate dimensional information in-

cluded 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 reference. Formore specific requirements, work with your local Kenworth Dealer. Please read the instructions carefully. The following

dimensions are consistent across the entire section to aid in the comparison of one layout option versus another.

The visual index that follows will give you a quick overview of the layout that is included.

Visual IndexTable 5-1 Symbols

Symbol DescriptionHorizontal CrossoverDPF/SCR

Battery Box

Air Dryer

DEF Tank

Fuel Tank

Batt

DEF

Fuel


43/95

5-2

Section 5Frame Layouts and Body

Mounting

Acronyms IndexThroughout the Frame Layout section you will see these acronyms. They are defined here to help you decode

the layouts.

BOC - Back Of Cab

LHUC - Left Hand under Cab

CBOC - Clear Back of CabRHUC - Right Hand under Cab

DEF - Diesel Exhaust Fluid

SOC - Side Of Cab

DSOC - Dual Side Of Cab

Figure 5-1: Horizontal Crossover DPF/SCR, LH horizontal tailpipe, RH BOC rectangular fuel tank, RH BOC rec-

tangular DEF tank and LH BOC battery box


44/95

5-3

Section 5

Frame Layouts andBody Mounting

CRITICAL CLEARANCES

Rear Wheels and Cab

CAUTION: I nsuf fi cient clearance betweenreartiresandbody structure could causedamageto thebodydur ing suspension movement. Allow atleast8inches clearance (See Figure 5-2.)

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 shouldbe

measured with the body empty. See Figure 5-2.

Figure 5-2. Minimum Clearance Between Top Of Rear Tires And Body Structure Overhang.

CAUTION: Maintain adequate clearance between back of cab and the front (leading edge) ofmountedbody. See Figure 5-2.

Note: Be sure to provide maintenance access to battery box and fuel tank fillneck.

The true distance from the centerline of the front axle to the back of the cab is 13.3 inches (337.8mm) for K270 and 11

inches for K370 (279.4 mm).It is recommended that the leading edge of the body be mounted a minimum of 4inches

(102 mm) behind the cab. The result is a minimum backofcab clearance of 17.3for K270 and 15 inches for K370 (381

mm) from the front axle to the leading edge of the body (A).

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

A

Figure 5-3. Minimum Back of Cab Clearance


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5-4


Mounting

WARNING:Ifthe frame rail flanges are modified ordamaged, the rail could failprematurely and cause anaccident. When mounting a body to the chassis, DO NOT drill holes in the upper or lowerflange of

the frame rail. Mount the body using body mountingbrackets orUbolts.

Body Mounting Using Brackets

CAUTION: Always install a spacer between the body subframe and the top flange of the frame rail. Failureto do so could result in corrosion due to dissimilar materials.

Installation of a spacer between the body subframe and the top flange of the frame rail will help preventpremature

wear of the components due to chafing orcorrosion.

Frame SillIf the body is mounted to the frame with brackets, we recommend that the frame sill spacer be made from a strip ofrubber 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 5-4.


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5-5

Section 5


Body Subframe

(Rail)

Chassis Frame

(Rail) Sill

Spacer

Figure 5-4. Spacer Between Frame Sill and Body Rail - Rubber or Plastic

BracketsWhen mounting a body to the chassis with brackets, we recommend designs that offer limited amount of relative move-

ment, bolted securely but not too rigid. Brackets should allow for slight movement between the body and the chassis.

Forinstance, Figure 55 shows a high compression spring between the bolt and the bracket.

Figure 5-5. High Compression Spring Between theMounting Bolt and Upper Bracket

Figure 5-6. Rubber SpacerBetween Brackets

Another possibility is mounting a rubberspacer between the brackets. See Figure 5-6.

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

Extreme frame racking and mountings that are too rigid, could cause damage to the body. This is particularly true with

tanker installations.

Mounting HolesWhen 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 5-7. The hole diametershould not exceed the bolt diam

eterby more than .060 inches (1.5 mm).

Upper

Frame

Flange

Lower Frame

Flange

A

A or B Equal to or

GreaterThan 2 Inches

(50 mm)

Figure 5-7. Hole Locations Guidelines for

Frame Rail and Bracket


47/95

5-6


Mounting

Figure 5-8. Crossmember-Gusset Hole Pattern Requirements. [inch(mm)]

Frame Drilling

WARNING: When mounting a body to the chassis, DO NOT drill holesin theupper or lower flange of the frame rail. If the framerail flangesare modified or damaged, the rail could fail prematurely and

cause an accident. Mount the body using body mounting brack-

ets or Ubolts.

WARNING: Use care when drilling the frame web so the wires and air lines routed inside the railare not damaged, Failure to do so could cause an inoperable electrical or air sys-tem circuit.

WARNING:Do not drill new holes any closer than 2 inches (50 mm) to existing holes. Framedrilling affects the strength of the rails.

Hole Location GuidelinesHoles must be located from the flangeas indicated in Figure 5-7. They must be no closer than 2 inches (50 mm) to

each other.

Note: Ifyourdesignpermitsplacement of body mountingbrackets at crossmember locations, youcan use the crossmember gussetbolt holes forbody mounting. See Figure 5-8

BODY MOUNTING USING UBOLTSSpacers

Ifthe body is mounted to the frame with Ubolts, use a hardwood sill [minimum 1/2 inch (12 mm) thick]

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


48/95

5-7

Section 5


WARNING!Do not allow the frame rails orflanges to deform when tightening the Ubolts. It willweaken 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 flanges.

Use ahardwood spacer between

the bottom flange and the Ubolt to prevent the Ubolt from notching the frameflange.

See Figure 5-9.

Body Structure

Wood Sill 0.5 (12mm) Minimum

TruckFrame

Frame Rail Spacer

(Fabricated Steel or

Hardwood)

U-Bolt

U-Bolt Spacer(Hardwood)

Figure 5-9. Acceptable U-Bolt Mounting with Wood and Fabricated Spacers

WARNING!

CAUTION:

Do not allow spacers and other body mounting parts to interfere with brake lines, fuel lines, or

wiring harnesses routed inside the frame rail. Crimped ordamagedbrake lines, fuel lines, orwir-

ing could result in loss of braking, fuel leaks, electrical overload or a fire. Carefully inspect the in-

stallation to ensure adequate clearances forair brake lines, fuel lines, and wiring.See Figure 510.

Mount Ubolts so they do not chafe on frame rail. Failure to do so could result inpremature wear

of the U-bolt or frame rail.

Frame Rail

AirLines and Wiring

Harness

CheckClearance

Space for Air

Lines and Wiring

U-Bolt

Frame Rail Spacer

(Hardwood orSteel

U-Bolt Spacer

Figure 5-10. Clearance Space for Air Lines and Cables


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5-8

WARNING! Do not notch frame rail flanges to force a Ubolt fit. Notched or damaged frameflanges could re-sult in premature frame failure. Use a larger size Ubolt. Use a hardwood spacer as shown in Fig-ure 5-9.

REAR BODY MOUNT

When Ubolts are used to mount a body, we recommend that the last body attachment be made with a fishplate bracket.

See Figure 5-11. This provides a firm attaching point and helps prevent any relative fore or aft movement between the

body and frame.

Body Structure

Frame Rail

Figure 5-11 Example ofFishplate Bracket at Rear End of Body, used with U-Bolts


Mounting


50/95

6-1

Section 6Frame Modifications

FRAME MODIFICATIONS

IntroductionThe K270/K370 offers customer specified wheelbases, so, in most cases frame modifications to produce a certain wheel-

base should not be necessary.

However, some installations may require slight modifications, while otherinstallations will require extensive

modifications. Sometimes an existing dealerstockchassis may need to have the wheelbase changed to betterfita customers application. The modificationsmay be as simple as shortening orlengthening the frame cutoff, or

they may be as complex as changing the wheelbase.

DRILLING RAILS

Location and Hole PatternIfholes need to be drilled to attach anything to the rail, see SECTION 5 BODYMOUNTING formore information. Follow

the general spacing and hole location guidelines. See Figure 5-7.

WARNING!

WARNING!

CAUTION:

WARNING!:

CAUTION:

CAUTION:

When mounting a body to the chassis, DO NOT drill holes in the upper or lowerflange of the

frame rail. Ifthe frame rail flanges are modified ordamaged, the rail could failprematurely and

cause an accident. Mount the body using body mountingbrackets orUbolts

Do not drill new holes any closer than 2 inches (50 mm) to existing holes. Frame drilling af-

fects the strength of the rails.

An appropriately sized bolt and nut must be installed and torquedproperly 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 cause an inoperable electrical or airsystem circuit.

Never use a torch to make holes in the rail. Use the appropriate diameterdrillbit. Heat

from a torch will affect the materialproperties of the frame rail and could result in frame

rail cracks.

Hole diametershould not exceed the bolt diameterby more than .060 inches (1.5 mm).

Oversized holes could result in excessive frame wear around the hole.

Hole pattern dimensions forcrossmember designs see Figure 5-8


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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 normallybe confinedto with-

in 1 to 2 inches (25 to 50 mm) of the flame cut and may not adversely affect the strength of the chassis orbody installation.

The frame cutoff can be lengthenedby adding frame extenders.

WARNING!Do not drill new holes any closer than 2 inches (50 mm) to existing holes. Frame drilling af-fects the strength of the rails.

Frame Insert

A frame insert must be added after welding a frame rail extension to compensate forlost strength.The insert shouldbe of

the same material as the frame member, or of steel, and at least equal to the frame rail in thickness. Attachment ofthe insert to the frame should be made with Ream-Fit heat-treated bolts, 5/8 in. (16 mm) dia. or the next larger size. Both the

reinforcement and frame holes should be reamed to provide a fit 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 in. (610 mm) on either side ofthe crack to in-

sure an even distribution ofstresses. Cut the ends of the insert at 45 as shown in Figure 6-2 unless the insert extends to the

end of the frame.

Figure 6-1. Detail of Frame Figure 6-2. Frame Insert

Extension and Joint Welding


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Section 6

Frame Modifications

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

frame flanges than the presentboltpattern.

Ifthe insert isplaced in a section of the main frame where few bolts are located, additional bolts are required. Use the

following guideline forlocating additional bolt holes.

ChangingWheelbaseWe 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!

When changing the wheelbase, be sure to follow the driveline manufacturers recommenda-

tions fordriveline length or angle changes. Incorrectly modified drivelines can fail prematurely

due to excessive vibration. This can cause an accident.

When changing the wheelbase, a continuousblank 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 and the insert/outsert. Failure to do so could cause excessive stress in the original

rail due to additional holes.

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 manufacturerforappropriate recommendations.

WARNING! Do not drill new holes any closer than 2 inches (50 mm) to existing holes. Frame drilling affectsthe strength of the rails.

Before the rear suspension is relocated, check the new location of the spring hangerbrackets. The new holes forthe 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! When relocating a suspensionbracket, do not mount it on the extended (added) section of aframe rail.Thesuspension loading could result inpremature failure of the added section splice.

This could cause an accident. Use care when planning the wheelbase so that the rear suspen-

sionbracket is always mounted on the original rail section. See Figure 6-3.

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 6-3.

When reducing the wheelbase, we recommend that the suspensionbe 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 6-3.


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WARNING! Do not drill new holes any closer than 2 inches (50 mm) to existing holes. Frame drilling affects thestrength of the rails.

Before the rear suspension is relocated, check the new location of the spring hangerbrackets. The new holes forthe springhanger brackets must not overlap existing holes and should not come any closer than 2 inches (50 mm) to existing

holes. Mount the suspension Brackets On the

Original Rail (see frame insert section &figures 6-1 and 6-2.)

Extended WheelbaseDo Not Mount the

Suspension Bracket

On the Added

Frame Rail

Original Wheelbase

Relocated Rear

Suspension

Shortened Wheelbase

Figure 6-3 Comparison of Original, Shortened, and Extended Wheelbases.

Crossmembers

Cut Frame at Rearto

Obtain Desired Cutoff

Afterchanging a wheelbase, an additional crossmembermay be required to maintain the original frame strength. The

maximum allowable distance between adjacent crossmembers is 60 inches (1524 mm). Ifthe distancebetween adja-

cent crossmembers exceeds this dimension, add a crossmember between them. See Figure 6-4.

Less Than 60

Before Wheelbase is Lengthened

GreaterThan 60

Additional Crossmember

Figure 6-4. Crossmember Added When Distance Exceeds 60 Inches (1524 mm)


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ELECTRICAL

IntroductionElectrical wiring can sometimesbe very frustrating. This is especially true when adding circuits to an existing setup.

Through the use of an optional body harness and additional spare circuits, we have tried to reduce the complexity as-

sociated with adding common circuits to a body installation.

Note:The most common circuits that body builders may need are pre-connected to this optional wiringharness.

The new body related circuits can be addedby connecting the added circuit wires to the appropriate wires in this harness.

ELECTRICAL CIRCUITS

Capacity

WARNING!Do not install an electrical circuit that requires more amperage (electrical capacity) than what isavailable in the specific chassis circuit. An overloaded circuit could cause a fire. Compare the

amperage requirements of the new circuit to the electrical current capacity of the existing

chassis circuit before adding the body or other equipment.

When adding an electrical circuit, you must know the current capacity (amperes) ofeach circuit.

The capacity of the existing system in the chassis must be enough to power the additional circuit. The new circuit will require a

certain amount of power to operate; so, the existing (battery or alternator) power source must have the capacity toprovide addi-

tional power or the new circuit will not function properly.

Check the current (ampere) demand of the circuit to be added. Compare it to the current capacity of the circuit you are connecti

into. The current carrying capacity of the wires, controls, switches, and circuitbreakers that provide current to the circuit must be

equal to orgreaterthan the demand of the added circuit otherwise these components may not workproperly. See Table 71.1 an

forrelevant circuit information.

Section 7Electrical


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Dashboard Identification.

Note: For switches 512, use switch part number 1435592. For switch 13, use switch part number 1425594. Both switch numbers are 2-position switches.

Figure 7-1. Instrument Layout

1 ISO diagnostic plug (powertrain) 8 Spare switch

2 OBD diagnostic plug (cab) 9 Spare switch

3 Radio recess 10 Spare switch

4 Accessory plug 12V/10A 11 PTO

5 Spare switch 12 Spare switch

6 Spare switch 13 Dump Valve Switch

7 Spare switch (Optional)

Section 7Electrical


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Section 7

Electrical

Data Bus Communication

Abbreviation List:

ABS-E AntilockBrakingSystemTCM TransmissionControlModuDIP-4 DigitalInstrumentPackMTCO DigitalTachographDCU DosingControlUnitECM EngineControlModuleSWS SteeringWheelSwitchesVIC3 Lite VehicleIntelligenceCenter

Figure 7-2. Data Bus Communication Architecture


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REMOVAL AND INSTALLATION

Removal and Installation, Switches

Removing switches

1.Insert a feeler gauge of approx. 1 mm (0.04 in) thick between the switch and the panel at the side of the finger-sized depression (A), it touches the inside of the panel.

2.Remove the switch from its locked position by carefully moving the feeler gauge in the direction of the arrow (B).

3.Carefully remove the switch from the panel. In doing so, ensure that the connector lock does not catch behind the panel, causing the nector to fall behind the panel.

If necessary, remove the switch from the connector.

nstalling switches

1.Connect the connector.2.Insert the switch into the opening in the panel and press until you can feel it locked.

Removal and Installation, Dashboard Panels

Note: Removal and installation of the dashboard panels have indicated in the proper sequence. In order to remove each subsequent panel, t

anels described in the preceding text must have been removed.

Removing steering column dashboard panel

1.If necessary, remove the floor mat.2.Using the steering column setting, move the steering wheel to its highest possible position.

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3.Remove the attachment bolts (1) and the panel plug (2) and remove the steering column dashboard panel.

Removing lower dashboard panel, co-drivers side

1.Remove the attachment bolts from the lower dashboard panel on the co-driver's side. Remove the lower dashboard panel on the co-driver's side.

Removing engine tunnel dashboard panel

1.Remove the attachment bolts (1) and panel plugs (2). Remove the engine tunnel cover panel.2.Disconnect the 12-V power supply connector at the rear.

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Removing instrument panel

1.Remove the attachment bolts (1) from the decorative strip (2) around the instrument panel (3).

2.Pull the fixing clamps (see arrows) which attach the decorative strip (2) to the dashboard panel carefully out of the dashboard panel.3.Remove the attachment bolts from the instrument panel (3).4.Remove the instrument panel (3).5.Remove the connector from the instrument panel (3).

Removing lower dashboard panel, drivers side

1.Remove the attachment bolts (1). Remove the dashboard panel.

2.Disconnect the headlamp height adjustment unit connector at the rear.3.Remove the attachment bolts from the connector block at the rear of the dashboard panel.4.Remove the connector block.

Removing surrounding frame cover panel

1.Remove the attachment bolts (1) in the surrounding frame.2.Take the cover panel out of the surrounding frame.

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Removing upper cover

1.Remove the attachment bolts from the underside of the cover.2.Tilt the cover upwards out of the upper cover panel.

Removing central console control panel

1.Remove the switches (3) from the central console control panel (5).2.Remove the ashtray (2) from the central console control panel (5).

3.Remove the attachment bolts (1) from the central console control panel (5).4.Remove the central console control panel (5).5.Disconnect the cigarette lighter (4) connector.

Removing dashboard panel on right-hand side

1.Remove the attachment bolts from the dashboard panel.2.Remove the connector of the stepwell lighting door switch.

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Removing upper dashboard panel, drivers side

1.Remove the attachment bolts (1) from the radio panel (2).2.Remove the attachment bolts (3) from the dashboard panel.3.Cut the cable ties that attach the wiring harnesses to the dashboard panel.

4.Remove the dashboard panel. Unhook the radio panel (2) out of the dashboard panel.

5.Disconnect the connectors of the light switch (4) and the stepwell lighting door switch.

nstalling upper dashboard panel, drivers side

1.Fit the connectors of the light switch (4) and the stepwell lighting door switch.2.Fit the dashboard panel. Hook the radio panel (2) into the dashboard panel.

3.Attach any removed cable harnesses to the dashboard panel using cable ties.4.Fit the attachment bolts (3) for the dashboard panel.5.Fit the attachment bolts (1) of the radio panel (2) into the dashboard panel.

nstalling dashboard panel, right-hand side

1.Fit the connector of the stepwell lighting door switch to the right-hand side dashboard panel.2.Fit the right-hand side dashboard panel using the attachment bolts.

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nstalling central console control panel

1.Fit the cigarette lighter (4) connector to the rear of the central console control panel (5).2.Fit the central console control panel (5) to the dashboard.3.Connect the switches (3) of the central console control panel (5) to the connectors. Fit the switches (3) to the central console control

el (5).

4.Attach the central console control panel (5) using the attachment bolts (1).

5.Fit the ashtray (2) into the central console control panel (5).

nstalling upper cover

1.Hook the cover into the cover panel. Attach the cover to the cover panel using the attachment bolts.

nstalling surrounding frame cover panel

1.Fit the cover panel into the surrounding frame using the attachment bolts (1).

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nstalling lower dashboard panel, drivers side

1.Fit the connector block to the rear of the dashboard panel using the attachment bolts.2.Fit the connector of the headlamp height adjustment unit to the dashboard panel.3.Fit the dashboard panel using the attachment bolts (1).

nstalling instrument panel

1.Fit the instrument panel (3) connector.2.Fit the instrument panel (3) to the dashboard panel using the attachment bolts.3.Push the decorative strip (2) back onto the dashboard panel using the fixing clamps. Fix the decorative strip (2) to the dashboard pan

using the attachment bolts (1).

nstalling engine tunnel dashboard panel

1.Fit the 12-V power supply connector to the rear of the engine tunnel dashboard panel.2.Fit the dashboard panel to the engine tunnel using the attachment bolts (1) and the panel plug (2).

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nstalling lower dashboard panel, co-drivers side

1.Fit the lower dashboard panel on the co-driver's side using the attachment bolts.

nstalling steering column dashboard panel

1.Fit the steering column dashboard panel using the attachment bolts (1) and the panel plug (2).

REMOVAL AND INSTALLATION, COMPLETE DASHBOARDRemoving dashboard

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1.Disconnect the earth lead from the battery terminal.2.Remove the attachment bolts and panel plug (6) and remove the steering column cover panel.3.Remove the attachment bolts (1), (2) and (3) and remove the cover panel on the co-driver's side.4.Remove the attachment bolts (4) and the panel plugs (5) and remove the engine tunnel cover panel. Remove the12-V power supply c

nector.

5.Remove the attachment bolts (7) and remove the upper cover panel.6.Open the grille.7.Remove the attachment bolt (1).8.Remove the protective cover by pressing the retainer (2) to one side.

k270 k370 body builder manual 2012

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