t470bodybuildermanual

7/31/2019 t470bodybuildermanual

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Kenworth T470

Body Builder Manual


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Kenworth T470Body Builder Manual


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Body Builder Manual

Contents

08/06

iv

Section 1: introduction 1-1

Section 2: Safety and compliance 2-1

SAFETY SIGNALS 2-1

FEDERAL MOTOR VEHICLE SAFETY STANDARDS COMPLIANCE 2-2

Section 3: dimenSionS 3-1

DIMENSIONS 3-1ABBREVIATIONS 3-1

TURNING RADIUS 3-1

AxLE TRACk AND TIRE wIDTH 3-4

OVERALL DIMENSIONS 3-5

T470 STRAIGHT HOOD 3-6

T470 ExTENDED DAY CAB 3-7

RIDE HEIGHTS 3-8

REAR SUSPENSION LAYOUTS 3-10

REYCO 79kB SINGLE REAR AxLE 3-10

REYCO 102 TANDEM REAR AxLE 3-11

NEwAY AD 123 SINGLE REAR AxLE 3-12

NEwAY AD 246 TANDEM SUSPENSION 3-13NEwAY AD 369 TRIDEM SUSPENSION 3-18

HENDRICkSON PRIMAAx TANDEM SUSPENSION 3-14

HENDRICkSON HMx TANDEM SUSPENSION 3-15

HENDRICkSON RT TANDEM SUSPENSION 3-16

HENDRICkSON RT TANDEM SUSPENSION 3-17

kENwORTH AG 380 TANDEM SUSPENSION 3-18

kENwORTH AG 400/460 TANDEM SUSPENSION 3-19

kENwORTH AG 400L TANDEM SUSPENSION 3-20

kENwORTH AG 460 60 AxLE SPACING 3-21

CHALMERS 856-46 TANDEM SUSPENSION 3-22

PUSHER AxLES 3-23

GROUND CLEARANCE 3-25

ExHAUST INFORMATION 3-27

PTO CLEARANCES 3-28

FRAME LAYOUTS 3-30

FRAME LAYOUT INDEx 3-31

CHARTS 3-34

Section 4: Body mounting 4-1

FRONT FRAME DIMENSIONS 4-1

FRAME INFORMATION 4-2

CRITICAL CLEARANCES 4-2

BODY MOUNTING USING BRACkETS 4-3

MOUNTING HOLES 4-5

BODY MOUNTING USING UBOLTS 4-6REAR BODY MOUNT 48

Section 5: frame modificationS 5-1

FRAME MODIFICATIONS 5-1

DRILLING RAILS 5-1

MODIFYING FRAME LENGTH 5-2

CHANGING wHEELBASE 5-3

CROSSMEMBERS 5-5

wELDING 5-6

TORqUE REqUIREMENTS 5-7


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Body Builder Manual

Contents

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v

Section 6: electrical 6-1

ELECTRICAL 6-1

MULTIPLEx INSTRUMENTATION 6-1

INTERIOR IDENTIFICATION 6-2

ACCESSING GAUGES AND SwITCHES 6-9

ACCESSING SwITCHES IN THE UPPER DASH 6-15

TELLTALE SYMBOLS 6-18ADDITIONAL SPARE CIRCUITS 6-21

MULTIFUNCTION TURN SIGNAL STALk 6-24

REMOTE PTO/THROTTLE HARNESS 6-25

Section 7: routingS 7-1

DEFINITIONS 7-1

ROUTING REqUIREMENTS 72

appendix a: vehicle identification a-1

LABELS A-1

COMPONENT IDENTIFICATION A-3


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Figures

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vi

figure 2-1. INCOMPLETE VEHICLE CERTIFICATION DOCUMENT 2-2

figure 2-2. LOCATIONS OF CERTIFICATION LABELS - DRIVERS DOORAND FRAME 2-2

figure 3-1. PROSPECTER TURN CIRCLE ANALYSIS 3-3

figure 4-1. MINIMUM CLEARANCE BETwEEN TOP OF REAR TIRES AND

BODY STRUCTURE OVERHANG 4-2figure 4-2. MINIMUM BACk OF CAB CLEARANCE 4-3

figure 4-3. SPACER BETwEEN FRAME SILL AND BODY RAIL -RUBBER OR PLASTIC 4-4

figure 4-4. HIGH COMPRESSION SPRING 4-4

figure 4-5. RUBBER SPACER BETwEEN BRACkETS BETwEEN THEMOUNTING BOLT AND UPPER BRACkET 4-4

figure 4-6. CROSSMEMBER-GUSSET HOLE PATTERNREqUIREMENTS [INCH (MM)] 4-5

figure 4-7. ACCEPTABLE U-BOLT MOUNTING wITH wOOD ANDFABRICATED SPACERS [INCH (MM)] 4-6

figure 4-8. CLEARANCE SPACE FOR AIR LINES AND CABLES 4-7

figure 4-9. ExAMPLE OF FISHPLATE BRACkET AT REAR END OF BODY,USED wITH U-BOLTS 4-8

figure 5-1. DETAIL OF FRAME ExTENSION AND JOINT wELDING 5-2

figure 5-2. FRAME INSERT 5-3

figure 5-3. COMPARISON OF ORIGINAL, SHORTENED, ANDExTENDED wHEELBASES 5-4

figure 5-4. CROSSMEMBER ADDED wHEN DISTANCEExCEEDS 60 INCHES (1524 MM) 5-5

figure 6-1. CECU LOCATION 6-2

figure 6-2. INSTRUMENT CLUSTER COMPONENTRY 6-3

figure 6-3. CVSG GAUGES 6-5

FIGURE 6-4 MULTIPLExED INSTRUMENTATION BLOCk DIAGRAM 6-6

figure 6-5. INSTRUMENTATION HARNESS INTERFACE DIAGRAM 6-7

figure 6-6. FIREwALL AIR JUNCTION BLOCk 6-8figure 6-7. FUEL FILTER RESTRICTION PRESSURE GAUGE SENSOR

LOCATION (TYPICAL) 6-8

figure 6-8. TELLTALE SYMBOL STANDARD CARDS 6-18

figure 6-9. BLANk TELLTALE CARD 6-18

figure 6-10. TELLTALE ICONS 6-19

figure 6-11. SPARE BULLET CONNECTORS 6-22

figure 6-12. SPARE PIGTAIL CONNECTOR 6-22

figure 6-13. SPARE RELAY CONNECTORS 6-23

figure 7-1. CLAMP AND BUTTERFLY CLAMP 7-1

figure 7-2. BUTTERFLY TIE 7-1

figure 7-3. TIE STRAP 7-1

figure 7-4. HEAVY DUTY MOUNT 7-2

figuer 7-5. DEFINITION OF MEASUREMENTS 7-4

figure a-1. VEHICLE IDENTIFICATION NUMBER A-3

figure a-4. FRONT AxLE IDENTIFICATION A-4

figure a-5. AxLE IDENTIFICATION A-5


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Tables

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vii

taBle 3-1. ABBREVIATIONS USED 3-1

taBle 3-2. TURNING RADIUS 3-1, 3-2

taBle 3-3. AxLE TRACk 3-3

taBle 3-4. RIDE HEIGHTS 3-8

taBle 3-5. REAR SUSPENSION - REYCO 79kB 3-10

taBle 3-6. REAR SUSPENSION - REYCO 102 3-11

taBle 3-7. REAR SUSPENSION - NEwAY AD SINGLE 3-12

taBle 3-8. REAR SUSPENSION - NEwAY AD TANDEM 3-13

taBle 3-9. REAR SUSPENSION - HENDRICkSON PRIMAAx TANDEM 3-14

taBle 3-10. REAR SUSPENSION - HENDRICkSON HMx TANDEM 3-15

taBle 3-11. REAR SUSPENSION - HENDRICkSON RT TANDEM 3-16

taBle 3-12. REAR SUSPENSION - HENDRICkSON RT TANDEM 3-17

taBle 3-13. REAR SUSPENSION - kENwORTH AG 380 3-18

taBle 3-14. REAR SUSPENSION - kENwORTH AG 400/460 3-19

taBle 3-15. REAR SUSPENSION - kENwORTH AG 400L 3-20

taBle 3-16. REAR SUSPENSION - kENwORTH AG460 3-21

taBle 3-17. REAR SUSPENSION - CHALMERS 856-46 3-22

taBle 3-18. GROUND CLEARANCE 3-25taBle 3-19. GROUND CLEARANCE 3-26

taBle 3-20. TAILPIPE STACk HEIGHT 3-27

taBle 3-21. UNLADEN STACk HEIGHT 3-27

taBle 3-22. FRAME LAYOUT DIMENSIONS 3-30

taBle 3-23. VISUAL INDEx 3-30







taBle 3-30. FRAME LAYOUT DIMENSIONS 3-40taBle 3-31. FRAME LAYOUT DIMENSIONS 3-41




taBle 4-1. SINGLE STEEL RAILS 4-2

taBle 4-2. INSERTED STEEL RAILS 42

taBle 5-1. CUSTOMARY GRADE 8 UNF OR UNC 5-7

taBle 5-2. US CUSTOMARY GRADE 8 METRIC CLASS 109 5-7

taBle 6-1. TELLTALES POSITION AND COLOR 6-20

taBle 6-2. TSM GUIDELINE 6-24

taBle 6-3. 2007 CUMMINS ISL 6-25

taBle 7-1. ExHAUST - SYSTEM CLEARANCE 7-4taBle a-1. MODEL YEAR DESIGNATIONS 7-5


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Section 1

Introduction

08/06

1-1

This manual as created to provide body builders ith appropriate information and guidelines

useful in the body planning and installation process This information ill be helpful hen installingbodies or other associated euipment

This manual contains appropriate dimensional information, guidelines for mounting bodies, guide-lines for modifying frames, electrical iring information, and other information useful in the bodyinstallation process

The Body Builder Manual can be very useful hen specifying a vehicle, particularly hen the body

builder is involved in the vehicle denition and ordering process. Early in the process, professionalbody builders can often contribute valuable information that reduces the ultimate cost of the bodyinstallation

In the interest of continuing product development, kenorth reserves the right to change speci-cations or products at any time without prior notice. It is the responsibility of the user to ensurethat he is oring ith the latest released information Chec kenorthcom for the latest released

version

If you reuire additional information or reference materials, please contact your local kenorthdealer


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Section 2

Safety & Compliance

08/09

2-1

Safety SignalS

weve put a number of alerting messages in this boo Please read and follo them They are there for your protectionand 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 ords are used to indicate hat ind of message is going to follo Pay special attention to

comments prefaced by wARNING, CAUTION, and NOTE Please dont ignore any of these alerts

Ws, s, s

when you see this ord and symbol, the message that follos is especially vital It signals a

zs s hich, if not avoided, could result in death or serious injuryThis message ill tell you hat the haard is, hat can happen if you dont heed the arning,

and ho to avoid it

Eample: Warning! B s s bk s reqireet. A icrrect pecied circit breaker cd ret i a

eectrica verad r re itati. F te iftate itaati itrctiad e a circit breaker it te receded capacit.

Signals a zs s hich, if not avoided, could result in minor ormoderate injury or damage to the vehicle

Eample: caution: n s k . us b.

Provides general information: for eample, the note could arn you on ho to avoid damagingyour vehicle or how to drive the vehicle more efciently.

Example: Note: Be sure to provide maintenance access to the battery box and fuel tank llnec

Peae take te tie t read tee eae e ee te, ad reeber:

Warning

Indicates a potentially haardous situation hich, if not avoided, could result in death or serious injury

caution

Signals a potentially haardous situation hich, if not avoided, could result in minor or moderateinjury or damage to the vehicle

noteUseful information that is related to the topic being discussed

Warning

caution

note


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Section 2

Safety & Compliance

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2-2

federal motor vehicle SafetyStandardS compliance

As an Original Euipment Manufacturer (OEM), kenorth Truc Co ensures that our products comply ith all applicable

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

incomplete hen it left the build plant See net section and Appendi A for additional information

Icpete Veice Certicati

An Incomplete Vehicle Document is shipped ith the vehicle, certifying that the vehicle is not complete See Figure 21

In addition, afxed to the drivers side door frame or edge is an Incomplete Vehicle Certication label. See Figure 22 Forfurther information on Vehicle Certication and Identication, see APPENDIx A VEHICLE IDENTIFICATION

These documents list the US or Canadian Federal Motor Vehicle Safety Standard regulations that thevehicle complied ith hen it left the build plant You should be aare that if you add, modify or alter any

of the components or systems covered by these regulations, it is your responsibility as the Intermediateor Final Stage Manufacturer to ensure that the complete vehicle is in compliance ith the particular

regulations upon completion of the modications.

figure 2-1. Incomplete Ve-

hicle Certication Document

figure 2-2. Locations of Certica-

tion Labels - Drivers Door and Frame

note

US EPA Noise Label (US registered vehicles only)

Final Stage ManufacturerLabel to be Installed byFinal Stage Manufacturer

Chassis SerialNumber

Major Components andweights Label

Incomplete VehicleCertication Label

Safety Mar (CanadianRegistry Only)

Tire, Rim andweight RatingData label

As the Intermediate or Final Stage Manufacturer, you should retain the Incomplete Vehicle Document for your records Inaddition, 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 modications), you should afx your certication label to the vehicle asrequired by Federal law. This tag identies you as the Intermediate or Final Stage Manufacturer and certies that the veh

complies ith Federal Motor Vehicle Safety Standards (See Figure 22) Be advised that effective September 1, 2006, a nregulation affects the intermediate and nal stage manufacturer certication process and documentation.

In part, if the nal stage manufacturer can complete and certify the vehicle within the instruction in the incomplete vehicledocument (IVD) the certication label would need a statement that reads, This vehicle has been completed in accordanceith the prior manufacturers IVD here 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 certied 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 nstage manufactures certication 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)


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Section 2

Safety & Compliance

08/09

2-3

These statements are just part of the changes to the new certication regulation. Please refer to the February15, 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://canadagaettegcca/partII/2002/20020213/html/sor55-ehtml and

http://tcgcca/acts-regulations/GENERAL/M/mvsa/regulations/mvsrg/toc_mvsrghtm for the regulations

Or contact:

Transport CanadaToer C, Place de Ville, 330 Spars Street

Ottaa, Ontario k1A 0N5(613) 990-2309

TTY: 1-888-675-6863

ns esss rs

Kert deied te 2007 eat te t eet te reqireet f tepecic eie afactrer. Tee dei eet r eceed te EPA ei-

ss s 2007 .

A a rt pririt Kert reced tat te deaer / cter / bd

bider aitai te te a deied ad itaed b Kert.

If i certai itati te eat te eed t be revied, it i be terepibiit f te difi part t f te ideie etabied b

b s s-. ts s b s sb-

tr. Be advied tat te eat te ad reqireet are cpe ade f te factr tat i ave t be cidered i te dicati are:

eat back prere, cati & trctra ti reqireet f tedpf (eie afactrer prvide arrat fr te DPF) ateria ed fr te

pipe, eakae reqireet, teperatre drp, etc. ad tee dicatii ave t be veried ad teted b te ca eie ditribtr.

If te died te i apprved b te eie afactrer Kert iarrat te Kert cpet ed.

Itaati ad rkaip i te repibiit f te difi part.

caution


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Section 3

Dimensions

08/09

3-1

dimenSionS

This section has been designed to provide enough information to successfully layout chassis in the body planningprocess Optional euipment may not be depicted Please contact your local kenorth dealer if more dimensional

information is desired

aBBreviationSThroughout this section, and in other sections as ell, abbreviations are used to describe certain characteristics on your

vehicle The chart belo lists the abbreviated terms used

taBle 3-1. Abbreviations Used

CA BACk OF CAB TO CENTERLINE OF REAR AxLE OR CENTERLINE OF TANDEMS ON TANDEM SUSPENSION

EOF FRAME RAIL OVERHANG BEHIND REAR AxLE MEASURED FROM THE CENTERLINE OF TANDEMS

FS FRONT SUSPENSION HEIGHT

RS REAR SUSPENSION HEIGHT

wB wHEELBASE

SOC SIDE OF CABBOC BACk OF CAB

turning radiuS

Approximate turning radius specications are listed in the following tables as a general guide. It is important to note that

optional components may alter the results

taBle 3-2. Turning Radius

m S g Frt Ae f W f tr

SssW Bs

es cb cb t

Radi (ft)

T470SingleTAS 65

Dana SpicerE-1202I 12k

Accuride 28487225 x 825

BridgestoneR287

295/75R225

Tandem52 AleSpacing

181 28

193 295

201 305

213 32

220 33

232 345

240 355

252 37

260 38

272 395

280 405

291 42

303 435

323 46

331 47

TABLE 3-2 CONTINUES ON NExT PAGE


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Section 3

Dimensions

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3-2

m S g Frt Ae f W f tr

SssW Bs

es cb cb t

Radi (ft)

T470Dual

TAS 65

Dana SpicerEFA-20F4 20kStandard Trac

Alcoa 82365225 x 1225

BridgestoneM844

425/65R225

Tandem52 AleSpacing

181 315

193 335

201 345

213 365

220 375

232 39

240 40

252 42

260 43

272 45

280 46

291 475

303 495

323 525

331 535

TABLE 3-2 CONTINUED


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Section 3

Dimensions

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3-3

ps t c ass:

Please see Figure 3-2 as an example of Kenworths turn circle calculation made in Prospector for your specic chassis.

Your local kenorth dealer can provide this information to you

figure 3-1. Prospector Turn Circle Analysis

Please consult your local Kenworth Dealer for this information, as it is chassis specic.

T470

T470


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Section 3

Dimensions

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3-4

KEnwoRTh AxlE TRACK/TIRE wIDTh summARy

Ae - Drive W t Crati tkd a

o Wd B

Dana Spicer D46-170(H)(P)46k Dual

Alcoa 88364225x825

BR M726EL11R225

4-4 733 978


Alcoa 98364245x825

BR M726EL11R245

4-4 736 980

Dana Spicer D46-170w(H)(P)46k Dual wide Trac

Alcoa 88364225x825

BR M726EL11R225

4-4 792 1037


Alcoa 98364245x825

BR M726EL11R245

4-4 795 1039


Alcoa 82360225x1225

BR M844F425/65R225

2-4 727 889


Alcoa 82360225x1225

BR M844F425/65R225

2-4 787 949

Ae - steer W t Bk d

t

tk

d a

o W

d B

Dana Spicer E-1322I 132k Alcoa 98364

245x825

BR R250F

11R245

Cast 802 910

Dana Spicer E-1322w 132k Alcoa 98364245x825 BR R250F11R245 Cast 822 930

Dana Spicer D2000 20k Alcoa 82365

245x1225

BR M844F

425/65R225

Cast 865 1027

Dana Spicer D2000 20k Alcoa 82364

245x1225

BR M844F

425/65R225

Cast 826 988

Ae - Per n-steerabe W t Wo

tkd a

o Wd B

NS PSHR: wCAL ATLASStd Trac (725) 16k GAwR

Alcoa 82365245x1225

BR M844F425/65R225

Default-Same as RR

794 956

NS PSHR: wCAL ATLASwide Trac (775)

Alcoa 82365245x1225

BR M844F425/65R225

OptionSame as FR

711 873

taBle 3-3. Ale Trac

axle tracK and tire WidthThe dimensions provided in this section are representative of some typical product combinations The purpose of this section isto demonstrate some of the typical dimensions

Ale Trac: The distance beteen the dual tire centerlines on a dual tire arrangement or the distance beteen the tire centerlineson a single tire arrangement

width: The distance over the outermost tire sideall to sideall

These dimensions may be signicant to the following:

Appearance relative to other tires and chassis mounted euipment

Load carrying capacity Different heel disc offset can have a positive or negative impact on the ale carrying capacity of theale


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Section 3

Dimensions

08/09

3-5

overall dimenSionS

This section includes draings and charts The Etended Day Cab is also included

On the pages that follo, detail draings sho particular vies of each vehicle, all dimensions are in inches (in) They

illustrate important measurements critical to designing bodies of all types See the Contents at the beginning of themanual to locate the draing that you need

Note: To determine overall height please locate the chart Table 3-4 on page 3-8 and 3-9 and add that value to the heightAll heights are given from the bottom of the frame rail

Kenworth also offers .dxf les and frame layouts of ordered chassis four weeks prior to build. Please speak with yoursalesman to reuest this feature hen specifying your chassis

T470 FIxED gRIllE hooD w/o ExTEnDED FRonT FRAmE

The following drawings are shown with standard chassis components and the T470 xed grille hood.


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Section 3

Dimensions

08/09

3-6

t470 fixed grille hood With extended front frame

The following drawings are of a T470 xed grille hood with the optional extended front frame. These extended frame railscan be used ith or ithout FEPTO adapters


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Section 3

Dimensions

08/09

3-7

extended day caB

It is important to note that the Etended Day Cab ill increase any of the models bumper to bac of cab dimension andfront ale to bac of cab dimension by 57 The height (from the bottom of the frame rail) ill be 869 Belo draings

shown with T470 xed grille hood.

Suspension heights are measured from the centerlines of the ale spindle to the bottom of the frame rail Add the tireradius dimension to determine overall height to the bottom of the frame rail Note: The frame rail height itself ill not affectthe overall cab height as all components are located from the bottom of the frame rail


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Section 3

Dimensions

08/09

3-8

ride heightS

The front (FS) and rear (RS) suspension ride heights are provided as a basic tool to determine the overall height of thecab, height of ehaust components, and frame heights The heights are all calculated from the centerlines of the ales,

please be sure to include the tire radius dimension to determine overall height Note: the frame rail height itself ill notaffect the overall height as all components are located from the bottom of the frame rail

taBle 3-4. Ride Heights In Inches

f Sss l u

12k Taperleaf 103 115





22k Multi-stage Taperleaf 107 127

r Ssss

kenorth AG380 85 85

kenorth AG400L 85 85

kenorth AG400 90 90

kenorth AG460 105 105Reyco 79kB 21k Rating 66 90

Reyco 79kB 23k Rating 83 108

Reyco 79kB 26k Rating 82 113

Reyco 102 38k Rating 92 108

Reyco 102 40 k Rating 92 108

Chalmers 854-40-L-HS 40k Rating 96 110


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Section 3

Dimensions

08/09

3-9

Chalmers 854-40-H-HS 109 124

Chalmers 854-46-L 46k Rating 89 113

Chalmers 854-46-L-HS 46k Rating 96 113

Chalmers 854-46-H 46k Rating 101 124

Chalmers 854-46-H-HS 46k Rating 109 125

Chalmers 860-46-H-HS 109 125

Chalmers 872-46-H-HS 110 125

Hendricson HAS 230 23k Rating 100 100

Hend HMx460 165 Saddle 95 106

Hend HMx460 175 Saddle 105 116

Hend HMx460 46k 185 Saddle 115 126

Hendricson Primaa 46k Rating 100 100

Hendricson RT403 40k Rating 97 107

Hendricson RT463 60 Saddle 100 111



Neay AD123 23k Rating 100 100




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Section 3

Dimensions

08/09

3-10

rear SuSpenSion layoutS

The rear suspension layouts are provided as a tool to help layout bodies prior to arrival Be sure to chec the ale spacingthat is shon, as alternate spacings may eist and could change some of the dimensions The dimensions shon belo

are the most typical installations, in special cases some hole locations ill move If you are planning on using the holesshown for your body installation, please conrm with your local KW dealer that the drawing below will be the installation

used on your specic truck. Ensure that proper torque is used to reinstall any suspension components. See Tables 5-1 and5-2 on page 5-7

It ould be a good idea in this case to order the frame layout of your chassis along ith your truc order This can be doneon any kenorth truc, and ill be provided 4 ees ahead of the build schedule

If there are hole locations that are not detailed please or ith your local kenorth Dealer to reuest that information

Additionally optional ale spacings are shon in the charts, if you ould lie details on the frame drilling ith optionalspacings, please contact your local kenorth dealer

reyco 79KB Single rear axle

o r 79KB Ssss

taBle 3-5. Rear Suspension Options

Sss t r Ae spacil r

h

u r

h

Reyco 79kB single 21k - 83 108




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Section 3

Dimensions

08/09

3-11

reyco 102 tandem rear axle

Shon ith a 52 Ale Spacing

r 102 Sss d


Suspension Type Rating Ale Spacing Laden Ride HeightUnladen Ride

Height

Reyco 102 Tandem 38k 52 92 108

Reyco 102 Tandem 40k 52 92 108


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Section 3

Dimensions

08/09

3-12

neWay ad 123 Single rear axle

optia nea AD sie spei


Sss t r Ae spacil r

hu r

h

Neay AD123 single 23k - 10 10

Neay AD126 single 26k - 10 10


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Section 3

Dimensions

08/09

3-13

neWay ad 246 tandem SuSpenSion


optia nea AD Tade spei


Sss t r Ae spacil r

h

u r

h

Neay AD246 tandem 46k 54 10 10

Neay AD246 tandem 46k 60 10 10


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Section 3

Dimensions

08/09

3-14

hendricKSon primaax tandem SuSpenSion

Shon ith 54 Ale Spacings

optia hedrick Priaa Tade spei


Sss t r Ae spacil r

h

u r

h

Hendricson Primaa Tandem 46k 54 10 10




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Section 3

Dimensions

08/09

3-15

hendricKSon hmx tandem SuSpenSion

Shon ith 54 Ale Spacing

o hks hmx t Ssss


Sss t r Ae spacil r

h

u r

h

Hendricson HMx400 165 saddle 40k 54 95 106







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Section 3

Dimensions

08/09

3-16

hendricKSon rt tandem SuSpenSion

Shon ith a 54 Ale Spacing without Trac Rods

o hks rt t Ssss


Sss t r Ae spacil r

hu r

h

Hendricson RT463 6 saddle 46k 54 100 111






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Section 3

Dimensions

08/09

3-17

hendricKSon rt tandem SuSpenSionShon ith a 54 Ale Spacing without Trac Rods

o hks rt t Ssss


Sss t r Ae spacil r

h

u r

h



32/110

Section 3

Dimensions

08/09

3-18

KenWorth ag 380 tandem SuSpenSion


Kert Ag 380 spei Data


Sss t r Ae spacil r

hu r

h

AG 380 38k 52 85 85


33/110

Section 3

Dimensions

08/09

3-19

KEnwoRTh Ag 400/460 TAnDEm susPEnsIon


optia Kert Tade spei


Sss t r Ae spacil r

hu r

h

kenorth AG 400 40k 52 9 9

kenorth AG 400 40k 54 9 9

kenorth AG 460 46k 54 105 105


34/110

Section 3

Dimensions

08/09

3-20

KenWorth ag 400l tandem SuSpenSion




Sss t r Ae spacil r

hu r

h

kenorth AG 400L 40k 52 85 85

kenorth AG 400L 40k 54 85 85


35/110

Section 3

Dimensions

08/09

3-21

KenWorth ag 460 tandem SuSpenSion




Sss t r Ae spacil r

hu r

h

kenorth AG 460 46k 60 105 105


36/110

Section 3

Dimensions

08/09

3-22

chalmerS 856-46 tandem SuSpenSion


o cs t Ssss


Sss t r Ae spacil r

hu r

h

Chalmers 854-40-L-HS 40k 54 96 111

Chalmers 854-40-H-HS 40k 54 109 124

Chalmers 854-46-L 46k 54 89 113

Chalmers 854-46-L-HS 46k 54 96 113

Chalmers 854-46-H 46k 54 101 125

Chalmers 854-46-H-HS 46k 54 109 125

Chalmers 860-46-H-HS 46k 60 109 125

Chalmers 872-46-H-HS 46k 72 110 125


37/110

Section 3

Dimensions

08/09

3-23

puSher axleS

The rear pusher ale layouts are provided as a tool to help layout bodies prior to arrival when using the pusher layouts todetermine available frame space please be aare that clearances reuired are not shon For information that may not be

detailed in these draings or ith your local kenorth Dealer to reuest that information

wat & Cai Tr Track Aiite 13.2K steerabe Per

wat & Cai Tr Track 20K steerabe Per


38/110

Section 3

Dimensions

08/09

3-24

wat & Cai Ata 22.5K n-steerabe Per


39/110

Section 3

Dimensions

08/09

3-25

ground clearance

This information is provided as a reference, not all optional euipment is included In order to calculate the height on yourspecic chassis, please use the ride height information provided on page 3-14. For comparison the FS value shown is

114 unladen and 104 laden

taBle 3-18. Ground Clearance for Fuel Tans

fSss

f tsr

Sssr ts c

dsa

ds

B f r

(i)

ds B g

Cearace (i)

u l

20k Taper-

leaf Spring

M844F425/65R225

Tires

HendricsonHMx 460

175 SaddleHeight

M711

11R245

22 Fuel Tan 163 172 149

245 FuelTan

182 153 13

A

B


40/110

Section 3

Dimensions

08/09

3-26

taBle 3-19. Ground Clearance for Battery Boes

f

Sssf ts

r

Sssr ts c

ds

ads

B f r

(i)

ds B g

Cearace (i)

u l

20k Taper-

leaf Spring

M844F425/65R225

Tires

HendricsonHMx 460

175 SaddleHeight

M711

11R245

Battery Bo

ith Air Tans173 162 139

VocationalBattery Bo

ith Air Tans

178 157 134

Single DPF

Bo155 179 156

A

B


41/110

Section 3

Dimensions

08/09

3-27

exhauSt information

This section includes information on ho to calculate tailpipe heights, and reference information for PTO clearanceOptional euipment is not shon

t Sk h ctaBle 3-20. Stac Height

ds a

DPF mounted independent bacof cab or sleeper

765

Tailpipes side of cab mount, DPF

RH under

Tailpipes bac of cab mount, DPF

RH under

680

DIMENSION B IS THE TAILPIPE LENGTH

taBle 3-21. Unladen Stac Height

For approimate unladen stac height (12,000 pound springs) use the folloing frame heights:

t Sz t r f. Sss11R245 435 12k

11R225 425 12k

285/75R245 42 12k

295/75R225 415 12k

425/65R225 432 20k

385/65R225 424 20k

*Use Prospector frame heights for more accurate results

S: Tailpipe height 136 = Desired overall stac height = 1620() Prospector frame height () 435

(+) Frame rail depth (+) 106() Dimension A from chart () 686

= Tail pipe length = 605


42/110

Section 3

Dimensions

08/09

3-28

pto clearanceS

The following visuals are provided to help aid in determining PTO locations and clearances. For specic dimensionsplease or through your local kenorth dealer Multiple PTOs are shon for layout purposes only Poer euipment,

ie, drive shafts & poer pumps are not included Body builders should select the appropriate PTO for their applicationand customer reuirements

m tsss:

Bottom vie from right rear of chassis Vie from Front

Bottom vie from forard right Bottom vie from front left under


43/110

Section 3

Dimensions

08/09

3-29

as tsss:

Allison transmission are 10 bolt

Bottom vie Right front

Left vie Front vie


44/110

Section 3

Dimensions

08/09

3-30

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, and the diesel particulate lter (DPF). For your application, the layouts focus onthe under cab area, ith appropriate dimensional information included for pertinent bac of cab components Not all optionaleuipment is included in this section Additional components may be placed on the rail behind components sho The Bacof Cab components are shown primarily for reference. For more specic requirements please work with your local KenworthDealer Please read the instructions carefully

The folloing dimensions are consistent across the entire section to aid in the comparison of one layout option versus anothe

taBle 3-22. Frame Layout Dimensions

ds l

A RH Side, Under Cab, Belo Rail

B RH Side, Above Rail

C LH Side, Under Cab, Belo Rail

D LH Side, Above Rail

E RH Side, Under Rail Bac of Cab

F LH Side, Under Rail Bac of Cab

BOC Bac of Cab

The layouts are organized by type, specically the arrangement of under cab components. The visual index that follows wigive you a uic overvie of the layouts that are included Using the inde locate the layout that you are interested in, then

turn to the specied pages. The charts that follow are then model specic. It is important that the correct chart is used foraccurate dimensional information

Via Ide

taBle 3-23. Visual Inde

Sb ds

Diesel Particulate Filter

Vertical Diesel Particulate Filter

Standard Battery Bo

Vocational Battery Bo

Fuel Tan

, Tailpipes (Horiontal, Vertical)


45/110

Section 3

Dimensions

08/09

3-31

frame layout index

d cb csss l os

d1 is used for single ehaust located side of cab (SOC) ith battery bo LH under, DPF RH under and fuel tans bac of

cab (BOC) Charts located on pages 3-34

d2 is used for single ehaust located side of cab ith the vocational style battery bo LH BOC, fuel tan LH under, andDPF RH under Charts located on pages 3-35

d3 is used for single ehaust located side of cab ith fuel tan LH under, DPF RH under and battery bo BOC Note: Thislayout can be used ith a modular sleeper, dimensions ill not change Charts located on pages 3-36

d4 is used for single ehaust right hand (RH) bac of cab ith battery bo LH under, DPF RH under and fuel tans BOCCharts located on pages 3-37


46/110

Section 3

Dimensions

08/09

3-32

d5 is used for single ehaust RH bac of cab ith vocational style battery bo LH BOC, fuel tan LH under and DPF RH

under Charts located on pages 3-38

d6 is used for single ehaust RH bac of cab ith fuel tan LH under, DPF RH under and battery bo LH BOC Chartslocated on pages 3-39

d7 is used for vertical independent ehaust RH bac of cab, including DPF, battery bo LH under, and fuel tan RH

under Charts located on pages 3-40

d8 is used for vertical independent ehaust RH bac of cab, including DPF, battery bo LH under, tool bo RH under

and fuel tans located BOC Charts located on pages 3-41

d9 is used for vertical independent ehaust RH bac of cab, including DPF, vocational style battery bo LH BOC,fuel tan LH under and tool bo RH under Charts located on pages 3-42


47/110

Section 3

Dimensions

08/09

3-33

d10 is used for vertical independent ehaust RH bac of cab, including DPF, vocational style battery bo LH BOC,fuel tan LH under and fuel tan RH under Charts located on page 3-43

d11 is used for vertical independent ehaust RH bac of cab, including DPF, fuel tans LH and RH under, and battery

bo LH BOC Charts located on page 3-44


48/110

Section 3

Dimensions

08/09

3-34

chartS

d1

DPF Location: RH Under Cab

Battery Bo: LH Under CabFuel Tan: BOC

taBle 3-24.

m Cab Crati Taipipe Cratids a

DPF t BoC (i.)

T470

Day Cab Single RH SOC 72

Etended Day Cab Single RH SOC 15

22 f tk 24.5 f tk

gstk

l(i.)

d. fd cbBoc e

f tk(i.)

d. fEtededd cbBoc e

f tk(i.)

gstk

l(i.)

d. fd cbBoc e

f tk(i.)

d. fEtededd cbBoc e

f tk(i.)

40 256 225 168 45 229 198 141

56 355 324 267 60 305 274 217

60 380 349 292 75 385 354 297

75 473 442 385 90 455 424 367

100 622 591 534 100 500 469 412

120 742 711 654 110 549 518 461

120 605 574 517

135 672 641 584

150 745 714 657


49/110

Section 3

Dimensions

08/09

3-35

d2

DPF Location: RH Under CabBattery Bo: Vocational LH BOC

Fuel Tan: LH Under Cab

taBle 3-25.


DPF t BoC (i.)

T470Day Cab Single RH SOC 72


22 f tk 24.5 f tk

gstk

l(i.)

d. cd cbBoc

Batt. B(i.)

d. cEtededd cbBoc

Batt. B(i.)

gstk

l(i.)

d. cd cbBoc

Batt. B(i.)

d. cEtededd cbBoc

Batt. B(i.)

56 355 126 69 602 305 76 19

60 380 151 94 75 385 156 99

75 473 244 187 90 455 226 169

100 622 393 336 100 500 271 214

120 742 513 456 110 549 320 263

120 605 376 319

135 672 443 386

150 745 516 459


50/110

Section 3

Dimensions

08/09

3-36

d3

DPF Location: RH Under CabBattery Bo: BOCFuel Tan: LH Under Cab

taBle 3-26.


DPF t BoC (i.)

T470

Day Cab Single RH SOC 72


22 f tk 24.5 f tk

gstk

l(i.)

d. cd cbBoc e

f tk(i.)

d. cEtededd cbBoc e

f tk(i.)

gstk

l(i.)

d. cd cbBoc e

f tk(i.)

d. cEtededd cbBoc e

f tk(i.)

56 355 -37 -94 60 305 -87 -144

60 380 -12 -69 75 385 -07 -64

751, 2 473 81 24 901, 2 455 63 06

100 622 230 173 100 500 108 51

120 742 350 293 110 549 157 100

120 605 213 156

135 672 280 223

150 745 353 296

1 MAxIMUM DAY CAB FUEL TANk TO MATCH DIMENSION A2 MAxIMUM ExTENDED DAY CAB FUEL TANk TO MATCH DIMENSION A


51/110

Section 3

Dimensions

08/09

3-37

d4

DPF Location: RH Under CabBattery Bo: LH Under Cab

Fuel Tan: BOC

taBle 3-27.

m Cab Cratit

Cratids a

DPF t BoC (i.)ds B

ma fr BoC (i.)

T470 Day Cab RH BOC 72 109

22 f tk 24.5 f tk

gstk l

(i.)

d. f dcb Boc e fTak (i.)

gstk l

(i.)

d. f dcb Boc e fTak (i.)

40 256 225 45 229 198

56 355 324 60 305 274

60 380 349 75 385 354

75 473 442 90 455 424

100 622 591 100 500 469

120 742 711 110 549 518

120 605 574

135 672 641

150 745 714

NOTE: DIMENSION F IS CALCULATED USING A STANDARD SIzED BATTERY BOx OPTIONAL ExTENDED BOxES wILL CHANGE DIMENSION F


52/110

Section 3

Dimensions

08/09

3-38

d5

DPF Location: RH Under Cab

Battery Bo: Vocational LH BOCFuel Tan: LH Under Cab

taBle 3-28.

m Cab Cratit

Cratids a

DPF t BoC (i.)ds B

ma fr BoC (i.)


22 f tk 24.5 f tk

gstk l

(i.)

d. c dcb Boc

Batt. B (i.)gs

tk l(i.)

d. c dcb Boc

Batt. B (i.)

56 355 127 602 305 76

60 380 152 75 385 157

75 473 245 90 455 227

100 622 394 100 500 272

120 742 514 110 549 321

120 605 377

135 672 444

150 745 517

1 MAxIMUM DAY CAB FUEL TANk TO MATCH DIMENSION A2 MAxIMUM DAY CAB FUEL TANk TO MATCH DIMENSION B


53/110

Section 3

Dimensions

08/09

3-39

d6

DPF Location: RH Under CabBattery Bo: Vocational LH BOCFuel Tan: LH Under Cab

taBle 3-29.

m Cab Cratit

Cratids a

DPF t BoC (i.)ds B

ma fr BoC (i.)


22 f tk 24.5 f tk

gstk l

(i.)

d. c dcb Boc

Batt. B (i.)gs

tk l(i.)

d. c dcb Boc

Batt. B (i.)

56 355 126 601, 2 305 76

60 380 151 75 385 156

75 473 244 90 455 226

100 622 393 100 500 271

120 742 513 110 549 320

120 605 376

135 672 443

150 745 516


54/110

Section 3

Dimensions

08/09

3-40

d7

DPF Location: RH Vertical BOCBattery Bo: LH Under Cab

Fuel Tan: RH Under Cab

taBle 3-30.

m Cab Cratit

Cratids B

ma fr BoC (i.)

T470

Day Cab

Vertical 198

Etended Day Cab

22 f tk 24.5 f tk

gstk

l(i.)

d. ad cbBoC (i.)

d. aEtededd cbBoC (i.)

gstk

l(i.)

d. ad cbBoC (i.)

d. aEtededd cbBoC (i.)

56 355 -37 -94 60 305 -87 -144

60 380 -12 -69 75 385 -07 -64

751 473 81 24 90 455 63 06

1002 622 230 173 100 500 108 51

120 742 350 293 1101 549 157 100

1202 605 213 156

135 672 280 223

150 745 353 296

1 MAxIMUM DAY CAB FUEL TANk TO MATCH DIMENSION B2 MAxIMUM ExTENDED DAY CAB FUEL TANk TO MATCH DIMENSION B


55/110

Section 3

Dimensions

08/09

3-41

d8

DPF Location: RH Vertical BOCBattery Bo: LH Under CabFuel Tan: BOC

taBle 3-31.

m Cab Cratit

Cratids B

ma fr BoC (i.)

T470

Day Cab

Vertical 198

Etended Day Cab

22 f tk 24.5 f tk

gstk

l(i.)

d. fd cbBoc e

f tk

d. fEtededd cbBoc e

f tk

gstk

l(i.)

d. fd cbBoc e

f tk

d. fEtededd cbBoc e

f tk

40 256 225 168 45 229 198 141

56 355 324 267 60 305 274 217

60 380 349 292 75 385 354 297

75 473 442 385 90 455 424 367

100 622 591 534 100 500 469 412

120 742 711 654 110 549 518 461

120 605 574 517

135 672 641 584

150 745 714 657

NOTE: DIMENSION F IS CALCULATED USING A STANDARD SIzED BATTERY BOx OPTIONAL ExTENDED BOxES wILL CHANGE DIMENSION F


56/110

Section 3

Dimensions

08/09

3-42

d9

DPF Location: RH Vertical BOC


taBle 3-32.

m Cab Cratit

Cratids B

ma fr BoC (i.)

T470

Day Cab

Vertical 198

Etended Day Cab

22 f tk 24.5 f tk

gstk

l(i.)

d. cd cbBoc

Batt. B(i.)

d. cEtededd cbBoc

Batt. B(i.)

gstk

l(i.)

d. cd cbBoc

Batt. B(i.)

d. cEtededd cbBoc

Batt. B(i.)

56 355 126 69 60 305 76 19

601 380 151 94 751 385 156 99

752 473 244 187 902 455 226 169

100 622 393 336 100 500 271 214

120 742 513 456 110 549 320 263

120 605 376 319

135 672 443 386

150 745 516 459



57/110

Section 3

Dimensions

08/09

3-43

d10



RH Under Cab

taBle 3-33.

m Cab Cratit

Cratids B

DPF t BoC (i.)

T470 Day Cab Vertical 198

22 f tk 24.5 f tk

gstk

l(i.)

d. ad cbBoC (i.)

d. c

d cbBoc

Batt. B(i.)

gstk

l(i.)

d. ad cbBoC (i.)

d. c

d cbBoc

Batt. B(i.)

56 355 -37 126 60 305 -87 76

602 380 -12 151 752 385 -07 156

751 473 81 244 90 455 63 226

100 622 230 393 100 500 108 271

120 742 350 513 1101 549 157 320

120 605 213 376

135 672 280 443

150 745 353 516

1 MAxIMUM RH DAY CAB FUEL TANk TO MATCH DIMENSION B2 MAxIMUM LH DAY CAB FUEL TANk TO MATCH DIMENSION B


58/110

Section 3

Dimensions

08/09

3-44

d11


Battery Bo: BOCFuel Tan: LH Under Cab

RH Under Cab

taBle 3-34.

m Cab Cratit

Cratids B

DPF t BoC (i.)

T470

Day Cab

Vertical 198

Etended Day Cab

22 f tk 24.5 f tk

gstk

l(i.)

d. a& C Da

cb Boc f

Tak (i.)

d.A & C

Etededd cbBoc

f tk(i.)

gstk

l(i.)

d. a& C Da

cb Boc f

Tak (i.)

d.A & C

Etededd cbBoc

f tk(i.)

56 355 -37 -94 60 305 -87 -144

60 380 -12 -69 75 385 -07 -64

751 473 81 24 90 455 63 06

1002 622 230 173 100 500 108 51

120 742 350 293 1101 549 157 100

1202 605 213 156

135 672 280 223

150 745 353 296



59/110

08/06

Section 4

Body Mounting

4-1

front frame dimenSionS

Eteded Frt Frae S f f

Eteded Frt Frae S f f

448 448 270270

728

102

503

102

This section includes draings of the T470 etended front frame (73) and standard (505) front frame settings Alldimensions are in inches (in) They illustrate measurements useful to the installation of front frame euipment and

bumpers. Kenworth also offers .dxf les and frame layouts of ordered chassis four weeks prior to build. Please work withyour kenorth sales representative to reuest this feature hen specifying your chassis


60/110

08/06

Section 4

Body Mounting

4-2

frame information

Frame information provided is per rail, some specications are written for RBM requirements per pair of rails. Make sureto no the reuirement before deciding on the frame rail

taBle 4-1. Single Steel Rails

r h f W Wb tkss S ms RBm (i b) weit (b/i)h W t S r W

10 - 5/8 3 -1/2 5/16 1480 1,776,000 290

10 - 3/4 3 -1/2 3/8 1780 2,132,000 346

10 -11/16 3 -1/2 1/2 2235 2,683,000 453

taBle 4-2. Inserted Steel Rails

r h is m S ms RBm (i b) weit (b/i)

10 - 5/8 Single 9-7/8 2-7/8 1/4 2437 2,925,000 496

10 - 3/4 Single 9-7/8 2-7/8 1/4 2733 3,280,000 553

critical clearanceS

r Ws cb

Ifciet cearace betee rear tire ad bd trctre a cae daae t tebd dri pei veet. A at eat 8 ice cearace (see Fire 41.)

Normal suspension movement could cause contact beteen the tires and the body To prevent this, mount the body sothat the minimum clearance beteen the top of the tire and the bottom of the body is 8 inches (203 mm) This should be

measured ith the body empty See Figure 41

figure 4-1. Minimum Clearance Beteen Top Of Rear Tires And Body Structure Overhang

maitai adeqate cearace betee back f cab ad te frt (eadi ede) f tedbd. Faire t cp a ret i eqipet daae. see Fire 42.

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

caution:

caution:

n:


61/110

08/06

Section 4

Body Mounting

4-3

figure 4-2. Minimum Bac of Cab Clearance

If te frae rai ae are died r daaed, te rai a fai preatre ad cae

. W b sss, do not s er ae f te frae rai. mt te bd i bd ti bracket r ubt.f s s j, , .

Body mounting uSing BracKetS

Aa ita a pacer betee te bd bfrae ad te tp ae f te frae

. f s s s ss s .

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

Warning:

caution:

4


62/110

08/06

Section 4

Body Mounting

4-4

f S

If the body is mounted to the frame ith bracets, e recommend that the frame sill spacer be made from a strip of rub-ber or plastic (delrin or nylon) These materials ill not undergo large dimensional changes during periods of high or lo

humidity The strip ill be less liely to fall out during etreme relative motion beteen body and chassis See Figure 43

figure 4-3. Spacer Beteen Frame Sill and Body Rail - Rubber or Plastic

Bks

when mounting a body to the chassis ith bracets, e recommend designs that offer limited amount of relative move-

ment, bolted securely but not too rigid Bracets should allo for slight movement beteen the body and the chassis Forinstance, Figure 44 shos a high compression spring beteen the bolt and the bracet

figure 4-4. High Compression Spring figure 4-5. Rubber Spacer Beteen BracetsBeteen the Mounting Bolt and Upper Bracet

Another possibility is mounting a rubber spacer beteen the bracets See Figure 45

These designs ill allo relative movement beteen the body and the chassis during etreme frame racing situationsEtreme frame racing, and mountings that are too rigid, could cause damage to the body This is particularly true ith

taner installations

Body Subframe(Rail)

Chassis Frame(Rail) Sill

Spacer

Spring

Rubber Spacer


63/110

08/06

Section 4

Body Mounting

4-5

mounting holeS

when installing the loer bracet on frame rails the mounting holes in the chassis frame bracet and frame rail must com-ply ith the general spacing and location guidelines illustrated in Figure 46 The hole diameter should not eceed the bolt

diameter by more than 060 inches (15 mm)

4 HOLES

.5 IN. DIA.

(12.7mm)

5.5

(140mm)

2.0

(50mm)

5.63

(143mm)

5.5

(140mm)

2.0

(50mm)

5.63

(143mm)

11.0

(279mm)

6 HOLES

.5 IN. DIA.

(12.7mm)

figure 4-6. Crossmember-Gusset Hole Pattern Reuirements [inch (mm)]

f d

W b sss, do not s pper r er ae f te frae rai. If te frae rai ae are

died r daaed, te rai a fai preatre. mt te bd -i bd ti bracket r ubt. Faire t cp a ret

s j, , .

ue care e drii te frae eb te ire ad air ie rted iide te rai are

, s s b ss .f s s j, , .

D t dri ce paced e i te frae rai. he ceter f t adjacet e

d be paced e ta tice te diaeter f te aret e. Cer paci aidce a faire betee te e. Faire t cp a ret i pera ijr, deat, .

Warning:

Warning:

Warning:


64/110

08/06

Section 4

Body Mounting

4-6

BoDy mounTIng usIng uBolTs

Ss

If the body is mounted to the frame ith Ubolts, use a hardood sill (minimum 1/2 inch (12 mm) thic) beteen the frame

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

D t a te frae rai r ae t defr e titei te ubt. It i eak-e te frae. ue itabe pacer ade f tee r ardd te iide f te fraerai t prevet cape f te frae ae. Faire t cp a ret i pera

j, , .

Use a hardwood spacer between the bottom ange and the Ubolt to prevent the Ubolt from notching the frame ange.See Figure 47

Body Structure

wood Sill 05 (12) Minimum

Truc Frame

Frame Rail Spacer(Fabricated Steel or

Hardood)

U-Bolt Spacer (Hardood)

U-Bolt

figure 4-7. Acceptable U-Bolt Mounting ith wood and Fabricated Spacers [inch (mm)]

D t a pacer ad ter bd ti part t iterfere it brake ie, feie, r iri aree rted iide te frae rai. Criped r daaed brake ie,

fe ie, r iri a ret i f braki, fe eak, eectrica verad r a re.c s s s s bk s,

ie, ad iri. Faire t cp a ret i pera ijr, deat, eqipet rprpert daae. see Fire 48.

mt ubt te d t cafe frae rai. Faire t d a ret ipreatre ear f te u-bt r frae rai.

Warning:

caution:

Warning:


65/110

08/06

Section 4

Body Mounting

4-7

figure 4-8. Clearance Space for Air Lines and Cables

D t tc frae rai ae t frce a ubt t. ntced r daaed frae aea ret i preatre frae faire . ue a arer ize ubt. ue a ardd pacer a

i Fire 4-7. Faire t cp a ret i pera ijr, deat, eqipet r .

Frame Rail

Air Lines and wiring

Harness

Chec ClearanceSpace for Air

Lines and wiring

U-Bolt

Frame Rail Spacer

(Hardood or Steel

U-Bolt Spacer

Warning:


66/110

08/06

Section 4

Body Mounting

4-8

r B m

When Ubolts are used to mount a body we recommend that the last body attachment be made with a shplate bracket.See Figure 49. This provides a rm attaching point and helps prevent any relative fore or aft movement between the body

and frame

figure 4-9. Eample of Fishplate Bracet at Rear End of Body, used ith U-Bolts

Body Structure

Frame Rail


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Section 5

Frame Modifcations

5-1

frame modificationS

i

Kenworth offers customer specied wheelbases. So, in most cases frame modications to produce a certain wheelbase

should not be necessaryHowever, some installations may require slight modications, while other installations will require extensive modications.Sometimes an existing dealer stock chassis may need to have the wheelbase changed to better t a customers applica-

tion. The modications may be as simple as shortening or lengthening the frame cutoff, or they may be as complex aschanging the heelbase

drilling railS

l h p

If holes need to be drilled to attach anything to the rail, see SECTION 4 BODY MOUNTING for more information Follo

the general spacing and hole location guidelines on Page 45, Figure 46

we ti a bd t te cai, Do noT dri e i te pper r er ae f

te frae rai. If te frae rai ae are died r daaed, te rai a fai preatre. mt te bd i bd ti bracket r ubt. Faire t cp a re

s j, , .

D t dri ce pare e i te eb f te frae. he ceter f t adjacet e

d be paced e ta tice te diaeter f te aret e. Cer paci aidce a faire betee te e. Faire t cp a ret i pera ijr, deat,

.

a sz b s b s s s. f s s k

.

ue care e drii te frae eb te ire ad air ie rted iide te rai are

, s s b ss .f s s j, , .

n s k s . us b. hfr a trc i affect te ateria prpertie f te frae rai ad a ret i frae rai

ks .

he diaeter d t eceed te bt diaeter b re ta .060 ice (1.5 ).overized e a ret i eceive frae ear ard te e ad eqipet da-

.

Warning!

caution:

Warning!

caution:

caution:

Warning!


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Section 5

Frame Modifcations

5-2

modifying frame length

The frame cutoff after the rear ale can be shortened to match a particular body length Using a torch is acceptable;hoever, heat from a torch ill affect the material characteristics of the frame rail The affected material ill normally be

conned to within 1 to 2 inches (25 to 50 mm) of the ame cut and may not adversely affect the strength of the chassis orbody installation

The frame cutoff can be lengthened by adding frame etenders

when etending 105 frame rails, the additional sections can be elded to the eisting rails The joint should be elded

and reinforced as illustrated in Figure 51

See page 5-6 for more information on elding frames

f is

A frame insert must be added after elding a frame rail etension to compensate for lost strength The insert should beof the same material as the frame member, or of steel, and at least eual to the frame rail in thicness Attachment ofthe insert to the frame should be made ith Ream-Fit heat-treated bolts, 5/8 in (16 mm) dia or the net larger sie Both

the reinforcement and frame holes should be reamed to provide a t of from .001 in. to .003 in. (.025 to .076 mm) clear-ance Do not eld reinforcing members The insert should span a distance of at least 24 in (610 mm) on either side of the

joint to insure an even distribution of stresses Cut the ends of the insert at 45 as shon in Figure 52 unless the insertetends to the end of the frame

figure 5-1. Detail of Frame Etension and Joint welding

n:


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Section 5

Frame Modifcations

5-3

figure 5-2. Frame Insert

where possible, use eisting 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 here fe bolts are located, additional bolts are reuired Use the fol-loing guideline for locating additional bolt holes

changing WheelBaSe

we do not recommend modifying the heelbase Occasionally, hoever, a chassis heelbase ill need to be reduced or

lengthened when this needs to be done there are a fe guidelines that should to be considered

we cai te eebae, be re t f te driveie afactrer rece-dati fr driveie et r ae cae. Icrrect died driveie a fai pre-

atre de t eceive vibrati. Faire t cp a ret i pera ijr, deat .

we cai te eebae, a cti bak frae iert/tert t be added ite area f te e rear pei ti bt. A e ti e t pa

tr te riia rai ad te iert/tert. Faire t d a cae eceivesss s. f s sj, , .

we recati a pei bracket, d t t it te eteded (added) ecti . t sss s s-

ti pice. ue care e pai te eebae tat te rear pei bracket iaa ted te riia rai ecti. see Fire 53. Faire t cp a ret

s j, , .

24 InchMinimum(610 mm)

Warning!

Warning!

Warning!

wELDEDJOINT

Before changing the heelbase the driveline angles of the proposed heelbase need to be eamined to ensure that noharmful vibrations are created Consult the driveline manufacturer for appropriate recommendations

Before the rear suspension is relocated, chec the ne location of the spring hanger bracets The ne holes for thespring hanger bracets must not overlap eisting holes and should not come any closer than 2 inches (50 mm) to eisting

holes in the frame


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Section 5

Frame Modifcations

5-4

when reducing the heelbase, e recommend that the suspension be moved forard and relocated on the original railThe rail behind the suspension can then be cut to achieve the desired frame cutoff See Figure 53

D t dri e e a cer ta 2 ice (50 ) t eiti e. Frae drii

s s s. f s s j, ,

.

Before the rear suspension is relocated, chec the ne location of the spring hanger bracets The ne holes for thespring hanger bracets must not overlap eisting holes and should not come any closer than 2 inches (50 mm) to eistingholes

figure 5-3. Comparison of Original, Shortened, and Etended wheelbases

Warning!

Original wheelbase

Etended wheelbase

Shortened wheelbase

Cut Frame at Rear toObtain Desired Cutoff

Do Not Mount theSuspension Bracet

On the AddedFrame Rail

Mount the suspension Bracets On the

Original Rail (see frame insert section &

Figures 5-1 and 5-2)

Relocated RearSuspension


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Section 5

Frame Modifcations

5-5

croSSmemBerS

After changing a heelbase, an additional crossmember may be reuired to maintain the original frame strengthThe maimum alloable distance beteen adjacent crossmembers is 60 inches (1524 mm) If the distance beteen adja-

cent crossmembers eceeds this dimension, add a crossmember beteen them See Figure 54

Before wheelbase is Lengthened

Less Than 60

Greater Than 60

Additional Crossmember

figure 5-4. Crossmember Added when Distance Eceeds 60 Inches (1524 mm)


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Section 5

Frame Modifcations

5-6

Welding

Kenworth DOES NOT recommend frame welding. The high heat of welding nullies the special heat treatment of therails, greatly reducing the tensile strength of the frame rail If a frame member becomes craced from overloading, fatigue,

surface damage or a collision, the only permanent repair is to replace the damaged frame member ith a ne part

The folloing information is provided (for temporary emergency repair) Prior to elding a craced frame rail, the area

should be beveled (Vd out) to allo for a better eld To prevent spreading of the crac, a 7 to 9 mm (1/4 in to 3/8 in) diahole should be drilled at the end of the crac widen the crac along its full length by using to hac sa blades together

when elding steel frames use the shielded arc method when elding aluminum frames use either the tungsten inertgas (TIG) or consumable electrode method Be sure to obtain full eld penetration along the entire length of the crac

ps

Befre edi, dicect te eative teria batter cabe. Faire t cp a

s .

Befre edi, dicect te ateratr teria. Faire t d a ret idaae t te vtae reatr ad/r ateratr.

T prevet daae t eectrica eqipet, dicect batter cabe befre arc-edi

a trck, ad be re tat te edi rd ead i cected t te frae. Beariad ter part i be daaed if crret t pa tr te i rder t cpete

.

W ps: a e es

Before elding on vehicles ith electronic engines, the folloing 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 elding probe

4 Ensure that the ground connection for the elder is as close to the eld point as possible This ensures mai-mum eld current and minimum ris to damage electrical components on the vehicle

5 Turn off ey

Bosch ABS and wabco ABS: Disconnect ECU

caution:

caution:

caution:

n:


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Section 5

Frame Modifcations

5-7

torque requirementS

taBle 5-1. Customary Grade 8 UNF or UNC

fs t

Sz n lb.-f

5/16 2230 16223/8 4154 3040

7/16 7588 5565

1/2 109122 8090

9/16 156190 115-140

5/8 224265 165195

3/4 394462 290340

7/8 517626 380460

1 9521129 800830

1-1/8 13461591 9901170

1-1/4 18772217 13801630

Torue values apply to fasteners ith clean threads, lightly lubricated, ith hardened steel ashers, and nylon-insert nuts

taBle 5-2. US Customary Grade 8 Metric Class 109

t

fs n lb-f

M6 915 711

M8 2331 1723

M10 3343 2432

M12 75101 5575

M14 134164 99121

M16 163217 120160

M20 352460 260340


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6-1

electrical

Electrical iring can sometimes be very frustrating This is especially true hen adding circuits to an eisting setupThrough the use of optional engine connectors and additional spare circuits, e have tried to reduce the compleity as-

sociated ith adding common circuits to a body installation

Information in this section ill cover the folloing topics:

Overview of Kenworths multiplex instrumentation

Access instructions for the dash, gauges, and switches.

Wiring instructions for telltale (warning light) symbols

Spare circuits (standard and adding)

Multifunction turn signal stalk

Remote PTO/Throttle harness

multiplex inStrumentationkenorth utilies Multiple instrumentation and iring to improve uality and the capability of our trucs Multipleing uti-lies the industry standard J1939 data bus to send multiple signals over a single tisted pair of ires

instead of individual ires for each function The advantages are feer ires, sensors, and connections that providegreater consistency and improved reliability The folloing information is provided to increase your aareness about the

kenorth product, it may be useful in installing telltales (arning lights) and gauges

Dt ct r tap it ree/e tited pair. o e T cectr, ad addapprved J1939 cpet it vaidated ftare. Faire t cp a ret i per-

s j, , .

Warning!


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6-2

interior identification

All T470 dashes utilie multiple iring

The information contained in this manual is specic to chassis with 2007 engines.

f ds

Cab Electronic Control Unit (CECU)

The heart of the multipleed instrumentation system is the Cab Electronic Control Unit (CECU) The CECU is locatedbehind the center console See Figure 6-1

figure 6-1. CECU Location

Vehicle component inputs are sent to the CECU through the J1939 data bus or conventional iring The CECU interprets

the various inputs and monitors/controls the functions for each input through the CECU softare Output signals from theCECU provide data for the gauges, arning lamps, audible alarms, and displays inside the cluster

n:

cecu


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6-3

Central Instrument Cluster

The central instrument cluster includes the speedometer (including odometer and trip meter) and tachometer (includingengine hour meter and outside temperature display), plus pre-installed standard and/or editable arning light symbols

called telltale cards

Each telltale card slides into the left and right sides of the cluster The standard cards cover most arning light

reuirements; editable cards can be used for less common components that also reuire arning lights

The central instrument cluster receives input data from the CECU via the I-CAN (see Figure 6-6) data bus when the ig-

nition key is rst turned ON, the cluster will perform a calibration power on self-test. Please see pages 6-18 through 6-20for more detailed information on customiing telltails

Power On Self-Test

Ignition key turned ON.

The speedometer and tachometer gauge pointers move from pointing at zero, counter-clockwise to their me-chanical limit (appro -8), stay there for one second and go bac to pointing at ero

At the same time, all LED indicators and telltales are switched on together, and then switched off together.

A Warning sound sequence is also activated ve times without break.

The arning lamps in the cluster are all activated by the CECU, ecept for Telltale Position 5 (usually Refrigerator) andPosition 11 (editable) hich are ired directly to the cluster The CECU receives direct ire inputs for all arning lamps

ith the eception of the Lo Coolant Level arning and the Traction Control/Stability Control lamp These lamp inputsare received via the J1939 (Vehicle CAN) data lin The CECU typically receives the Trailer ABS arnings via the J1939

(Vehicle CAN) data lin, hoever it can also be direct ired to the CECU from the ABS unit on the trailer, if reuired

figure 6-2. Instrument Cluster Componentry

Card locks into place -Installation tab breaks off

Telltale cardspre-installedin slots onboth sides of

cluster

Baseline Cluster

Card locs into place installation tab breas off

Telltale cards

The cluster is installed ith four scres

Single electrical connection on bac of cluster

Standard card

Editable card


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6-4

CVSG Gauges

The right and left instrument panel gauges used ith the multipleed instrumentation are commonly referred to as

Commercial Vehicle Smart Gauges (CVSG) Lie the central instrument cluster, the 2-inch gauges also receive inputdata directly from the CECU CVSGs may be either electronic or mechanical The electronic CVSGs receive digital data

from the CECU via the CVSG data bus The mechanical gauges (ie suspension air pressure, etc) are driven directly byair pressure Both types of gauges receive baclighting signals from the CECU via a 4-ire daisy chained jumper har-

ness that lins one gauge to another

When the ignition key is rst turned ON, all the electronic 2-inch gauges will perform a calibration power on self-test.

The mechanical CVSG do not perform a poer on self-test

Power On Self-Test

Ignition key turned ON.

The gauge pointers move from pointing at zero, counter-clockwise to their mechanical limit (approx. -5), staythere for one second and go bac to pointing at ero

At the same time, all LED indicators are switched on together, and then switched off together.

Additional CVSG gauge information body builders should be aare of:

The CECU sends 2-inch electronic gauges information over a data link (blue wire) between the CECU and

the gauge

2-inch electronic gauges get their power from the CECU.

Yellow = Power wire (9-16 volts) White = Ground (return) wire.

4-way jumper harnesses link each 2-inch gauge together.

p # c f

1 Blue Data, baclighting for Electronic Gauges

2 Bron Baclighting for Mechanical Gauges

3 white Return

4 Yello Poer

Backlighting for 2-inch electronic gauges is sent from the CECU to the gauges via the data link (blue wire).

Optional mechanical gauge (i.e. air suspension) needles are driven mechanically with air pressure. There is

no red arning lamp and the baclighting is poered through the bron ire from the CECU (a pulse-idthmodulated signal) The 4-ay jumper harness is still used to pass all 4 circuits through the gauge to the net

gauge in the chain

Specialty CVSG gauges (i.e. clock, PTO hour meter) are stand alone gauges and are independent of the

CECU

Gauges can be relocated to any position in the dash. To relocate a gauge unhook the connector at thebac and move it to the desired position Plug the jumper ire in (See page 6-9 for instructions on physically

moving the gauge). The connector will require a rm pull to remove it. When reinstalling the connector ensurethat it is fully inserted Both connector socets on the rear of the gauge are the same, either one can be used

n:


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6-5

Panel is held to dashwith four screws

Gauge is heldto panel withthreaded lockcollar

Back of 2-inch gauges

Jumpers

Gauge Collar

TorqueTool

figure 6-3. CVSG Gauges

Data Bus Communication

The multipleed instrumentation system uses several different data lins to transmit input/output data from other systems

to the Cab Electronic Control Unit (CECU), and ultimately to the Central Instrument Cluster and CVSG Gauges SeeFigure 4, Multipleed Instrumentation Bloc Diagram on page 6-6

Panel is held to dashith four scres

Gauge is heldto panel iththreaded loccollar

Bac of 2-inch gauges

Jumpers


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6-6

figure 6-4. Multipleed Instrumentation Bloc Diagram

V-CAN = Vehicle Controller Area Network

The V-CAN, also referred to as the J1939, is used to transmit data beteen the transmission, ABS system,

engine, etc to the Cab Electronic Control Unit (CECU)

I-CAN = Instrumentation Controller Area Netor

The I-CAN provides data lin communication from the Cab Electronic Control Unit (CECU) to the CentralInstrument Cluster

K-Line = Serial Data Bus Line for Diagnostics

The k-Line interface is used to provide data lin communication to and from the Electronic Service Analyst

(ESA) hardare/softare diagnostic service tool and to and from the Cab Electronic Control Unit (CECU)

CVSG Bus

The CVSG bus is a private data bus used to transmit data from the Cab Electronic Control Unit (CECU) tothe individual 2-inch gauges A series of daisy chained jumper harnesses lin each gauge to another


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6-7

The folloing diagram shos the locations of standard connectors in the iring harnesses This allos you to easily locateconnectors to add gauges To add an electronic gauge install the sensor (available from your local kenorth dealer) in the

noted location, plug in the iring harness, and then install the gauge in the dash The gauge ill then need to be activatedYour local kenorth dealer can easily activate the gauge using kenorths Electronic Service Analyst (ESA)

figure 6-5. Instrumentation Harness Interface Diagram


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6-8

The following diagrams show the location of sensors on the rewall junction block. This is to aid in locating these sensors.

figure 6-6. Fireall Air Junction Bloc

figure 6-7. Fuel Filter Restriction Pressure Gauge Sensor Location (typical)

Rear

PrimaryAir

Sensor

Brae

ApplicationSensor

Front

Air LineSensor

Stop

LightSitch

vieW from caB


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6-9

acceSSing gaugeS and SWitcheS

In order to access and install components described later on in the manual, you ill need to no ho to correctly remove

the dash panels ithout causing damage

1 Remove trim beel by prying upard at one of the four pry points Carefully pry the remaining clips

2 Remove (4) scres to remove Speedo - Tach panel

The T470 comes standard

ith a accessory dashpanel - 75 5(193mm 128mm)


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6-10

3 Unclip harness and remove Speedo - Tach panel

4 Remove (7) scres to remove right gauge panel

5 Unclip leads to gauges, effort is reuired to separate the friction loc


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6-11

6 Pinch to unloc connector and remove right gauge panel

7 Unscre gauge collar to remove gauge

8 To remove sitches, push both tabs don

and then push sitch out of plate on top side


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6-12

...then ip over and do the same on the bottom side.

9 Push don to unhoo connector from sitch

10 Remove (4) scres to remove left gauge panel


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6-13

11 Pinch to unloc connectors from sitches

12 Unclip harness and remove left gauge panel

13 Unscre gauge collar to remove gauge


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6-14

14 To remove sitches, push both tabs don





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6-15

acceSSing SWitcheS in the upper daSh

1 Remove trim beel by prying upard at one of the four pry points Carefully unip the remaining clips

2 Remove (4) scres to remove Upper Sitch Cluster


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6-16

3 Pinch to unloc connector and remove Upper Sitch Cluster

4 To remove sitches push both tabs don




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6-17



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6-18

telltale SymBolS

kenorths interior allos Body Builders to customie the dash telltale symbols (arning lights) The editable telltalesymbols are located on removable cards inside the baseline cluster This section ill describe ho to replace and insert

editable cards, as ell as ho to activate the telltale lights

To remove the editable cards follo steps 1-3 in the instructions for accessing gauges and sitches (page 6-9) Remove

the rubber access cover on the side of the cluster by pulling by hand The access cards have a positive loc To removethe card pry upards on the loc ith a small scredriver and pull the card out ith pliers See Figure 6-8 belo that

details the cards To reinstall a card slide it in either by hand or ith pliers Ne cards ill come ith the installation tab(as shown in the gure). After installing the card simply break off the tab by bending.

figure 6-8. Telltale Symbol Standard Cards

All clusters come ith cards that contain a basic set of optional symbols, even if the chassis you have as not orderedith related components The standard cards are shon above (in Figure 6-8) Editable cards are also available from

your local kenorth dealer The left side editable card is shon in Figure 6-9 belo

figure 6-9. Blan Telltale Card


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6-19

Your local kenorth dealer ill also sell a sheet of telltale light icons to install on the editable card The symbols that areavailable are shon in Figure 6-10 belo

figure 6-10. Telltale Icons

Courtesy Lamp Mounting Plate


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6-20

The telltales can then be peeled off of the sheet and applied directly to the card The color of the telltale is controlled bythe light, all of the icons are clear Please see Table 6-1 belo to determine the position and color of the telltales (Posi-

tions are shon on Figure 6-8)

tb 6-1. Telltales Position and Color

ps S f l c Editabe r Fied?

1 Engine Retarder Green Fied

2 wait To Start Yello Fied

3 Fifth wheel Slide Red Fied

4 king Pin Loc Red Editable

5 Refrigerator Green Fied

6 Par Brae Red Fied

7 Chec Transmission Red Editable

8 Transmission Temp Yello Editable

9 Pump Mode Green Editable

10 Fasten Seatbelt Red Fied

11 Blan Yello Editable

12 PTO Yello Editable

13 Emission Temp warning Yello Fied

14 Message waiting Green Editable

15 Trans Ale Loc Green Fied

16 Trailer Body Up Red Fied

Only the positions labeled as editable in the chart above can be changed You must apply the

standard icons on the editable card on all the positions that r

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