2010 Kenworth T440 T470 Body Builder Manual-Books Pdf

2010 Kenworth T440 T470 Body Builder Manual
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2010 Emissions, Kenworth T440 T470, Body Builder Manual. T470 T440 Body Builder, Manual Contents, SECTION 1 INTRODUCTION 1 1. SECTION 2 SAFETY AND COMPLIANCE 2 1, SAFETY SIGNALS 2 1. FEDERAL MOTOR VEHICLE SAFETYSTANDARDS COMPLIANCE 2 2. SECTION 3 DIMENSIONS 3 1, DIMENSIONS 3 1, ABBREVIATIONS 3 1. TURNING RADIUS 3 1, KENWORTH AXLE TRACK TIRE WIDTH SUMMARY 3 4.
OVERALL DIMENSIONS 3 5, T470 FIXED GRILLE HOOD W O EXTENDED FRONT FRAME 3 6. T440 DAYCAB 3 7, T470 FIXED GRILLE HOOD WITH EXTENDED FRONT FRAME 3 9. 38 AEROCAB 3 10, RIDE HEIGHTS 3 12, REAR SUSPENSION LAYOUTS 3 14. REYCO 79KB SINGLE REAR AXLE 3 14, REYCO 102 TANDEM REAR AXLE 3 15. NEWAY AD 123 SINGLE REAR AXLE 3 16, NEWAY AD 246 TANDEM SUSPENSION 3 17.
HENDRICKSON PRIMAAX TANDEM SUSPENSION 3 18, HENDRICKSON HMX TANDEM SUSPENSION 3 19. HENDRICKSON RT TANDEM SUSPENSION 3 20, KENWORTH AG 380 TANDEM SUSPENSION 3 22. KENWORTH AG 400 460 TANDEM SUSPENSION 3 23, KENWORTH AG 400L TANDEM SUSPENSION 3 24. KENWORTH AG 460 TANDEM SUSPENSION 3 25, CHALMERS 856 46 TANDEM SUSPENSION 3 26. PUSHER AXLES 3 27, PTO CLEARANCES 3 32, SECTION 4 EXHAUST AND AFTERTREATMENT 4 1.
EXHAUST AND AFTER TREATMENT INFORMATION 4 1, GENERAL GUIDELINES FOR DEF SYSTEM 4 3. INSTALLATION REQUIREMENTS AND DIMENSIONS FOR DEF SYSTEM 4 3. MEASUREMENT REFERENCE POINTS 4 4, GENERAL EXHAUST INFORMATION 4 10. EXHAUST INFORMATION 4 19, SECTION 5 FRAME LAYOUTS 5 1. FRAME LAYOUTS 5 1, COMMON OPTIONAL COMPONENTS 5 2, FRAME LAYOUT INDEX 5 4. CHARTS 5 5, SECTION 6 BODY MOUNTING 6 1, FRONT FRAME DIMENSIONS 6 1.
FRAME INFORMATION 6 2, BODY MOUNTING USING BRACKETS 6 3. MOUNTING HOLES 6 5, BODY MOUNTING USING U BOLTS 6 6. T470 T440 Body Builder, Manual Contents, SECTION 7 FRAME MODIFICATIONS 7 1. FRAME MODIFICATIONS 7 1, MODIFYING FRAME LENGTH 7 2. CHANGING WHEELBASE 7 3, CROSSMEMBERS 7 5, WELDING 7 6.
TORQUE REQUIREMENTS 7 7, SECTION 8 ELECTRICAL 8 1, ELECTRICAL 8 1. MULTIPLEX INSTRUMENTATION 8 1, ACCESSING GAUGES AND SWITCHES 8 9. TELLTALE SYMBOLS 8 17, SPARE RELAYS BODY BUILDER INSTALLED FOR LOADS EXCEEDING 20 AMPS 8 23. ADDITIONAL SPARE CIRCUITS 8 25, REMOTE PTO THROTTLE HARNESS 8 27. MULTIFUNCTION TURN SIGNAL STALK CHASSIS NODE CHASSIS LOAD CENTER 8 28. CHASSIS LOAD CENTER DIMENSIONS 8 30, 2010 ELECTRICAL HARDWARE 8 31.
TRAILER CABLE CONNECTIONS 8 35, FACTORY INSTALLED SNOW PLOW LIGHT WIRING 8 37. SECTION 9 ROUTING 9 1, ROUTING 9 1, ROUTING REQUIREMENTS 9 2. APPENDIX A VEHICLE IDENTIFICATION A 1, VEHICLE IDENTIFICATION LABELS A 2. FIGURE 2 1 INCOMPLETE VEHICLE CERTIFICATION DOCUMENT 2 2. FIGURE 2 2 LOCATIONS OF CERTIFICATION LABELS 2 2, FIGURE 2 3 WEST COAST MIRROR OAT SENSOR 2 6. FIGURE 2 4 AERODYNAMIC MIRROR OAT SENSOR LOCATION 2 7. FIGURE 2 5 INSTRUMENT CLUSTER FOR T440 T470 USED WITH. EPA2010 EMISSION COMPLIANT ENGINES 2 7, FIGURE 3 1 PROSPECTOR TURN CIRCLE ANALYSIS 3 3.
FIGURE 4 1 MEASUREMENT LOCATION OF DEF SUPPLY MODULE PUMP 4 4. FIGURE 4 2 MEASUREMENT LOCATION OF DEF DOSING MODULE INJECTOR 4 4. FIGURE 4 3 ORIENTATION OF DOSING MODULE 4 5, FIGURE 4 4 RH UNDER CAB EXHAUST WITH SMALL MEDIUM OR LARGE TANKS 4 5. FIGURE 4 5 VERTICAL EXHAUST WITH SMALL MEDIUM OR LARGE TANKS 4 6. FIGURE 4 6 RH UNDER CAB EXHAUST WITH CLEAR BACK OF CAB TANK 4 7. FIGURE 4 7 VERTICAL WITH CLEAR BACK OF CAB TANK 4 8. FIGURE 4 8 ROUTING DEF LINES AND DEF TRAP 4 9, FIGURE 4 9 SUPPLY MODULE ALLOWED CLOCKING ANGLES 4 9. FIGURE 4 10 ISOMETRIC VIEW OF RIGHT HAND UNDER DPF AND SCR. WITH SINGLE SOC TAILPIPE 4 11, FIGURE 4 11 TOP VIEW OF RIGHT HAND UNDER DPF AND SCR. WITH SINGLE SOC TAILPIPE 4 11, FIGURE 4 12 RIGHT VIEW OF RIGHT HAND UNDER DPF AND SCR. WITH SINGLE SOC TAILPIPE 4 12, FIGURE 4 13 BACK VIEW OF RIGHT HAND UNDER DPF AND SCR.
WITH SINGLE SOC TAILPIPE 4 12, FIGURE 4 14 ISOMETRIC VIEW OF RIGHT HAND UNDER DPF AND SCR. WITH SINGLE BACK OF CAB TAILPIPE 4 13, FIGURE 4 15 TOP VIEW OF RIGHT HAND UNDER DPF AND SCR. WITH SINGLE BACK OF CAB TAILPIPE 4 13, FIGURE 4 16 RIGHT VIEW OF RIGHT HAND UNDER DPF AND SCR. WITH SINGLE BACK OF CAB TAILPIPE 4 14, FIGURE 4 17 BACK VIEW OF RIGHT HAND UNDER DPF AND SCR. WITH SINGLE BACK OF CAB TAILPIPE 4 14, FIGURE 4 18 ISOMETRIC VIEW OF VERTICAL DPF AND SCR 4 15.
FIGURE 4 19 TOP VIEW OF VERTICAL DPF AND SCR 4 15, FIGURE 4 20 RIGHT VIEW OF VERTICAL DPF AND SCR 4 16. FIGURE 4 21 BACK VIEW OF VERTICAL DPF AND SCR 4 16. FIGURE 4 22 ISOMETRIC VIEW OF RIGHT HAND UNDER DPF AND SCR ON. AEROCAB WITH SINGLE SOC TAILPIPE 4 17, FIGURE 4 23 TOP VIEW OF RIGHT HAND UNDER DPF AND SCR ON. AEROCAB WITH SINGLE SOC TAILPIPE 4 17, FIGURE 4 24 RIGHT VIEW OF RIGHT HAND UNDER DPF AND SCR ON. AEROCAB WITH SINGLE SOC TAILPIPE 4 17, FIGURE 4 25 BACK VIEW OF RIGHT HAND UNDER DPF AND SCR ON. AEROCAB WITH SINGLE SOC TAILPIPE 4 18, FIGURE 5 1 DEF TANK DIMENSIONS 5 3.
FIGURE 6 1 MINIMUM CLEARANCE BETWEEN TOP OF REAR TIRES. AND BODY STRUCTURE OVERHANG 6 2, FIGURE 6 2 MINIMUM BACK OF CAB CLEARANCE 6 3. FIGURE 6 3 SPACER BETWEEN FRAME SILL AND BODY RAIL 6 4. FIGURE 6 4 HIGH COMPRESSION SPRING 6 4, FIGURE 6 5 RUBBER SPACER BETWEEN BRACKETS BETWEEN THE. MOUNTING BOLT AND UPPER BRACKET 6 4, FIGURE 6 6 CROSSMEMBER GUSSET HOLE PATTERN REQUIREMENTS 6 5. FIGURE 6 7 ACCEPTABLE U BOLT MOUNTING WITH WOOD AND. FABRICATED SPACERS 6 6, FIGURE 6 8 CLEARANCE SPACE FOR AIR LINES AND CABLES 6 7. FIGURE 6 9 EXAMPLE OF FISHPLATE BRACKET AT REAR END OF BODY. USED WITH U BOLTS 6 8, FIGURE 7 1 DETAIL OF FRAME EXTENSION AND JOINT WELDING 7 2.
FIGURE 7 2 FRAME INSERT 7 3, FIGURE 7 3 COMPARISON OF ORIGINAL SHORTENED AND. EXTENDED WHEELBASES 7 4, FIGURE 7 4 CROSSMEMBER ADDED WHEN DISTANCE. EXCEEDS 60 INCHES 1524 MM 7 5, FIGURE 8 1 KENWORTH T440 T470 DASH 8 2. FIGURE 8 2 DIESEL EXHAUST FLUID GAUGE 8 2, FIGURE 8 3 MULTIPLEXED INSTRUMENTATION BLOCK DIAGRAM 8 3. FIGURE 8 4 CECU LOCATION 8 4, FIGURE 8 5 INSTRUMENT CLUSTER COMPONENTS 8 5.
FIGURE 8 6 CVSG GAUGES 8 6, FIGURE 8 7 FIREWALL AIR JUNCTION BLOCK VIEW FROM INSIDE OF CAB 8 7. FIGURE 8 8 AIR FILTER RESTRICTION SENSOR ON FIREWALL. AIR JUNCTION BLOCK VIEW FROM ENGINE 8 7, FIGURE 8 9 FUEL FILTER RESTRICTION PRESSURE GAUGE SENSOR LOCATION. TYPICAL 8 8, FIGURE 8 10 TELLTALE SYMBOL STANDARD CARDS 8 17. FIGURE 8 11 BLANK TELLTALE CARD 8 18, FIGURE 8 12 TELLTALE ICONS 8 19. FIGURE 8 13 KENWORTH SPARE SWITCHES 8 20, FIGURE 8 14 SPARE SWITCH HARNESS 8 21.
FIGURE 8 15 SPECIALTY SWITCHES 8 22, FIGURE 8 16 SPARE RELAY CONNECTORS 8 23. FIGURE 8 17 SPARE RELAY HARNESSES 8 24, FIGURE 8 18 SPARE BULLET CONNECTORS 8 25. FIGURE 8 19 SPARE PIGTAIL CONNECTOR 8 26, FIGURE 8 21 CHASSIS POWER DISTRIBUTION CENTER DIMENSIONS 8 30. FIGURE 8 22 DAYCAB HARDWARE LOCATIONS 8 31, FIGURE 8 23 AEROCAB STANDARD HARDWARE LOCATIONS 8 31. FIGURE 8 25 CHASSIS NODE DIMENSIONS 8 32, FIGURE 8 25 SAE J560 TRAILER CONNECTOR.
FIGURE 8 26 ISO 3731 TRAILER CONNECTOR 8 35, FIGURE 8 27 JUNCTION BOX 8 36. FIGURE 8 31 SNOW PLOW ICON 8 37, FIGURE 8 32 CIRCUIT LOCATION 8 37. FIGURE 9 1 CLAMP AND BUTTERFLY CLAMP 9 1, FIGURE 9 2 BUTTERFLY TIE 9 1. FIGURE 9 3 TIE STRAP 9 1, FIGURE 9 4 HEAVY DUTY HD MOUNT 9 2. FIGURE 9 5 DEFINITION OF MEASUREMENTS 9 4, FIGURE A 1 VEHICLE IDENTIFICATION NUMBER VIN A 1.
FIGURE A 2 DRIVERS DOOR AND DOOR FRAME LABELS A 2, FIGURE A 4 FRONT AXLE IDENTIFICATION A 4. FIGURE A 5 REAR AXLE IDENTIFICATION A 4, TABLE 3 1 ABBREVIATIONS USED 3 1. TABLE 3 2 TURNING RADIUS 3 1, TABLE 3 3 AXLE TRACK 3 4. TABLE 3 4 RIDE HEIGHTS IN INCHES 3 12, TABLE 3 5 REAR SUSPENSION OPTIONS 3 14. TABLE 3 6 REAR SUSPENSION OPTIONS 3 15, TABLE 3 7 REAR SUSPENSION OPTIONS 3 16.
TABLE 3 8 REAR SUSPENSION OPTIONS 3 17, TABLE 3 9 REAR SUSPENSION OPTIONS 3 18. TABLE 3 10 REAR SUSPENSION OPTIONS 3 19, TABLE 3 11 REAR SUSPENSION OPTIONS 3 20. TABLE 3 13 REAR SUSPENSION OPTIONS 3 22, TABLE 3 14 REAR SUSPENSION OPTIONS 3 23. TABLE 3 15 REAR SUSPENSION OPTIONS 3 24, TABLE 3 16 REAR SUSPENSION OPTIONS 3 25. TABLE 3 17 REAR SUSPENSION OPTIONS 3 26, TABLE 3 18 GROUND CLEARANCE FOR FUEL TANKS 3 29.
TABLE 3 19 GROUND CLEARANCE FOR BATTERY BOXES 3 30. TABLE 3 20 GROUND CLEARANCE FOR BATTERY BOXES 3 31. TABLE 5 1 ABBREVIATIONS 5 1, TABLE 5 2 FUEL TANK OVERALL LENGTH IN 5 2. TABLE 5 3 BATTERY BOX CENTERFRAME LENGTHS IN 5 2, TABLE 5 4 DEF TANKS SYSTEMS 5 3. TABLE 6 1 SINGLE STEEL RAILS 6 2, TABLE 6 2 INSERTED STEEL RAILS 6 2. TABLE 7 1 CUSTOMARY GRADE 8 UNF OR UNC 7 7, TABLE 7 2 U S CUSTOMARY GRADE 8 METRIC CLASS 10 9 7 7. TABLE 8 1 TELLTALES POSITION AND COLOR 8 18, TABLE 8 3 CHASSIS NODE GUIDELINE 8 28.
TABLE 8 4 WIRE NUMBER GENERAL CATEGORIES 8 33, TABLE 8 6 SAE J560 CONNECTOR 8 34. TABLE 8 7 ISO 3731 CONNECTOR 8 35, TABLE 9 1 EXHAUST SYSTEM CLEARANCE 9 4. TABLE A 1 MODEL YEAR CODE DESIGNATIONS A 1, 12 09 viii. Introduction, This manual was created to provide body builders with appropriate information and guidelines. useful in the body planning and installation process This information will be helpful when installing. bodies or other associated equipment, This manual contains appropriate dimensional information guidelines for mounting bodies guide.
lines for modifying frames electrical wiring information and other information useful in the body. installation process This manual is specific to chassis with 2010 engines. The Body Builder Manual can be very useful when specifying a vehicle particularly when the body. builder is involved in the vehicle definition and ordering process Early in the process professional. body builders can often contribute valuable information that reduces the ultimate cost of the body. installation, In the interest of continuing product development Kenworth reserves the right to change speci. fications or products at any time without prior notice It is the responsibility of the user to ensure. that he is working with the latest released information Check Kenworth com for the latest released. If you require additional information or reference materials please contact your local Kenworth. Safety Compliance, SAFETY SIGNALS, We ve put a number of alerting messages in this book Please read and follow them They are there for your protection. and information These alerting messages can help you avoid injury to yourself or others and help prevent costly dam. age to the vehicle, Key symbols and signal words are used to indicate what kind of message is going to follow Pay special attention to. comments prefaced by WARNING CAUTION and NOTE Please don t ignore any of these alerts. Warnings cautions and notes, WARNING When you see this word and symbol the message that follows is especially vital It signals a. potentially hazardous situation which if not avoided could result in death or serious injury. This message will tell you what the hazard is what can happen if you don t heed the warning. and how to avoid it, WARNING Be sure to use a circuit breaker designed to meet liftgate amperage requirements An incor.
rectly specified circuit breaker could result in a electrical overload or fire situation Follow the liftgate. installation instructions and use a circuit breaker with the recommended capacity. CAUTION Signals a potentially hazardous situation which if not avoided could result in minor or mod. erate injury or damage to the vehicle, CAUTION Never use a torch to make a hole in the rail Use the appropriate drill bit. Provides general information for example the note could warn you on how to avoid damaging. NOTE your vehicle or how to drive the vehicle more efficiently. Note Be sure to provide maintenance access to the battery box and fuel tank fill neck. Please take the time to read these messages when you see them and remember. Indicates a potentially hazardous situation which if not avoided could result in death or serious injury. Signals a potentially hazardous situation which if not avoided could result in minor or moderate. injury or damage to the vehicle, Useful information that is related to the topic being discussed. Safety Compliance, FEDERAL MOTOR VEHICLE SAFETY, STANDARDS COMPLIANCE. As an Original Equipment Manufacturer OEM Kenworth Truck Co ensures that our products comply with all applicable. U S or Canadian Federal Motor Vehicle Safety Standards However the fact that this vehicle has no fifth wheel and that a. Body Builder Intermediate or Final Stage Manufacturer will be doing additional modifications means that the vehicle was. incomplete when it left the build plant See next section and Appendix A for additional information. Incomplete Vehicle Certification, An Incomplete Vehicle Document is shipped with the vehicle certifying that the vehicle is not complete See Figure 2 1. In addition affixed to the driver s side door frame or edge is an Incomplete Vehicle Certification label See Figure 2 2 For. further information on Vehicle Certification and Identification see APPENDIX A VEHICLE IDENTIFICATION. NOTE These documents list the U S or Canadian Federal Motor Vehicle Safety Standard regulations that the. vehicle complied with when it left the build plant You should be aware that if you add modify or alter any. of the components or systems covered by these regulations it is your responsibility as the Intermediate or. Final Stage Manufacturer to ensure that the complete vehicle is in compliance with the particular regula. T470 T440 Body Builder Manual Contents 12 09 iv SECTION 1 lines for modifying frames electrical wiring information and other information useful in the body

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