Kenworth T470, Manual

Page 1: ...Kenworth T470 Body Builder Manual ...

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Page 3: ...Kenworth T470 Body Builder Manual ...

Page 4: ... 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...

Page 5: ...cessing Gauges and Switches 6 9 Accessing Switches in the Upper Dash 6 15 TELLTALE SYMBOLS 6 18 ADDITIONAL 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 7 2 appendix a vehicle identification A 1 labels A 1 component identification a 3 ...

Page 6: ...nd Joint Welding 5 2 FIGURE 5 2 Frame Insert 5 3 FIGURE 5 3 Comparison of Original Shortened and Extended Wheelbases 5 4 FIGURE 5 4 Crossmember Added When Distance Exceeds 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 Di...

Page 7: ...8 ground clearance 3 25 Table 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 24 frame layout dimensions 3 34 table 3 25 frame layout dimensions 3 34 table 3 26 frame layout dimensions 3 36 table 3 27 frame layout dimensions 3 37 table 3 28 frame layout dimensions 3 38...

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Page 9: ...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 p...

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Page 11: ...ate amperage requirements An incorrectly 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 Signals a potentially hazardous situation which if not avoided could result in minor or moderate injury or damage to the vehicle Example CAUTION Never use a torch to make a ho...

Page 12: ...age Manufacturer Chassis Serial Number Major Components and Weights Label Incomplete Vehicle Certification Label Safety Mark Canadian Registry Only Tire Rim and Weight Rating Data label 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 veh...

Page 13: ...As a first priority Kenworth recommends that the dealer customer body builder maintain the system as designed and installed by Kenworth If in certain situations the exhaust systems needs to be revised it will be the responsibility of the modifying party to follow the guidelines established by the engine manufacturer and to obtain their approval for the revised installa tion These guidelines are av...

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Page 15: ...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 Cab BOC Back of Cab TURNING RADIUS Approximate turning radius specifications 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 Mod...

Page 16: ... Est Curb to Curb Turning Radius ft T470 Dual TAS 65 Dana Spicer EFA 20F4 20K Standard Track Alcoa 82365 22 5 X 12 25 Bridgestone M844 425 65R22 5 Tandem 52 Axle Spacing 181 31 5 193 33 5 201 34 5 213 36 5 220 37 5 232 39 240 40 252 42 260 43 272 45 280 46 291 47 5 303 49 5 323 52 5 331 53 5 Table 3 2 continued ...

Page 17: ...xample of Kenworth s turn circle calculation made in Prospector for your specific chassis Your local Kenworth 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 specific T470 T470 ...

Page 18: ...000 20K Alcoa 82365 24 5X12 25 BR M844F 425 65R22 5 Cast 86 5 102 7 Dana Spicer D2000 20K Alcoa 82364 24 5X12 25 BR M844F 425 65R22 5 Cast 82 6 98 8 Axle Pusher Non Steerable Wheel Tire Wheel Orientation Track Dim A Overall Width Dim B NS PSHR WCAL ATLAS Std Track 72 5 16K GAWR Alcoa 82365 24 5X12 25 BR M844F 425 65R22 5 Default Same as RR 79 4 95 6 NS PSHR WCAL ATLAS Wide Track 77 5 Alcoa 82365 2...

Page 19: ...ing of the manual to locate the drawing 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 height All heights are given from the bottom of the frame rail Kenworth also offers dxf files and frame layouts of ordered chassis four weeks prior to build Please speak with your salesman to request this feature when specifying your...

Page 20: ...08 09 3 6 T470 fIXED gRILLE hOOD with Extended Front frame The following drawings are of a T470 fixed grille hood with the optional extended front frame These extended frame rails can be used with or without FEPTO adapters ...

Page 21: ...m the bottom of the frame rail will be 86 9 Below drawings shown with T470 fixed grille hood Suspension heights are measured from the centerlines of the axle spindle to the bottom of the frame rail Add the tire radius dimension to determine overall height to the bottom of the frame rail Note The frame rail height itself will not affect the overall cab height as all components are located from the ...

Page 22: ...e overall height as all components are located from the bottom of the frame rail TABLE 3 4 Ride Heights In Inches Front Suspension Laden Unladen 12K Taperleaf 10 3 11 5 13 2K Taperleaf 10 3 11 5 14 6K Taperleaf 10 3 11 7 16K Taperleaf 10 6 12 3 20K Taperleaf 10 4 11 9 22K Multi stage Taperleaf 10 7 12 7 Rear Suspensions Kenworth AG380 8 5 8 5 Kenworth AG400L 8 5 8 5 Kenworth AG400 9 0 9 0 Kenworth...

Page 23: ...872 46 H HS 11 0 12 5 Hendrickson HAS 230 23K Rating 10 0 10 0 Hend HMX460 16 5 Saddle 9 5 10 6 Hend HMX460 17 5 Saddle 10 5 11 6 Hend HMX460 46K 18 5 Saddle 11 5 12 6 Hendrickson Primaax 46K Rating 10 0 10 0 Hendrickson RT403 40K Rating 9 7 10 7 Hendrickson RT463 6 0 Saddle 10 0 11 1 Hendrickson RT463 7 19 Saddle 11 2 12 5 Hendrickson RT463 7 94 Saddle 11 9 13 3 Neway AD123 23K Rating 10 0 10 0 N...

Page 24: ... suspension components See Tables 5 1 and 5 2 on page 5 7 It would be a good idea in this case to order the frame layout of your chassis along with your truck order This can be done on any Kenworth truck and will be provided 4 weeks ahead of the build schedule If there are hole locations that are not detailed please work with your local Kenworth Dealer to request that information Additionally opti...

Page 25: ...andem Rear Axle Shown with a 52 Axle Spacing Reyco 102 Suspension Data TABLE 3 6 Rear Suspension Options Suspension Type Rating Axle Spacing Laden Ride Height Unladen Ride Height Reyco 102 Tandem 38K 52 9 2 10 8 Reyco 102 Tandem 40K 52 9 2 10 8 ...

Page 26: ... Neway AD 123 Single Rear Axle Optional Neway AD Single Suspensions TABLE 3 7 Rear Suspension Options Suspension Type Rating Axle Spacing Laden Ride Height Unladen Ride Height Neway AD123 single 23K 10 10 Neway AD126 single 26K 10 10 ...

Page 27: ...em Suspension Shown with a 54 Axle Spacing Optional Neway AD Tandem Suspensions TABLE 3 8 Rear Suspension Options Suspension Type Rating Axle Spacing Laden Ride Height Unladen Ride Height Neway AD246 tandem 46K 54 10 10 Neway AD246 tandem 46K 60 10 10 ...

Page 28: ...le Spacings Optional Hendrickson Primaax Tandem Suspensions TABLE 3 9 Rear Suspension Options Suspension Type Rating Axle Spacing Laden Ride Height Unladen Ride Height Hendrickson Primaax Tandem 46K 54 10 10 Hendrickson Primaax Tandem 46K 60 10 10 Hendrickson Primaax Tandem 46K 72 10 10 ...

Page 29: ...ptions Suspension Type Rating Axle Spacing Laden Ride Height Unladen Ride Height Hendrickson HMX400 16 5 saddle 40K 54 9 5 10 6 Hendrickson HMX400 17 5 saddle 40K 54 10 5 11 6 Hendrickson HMX460 16 5 saddle 46K 54 9 5 10 6 Hendrickson HMX460 17 5 saddle 46K 54 10 5 11 6 Hendrickson HMX460 18 5 saddle 46K 54 11 5 12 6 Hendrickson HMX460 18 5 saddle 46K 60 11 5 12 6 ...

Page 30: ...uspensions TABLE 3 11 Rear Suspension Options Suspension Type Rating Axle Spacing Laden Ride Height Unladen Ride Height Hendrickson RT463 6 saddle 46K 54 10 0 11 1 Hendrickson RT463 7 19 saddle 46K 54 11 2 12 5 Hendrickson RT463 7 94 saddle 46K 54 11 9 13 3 Hendrickson RT463 6 saddle 46K 60 10 0 11 1 Hendrickson RT403 7 19 saddle 40K 52 9 7 10 7 ...

Page 31: ...m Suspension Shown with a 54 Axle Spacing Without Track Rods Optional Hendrickson RT Tandem Suspensions TABLE 3 12 Rear Suspension Options Suspension Type Rating Axle Spacing Laden Ride Height Unladen Ride Height Hendrickson RT403 6 saddle 40K 52 7 6 8 6 ...

Page 32: ... 18 kenworth ag 380 Tandem Suspension Shown with a 52 Axle Spacing Kenworth AG 380 Suspension Data TABLE 3 13 Rear Suspension Options Suspension Type Rating Axle Spacing Laden Ride Height Unladen Ride Height AG 380 38K 52 8 5 8 5 ...

Page 33: ...sion Shown with a 52 Axle Spacing Optional Kenworth Tandem Suspensions TABLE 3 14 Rear Suspension Options Suspension Type Rating Axle Spacing Laden Ride Height Unladen Ride Height Kenworth AG 400 40K 52 9 9 Kenworth AG 400 40K 54 9 9 Kenworth AG 460 46K 54 10 5 10 5 ...

Page 34: ...dem Suspension Shown with a 52 Axle Spacing Optional Kenworth Tandem Suspensions TABLE 3 15 Rear Suspension Options Suspension Type Rating Axle Spacing Laden Ride Height Unladen Ride Height Kenworth AG 400L 40K 52 8 5 8 5 Kenworth AG 400L 40K 54 8 5 8 5 ...

Page 35: ...orth AG 460 Tandem Suspension Shown with a 60 Axle Spacing Optional Kenworth Tandem Suspensions TABLE 3 16 Rear Suspension Options Suspension Type Rating Axle Spacing Laden Ride Height Unladen Ride Height Kenworth AG 460 46K 60 10 5 10 5 ...

Page 36: ...Suspension Type Rating Axle Spacing Laden Ride Height Unladen Ride Height Chalmers 854 40 L HS 40K 54 9 6 11 1 Chalmers 854 40 H HS 40K 54 10 9 12 4 Chalmers 854 46 L 46K 54 8 9 11 3 Chalmers 854 46 L HS 46K 54 9 6 11 3 Chalmers 854 46 H 46K 54 10 1 12 5 Chalmers 854 46 H HS 46K 54 10 9 12 5 Chalmers 860 46 H HS 46K 60 10 9 12 5 Chalmers 872 46 H HS 46K 72 11 0 12 5 ...

Page 37: ... using the pusher layouts to determine available frame space please be aware that clearances required are not shown For information that may not be detailed in these drawings work with your local Kenworth Dealer to request that information Watson Chalin Tru Track Alumilite 13 2K Steerable Pusher Watson Chalin Tru Track 20K Steerable Pusher ...

Page 38: ...Section 3 Dimensions 08 09 3 24 Watson Chalin Atlas 22 5K Non Steerable Pusher ...

Page 39: ...on page 3 14 For comparison the FS value shown is 11 4 unladen and 10 4 laden TABLE 3 18 Ground Clearance for Fuel Tanks Front Suspension Front Tires Rear Suspension Rear Tires Component Dimension A Distance from Bottom of Frame Rail in Dimension B Ground Clearance in Unladen Laden 20K Taper leaf Spring M844F 425 65R22 5 Tires Hendrickson HMX 460 17 5 Saddle Height M711 11R24 5 22 Fuel Tank 16 3 1...

Page 40: ...s Component Dimension A Distance from Bottom of Frame Rail in Dimension B Ground Clearance in Unladen Laden 20K Taper leaf Spring M844F 425 65R22 5 Tires Hendrickson HMX 460 17 5 Saddle Height M711 11R24 5 Battery Box with Air Tanks 17 3 16 2 13 9 Vocational Battery Box with Air Tanks 17 8 15 7 13 4 Single DPF Box 15 5 17 9 15 6 A B ...

Page 41: ...ipes back of cab mount DPF RH under 68 0 Dimension B is the tailpipe length TABLE 3 21 Unladen Stack Height For approximate unladen stack height 12 000 pound springs use the following frame heights Tire Size Top of Rail Ft Suspension 11R24 5 43 5 12K 11R22 5 42 5 12K 285 75R24 5 42 12K 295 75R22 5 41 5 12K 425 65R22 5 43 2 20K 385 65R22 5 42 4 20K Use Prospector frame heights for more accurate res...

Page 42: ...ough your local Kenworth dealer Multiple PTO s are shown for layout purposes only Power equipment i e drive shafts power pumps are not included Body builders should select the appropriate PTO for their application and customer requirements Manual Transmission Bottom view from right rear of chassis View from Front Bottom view from forward right Bottom view from front left under ...

Page 43: ...Section 3 Dimensions 08 09 3 29 Allison Transmission Allison transmission are 10 bolt Bottom view Right front Left view Front view ...

Page 44: ...tent across the entire section to aid in the comparison of one layout option versus another TABLE 3 22 Frame Layout Dimensions Dimension Location A RH Side Under Cab Below Rail B RH Side Above Rail C LH Side Under Cab Below Rail D LH Side Above Rail E RH Side Under Rail Back of Cab F LH Side Under Rail Back of Cab BOC Back of Cab The layouts are organized by type specifically the arrangement of un...

Page 45: ...de of cab with the vocational style battery box LH BOC fuel tank LH under and DPF RH under Charts located on pages 3 35 D3 is used for single exhaust located side of cab with fuel tank LH under DPF RH under and battery box BOC Note This layout can be used with a modular sleeper dimensions will not change Charts located on pages 3 36 D4 is used for single exhaust right hand RH back of cab with batt...

Page 46: ...n pages 3 39 D7 is used for vertical independent exhaust RH back of cab including DPF battery box LH under and fuel tank RH under Charts located on pages 3 40 D8 is used for vertical independent exhaust RH back of cab including DPF battery box LH under tool box RH under and fuel tanks located BOC Charts located on pages 3 41 D9 is used for vertical independent exhaust RH back of cab including DPF ...

Page 47: ...ack of cab including DPF vocational style battery box LH BOC fuel tank LH under and fuel tank RH under Charts located on page 3 43 D11 is used for vertical independent exhaust RH back of cab including DPF fuel tanks LH and RH under and battery box LH BOC Charts located on page 3 44 ...

Page 48: ...ank Length in Dim F Day Cab BOC to End of Fuel Tank in Dim F Extended Day Cab BOC to End of Fuel Tank in Gallons Tank Length in Dim F Day Cab BOC to End of Fuel Tank in Dim F Extended Day Cab BOC to End of Fuel Tank in 40 25 6 22 5 16 8 45 22 9 19 8 14 1 56 35 5 32 4 26 7 60 30 5 27 4 21 7 60 38 0 34 9 29 2 75 38 5 35 4 29 7 75 47 3 44 2 38 5 90 45 5 42 4 36 7 100 62 2 59 1 53 4 100 50 0 46 9 41 2...

Page 49: ... 5 22 Fuel Tank 24 5 Fuel Tank Gallons Tank Length in Dim C Day Cab BOC to Batt Box in Dim C Extended Day Cab BOC to Batt Box in Gallons Tank Length in Dim C Day Cab BOC to Batt Box in Dim C Extended Day Cab BOC to Batt Box in 56 35 5 12 6 6 9 602 30 5 7 6 1 9 60 38 0 15 1 9 4 75 38 5 15 6 9 9 75 47 3 24 4 18 7 90 45 5 22 6 16 9 100 62 2 39 3 33 6 100 50 0 27 1 21 4 120 74 2 51 3 45 6 110 54 9 32 ...

Page 50: ...nd of Fuel Tank in Dim C Extended Day Cab BOC to End of Fuel Tank in Gallons Tank Length in Dim C Day Cab BOC to End of Fuel Tank in Dim C Extended Day Cab BOC to End of Fuel Tank in 56 35 5 3 7 9 4 60 30 5 8 7 14 4 60 38 0 1 2 6 9 75 38 5 0 7 6 4 751 2 47 3 8 1 2 4 901 2 45 5 6 3 0 6 100 62 2 23 0 17 3 100 50 0 10 8 5 1 120 74 2 35 0 29 3 110 54 9 15 7 10 0 120 60 5 21 3 15 6 135 67 2 28 0 22 3 1...

Page 51: ...4 5 Fuel Tank Gallons Tank Length in Dim F Day Cab BOC to End of Fuel Tank in Gallons Tank Length in Dim F Day Cab BOC to End of Fuel Tank in 40 25 6 22 5 45 22 9 19 8 56 35 5 32 4 60 30 5 27 4 60 38 0 34 9 75 38 5 35 4 75 47 3 44 2 90 45 5 42 4 100 62 2 59 1 100 50 0 46 9 120 74 2 71 1 110 54 9 51 8 120 60 5 57 4 135 67 2 64 1 150 74 5 71 4 NOTE Dimension F is calculated using a standard sized ba...

Page 52: ...y Cab RH BOC 5 4 10 9 22 Fuel Tank 24 5 Fuel Tank Gallons Tank Length in Dim C Day Cab BOC to Batt Box in Gallons Tank Length in Dim C Day Cab BOC to Batt Box in 56 35 5 12 7 602 30 5 7 6 60 38 0 15 2 75 38 5 15 7 75 47 3 24 5 90 45 5 22 7 100 62 2 39 4 100 50 0 27 2 120 74 2 51 4 110 54 9 32 1 120 60 5 37 7 135 67 2 44 4 150 74 5 51 7 1 Maximum Day Cab Fuel Tank to Match Dimension A 2 Maximum Day...

Page 53: ...PF to BOC in Dimension B Max from BOC in T470 Day Cab RH BOC 7 2 10 9 22 Fuel Tank 24 5 Fuel Tank Gallons Tank Length in Dim C Day Cab BOC to Batt Box in Gallons Tank Length in Dim C Day Cab BOC to Batt Box in 56 35 5 12 6 601 2 30 5 7 6 60 38 0 15 1 75 38 5 15 6 75 47 3 24 4 90 45 5 22 6 100 62 2 39 3 100 50 0 27 1 120 74 2 51 3 110 54 9 32 0 120 60 5 37 6 135 67 2 44 3 150 74 5 51 6 ...

Page 54: ...Tank Length in Dim A Day Cab BOC in Dim A Extended Day Cab BOC in Gallons Tank Length in Dim A Day Cab BOC in Dim A Extended Day Cab BOC in 56 35 5 3 7 9 4 60 30 5 8 7 14 4 60 38 0 1 2 6 9 75 38 5 0 7 6 4 751 47 3 8 1 2 4 90 45 5 6 3 0 6 1002 62 2 23 0 17 3 100 50 0 10 8 5 1 120 74 2 35 0 29 3 1101 54 9 15 7 10 0 1202 60 5 21 3 15 6 135 67 2 28 0 22 3 150 74 5 35 3 29 6 1 Maximum Day Cab Fuel Tank...

Page 55: ...ded Day Cab BOC to End of Fuel Tank Gallons Tank Length in Dim F Day Cab BOC to End of Fuel Tank Dim F Extended Day Cab BOC to End of Fuel Tank 40 25 6 22 5 16 8 45 22 9 19 8 14 1 56 35 5 32 4 26 7 60 30 5 27 4 21 7 60 38 0 34 9 29 2 75 38 5 35 4 29 7 75 47 3 44 2 38 5 90 45 5 42 4 36 7 100 62 2 59 1 53 4 100 50 0 46 9 41 2 120 74 2 71 1 65 4 110 54 9 51 8 46 1 120 60 5 57 4 51 7 135 67 2 64 1 58 ...

Page 56: ...Cab BOC to Batt Box in Dim C Extended Day Cab BOC to Batt Box in Gallons Tank Length in Dim C Day Cab BOC to Batt Box in Dim C Extended Day Cab BOC to Batt Box in 56 35 5 12 6 6 9 60 30 5 7 6 1 9 601 38 0 15 1 9 4 751 38 5 15 6 9 9 752 47 3 24 4 18 7 902 45 5 22 6 16 9 100 62 2 39 3 33 6 100 50 0 27 1 21 4 120 74 2 51 3 45 6 110 54 9 32 0 26 3 120 60 5 37 6 31 9 135 67 2 44 3 38 6 150 74 5 51 6 45...

Page 57: ... Length in Dim A Day Cab BOC in Dim C Day Cab BOC to Batt Box in Gallons Tank Length in Dim A Day Cab BOC in Dim C Day Cab BOC to Batt Box in 56 35 5 3 7 12 6 60 30 5 8 7 7 6 602 38 0 1 2 15 1 752 38 5 0 7 15 6 751 47 3 8 1 24 4 90 45 5 6 3 22 6 100 62 2 23 0 39 3 100 50 0 10 8 27 1 120 74 2 35 0 51 3 1101 54 9 15 7 32 0 120 60 5 21 3 37 6 135 67 2 28 0 44 3 150 74 5 35 3 51 6 1 Maximum RH Day Cab...

Page 58: ...ab BOC to Fuel Tank in Dim A C Extended Day Cab BOC to Fuel Tank in Gallons Tank Length in Dim A C Day Cab BOC to Fuel Tank in Dim A C Extended Day Cab BOC to Fuel Tank in 56 35 5 3 7 9 4 60 30 5 8 7 14 4 60 38 0 1 2 6 9 75 38 5 0 7 6 4 751 47 3 8 1 2 4 90 45 5 6 3 0 6 1002 62 2 23 0 17 3 100 50 0 10 8 5 1 120 74 2 35 0 29 3 1101 54 9 15 7 10 0 1202 60 5 21 3 15 6 135 67 2 28 0 22 3 150 74 5 35 3 ...

Page 59: ...rawings of the T470 extended front frame 73 and standard 50 5 front frame settings All dimensions are in inches in They illustrate measurements useful to the installation of front frame equipment and bumpers Kenworth also offers dxf files and frame layouts of ordered chassis four weeks prior to build Please work with your Kenworth sales representative to request this feature when specifying your c...

Page 60: ...7 8 x 2 7 8 x 1 4 27 33 3 280 000 5 53 Critical Clearances Rear Wheels and Cab Insufficient clearance between rear tires and body structure may cause damage to the body during suspension movement Allow at least 8 inches clearance See Figure 4 1 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 ...

Page 61: ...y mounting brackets or U bolts Failure to comply may result in personal injury death equipment or property damage Body Mounting Using Brackets Always install a spacer between the body subframe and the top flange of the frame rail Failure to do so may result in corrosion due to dissimilar materials and equipment damage Installation of a spacer between the body subframe and the top flange of the fra...

Page 62: ... limited amount of relative move ment bolted securely but not too rigid Brackets should allow for slight movement between the body and the chassis For instance Figure 4 4 shows a high compression spring between the bolt and the bracket Figure 4 4 High Compression Spring Figure 4 5 Rubber Spacer Between Brackets Between the Mounting Bolt and Upper Bracket Another possibility is mounting a rubber sp...

Page 63: ...e of the frame rail If the frame rail flanges are modified or damaged the rail may fail prematurely Mount the body us ing body mounting brackets or U bolts Failure to comply may result in personal injury death equipment or property damage Use care when drilling the frame web so the wires and air lines routed inside the rail are not damaged failure to do so may cause an inoperable electrical or air...

Page 64: ...g the frame flange See Figure 4 7 Body Structure Wood Sill 0 5 12 Minimum Truck Frame Frame Rail Spacer Fabricated Steel or Hardwood U Bolt Spacer Hardwood U Bolt FIGURE 4 7 Acceptable U Bolt Mounting with Wood and Fabricated Spacers inch mm Do not allow spacers and other body mounting parts to interfere with brake lines fuel lines or wiring harnesses routed inside the frame rail Crimped or damage...

Page 65: ...d frame flanges may result in premature frame failure Use a larger size U bolt Use a hardwood spacer as shown in Figure 4 7 Failure to comply may result in personal injury death equipment or property damage Frame Rail Air Lines and Wiring Harness Check Clearance Space for Air Lines and Wiring U Bolt Frame Rail Spacer Hardwood or Steel U Bolt Spacer WARNING ...

Page 66: ...nd that the last body attachment be made with a fishplate bracket See Figure 4 9 This provides a firm attaching point and helps prevent any relative fore or aft movement between the body and frame FIGURE 4 9 Example of Fishplate Bracket at Rear End of Body used with U Bolts Body Structure Frame Rail ...

Page 67: ...lure to comply may result in personal injury death equipment or property damage Do not drill closely spare holes in the web of the frame Hole centers of two adjacent holes should be spaced no less than twice the diameter of the largest hole Closer spacing may induce a failure between the holes Failure to comply may result in personal injury death equipment or property damage An appropriately sized...

Page 68: ...1 See page 5 6 for more information on welding frames Frame Insert A frame insert must be added after welding a frame rail extension to compensate for lost strength The insert should be of the same material as the frame member or of steel and at least equal to the frame rail in thickness Attachment of the insert to the frame should be made with Ream Fit heat treated bolts 5 8 in 16 mm dia or the n...

Page 69: ... the new rear suspension mounting bolts All new mounting holes must pass through the original rail and the insert outsert Failure to do so may cause excessive stress in the original rail due to additional holes Failure to comply may result in personal injury death equipment or property damage When relocating a suspension bracket do not mount it on the extended added section of a frame rail The sus...

Page 70: ... equipment or property damage Before the rear suspension is relocated check the new location of the spring hanger brackets The new holes for the spring hanger brackets must not overlap existing holes and should not come any closer than 2 inches 50 mm to existing holes FIGURE 5 3 Comparison of Original Shortened and Extended Wheelbases WARNING Original Wheelbase Extended Wheelbase Shortened Wheelba...

Page 71: ...rength The maximum allowable distance between adjacent crossmembers is 60 inches 1524 mm If the distance between adja cent crossmembers exceeds this dimension add a crossmember between them See Figure 5 4 Before Wheelbase is Lengthened Less Than 60 Greater Than 60 Additional Crossmember FIGURE 5 4 Crossmember Added When Distance Exceeds 60 Inches 1524 mm ...

Page 72: ... the entire length of the crack Precautions Before welding disconnect the negative terminal battery cable Failure to comply may result in equipment damage Before welding disconnect the alternator terminals Failure to do so may result in damage to the voltage regulator and or alternator To prevent damage to electrical equipment disconnect battery cables before arc welding on a truck and be sure tha...

Page 73: ...65 195 3 4 394 462 290 340 7 8 517 626 380 460 1 952 1129 800 830 1 1 8 1346 1591 990 1170 1 1 4 1877 2217 1380 1630 Torque values apply to fasteners with clean threads lightly lubricated with hardened steel washers and nylon insert nuts TABLE 5 2 U S Customary Grade 8 Metric Class 10 9 Torque Fastener Nm Lb Ft M6 9 15 7 11 M8 23 31 17 23 M10 33 43 24 32 M12 75 101 55 75 M14 134 164 99 121 M16 163...

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Page 75: ...emote PTO Throttle harness MULTIPLEX INSTRUMENTATION Kenworth utilizes Multiplex instrumentation and wiring to improve quality and the capability of our trucks Multiplexing uti lizes the industry standard J1939 data bus to send multiple signals over a single twisted pair of wires instead of individual wires for each function The advantages are fewer wires sensors and connections that provide great...

Page 76: ...ion system is the Cab Electronic Control Unit CECU The CECU is located behind 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 wiring The CECU interprets the various inputs and monitors controls the functions for each input through the CECU software Output signals from the CECU provide data for the g...

Page 77: ...l LED indicators and telltales are switched on together and then switched off together A Warning sound sequence is also activated five times without break The warning lamps in the cluster are all activated by the CECU except for Telltale Position 5 usually Refrigerator and Position 11 editable which are wired directly to the cluster The CECU receives direct wire inputs for all warning lamps with t...

Page 78: ...e 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 Pin Color Function 1 Blue Data backlighting for Electronic Gauges 2 Brown Backlighting for Mechanical Gauges 3 White Return 4 Ye...

Page 79: ...auge is held to panel with threaded lock collar Back of 2 inch gauges Jumpers Gauge Collar Torque Tool FIGURE 6 3 CVSG Gauges Data Bus Communication The multiplexed instrumentation system uses several different data links 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 See Figure 4 Multiplexed...

Page 80: ... communication from the Cab Electronic Control Unit CECU to the Central Instrument Cluster K Line Serial Data Bus Line for Diagnostics The K Line interface is used to provide data link communication to and from the Electronic Service Analyst ESA hardware software 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 transmi...

Page 81: ...es To add an electronic gauge install the sensor available from your local Kenworth dealer in the noted location plug in the wiring harness and then install the gauge in the dash The gauge will then need to be activated Your local Kenworth dealer can easily activate the gauge using Kenworth s Electronic Service Analyst ESA FIGURE 6 5 Instrumentation Harness Interface Diagram ...

Page 82: ...n the firewall junction block This is to aid in locating these sensors FIGURE 6 6 Firewall Air Junction Block FIGURE 6 7 Fuel Filter Restriction Pressure Gauge Sensor Location typical Rear Primary Air Sensor Brake Application Sensor Front Air Line Sensor Stop Light Switch View from cab ...

Page 83: ...n in the manual you will need to know how to correctly remove the dash panels without causing damage 1 Remove trim bezel by prying upward at one of the four pry points Carefully pry the remaining clips 2 Remove 4 screws to remove Speedo Tach panel The T470 comes standard with a accessory dash panel 7 5 x 5 193mm x 128mm ...

Page 84: ...08 06 Section 6 Electrical 6 10 3 Unclip harness and remove Speedo Tach panel 4 Remove 7 screws to remove right gauge panel 5 Unclip leads to gauges effort is required to separate the friction lock ...

Page 85: ...Section 6 Electrical 6 11 6 Pinch to unlock connector and remove right gauge panel 7 Unscrew gauge collar to remove gauge 8 To remove switches push both tabs down and then push switch out of plate on top side ...

Page 86: ...08 06 Section 6 Electrical 6 12 then flip over and do the same on the bottom side 9 Push down to unhook connector from switch 10 Remove 4 screws to remove left gauge panel ...

Page 87: ...08 06 Section 6 Electrical 6 13 11 Pinch to unlock connectors from switches 12 Unclip harness and remove left gauge panel 13 Unscrew gauge collar to remove gauge ...

Page 88: ...Section 6 Electrical 6 14 14 To remove switches push both tabs down and then push switch out of plate on top side then flip over and do the same on the bottom side 15 Push down to unhook connector from switch ...

Page 89: ...tion 6 Electrical 6 15 Accessing Switches in the Upper Dash 1 Remove trim bezel by prying upward at one of the four pry points Carefully unzip the remaining clips 2 Remove 4 screws to remove Upper Switch Cluster ...

Page 90: ... 6 Electrical 6 16 3 Pinch to unlock connector and remove Upper Switch Cluster 4 To remove switches push both tabs down and then push switch out of plate on top side then flip over and do the same on the bottom side ...

Page 91: ...08 06 Section 6 Electrical 6 17 5 Push down to unhook connector from switch ...

Page 92: ...o remove the card pry upwards on the lock with a small screwdriver and pull the card out with pliers See Figure 6 8 below that details the cards To reinstall a card slide it in either by hand or with pliers New cards will come with the installation tab as shown in the figure After installing the card simply break off the tab by bending Figure 6 8 Telltale Symbol Standard Cards All clusters come wi...

Page 93: ...6 19 Your local Kenworth dealer will also sell a sheet of telltale light icons to install on the editable card The symbols that are available are shown in Figure 6 10 below Figure 6 10 Telltale Icons Courtesy Lamp Mounting Plate ...

Page 94: ...ission Temp Yellow Editable 9 Pump Mode Green Editable 10 Fasten Seatbelt Red Fixed 11 Blank Yellow Editable 12 PTO Yellow Editable 13 Emission Temp Warning Yellow Fixed 14 Message Waiting Green Editable 15 Trans Axle Lock Green Fixed 16 Trailer Body Up Red Fixed 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 t...

Page 95: ...the amperage requirements of the new circuit to the electrical current capacity of the existing chassis circuit before adding the body or other equipment Failure to com ply may result in personal injury death equipment or property damage The central electrical panel CEP has a total of 17 spare circuits 3 of which can be connected to spare relays on the CEP They include 9 spare battery circuits 4 s...

Page 96: ...e 6 11 Spare Bullet Connectors 3 Plug one end of a K333 127 2 pigtail harness into the appropriate spare circuit bullet connector See Figure 6 12 Figure 6 12 Spare Pigtail Connector 4 Connect the other end of the pigtail harness to the accessory If the accessory is to be controlled by a dash switch connect a ground wire to the switch then to the accessory 5 Install the correct rated fuse or circui...

Page 97: ...he gauge panel locate one of the spare relay connectors not currently used See Figure 6 13 Figure 6 13 Spare Relay Connectors 3 Plug one end of a spare relay harness PN P92 1947 X into the appropriate spare relay circuit connector Use a P92 1947 1 or 3 harness for a Normally Open NO spare relay circuit Use a P92 1947 2 or 4 harness for a Normally Closed NC spare relay circuit Note ...

Page 98: ...guideline to avoid exceeding the current limits of the TSM TABLE 6 2 TSM Guideline Circuit TSM Current Limit General Lamp Limits Low Beam Headlamp LH or RH 6 1A for T470 1 65W bulb each side maximum High Beam Headlamp LH or RH 6 7A for T470 1 65W bulb each side maximum Left Turn Left Trailer Turn Lamps 20A combined between left turn and left trailer turn 9 1156 or 1157 bulbs on left side of truck ...

Page 99: ...ollow the engine manufacturer s guidelines for use of these circuits See your engine manufacturer to verify that the engine is programed correctly for the intended applications Failure to comply may result in personal injury death equipment or property damage Mating View Contact Function Circuit No 1 2 3 COMMON RTN 1 SWITCH GRN3115 4 REMOTE THROTTLE SIGNAL BLU3144 5 PTO ON OFF GRA3511 6 REMOTE THR...

Page 100: ...ther to separate components is referred to as a butterfly clamp Note the metal portion of clamps shall be stainless steel or otherwise made capable through plating or other means of passing a 200 hour salt spray test per ASTM B117 without rusting Figure 7 1 Clamp and Butterfly Clamp Butterfly Tie A tough plastic nylon or equivalent locking dual clamp tie strap used to separate bundles or single li...

Page 101: ... or coolant hose bundles may be in cluded in the bundle if they are isolated from the hoses with a covering of convoluted plastic tubing EXCEPTIONS Battery cables including jump start cables may be bundled with or tied to the charging wire harness They shall not be bundled with or tied directly to any other components including hoses wires or bundles They shall be separated from other routed compo...

Page 102: ...scharge Hoses Wires or hoses shall not be tied to the high temperature air compressor discharge hose Hoses and wires may be routed across the air compressor discharge hose at a distance of 18 inches 457 mm or greater from the compressor discharge port In this case the crossing hoses and wires shall be butterfly clamped to the air compressor discharge hose and cov ered with convoluted tubing at the...

Page 103: ...and hydraulic tanks crossing tank parallel to tank end of tank aluminum ceramic coated exhaust pipe crossing tank n a n a n a n a 2 minimum 2 minimum 1 minimum 1 5 minimum Air hose nylon wire braid 3 minimum 2 minimum 8 minimum 3 minimum Exhaust system pipe muffler Heatshield or blanket Component Shielded dimension Unshielded dimension Figure 7 5 Definition of measurements Heat shielding must not ...

Page 104: ... marked on the Incomplete Vehicle Certification Label on trucks It is located either on the driver s door edge or door frame See Figure A 2 Chassis Number Locations The Chassis Number comprises the last six characters of the VIN The vehicle chassis number is shown in multiple locations Left side of cab lower right corner of door frame stamped plate Tire Rim and Weight Rating Data label Major Compo...

Page 105: ...Front and Rear Axle TIRE RIM SIZES AND INFLATION PRESSURES Tire Rim Sizes and Cold Pressure Minimums GVWR is the TOTAL WEIGHT the vehicle is designed to carry This includes the weight of the empty vehicle loading platform occupants fuel and any load Incomplete Vehicle Certification Label The Incomplete Vehicle Certification Label contains the chassis VIN date of manufacture and listing of applicab...

Page 106: ... cab in terior and exterior colors This label is located either underneath the dash to the left of the steering column support inside the glovebox or on the passenger s door frame COMPONENT IDENTIFICATION Each of the following components has their own identification label Engine Identification The engine serial number is stamped on a plate located on the left front of the engine For further inform...

Page 107: ...ication Illustrated identification tag locations are typical Actual locations may vary by axle manufacturer and with single versus tandem axles The rear axle identification numbering system includes two labels or stamps Axle Housing Number Tag located on the left forward side of the housing arm This tag identifies the 1 axle housing Axle Differential Carrier Identification located on the top side ...

Page 108: ...rame Dimensions 4 4 Frame drilling 5 1 Frame layouts 3 34 through 3 44 Frame modifications 5 1 Frame welding 5 1 5 5 Front axle serial number A 4 G Ground clearance 3 25 and 3 26 H Height Ride 3 18 I Incomplete vehicle certification 2 2 Incomplete Vehicle Certification Label A 2 M Mounting holes frame 4 3 Multiplexed Instrumentation 6 1 N Noise Emission Label A 3 Noise Requirements 2 3 Notes 2 1 P...

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Page 110: ...08 09 Kenworth Truck Company P O Box 1000 Kirkland WA 98083 425 828 5000 ...