Kenworth T440 2010 User manual

®
2010
Kenworth T440/T470
Body Builder Manual

2010 Emissions
Kenworth T440/T470
Body Builder Manual

T470/T440 Body Builder
Manual Contents
iv
12/09
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
v12/09
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

Figures
vi
12/09
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 LARGETANKS. 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 REARTIRES
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

vii 12/09
Figures
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: BUTTERFLYTIE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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

viii
12/09
Tables
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: MODELYEAR (CODE) DESIGNATIONS. . . . . . . . . . . . . . . . . . . . A-1

Section 1
Introduction
12/09
1-1
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
version.
If you require additional information or reference materials, please contact your local Kenworth
dealer.

Section 2
Safety & Compliance
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2-1
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
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.
Example:
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.
Signals a potentially hazardous situation which, if not avoided, could result in minor or mod-
erate injury or damage to the vehicle.
Example:
CAUTION: Never use a torch to make a hole in the rail. Use the appropriate drill bit.
Provides general information: for example, the note could warn you on how to avoid damaging
your vehicle or how to drive the vehicle more efficiently.
Example:
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:
WARNING
Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.
CAUTION
Signals a potentially hazardous situation which, if not avoided, could result in minor or moderate
injury or damage to the vehicle.
NOTE Useful information that is related to the topic being discussed.
WARNING
CAUTION
NOTE

Section 2
Safety & Compliance
12/09 2-2
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 MotorVehicle 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.
IncompleteVehicle 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.”
These documents list the U.S.or Canadian Federal MotorVehicle 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-
tions upon completion of the modifications.
FIGURE 2-1. Incomplete Ve-
hicle Certification Document FIGURE 2-2. Locations of Certifica- tion Labels - Driver’s Door and Frame
NOTE
U.S.EPA Noise Label (U.S. registered vehicles only)
Final Stage Manufacturer
Label to be Installed by
Final Stage 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 vehicle.Upon completion
of the vehicle (installation of the body and any other modifications), you should affix your certification label to the vehicle
as required by Federal law.This tag identifies you as the “Intermediate or Final Stage Manufacturer” and certifies that the
vehicle complies with Federal Motor Vehicle Safety Standards. (See Figure 2–2.) Be advised that regulations affecting the
intermediate and final stage manufacturer may change without notice. Ensure you are referencing the most updated copy
of the regulation during the certification and documentation processes.
In part, if the final stage manufacturer can complete and certify the vehicle within the instruction in the incomplete vehicle
document (IVD) the certification label would need a statement that reads, “This vehicle has been completed in accordance
with the prior manufacturers‚ IVD where applicable.This vehicle conforms to all applicable Federal Motor Vehicle Safety
Standards [and Bumper and Theft Prevention Standards if applicable] in effect in (month, year).”
However, if the vehicle can not be completed and certified with in the guidance provided in the IVD, the final stage manu-
facturer must ensure the vehicle conforms to all applicable Federal Motor Vehicle Safety Standards (FMVSS).The final
stage manufactures certification label would need a statement that reads, “This vehicle conforms to all applicable Federal
Motor Vehicle Safety Standards [and Bumper andTheft Prevention Standards if applicable] in effect in (month, year).”