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Kenworth t800 User Manual

Kenworth t800
276 pages
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Kenworth Heavy Duty
Body Builder Manual
2012
®

Table of Contents

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Kenworth t800 Specifications

General IconGeneral
TorqueUp to 2, 050 lb-ft
Front Axle Capacity12, 000 lbs
Rear Axle Capacity40, 000 lbs
Cab ConfigurationDay cab
SuspensionAir ride

Summary

Introduction

Introduction

Purpose of the manual for body builders in planning and installation.

Safety and Compliance

SAFETY SIGNALS

Explains the use of signal words and symbols for safety alerts.

FEDERAL MOTOR VEHICLE SAFETY STANDARDS COMPLIANCE

Details compliance requirements for incomplete vehicles and body builder responsibilities.

Incomplete Vehicle Certification

Information on the Incomplete Vehicle Document and certification labels.

Noise and Emissions Requirements

Discusses compliance with noise and exhaust emissions regulations and system modifications.

Fuel System

Highlights critical aspects of the fuel system for body builders.

Compressed Air System

Highlights critical aspects of the compressed air system for body builders.

Exhaust and Exhaust After-treatment System

Critical aspects of the exhaust and after-treatment systems that cannot be modified.

Cooling System

Critical aspects of the cooling system for body builders, including warranty considerations.

Electrical System

Highlights critical aspects of the electrical system, including harnesses and sensors.

Air Intake System

Critical aspects of the air intake system that must not be modified.

Charge Air Cooler System

Critical aspects of the charge air cooler system that must not be modified.

Dimensions

DIMENSIONS

Provides dimensional information for chassis layout and body planning.

ABBREVIATIONS

Lists abbreviations used for vehicle characteristics.

TURNING RADIUS

Lists approximate turning radius specifications for various models.

OVERALL DIMENSIONS

Includes drawings and charts for various Class 8 models' overall dimensions.

RIDE HEIGHTS

Provides front and rear suspension ride heights to determine overall height.

REAR SUSPENSION LAYOUTS

Provides rear suspension layouts to aid body layout prior to arrival.

AXLE TRACK AND TIRE WIDTH

Demonstrates typical axle dimensions and width calculations.

GROUND CLEARANCE

Information on ground clearance for fuel tanks and DEF tanks.

PTO CLEARANCES

Visuals to aid in determining PTO locations and clearances.

Exhaust & Aftertreatment

EXHAUST AND AFTER-TREATMENT INFORMATION

Information on exhaust and after-treatment systems, including SCR and DEF.

DEF System Schematic

Schematic detailing DEF lines routing to the after-treatment system.

General Guidelines for DEF System

Guidelines for installing and relocating DEF tanks and components.

Installation Requirements and Dimensions for DEF System

Requirements for DEF system component locations, clearances, and routing.

General Exhaust Information

Overview of three main DPF and SCR exhaust systems and body builder modification restrictions.

Frame Layouts

FRAME LAYOUTS

Aids in chassis layout and determining component combinations.

Day Cab Chassis Layout Options

Describes various frame layout configurations for Day Cab chassis.

Sleeper Chassis Layout Options

Describes various frame layout configurations for Sleeper chassis.

Frame Layout Tables

Provides detailed dimensional data for various frame layout configurations and models.

Body Mounting

FRAME INFORMATION

Provides specifications for frame rails and RBM requirements.

CRITICAL CLEARANCES

Discusses clearances needed between rear wheels, cab, and body structure.

BODY MOUNTING USING BRACKETS

Recommendations for installing bodies using brackets, including spacers.

MOUNTING HOLES

Guidelines for spacing and diameter of mounting holes in frame rails.

Frame Drilling

Warnings and cautions related to drilling frame rails, especially near wires and air lines.

BODY MOUNTING USING U–BOLTS

Proper use of U-bolts and spacers for body mounting to frame rails.

Frame Modifications

FRAME MODIFICATIONS

Information on modifying frame rails for wheelbase and length adjustments.

DRILLING RAILS

Guidelines for drilling holes in frame rails, including location and pattern.

MODIFYING FRAME LENGTH

Procedures for shortening or lengthening frame rails.

Changing Wheelbase

Considerations for modifying wheelbase, including driveline angles and suspension relocation.

WELDING

Recommendations and precautions for temporary frame welding repairs.

TORQUE REQUIREMENTS

Specifies torque values for customary and metric fasteners.

Electrical

ELECTRICAL

Covers topics like multiplex instrumentation, dash access, and wiring.

MULTIPLEX INSTRUMENTATION

Explains the multiplex wiring system using SAE J1939 data bus.

ACCESSING GAUGES AND SWITCHES

Step-by-step instructions for removing dash panels, gauges, and switches.

TELLTALE SYMBOLS

How to customize dash telltale symbols using editable cards.

SPARE RELAYS BODY BUILDER INSTALLED

Instructions for installing spare relays for loads exceeding 20 amps.

REMOTE PTO/THROTTLE HARNESS

Explains connections for remote control of engine throttle and PTOs.

TRAILER CABLE CONNECTIONS

Details on SAE J560 and ISO 3731 trailer connector configurations.

BENDIX ELECTRONIC STABILITY PROGRAM

Information on the Bendix ESP pre-wire option and installation requirements.

ELECTRICAL WIRE NUMBER AND COLOR

Explains Kenworth's wire numbering system and color coding.

Routing

ROUTING

General requirements for securing hoses and electrical wires.

ROUTING REQUIREMENTS

Guidelines for wiring, wires in bundles, and exceptions.

Wires Crossing other Components

How to isolate electrical wires crossing over other components.

Hoses Crossing Components

Protection requirements for hoses crossing over components.

Routing of Wires and Hoses near Moving Components

Clearance requirements for routing near moving parts.

Routing of Wires and Hoses near Exhaust System

Clearance requirements for wires and hoses near exhaust systems.

Vehicle Identification

VEHICLE IDENTIFICATION NUMBER

Explains the 17-character VIN and its components.

VIN Location

Location of the VIN marking on the vehicle.

Chassis Number Locations

Lists various locations where the chassis number is found.

vehicle identification labels

Locations of various identification labels on the vehicle.

Front Axle Identification

How to find front axle identification information.

Rear Axle Identification

Information on rear axle identification numbering system.

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