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Kenworth t800 User Manual
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Kenwor
th Heavy Duty
Body Builder Manual
2012
®
2
Table of Contents
Table of Contents
4
Section 1: Introduction
11
Section 2: Safety and Compliance
13
Federal Motor Vehicle Safetystandards Compliance
14
Figure 2-1: INCOMPLETE VEHICLE CERTIFICATION DOCUMENT
14
Figure 2-2: LOCATIONS of CERTIFICATION LABELS - DRIVER'S DOOR and FRAME
14
Figure 2-4: AERODYNAMIC MIRROR OAT SENSOR LOCATION
19
Figure 2-5: INSTRUMENT CLUSTER for T4/T6/T8/W9/C5
19
Table 3-1: ABBREVIATIONS USED
21
Table 3-2: TURNING RADIUS
21
Section 3: Dimensions
21
Figure 3-1: PROSPECTER TURN CIRCLE ANALYSIS
24
Overall Dimensions
25
T800 with SPLIT FENDERS
26
T800 Short Hood
27
T800 with FEPTO (FRONT ENGINE Power Take OFF)
28
T800 Wide HOOD
29
W900S
30
W900B
31
W900L
32
C500
33
Extended Day Cab
34
Aerocab
35
Table 3-3: RIDE HEIGHTS
36
Rear Suspension Layouts
38
Ag400L Tandem
39
Table 3-4: REAR SUSPENSION OPTIONS
39
Ag400 Tandem
40
Ag460 Tandem
41
Ag690 Tridem
42
REYCO 79Kb SINGLE REAR AXLE
43
Reyco 102 Tandem Rear Axle
44
Hendrickson HMX TANDEM SUSPENSION
50
Hendrickson RT TANDEM SUSPENSION
51
Chalmers 856-46 Tandem Suspension
52
Pusher Axles
54
AXLE Track and TIRE Width
56
Table 3-18: AXLE Width CALCULATION
56
Table 3-19: GROUND CLEARANCE for FUEL Tanks
58
Table 3-20: GROUND CLEARANCE for BATTERY BOXES
59
Pto Clearances
60
Section 4: Exhaust & Aftertreatment
63
General Guidelines for Def System
65
Figure 4-1: MEASUREMENT LOCATION of DEF SUPPLY MODULE (PUMP)
66
Figure 4-2: MEASUREMENT LOCATION of DEF DOSING MODULE (Injector)
66
Measurement Reference Points
66
Figure 4-3: ORIENTATION of DOSING MODULE
67
Figure 4-4: RH under CAB EXHAUST with SMALL, MEDIUM, or LARGE Tanks
67
Figure 4-5: Horizontal EXHAUST with SMALL, MEDIUM, or LARGE Tanks
68
Figure 4-6: VERTICAL EXHAUST with SMALL, MEDIUM, or LARGE Tanks
68
Figure 4-7: RH under CAB EXHAUST with CLEAR Back of CAB Tank
69
Figure 4-8: VERTICAL with CLEAR Back of CAB Tank
70
Figure 4-10: SUPPLY MODULE Allowed Clocking ANGLES
71
Figure 4-9: ROUTING DEF LINES and DEF TRAP
71
General Exhaust Information
72
Figure 4-11: ISOMETRIC View of RIGHT HAND under DPF and SCR with SINGLE SOC TAILPIPE
73
Figure 4-12: TOP View of RIGHT HAND under DPF and SCR with
73
Figure 4-13: Right View of Right Hand under DPF and SCR with Single SOC Tailpipe
74
Figure 4-14: Back View of RIGHT HAND under DPF and SCR with SINGLE
74
Figure 4-15: Isometric View of Right Hand under DPF and SCR with Dual SOC Tailpipes
75
Figure 4-16: TOP View of RIGHT HAND under DPF and SCR with DUAL
75
Figure 4-17: Right View of Right Hand under DPF and SCR with Dual SOC Tailpipes
76
Figure 4-18: Back View of RIGHT HAND under DPF and SCR with DUAL
76
Figure 4-19: Isometric View of Right Hand under DPF and SCR on Aerocab with Single SOC Tailpipe
77
Figure 4-20: TOP View of RIGHT HAND under DPF and SCR on AEROCAB
77
Figure 4-21: Right View of Right Hand under DPF and SCR on Aerocab with Single SOC Tailpipe
78
Figure 4-22: Back View of RIGHT HAND under DPF and SCR on AEROCAB
78
Figure 4-23: Isometric View of Right Hand under DPF and SCR on Aerocab with Dual SOC Tailpipes
79
Figure 4-24: TOP View of RIGHT HAND under DPF and SCR on AEROCAB
79
Figure 4-25: Right View of Right Hand under DPF and SCR on Aerocab with Dual SOC Tailpipes
80
Figure 4-26: Back View of RIGHT HAND under DPF and SCR on AEROCAB
80
Figure 4-27: ISOMETRIC View of Horizontal DPF and SCR with Horizontal TAILPIPE
81
Figure 4-28: TOP View of Horizontal DPF and SCR with Horizontal TAILPIPE
81
Figure 4-29: RIGHT View of Horizontal DPF and SCR with Horizontal TAILPIPE
82
Figure 4-30: Back View of Horizontal DPF and SCR with Horizontal TAILPIPE
82
Figure 4-31: ISOMETRIC View of VERTICAL DPF and SCR
83
Figure 4-32: TOP View of VERTICAL DPF and SCR
83
Figure 4-33: RIGHT View of VERTICAL DPF and SCR
84
Figure 4-34: Back View of VERTICAL DPF and SCR
84
Exhaust Information
85
Section 5: Frame Layouts
87
Table 5-2: FUEL Tank OVERALL LENGTH (IN)
88
Table 5-3: BATTERY BOX CENTERFRAME LENGTHS (IN)
88
Table 5-4: DEF Tanks SYSTEMS
89
Frame Layout Index
90
Figure 6-1: ISOMETRIC View of T800 FEPTO FRONT END with
203
Table 6-1: SINGLE STEEL RAILS
203
Table 6-2: INSERTED STEEL RAILS
203
Section 6: Body Mounting
203
Figure 6-2: T800 FEPTO FRONT END with 66" BUMPER SETTING
204
Figure 6-3: ISOMETRIC View of T800 FEPTO FRONT END with
204
Figure 6-4: T800 FEPTO FRONT END with 73" BUMPER SETTING
204
Critical Clearances
205
Figure 6-5: MINIMUM CLEARANCE between TOP of REAR TIRES and
205
BODY MOUNTING USING Brackets
206
Figure 6-6: MINIMUM Back of CAB CLEARANCE
206
Figure 6-7: SPACER between FRAME SILL and BODY RAIL - RUBBER or PLASTIC
207
Figure 6-8: HIGH COMPRESSION SPRING
207
Figure 6-10: CROSSMEMBER-GUSSET HOLE PATTERN Requirements [INCH (MM)]
208
Figure 6-11: ACCEPTABLE U-BOLT MOUNTING with Wood and FABRICATED SPACERS [INCH (MM)]
209
Figure 6-12: CLEARANCE SPACE for AIR LINES and CABLES
210
FIGURE 6-13. Example of Fishplate Bracket at Rear End of Body, Used with U-Bolts
211
Section 7: Frame Modifications
213
Figure 7-1: DETAIL of FRAME EXTENSION and Joint Welding
214
Modifying Frame Length
214
CHANGING Wheelbase
215
Figure 7-2: FRAME INSERT
215
Figure 7-3: COMPARISON of ORIGINAL, SHORTENED, and EXTENDED Wheelbases
216
Crossmembers
217
Figure 7-4: CROSSMEMBER ADDED When DISTANCE EXCEEDS 60 INCHES (1524 MM)
217
Welding
218
Table 7-1: CUSTOMARY GRADE 8 UNF or UNC
219
Torque Requirements
219
Remote Pto/Throttle Harness
221
Figure 8-1: Kenworth B-CAB DASH
222
Figure 8-2: DIESEL EXHAUST FLUID GAUGE
222
Figure 8-3: MULTIPLEXED INSTRUMENTATION Block DIAGRAM
223
Figure 8-4: CECU LOCATION
224
Figure 8-5: INSTRUMENT CLUSTER COMPONENTS
225
Figure 8-6: CVSG GAUGES
226
Figure 8-7: Firewall AIR Junction Block (View from INSIDE of CAB)
227
Figure 8-8: AIR FILTER RESTRICTION SENSOR on Firewall AIR Junction Block (View from ENGINE)
227
Figure 8-9: FUEL FILTER RESTRICTION PRESSURE GAUGE SENSOR LOCATION (TYPICAL)
228
Figure 8-10: TELLTALE SYMBOL STANDARD CARDS
237
Figure 8-11: Blank TELLTALE CARD
238
Table 8-1: TELLTALES POSITION and COLOR
238
Figure 8-12: TELLTALE ICONS
239
Figure 8-13: Kenworth SPARE Switches
240
Figure 8-14: SPARE Switch HARNESS
241
Figure 8-15: SPECIALTY Switches
242
Figure 8-16: SPARE RELAY CONNECTORS
243
Figure 8-17: SPARE RELAY HARNESSES
244
Figure 8-18: SPARE BULLET CONNECTORS
245
Figure 8-19: SPARE PIGTAIL CONNECTOR
246
MULTIFUNCTION TURN SIGNAL Stalk, CHASSIS NODE & CHASSIS LOAD CENTER
253
Chassis Load Center Dimensions
255
ELECTRICAL Hardware
256
Trailer Cable Connections
260
Figure 8-32
261
Bendix Electronic Stability Program
262
FACTORY INSTALLED Snow Plow LIGHT Wiring
263
Figure 9-1: CLAMP and BUTTERFLY CLAMP
267
Figure 9-2: BUTTERFLY TIE
267
Figure 9-3: TIE STRAP
267
Section 9: Routing
267
Figure 9-4: HEAVY DUTY (HD) MOUNT
268
ROUTING Requirements
268
Figure 9-5: DEFINITION of MEASUREMENTS
270
Table 9-1: EXHAUST - SYSTEM CLEARANCE
270
Figure A-1: VEHICLE IDENTIFICATION NUMBER (VIN
271
Table A-1: MODEL YEAR (CODE) DESIGNATIONS
271
Appendix A: Vehicle Identification
272
Vehicle Identification Labels
272
Component Identification
273
Figure A-3: FRONT AXLE IDENTIFICATION
273
Figure A-4: REAR AXLE IDENTIFICATION
274
Figure A-2: DRIVERS DOOR and DOOR FRAME LABELS
272
4
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Kenworth t800 Specifications
General
Torque
Up to 2, 050 lb-ft
Front Axle Capacity
12, 000 lbs
Rear Axle Capacity
40, 000 lbs
Cab Configuration
Day cab
Suspension
Air ride
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Kenworth t800 2012
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