Kenworth t800 Heavy Duty Truck Manuals (2024)

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

  See Also

  Troubleshooting the Electrical System: Kenworth T800 Fuse Panel Diagram - Travelling Apples2006 Kenworth T800 Fuse Panel Diagram » Wiring Diagram

• 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

• 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

• 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