Kenworth Heavy Duty Body Builder Manual (T800, W900, C500) (EN)

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Body Builder Manual Contents 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 OVERALL DIMENSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5 T800 . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5 T800 with Split Fenders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 T800 Short Hood . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7 T800 with FEPTO (Front Engine Power Take Off) . . . . . . . . . . . . . . . . . . 3-8 T800 Wide Hood . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9 W900S . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10 W900B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11 W900L . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . 3-12 C500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13 EXTENDED DAY CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14 38” Aerocab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15 RIDE HEIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16 REAR SUSPENSION LAYOUTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18 AG400L Tandem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19 AG400 Tandem . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . 3-20 AG460 Tandem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21 AG690 TRIdem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22 Reyco 79KB Single Rear Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23 Reyco 102 Tandem Rear Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24 Neway AD 123 Single Rear Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25 Neway AD 246 Tandem Suspension . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26 Neway AD 369 Tridem Suspension . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-27 Hendrickson Primaax Tandem Suspension . . . . . . . . . . . . . . . . . . . . 3-28 Hendrickson Primaax Tridem Suspension . . . . . . . . . . . . . . . . . . . . . 3-29 Hendrickson HMX Tandem Suspension . . . . . . . . . . . . . . . . . . . . . . . 3-30 Hendrickson RT Tandem Suspension . . . . . . . . . . . . . . . . . . . . . . . . 3-31 Chalmers 856-46 Tandem Suspension . . . . . . . . . . . . . . . . . . . . . . . . 3-32 PUSHER AXLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-34 Axle TRACK AND TIRE WIDTH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-36 PTO Clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . 3-40 Section 4: exhaust & 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23 Section 5: frame layouts 5-1 FRAME LAYOUTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-1 FRAME LAYOUT INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4 08/12 ii

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Body Builder Manual Contents Section 6: Body Mounting 6-1 FRAME INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 Critical Clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3 Body Mounting Using Brackets . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4 Mounting Holes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6 BODY MOUNTING USING U–BOLTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7 Section 7: Frame Modifications 7-1 FRAME MODIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 DRILLING RAILS . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . 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 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 Bendix Electronic Stability Program . . . . . . . . . . . . . . . . . . . . . . . 8-37 FACTORY INSTALLED SNOW PLOW LIGHT WIRING . . . . . . . . . . . . . . . . . . . . 8-38 Section 9: routing 9-1 ROUTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1 ROUTING REQUIREMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2 appendix a: vehicle identification A-1 Vehicle Identification number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1 vehicle identification labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2 Component identification . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . A-3 08/12 iii

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Figures Figure 2-1: Incomplete Vehicle Certification Document . . . . . . . . . . . . 2-2 Figure 2-2: Locations of Certification Labels - Driver’s Door and Frame . 2-2 Figure 2-3: vWest Coast Mirror OAT sensor, . . . . . . . . . . . . . . . . . . . . 2-6 Figure 2-4: Aerodynamic Mirror OAT Sensor Location . . . . . . . . . . . . . 2-7 Figure 2-5: Instrument Cluster for T4/T6/T8/W9/C5 . . . . . . . . . . . . . . . . 2-7 Figure 3-1: Prospecter Turn Circle Analysis . . . . . . . . . . . . . . . . . . . 3-4 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 Large Tanks. . . 4-5 FIGURE 4-5: Horizontal Exhaust with Small, Medium, or Large Tanks. . . . . 4-6 FIGURE 4-6: Vertical Exhaust with Small, Medium, or Large Tanks. . . . . . . 4-6 FIGURE 4-7: RH Under Cab Exhaust with Clear Back of Cab Tank. . . . . . . . 4-7 FIGURE 4-8: Vertical with Clear Back of Cab Tank . . . . . . . . . . . . . . . . . 4-8 FIGURE 4-9: Routing DEF Lines and DEF Trap . . . . . . . . . . . . . . . . . . . . . 4-9 FIGURE 4-10: Supply Module Allowed Clocking Angles . . . . . . . . . . . . . 4-9 FIGURE 4-11:

Isometric View of Right Hand Under DPF and SCR with Single SOC Tailpipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11 FIGURE 4-12: Top View of Right Hand Under DPF and SCR with Single SOC Tailpipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11 FIGURE 4-13: Right View of Right Hand Under DPF and SCR with Single SOC Tailpipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12 FIGURE 4- 1 4: Back View of Right Hand Under DPF and SCR with Single SOC Tailpipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12 FIGURE 4-15: Isometric View of Right Hand Under DPF and SCR with Dual SOC Tailpipes . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13 FIGURE 4-16: Top View of Right Hand Under DPF and SCR with Dual SOC Tailpipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13 FIGURE 4-17: Right View of Right Hand Under DPF and SCR with Dual SOC Tailpipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14 FIGURE 4-18: Back View of Right Hand Under DPF and SCR with Dual SOC Tailpipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14 FIGURE 4-19: Isometric View of Right Hand Under DPF and SCR on Aerocab with Single SOC Tailpipe . . . . . . . . . . . . . . . . . . . . . . . .

4-15 FIGURE 4-20: Top View of Right Hand Under DPF and SCR on Aerocab with Single SOC Tailpipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15 FIGURE 4-21: Right View of Right Hand Under DPF and SCR on Aerocab with Single SOC Tailpipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16 FIGURE 4-22: Back View of Right Hand Under DPF and SCR on Aerocab with Single SOC Tailpipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16 FIGURE 4-23: Isometric View of Right Hand Under DPF and SCR on Aerocab with Dual SOC Tailpipes . . . . . . . . . . . . . . . . . . . . . . . . 4-17 FIGURE 4-24:

Top View of Right Hand Under DPF and SCR on Aerocab with Dual SOC Tailpipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17 FIGURE 4-25: Right View of Right Hand Under DPF and SCR on Aerocab with Dual SOC Tailpipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18 FIGURE 4-26: Back View of Right Hand Under DPF and SCR on Aerocab with Dual SOC Tailpipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18 FIGURE 4-27: Isometric View of Horizontal DPF and SCR with Horizontal Tailpipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19 FIGURE 4-28: Top View of Horizontal DPF and SCR with Horizontal Tailpipe . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . 4-19 FIGURE 4-29: Right View of Horizontal DPF and SCR with Horizontal Tailpipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20 08/12 iv

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