Medium Duty Body Builder Manual

Transcription

Medium Duty
Body Builder Manual
Model 330
Model 325
Model 337
Model 348
Table of Contents
MEDIUM DUTY BODY BUILDER’S MANUAL
CONTENT
SECTION 1
INTRODUCTION
SCOPE.....................................................................................................................................1-1
SECTION 2 SAFETY AND COMPLIANCE
SAFETY SIGNALS.......................................................................................................................2-1
Warnings, cautions, and notes.........................................................................................2-1
FEDERAL MOTOR VEHICLE SAFETY STANDARDS (FMVSS) & CANADIAN MOTOR VEHICLE SAFETY
STANDARDS (CMVSS) COMPLIANCE.............................................................................................2-1
Incomplete Vehicle Certification.......................................................................................2-2
Noise and Emissions Requirements..................................................................................2-2
SECTION 3 DIMENSIONS
DIMENSIONS.............................................................................................................................3-1
ABBREVIATIONS........................................................................................................................3-1
TURNING RADIUS......................................................................................................................3-1
OVERALL DIMENSIONS
Side View - Single Rear Axle – Model 330,337,348.............................................................3-2
Side View - Single Rear Axle – Model................................................................................3-3
Side View - Tandem Rear Axle – Model 348.......................................................................3-4
Front and Rear Views ....................................................................................................3-5
Rear Window.................................................................................................................3-6
Cab and Hood - Standard Cab.........................................................................................3-7
Cab and Hood - Crew Cab...............................................................................................3-8
Battery Box - Location - Model 330,337,348......................................................................3-9
Battery Box - Location - Model 325.................................................................................3-10
Battery Box - Step Height - Model 330,337,348...............................................................3-11
Battery Box - Step Height - Model 325............................................................................3-12
Fuel Tank – Location - Model 330,337,348.......................................................................3-13
Fuel Tank – Location - Model 325...................................................................................3-14
Fuel Tank – Location - Model 325...................................................................................3-15
Fuel Tank - Step Height - Model 325...............................................................................3-16
Fuel Tank - Step Height - Model 330,335,348..................................................................3-17
DEF Tank – System Overview........................................................................................3-18
DEF Tank – Tank Measurements....................................................................................3-19
DEF Tank – Ground Clearance – Rectangular...................................................................3-20
DEF Tank – Ground Clearance – Round...........................................................................3-21
Exhaust Location – 2007 Horizontal DPF w/Horizontal Diffuser...........................................3-22
Exhaust Location – 2007 Horizontal DPF w/ Vertical Stack – Model 330,337,348...................3-23
Exhaust Location – 2007 Under Cab DPF w/side of Cab Stack – Model 330,337,348..............3-24
Exhaust Location – 2010 Horizontal In-series DPF/SCR w/Horizontal Tailpipe.......................3-25
Exhaust Location – 2010 Horizontal Crossover DPF/SCR w/Horizontal Tailpipe......................3-26
Exhaust Location – 2010 RH Under Cab DPF/SCR w/Side of Cab.........................................3-27
PTO Layouts – 2010 Manual Transmission with PX6..........................................................3-28
PTO Layouts – 2010 Automatic Transmission with PX6......................................................3-29
PTO Layouts – 2010 Manual Transmission with PX8..........................................................3-30
PTO Layouts – 2010 Automatic Transmission with PX8......................................................3-31
FEPTO Extension and Bumper - Model 337,348................................................................3-32
Air Horn - Model 330,337,348........................................................................................3-33
Rear Frame Height - Single Rear Axle.............................................................................3-34
Rear Frame Height - Tandem Rear Axles - Model 348........................................................3-35
Rear Suspension and Tire Clearance - Single Rear Axle.....................................................3-36
Rear Suspension & Tire Clearance - Tandem Rear Axles - Model 348...................................3-37
Frame Rail Sections......................................................................................................3-38
Crossmember Drillings..................................................................................................3-39
SECTION 4
BODY MOUNTING
CRITICAL CLEARANCES...............................................................................................................4-1
Rear Wheels and Cab.....................................................................................................4-1
BODY MOUNTING USING BRACKETS.............................................................................................4-1
Frame Sill.....................................................................................................................4-1
ii
Medium Duty Body Builder Manual 1/2010
Table of Contents
Brackets.......................................................................................................................4-2
Mounting Holes..............................................................................................................4-2
Frame Drilling...............................................................................................................4-3
BODY MOUNTING USING U–BOLTS...............................................................................................4-4
Spacers........................................................................................................................4-4
Rear Body Mount...........................................................................................................4-5
SECTION 5
FRAME MODIFICATIONS
INTRODUCTION.........................................................................................................................5-1
DRILLING RAILS........................................................................................................................5-1
Location and Hole..........................................................................................................5-1
MODIFYING FRAME LENGTH........................................................................................................5-1
Frame Insert.................................................................................................................5-1
Changing Wheelbase......................................................................................................5-2
Crossmembers..............................................................................................................5-4
WELDING..................................................................................................................................5-4
Precautions...................................................................................................................5-4
TORQUE REQUIREMENTS............................................................................................................5-5
SECTION 6
ELECTRICAL
INTRODUCTION.........................................................................................................................6-1
BODY LIGHTS JUNCTION BOX......................................................................................................6-1
REMOTE PTO HARNESS...............................................................................................................6-2
THIRD BATTERY.........................................................................................................................6-2
ENGINE CONNECTIONS...............................................................................................................6-2
SECTION 7 HYBRID
HYBRID - Model 330, Model 337...................................................................................................7-1
Power Electric Carrier Placement (PEC).............................................................................7-1
General Notes and Cautions............................................................................................7-1
HYBRID UTILITY APPLICATION.....................................................................................................7-2
EPTO Functionality.........................................................................................................7-2
EPTO Connection...........................................................................................................7-2
Body Builder Connection.................................................................................................7-3
Sections of the MD Hybrid Electrical Schematics on Body Builder Connections....................................7-4
HYBRID BATTERY BOX ACCESS....................................................................................................7-5
APPENDIX A
VEHICLE IDENTIFICATION
VEHICLE IDENTIFICATION NUMBER .............................................................................................A-1
VIN Location.................................................................................................................A-1
Chassis Number Locations..............................................................................................A-1
CERTIFICATION LABELS..............................................................................................................A-2
Components and Weights Label.......................................................................................A-2
Tire and Rim Data Label.................................................................................................A-2
Incomplete Vehicle Certification Label...............................................................................A-2
Noise Emission Label......................................................................................................A-2
Paint Identification Label................................................................................................A-2
COMPONENT IDENTIFICATION.....................................................................................................A-3
Engine Identification......................................................................................................A-3
Transmission Identification.............................................................................................A-3
Front Axle Identification.................................................................................................A-3
Rear Axle Identification..................................................................................................A-3
APPENDIX B
WEIGHT DISTRIBUTION
INTRODUCTION.........................................................................................................................B-1
BODY BUILDER’S RESPONSIBILITIES ..........................................................................................B-1
APPENDIX C
ROUTING
INTRODUCTION.........................................................................................................................C-1
ELECTRICAL CIRCUITS...............................................................................................................C-1
Capacity.......................................................................................................................C-1
ROUTING..................................................................................................................................C-1
Definitions....................................................................................................................C-1
ROUTING REQUIREMENTS...........................................................................................................C-2
Wiring..........................................................................................................................C-2
iii
Table of Contents
Wires in Bundles............................................................................................................C-2
Exceptions....................................................................................................................C-2
Wires Crossing other Components....................................................................................C-3
Piping..........................................................................................................................C-3
Hoses Crossing Components...........................................................................................C-3
Air Compressor Discharge Hoses......................................................................................C-3
Bundles........................................................................................................................C-3
Routing of Wires & Hoses near Moving Components...........................................................C-3
Routing of Wires & Hoses near Exhaust System.................................................................C-4
iv
SECTION 1 INTRODUCTION
SCOPE
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.
and ordering process. Early in the process, professional body builders can often contribute valuable
information that reduces the ultimate cost of the body
installation.
This manual is not a maintenance
manual or an operation manual.
This manual contains appropriate dimensional information, guidelines for mounting bodies, guidelines for
modifying frames, electrical wiring information, and
other information useful in the body installation process.
• For chassis maintenance and repair information
consult the model-appropriate Maintenance Manual
available in the Service Department of the selling
dealer or you can order your own copy of the
maintenance manual from your local dealer.
The intended primary users of this manual are body
builders who install bodies and associated equipment
on Peterbilt Medium Duty vehicles. Dealers who sell and
service the vehicle will also find this information useful.
• For chassis operating information consult the Operator’s Manual, included with each vehicle. It also
can be ordered from your local dealer.
This Medium Duty Body Builder Manual can be very
useful when specifying a vehicle, particularly when
the body builder is involved in the vehicle definition
1-1
10/2009
Page Intentionally Left Blank.
Peterbilt Motors Co.
SECTION 2 SAFETY AND COMPLIANCE
SAFETY SIGNALS
A number of alerting messages are shown 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 damage 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
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
WARNING
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 incorrectly specified circuit
breaker could result in a electrical overload
or fire situation. Follow the liftgate installation instructions and use a circuit breaker
with the recommeded capacity.
CAUTION
S ignals a potentially hazardous situation
which, if not avoided, could result in minor or moderate injury or damage to the vehicle.
Example:
CAUTION: Never use a torch to make a hole
in the rail. Use the appropriate drill bit.
2-1
NOTE
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.
FEDERAL MOTOR VEHICLE SAFETY
STANDARDS (FMVSS) AND
CANADIAN MOTOR VEHICLE
SAFETY STANDARDS (CMVSS)
COMPLIANCE
As an Original Equipment Manufacturer (OEM), Peterbilt Motors Company ensures that our products comply
with all applicable Federal Motor Vehicle Safety Standards (FMVSS) and Canadian Motor Vehicle Safety
Standards (CMVSS) where applicable. However, the
fact that this vehicle has no fifth–wheel and that a Body
10/2009
SAFETY AND COMPLIANCE
Builder (Final Stage Manufacturer) will be doing additional modifications means that the vehicle was incomplete when it left the build plant.
Incomplete Vehicle Certification
An Incomplete Vehicle Document is shipped with the
vehicle, certifying that the vehicle is not complete (see
figure below). In addition, affixed to the driver’s side
door frame or edge is an Incomplete Vehicle Certification label.
NOTE: These documents list the FMVSS (or
CMVSS) regulations that the vehicle complied
with when it left the build plant. You should be
aware that if you modify or alter any of the
components or systems covered by these
FMVSS (or CMVSS) regulations, it is your
responsibility as the Final Stage Manufacturer to
ensure that the complete vehicle maintains
compliance with the particular FMVSS (or
CMVSS) regulations when you complete your
modifications.
2
As the 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 “Final Stage Manufacturer” and certifies that the vehicle complies with Federal Motor
Vehicle Safety Standards.
Figure 2-2.
Location of Certification
Labels - Driver’s Door
Frame
Noise and Emissions Requirements
NOTE: This truck may be equipped with a Diesel
Particulate Filter (DPF) muffler unit in order to
meet both noise and exhaust emissions requirements. Removal or tampering with the DPF
muffler will not improve engine performance. Also
tampering with the exhaust system is against the
rules that are established by the U.S. Code of
Federal Regulations and Environment Canada
Regulations. The DPF muffler may only be
replaced with an approved part.
NOTE: 2007/10 emissions engines are integrated
Figure 2-1.
Incomplete Vehicle Certification Document
with particulate filters for 2007/10 EPA certification.
The particulate filter assembly may consist of one
or more of the following components: a diesel
oxidation catalyst, a diesel particulate filter,
temperature sensors, differential pressure sensor,
and exhaust silencing components integrated
into a modular housing. Body Builders must not
modify or relocate this assembly or any components associated with it. It is also the case that
there should not be any modifications made to the
exhaust piping from turbo outlet to aftertreatment
inlet.
2-2
SECTION 3 DIMENSIONS
TURNING RADIUS
DIMENSIONS
The curb-to-curb turning radius is the minimum radius
the outermost portion of the outboard front tire would
follow in a turn.
This section includes dimensions for a standard
Medium Duty configuration, plus several optional configurations. See the CONTENTS section at the beginning of
the manual to locate the information you need.
The wall-to-wall turning radius is the minimum radius
the outermost tip of the front bumper would follow in a
turn.
ABBREVIATIONS
Both the curb-to-curb and wall-to-wall turning radius
depend on the wheelbase, front axle, front tire and
wheel sizes, and many other factors. Approximate turning radius figures are listed in Table 3-1. Optional
components may result in different figures.
Throughout this manual, we use the following abbreviations for various critical dimensions:
BBC
Bumper to back of cab.
BFA
Bumper to front axle.
CA
Cab to axle. Measured from the back of the
cab to the centerline of the rear axle(s).
FAB
Front axle to back of cab.
FEPTO
Front engine PTO extension. Measured from
the front of the grille to the front of the
bumper.
OAL
Overall vehicle length. Measured from the
bumper to the end of frame.
OH
Frame overhang. Measured from the centerline of the rear axle(s) to the end of frame.
WB
Wheelbase.
The figures in Table 3-1 are based on the following
components (for all models except Model 325):
• Eaton Spicer E1002I and E1202I front axles
• TRW TAS 65 steering gear
• PHP-10 iron hubs/cast drums
• Bridgestone R250F295/75R22.5 14-ply front
tires
• Accuride 28408E 22.5 x 8.25 steel front wheels
• No FEPTO
• Without tandem drive
Model 325 components:
• Dana Spicer D800F front axle
• TRW TAS 40 steering gear
• Hydraulic disc brakes
• Bridgestone R250F 225/70R19.5 12-ply front tires
• Accuride 28680 19.5 x 6.75 steel front wheels
To obtain the turning circle diameter, multiply the
radius by 2.
TABLE 3-1.
Turning Radius
Left-Hand Turn
Models 330,337,348
Right-Hand Turn
Models 330,337,348
Model 325
Model 325
WHEELBASE
[IN. (mm)]
CURB TO CURB
[FT. (m)]
WALL TO WALL CURB TO CURB WALL TO WALL CURB TO CURB WALL TO WALL CURB TO CURB WALL TO WALL
[FT. (m)]
[FT. (m)]
[FT. (m)]
[FT. (m)]
[FT. (m)]
[FT. (m)]
[FT. (m)]
150 (3810)
22.6 (6.9)
24.9 (7.6)
16.3 (5.0)
18.5 (5.6)
23.2 (7.1)
25.3 (7.7)
16.3 (5.0)
18.5 (5.6)
154 (3912)
23.2 (7.1)
25.4 (7.7)
16.8 (5.1)
19 (5.8)
23.8 (7.3)
25.9 (7.9)
16.8 (5.1)
19 (5.8)
164 (4166)
n/a
n/a
17.8 (5.4)
20 (6.1)
n/a
n/a
17.8 (5.4)
20 (6.1)
178 (4521)
26.7 (8.1)
28.9 (8.8)
19.4 (5.9)
21.6 (6.6)
27.4 (8.4)
29.5 (9.0)
19.4 (5.9)
21.6 (6.6)
190 (4826)
28.5 (8.7)
30.7 (9.4)
20.7 (6.3)
22.9 (7.0)
29.2 (8.9)
31.3 (9.5)
20.7 (6.3)
22.9 (7.0)
208 (5283)
31.1 (9.5)
33.3 (10.1)
22.6 (6.9)
24.8 (7.6)
31.8 (9.7)
34.0 (10.4)
22.6 (6.9)
24.8 (7.6)
220 (5588)
32.8 (10.0)
35.0 (10.7)
23.9 (7.3)
26.1 (8.0)
33.6 (10.2)
35.8 (10.9)
23.9 (7.3)
26.1 (8.0)
238 (6045)
35.4 (10.8)
37.7 (11.5)
25.9 (7.9)
28.1 (8.6)
36.3 (11.1)
38.5 (11.7)
25.9 (7.9)
28.1 (8.6)
256 (6502)
38.0 (11.6)
40.3 (12.3)
n/a
n/a
39.0 (11.9)
41.1 (12.5)
n/a
n/a
274 (6960)
40.7 (12.4
42.9 (13.1)
n/a
n/a
41.7 (12.7)
43.8 (13.4)
n/a
n/a
* 50 degree wheel cut L/R
3-1
10/2009
DIMENSIONS
3
Side View —Single Rear Axle - Overall Dimensions - Model 330, Model 337, Model 348
Figure 3-1.
Side View w/ Single Rear Axle: Overall Dimensions.
TABLE 3-2. Side view with single rear axle - overall dimensions - lengths [inches (mm)]
WB
150 (3810)
154 (3912)
178 (4521)
190 (4826)
208 (5283)
220 (5588)
238 (6045)
256 (6502)
274 (6960)
OAL
234 (5944)
238 (6045)
279 (7087)
301 (7645)
328 (8331)
352 (8941)
376 (9550)
419 (10643)
419 (10643)
OH
45.8 (1163)
45.8 (1163)
62.8 (1595)
74.8 (1900)
81.8 (2078)
93.8 (2383)
99.8 (2535)
124.8 (3170)
106.8 (2713)
CA*
80.2 (2037)
84.2 (2139)
108.2 (2748)
120.2 (3053)
138.2 (3510)
150.2 (3815)
168.2 (4272)
186.2 (4729)
204.2 (5187)
* Measured from the back of cab to the centerline of the rear axle as shown.
TABLE 3-3. Side view with single rear axle - overall dimensions - height [inches (mm)]
WB
150 (3810)
154 (3912)
Greater than 157
(3988)
H EIGHT**
REYCO 79KB
21,000 LB.
REYCO 79KB
23,000 AND 26,000 LB.
PETERBILT LOW AIR
LEAF 21,000 LB.
105.3 (2675)
105.3 (2675)
103.9 (2639)
105.9 (2690)
105.9 (2690)
105.9 (2690)
105.3 (2675)
105.3 (2675)
105.3 (2675)
** Measured in the light (unloaded) condition with an Eaton Spicer E1002I or E1202I front axle, required front axle spacer
blocks, 10,000 lb or 12,000 lb taperleaf front suspension, 10-½ or 10-5/8 inch frame rails, and Bridgestone R250F
295/75R22.5 front tires. Does not include height of optional roof-mounted air horn or optional vertical exhaust stack.
3-2
3
DIMENSIONS
Side View —Single Rear Axle - Overall Dimensions - Model 325
Figure 3-1.
Side View w/ Single Rear Axle: Overall Dimensions.
TABLE 3-4.
Side view with single rear axle - overall dimensions - lengths [inches (mm)] - Model 325
WB
150 (3810)
154 (3912)
164 (4166)
178 (4521)
190 (4826)
208 (5283)
220 (5588)
238 (6045)
OAL
234 (5943)
240.2 (6101)
257 (6528)
279 (7086)
303 (7696)
328 (8331)
352 (8941)
376 (9550)
OH
45.8 (1163)
48 (1219.4)
54.8 (1392.4)
62.8 (1594.8)
74.8 (1900)
81.8 (2077.8)
93.8 (2383)
99.8 (2534.8)
* Measured from the back of cab to the centerline of the rear axle as shown.
TABLE 3-5.
WB
ALL
CA*
80.2 (2037)
84.2 (2138.6)
94.2 (2392.6)
108.2 (2748.2)
120.2 (3053)
138.2 (3510.2)
150.2 (3815)
168.2 (4272.2)
Rev. 6-07
Side view with single rear axle - overall dimensions - height [inches (mm)] - Model 325
HEIGHT**
REYCO 79KB
11,500 LB.
99 (2515)
**Measured in the laden (loaded) condition with a Dana D800F front axle, required front axle spacer blocks,
8,000 lb taperleaf spring, 9 7/8 inch frame rails, and Bridgestone R250F 225/70 R19.5 front tires.
3-3
10/2009
DIMENSIONS
3
Side View —Tandem Rear Axle - Overall Dimensions - Model 348
Figure 3-2.
Side View w/ Tandem Rear Axle - Overall Dimensions.
TABLE 3-6. Side view with tandem rear axle - overall dimensions - lengths [inches (mm)]
WB
OAL
OH
CA*
150 (3810)
234 (5944)
45.8 (1163)
80.2 (2037)
154 (3912)
238 (6045)
45.8 (1163)
84.2 (2139)
178 (4521)
279 (7087)
62.8 (1595)
108.2 (2748)
190 (4826)
301 (7645)
74.8 (1900)
120.2 (3053)
208 (5283)
328 (8331)
81.8 (2078)
138.2 (3510)
220 (5588)
352 (8941)
93.8 (2383)
150.2 (3815)
238 (6045)
376 (9550)
99.8 (2535)
168.2 (4272)
256 (6502)
419 (10643)
124.8 (3170)
186.2 (4729)
274 (6960)
419 (10643)
106.8 (2713)
204.2 (5187)
* Measured from the back of cab to the centerline of the rear tandem as shown.
TABLE 3-7. Side view with tandem rear axle - overall dimensions - height [inches (mm)]
WB
REYCO 102
38,000 LB.
ALL
106.9 (2715)
H EIGHT**
HENDRICKSON
RT2-400
40,000 LB.
106.9 (2715)
PETERBILT LOW AIR
LEAF 38,000 LB.
105.3 (2675)
** Measured in the light (unloaded) condition with an Eaton Spicer E1202I front axle, required front axle spacer
blocks, 12,000 lb taperleaf front suspension, 10-5/8 inch frame rails, and Bridgestone R250F
295/75R22.5 front tires. Does not include height of optional roof-mounted air horn or optional vertical exhaust stack.
3-4
3
DIMENSIONS
Front and Rear Views — Overall Dimensions
Figure 3-3.
Front View - Overall Dimensions
* with 10 5/8 inch rails.
A dd 0 .1 inc h (3 mm)
when measuring from top.
Add 0.7 inch (17.8 mm)
when measuring from top
on 9 7/8 inch rails. Subtract 0.27 inch (6.8 mm)
when measuring from top
of 10 3/4 inch rails.
** with Bridgestone
R250F 295/75R22.5 tires
a nd Ac cu rid e 2 84 08 E
22.5 X 8.25 steel wheels.
Figure 3-4.
3-5
Rear View - Overall Dimensions
10/2009
DIMENSIONS
3
Rear Window
* with 1 0 5/8 in ch rails. A dd
0 .1 inch (3 mm) when measuring from top of 10 1/2 inch rails.
A dd 0.7 inch (17.8 mm) when
measuring from top of 9 7/8 inch
rails. Subtract 0.27 inch (6.8
mm) when measuring from top
of 10 3/4 inch rails.
Figure 3-5.
Rear Window
Contact Dealer for loadlight locations.
3-6
3
DIMENSIONS
Cab and Hood - Standard Cab
AREA OF
CONTACT
WITH ROOF
SKIN
DETAIL A
ROOF SKIN
2.0 (51)
SECTION A-A
Figure 3-6.
3-7
Cab and Hood - Standard cab
10/2009
DIMENSIONS
3
Cab and Hood - Crew Cab
* WITH 10 5/8 INCH RAILS
Figure 3-7.
Cab and Hood - Crew cab
NOTE: This configuration is not available from the factory.
3-8
3
DIMENSIONS
Battery Box - Location - Model 330, Model 337, Model 348
(STEEL BATTERY
BOX SHOWN)
Figure 3-8.
Battery Box - Location
TABLE 3-8. Battery box location [inches (mm)]
DIMENSION*
X
Y **
Z
STEEL BATTERY BOX
ALUMINUM BATTERY
BOX
25.6 (650)
30.2 (767)
8.4 (213)
0.9 (22)
30.5 (775)
30.4 (772)
* Dimensions are for battery boxes located left-hand under-cab. The location of battery boxes located back of cab varies according to the location of
other frame-mounted components.
** A minimum clearance of 4.0 in. (101 mm) is required to the rear of the
battery box to allow the release of the cover latches and to access the air
tank drain valve.
3-9
10/2009
DIMENSIONS
3
Battery Box - Location - Model 325
Figure 3-9.
Battery Box - Location - Model 325
TABLE 3-9.
Battery box location [inches (mm)]
Dimension
X
30.1 (765)
Y
6.3 (159)
Z
27.7 (703)
3-10
3
DIMENSIONS
Battery Box - Step Height - Model 330, Model 337, Model 348
Figure 3-10. Battery Box - Step Height
TABLE 3-10. Battery box - step height [inches (mm)]
STEEL
BATTERY BOX
ALUMINUM
BATTERY BOX
STEP HEIGHT*
STD CROSSMEMBER
HD CROSSMEMBER
HD CROSSMEMBER
A** (ground to first
step)
18.7 (475)
17.2 (437)
14.5 (368)
B (first step to second
step)
14.0 (356)
14.0 (356)
16.1 (409)
C (second step to cab
floor)
12.0 (305)
13.5 (343)
15.0 (381)
*Measured in the light (unloaded) condition with a left-hand under-cab battery box, Eaton Spicer E1002I or
E1202I front axle, required front axle spacer blocks, 10,000 lb or 12,000 lb taperleaf front suspension, 10-1/2 or
10-5/8 inch frame rails, Bridgestone R250F or R299PFE 295/75R22.5 front tires, wheelbases less than 157 inch,
and a Reyco 79KB 21,000 lb rear suspension. Other components may result in different "A" step heights.
**Make the following corrections to step height "A" for the conditions listed above with these optional wheelbases
and rear suspensions:
· Wheelbases greater than 157 inch with Reyco 79KB 21,000 lb suspension - subtract 1.4 inch (36 mm)
· All wheelbases with Reyco 79KB 23,000 or 26,000 lb suspensions - add .6 inch (15 mm)
· All wheelbases with Peterbilt Low Air Leaf 21,000 lb suspension - subtract 1.4 inch (35 mm)
· All wheelbases with Reyco 102 38,000 lb suspension - add 1.6 inch (41 mm)
· All wheelbases with Hendrickson RT2-400 40,000 lb suspension - add 1.6 inch (41 mm)
· All wheelbases with Peterbilt Low Air Leaf 38,000 lb suspension - no correction required
NOTE: Vehicles designed for use as fire apparatus must have an "A" step height of no more than 24.0
inches (610 mm) to comply with NFPA 1901 Standard for Automotive Fire Apparatus, 1999 Edition.
3-11
10/2009
DIMENSIONS
3
Battery Box - Step Height - Model 325
Figure 3-11. Battery Box - Step Height - Model 325
TABLE 3-11. Battery box - step height [inches (mm)]
Step Height
A (ground to first step)
B (first step to cab floor)
21.7 (550)
19.7 (500)
3-12
3
DIMENSIONS
Fuel Tank - Location - Model 330, Model 337, Model 348
Rectangular 50-gal steel
fuel tank shown
Figure 3-12. Fuel Tank - Location
TABLE 3-12. Fuel tank location [inches (mm)]
STEEL FUEL TANK
ALUMINUM FUEL TANK
STD
CROSSMEMBER
HD
CROSSMEMBER
RECT
50 GAL
RECT
50 GAL
23 IN. RND
50 GAL
23 IN. RND
70 GAL
23 IN. RND
100 GAL
X
33.5 (851)
33.5 (851)
34.5 (876)
46.8 (1189)
65.1
Y**
+ 2.5 (64)
- 1.9 (48)
- 1.5 (38)
+ 10.8 (275)
+ 28.0 (711)
Z
25 (634)***
25 (634)***
30.7 (779)****
30.7 (779)****
DIMENSION*
HD CROSSMEMBER
(1654)
30.7 (779)****
*Dimensions are for fuel tanks located right-hand under-cab. The location of fuel tanks located back of cab varies
according to the location of other frame-mounted components.
**Positive numbers for the Y dimension indicate distance rearward from the back of cab. Negative numbers indicate
distance forward from the back of cab.
***The fuel filler neck on steel rectangular fuel tanks protrudes an additional 1.4 inch (36 mm) outboard from the outboard edge of the fuel tank.
****This dimension includes 6.2 inch (157 mm) for the fuel tank steps. The outboard edge of the fuel tank itself is 24.5
inch (622 mm) outboard from the frame rail.
3-13
10/2009
DIMENSIONS
3
Fuel Tank - Location - Model 325
Figure 3-13. Fuel Tank - Location
TABLE 3-13. Fuel tank location [inches (mm)]
STEEL FUEL TANK
DIMENSION*
RECT 30 GAL
X
37.7 (958)
Y **
1.4 (35.2)
Z
27.5 (698)
*Dimensions are for fuel tanks located right-hand under-cab.
**Positive numbers for the Y dimension indicate distance
rearward from the back of cab.
Right hand under cab tank shown, dual tanks similar
3-14
3
DIMENSIONS
Fuel Tank - Location - Model 325
Figure 3-14.
Fuel Tank - Location
TABLE 3-14. Fuel tank location [inches (mm)] - Model 325
RECTANGULAR 35 GAL
WB
3-15
X
Y
Z
150 (3810)
43.7 (1110)
3.4 (86.5)
21.6 (548)
154 (3912)
43.7 (1110)
3.4 (86.5)
21.6 (548)
164 (4166)
43.7 (1110)
18.4 (466.7)
21.6 (548)
178 (4521)
43.7 (1110)
23.9 (606.7)
21.6 (548)
190 (4826)
43.7 (1110)
23.9 (606.7)
21.6 (548)
208 (5283)
43.7 (1110)
57.0 (1446.7)
21.6 (548)
220 (5588)
43.7 (1110)
68.0 (1726.7)
21.6 (548)
238 (6045)
43.7 (1110)
79.0 (2006.7)
21.6 (548)
10/2009
DIMENSIONS
3
Fuel Tank - Step Height - Model 325
fuel tank shown
Figure 3-15. Fuel Tank - Step Height
TABLE 3-15. Fuel tank - step height [inches (mm)]
STEP HEIGHT
STEEL FUEL TANK
A** (ground to step)
19.5 (495)
B (step to cab floor)
20.4 (517)
Measured in the light (unloaded) condition with a right-hand under-cab fuel tank, Dana D800F front
axle, required front axle spacer blocks, 8,000 lb taperleaf front suspension, 9 7/8 inch frame rails,
Bridgestone R250F 245/70R19.5 front tires, wheel base less than 157 inch, and a Reyco 79KB
11,500 lb rear suspension. Other components may result in different "A" step heights.
3-16
3
DIMENSIONS
Fuel Tank - Step Height - Model 330, Model 337, Model 348
fuel tank shown
Figure 3-16. Fuel Tank - Step Height
TABLE 3-16. Fuel tank - step height [inches (mm)]
STEP HEIGHT*
STEEL FUEL TANK
ALUMINUM FUEL TANK
A** (ground to first step)
23.3 (592)
17.4 (442)
B (first step to second step)
C (second step to cab floor)
14.8 (376)
6.5 (165)
15.2 (386)
12.1 (308)
*Measured in the light (unloaded) condition with a right-hand under-cab fuel tank, Eaton Spicer E1002I or E1202I
front axle, required front axle spacer blocks, 10,000 lb or 12,000 lb taperleaf front suspension, 10-1/2 or 10-5/8 inch
frame rails, Bridgestone R250F or R299PFE 295/75R22.5 front tires, wheelbases less than 157 inch, and a Reyco
79KB 21,000 lb rear suspension. Other components may result in different "A" step heights.
**Make the following corrections to step height "A" for the conditions listed above with these optional wheelbases and
rear suspensions:
· Wheelbases greater than 157 inch with Reyco 79KB 21,000 lb suspension - subtract 1.4 inch (36 mm)
· All wheelbases with Reyco 79KB 23,000 or 26,000 lb suspensions - add .6 inch (15 mm)
· All wheelbases with Peterbilt Low Air Leaf 21,000 lb suspension - subtract 1.4 inch (35 mm)
· All wheelbases with Reyco 102 38,000 lb suspension - add 1.6 inch (41 mm)
· All wheelbases with Hendrickson RT2-400 40,000 lb suspension - add 1.6 inch (41 mm)
· All wheelbases with Peterbilt Low Air Leaf 38,000 lb suspension - no correction required
NOTE: Vehicles designed for use as fire apparatus must have an "A" step height of no more than 24.0
inches (610 mm) to comply with NFPA 1901 Standard for Automotive Fire Apparatus, 1999 Edition.
3-17
10/2009
3 DIMENSIONS
2010 DEF TANK and AFTERTREATMENT SYSTEM
SCR System Overview
(Cross-Over System Shown)
3-18
3 DIMENSIONS
2010 DEF TANK MEASUREMENTS
DEF Tank Information
Tank Shape
Round
Round
Rectangular
DEF Tank
Size
Useable Capacity
Gallons
9
18
6.6
Width (x)
mm (in)
265 (10.4)
480.4 (18.9)
250 (9.8)
Length (y)
mm (in)
586 (23.0)
580 (22.8)
386 (15.2)
Height (z)
mm (in)
609 (23.9)
609 (23.9)
496 (19.5)
Assembly Weight
lbs
53
75
74
Assy Weight w/Urea
lbs
160
270
150
Gallons
150
300
110
Max Fuel Capacity
D-Tank: Small D-Tank: Medium Class 5, 6 & 7
Note: Rectangular DEF tanks are only available with rectangular fuel tanks on Medium Duty
Models
3-19
3 DIMENSIONS
2010 DEF TANK GROUND CLEARANCE - RECTANGULAR
TOP OF SENDING UNIT BOOT C = 245.3 mm (9.7 in) BOTTOM OF RAIL B = 312.5 mm (12.3 in) BOTTOM OF PUMP PLATE A = 636.1 mm (25.0 in) D = 657.4 mm (25.9 in) 3-20
3 DIMENSIONS
2010 DEF TANK GROUND CLEARANCE - ROUND
TOP OF SENDING UNIT BOOT C = 267.7 mm (10.5 in) BOTTOM OF RAIL B = 391.7 mm (15.4 in) BOTTOM OF PUMP PLATE A = 673.9 mm (26.5 in) D = 702.8 mm (27.7 in) 3-21
DIMENSIONS
3
Exhaust Location - 2007 Horizontal DPF with Horizontal Diffuser
** Dimension shown is for 10 5/8
inch rails. Add 0.125 inch (3.2
mm) for 10 3/4 inch rail. Add 0.7
inch (17.8 mm) when measuring
from top of 9 7/8 inch rail.
Figure 3-17. Exhaust Location - Horizontal DPF with Horizontal Diffuser
TABLE 3-17. Exhaust Location - Horizontal DPF with Horizontal Diffuser
Engine
Transmission
DPF Location*
X
All manual
PX-6
2275
15.8 (402)
Allison 2000 series
Allison 3000 HS
PX-6
Allison 3000 RDS
2475
21.7 (552)
Allison 3500 RDS
Fuller FS series
Fuller FR series
PX-8
2375
23.2 (590)
Allison 2000 series
Allison 3000 HS
Fuller RT series
Allison 3000 RDS-P
PX-8
Allison 3500 RDS-P
2513
28.7 (728)
Allison 3000 EVS-P
Allison 3500 EVS-P
* DPF LOCATION IS MEASURED FRONT OF FRAME TO FRONT MOUNTING BRACKET.
3-22
3
DIMENSIONS
Exhaust Location - 2007 Horizontal DPF with Vertical Stack - Model 330, 337, 348
Figure 3-18. Exhaust Location - Horizontal DPF with Vertical Stack
TABLE 3-18
Engine
Exhaust Location - Horizontal DPF with Vertical Stack
Transmission
DPF Location*
X
Y
All manual
PX-6
2275
21.4 (543)
16.8 (426)
Allison 2000 series
Allison 3000 HS
PX-6
Allison 3000 RDS
2475
27.4 (695)
22.6 (575)
Allison 3500 RDS
Fuller FS series
Fuller FR series
PX-8
2375
25.3 (643)
19.6 (499)
Allison 2000 series
Allison 3000 HS
Fuller RT series
Allison 3000 RDS-P
PX-8
Allison 3500 RDS-P
2513
30.9 (784)
26.3 (668)
Allison 3000 EVS-P
Allison 3500 EVS-P
* DPF LOCATION IS MEASURED FRONT OF FRAME TO FRONT MOUNTING BRACKET.
3-23
1/2010
DIMENSIONS
3
Exhaust Location - 2007 Under Cab DPF w/Side of Cab Stack - Model 330, 337, 348
Figure 3-19. Exhaust Location - Under Cab DPF w/Side of Cab Stack
TABLE 3-19. Exhaust Location - Under Cab DPF w/Side of Cab Stack
Engine
DPF Location*
X
Y
PX-6
2063
4.5 (115)
2.8 (70)
PX-8
2063
4.5 (115)
2.8 (70)
PX-8
2163
8.5 (215)
6.7 (170)
* DPF LOCATION IS MEASURED FRONT OF FRAME TO
FRONT MOUNTING BRACKET.
3-24
3 DIMENSIONS
2010 UNDER FRAME IN-SERIES DPF/SCR with HORIZONTAL EXHAUST
14.3”
12.4”
105”
Reference option code 3365060
3-25
3 DIMENSIONS
2010 UNDER FRAME CROSSOVER DPF/SCR with HORIZONTAL EXHAUST
14.3”
12.4”
51”
Reference option code 3365070
3-26
3 DIMENSIONS
2010 RIGHT HAND UNDER CAB DPF/SCR with SIDE OF CAB EXHAUST
B
15.9”
A
31.5”
A = Lower step to upper step = 14.2”
B = Upper step to cab floor = 15.5”
Reference option 3365040
3-27
3 DIMENSIONS
2010 MANUAL TRANSMISSION – PX6 PTO FRAME CLEARANCE
Bottom view from right rear
Bottom view from forward side
3-28
Rear view
Bottom view from side
3 DIMENSIONS
2010 ALLISON TRANSMISSION – PX6 PTO FRAME CLEARANCE
Bottom view from right side
3-29
Bottom view
Rear view
3 DIMENSIONS
2010 MANUAL TRANSMISSION – PX8 PTO FRAME CLEARANCE
Bottom view from forward side
3-30
Rear view
Bottom view from side
3 DIMENSIONS
2010 ALLISON TRANSMISSION – PX8 PTO FRAME CLEARANCE
Bottom view from right side
3-31
Bottom view
Rear view
3
DIMENSIONS
FEPTO Extension and Bumper - Model 337, Model 348
* FEPTO extension is measured from the front of the
grille to the front of the bumper. 2007=25.5, 2010=27.8
** 6.0 in X 3.45 in (152 mm X 88 mm) “L” section
Figure 3-20. FEPTO Extension and Bumper
3-32
1/2010
DIMENSIONS
3
Air Horn - Model 330, Model 337, Model 348
* Single air horn shown. Second air horn would be
mounted symmetrically opposite on the right side.
** with 10 5/8 inch rails. Add 0.1 inch (3 mm) when
measuring from top of 10 1/2 inch rails.
Subtract 0.27 inch (6.8 mm) when measuring from
top of 10 3/4 inch rails.
Figure 3-21. Air Horn
3-33
3
DIMENSIONS
Rear Frame Height - Single Rear Axle
Rear Frame Height = RSH + RTH
Figure 3-22. Rear Frame Height - Single Rear Axle
TABLE 3-20. Rear Suspension Height (RSH*) - single rear axle [inches(mm)] Models 330, 337, 348
CROSSMEMBER
REYCO 79KB
21,000 LB.
19.8 (503)
20.4 (518)
STD
HD
REAR SUSPENSION HEIGHT (RSH*)
REYCO 79KB
REYCO 79KB
PB LOW AIR LEAF
23,000 LB.
26,000 LB.
21,000 LB.
21.6 (549)
N/A
17.4 (441)
22.2 (564)
22.6 (574)
17.4 (441)
PB AIR TRAC
23,000 LB.
N/A
22.1 (561)
*Same as "C" height in Peterbilt Engineering Data Book. Measured in the light (unloaded) condition with 10-5/8 inch frame rails. Add 0.125 inch (3.2
mm) for 10 3/4 inch rail.
TABLE 3-21.
Rear Suspension Height (RSH) - single rear axle [inches(mm)] - Model 325
REYCO 79 KB
11,500 LB
15.8 (401)
TABLE 3-22. Rear Tire Height (RTH**) - single rear axle [inches(mm)] Models 330, 337, 348
BRIDGESTONE
R250F 14-PLY
295/75R22.5
BRIDGESTONE
M711 14-PLY
11R22.5
REAR TIRE HEIGHT (RTH**)
BRIDGESTONE
M711 16-PLY
11R22.5
BRIDGESTONE
R250F 16-PLY
12R22.5
MICHELIN
XDHT 14-PLY
11R22.5
18.8 (478)
19.7 (500)
19.7 (500)
19.8 (503)
19.5 (495)
** Same as "D" height in Peterbilt Engineering Data Book. Measured in the static (non-rolling) condition.
TABLE 3-23.
Rear Tire Height (RTH) - single rear axle [inches(mm)] - Model 325
BRIDGESTONE
R250 F 12-PLY
225/70 R19.5
15 (381)
3-34
REAR TIRE HEIGHT (RTH)
BRIDGESTONE
BRIDGESTONE
R250F 12-PLY
M724F 12-PLY
245/70 R19.5
225/70 R19.5
15.5 (394)
15.3 (389)
BRIDGESTONE
M724F 12-PLY
245/70 R19.5
15.6 (396)
1/2010
DIMENSIONS
3
Rear Frame Height - Tandem Rear Axles - Model 348
Rear Frame Height = RSH + RTH
Figure 3-23. Rear Frame Height - Tandem Rear Axle
TABLE 3-24. Rear Suspension Height (RSH*) - tandem rear axle [inches(mm)]
REAR SUSPENSION HEIGHT (RSH*)
REYCO 102
HENDRICKSON RT2-400
PB LOW AIR LEAF
PB AIR TRAC
40,000 LB.
38,000 LB.
40,000 LB.
40,000 LB.
22.3 (566)
21.8 (554)
19.4 (441)
22.0 (559)
*Same as "C" height in Peterbilt Engineering Data Book. Measured in the light (unloaded) condition with 10-5/8 inch frame rails.
TABLE 3-25. Rear Tire Height (RTH**) - tandem rear axle [inches(mm)]
REAR TIRE HEIGHT (RTH**)
BRIDGESTONE
BRIDGESTONE
BRIDGESTONE
BRIDGESTONE
R250F 14-PLY
M711 14-PLY
M711 16-PLY
R250F 16-PLY
295/75R22.5
11R22.5
12R22.5
11R22.5
18.8 (478)
19.7 (500)
19.7 (500)
19.8 (503)
** Same as "D" height in Peterbilt Engineering Data Book. Measured in the static (non-rolling) condition.
MICHELIN
XDHT 14-PLY
11R22.5
19.5 (495)
3-35
3
DIMENSIONS
Rear Suspension and Tire Clearance - Single Rear Axle
Figure 3-24. Rear Suspension and Tire Clearance - Single Rear Axle
Rear Suspension Clearance (RSC) determines the minimum distance to frame-mounted components without
interference with the rear suspension.
Rear Tire Clearance (RTC) may be used to determine the distance from the end of frame to the rear tire; for
example, for an asphalt dump truck. RTC also determines the minimum height of the body above the frame rail.
Minimum body height above frame rail = RTC + 8.0 inches (203 mm) - RSH (from Table 3-18 and Table 3-19).
TABLE 3-26. Rear Suspension Clearance (RSC) - Single Rear Axle [inches(mm)] - Models 330, 337, 348
REAR SUSPENSION CLEARANCE (RSC)
REYCO 79KB
21,000 to 26,000 LB.
27.7 (704)
PETERBILT LOW AIR LEAF
21,000 LB.
36.5 (926)
PB AIR TRAC
23,000 LB.
27.0 (686)
Rear Suspension Clearance (RSC) - Single Rear Axle [inches(mm)] - Model 325
TABLE 3-27.
REAR SUSPENSION CLEARANCE
REYCO 79KB
11,500 LB
29.8 (757)
TABLE 3-28. Rear Tire Clearance (RTC) - Single Rear Axle [inches(mm)] - Models 330, 337, 348
REAR TIRE CLEARANCE (RTC) *
BRIDGESTONE
M843
12R24.5
BRIDGESTONE
M725
285/75R24.5
BRIDGESTONE
M844F
425/65R22.5
BRIDGESTONE
R294
255/70R22.5
BRIDGESTONE
M724F
245/70R19.5
BRIDGESTONE
M729F
285/70R19.5
22.7 (576.6)
21.1 (536)
23.0 (584.2)
18.4 (467.4)
16.8 (426.7)
17.7 (449.6)
*Largest and smallest tires offered in the three basic tire diameters: 24.5, 22.5 and 19.5
TABLE 3-29. Rear Tire Clearance (RTC) - Single Rear Axle [inches(mm)] - Model 325
REAR TIRE CLEARANCE (RTC)
BRIDGESTONE
R250F
225/75R19.5
16.1 (408.9)
3-36
10/2009
DIMENSIONS
3
Rear Suspension and Tire Clearance - Tandem Rear Axles - Model 348
Figure 3-25. Rear Suspension and Tire Clearance - Tandem Rear Axle
* Based on 52 inch axle spacing.
Rear Suspension Clearance (RSC) determines the minimum distance to frame-mounted components without interference with the rear suspension.
Rear Tire Clearance (RTC) may be used to determine the distance from the end of frame to the rear tire; for
example, for an asphalt dump truck. RTC also determines the minimum height of the body above the frame
rail.
Minimum body height above frame rail = RTC + 8.0 inches (203 mm) - RSH (from Table 3-22).
TABLE 3-30. Rear Suspension Clearance (RSC)** - Tandem Rear Axles [inches(mm)]
REYCO 102
38,000 LB.
55.0 (1397)
REAR SUSPENSION CLEARANCE (RSC)**
HENDRICKSON RT2-400
PB LOW AIR LEAF
40,000 LB.
38,000 LB.
53.0 (1346)
57.5 (1460)
PB AIR TRAC
40,000 LB.
53.0 (1346)
TABLE 3-31. Rear Tire Clearance (RTC)** - Tandem Rear Axles [inches(mm)
BRIDGESTONE
M843
12R24.5
22.7 (576.6)
REAR TIRE CLEARANCE (RTC)**
BRIDGESTONE
BRIDGESTONE
M725
M844F
285/75R24.5
425/65R22.5
21.1 (536)
23.0 (584.2)
BRIDGESTONE
R294
255/70R22.5
18.4 (467.4)
**Largest and smallest tires offered in the two basic tire diameters: 24.5 and 22.5
3-37
3
DIMENSIONS
Frame Rail Sections
9 7/8–INCH RAIL
10 1/2–INCH RAIL
YIELD: 120,000 psi
YIELD: 120,000 psi
SECTION MODULUS:
SECTION MODULUS:
RBM: 1,200,000 lb. in.
RBM: 1,416,000 lb. in.
11.8 cu in.
10 cu in.
3.5
(88.9)
.25
(6)
9.4
(239)
10.5
(267)
9.88
(251)
.25
(6)
10
(254)
3.5
(89)
10 5/8–INCH RAIL
HEAT TREATED
10 5/8–INCH RAIL WITH LINER
HEAT TREATED
10 3/4–INCH RAIL
HEAT TREATED
YIELD: 120,000 psi
YIELD: 120,000 psi
YIELD: 120,000 psi
SECTION MODULUS:
SECTION MODULUS:
SECTION MODULUS:
RBM: 1,776,000 lb. in.
RBM: 2,832,000 lb. in.
RBM: 2,136,000 lb. in.
14.8 cu in.
.31
(8)
17.8 cu in.
23.6 cu in.
3.45
(88)
3.45
(88)
.38
(10)
3.50
(89)
.31
(8)
10
(254)
10.62
(270)
9.38
(238)
10.62
(270)
10
(254)
10.75
(273)
.25
(6)
2.87
(73)
Figure 3-26. Frame Rail Sections
3-38
10/2009
DIMENSIONS
3
Crossmember Drillings
6 HOLES
0.53 IN. DIA
(13.5 MM)
5 HOLES
0.66 IN DIA
(16.7 MM)
6.30 IN
(160 MM)
5.63 IN
(143 MM)
2.0 IN
(50 MM)
2.5 IN
(63 MM)
5.5 IN
(140 MM)
11.0 IN
(280 MM)
STANDARD CROSSMEMBER
3.94 IN
(100 MM)
7.87 IN
(200 MM)
THREE-PIECE CROSSMEMBER
01022-01
Figure 3-27. Crossmember Drillings
3-39
SECTION 4 BODY MOUNTING
CRITICAL CLEARANCES
Rear Wheels and Cab
CAUTION: Insufficient clearance between
rear tires and body structure could cause
damage to the body during suspension
movement. Allow at least 8 inches clearance (See Figure 4-1.)
Normal suspension movement could cause contact
between the tires and the body. To prevent this, mount
the body so that the minimum clearance between the top
of the tire and the bottom of the body is 8 inches (203
mm). This should be measured with the body empty.
See Figure 4-1.
Figure 4-2. Minimum Back–of–Cab Clearance.
The true distance from the centerline of the front axle to
the back of the cab is 69.8 inches (1773 mm). It is recommended that the leading edge of the body be
mounted 4 inches (102 mm) behind the cab. The result
is a minimum dimension of 73.8 inches (1875 mm) from
the front axle to the leading edge of the body.
8 in.
(203 mm)
NOTE: The distance from the back of cab to
the front of the body may vary depending on
the location of vehicle components. See SECTION 3 “DIMENSIONS” for further details on
dimensions and clearances.
02866
Figure 4-1.
Minimum Clearance Between Top of Rear
Tires and Body Structure Overhang.
CAUTION:
Maintain adequate clearance
between back of cab and the front (leading
edge) of mounted body. See Figure 4-2.
NOTE:
Be sure to provide maintenance
access to battery box and fuel tank fill neck.
BODY MOUNTING USING
BRACKETS
CAUTION: Always install a spacer between
the body subframe and the top flange of
the frame rail.
Installation of a spacer between the body subframe and
the top flange of the frame rail will help prevent premature wear of the components due to chafing or
corrosion.
Frame Sill
If the body is mounted to the frame with brackets, we
recommend that the frame sill spacer be made from a
4-1
10/2009
4
BODY MOUNTING
strip of rubber or plastic (delrin or nylon). These materials will not undergo large dimensional changes during
periods of high or low humidity. The strip will be less
likely to fall out during extreme relative motion between
body and chassis. See Figure 4-3.
RUBBER
SPACER
BODY
SUBFRAME
(RAIL)
SPACER
01445
Figure 4-5.
CHASSIS FRAME
(RAIL) SILL
01016
Figure 4-3.
Spacer Between Frame Sill and Body Rail —
Rubber or Plastic.
Brackets
When mounting a body to the chassis with brackets, we
recommend designs that offer limited amount of relative
movement, bolted securely but not too rigid. Brackets
should allow for slight movement between the body and
the chassis. For instance, Figure 4-4 shows a high compression spring between the bolt and the bracket.
Rubber Spacer Between Brackets.
Another possibility is mounting a rubber spacer
between the brackets. See Figure 4-5. These designs
will allow relative movement between the body and the
chassis during extreme frame racking situations.
Mountings that are too rigid could cause damage to the
body. This is particularly true with tanker installations.
Mounting Holes
When installing brackets on the frame rails, the mounting holes in the chassis frame bracket and frame rail
must comply with the general spacing and location
guidelines illustrated in Figure 4-6. The hole diameter
should not exceed the bolt diameter by more than .060
inches (1.5mm).
“A” MUST BE EQUAL TO OR
GREATER THAN 2 IN. (50mm)
UPPER FRAME
FLANGE
A
A
SPRING
LOWER FRAME
FLANGE
A
A
01023
01446
Figure 4-4.
High Compression Spring Between the
Mounting Bolt and Upper Bracket.
Figure 4-6.
Hole Location Guidelines for Frame Rail and
Bracket.
4-2
4
BODY MOUNTING
6 HOLES
0.53 IN. DIA
(13.5 MM)
5 HOLES
0.66 IN DIA
(16.7 MM)
6.30 IN
(160 MM)
5.63 IN
(143 MM)
2.0 IN
(50 MM)
2.5 IN
(63 MM)
5.5 IN
(140 MM)
11.0 IN
(280 MM)
STANDARD CROSSMEMBER
3.94 IN
(100 MM)
7.87 IN
(200 MM)
THREE-PIECE CROSSMEMBER
01022-01
Figure 4-7.
Crossmember - Gusset Hole Patterns.
Frame Drilling
WARNING! When mounting a body to the
chassis, DO NOT drill holes in the upper or
lower flange of the frame rail. If the frame
rail flanges are modified or damaged, the
rail could fail prematurely and cause an
accident. Mount the body using body
mounting brackets or U–bolts.
WARNING! Do not drill new holes any
closer than 2 inches (50mm) to existing
holes. Frame drilling affects the strength of
the rails. If the holes are too close together,
the rail could fail prematurely and cause an
accident. See Figure 4-6.
Hole Location Guidelines
Holes must be located at least two inches (50 mm) from
the flange as indicated in Figure 4-6. They must be no
closer than 2 inches (50mm) to each other.
NOTE: If your design permits placement of
body mounting brackets at crossmember locations, you can use the crossmember gusset
bolt holes for body mounting. See Figure 4-7.
CAUTION: Use care when drilling the
frame web so the wires and air lines routed
inside the rail are not damaged.
4-3
10/2009
BODY MOUNTING
BODY MOUNTING USING U–BOLTS
Spacers
If the body is mounted to the frame with U–bolts, use a
hardwood sill (minimum 1/2 inch (12.7 mm) thick)
between the frame rail and body frame to protect the
top surface of the rail flange.
WARNING! Do not allow the frame rails or
flanges to deform when tightening the
U–bolts. It will weaken the frame and could
cause an accident. Use suitable spacers
made of steel or hardwood on the inside of
the frame rail to prevent collapse of the
frame flanges.
• Use a hardwood spacer between the bottom
flange and the U–bolt to prevent the U–bolt
from notching the frame flange. See Figure 4-8.
4
inspect the installation to ensure adequate clearances for air brake lines, fuel lines, and wiring. See
Figure 4-9.
FRAME
RAIL
U–BOLT
AIR LINES
AND WIRING
HARNESSES
FRAME RAIL
SPACER
(HARDWOOD
OR STEEL)
CHECK
CLEARANCE
SPACE FOR AIR
LINES AND
WIRING
U–BOLT
SPACER
01027
BODY
STRUCTURE
U–BOLT
Figure 4-9.
Clearance Space for Air Lines and Cables.
WARNING! Do not notch frame rail flanges
to force a U–bolt fit. Notched or damaged
frame flanges could result in premature
frame failure. Use a larger size U–bolt.
WOOD SILL
½ in. (12.7 mm)
MINIMUM
TRUCK FRAME
FRAME RAIL
SPACER
(FABRICATED
STEEL OR
HARDWOOD)
Figure 4-8.
U–BOLT
SPACER
(HARDWOOD)
01018
Acceptable U–Bolt Mounting with Wood and
Fabricated Spacers.
WARNING! Do not allow spacers and other
body mounting parts to interfere with
brake lines, fuel lines, or wiring harnesses
routed inside the frame rail. Crimped or
damaged brake lines, fuel lines, or wiring
could result in loss of braking, fuel leaks,
electrical overload or a fire. Carefully
CAUTION: Mount U–bolts so they do not
chafe on frame rail, air or electric lines.
4-4
4
BODY MOUNTING
Rear Body Mount
When U–bolts are used to mount a body we recommend that the last body attachment be made with a
“fishplate” bracket. See Figure 4-10. This provides a
firm attaching point and helps prevent any relative fore
or aft movement between the body and frame. For hole
location guidelines, See Figure 4-6.
01021
Figure 4-10. Example of Fishplate Bracket at Rear End of
Body, used with U–Bolts.
4-5
10/2009
SECTION 5 FRAME MODIFICATIONS
INTRODUCTION
There are several standard wheelbase choices for
single and tandem rear axles. In addition, customerspecified wheelbases are available. So, in most cases
frame modifications to produce a certain wheelbase
should not be necessary.
However, some installations may require slight modifications, while other installations will require extensive
modifications. Sometimes an existing dealer stock
chassis may need to have the wheelbase changed to
better fit a customer’s application. The modifications
may be as simple as shortening or lengthening the
frame overhang, or they may be as complex as changing the wheelbase.
DRILLING RAILS
Location and Hole Pattern
If holes need to be drilled to attach anything to the rail,
see SECTION 4 “BODY MOUNTING” for more information. Follow the general spacing and hole location
guidelines on Page 4–2, Figure 4-6.
WARNING!
When mounting a body to the
chassis, DO NOT drill holes in the upper or
lower flange of the frame rail. If the frame
rail flanges are modified or damaged, the
rail could fail prematurely and cause an
accident. Mount the body using body
mounting brackets or U–bolts.
WARNING! Do not drill new holes any
accident.
CAUTION:
Use care when drilling the
frame web so the wires and air lines routed
inside the rail are not damaged.
• Never use a torch to make a hole in the rail. Use
the appropriate diameter drill bit.
Hole pattern dimensions for crossmember designs are
illustrated on Page 4-3, Figure 4-7.
Hole diameter should not exceed the bolt diameter by
more than .060 inches (1.5 mm).
MODIFYING FRAME LENGTH
The frame overhang after the rear axle can be shortened to match a particular body length. Using a torch is
acceptable; however, heat from a torch will affect the
material characteristics of the frame rail. The affected
material will normally be confined to within 1 to 2 inches
(25 to 50mm) of the flame cut and may not adversely
affect the strength of the chassis or body installation.
The frame overhang on the 10.5-inch rail can be lengthened by adding frame extenders.
When extending the 10.5-inch rails, the additional sections can typically be welded to the existing rails. The
joint should be welded and reinforced as illustrated in
Figure 5-1.
NOTE: See page 5–4 for more information on
welding frames.
Frame Insert
A frame insert must be added after welding a 10.5-inch
frame rail to compensate for lost strength. The insert
should be of the same material as the frame member
and at least equal to the frame rail in thickness.
5-1
10/2009
FRAME MODIFICATIONS
Attachment of the insert to the frame should be made
with Ream-Fit Class 8 5/8 in. dia. or Class 10.9 16 mm
dia. bolts or the next larger size. Both the reinforcement and frame holes should be reamed to provide a fit
of from .001 in. to .003 in. (.025 to .076 mm) clearance.
Do not weld the insert. The insert must be a full Cchannel, not a fishplate or “L” channel, and should
span a distance of at least 24 in. (610 mm) on either
side of the joint to insure an even distribution of
stresses. Cut the ends of the insert at 45° as shown
in Figure 5-2 unless the insert extends to the end of the
frame.
5
Where possible, use existing bolt holes to attach the
insert to the frame. Bolt holes must not be located
closer to the frame flanges than the present bolt pattern.
If the insert is placed in a section of the main frame
where few bolts are located, additional bolts are
required. Use the following guideline for locating additional bolt holes.
8.1 in
(205 mm)
2.4 in
(62 mm)
7.9 in
(200 mm)
.15 IN (4 mm)
WELD FRAME RAILS ON
THE OUTSIDE ONLY
Figure 5-1.
45°
01019
Detail of Frame Extensions and Joint Welding.
Changing Wheelbase
We do not recommend modifying the wheelbase. Occasionally, however, a chassis wheelbase will need to be
shortened or lengthened. Before this is done there are
a few guidelines that should to be considered.
min
in. m)
24 10 m
(6
WELDED
JOINT
210003
Figure 5-2.
WARNING! When changing the wheelbase,
be sure to follow the driveline manufacturer’s recommendations for driveline
length or angle changes. Incorrectly modified drivelines can fail prematurely due to
excessive vibration. This can cause an
accident and severe personal injury.
Frame Insert
5-2
5
FRAME MODIFICATIONS
Before changing the wheelbase the driveline angles of
the proposed wheelbase need to be examined to
ensure that no harmful vibrations are created. Consult
the driveline manufacturer for appropriate recommendations.
Before the rear suspension is relocated, check the new
location of the spring hanger brackets. The new holes
for the spring hanger brackets must not overlap existing
holes and should not come any closer than 2 inches
(50mm) to existing holes.
WARNING!
Do not drill new holes any
accident.
Before the rear suspension is relocated, check the new
location of the spring hanger brackets. The new holes
for the spring hanger brackets must not overlap existing
holes and should not come any closer than 2 inches
(50mm) to existing holes in the frame.
MOUNT THE SUSPENSION
BRACKETS ON THE
ORIGINAL RAIL
10 IN (254 mm) Minimum
LENGTHENED WHEELBASE
DO NOT MOUNT THE
SUSPENSION BRACKET ON
THE ADDED FRAME RAIL
WARNING! When relocating a suspension
bracket, do not mount it on the extended
(added) section of a frame rail. The suspension loading could result in premature
failure of the added section splice. This
could cause an accident. Use care when
planning the wheelbase so that the rear
suspension bracket is always mounted on
the original rail section. See Figure 5-3.
If you are lengthening the wheelbase, you may also
have to extend the frame length to accommodate a
body. When you reposition the rear suspension spring
hangers, do not mount them on the added extended
portion of the rail. The relocated rear suspension
bracket should be located on the original frame rails
with a miniumum of 10 inches (254 mm) between the
suspension bracket and the spliced section.
See Figure 5-3.
When shortening the wheelbase, we recommend that
the suspension be moved forward and relocated on the
original rail. The rail behind the suspension can then be
cut to achieve the desired frame overhang.
See Figure 5-3.
ORIGINAL WHEELBASE
RELOCATED REAR
SUSPENSION
SHORTENED WHEELBASE
CUT FRAME AT REAR TO
OBTAIN DESIRED CUTOFF
Figure 5-3.
5-3
Comparison of Original, Shortened,
and Lengthened Wheelbases.
10/2009
FRAME MODIFICATIONS
5
WELDING
Crossmembers
After lengthening a wheelbase, an additional crossmember
may be required to maintain the original frame strength. Contact Dealer for crossmember locations.
• The maximum allowable distance between the forward suspension crossmember and the next crossmember forward is 47.2 inches (1200 mm). If the
distance exceeds 47.2 inches (1200 mm) after the
wheelbase is lengthened, add a crossmember
between them. See Figure 5-4. See Figure 4-7 on
page 4-3 for crossmember hole patterns.
The 9.88 (9 7/8), 10.5 (10 1/2), 10.62 (10 5/8),
10.75 (10 3/4), 11.625 (11 5/8) inch rails are heat
treated and are not weldable.
Precautions
CAUTION: The 9.88 (9 7/8), 10.5 (10 1/2)
10.62 (10 5/8), 10.75 (10 3/4), and 11.625
(11 5/8) inch rails are heat treated;
therefore, they are not weldable.
LESS THAN
47.2 IN.
(1200 mm)
BEFORE WHEELBASE IS LENGTHENED
GREATER
THAN 47.2 IN.
ADDITIONAL CROSSMEMBER REQUIRED
AFTER WHEELBASE IS LENGTHENED
00627B
Figure 5-4.
Additional Crossmember Required When
Distance Exceeds 47.2 Inches (1200 mm).
5-4
5
FRAME MODIFICATIONS
TORQUE REQUIREMENTS
TORQUE REQUIREMENTS
TABLE
5-1.
Customary
TABLE
5-1.
Customary
GradeGrade
8 UNF 8
or UNF
UNC
Fastener
or UNC.
Torque
Size
Nm
Lb.-Ft
5/16
22–30
16–22
3/8
41–54
30–40
7/16
75–88
55–65
1/2
109–122
80–90
9/16
156–190
115-140
5/8
224–265
165–195
3/4
394–462
290–340
7/8
517–626
380–460
1
952–1129
800–830
1-1/8
1346–1591
990–1170
1-1/4
1877–2217
1380–1630
Torque values apply to fasteners with clean threads, lightly lubricated,
with hardened steel washers, and nylon-insert nuts.
TABLE5-2.
5-2.U.S.
U.S.
Customary
– Grade
Metric
TABLE
Customary
- Grade
8 Metric 8.
Class
10.9
Class 10.9
Torque
5-5
Fastener
Nm
Lb-Ft
M6
9–15
7–11
M8
23–31
17–23
M10
33–43
24–32
M12
75–101
55–75
M14
134–164
99–121
M16
163–217
120–160
M20
352–460
260–340
1/2010
SECTION 6 ELECTRICAL
INTRODUCTION
Peterbilt offers several options to provide power and
electrical connections between the chassis electrical
system and the electrical components on the body.
These options include:
• a junction box to provide power and ground for
body lights
• an engine harness to install a remote PTO control
• a third battery to provide power for lift gates and
other high-amperage electrical devices
By specifying these options, the body can often be
installed in less time and with fewer possibilities of
maintenance problems.
NOTE: These options should be specified at
the time the truck is ordered to ensure proper
installation. Consult the current pricebook for
appropriate
option
codes,
prices,
and
restrictions.
BODY LIGHTS JUNCTION BOX
The body lights junction box option provides a wiring
harness from the firewall to a junction box located at the
back of cab. The box is strapped to the back-of-cab- or
intermediate-crossmember for shipping and is designed
to be permanently mounted by the body builder.
The harness is sufficiently long to allow a certain flexibility in installation. It provides power and ground circuits for clearance lights, marker lights, brake lights,
and rear turn signals.
WARNING! This option is intended for
lighting circuits only. It is not intended to
provide power to any other electrical component. Using a circuit for any other purpose may result in an electrical overload,
which could cause a fire.
The circuits terminate with ring terminals in the junction
box. See Figure 6-1 for circuit identification.
5 CLEARANCE LIGHTS
8 MARKER LIGHTS
66 GROUND
227 RIGHT TURN SIGNAL
228 LEFT TURN SIGNAL
279 BRAKE LIGHTS
BODY CONNECTION
AT FIREWALL
66 GROUNDED TO
CAB FIREWALL
Figure 6-1.
6-1
Body Lights Junction Box Circuits.
10/2009
ELECTRICAL
6
THIRD BATTERY
REMOTE PTO HARNESS
This option provides wiring from the engine to end of frame
for remote control of engine throttle and a customer installed
PTO. Controls are not provided with this option. Included is
a 354.3 inch (9000 mm) wiring harness with a 7-pin connector that is routed to the end of frame. Any excess is coiled
and secured there. See Table 6-1 for wiring harness connector pin outs and Figure 6-2 for end of frame connector
configuration.
WARNING!
Follow the engine manufacturer’s
guidelines for use of these circuits. See your
engine manufacturer to verify that the engine is
programed correctly for the intended applications. Failure to properly program the engine or
wire these circuits could cause an accident.
This option provides a third battery installed in the battery
box. It includes three batteries as specified in the pricebook, a battery holddown designed for three batteries, and
the appropriate inter-connecting battery cables.
NOTE:
This option does not include the
cables or circuit breakers required to connect
the batteries to the auxiliary electrical devices.
This option is required when auxiliary high-amperage
electrical devices such as electric winches, lift gates,
and electromechanical sirens are to be installed by the
body builder.
WARNING!
Follow the manufacturer’s
installation instructions when installing
high-amperage electrical devices such as
electric winches, lift gates, and electromechanical sirens. Failure to properly install
these devices could result in an electrical
overload and fire.
ENGINE CONNECTIONS
Figure 6–2.
TABLE 6-1.
Remote PTO/Throttle Control Wiring Harness
Connector Pinouts.
Electronic engines have the ability to send and receive
control and warning signals from other components on
the chassis and body. Consult the appropriate engine
manufacturer’s application or body builder manuals
before making connections to the engine electronic
control unit (ECU) or to other electronic engine
components.
Remote PTO/Throttle Wiring Harness.
Remote PTO/Throttle Connection
Circurt Function Name
Engine
ECU Pin
PB Circuit
Number
Wire
Wire Color Gauge
NOT USED
NOT USED
COMMON RETURN #1 (SWITCH)
REMOTE THROTTLE SIGNAL
PTO ON/OFF
REMOTE THROTTLE ENABLE
SWITCH POWER
GROUND
TORQUE LIMIT SWITCH
5V SUPPLY
COMMON RETURN #3(SENSOR)
REMOTE THROTTLE ON/OFF
NONE
NONE
41
37
18
NONE
NONE
NONE
17
26
22
8
NONE
NONE
EE03
EE39
EE18
EE11
242
239
EE64
EE58
EE02
EE63
NONE
NONE
BLK/WHT
BRN/YEL
GRN/WHT
BLK/WHT
RED
BLK
LT BLU
GRN/BLU
BLK/WHT
WHT/BLK
NONE
NONE
18
18
18
18
14
14
18
18
18
18
Connector
Pinout
1
2
3
4
5
6
7
8
9
10
11
12
6-2
SECTION 7 HYBRID
Hybrid - Model 330, Model 337
Figure 7-1.
Hybrid Model 337 shown
TABLE 7-1. Power Electric Carrier (PEC) Placement -
Model 330, Model 337
Power Electric Carrier Placement
Configuration
"A" Dimension
Pick up & delivery
5 (127)
Utility W/O outrigger
5 (127)
Utility with outrigger
15 (381)
CAUTION: Do not weld chassis.
CAUTION: Do not paint the orange high
voltage cables.
7-1
General Notes:
 All guidelines outlined in the Eaton Installation Guide
must be followed and are available at
www.roadranger.com.
 The high voltage cables and hybrid electric
harnesses must have at least 6 inches of clearance
to any vehicle exhaust system component or any
heat source exceeding 150 degrees Celsius.
 All high voltage cables and hybrid electric harnesses
must have sufficient clearance to any other component to prevent abrasion, chaffing or other damage.
 The Power Electric Carrier (PEC) can be remote
mounted. Peterbilt offers a 9 ft. long high voltage
cable and extended electrical harnesses so that the
PEC can be relocated per the Eaton Installation
Guide. Service switch must be accessible.
 Do not install components on or adjacent to the
under cab battery box. This area needs to remain
unobstructed for proper function of the hybrid
cooling system.
1/2010
HYBRID
7
HYBRID UTILITY APPLICATION
EPTO Functionality
In order to make the EPTO functional on the Hybrid Utility
Application trucks, the Body Builder must install a J1939
compatible Body controller capable of transmitting the CAN
AuxIO messages listed on the EPTO installation requirements section of the Eaton Installation Guide TRIG1000 to
the Hybrid Control Module (HCM).
TRIG1000 also provides an engagement flowchart of the
EPTO requirements.
EPTO Connection
Locate connector labeled “J5-EPTO” on the hybrid power
train harness attached and zip tied at the bottom of the transmission (see Figure 7-2 and Figure 7-3).
Figure 7–2.
J5-EPTO Connector
This connector provides two signals coming from the HCM
on the transmission to the body builder interconnection and
receives a PTO engaged confirmation signal from the body
builder to the HCM.
• Terminal B: provides a negative signal (GND) intended
for the EPTO solenoid.
• Terminal C: provides a positive signal (12 VDC)
intended for the EPTO solenoid.
• Terminal A: provides the PTO status analog signal to
the HCM under EPTO operation.
Figure 7–3.
Transmission for EPTO Connection
7-2
7
HYBRID
Body Builder Connection
The body builder connector labeled “P7-BODY CONNECTION” is located attached to the left side chassis rail. This
connector has a 1000 mm break out which is left zip tied
from factory behind the BOC cross member junction (see
Figure 7-4 and Figure 7-5).
This connector provides and receives the following signals:
• Terminal 2: (inserted by Body Builder) a safety interlock
ground signal which first goes throughout the Park
Brake interlock and returns through the Hood tilt switch
back to terminal 1 to the body controller.
• Terminal 1: returns to the body controller a safety
interlock ground signal inserted through terminal 2.
• Terminal 3: provides a 12VDC, 10Amps ignition power
signal.
• Terminal 5: provide a chassis ground signal.
• Terminal 7: interfaces the J1939 Data Link Minus
• Terminal 8: interfaces the J1939 Data Link Plus
• Terminals 4 and 6: Not used.
Figure 7–5.
7-3
Figure 7–4.
P7 Body Connector
Location on Frame Rail of Body Builder Connection
10/2009
HYBRID
7
Sections of the MD Hybrid Electrical Schematics on Body Builder connections
Figure 7.6 and Figure 7.7, shown below, refer to the MD
Hybrid Electrical Schematic P94-6069.
Reference Drawings:
a)
b)
P94-6069
P97-6250
c)
P95-6269
SCHEMATIC – MD HYBRID SYSTEM
INSTL – HYBRID XMSN AND POWERTRAIN HARN
ROUTING – CHASSIS, HYBRID
Figure 7–6.
EPTO Section - Medium Duty Hybrid Electrical Schematic P94-6069
Figure 7–7.
Body Connection Section - Medium Duty Hybrid Electrical Schematic P94-6069
7-4
7 HYBRID
HYBRID SYSTEM BATTERY BOX ACCESS
To prevent damage from the box lid, additional routing of cables to the batteries should
utilize feature located in the back wall of the box and secured using the provided hole.
7-5
APPENDIX A VEHICLE IDENTIFICATION
VEHICLE IDENTIFICATION NUMBER
A 17–character number (numeral and letter combination) forms the Vehicle Identification Number (VIN) and
Chassis Number. It contains among other information,
the model year (4), assembly plant (5), and vehicle
serial number (6). See Figure A–1.
2NP
NHD 8 X
X
YM 5 6 7 8 9 0
1
2
3
4 5
6
1 - Manufacturer Identifier
2 - Vehicle Attributes
3 - Check Digit
4 - Model Year
5 - Assembly Plant
6 - Serial/Chassis Number
Vehicle Identification Number (VIN).
The model year (4) is designated by a letter or numeric
code in the tenth character position in the VIN. See
Table A-1 and Figure A–1.
TABLE A-1.
A-1
The VIN is marked on the Incomplete Vehicle Certification Label (on trucks) or on the Tire, Rim, and Weight
Rating Data Label (on tractors). Both labels are located
on the driver’s door frame. See Figure A–2.
Chassis Number Locations
SAMPLE VIN
Figure A–1.
VIN Location
The Chassis Number (comprising the last seven characters of the VIN) includes an assembly plant designator (5) and a six–digit serial number (6). See Figure
A–1.
The chassis number is shown in six places:
• Right frame rail, top flange, about 3 ft. from the
front end: stamped.
• Left side back of cab, stamped plate.
• Tire, Rim, and Weight Rating Data label (truck).
• Components and Weights label.
• Noise Emission label.
• Paint Identification label.
Model Year Letter (CODE) Designations.
CODE
YEAR
5
2005
6
2006
7
2007
8
2008
9
2009
10/2009
CERTIFICATION LABELS
Components and Weights Label
The Components and Weights Label is located on
either the driver’s side door edge for truck/tractors, or
on the door frame for trucks. See Figure A–2. It
includes: chassis weight and gross weight; plus, model
and serial numbers for the vehicle, engine, transmission, and axles.
A
Tire and Rim Data Label
The Tire and Rim Data Label is located on the driver’s
side door frame, below the door latch. See Figure A–2.
It contains the following information:
• GVWR — Gross Vehicle Weight Rating
• GAWR FRONT and REAR — Gross Axle
Weight Ratings for Front and Rear Axle
• TIRE/RIM SIZES AND INFLATION PRESSURES — Tire/Rim Sizes and Cold Pressure
Minimums
• Chassis (Serial) Number
FINAL STAGE MANUFACTURER
LABEL (TO BE INSTALLED BY
FINAL STAGE MANUFACTURER)
NOTE: GVWR is the TOTAL WEIGHT the
vehicle is designed to carry. This includes the
weight of the empty vehicle, loading platform,
occupants, fuel, and any load. Axle weight ratings are listed on the edge of the driver’s door.
Incomplete Vehicle Certification Label
The Incomplete Vehicle Certification Label (for trucks)
is located on the driver’s side door edge. See Figure
A–2. It contains the following information:
• DATE OF MANUFACTURE
• VIN — Vehicle Identification Number
• LISTING OF APPLICABLE FEDERAL MOTOR
VEHICLE SAFETY STANDARDS
Noise Emission Label
The Noise Emission Label is located in the map compartment. It contains information regarding U.S. noise
emission regulations, chassis number, and date of
manufacture.
TIRE, RIM, AND WEIGHT RATING
DATA LABEL (TRUCK)
TIRE, RIM, CERTIFICATION AND
WEIGHT LABEL (TRACTOR) OR
INCOMPLETE VEHICLE CERTIFICATION LABEL
FMVSS 121 BRAKE CAUTION
LABEL (TRUCK)
Paint Identification Label
The Paint Identification Label contains the paint colors
used by the factory to paint your truck/tractor. It lists
frame, wheels, cab interior and exterior colors. This
label is located in the map compartment.
MAJOR COMPONENTS AND
WEIGHTS LABEL (TRUCK OR
TRACTOR)
Figure A–2.
Driver’s Door Frame
A-2
A
COMPONENT IDENTIFICATION
Each of the following components has their own identification label.
Engine Identification
The PACCAR engine serial number is stamped on a
plate located on the front driver side of the engine. For
further information, please refer to the Engine Operation and Maintenance Manual (included in the glove
compartment of each vehicle).
Figure A–4.
Front Axle Identification.
1. Axle Specification Number, stamped on the right
rear side of the axle housing. This number identifies
the complete axle.
Engine Identification
Location
(PX-8 Shown)
Figure A–3.
2. Axle Housing Number Tag, located on the left forward side of the housing arm. This tag identifies the
axle housing.
3. Axle Differential Carrier Identification, located on
the top side of the differential carrier. The following
information is either stamped, or marked with a
metal tag: Model No., Production Assembly No.,
Serial No., Gear Ratio, and Part Number.
3
Engine Identification Location and Label (PX-8 Shown)
Transmission Identification
2
The transmission identification number is stamped on a
tag affixed to the right rear side of the transmission
case. It includes among other specifications the transmission model number, serial number, and part number.
1
Front Axle Identification
The front axle serial number is stamped on a plate
located on the front axle beam. See Figure A–4.
Rear Axle Identification
The rear axle identification numbering system includes
three labels or stamps. See Figure A–5.
A-3
01053
Figure A–5.
Rear Axle Identification Labels.
NOTE: Illustrated identification tags are typical. Actual locations may vary by axle manufacturer.
10/2009
APPENDIX B WEIGHT DISTRIBUTION
INTRODUCTION
As the final stage manufacturer of a vehicle, the body
builder is responsible for ensuring and certifying that
the weight distribution of the completed truck with the
body and intended payload does not exceed the
Gross Axle Weight Rating (GAWR) for each axle. To
help the body builder in that process, Peterbilt can
supply the GAWR for each axle based on the
published ratings of the tires, wheels, axles, and
suspensions. Peterbilt can also supply the distributed
weight of the bare chassis on the front and rear axles.
NOTE: The distributed weight should be
requested at the time the vehicle is ordered.
It can be automatically calculated as part of
the electronic ordering process.
TABLE B-1.
BODY BUILDER’S
RESPONSIBILITIES
The body builder is responsible for designing and
installing the body such that the weight distribution of
the bare chassis, body, and intended payload does not
exceed the GAWR for each axle. Each body builder
needs to develop a system for calculating weight distribution. This would include tabulation of the weight and
location of every body component, as well as an understanding of the weights and locations (point load versus
distributed load) of various payloads. See Table B-1. for
the weights of various common payloads.
WARNING! Incorrect calculation of the
weight distribution on the front and rear
axles may result in poor vehicle performance, component failure, or loss of
vehicle control with the resulting possibility of serious personal injury or
death.
Weights of common payloads [lb(kg)]
Pay l o ad
Wei g h t /Un i t o f Meas u r e
Construction Materials
Asphalt
2399 (1045) /cubic yard
Concrete
4150 (1886) /cubic yard
Earth, Dry
2000 (909) /cubic yard
Earth, Wet
3000 (1364) /cubic yard
Gravel, Dry
3100 (1409) /cubic yard
Gravel, Wet
3400 (1545) /cubic yard
Sand, Dry
2700 (1227) /cubic yard
Sand, Wet
3400 (1545) /cubic yard
Liquids
B-1
Asphalt Oil
10 (4.5) /gallon
Butane/LNG
4 (1.8) /gallon
Diesel Fuel
7 (3.2) /gallon
Gasoline
6 (2.7) /gallon
Milk
9 (4.1) /gallon
Water
8 (3.6) /gallon
10/2009
APPENDIX C ROUTING
INTRODUCTION
Electrical wiring can sometimes be very frustrating. This is
especially true when adding circuits to an existing setup.
Through the use of a optional body harness and additional
spare circuits, we have tried to reduce the complexity associated with adding common circuits to a body installation.
Note: The most common circuits that body builders may need are pre-connected to this optional
wiring harness.
The new body related circuits can be added by connecting
the added circuit wires to the appropriate wires in this
harness.
ELECTRICAL CIRCUITS
Capacity
WARNING! Do not install an electrical circuit that
requires more amperage (electrical capacity) than
what is available in the specific chassis circuit. An
overloaded circuit could cause a fire. Compare
the amperage requirements of the new circuit to
the electrical current capacity of the existing chassis circuit before adding the body or other
equipment.
When adding an electrical circuit, you must know the current
capacity (amperes) of each circuit.
current to the circuit must be equal to or greater than the
demand of the added circuit otherwise these components
may not work properly.
ROUTING
This section specifies the general requirements for securing hoses and electrical wires to present an orderly
appearance; facilitate inspection and maintenance; and to
prevent potential damage to these lines.
Definitions
Bundle: Two or more air, electrical, fuel, or other lines tied
together to form a unitized assembly.
Clamp: A cushioned rigid or semi-rigid, anti-chafing device
for containing the bundle and securing it to the frame or
other structural support. Standard clamps have a black
elastomer lining. High temperature clamps (e.g., those
used with compressor discharge hose) have a white or red
elastomer lining (most applications for these are called out
in the bills of material). An assembly of two clamps fastened
together to separate components is referred to as a
“butterfly” clamp. Note: the metal portion of clamps shall be
stainless steel or otherwise made capable, through plating
or other means, of passing a 200 hour salt spray test per
ASTM B117 without rusting.
The capacity of the existing system in the chassis must be
enough to power the additional circuit. The new circuit will
require a certain amount of power to operate; so, the existing
(battery or alternator) power source must have the capacity
to provide additional power or the new circuit will not function
properly.
Check the current (ampere) demand of the circuit to be
added. Compare it to the current capacity of the circuit you
are connecting into. The current carrying capacity of the
wires, controls, switches, and circuit breakers that provide
C-1
Figure C-1
Clamp and Butterfly Clamp
10/2009
Butterfly Tie: A tough plastic (nylon or equivalent) locking
Dual Clamp Tie strap used to separate bundles or single
lines, hoses, etc. These straps must be UV stable. (Tyton
DCT11)
ROUTING
C
Excess of material: More than 3 inches of slack for every
14 inch section of hose routing, except for air conditioner
hoses.
Shortness of material: Less than 1 inch of slack on a 14
inch section of hose routing.
Figure C-2
Butterfly Tie
Tie Strap: A tough plastic (nylon, or equivalent) locking
strap used to tie the lines in a bundle together between
clamps or to otherwise secure hoses and wires as noted
below. These straps must be UV stable.
Figure C-3
Tie Strap
Heavy Duty (HD) Mount: A black rigid device used for
securing a tie strap to the frame or other structural support.
Mounts are made of impact modified, heat stabilized UV
resistant nylon capable of continuous operation between
temperatures 220°F (150°) and -40°F (-40°).
NOTE: Heavy duty tie straps 0.50 in (12.7mm)
wide (Tyton T255ROHIR or similar) shall be used
whenever HD mounts are specified. Although
0.25 in (6.4mm) tie straps may be used in some
specified applications.
Figure C-4
Heavy Duty (HD) Mount
ROUTING REQUIREMENTS
Wiring
Electrical ground wire terminals must be securely attached
and the complete terminal surface must contact a clean
bare metal surface. Apply electrical contact corrosion
inhibitor Nyogel 759G grease (made by William F. Nye, Inc.,
New Bedford, MA) .
Don’t bend wires or use tie straps within 75 mm of
(connected) wire connectors or plugs.
Wires in Bundles
Electrical wires (other than the exceptions covered below)
running parallel with air or coolant hose bundles, may be included in the bundle if they are isolated from the hoses with
a covering of convoluted plastic tubing.
Exceptions
Battery cables (including jump start cables) may be
bundled with or tied to the charging wire harness. They
shall not be bundled with or tied directly to any other
components, including hoses, wires, or bundles. They
shall be separated from other routed components using
butterfly ties at intervals not exceeding 356 mm (14 in).
Battery strap tie down shall be used without exception to
secure battery cables to frame mounted or other major
component (e.g. engine, tmsn, etc.) mounted standoffs at
intervals not exceeding 356 mm (14 in). The (positive)
battery cable shall be covered with convoluted plastic
tubing from terminal to terminal.
C-2
C
ROUTING
110/220 volt wires for engine heaters, oil pan heaters, transmission oil heaters and battery pad warmers, shall not be
included in any hose/wire bundle with a fuel hose. Individual
heater wires not in a bundle shall be separated from other
components by using butterfly clamps or butterfly ties at
intervals not exceeding 356 mm (14 in). Heater wires with a
secondary covering shall be covered with convoluted tubing
whether they are in bundles or not.
Wires Crossing other Components
Electrical wires crossing over other components, such as
lines, bolt heads, fittings, engine components lifting eyes,
engine block, cylinder head, etc., close enough to rub shall
be isolated with a covering of convoluted tubing and separated from the component by using butterfly clamps, butterfly
ties, or plastic sheathing. 110/220 volt engine heater wiring
shall be installed with butterfly ties or butterfly clamps
Piping
Use no street elbows in air brake, water, fuel, or hydraulic
systems unless specified on the piping diagram and the
build instructions.
Use no elbows in the air brake system unless specified on
the air piping diagram and the build instructions.
Hoses Crossing Components
Hoses crossing over other components close enough to rub
shall be protected with a secured covering of convoluted
plastic tubing, another section of hose, or plastic sheathing.
The usage of butterfly ties, or butterfly clamps are also
recommended.
C-3
Air Compressor Discharge Hoses
Wires or hoses shall not be tied to the high temperature air
compressor discharge hose. Hoses and wires may be
routed across the air compressor discharge hose at a
distance of 457 mm (18 in) or greater from the compressor
discharge port. In this case the crossing hoses and wires
shall be “butterfly” clamped to the air compressor
discharge hose and covered with convoluted tubing at the
clamp point (use high temperature clamps on the
compressor hose).
Bundles
HD mount and tie strap, or clamp shall be located at
intervals not to exceed 356 mm (14 in) along the bundle.
Regular tie straps shall be located at intervals not to
exceed 178 mm (7 in) between HD mount or clamps. Extra
tie straps may be used as needed to contain the hoses and
wires in the bundle.
Routing of Wires and Hoses near Moving
Components
Wires and Hoses shall be routed away from moving
components, such as fans, shackle links, drivelines, steering linkages, etc. so that there is at least 12.7 mm (0.5 in)
clearance when the component is operating at its maximum travel limits.
A minimum clearance of 25.4 mm (1.0 in) shall be maintained between steering axle tires (and associated rotating
parts) in all positions and routed components, such as
hoses, oil lines, wires, pipes, etc.
10/2009
ROUTING
C
Routing of Wires and Hoses near Exhaust System
Table C-1
Exhaust – System Clearance
Description
Shielded
Coolant hoses, HVAC hoses and tubing, and electrical wires
within 15” of the turbo and/or over 15” from the turbo
2” minimum 3” minimum
Fuel hoses
within 15” of the turbo
over 15” from the turbo
n/a
4” minimum
Fuel tanks and hydraulic tanks
crossing tank
parallel to tank
end of tank
aluminum/ceramic-coated exhaust pipe crossing ttank
n/a
n/a
n/a
n/a
Air hose
nylon
wire braid
Unshielded
2” minimum
2” minimum
1” minimum
1.5” minimum
C-4
Peterbilt Motors Company
P.O. Box 90208
Denton, Texas 76202
-/Rev.
1/10 dpt
A DIVISION OF

Medium Duty Body Builder Manual

Transcription

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