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Medium DutyBody Builder Manual

Model 330Model 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

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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 Medium Duty Body Builder Manual 1/2010

Medium Duty Body Builder Manual 10/20091-1

This Medium Duty Body Builder Manual can be very

SCOPE

This manual was created to provide body builders withappropriate information and guidelines useful in thebody planning and installation process. This informationwill be helpful when installing bodies or other associ-ated equipment.

This manual contains appropriate dimensional informa-tion, guidelines for mounting bodies, guidelines formodifying frames, electrical wiring information, andother information useful in the body installation process.

The intended primary users of this manual are bodybuilders who install bodies and associated equipmenton Peterbilt Medium Duty vehicles. Dealers who sell andservice the vehicle will also find this information useful.

useful when specifying a vehicle, particularly whenthe body builder is involved in the vehicle definition

• For chassis maintenance and repair informationconsult the model-appropriate Maintenance Manualavailable in the Service Department of the sellingdealer or you can order your own copy of themaintenance manual from your local dealer.

• For chassis operating information consult the Oper-ator’s Manual, included with each vehicle. It alsocan be ordered from your local dealer.

and ordering process. Early in the process, profes-sional body builders can often contribute valuableinformation that reduces the ultimate cost of the bodyinstallation. This manual is not a maintenancemanual or an operation manual.

SECTION 1 INTRODUCTION

Peterbilt Motors Co.

Page Intentionally Left Blank.


SAFETY SIGNALS

Warnings, cautions, and notes

WARNING

When you see this word and symbol, the mes-sage that follows is especially vital. It signals apotentially hazardous situation which, if notavoided, 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 breakerdesigned to meet liftgate amperage require-ments. An incorrectly specified circuitbreaker could result in a electrical overloador fire situation. Follow the liftgate installa-tion instructions and use a circuit breakerwith the recommeded capacity.

CAUTION

Signals a potentially hazardous situationwhich, if not avoided, could result in minor or mod-erate injury or damage to the vehicle.

Example:

CAUTION: Never use a torch to make a holein the rail. Use the appropriate drill bit.

NOTE

Provides general information: for example, thenote could warn you on how to avoid damagingyour vehicle or how to drive the vehicle more effi-ciently.

Example:

NOTE: Be sure to provide maintenance accessto the battery box and fuel tank fill neck.

FEDERAL MOTOR VEHICLE SAFETYSTANDARDS (FMVSS) ANDCANADIAN MOTOR VEHICLESAFETY STANDARDS (CMVSS)COMPLIANCE

As an Original Equipment Manufacturer (OEM), Peter-bilt Motors Company ensures that our products complywith all applicable Federal Motor Vehicle Safety Stan-dards (FMVSS) and Canadian Motor Vehicle SafetyStandards (CMVSS) where applicable. However, thefact that this vehicle has no fifth–wheel and that a Body

Please take the time to read these mes-sages when you see them, and remember:

WARNING

Indicates a potentially hazardous situationwhich, if not avoided, could result in death orserious injury.

CAUTION

Signals a potentially hazardous situation which,if not avoided, could result in minor or moderateinjury or damage to the vehicle.

NOTE

Useful information that is related to the topicbeing discussed.

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.

SECTION 2 SAFETY AND COMPLIANCE

2-2Peterbilt Motors Co.

2SAFETY AND COMPLIANCE

Builder (Final Stage Manufacturer) will be doing addi-tional modifications means that the vehicle was incom-plete when it left the build plant.

Incomplete Vehicle Certification

An Incomplete Vehicle Document is shipped with thevehicle, certifying that the vehicle is not complete (seefigure below). In addition, affixed to the driver’s sidedoor frame or edge is an Incomplete Vehicle Certifica-tion label.

NOTE: These documents list the FMVSS (orCMVSS) regulations that the vehicle compliedwith when it left the build plant. You should beaware that if you modify or alter any of thecomponents or systems covered by theseFMVSS (or CMVSS) regulations, it is yourresponsibility as the Final Stage Manufacturer toensure that the complete vehicle maintainscompliance with the particular FMVSS (orCMVSS) regulations when you complete yourmodifications.

As the Final Stage Manufacturer, you should retain theIncomplete Vehicle Document for your records. In addi-tion, you should record and retain the manufacturer andserial number of the tires on the vehicle. Upon comple-tion of the vehicle (installation of the body and any othermodifications), you should affix your certification labelto the vehicle as required by Federal law. This tag iden-tifies you as the “Final Stage Manufacturer” and certi-fies that the vehicle complies with Federal MotorVehicle Safety Standards.

Figure 2-1. Incomplete Vehicle Certification Document

NOTE: This truck may be equipped with a Diesel Particulate Filter (DPF) muffler unit in order to meet both noise and exhaust emissions require-ments. 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 integratedwith particulate filters for 2007/10 EPA certification.The particulate filter assembly may consist of oneor more of the following components: a dieseloxidation catalyst, a diesel particulate filter,temperature sensors, differential pressure sensor,and exhaust silencing components integratedinto a modular housing. Body Builders must notmodify or relocate this assembly or any compon-ents associated with it. It is also the case thatthere should not be any modifications made to theexhaust piping from turbo outlet to aftertreatmentinlet.

Noise and Emissions Requirements

Figure 2-2.Location of CertificationLabels - Driver’s DoorFrame


components (for all models except Model 325):

DIMENSIONS

This section includes dimensions for a standardMedium Duty configuration, plus several optional configu-rations. See the CONTENTS section at the beginning ofthe manual to locate the information you need.

ABBREVIATIONS

Throughout this manual, we use the following abbrevia-tions for various critical dimensions:

BBC Bumper to back of cab.

BFA Bumper to front axle.

CA Cab to axle. Measured from the back of thecab to the centerline of the rear axle(s).

FAB Front axle to back of cab.

FEPTO Front engine PTO extension. Measured fromthe front of the grille to the front of thebumper.

OAL Overall vehicle length. Measured from thebumper to the end of frame.

OH Frame overhang. Measured from the center-line of the rear axle(s) to the end of frame.

WB Wheelbase.

TABLE 3-1. Turning Radius

TURNING RADIUS

The curb-to-curb turning radius is the minimum radiusthe outermost portion of the outboard front tire wouldfollow in a turn.

The wall-to-wall turning radius is the minimum radiusthe outermost tip of the front bumper would follow in aturn.

Both the curb-to-curb and wall-to-wall turning radiusdepend on the wheelbase, front axle, front tire andwheel sizes, and many other factors. Approximate turn-ing radius figures are listed in Table 3-1. Optionalcomponents may result in different figures.

The figures in Table 3-1 are based on the following

• 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

To obtain the turning circle diameter, multiply theradius by 2.

WHEELBASE CURB TO CURB WALL TO WALL CURB TO CURB WALL TO WALL CURB TO CURB WALL TO WALL CURB TO CURB WALL TO WALL[IN. (mm)] [FT. (m)] [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/a274 (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

Left-Hand Turn Right-Hand TurnModels 330,337,348 Model 325 Models 330,337,348 Model 325

• 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

Model 325 components:

* 50 degree wheel cut L/R

SECTION 3 DIMENSIONS


3DIMENSIONS

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)]

*ACHOLAOBW150 (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 axle as shown.

TABLE 3-3. Side view with single rear axle - overall dimensions - height [inches (mm)]

**THGIEHBWREYCO 79KB

21,000 LB.REYCO 79KB

23,000 AND 26,000 LB.PETERBILT LOW AIR

LEAF 21,000 LB.150 (3810) 105.3 (2675) 105.9 (2690) 105.3 (2675)154 (3912) 105.3 (2675) 105.9 (2690) 105.3 (2675)

Greater than 157(3988)

103.9 (2639) 105.9 (2690) 105.3 (2675)

** Measured in the light (unloaded) condition with an Eaton Spicer E1002I or E1202I front axle, required front axle spacerblocks, 10,000 lb or 12,000 lb taperleaf front suspension, 10-½ or 10-5/8 inch frame rails, and Bridgestone R250F295/75R22.5 front tires. Does not include height of optional roof-mounted air horn or optional vertical exhaust stack.


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

TABLE 3-5. Side view with single rear axle - overall dimensions - height [inches (mm)] - Model 325

WB OAL OH CA*150 (3810) 234 (5943) 45.8 (1163) 80.2 (2037)154 (3912) 240.2 (6101) 48 (1219.4) 84.2 (2138.6)164 (4166) 257 (6528) 54.8 (1392.4) 94.2 (2392.6)178 (4521) 279 (7086) 62.8 (1594.8) 108.2 (2748.2)190 (4826) 303 (7696) 74.8 (1900) 120.2 (3053)208 (5283) 328 (8331) 81.8 (2077.8) 138.2 (3510.2)220 (5588) 352 (8941) 93.8 (2383) 150.2 (3815)238 (6045) 376 (9550) 99.8 (2534.8) 168.2 (4272.2)

* Measured from the back of cab to the centerline of the rear axle as shown.

WB HEIGHT**REYCO 79KB

11,500 LB.ALL 99 (2515)

8,000 lb taperleaf spring, 9 7/8 inch frame rails, and Bridgestone R250F 225/70 R19.5 front tires.**Measured in the laden (loaded) condition with a Dana D800F front axle, required front axle spacer blocks,

Rev. 6-07


3DIMENSIONS

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)]

*ACHOLAOBW150 (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)]

**THGIEHBWREYCO 10238,000 LB.

HENDRICKSONRT2-400

40,000 LB.

PETERBILT LOW AIRLEAF 38,000 LB.

ALL 106.9 (2715) 106.9 (2715) 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 R250F295/75R22.5 front tires. Does not include height of optional roof-mounted air horn or optional vertical exhaust stack.


3 DIMENSIONS

Front and Rear Views — Overall Dimensions

Figure 3-3. Front View - Overall Dimensions

Figure 3-4. Rear View - Overall Dimensions

** w i th B r idg es ton eR250F 295/75R22.5 tiresand Accuride 28408E22.5 X 8.25 steel wheels.

* 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. Sub-tract 0.27 inch (6.8 mm)when measuring from topof 10 3/4 inch rails.


3DIMENSIONS

Rear Window

Figure 3-5. Rear Window

* with 10 5/8 inch rails. Add0 .1 inch (3 mm) when measur-ing from top of 10 1/2 inch rails. Add 0.7 inch (17.8 mm) when measuring from top of 9 7/8 inch rails. Subtract 0.27 inch (6.8mm) when measuring from topof 10 3/4 inch rails.

Contact Dealer for loadlight locations.


3 DIMENSIONS

Cab and Hood - Standard Cab

Figure 3-6. Cab and Hood - Standard cab

DETAIL A

AREA OFCONTACTWITH ROOFSKIN

SECTION A-A

2.0 (51)

ROOF SKIN


3DIMENSIONS

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 DIMENSIONS

Battery Box - Location - Model 330, Model 337, Model 348

(STEEL BATTERYBOX SHOWN)

Figure 3-8. Battery Box - Location

TABLE 3-8. Battery box location [inches (mm)]

DIMENSION* STEEL BATTERY BOX ALUMINUM BATTERYBOX

X 25.6 (650) 30.2 (767)Y ** 8.4 (213) 0.9 (22)Z 30.5 (775) 30.4 (772)

* Dimensions are for battery boxes located left-hand under-cab. The loca-tion of battery boxes located back of cab varies according to the location ofother frame-mounted components.** A minimum clearance of 4.0 in. (101 mm) is required to the rear of thebattery box to allow the release of the cover latches and to access the airtank drain valve.


3DIMENSIONS

TABLE 3-9. Battery box location [inches (mm)]

Battery Box - Location - Model 325

Figure 3-9. Battery Box - Location - Model 325

X 30.1 (765)Y 6.3 (159)Z 27.7 (703)

Dimension


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)]

STEELBATTERY BOX

ALUMINUMBATTERY BOX

STEP HEIGHT*A** (ground to first

step)B (first step to second

step)C (second step to cab

floor)

STD CROSSMEMBER HD CROSSMEMBER HD CROSSMEMBER18.7 (475) 17.2 (437) 14.5 (368)

14.0 (356) 14.0 (356) 16.1 (409)

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 orE1202I front axle, required front axle spacer blocks, 10,000 lb or 12,000 lb taperleaf front suspension, 10-1/2 or10-5/8 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 wheelbasesand 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 requiredNOTE: Vehicles designed for use as fire apparatus must have an "A" step height of no more than 24.0inches (610 mm) to comply with NFPA 1901 Standard for Automotive Fire Apparatus, 1999 Edition.


3DIMENSIONS

TABLE 3-11. Battery box - step height [inches (mm)]

Figure 3-11. Battery Box - Step Height - Model 325

Battery Box - Step Height - Model 325

Step HeightA (ground to first step) 21.7 (550)B (first step to cab floor) 19.7 (500)


3 DIMENSIONS

Fuel Tank - Location - Model 330, Model 337, Model 348

Rectangular 50-gal steelfuel tank shown

Figure 3-12. Fuel Tank - Location

TABLE 3-12. Fuel tank location [inches (mm)]

KNATLEUFMUNIMULAKNATLEUFLEETS

DIMENSION*STD

CROSSMEMBERHD

REBMEMSSORCDHREBMEMSSORC

RECT50 GAL

RECT50 GAL

23 IN. RND50 GAL

23 IN. RND70 GAL

23 IN. RND100 GAL

X 33.5 (851) 33.5 (851) 34.5 (876) 46.8 (1189) 65.1 (1654)

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)**** 30.7 (779)*****Dimensions are for fuel tanks located right-hand under-cab. The location of fuel tanks located back of cab variesaccording to the location of other frame-mounted components.**Positive numbers for the Y dimension indicate distance rearward from the back of cab. Negative numbers indicatedistance 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 out-board 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 24.5inch (622 mm) outboard from the frame rail.


3DIMENSIONS

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

KNATLEUFLEETS

DIMENSION*

Fuel Tank - Location - Model 325


TABLE 3-13. Fuel tank location [inches (mm)]


3 DIMENSIONS


TABLE 3-14. Fuel tank location [inches (mm)] - Model 325

WB X Y Z150 (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)

RECTANGULAR 35 GAL

Fuel Tank - Location - Model 325


3DIMENSIONS

Fuel Tank - Step Height - Model 325

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 DIMENSIONS

Fuel Tank - Step Height - Model 330, Model 337, Model 348


Figure 3-16. Fuel Tank - Step Height

TABLE 3-16. Fuel tank - step height [inches (mm)]

STEP HEIGHT* STEEL FUEL TANK ALUMINUM FUEL TANK)244(4.71)295(3.32)petstsrifotdnuorg(**A)683(2.51)673(8.41)petsdnocesotpetstsrif(B)803(1.21)561(5.6)roolfbacotpetsdnoces(C

*Measured in the light (unloaded) condition with a right-hand under-cab fuel tank, Eaton Spicer E1002I or E1202Ifront axle, required front axle spacer blocks, 10,000 lb or 12,000 lb taperleaf front suspension, 10-1/2 or 10-5/8 inchframe rails, Bridgestone R250F or R299PFE 295/75R22.5 front tires, wheelbases less than 157 inch, and a Reyco79KB 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 24.0inches (610 mm) to comply with NFPA 1901 Standard for Automotive Fire Apparatus, 1999 Edition.

DIMENSIONS

3

2010 DEF TANK and AFTERTREATMENT SYSTEM

SCR System Overview

(Cross-Over System Shown)

3-18 Medium Duty Body Builder Manual 1/2010

DIMENSIONS

3

2010 DEF TANK MEASUREMENTS

Note: Rectangular DEF tanks are only available with rectangular fuel tanks on Medium Duty Models

DEF Tank Information

Tank Shape Round Round Rectangular

DEF Tank Size D-Tank: Small D-Tank: Medium Class 5, 6 & 7

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

Max Fuel Capacity Gallons 150 300 110


DIMENSIONS

3

2010 DEF TANK GROUND CLEARANCE - RECTANGULAR

C = 245.3 mm (9.7 in)

B = 312.5 mm (12.3 in)

A = 636.1 mm (25.0 in)

D = 657.4 mm (25.9 in)

TOP OF SENDING UNIT BOOT

BOTTOM OF RAIL

BOTTOM OF PUMP PLATE


DIMENSIONS

3

2010 DEF TANK GROUND CLEARANCE - ROUND

C = 267.7 mm (10.5 in)

B = 391.7 mm (15.4 in)

A = 673.9 mm (26.5 in)

D = 702.8 mm (27.7 in)

TOP OF SENDING UNIT BOOT

BOTTOM OF RAIL

BOTTOM OF PUMP PLATE



3DIMENSIONS

TABLE 3-17. Exhaust Location - Horizontal DPF with Horizontal Diffuser

Exhaust Location - 2007 Horizontal DPF with Horizontal Diffuser

Figure 3-17. Exhaust Location - Horizontal DPF with Horizontal Diffuser

** Dimension shown is for 10 5/8inch rails. Add 0.125 inch (3.2mm) for 10 3/4 inch rail. Add 0.7inch (17.8 mm) when measuringfrom top of 9 7/8 inch rail.

Engine Transmission DPF Location* X

PX-6 All manualAllison 2000 series 2275 15.8 (402)

PX-6Allison 3000 HS

Allison 3000 RDSAllison 3500 RDS

2475 21.7 (552)

PX-8

Fuller FS seriesFuller FR series

Allison 2000 seriesAllison 3000 HS

2375 23.2 (590)

PX-8

Fuller RT seriesAllison 3000 RDS-PAllison 3500 RDS-PAllison 3000 EVS-PAllison 3500 EVS-P

2513 28.7 (728)

* DPF LOCATION IS MEASURED FRONT OF FRAME TO FRONT MOUNTING BRACKET.


3 DIMENSIONS

TABLE 3-18 Exhaust Location - Horizontal DPF with Vertical Stack

Figure 3-18. Exhaust Location - Horizontal DPF with Vertical Stack

Exhaust Location - 2007 Horizontal DPF with Vertical Stack - Model 330, 337, 348

Engine Transmission DPF Location* X Y

PX-6 All manualAllison 2000 series 2275 21.4 (543) 16.8 (426)

PX-6Allison 3000 HS

Allison 3000 RDSAllison 3500 RDS

2475 27.4 (695) 22.6 (575)

PX-8

Fuller FS seriesFuller FR series

Allison 2000 seriesAllison 3000 HS

2375 25.3 (643) 19.6 (499)

PX-8

Fuller RT seriesAllison 3000 RDS-PAllison 3500 RDS-PAllison 3000 EVS-PAllison 3500 EVS-P

2513 30.9 (784) 26.3 (668)

* DPF LOCATION IS MEASURED FRONT OF FRAME TO FRONT MOUNTING BRACKET.



3DIMENSIONS

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.

TABLE 3-19. Exhaust Location - Under Cab DPF w/Side of Cab Stack

Figure 3-19. Exhaust Location - Under Cab DPF w/Side of Cab Stack

Exhaust Location - 2007 Under Cab DPF w/Side of Cab Stack - Model 330, 337, 348


DIMENSIONS3

2010 UNDER FRAME IN-SERIES DPF/SCR with HORIZONTAL EXHAUST

14.3”

12.4”

105”

Reference option code 3365060


DIMENSIONS

3

2010 UNDER FRAME CROSSOVER DPF/SCR with HORIZONTAL EXHAUST

14.3”

12.4”

51”

Reference option code 3365070


DIMENSIONS

3

2010 RIGHT HAND UNDER CAB DPF/SCR with SIDE OF CAB EXHAUST

B

A15.9”

31.5”

A = Lower step to upper step = 14.2” B = Upper step to cab floor = 15.5”

Reference option 3365040


DIMENSIONS

3

2010 MANUAL TRANSMISSION – PX6 PTO FRAME CLEARANCE Bottom view from right rear Rear view

Bottom view from forward side Bottom view from side


DIMENSIONS

3

2010 ALLISON TRANSMISSION – PX6 PTO FRAME CLEARANCE Bottom view from right rear Bottom view

Bottom view from right side Rear view


DIMENSIONS

3

2010 MANUAL TRANSMISSION – PX8 PTO FRAME CLEARANCE Bottom view from right rear Rear view

Bottom view from forward side Bottom view from side


DIMENSIONS

3

2010 ALLISON TRANSMISSION – PX8 PTO FRAME CLEARANCE Bottom view from right rear Bottom view

Bottom view from right side Rear view



3 DIMENSIONS

FEPTO Extension and Bumper - Model 337, Model 348

* FEPTO extension is measured from the front of thegrille 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


3DIMENSIONS

Air Horn - Model 330, Model 337, Model 348

* Single air horn shown. Second air horn would bemounted symmetrically opposite on the right side.

Figure 3-21. Air Horn

** with 10 5/8 inch rails. Add 0.1 inch (3 mm) whenmeasuring from top of 10 1/2 inch rails. Subtract 0.27 inch (6.8 mm) when measuring fromtop of 10 3/4 inch rails.


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, 348REAR SUSPENSION HEIGHT (RSH*)

CROSSMEMBER REYCO 79KB21,000 LB.

REYCO 79KB23,000 LB.

REYCO 79KB26,000 LB.

PB LOW AIR LEAF21,000 LB.

PB AIR TRAC23,000 LB.

STD 19.8 (503) 21.6 (549) N/A 17.4 (441) N/AHD 20.4 (518) 22.2 (564) 22.6 (574) 17.4 (441) 22.1 (561)

TABLE 3-22. Rear Tire Height (RTH**) - single rear axle [inches(mm)] Models 330, 337, 348

BRIDGESTONER250F 14-PLY295/75R22.5

BRIDGESTONEM711 14-PLY

11R22.5

REAR TIRE HEIGHT (RTH**)BRIDGESTONE

M711 16-PLY11R22.5

BRIDGESTONER250F 16-PLY

12R22.5

MICHELINXDHT 14-PLY

11R22.518.8 (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 3-21. Rear Suspension Height (RSH) - single rear axle [inches(mm)] - Model 325REYCO 79 KB

11,500 LB15.8 (401)

TABLE 3-23. Rear Tire Height (RTH) - single rear axle [inches(mm)] - Model 325

BRIDGESTONER250 F 12-PLY225/70 R19.5

BRIDGESTONER250F 12-PLY245/70 R19.5

BRIDGESTONEM724F 12-PLY225/70 R19.5

BRIDGESTONEM724F 12-PLY245/70 R19.5

15 (381) 15.5 (394) 15.3 (389) 15.6 (396)

REAR TIRE HEIGHT (RTH)

*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 (3.2mm) for 10 3/4 inch rail.


3DIMENSIONS

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 10238,000 LB.

HENDRICKSON RT2-40040,000 LB.



)955(0.22)144(4.91)455(8.12)665(3.22*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)]

BRIDGESTONER250F 14-PLY295/75R22.5

BRIDGESTONEM711 14-PLY

11R22.5

REAR TIRE HEIGHT (RTH**)BRIDGESTONE

M711 16-PLY11R22.5

BRIDGESTONER250F 16-PLY

12R22.5

MICHELINXDHT 14-PLY

11R22.518.8 (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.


3 DIMENSIONS

Rear Suspension and Tire Clearance - Single Rear Axle

Figure 3-24. Rear Suspension and Tire Clearance - Single Rear Axle

TABLE 3-26. Rear Suspension Clearance (RSC) - Single Rear Axle [inches(mm)] - Models 330, 337, 348

REYCO 79KB21,000 to 26,000 LB.

REAR SUSPENSION CLEARANCE (RSC)PETERBILT LOW AIR LEAF

21,000 LB.PB AIR TRAC

23,000 LB.)686(0.72)629(5.63)407(7.72

TABLE 3-28. Rear Tire Clearance (RTC) - Single Rear Axle [inches(mm)] - Models 330, 337, 348REAR TIRE CLEARANCE (RTC) *

BRIDGESTONEM843

12R24.5

BRIDGESTONEM725

285/75R24.5

BRIDGESTONEM844F

425/65R22.5

BRIDGESTONER294

255/70R22.5

BRIDGESTONEM724F

245/70R19.5

BRIDGESTONEM729F

285/70R19.522.7 (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

Rear Suspension Clearance (RSC) determines the minimum distance to frame-mounted components withoutinterference with the rear suspension.

Rear Tire Clearance (RTC) may be used to determine the distance from the end of frame to the rear tire; forexample, 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).

REAR SUSPENSION CLEARANCEREYCO 79KB

11,500 LB29.8 (757)

TABLE 3-27. Rear Suspension Clearance (RSC) - Single Rear Axle [inches(mm)] - Model 325

REAR TIRE CLEARANCE (RTC)BRIDGESTONE

R250F225/75R19.5

16.1 (408.9)

TABLE 3-29. Rear Tire Clearance (RTC) - Single Rear Axle [inches(mm)] - Model 325


3DIMENSIONS

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 with-out 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; forexample, for an asphalt dump truck. RTC also determines the minimum height of the body above the framerail.

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)]

REAR SUSPENSION CLEARANCE (RSC)**REYCO 10238,000 LB.

HENDRICKSON RT2-40040,000 LB.



)6431(0.35)0641(5.75)6431(0.35)7931(0.55

TABLE 3-31. Rear Tire Clearance (RTC)** - Tandem Rear Axles [inches(mm)

**Largest and smallest tires offered in the two basic tire diameters: 24.5 and 22.5

REAR TIRE CLEARANCE (RTC)**BRIDGESTONE

M84312R24.5

BRIDGESTONEM725

285/75R24.5

BRIDGESTONEM844F

425/65R22.5

BRIDGESTONER294

255/70R22.5)4.764(4.81)2.485(0.32)635(1.12)6.675(7.22


3 DIMENSIONS

Frame Rail Sections

120,000 psi

10 3/4–INCH RAILHEAT TREATEDYIELD: 120,000 psi

SECTION MODULUS:17.8 cu in.

RBM: 2,136,000 lb. in.

Figure 3-26. Frame Rail Sections

.31(8)

3.45(88)

10(254)

10.62(270)

.38(10)

3.50(89)

10(254)

10.75(273)

.31

3.45(88)

(8)

9.38(238)

10.62(270)

.25(6)

2.87(73)

10 5/8–INCH RAILHEAT TREATED

YIELD:


RBM: 1,776,000 lb. in.

10 5/8–INCH RAIL WITH LINERHEAT TREATED

YIELD: 120,000 psi


RBM: 2,832,000 lb. in.

10 1/2–INCH RAILYIELD: 120,000 psi

SECTION MODULUS:11.8 cu in.RBM: 1,416,000 lb. in.

10.5(267)

10(254)

.25(6) 3.5

(89)

3.5(88.9)

9.4(239)

9.88(251)

.25(6)

9 7/8–INCH RAILYIELD: 120,000 psi

SECTION MODULUS:10 cu in.RBM: 1,200,000 lb. in.


3DIMENSIONS

Crossmember Drillings

Figure 3-27. Crossmember Drillings

01022-01

6 HOLES0.53 IN. DIA(13.5 MM)

5.63 IN(143 MM)

2.5 IN(63 MM)

11.0 IN(280 MM)

STANDARD CROSSMEMBER

5.5 IN(140 MM)

THREE-PIECE CROSSMEMBER

5 HOLES0.66 IN DIA(16.7 MM)

6.30 IN(160 MM)

2.0 IN(50 MM)

3.94 IN(100 MM)

7.87 IN(200 MM)


CRITICAL CLEARANCES

Rear Wheels and Cab

CAUTION: Insufficient clearance betweenrear tires and body structure could causedamage to the body during suspensionmovement. Allow at least 8 inches clear-ance (See Figure 4-1.)

Figure 4-2. Minimum Back–of–Cab Clearance.

8 in.(203 mm)

The true distance from the centerline of the front axle tothe back of the cab is 69.8 inches (1773 mm). It is rec-ommended that the leading edge of the body bemounted 4 inches (102 mm) behind the cab. The resultis a minimum dimension of 73.8 inches (1875 mm) fromthe front axle to the leading edge of the body.

NOTE: The distance from the back of cab tothe front of the body may vary depending onthe location of vehicle components. See SEC-TION 3 “DIMENSIONS” for further details ondimensions and clearances.

02866

Figure 4-1. Minimum Clearance Between Top of RearTires and Body Structure Overhang.

CAUTION: Maintain adequate clearancebetween back of cab and the front (leadingedge) of mounted body. See Figure 4-2.

NOTE: Be sure to provide maintenanceaccess to battery box and fuel tank fill neck.

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.

BODY MOUNTING USINGBRACKETS

CAUTION: Always install a spacer betweenthe body subframe and the top flange ofthe frame rail.

Installation of a spacer between the body subframe andthe top flange of the frame rail will help prevent prema-

corrosion.

Frame Sill

If the body is mounted to the frame with brackets, werecommend that the frame sill spacer be made from a

ture wear of the components due to chafing or

SECTION 4 BODY MOUNTING


4BODY MOUNTING

Figure 4-3. Spacer Between Frame Sill and Body Rail —Rubber or Plastic.

Figure 4-4. High Compression Spring Between theMounting Bolt and Upper Bracket.

SPACER

CHASSIS FRAME(RAIL) SILL

BODYSUBFRAME

01016

(RAIL)

SPRING

01446

Figure 4-5. Rubber Spacer Between Brackets.

Figure 4-6. Hole Location Guidelines for Frame Rail andBracket.

RUBBERSPACER

01445

“A” MUST BE EQUAL TO ORGREATER THAN 2 IN. (50mm)

UPPER FRAMEFLANGE

LOWER FRAMEFLANGE

01023

A

AA

A

Brackets

When mounting a body to the chassis with brackets, werecommend designs that offer limited amount of relativemovement, bolted securely but not too rigid. Bracketsshould allow for slight movement between the body andthe chassis. For instance, Figure 4-4 shows a high com-pression spring between the bolt and the bracket.

Another possibility is mounting a rubber spacerbetween the brackets. See Figure 4-5. These designswill allow relative movement between the body and thechassis during extreme frame racking situations.Mountings that are too rigid could cause damage to thebody. This is particularly true with tanker installations.

Mounting HolesWhen installing brackets on the frame rails, the mount-ing holes in the chassis frame bracket and frame railmust comply with the general spacing and locationguidelines illustrated in Figure 4-6. The hole diametershould not exceed the bolt diameter by more than .060inches (1.5mm).

strip of rubber or plastic (delrin or nylon). These materi-als will not undergo large dimensional changes duringperiods of high or low humidity. The strip will be lesslikely to fall out during extreme relative motion betweenbody and chassis. See Figure 4-3.


4 BODY MOUNTING

Frame Drilling

WARNING! When mounting a body to thechassis, DO NOT drill holes in the upper orlower flange of the frame rail. If the framerail flanges are modified or damaged, therail could fail prematurely and cause anaccident. Mount the body using bodymounting brackets or U–bolts.

WARNING! Do not drill new holes anycloser than 2 inches (50mm) to existingholes. Frame drilling affects the strength ofthe rails. If the holes are too close together,the rail could fail prematurely and cause anaccident. See Figure 4-6.

Hole Location Guidelines

Holes must be located at least two inches (50 mm) fromthe flange as indicated in Figure 4-6. They must be nocloser than 2 inches (50mm) to each other.

NOTE: If your design permits placement ofbody mounting brackets at crossmember loca-tions, you can use the crossmember gussetbolt holes for body mounting. See Figure 4-7.

CAUTION: Use care when drilling theframe web so the wires and air lines routedinside the rail are not damaged.

Figure 4-7. Crossmember - Gusset Hole Patterns.

01022-01

6 HOLES0.53 IN. DIA(13.5 MM)

5.63 IN(143 MM)

2.5 IN(63 MM)

11.0 IN(280 MM)

STANDARD CROSSMEMBER

5.5 IN(140 MM)

THREE-PIECE CROSSMEMBER

5 HOLES0.66 IN DIA(16.7 MM)

6.30 IN(160 MM)

2.0 IN(50 MM)

3.94 IN(100 MM)

7.87 IN(200 MM)


4BODY MOUNTING

BODY MOUNTING USING U–BOLTS

Spacers

inspect the installation to ensure adequate clear-ances for air brake lines, fuel lines, and wiring. SeeFigure 4-9.

If the body is mounted to the frame with U–bolts, use ahardwood sill (minimum 1/2 inch (12.7 mm) thick)between the frame rail and body frame to protect thetop surface of the rail flange.

WARNING! Do not allow the frame rails orflanges to deform when tightening theU–bolts. It will weaken the frame and couldcause an accident. Use suitable spacersmade of steel or hardwood on the inside ofthe frame rail to prevent collapse of theframe flanges.

• Use a hardwood spacer between the bottomflange and the U–bolt to prevent the U–boltfrom notching the frame flange. See Figure 4-8.

Figure 4-9. Clearance Space for Air Lines and Cables.

WARNING! Do not notch frame rail flangesto force a U–bolt fit. Notched or damagedframe flanges could result in prematureframe failure. Use a larger size U–bolt.

Figure 4-8. Acceptable U–Bolt Mounting with Wood andFabricated Spacers.

WARNING! Do not allow spacers and otherbody mounting parts to interfere withbrake lines, fuel lines, or wiring harnessesrouted inside the frame rail. Crimped ordamaged brake lines, fuel lines, or wiringcould result in loss of braking, fuel leaks,electrical overload or a fire. Carefully

CAUTION: Mount U–bolts so they do notchafe on frame rail, air or electric lines.

BODYSTRUCTURE

TRUCK FRAME

WOOD SILL½ in. (12.7 mm)

U–BOLT

FRAME RAILSPACER

(FABRICATEDSTEEL OR

HARDWOOD)

U–BOLTSPACER

(HARDWOOD)01018

MINIMUM

FRAMERAIL

U–BOLT

U–BOLTSPACER

AIR LINESAND WIRINGHARNESSES

FRAME RAILSPACER

(HARDWOODOR STEEL)

01027

CHECKCLEARANCE

SPACE FOR AIRLINES AND

WIRING


4 BODY MOUNTING

Rear Body Mount

When U–bolts are used to mount a body we recom-mend that the last body attachment be made with a“fishplate” bracket. See Figure 4-10. This provides afirm attaching point and helps prevent any relative foreor aft movement between the body and frame. For holelocation guidelines, See Figure 4-6.

Figure 4-10. Example of Fishplate Bracket at Rear End ofBody, used with U–Bolts.

01021


INTRODUCTION

There are several standard wheelbase choices forsingle and tandem rear axles. In addition, customer-specified wheelbases are available. So, in most casesframe modifications to produce a certain wheelbaseshould not be necessary.

However, some installations may require slight modifi-cations, while other installations will require extensivemodifications. Sometimes an existing dealer stockchassis may need to have the wheelbase changed tobetter fit a customer’s application. The modificationsmay be as simple as shortening or lengthening theframe overhang, or they may be as complex as chang-ing 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 informa-tion. Follow the general spacing and hole locationguidelines on Page 4–2, Figure 4-6.

WARNING! When mounting a body to thechassis, DO NOT drill holes in the upper orlower flange of the frame rail. If the framerail flanges are modified or damaged, therail could fail prematurely and cause anaccident. Mount the body using bodymounting brackets or U–bolts.

WARNING! Do not drill new holes anycloser than 2 inches (50mm) to existingholes. Frame drilling affects the strength ofthe rails. If the holes are too close together,the rail could fail prematurely and cause anaccident.

CAUTION: Use care when drilling theframe web so the wires and air lines routedinside the rail are not damaged.

• Never use a torch to make a hole in the rail. Usethe appropriate diameter drill bit.

Hole pattern dimensions for crossmember designs areillustrated on Page 4-3, Figure 4-7.

Hole diameter should not exceed the bolt diameter bymore than .060 inches (1.5 mm).

MODIFYING FRAME LENGTH

The frame overhang after the rear axle can be short-ened to match a particular body length. Using a torch isacceptable; however, heat from a torch will affect thematerial characteristics of the frame rail. The affectedmaterial will normally be confined to within 1 to 2 inches(25 to 50mm) of the flame cut and may not adverselyaffect the strength of the chassis or body installation.

The frame overhang on the 10.5-inch rail can be length-ened by adding frame extenders.

When extending the 10.5-inch rails, the additional sec-tions can typically be welded to the existing rails. Thejoint should be welded and reinforced as illustrated inFigure 5-1.

NOTE: See page 5–4 for more information onwelding frames.

Frame Insert

A frame insert must be added after welding a 10.5-inchframe rail to compensate for lost strength. The insertshould be of the same material as the frame memberand at least equal to the frame rail in thickness.

SECTION 5 FRAME MODIFICATIONS


5FRAME MODIFICATIONS

Where possible, use existing bolt holes to attach theinsert to the frame. Bolt holes must not be located

If the insert is placed in a section of the main framewhere few bolts are located, additional bolts arerequired. Use the following guideline for locating addi-tional bolt holes.

Changing Wheelbase

We do not recommend modifying the wheelbase. Occa-sionally, however, a chassis wheelbase will need to beshortened or lengthened. Before this is done there area few guidelines that should to be considered.

WARNING! When changing the wheelbase,be sure to follow the driveline manufac-turer’s recommendations for drivelinelength or angle changes. Incorrectly modi-fied drivelines can fail prematurely due toexcessive vibration. This can cause anaccident and severe personal injury.

Figure 5-1. Detail of Frame Extensions and Joint Welding.

Figure 5-2. Frame Insert

(610 mm)24 in. min

WELDEDJOINT

210003

01019

8.1 in(205 mm)

7.9 in(200 mm)

2.4 in(62 mm)

WELD FRAME RAILS ONTHE OUTSIDE ONLY

.15 IN (4 mm)

45°

closer to the frame flanges than the present bolt pattern.

Attachment of the insert to the frame should be madewith Ream-Fit Class 8 5/8 in. dia. or Class 10.9 16 mmdia. bolts or the next larger size. Both the reinforce-ment and frame holes should be reamed to provide a fitof from .001 in. to .003 in. (.025 to .076 mm) clearance.Do not weld the insert. The insert must be a full C-channel, not a fishplate or “L” channel, and shouldspan a distance of at least 24 in. (610 mm) on eitherside of the joint to insure an even distribution ofstresses. Cut the ends of the insert at 45° as shownin Figure 5-2 unless the insert extends to the end of theframe.


5 FRAME MODIFICATIONS

Before changing the wheelbase the driveline angles ofthe proposed wheelbase need to be examined toensure that no harmful vibrations are created. Consultthe driveline manufacturer for appropriate recommen-dations.

WARNING! Do not drill new holes anycloser than 2 inches (50mm) to existingholes. Frame drilling affects the strength ofthe rails. If the holes are too close together,the rail could fail prematurely and cause anaccident.

Before the rear suspension is relocated, check the newlocation of the spring hanger brackets. The new holesfor the spring hanger brackets must not overlap existingholes and should not come any closer than 2 inches(50mm) to existing holes in the frame.

WARNING! When relocating a suspensionbracket, do not mount it on the extended(added) section of a frame rail. The sus-pension loading could result in prematurefailure of the added section splice. Thiscould cause an accident. Use care whenplanning the wheelbase so that the rearsuspension bracket is always mounted onthe original rail section. See Figure 5-3.

If you are lengthening the wheelbase, you may alsohave to extend the frame length to accommodate abody. When you reposition the rear suspension springhangers, do not mount them on the added extendedportion of the rail. The relocated rear suspensionbracket should be located on the original frame rails

When shortening the wheelbase, we recommend thatthe suspension be moved forward and relocated on theoriginal rail. The rail behind the suspension can then becut to achieve the desired frame overhang.See Figure 5-3.

Before the rear suspension is relocated, check the newlocation of the spring hanger brackets. The new holesfor the spring hanger brackets must not overlap existingholes and should not come any closer than 2 inches(50mm) to existing holes.

MOUNT THE SUSPENSIONBRACKETS ON THE

ORIGINAL RAIL

LENGTHENED WHEELBASE

DO NOT MOUNT THESUSPENSION BRACKET ONTHE ADDED FRAME RAIL

ORIGINAL WHEELBASE

RELOCATED REARSUSPENSION

SHORTENED WHEELBASE

CUT FRAME AT REAR TOOBTAIN DESIRED CUTOFF

Figure 5-3. Comparison of Original, Shortened,and Lengthened Wheelbases.

10 IN (254 mm) Minimum

with a miniumum of 10 inches (254 mm) between the suspension bracket and the spliced section.See Figure 5-3.


5FRAME MODIFICATIONS

Crossmembers

• The maximum allowable distance between the for-ward suspension crossmember and the next cross-member forward is 47.2 inches (1200 mm). If thedistance exceeds 47.2 inches (1200 mm) after thewheelbase is lengthened, add a crossmemberbetween them. See Figure 5-4. See Figure 4-7 onpage 4-3 for crossmember hole patterns.

LESS THAN47.2 IN.

(1200 mm)

WELDING

Precautions

BEFORE WHEELBASE IS LENGTHENED

GREATERTHAN 47.2 IN.

ADDITIONAL CROSSMEMBER REQUIRED

AFTER WHEELBASE IS LENGTHENED00627B

Figure 5-4. Additional Crossmember Required WhenDistance Exceeds 47.2 Inches (1200 mm).

After lengthening a wheelbase, an additional crossmember may be required to maintain the original frame strength. Con-tact Dealer for crossmember locations.

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 heattreated and are not weldable.

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.

Medium Duty Body Builder Manual 1/2010 5-5

5 FRAME MODIFICATIONS

TORQUE REQUIREMENTSTABLE 5-1. Customary Grade 8 UNF or UNC.

Fastener TorqueSize Nm Lb.-Ft5/16 22–30 16–223/8 41–54 30–407/16 75–88 55–651/2 109–122 80–909/16 156–190 115-1405/8 224–265 165–1953/4 394–462 290–3407/8 517–626 380–4601 952–1129 800–830

1-1/8 1346–1591 990–11701-1/4 1877–2217 1380–1630

Torque values apply to fasteners with clean threads, lightly lubricated, with hardened steel washers, and nylon-insert nuts.

TABLE 5-2. U.S. Customary – Grade 8. Metric Class 10.9

TorqueFastener Nm Lb-Ft

M6 9–15 7–11M8 23–31 17–23M10 33–43 24–32M12 75–101 55–75M14 134–164 99–121M16 163–217 120–160M20 352–460 260–340

TORQUE REQUIREMENTS

TABLE 5-1. Customary Grade 8 UNF or UNC

TABLE 5-2. U.S. Customary - Grade 8 Metric Class 10.9


INTRODUCTION

Peterbilt offers several options to provide power andelectrical connections between the chassis electricalsystem and the electrical components on the body.These options include:

• a junction box to provide power and ground forbody lights

• an engine harness to install a remote PTO control

• a third battery to provide power for lift gates andother high-amperage electrical devices

By specifying these options, the body can often beinstalled in less time and with fewer possibilities ofmaintenance problems.

NOTE: These options should be specified atthe time the truck is ordered to ensure properinstallation. Consult the current pricebook forappropriate option codes, prices, andrestrictions.

BODY LIGHTS JUNCTION BOX

The body lights junction box option provides a wiringharness from the firewall to a junction box located at theback of cab. The box is strapped to the back-of-cab- orintermediate-crossmember for shipping and is designedto be permanently mounted by the body builder.

The harness is sufficiently long to allow a certain flexi-bility in installation. It provides power and ground cir-cuits for clearance lights, marker lights, brake lights,and rear turn signals.

WARNING! This option is intended forlighting circuits only. It is not intended toprovide power to any other electrical com-ponent. Using a circuit for any other pur-pose may result in an electrical overload,which could cause a fire.

The circuits terminate with ring terminals in the junctionbox. 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 CONNECTIONAT FIREWALL

66 GROUNDED TOCAB FIREWALL

Figure 6-1. Body Lights Junction Box Circuits.

SECTION 6 ELECTRICAL


6ELECTRICAL

REMOTE PTO HARNESS THIRD BATTERY

NOTE: This option does not include thecables or circuit breakers required to connectthe batteries to the auxiliary electrical devices.

This option is required when auxiliary high-amperageelectrical devices such as electric winches, lift gates,and electromechanical sirens are to be installed by thebody builder.

WARNING! Follow the manufacturer’sinstallation instructions when installinghigh-amperage electrical devices such aselectric winches, lift gates, and electrome-chanical sirens. Failure to properly installthese devices could result in an electricaloverload and fire.

ENGINE CONNECTIONS

Electronic engines have the ability to send and receivecontrol and warning signals from other components onthe chassis and body. Consult the appropriate enginemanufacturer’s application or body builder manualsbefore making connections to the engine electroniccontrol unit (ECU) or to other electronic enginecomponents.

This option provides a third battery installed in the battery box. It includes three batteries as specified in the price-book, a battery holddown designed for three batteries, and the appropriate inter-connecting battery cables.

This option provides wiring from the engine to end of framefor 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 connec-tor that is routed to the end of frame. Any excess is coiled and secured there. See Table 6-1 for wiring harness connec-tor pin outs and Figure 6-2 for end of frame connector configuration.

WARNING! Follow the engine manufacturer’sguidelines for use of these circuits. See yourengine manufacturer to verify that the engine is programed correctly for the intended applica-tions. Failure to properly program the engine or wire these circuits could cause an accident.

Figure 6–2. Remote PTO/Throttle Control Wiring HarnessConnector Pinouts.

TABLE 6-1. Remote PTO/Throttle Wiring Harness.

Circurt Function NameEngineECU Pin

PB CircuitNumber Wire Color

WireGauge

ConnectorPinout

NOT USED NONE NONE NONE NONE 1NOT USED NONE NONE NONE NONE 2COMMON RETURN #1 (SWITCH) 41 EE03 BLK/WHT 18 3REMOTE THROTTLE SIGNAL 37 EE39 BRN/YEL 18 4PTO ON/OFF 18 EE18 GRN/WHT 18 5REMOTE THROTTLE ENABLE NONE EE11 BLK/WHT 18 6SWITCH POWER NONE 242 RED 14 7GROUND NONE 239 BLK 14 8TORQUE LIMIT SWITCH 17 EE64 LT BLU 18 95V SUPPLY 26 EE58 GRN/BLU 18 10COMMON RETURN #3(SENSOR) 22 EE02 BLK/WHT 18 11REMOTE THROTTLE ON/OFF 8 EE63 WHT/BLK 18 12

Remote PTO/Throttle Connection


SECTION 7 HYBRID

Configuration "A" DimensionPick up & delivery 5 (127)Utility W/O outrigger 5 (127)Utility with outrigger 15 (381)

Power Electric Carrier Placement

TABLE 7-1. Power Electric Carrier (PEC) Placement -Model 330, Model 337

Figure 7-1. Hybrid Model 337 shown

CAUTION: Do not weld chassis.

CAUTION: Do not paint the orange high voltage cables.

Hybrid - Model 330, Model 337

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 compo-nent 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.


7HYBRID

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 require-ments 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 trans-mission (see Figure 7-2 and Figure 7-3).

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

Figure 7–2. J5-EPTO Connector


7 HYBRID

Body Builder Connection

The body builder connector labeled “P7-BODY CONNEC-TION” 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 7–4. P7 Body Connector

Figure 7–5. Location on Frame Rail of Body Builder Connection


7HYBRID

Sections of the MD Hybrid Electrical Sche-matics 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) P94-6069 SCHEMATIC – MD HYBRID SYSTEMb) P97-6250 INSTL – HYBRID XMSN AND POWER-

TRAIN HARNc) P95-6269 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

HYBRID

7

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.


Medium Duty Body Builder Manual 10/2009A-1

VEHICLE IDENTIFICATION NUMBERA 17–character number (numeral and letter combina-tion) forms the Vehicle Identification Number (VIN) andChassis Number. It contains among other information,the model year (4), assembly plant (5), and vehicleserial number (6). See Figure A–1.

VIN Location

The VIN is marked on the Incomplete Vehicle Certifica-tion Label (on trucks) or on the Tire, Rim, and WeightRating Data Label (on tractors). Both labels are locatedon the driver’s door frame. See Figure A–2.

Chassis Number Locations

The Chassis Number (comprising the last seven char-acters of the VIN) includes an assembly plant designa-tor (5) and a six–digit serial number (6). See FigureA–1.

Figure A–1. Vehicle Identification Number (VIN).

The model year (4) is designated by a letter or numericcode in the tenth character position in the VIN. SeeTable A-1 and Figure A–1.

The chassis number is shown in six places:

• Right frame rail, top flange, about 3 ft. from thefront 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.

TABLE A-1. Model Year Letter (CODE) Designations.

CODE YEAR

5 2005

6 2006

7 2007

8 2008

9 2009

2 PN

1 - Manufacturer Identifier2 - Vehicle Attributes3 - Check Digit4 - Model Year5 - Assembly Plant6 - Serial/Chassis Number

N H D 8 X X Y M 5 6 7 8 9 0

SAMPLE VIN

1 2 3 4 5 6

APPENDIX A VEHICLE IDENTIFICATION

A-2Peterbilt Motors Co.

AVEHICLE IDENTIFICATION

CERTIFICATION LABELS

Components and Weights Label

The Components and Weights Label is located oneither the driver’s side door edge for truck/tractors, oron the door frame for trucks. See Figure A–2. Itincludes: chassis weight and gross weight; plus, modeland serial numbers for the vehicle, engine, transmis-sion, and axles.

Tire and Rim Data Label

The Tire and Rim Data Label is located on the driver’sside 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 PRES-

SURES — Tire/Rim Sizes and Cold PressureMinimums

• Chassis (Serial) Number

NOTE: GVWR is the TOTAL WEIGHT thevehicle is designed to carry. This includes theweight of the empty vehicle, loading platform,occupants, fuel, and any load. Axle weight rat-ings 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 FigureA–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 com-partment. It contains information regarding U.S. noiseemission regulations, chassis number, and date ofmanufacture.

Paint Identification Label

The Paint Identification Label contains the paint colorsused by the factory to paint your truck/tractor. It listsframe, wheels, cab interior and exterior colors. Thislabel is located in the map compartment.

Figure A–2. Driver’s Door Frame

FINAL STAGE MANUFACTURERLABEL (TO BE INSTALLED BYFINAL STAGE MANUFACTURER)

TIRE, RIM, AND WEIGHT RATINGDATA LABEL (TRUCK)

TIRE, RIM, CERTIFICATION ANDWEIGHT LABEL (TRACTOR) ORINCOMPLETE VEHICLE CERTIFI-CATION LABEL

FMVSS 121 BRAKE CAUTIONLABEL (TRUCK)

MAJOR COMPONENTS ANDWEIGHTS LABEL (TRUCK ORTRACTOR)

Medium Duty Body Builder Manual 10/2009A-3

A VEHICLE IDENTIFICATION

COMPONENT IDENTIFICATIONEach of the following components has their own identifi-cation label.

Engine Identification

Transmission IdentificationThe transmission identification number is stamped on atag affixed to the right rear side of the transmissioncase. It includes among other specifications the trans-

Front Axle IdentificationThe front axle serial number is stamped on a platelocated on the front axle beam. See Figure A–4.

Rear Axle IdentificationThe rear axle identification numbering system includesthree labels or stamps. See Figure A–5.

Engine IdentificationLocation(PX-8 Shown)

Figure A–3. Engine Identification Location and Label (PX-8 Shown)

The PACCAR engine serial number is stamped on aplate located on the front driver side of the engine. Forfurther information, please refer to the Engine Opera-tion and Maintenance Manual (included in the glovecompartment of each vehicle).

Figure A–4. Front Axle Identification.

1. Axle Specification Number, stamped on the rightrear side of the axle housing. This number identifiesthe complete axle.

2. Axle Housing Number Tag, located on the left for-ward side of the housing arm. This tag identifies theaxle housing.

3. Axle Differential Carrier Identification, located onthe top side of the differential carrier. The followinginformation is either stamped, or marked with ametal tag: Model No., Production Assembly No.,Serial No., Gear Ratio, and Part Number.

3

1

Figure A–5. Rear Axle Identification Labels.

01053

NOTE: Illustrated identification tags are typi-cal. Actual locations may vary by axle manu-facturer.

2

mission model number, serial number, and part number.

Medium Duty Body Builder Manual 10/2009B-1

INTRODUCTION BODY BUILDER’SRESPONSIBILITIES

TABLE B-1. Weights of common payloads [lb(kg)]

erusaeMfotinU/thgieWdaolyaP

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

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

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.

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 distri-bution. This would include tabulation of the weight and location of every body component, as well as an under-standing 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 perfor-mance, component failure, or loss of vehicle control with the resulting possi-bility of serious personal injury or death.

APPENDIX B WEIGHT DISTRIBUTION

Medium Duty Body Builder Manual 10/2009C-1

APPENDIX C ROUTING

Electrical wiring can sometimes be very frustrating. This isespecially true when adding circuits to an existing setup.Through the use of a optional body harness and additionalspare circuits, we have tried to reduce the complexity asso-ciated with adding common circuits to a body installation.

Note: The most common circuits that body build-ers may need are pre-connected to this optionalwiring harness.

The new body related circuits can be added by connectingthe added circuit wires to the appropriate wires in thisharness.

WARNING! Do not install an electrical circuit thatrequires more amperage (electrical capacity) thanwhat is available in the specific chassis circuit. Anoverloaded circuit could cause a fire. Comparethe amperage requirements of the new circuit to

When adding an electrical circuit, you must know the currentcapacity (amperes) of each circuit.

The capacity of the existing system in the chassis must beenough to power the additional circuit. The new circuit willrequire a certain amount of power to operate; so, the existing(battery or alternator) power source must have the capacityto provide additional power or the new circuit will not functionproperly.

Check the current (ampere) demand of the circuit to beadded. Compare it to the current capacity of the circuit youare connecting into. The current carrying capacity of thewires, controls, switches, and circuit breakers that provide

INTRODUCTION

ELECTRICAL CIRCUITS

Capacity

current to the circuit must be equal to or greater than thedemand of the added circuit otherwise these componentsmay not work properly.

ROUTING

This section specifies the general requirements for secur-ing hoses and electrical wires to present an orderlyappearance; facilitate inspection and maintenance; and toprevent potential damage to these lines.

Definitions

Bundle: Two or more air, electrical, fuel, or other lines tiedtogether to form a unitized assembly.

Clamp: A cushioned rigid or semi-rigid, anti-chafing devicefor containing the bundle and securing it to the frame orother structural support. Standard clamps have a blackelastomer lining. High temperature clamps (e.g., thoseused with compressor discharge hose) have a white or redelastomer lining (most applications for these are called outin the bills of material). An assembly of two clamps fastenedtogether to separate components is referred to as a“butterfly” clamp. Note: the metal portion of clamps shall bestainless steel or otherwise made capable, through platingor other means, of passing a 200 hour salt spray test perASTM B117 without rusting.

Figure C-1 Clamp and Butterfly Clamp

the electrical current capacity of the existing chas-sis circuit before adding the body or other equipment.

C-2Peterbilt Motors Co.

C ROUTING

Butterfly Tie: A tough plastic (nylon or equivalent) lockingDual Clamp Tie strap used to separate bundles or singlelines, hoses, etc. These straps must be UV stable. (TytonDCT11)

Tie Strap: A tough plastic (nylon, or equivalent) lockingstrap used to tie the lines in a bundle together betweenclamps or to otherwise secure hoses and wires as notedbelow. These straps must be UV stable.

Heavy Duty (HD) Mount: A black rigid device used forsecuring a tie strap to the frame or other structural support.Mounts are made of impact modified, heat stabilized UVresistant nylon capable of continuous operation betweentemperatures 220°F (150°) and -40°F (-40°).

NOTE: Heavy duty tie straps 0.50 in (12.7mm)wide (Tyton T255ROHIR or similar) shall be usedwhenever HD mounts are specified. Although0.25 in (6.4mm) tie straps may be used in somespecified applications.

Excess of material: More than 3 inches of slack for every14 inch section of hose routing, except for air conditionerhoses.

Shortness of material: Less than 1 inch of slack on a 14inch section of hose routing.

ROUTING REQUIREMENTS

Wiring

Electrical ground wire terminals must be securely attachedand the complete terminal surface must contact a cleanbare metal surface. Apply electrical contact corrosioninhibitor 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 in-cluded in the bundle if they are isolated from the hoses witha covering of convoluted plastic tubing.

Exceptions

Battery cables (including jump start cables) may bebundled with or tied to the charging wire harness. Theyshall not be bundled with or tied directly to any othercomponents, including hoses, wires, or bundles. Theyshall be separated from other routed components usingbutterfly ties at intervals not exceeding 356 mm (14 in).Battery strap tie down shall be used without exception tosecure battery cables to frame mounted or other majorcomponent (e.g. engine, tmsn, etc.) mounted standoffs atintervals not exceeding 356 mm (14 in). The (positive)battery cable shall be covered with convoluted plastictubing from terminal to terminal.

Figure C-2 Butterfly Tie

Figure C-3 Tie Strap

Figure C-4 Heavy Duty (HD) Mount

Medium Duty Body Builder Manual 10/2009C-3

C ROUTING

components, such as fans, shackle links, drivelines, steer-

110/220 volt wires for engine heaters, oil pan heaters, trans-mission oil heaters and battery pad warmers, shall not beincluded in any hose/wire bundle with a fuel hose. Individualheater wires not in a bundle shall be separated from othercomponents by using butterfly clamps or butterfly ties atintervals not exceeding 356 mm (14 in). Heater wires with asecondary covering shall be covered with convoluted tubingwhether they are in bundles or not.

Wires Crossing other Components

Electrical wires crossing over other components, such aslines, bolt heads, fittings, engine components lifting eyes,engine block, cylinder head, etc., close enough to rub shallbe isolated with a covering of convoluted tubing and sepa-rated from the component by using butterfly clamps, butterflyties, or plastic sheathing. 110/220 volt engine heater wiringshall be installed with butterfly ties or butterfly clamps

Piping

Use no street elbows in air brake, water, fuel, or hydraulicsystems unless specified on the piping diagram and thebuild instructions.

Use no elbows in the air brake system unless specified onthe air piping diagram and the build instructions.

Hoses Crossing Components

Hoses crossing over other components close enough to rubshall be protected with a secured covering of convolutedplastic tubing, another section of hose, or plastic sheathing. The usage of butterfly ties, or butterfly clamps are alsorecommended.

Air Compressor Discharge Hoses

Wires or hoses shall not be tied to the high temperature aircompressor discharge hose. Hoses and wires may berouted across the air compressor discharge hose at adistance of 457 mm (18 in) or greater from the compressordischarge port. In this case the crossing hoses and wiresshall be “butterfly” clamped to the air compressordischarge hose and covered with convoluted tubing at theclamp point (use high temperature clamps on thecompressor hose).

Bundles

HD mount and tie strap, or clamp shall be located atintervals not to exceed 356 mm (14 in) along the bundle.

Regular tie straps shall be located at intervals not toexceed 178 mm (7 in) between HD mount or clamps. Extratie straps may be used as needed to contain the hoses andwires in the bundle.

Routing of Wires and Hoses near MovingComponents

Wires and Hoses shall be routed away from moving

ing linkages, etc. so that there is at least 12.7 mm (0.5 in)clearance when the component is operating at its maxi-mum travel limits.

A minimum clearance of 25.4 mm (1.0 in) shall be main-tained between steering axle tires (and associated rotatingparts) in all positions and routed components, such ashoses, oil lines, wires, pipes, etc.

C-4Peterbilt Motors Co.

C ROUTING

Routing of Wires and Hoses near Exhaust System

Table C-1 Exhaust – System Clearance

Description Shielded UnshieldedCoolant hoses, HVAC hoses and tubing, and electrical wires within 15” of the turbo and/or over 15” from the turbo 2” minimum 3” minimumFuel hoses

within 15” of the turboover 15” from the turbo

n/a2” minimum

4” minimum3” minimum

Fuel tanks and hydraulic tankscrossing tankparallel to tankend of tankaluminum/ceramic-coated exhaust pipe crossing ttank

n/an/an/an/a

2” minimum2” minimum1” minimum1.5” minimum

Air hosenylonwire braid



-/-

Peterbilt Motors CompanyP.O. Box 90208Denton, Texas 76202A DIVISION OF

Rev. 1/10 dpt

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