Peterbilt 220 Body Builder Manual

Peterbilt 220 Body Builder Manual
2017 Body Builder Manual
Body Builder’s Manual
Contents
Figures....................................................................................................................................................................................................................................................................iii
Tables .......................................................................................................................................................................................................................................................................v
Abbreviations.......................................................................................................................................................................................................................................................vi
Section1 Introduction
Section2Safety&Compliance
SAFETY SIGNALS
2-1
FEDERAL MOTOR VEHICLE SAFETY STANDARDS COMPLIANCE
2-2
Incomplete Vehicle Certification ........................................................................................... 2-2
Noise and Emissions Requirements ...................................................................................... 2-3
Section3 Dimensions
FRAME HEIGHT
3-1
TURNING RADIUS
3-2
CAB TILT
3-3
Model 220 W/19.5 Tires ....................................................................................................... 3-3
Model 220 W/22.5 Tires ....................................................................................................... 3-3
OVERALL DIMENSIONS
3-4
Side View - Model 220 ......................................................................................................... 3-4
Front and Rear Views — Model 220..................................................................................... 3-7
DETAIL VIEWS3-10
Left side: Chassis Heights – Model 220 ............................................................................ 3-10
Components Locations –Model 220 ....................................................................................... 3-12
Crossmember Locations—Model 220 ................................................................................ 3-14
Frame Rail Configurations ................................................................................................. 3-16
Battery Box, Fuel Tanks and Air Tanks — Model 220 ...................................................... 3-17
Exhaust Canister Locations –Model 220 ............................................................................ 3-18
Side View – Model 220 clear rail package ......................................................................... 3-19
Reyco 79KB Single Rear Axle Hendrickson HAS Single Rear Axle ............................. 3-20
TIRE DATA
3-20
FRAME AND CAB RELATED HEIGHTS
3-20
GROUND CLEARANCES
3-20
PTO CLEARANCES
3-21
Section4Exhaust & Aftertreatment
EXHAUST AND AFTERTREATMENT INFORMATION
4-1
General Guidelines for DEF System ..................................................................................... 4-3
Installation Requirements and Dimensions for DEF System................................................. 4-3
Measurement Reference Points ............................................................................................. 4-4
Routing to the Dosing Module (Injector) .............................................................................. 4-5
GENERAL EXHAUST INFORMATION
4-6
Section5 Frame layouts And Bodymounting
FRAME LAYOUTS
5-1
Visual Index .......................................................................................................................... 5-1
CRITICAL CLEARANCES
5-4
Rear Wheels and Cab ............................................................................................................ 5-4
Body Mounting Using Brackets ............................................................................................ 5-5
Frame Sill .............................................................................................................................. 5-5
Brackets ................................................................................................................................. 5-6
Mounting Holes ..................................................................................................................... 5-6
Frame Drilling ....................................................................................................................... 5-7
Hole Location Guidelines ...................................................................................................... 5-7
BODY MOUNTING USING U–BOLTS
5-7
Spacers .................................................................................................................................. 5-7
REAR BODY MOUNT
5-9
i
Body Builder’s Manual
Contents
Section6 Frame Modifications
FRAME MODIFICATIONS
6-1
Introduction ..................................................................................................................................... .6-1
DRILLING RAILS .......................................................................................................................................... 6-1
MODIFYING FRAME LENGTH ................................................................................................................... 6-1
CHANGING WHEELBASE ........................................................................................................................... 6-1
CROSSMEMBERS ......................................................................................................................................... 6-2
TORQUE REQUIREMENTS ......................................................................................................................... 6-3
Section7Electrical
ELECTRICAL INTRODUCTION .................................................................................................................. 7-1
ELECTRICAL CIRCUITS .............................................................................................................................. 7-1
Capacity........................................................................................................................................... .7-1
Data Bus Communication ............................................................................................................... 7-2
CAB/CHASSIS INTERFACE
7-3
The EJB (Electrical Junction Box) .................................................................................................. .7-3
CONTROLLERS
7-6
DASH CONTROLS
7-7
MODEL 220 PTO WIRING INFORMATION
7-11
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/Rim and Weight Rating Data Label ......................................................................................... A-2
Incomplete Vehicle Certification Label ........................................................................................... A-2
COMPONENT IDENTIFICATION ................................................................................................................ A-3
Engine Identification ....................................................................................................................... A-3
Transmission Identification ............................................................................................................. A-4
Front Axle Identification ................................................................................................................. A-4
Rear Axle Identification .................................................................................................................. A-4
Appendix B Weight Distribution
INTRODUCTION ........................................................................................................................................... B-1
Abbreviations .................................................................................................................................. B-1
CALCULATIONS .......................................................................................................................................... B-2
Weight Distribution without Body .................................................................................................. B-2
Weight Distribution with Body ....................................................................................................... B-4
Chassis Weights .............................................................................................................................. B-4
Weight Distribution Analysis .......................................................................................................... B-8
Body Length .................................................................................................................................... B-8
ii
Figures
Figure 2-1 Incomplete Vehicle Certification Document ........................................................................................ 2-2
Figure 2-2 Locations of Certification Labels – Driver’s Door & Frame ............................................................... 2-2
Figure 3-1.1 Side View —Model 220 W/19.5 Tires Cab tilt Height and Pivot location Measurement ................ 3-3
Figure 3-1.2 Side View —Model 220 W/22.5 Tires Cab tilt Height and Pivot location Measurement ................ 3-3
Figure 3-2.1 Side View —Model 220 W/19.5 Tires Height and Length Measurement ......................................... 3-4
Figure 3-2.2 Side View —Model 220 W/19.5 Tires Height and Length Measurement ......................................... 3-6
Figure 3-3.1 Front & Rear View —Model 220 ..................................................................................................... 3-7
Figure 3-3.2 Model 220 Laden 22.5 Tires Front view: Width & Ground clearance Measurements: inches(mm) 3-8
Figure 3-3.3 Model 220 Laden 19.5 Tires Front view: Width & Ground clearance Measurements: inches(mm) 3-8
Figure 3-3.4 Model 220 Laden Rear view: Width & Ground clearance Measurements: inches(mm) .................... 3-9
Figure 3-4.1 Cab Floor: Side View, Left Side w/ 19.5 Tires................................................................................. 3-10
Figure 3-4.2 Cab Floor: Side View, Left Side w/ 22.5 Tires................................................................................. 3-11
Figure 3-5.1 Model 220 W/22.5 Tires, Battery Box, Fuel Tank, Air Tank, DEF Tank and Crossmember
Location Measured From Front Axle: inches (mm).............................................................................. 3-12
Figure 3-5.2 Model 220 W/22.5 Tires, Battery Box, Dual Fuel Tanks, Air Tank, DEF Tank, and Crossmember
Location Measured From Front Axle: inches (mm).............................................................................. 3-12
Figure 3-5.3 Model 220 W/22.5 Tires, Short wheelbase, Air tanks on RH side, Battery Box, Fuel Tanks,
DEF Tanks And Crossmember Location Measured From Front Axle: inches (mm) ........................... 3-13
Figure 3-5.4 Model 220 W/22.5 Tires, clear rail Package, Battery Box, Air Tank, Fuel tanks, DEF Tank,
And Crossmember Location Measured From Front Axle: inches (mm) .............................................. 3-13
Figure 3-6.1 Model 220 Crossmember Locations ................................................................................................ 3-14
Figure 3-6.2 Model 220 Crossmember Locations Measured from front Axle Centerline inches(mm) ................ 3-14
Figure 3-7 Model 220 Rail Measurements ............................................................................................................ 3-16
Figure 3-8 Model 220 Battery Box, Fuel Tank and Air Tanks Measurement mm (in) ........................................ 3-17
Figure 3-9.1 Model 220 Exhaust Measurements .................................................................................................. 3-18
Figure 3-9.2 Model 220 Exhaust Measurements .................................................................................................. 3-18
Figure 3-10.1 Side View - Model 220 CRP Laden Height and Length Measurement ........................................ 3-19
Figure 3-10.2 Model 220 Vertical Exhaust Measurements inches(mm) .............................................................. 3-19
Figure 3-11 Model 220 Reyco & Hendrickson Single Rear Axle Measurements ............................................... 3-20
Figure 3-12.1 PTO models installed on a 2000 Series Allison transmission ......................................................... 3-21
Figure 3-12.2 Model 220 PTO Clearances 1 of 2.................................................................................................. 3-22
Figure 3-12.3 Model 220 PTO Clearances 2 of 2.................................................................................................. 3-22
Figure 4-1.1 The DEF lines route to the after-treatment system ............................................................................. 4.1
Figure 4-1.2 The DEF lines route to the Engine Coolant ....................................................................................... 4.2
Figure 4-2 Measurement Location of DEF Supply Module (Pump) ...................................................................... 4-4
Figure 4-3 Measurement Location of DEF Dosing Module (Injector) ................................................................... 4-4
Figure 4-4 Orientation of Dosing Module .............................................................................................................. 4-5
Figure 4-5 Routing DEF Lines and DEF Trap ....................................................................................................... 4-5
Figure 4-6.1 Horizontal Exhaust Canister with Horizontal Tailpipe ....................................................................... 4-6
Figure 4-6.2 Top view of Horizontal Exhaust Canister with Horizontal Tailpipe .................................................... 4-6
Figure 4-6.3 Right view of Horizontal Exhaust Canister with Horizontal Tailpipe ................................................. 4-7
Figure 4-6.4 Back view of Horizontal Exhaust Canister with Horizontal Tailpipe ................................................. 4-7
Figure 4-7.1 Vertical Exhaust Canister with Horizontal Tailpipe ............................................................................ 4-8
Figure 4-7.2 Top view of Vertical Exhaust Canister with Horizontal Tailpipe ........................................................ 4-8
Figure 4-7.3 Right view of Vertical Exhaust Canister with Horizontal Tailpipe ...................................................... 4-9
Figure 4-7.4 Back view of Vertical Exhaust Canister with Horizontal Tailpipe ...................................................... 4-9
iii
Figures
Figure 5-1.1 Horizontal Exhaust Canister, RH horizontal tailpipe, LH BOC rectangular fuel tank, LH
BOC rectangular DEF tank and RH BOC battery box ........................................................................ 5-2
Figure 5-1.2 Horizontal Exhaust Canister, RH horizontal tailpipe, Duel BOC rectangular fuel tank,
LH BOC rectangular DEF tank and RH BOC battery box .................................................................. 5-2
Figure 5-1.3 Vertical Exhaust Canister, BOC Vertical tailpipe, LH BOC rectangular fuel tank, LH
BOC rectangular DEF tank and BOC battery box............................................................................... 5-3
Figure 5-2 Minimum Clearance between Top Of Rear Tires And Body Structure Overhang ............................... 5-4
Figure 5-3 Minimum Back of Cab Clearance ........................................................................................................ 5-4
Figure 5-4 Spacer between Frame Sill and Body Rail - Rubber or Plastic............................................................. 5-6
Figure 5-5. High Compression Spring between the Mounting Bolt and Upper Bracket ........................................ 5-6
Figure 5-6 Rubber Spacers between Brackets ........................................................................................................ 5-6
Figure 5-7 Hole Locations Guidelines for Frame Rail and Bracket ....................................................................... 5-6
Figure 5-8 Crossmember-Gusset Hole Pattern Requirements. [inches(mm)]......................................................... 5-7
Figure 5-9 Acceptable U-Bolt Mounting with Wood and Fabricated Spacers ....................................................... 5-8
Figure 5-10 Clearance Space for Air Lines and Cables.......................................................................................... 5-8
Figure 5-11 Example of Fishplate Bracket at Rear End of Body, used with U-Bolts ............................................ 5-9
Figure 6-1 Wheelbase Customization ..................................................................................................................... 6-1
Figure 6-2 Crossmember Added When Distance Exceeds 60 Inches (1524 mm) .................................................. 6-2
Figure 7-1 Data Bus Communication Architecture ................................................................................................ 7-2
Figure 7-2.1 Electrical Junction Box Location....................................................................................................... 7-3
Figure 7-2.2 Inside View - Electrical Junction Box Location ................................................................................ 7-3
Figure 7-3 LF Euro 6 Cab Interface Names ........................................................................................................... 7-4
Figure 7-4 Controllers ............................................................................................................................................ 7-6
Figure 7-5.1 Dash Controls-1 ................................................................................................................................. 7-7
Figure 7-5.2 Dash Controls-2 ................................................................................................................................. 7-7
Figure 7-6.1 Power Distribution Center ................................................................................................................. 7-8
Figure 7-6.2 Power Distribution Center (Chassis) .................................................................................................. 7-9
Figure 7-7 Body Builder 9 Pin Connector ............................................................................................................ 7-10
Figure 7-8.1 Typical PTO Wiring for Euro 6 LFNA – 12V PTO Solenoid.......................................................... 7-12
Figure 7-8.2 Typical PTO Wiring for Euro 6 LFNA – 24V PTO Solenoid......................................................... 7-13
Figure 7-9 A 12-pin Deutsch connector and remote PTO Controls ..................................................................... 7-14
Figure A-1 Vehicle Identification Number (VIN) ................................................................................................ A-1
Figure A-2 Drivers Door and Door Frame Label ................................................................................................. A-2
Figure A-3 Engine Identification Location ............................................................................................................ A-3
Figure A-4 Front Axle Identification .................................................................................................................... A-4
Figure A-5 Rear Axle Identification ...................................................................................................................... A-4
Figure B-1 Balanced Load: CGf 100 in. from front axle ...................................................................................... B-2
Figure B-2 Unbalanced Load: CGf 133 In. From Front Axle ............................................................................... B-3
Figure B-3 Balanced Body Unloaded: CGf 184.7 in. (4691.45 mm) from front axle .......................................... B-5
Figure B-4 Liftgate Example: CGf 322.2 in (8183.9 mm) from front axle ........................................................... B-5
Figure B-5. Balanced Body Loaded: CGf 184.7 in (4691.45 mm) from front axle……………………………...B-7
iv
Tables
Table: Abbreviations Used ...................................................................................................................................... vi
Table 3-1 Frame Height........................................................................................................................................... 3-1
Table 3-2 Turning Radius ........................................................................................................................................ 3-2
Table 3-3 Cab Tilt Height ........................................................................................................................................ 3-3
Table 3-4 Cab Pivot Location .................................................................................................................................. 3-3
Table 3-5 Overall Dimensions ................................................................................................................................. 3-5
Table 3-6.1 Tires-Laden Ground clearance W/22.5 Tires....................................................................................... 3-8
Table 3-6.2 Tires-Laden Ground clearance W/19.5 Tires....................................................................................... 3-8
Table 3-7.1 Battery Box Step and Cab Floor Measurements w/ 19.5 Tires .......................................................... 3-10
Table 3-7.2 Battery Box Step and Cab Floor Measurements w/ 22.5 Tires .......................................................... 3-11
Table 3-8 Floor to Frame Measurements ............................................................................................................... 3-11
Table 3-9.1 Model 220 Crossmember Location Measured From Front Axle Centerline ...................................... 3-14
Table 3-9.2 Model 220 Crossmember Location Measured From Front Axle Centerline for Clear Rail Package . 3-15
Table 3-10 Frame Rail Strength Characteristics .................................................................................................... 3-16
Table 3-11 Model 220 Exhaust Location Measured From BOC inches (mm) ...................................................... 3-18
Table 3-12 Model 220 Exhaust Location Measured From BOC inches (mm) ...................................................... 3-18
Table 3-13 Model 220 Reyco & Hendrickson Single Rear Axle: Ride Height Measurement ............................... 3-20
Table 5-1 Symbols ................................................................................................................................................... 5-1
Table 6-1 Customary Grade 8 UNF or UNC ........................................................................................................... 6-3
Table 6-2 U.S. Customary – Grade 8 Metric Class 10.9 ......................................................................................... 6-3
Table 7-1 Additional Spare Circuits for Wiring ...................................................................................................... 7-9
Table 7.2 Body Builder 9 Pin Connector ............................................................................................................... 7-10
Table A-1. Model Year (Code) Designations ......................................................................................................... A-1
Table B-1. Model 220 Single Rear Axle “Bare” Chassis Tare Weights (no driver, no fuel) ................................. B-4
Table B-2.1. Model 220 Weight Distribution and Chassis Rating Calculation (sample) ....................................... B-7
Table B-3. Available Model 220 Body Lengths ..................................................................................................... B-9
v
Abbreviations
ABBREVIATIONS
Throughout this section and in other sections as well, abbreviations are used to describe certain characteristics on
your vehicle. The chart below lists the abbreviated terms used.
Abbreviations Used
AE
AXLE TO END
AF
BFA
BOC
CA
CA
CBOC
CGF
CH
CLA
FRAME RAIL OVERHANG LENGTH BEHIND REAR
FRONT BUMPER TO FRONT AXLE LENGTH
BACK OF CAB
BACK OF CAB TO REAR AXLE LENGTH/CARGO AREA
CAB TO AXLE
CLEAR BACK OF CAB
CENTER GRAVITY OF LOAD FROM FRONT AXLE
CAB HEIGHT
CENTER LINE OF AXLE
CRP
DEF
DSOC
EFF CA
EOF
CLEAR RAIL PACKAGE
DIESEL EXHAUST FLUID
DUAL SIDE OF CAB
USEABLE CARGO AREA
END OF FRAME
FAX
FRONT AXLE
FOC
FRONT OF CAB
FOR
FRONT OF RAIL
HA
HEIGHT AXLE
L
LOAD
LF
LOAD FRONT
LHUC
LEFT HAND UNDER CAB
LR
LOAD REAR
OAL
OVERALL VEHICLE LENGTH
R
ROOF
RHUC
RIGHT HAND UNDER CAB
SLR
STATIC LOAD RADIUS
SOC
SIDE OF CAB
TL
TOTAL LENGTH
TOC
TOP OF CLAMP
TOLC
TOP OF LOWER CLAMP
TOR
TOP OF RAIL
WB
WHEELBASE LENGTH
vi
Abbreviations
ACH-W
AEBS
AGC-A
ALS-S
ASTRONIC LITE
ASTE-MODULE
ASTMULTI-SPEED
AXM-F/AXM-R
BBM
CDS-4
DIP-5
DNR
DTCO
E-MODULE
EAS
AUXILIARY CAB HEATER WEBASTO
ADVANCED EMERGENCY BRELECTRONIC BRAKING SYSTEMAKING SYSTEM
AUTOMATIC GEARBOX CONTROL ALLISON
ALARM SYSTEM SCORPION
AUTOMATED GEARBOX CONTROL ZF
ASTRONIC SELECTOR ECU
AUTOMATED 12-SPEED GEARBOX
AXLE MODULATOR – FRONT/REAR
BODYBUILDER MODULE
CENTRAL DOOR LOCKING
DIGITAL INSTRUMENT PACK
DRIVE NEUTRAL REVERSE SWITCH
DIGITAL TECHNOGRAPH
AUTOMATED GEAR SELECTOR ZF
EXHAUST AFTER-TREATMENT SYSTEMN
EBS-3
ELECTRONIC BRAKING SYSTEM
ECSDC6
EURO 6 CUMMINS ENGINE
ECAS-4
AIR SUSPENSION
ELC
EXTERNAL LIGHTING CONTROLLER
ELS
EXTERNAL LIGHTING SWITCH
FMS
FLEET MANAGEMENT SYSTEM
IMMO
IMMOBILISER
LDWS
LANE DEPARTURE WARNING SYSTEM
MTCO
MECHANICAL TECHNOGRAPH
SAC
SAS
SAS
SMART AIR CONTROL
STEERING ANGLE SENSOR
SWA
STEERING WHEEL SWITCHES
TI-2
TELEPHONE INTERFACE
VIC3
VEHICLE INTELLIGENCE CENTRE 3
VGT
VARIABLE GEOMETRY TURBOCHARGER
VSC
VEHICLE STABILITY CONTROL
vii
Section 1
Introduction
This manual provides 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.
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.
The intended primary users of this manual are body builders who install bodies and associated equipment on
Model 220 Medium Duty vehicles. Dealers who sell and service the vehicle will also find this information useful.
This Body Builder’s Manual can be very useful when specifying a vehicle, particularly when the body builder is
involved in the vehicle definition and ordering process. Early in the process, professional body builders
can often contribute valuable information that reduces the ultimate cost of the body installation.
The DAVIE4 diagnostic tool is recommended for all Model 220’s built with the push button transmission shifter.
The DAVIE3 (XDc) tool should be used with all Model 220’s built with the lever style transmission shifter. Both
DAVIE4 and DAVIE3 should be connected to the blue, 16-pin OBD connector located on the passenger side of the
dash.
Contact your local Peterbilt dealer to utilize the DAVIE tools or order the required hardware and software.
This manual is not a maintenance manual or an operation manual.
• For chassis maintenance and repair information consult the PACCAR ServiceNet available in the Service
Department of the selling dealer or order a custom shop manual or parts catalog for your vehicle through
your local dealer.
•
For chassis operating information consult the Operator’s Manual, included with each vehicle. It can also
be ordered from your local dealer.
1-1
Section 2
Safety & Compliance
SAFETY SIGNALS
We have put a number of alerting messages 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 u s e d to indicate what kind of message is going to follow. Pay special attention to
comments prefaced by “WARNING”, “CAUTION”, and “NOTE.” Please do not ignore a n y of these alerts.
Warnings, Cautions, and Notes
WARNING:
When you see this word and symbo l, the message that follows is especially vital. It signals
a potentially hazardous situation which, if not avoided, could r e s u l t 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 an electrical overload or fire situation. Follow the
liftgate installation instructions and use a circuit breaker with the recommended capacity.
CAUTION:
Signals a potentially hazardous situation which, if not avoided, could result in minor
or moderate injury or damage to the v e h i c l e .
Example:
CAUTION: Never use a torch to make a hole in the rail. Use the appropriate drill bit.
NOTE:
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
Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.
CAUTION
Signals a potentially h a z a r d o u s 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.
2-1
Section 2
Safety & Compliance
FEDERAL MOTOR VEHICLE SAFETY STANDARDS COMPLIANCE
As an Original Equipment Manufacturer (OEM), Peterbilt Truck Co. ensures that our products comply with all applicable U.S.
or Canadian Federal Motor Vehicle Safety Standards. However, the fact that this vehicle has no fifth wheel and that a Body
Builder (Intermediate or Final Stage Manufacturer) will be doing additional modifications means that the vehicle was incomplete when it left the build plant. See next section and Appendix A for additional information.
Incomplete Vehicle Certification
An Incomplete Vehicle Document is shipped with the vehicle, certifying that the vehicle is not complete. See Figure 2–1.
In addition, affixed to the driver’s side door frame or edge is an Incomplete Vehicle Certification label. See Figure 2–2.. For further
information on Vehicle Certification and Identification, see APPENDIX A “VEHICLE IDENTIFICATION” or owner’s manual.
NOTE:
These documents list the U.S. or Canadian Federal Motor Vehicle Safety Standard regulations that the
vehicle complied with when it left the build plant. You should be aware that if you add, modify or alter
any of the components or systems covered by these regulations, it is your responsibility as the Intermediate or Final Stage Manufacturer to ensure that the complete vehicle is in compliance with the
particular regulations upon completion of the modifications.
U.S. EPA Noise Label (U.S. registered vehicles only)
Final Stage Manufacturer
Label to be Installed by
Final Stage Manufacturer
Tire, Rim and
Weight Rating
Data label
Chassis Serial
Number
Safety Mark (Canadian
Registry Only)
Figure 2-1. Incomplete Vehicle Certification
Document
Incomplete Vehicle
Certification Label
Major Components and
Weights Label
Figure 2-2. Locations of Certification Labels
- Driver’s Door and Frame
As the Intermediate or 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 “Intermediate or Final Stage Manufacturer” and certifies that the vehicle complies with Federal Motor Vehicle Safety Standards. (SeeFigure 2–2.) For Canadian final stage manufacturers
see:
http://www.gazette.gc.ca/index-eng.html and http://www.tc.gc.ca/eng/acts-regulations/menu.htm or the regulations.
Or contact:
Transport Canada
Tower C, Place de Ville, 330 Sparks Street Ottawa,
Ontario K1A 0N5
(613) 990-2309
TTY: 1-888-675-6863
2-2
Section 2
Safety & Compliance
Noise and Emissions Requirements
NOTE:
This truck may be equipped with a converter muffler unit in order to meet both noise and exhaust
emissions requirements. Removal or tampering with the converter muffler will not improve engine performance. Also tampering is against the rules that are established by the U.S. Code of Federal Regulations and Environment Canada Regulations. The converter muffler may only be replaced with an
approved part.
NOTE:
Relocation of converter muffler will affect noise and emission performance. Contact the engine manufacturer for any requirements and restrictions prior to any modifications. In particular, there are requirements and restrictions for exhaust pipe materials and for maximum exhaust system lengths from
turbo outlet to muffler inlet.
2-3
Section 3
Dimensions
Frame Height
Top of frame is the sum of the tires (SLR), the suspension, and the frame.
Table 3-1 Frame Height
Model
Model 220
Frame
10 ¼ inches
De-rated
10 ¼ inches
Front Suspension
Rating
12K
10K
Unladen
8.1”
8.1”
Laden
5.9”
5.9”
8.5”
8.5”
8.3”
8.3”
Unladen
9.18”
9.18”
Laden
6.75”
6.75”
Rear Suspension
HAS 210/230
Unladen
Laden
79KB 21,000#
Tires (SLR)
Tire GVWR
245/70R 19.5
G
N/A
15.5”
26,720
265/70R 19.5
G
N/A
15.9”
30,990
255/70R 22.5
H
N/A
17.2”
31,300
275/70R 22.5
J
17.6”
17.6”
39,580
295/75R 22.5
G
18.8”
18.8”
35,050
11R
G
25.8”
19.5”
35,710
22.5
3-1
Section 3
Dimensions
TURNING RADIUS
Approximate turning radius specifications for the Model 220 are listed (by wheelbase) in the following tables. Tables 3-2 Turning
Radius and 3-3 Cab Tilt Height information for chassis with standard components. Optional components may give different results.
Table 3-2 Turning Radius
Model
Model 220
Rear
Axles
Single
Wheelbase Range
Curb to Curb Est. Radius
Wall to Wall Radius Est.
Inch
121
mm
3073.4
ft
17.5
m
5.3
ft
23.5
m
7.2
142
3606.8
18.4
5.6
24.4
7.5
146
3708.4
19.40
5.9
25.40
7.7
156
35162.4
20.1
6.1
26.1
4.0
158
3962.4
20.50
6.2
26.50
8.1
164
4165.6
21.2
6.5
27.2
8.4
168
4267.2
21.7
6.6
27.7
8.5
170
4318
22.04
6.7
28.04
8.5
182
4622.8
23.36
7.1
29.36
8.9
194
4927.6
24.69
7.5
30.69
9.4
206
5232.4
26.01
7.9
32.01
9.8
218
5537.2
27.33
8.3
33.33
10.2
230
5842
29.13
8.9
35.13
10.7
242
6146.8
29.97
9.1
35.97
11.0
274
6959.6
33.5
13.1
39.35
15.5
3-2
Section 3
Dimensions
CAB TILT
Model 220 W/19.5 Tires
Table 3-3 Cab Tilt Height
CAB Tilt
220 W/19.5
Tires
220 W/22.5
Tires
Highest point inches (mm)
128 (3258.7)
132 (3355.2)
Figure 3-1.1 Side View —Model 220 W/19.5 Tires Cab Tilt Height and Pivot
location Measurement
Model 220 W/22.5 Tires
Table 3-4 Cab Pivot location
Behind CAB
Pivot location
Above FOF
44.5MM
WL
209MM
CTR-CTR
Figure 3-1.2 Side View —Model 220 W/22.5 Tires Cab Tilt Height and Pivot
location Measurement
3-3
978MM
Section 3
Dimensions
OVERALL DIMENSIONS
This section includes drawings of the base Model 220, which includes:
On the pages that follow, detail drawings show particular views of each component of the vehicle. They illustrate important
measurements critical to designing bodies of all types. See the “Contents” at the beginning of the manual to locate the drawing you
need.
Side View – Model 220
Figure 3-2.1 Side View —Model 220 Laden Height and Length Measurement
Overall Model 220 Dimensions:
1) FAX TO BOC = 11”
2)
O.A .Length = 52”+WB+AF
3) Frame Length = 49”+WB+AF
4) Effective CA = WB-24.3” (24.3” is from C/L of front axle to the air cleaner duct with considering a 5” body spacer)
3-4
Section 3
Dimensions
Side View - Model 220
Table 3-5 Overall Dimensions
Model
220
Horizontal
Exhaust
220**
Vertical
Exhaust
Wheelbase
(in)
FAX to
BOC
(in)
146
158
164
168
170
178
182
194
206
218
230
242
274
121
142
146
156
158
164
168
170
178
182
194
206
218
230
242
274
11
11
11
11
11
11
11
11
11
11
11
11
11
11
11
11
11
11
11
11
11
11
11
11
11
11
11
11
11
FAX to Back
of Intake /
FAX to Back
of Exhaust
for 220**
(in)
25.3
25.3
25.3
25.3
25.3
25.3
25.3
25.3
25.3
25.3
25.3
25.3
25.3
31.3
31.3
31.3
31.3
31.3
31.3
31.3
31.3
31.3
31.3
31.3
31.3
31.3
31.3
31.3
31.3
Body
Builder
Useable
CA*
(in)
Overhang
(in)
Cab to
EOF
(in)
Recommended
Body Length (ft)
120.7
132.7
138.7
142.7
144.7
152.7
156.7
168.7
180.7
192.7
204.7
216.7
248.7
89.7
110.6
114.6
124.6
126.6
132.6
136.6
138.6
146.6
150.6
162.6
174.6
186.6
198.6
210.6
242.6
72
72
72
72
72
88
84
96
108
120
132
144
160
72
72
72
72
72
72
72
72
88
84
96
108
120
132
144
160
192.7
204.7
210.7
214.7
216.7
240.7
240.7
264.7
288.7
312.7
336.7
360.7
408.7
155
176
180
190
192
198
202
204
228
228
252
276
300
324
348
396
16
17
18
18
18
18
20
22
24
26
28
30
34
10
13
14
15
15
16
16
16
18
18
20
22
24
26
27
30
*With 5 inch spacer.
3-5
Section 3
Dimensions
Figure 3-2.2 Side View —Model 220 Laden Height and Length Measurement
Overall Model 220 Dimensions:
1) FAX TO BOC = 11”
2)
O.A .Length = 52”+WB+AF
3) Frame Length = 49”+WB+AF
4) Effective CA = WB-31.5
3-6
Section 3
)
Dimensions
Front and Rear Views — Model 220
Inches (mm)
Figure 3-3.1 Front & Rear View —Model 220
3-7
Section 3
Dimensions
Front and Rear Views — Model 220
Table 3-6.1 Laden Ground
Clearance W/22.5 Tires
TIRE SIZE
SLR
RADIATOR
GROUND
275/22.5
295/22.5
11R/22.5
17.6
18.8
19.5
7.7
8.9
9.6
Figure 3-3.2 Model 220 Laden 22.5 Tires Front View: Width and Ground Clearance Measurements:
inches (mm).
Table 3-6.2 Laden Ground
Clearance W/19.5 Tire
Table 3-6.2 Laden Ground clearanceRADIATOR
W/19.5 Tire
TIRE SIZE
TIRE SIZE
245/19.5
245/19.5
265/19.5
265/19.5
SLR
SLR
15.5
15.5
15.9
15.9
GROUND
RADIATOR
GROUND
7.5
7.5
7.9
7.9
Figure 3-3.3 Model 220 Laden 19.5 Tires Front View: Width and Ground Clearance Measurements:
inches (mm).
3-8
Section 3
Dimensions
Front and Rear Views — Model 220
Figure 3-3.4 Model 220 Laden Rear View: Width and Ground Clearance Measurements:
inches (mm).
3-9
Section 3
Dimensions
Detail Views
Left side: Chassis Heights – Model 220
Figure 3-4.1 Cab Floor: Side View, Left Side w/ 19.5 Tires
Table 3-7.1. Battery Box Step and Cab Floor Measurements w/ 19.5 Tires
Model 220 19.5 Tires
Position
Unladen
Laden
In
mm
In
A FUEL SUPPORT STEP
10.5
269
7.5
191
B FIRST STEP
16.6
421
13.2
336
C SECOND STEP
27.2
690
23.8
605
D CAB FLOOR
38.6
977
35.2
894
3-10
mm
Section 3
Dimensions
3 Dimensions
Detail Views
Left side: Chassis Heights – Model220ction
3ions
Figure 3-4.2 Cab Floor: Side View, Left Side w/ 22.5 Tires
Table 3-7.2. Battery Box Step and Cab Floor Measurements w/ 22.5 Tires
Model 220 22.5 Tires
Position
*Unladen
In
A FUEL SUPPORT
B FIRST STEP
C SECOND STEP
D CAB FLOOR
mm
Laden
In
mm
15.8
401
14.3
363
18.4
467
16.9
430
32.7
830
31.2
794
41.4
1051
39.9
1013
Table 3-8 Floor to Top of Frame Measurements
Frame Heights
LOADED inches (mm)
Front Axle
Rear Axle
*UNLOADED inches (mm)
Front Axle
Rear Axle
Model 220 W/19.5
(15.6 SLR)
31 (787)
32.5(825)
36 .1(916)
35.6 (905)
Model 220
W/ 11R-22.5
(19.4 SLR)
34.8 (884)
36.3 (922)
39.1(992)
38.6(980)
* Unloaded Dimensions are estimated.
3-11
Section 3
Dimensions
Detail Views
Components Locations –Model 220
Figure 3-5.1 Model 220 W/22.5 Tires, Battery Box, Fuel Tank, Air Tank and DEF Tank
Location Measured From Front Axle: inches (mm).
Figure 3-5.2 Model 220 22.5 Tires, Battery Box, Dual Fuel Tanks, Air Tank and DEF Tank Location
Measured from Front Axle: inches (mm).
3-12
Section 3
Dimensions
3 Dimensions
Figure 3-5.3 Model 220 22.5 Tires, Short Wheelbase, Air Tanks on the RH Side, Battery Box and DEF Tank
Location Measured from Front Axle: inches (mm).
Figure 3-5.4 Model 220 22.5 Tires, Clear Rail Package, Air Tanks, Battery Box and DEF Tank Location
Measured from Front Axle: inches (mm).
3-13
Section 3
Dimensions
Detail Views
Crossmember Locations –Model 220
Figure 3-6.1 Model 220 Crossmember Locations
Figure 3-6.2 Model 220 Crossmember Location Measured From Front Axle Centerline inches (mm)
Composition
of use
CLASS 6
CLASS7
WO CLEAR
RAIL
PACKAGE
First
Midship
C/M
Second
Midship
C/M
Second
Fill in
C/M
Third
Midship
C/M
DIM “A”
DIM “B”
DIM “C”
DIM “D”
146 (3708.4)
3463.4
NA
NA
NA
158 (4013.2)
3463.4
NA
NA
NA
164(4165.6)
3463.4
NA
NA
NA
168(4267.2)
3463.4
NA
NA
NA
170 (4318)
3463.4
NA
NA
NA
178(4521.2)
3463.4
NA
NA
NA
182 (4622.8)
3463.4
4257
7180.4
NA
194 (4927.6)
3463.4
4257
7518
NA
206 (5232.4)
3463.4
4257
7975.2
NA
218 (5537.2)
3463.4
4663
8432.4
NA
230 (5842)
3463.4
4975
8781
NA
242 (6146.8)
3463.4
5075
9085.8
NA
274(6959.6)
3463.4
4975
9898.6
6100
WB
inches (mm)
Table 3-9.1 Model 220 Crossmember Location Measured from Front Axle Centerline inches (mm)
3-14
Section 3
Dimensions
3 Dimensions
WB
Composition
inches (mm)
of use
CLASS 6
CLASS7
CLEAR
RAIL
PACKAGE
First
Midship
C/M
Second
Midship
C/M
Second
Fill in
C/M
Third
Midship
C/M
DIM “A”
DIM “B”
DIM “C”
DIM “D”
121 (3073.4)
NA
NA
NA
NA
142 (3606.8)
3043.3
NA
NA
NA
146 (3708.4)
3043.3
NA
NA
NA
156 (3962.4)
3183.3
NA
NA
NA
158 (4013.2)
3183.3
NA
NA
NA
164(4165.6)
3183.3
NA
NA
NA
168(4267.2)
3183.3
NA
NA
NA
170 (4318)
3323.3
NA
NA
NA
178(4521.2)
3043.3
4257
NA
NA
182 (4622.8)
3043.3
4257
7180.4
NA
194 (4927.6)
3183.3
4397
7518
NA
206 (5232.4)
3183.3
4397
7975.2
NA
218 (5537.2)
3183.3
4663
8432.4
NA
230 (5842)
3463.3
4975
8781
NA
242 (6146.8)
3463.3
5075
9085.8
NA
274(6959.6)
3463.3
4975
9898.6
6100
Table 3-9.2 Model 220 Crossmember Location Measured From Front Axle Centerline for
Clear Rail Package inches (mm)
3-15
Section 3
Dimensions
Frame Rail Configurations
Model 220
10-1/4 STEEL RAIL
Figure 3-7 Model 220 Rail Measurements
Table 3-10 Frame Rail Strength Characteristics
RAIL
STRENGTH
Yield Strength, PSI
Section Modulus, in3
RBM, Lbs-Inch
10.25” Rail
(Per Rail)
120,000
11.65
1,398,664
3-16
Section 3
Dimensions
3 Dimensions
Battery Box, Fuel Tanks and Air Tanks — Model 220
Figure 3-8 Model 220 Battery Box, Fuel Tank and Air Tanks Measurement mm (in)
3-17
Section 3
Dimensions
Detail Views
Exhaust Canister Locations – Model 220
Figure 3-9.1 Model 220 Exhaust Measurements
Table 3-11 Model 220 Exhaust Location Measured From Front Axle in inches (mm)
Model
Model 220
A
54.3 (1378.3)
B
92.3 (2343.6)
C
101.3 (2572.2)
D
14.2 (360.7)
E
13.2 (360.7)
Figure 3-9.2 Model 220 Exhaust Measurements
Table 3-12 Model 220 Exhaust Location Measured From Outboard and Bottom of Rail inches (mm)
Model
Model 220
A
6.6 (167)
B
4.9 (125.3)
C
13.6 (345)
D
13.9 (353.5)
3-18
Section 3
Dimensions
3 Dimensions
Side View – Model 220 clear rail package
Figure 3-10.1 Side View —Model 220 CRP Laden Height and Length Measurement
Figure 3-10.2 Model 220 Vertical Exhaust Measurement inches (mm)
3-19
Section 3
Dimensions
Reyco 79KB Single Rear Axle
Hendrickson HAS Single Rear Axle
Figure 3-11 Model 220 Reyco & Hendrickson Single Rear Axle Measurements
Suspension
Rating
Laden Ride Height
Unladen Ride Height
Reyco 79KB Single
21K
7.5"
9.0"
23K
8.3"
8.5"
Hendrickson HAS
210L/230L
Table 3-13 Model 220 Reyco & Hendrickson Single Rear Axle: Ride Height Measurements
TIRE DATA
For dimensions of your particular tire, visit the manufacturer website.
FRAME AND CAB RELATED HEIGHTS
The bottom of the frame rail (BOF) at the front and rear axle can be used as a reference point to estimate vertical heights.
Use the following to calculate estimates for frame and cab related heights, such as top of frame rail, step height, top of
exhaust pipe, etc.:
1.) Tire radius data from the manufacturer
2.) Front and rear suspension ride heights in this section 3.)
Frame rail heights defined in this section if needed
4.) Component dimensions from bottom of rail defined in this section if needed
Note that there are many factors that will affect heights including, but not limited to, front and rear axle loading and tire
pressure. Placement of frame components such as fuel tanks will affect loads on the front axle and rear axle, as well as
distribution to the left and right sides of the vehicle. Heights calculated from this information are estimates only.
GROUND CLEARANCES
To calculate estimates for ground clearance for mounted components using the underside of the bottom of the frame rail
as a reference use the following:
1.) Tire radius data from the manufacturer
2.) Front and rear suspension ride heights in this section
3.) Component dimensions from bottom of rail defined in this section
Ground clearances, like height calculations, are affected by factors including, but not limited to, front and rear axle loading
and tire pressure. Placement of frame components, such as fuel tanks, will affect loads on the front axle and rear axle, as
well as distribution to the left and right side of the vehicle. Ground clearances calculated from this information are
estimates only.
3-20
Section 3
Dimensions
PTO Clearances
The following visuals are provided to help or aid in determining PTO locations and clearances. For specific dimensions
please work through your local Peterbilt dealer. Multiple PTO’s are shown for layout purposes only. Power equipment,
i.e., drive shafts & power pumps are not included. Body builders should select the appropriate Chelsea or Muncie 24V electric over
air PTO’s for their application and customer requirements.
NOTE: All installations are only RH side PTO locations shown below are for reference only.
In order to ensure the PTO area remains clear of air equipment, electrical and emissions equipment, Peterbilt recommends
always ordering PTO controls, even when installing the PTO aftermarket. Contact your local dealer for assistance.
Below are shown example of PTO models installed on a 2000 Series Allison transmission:
Automatic Transmission – Allison 2000:
Muncie PTO TG6S-A1BX
Muncie PTO CS6-H3KP
Chelsea PTO Model 230-270
Chelsea PTO Model 442
Figure 3-12.1 PTO models installed on a 2000 Series Allison transmission
3-21
Section 3
Dimensions
Figure 3-12.2 Model 220 PTO Clearances 1 of 2
Figure 3-12.3 Model 220 PTO Clearances 2 of 2
3-22
Section 4
Exhaust & Aftertreatment
EXHAUST AND AFTERTREATMENT INFORMATION (Did the Doser Change in
2017?)
The following section is designed to give you information regarding the exhaust and after-treatment systems on Peterbilt
chassis. All Peterbilt’s equipped with 2017 emission level engines will utilize Selective Catalyst Reduction (SCR). SCR is
a process in which Diesel Exhaust Fluid (DEF) is injected into the exhaust downstream of the engine. DEF is converted to
ammonia by the heat of the exhaust system. Inside of the SCR canister, a catalyst causes a chemical reaction between the
ammonia and NOx, turning it into water and nitrogen. For more information on the specific details of how SCR works,
please contact your local Peterbilt dealer.
On most Peterbilt chassis, the DEF Supply Module (or pump) is integrated into the DEF tank. Peterbilt does not allow
relocation of this pump. The following schematic details how the DEF lines route to the after-treatment system.
Figure 4-1.1 The DEF lines route to the after-treatment system
4-1
Section 4
Exhaust & Aftertreatment
DEF will freeze at approximately 11° F (-12° C). In order to keep DEF from freezing, all tanks will be heated with engine
coolant. The following schematic shows the routing of these lines. The coolant lines that run to and from the SCR system
must not be tampered with, or used for a source of heat and/or cooling for other components on the chassis. It is critical
that the system is not compromised in any manner.
Figure 4-1.2 The DEF lines route to the Engine Coolant
4-2
Section 4
Exhaust & Aftertreatment
General Guidelines for DEF System
The installation of the DEF tank is a critical component of the SCR system. While Peterbilt does not recommend relocating
the DEF tank, there are applications and body installations that will require it. The guidelines below must be strictly
followed by any entity relocating the tank. Failure to follow the guidelines completely and accurately may result in engine
shut down situations. Peterbilt offers a variety of DEF tank sizes to meet every application.
The DEF tank volume is regulated by the E.P.A.
Peterbilt advises against modifying the tank volume after the truck has been delivered from the factory.
•Total DEF capacity must meet or exceed 6% of the useable fuel capacity on the truck. The calculation
to determine DEF capacity is:
Minimum DEF Tank Volume = Useable Fuel Capacity (gal) x 0.06.
Example: For a truck with 45 useable gallons of fuel, the equation is:
DEF required = 45 x 0.06 = 2.7 gallons or more of DEF.
PACCAR-approved DEF hoses are required when retrofitting for system to function properly. The use of unapproved
hoses for DEF lines will void warranty and may cause engine shut down situations. The DEF pump (or Supply Module)
cannot be relocated from the DEF tank. In addition, the Medium Duty Rectangular DEF Tank that is used to meet clear
back of cab requirements cannot be relocated.
Installation Requirements and Dimensions for DEF System
When relocating any DEF system components, the locations must meet the guidelines below. Failure to comply may result
in non-conformance to EPA standards and engine shutdown.
DEF piping relative heights: In order to ensure proper functionality of DEF system, the height differences in the guidelines
below must be followed during line routing and component placement.
When relocating the components the maximum pressure DEF hose length from Supply module to Dosing Module is 3
meters (118”).
Maintain a minimum of 3” (76mm) clearance to shielded exhaust components when routing DEF lines to prevent possible
melting. If the DEF tank is relocated the coolant lines will need to be modified. During this process, if the tank is moved
forward on the chassis (ie closer to the engine), it is necessary to remove excess coolant lines and maintain the original
routing path. If the tank is moved rearward on the chassis, the additional length of the cooling line required to complete the
installation must be installed in a straight section of the existing coolant routing lines. This process will minimize the
change in coolant flow by minimizing changes in restrictions. Increase in restriction occurs with excessive line length and
bends. Work with your local Peterbilt dealer if you are unsure about the coolant line modifications.
4-3
Section 4
Exhaust & Aftertreatment
Measurement Reference Points
For all relocation procedures, the measurement points referenced in the guidelines are taken from the following specific
points:
Supply Module: The supply module is commonly called a pump. The measurement point on the supply module is the top
of the DEF fluid pressure line. See Figure 4-2.
Figure 4-2 Measurement Location of DEF Supply Module (Pump)
Dosing Module: The dosing module is commonly called an injector; this injector is located towards the center of the
Exhaust Canister. The measurement point on the dosing module is the top of the DEF fluid pressure line. See Figure 4-3.
Figure 4-3 Measurement Location of DEF Dosing Module (Injector)
The following relocation guidelines are dependent on exhaust configuration and DEF tank type and location.
The Dosing Module should not need to be relocated, however if it is removed for any reason, it is critical that the module
is reinstalled at the correct orientation. Figure 4-4 below illustrates the correct installation orientations. The angle
references the vertical plane.
4-4
Section 4
Exhaust & Aftertreatment
Figure 4-4 Orientation of Dosing Module
Routing to the Dosing Module (Injector)
It is important for the function of the dosing module to ensure that the dosing module is not routed downstream of DEF
lines or components. If this is unavoidable (for example on RH under exhaust systems) or Horizontal (Series) Exhaust, a
routing trap must be installed. A minimum of 12” of line length must be routed below the dosing module to catch
any leftover DEF when system is purged.
Horizontal Exhaust
Vertical Exhaust
Figure 4-5 Routing DEF Lines and DEF Trap
4-5
Section 4
Exhaust & Aftertreatment
GENERAL EXHAUST INFORMATION
Peterbilt will offer Horizontal and Vertical Exhaust Canister system on Model 220 chassis in 2017.
Figure 4-6.1 Horizontal Exhaust Canister with Horizontal Tailpipe
Figure 4-6.2 Top view of Horizontal Exhaust Canister with Horizontal Tailpipe
4-6
Section 4
Exhaust & Aftertreatment
Figure 4-6.3 Right view of Horizontal Exhaust Canister with Horizontal Tailpipe
Figure 4-6.4 Back view of Horizontal Exhaust Canister with Horizontal Tailpipe
4-7
Section 4
Exhaust & Aftertreatment
GENERAL EXHAUST INFORMATION
Figure 4-7.1 Vertical Exhaust Canister with Vertical Tailpipe
Figure 4-7.2 Top view of Vertical Exhaust Canister with Vertical Tailpipe
4-8
Section 4
Exhaust & Aftertreatment
Figure 4-7.3 Right view of Vertical Exhaust Canister with Vertical Tailpipe
Figure 4-7.4 Back view of Vertical Exhaust Canister with Vertical Tailpipe
4-9
Section 5
Frame Layouts and Body
Mounting
FRAME LAYOUTS
The dimensions in the frame layout section are intended to aid in layout of the chassis, and to help determine the best
possible combination of fuel tanks, battery boxes, Exhaust Canister, and Diesel Exhaust Fluid (DEF) tank. For your
application, the layouts focus on the under cab area, with appropriate dimensional information in- cluded for pertinent
back of cab components. Not all optional equipment is included in this section; additional components may be placed on
the rail behind components shown. The Back of Cab components are shown primarily for reference. For more specific
requirements, work with your local Peterbilt Dealer. Please read the instructions carefully. The following dimensions are
consistent across the entire section to aid in the comparison of one layout option versus another.
The visual index that follows will give you a quick overview of the layout that is included.
Visual Index
Table 5-1 Symbols
Symbol
Description
Horizontal Exhaust
Canister
Vertical Exhaust Canister
Battery Box
Air Dryer
DEF Tank
Fuel Tank
5-1
Section 5
Frame Layouts and Body
Mounting
Figure 5-1.1 Horizontal Exhaust Canister, RH horizontal tailpipe, LH BOC rectangular fuel tank, LH BOC
rectangular DEF tank, and RH BOC battery box
Figure 5-1.2 Horizontal Exhaust Canister, RH horizontal tailpipe, Duel BOC rectangular fuel tanks, LH BOC
rectangular DEF tank, and RH BOC battery box
5-2
Section 5
Frame Layouts and Body
Mounting
Figure 5-1.3 Vertical Exhaust Canister, BOC Vertical tailpipe, LH BOC rectangular fuel tank, LH BOC
rectangular DEF tank and BOC battery box
5-3
Section 5
Frame Layouts and 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 5-2.)
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 5-2.
Figure 5-2 Minimum Clearance Between Top Of Rear Tires And Body Structure Overhang.
The true distance from the centerline of the front axle to the back of the cab is 11 inches for Model 220 (279.4mm). It is
recommended that the leading edge of the body be mounted a minimum of 4 inches (102mm) behind the cab. The result is a
minimum back–of–cab clearance of 15 inches for Model 220 (381mm) from the front axle to the leading edge of the body (A).
CAUTION:
Maintain adequate clearance between back of cab and the front (leading edge) of mounted
body. See Figure 5-2.
Note: Be sure to provide maintenance access to battery
box and fuel tank fill neck.
See SECTION 3 “DIMENSIONS” for further details on dimensions and clearances.
Also, see APPENDIX B “WEIGHT DISTRIBUTION” for explanation of back–of–cab (BOC)/CA calculations.
A
Figure 5-3 Minimum Back of Cab Clearance
5-4
Section 5
Frame Layouts and Body
Mounting
WARNING:If the
frame rail flanges are modified or damaged, the rail could fail prematurely and cause an
accident. When mounting a body to the chassis, DO NOT drill holes in the upper or lower flange of
the frame rail. Mount the body using body mounting brackets or U–bolts.
Body Mounting Using Brackets
CAUTION:
Always install a spacer between the body subframe and the top flange of the frame rail. Failure
to do so could result in corrosion due to dissimilar materials.
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 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 5-4.
5-5
Section 5
Frame Layouts and Body
Mounting
Body Subframe
(Rail)
Spacer
Chassis Frame
(Rail) Sill
Figure 5-4 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 5–5 shows a high compression spring between the bolt and the bracket.
Figure 5-5 High Compression Spring Between the
Mounting Bolt and Upper Bracket
Figure 5-6 Rubber Spacer Between Brackets
Another possibility is mounting a rubber spacer between the brackets. See Figure 5-6.
These designs will allow relative movement between the body and the chassis during extreme frame racking situations.
Extreme frame racking and mountings that are too rigid, could cause damage to the body. This is particularly true with
tanker installations.
Mounting Holes
When installing the lower bracket on 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 5-7. The hole diameter should not exceed the bolt diameter by
more than .060 inches (1.5 mm).
A A or B Equal to or
Greater Than 2 Inches
(50 mm)
Upper
Frame
Flange
Lower Frame
Flange
Figure 5-7 Hole Locations Guidelines for Frame Rail and Bracket
5-6
Section 5
Frame Layouts and Body
Mounting
Figure 5-8 Crossmember-Gusset Hole Pattern Requirements. [inch(mm)]
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: Use care when drilling the frame web so the wires and air lines routed inside the rail
are not damaged, Failure to do so could cause an inoperable electrical or air system circuit.
WARNING:
Do not drill new holes any closer than 2 inches (50 mm) to existing holes. Frame
drilling affects the strength of the rails.
Hole Location Guidelines
Holes must be located from the flange as indicated in Figure 5-7. They must be no closer than 2 inches (50 mm) 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 5-8
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 mm) thick]
between the frame rail and body frame to protect the top surface of the rail flange.
5-7
Section 5
Frame Layouts and Body
Mounting
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 5-9.
U-Bolt
Body Structure
Wood Sill 0.5” (12mm) Minimum
Truck Frame
U-Bolt Spacer (Hardwood)
Frame Rail Spacer
(Fabricated Steel or
Hardwood)
Figure 5-9. Acceptable U-Bolt Mounting with Wood and Fabricated Spacers
WARNING!
CAUTION:
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 inspect the installation to ensure adequate clearances for air brake lines, fuel lines, and wiring.
See Figure 5–10.
Mount U–bolts so they do not chafe on frame rail. Failure to do so could result in premature wear
of the U-bolt or frame rail.
U-Bolt
Frame Rail
Air Lines and Wiring
Harness
Frame Rail Spacer
(Hardwood or Steel
U-Bolt Spacer
Check Clearance
Space for Air
Lines and Wiring
Figure 5-10. Clearance Space for Air Lines and Cables
5-8
Section 5
Frame Layouts and Body
Mounting
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. Use a hardwood spacer as shown in Figure 5-9.
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 5-11. This provides a firm attaching point and helps prevent any relative fore or aft movement between the
body and frame.
Body Structure
Frame Rail
Figure 5-11 Example of Fishplate Bracket at Rear End of Body, used with U-Bolts
5-9
Section 6
Frame Modifications
FRAME MODIFICATIONS
INTRODUCTION
Peterbilt offers customer specified wheelbases and frame overhangs. So, in most cases frame modifications should not be
necessary.
However, some body 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 modifying the frame cutoff, or as complex as modifying
the wheelbase.
DRILLING RAILS
If frame holes need to be drilled in the rail, see SECTION 4 BODY MOUNTING for more information.
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.
CHANGING WHEELBASE
Changing a chassis’ wheelbase is not recommended. 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.
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.
Before changing the wheelbase, the driveline angles of the proposed
wheelbase need to be examined to ensure no harmful vibrations are
created. Consult with 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 adhere to the guidelines in
the “FRAME DRILLING” section of this manual.
When shortening the wheelbase, the suspension should 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 6-1.
Figure 6-1 Wheelbase Customization
6-1
Section 6
Frame Modifications
CROSSMEMBERS
After lengthening a wheelbase, an additional crossmember may be required to maintain the original frame strength.
Con-tact 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.
FIGURE 6-2. Crossmember Spacing Requirements FRAME MODIFICATIONS Peterbilt Motors Company 6-2
Figure 6-1 Crossmember Added When Distance Exceeds 60 Inches (1524 mm)
6-2
Section 6
Frame Modifications
TORQUE REQUIREMENTS
Torque values apply to fasteners with clean threads, lightly lubricated, with hardened steel washers, and nylon-insert
nuts.
Table 6-1 Customary Grade 8 UNF or UNC
Fastener
Torque
Size
Nm
Lb-Ft
5/16
22-30
16-22
3/8
41-54
30-40
7/16
75-88
55-65
½
109-122
80-90
9/16
156-190
115-140
5/8
224-265
165-195
¾
394-462
290-340
7/8
517-626
380-460
1
952-1129
800-830
1-1/8
1346-1591
990-1170
1-1/14
1877-2217
1380-1630
Table 6-2 U.S. Customary - Grade 8 Metric Class 10.9
Fastener
Torque
Size
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
6-3
Section 7
Electrical
ELECTRICAL Introduction
Through the use of an optional body harness and additional spare circuits, we have reduced the complexity associated with
adding common circuits to a body installation.
Note: The most co mmo n circuits that body builders may need are p r e-connected to this optional wiring
harness.
.
ELECTRICAL C I R C U I T S
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 may cause severe damage. 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.
7-1
Section 7
Electrical
Data Bus Communication
WARNING!
The Data Buss for the communication between electronic control
units must adhere to the guidelines outlined under SAE J1939 documentation. The
Euro 6 LFNA Model has multiple CAN(Controller Area Networks) busses and care
must be taken if an interface is required. Please contact the local Paccar Service
Representative for appropriate assistance and information.
Figure 7-2 Data Bus Communication Architecture
7-2
Section 7
Electrical
Cab/Chassis Interface:
The EJB(Electrical Junction Box)
Location: Firewall(opposite side of steering column)
Figure 7-3.1 Electrical Junction Box Location
Figure 7-2.2 Inside View - Electrical Junction Box Location
EJB Connector Identifiers:
Front View = Front of Vehicle view
Rear View = Passenger Seat view
(see next page for clarity)
7-3
Section 7
Electrical
El
Figure 7-3 LF Euro 6 Cab Interface Names
The EJB contains both 24VDC and 12VDC circuitry for the vehicle. Contact the local Paccar Service Representative for the
appropriate circuitry identification if access to this panel is required.
7-4
Section 7
Electrical
7-5
Section 7
Electrical
Controllers
Figure 7-4 Contollers
The EJB is the electrical load center for the cab. The cab and the associated controllers listed operate on 24VDC. The 12/24 VDC
converter located in the battery box supplies the necessary power requirements.
The ELC(Electronic Lighting Controller) supplies the signals for all the lighting functions(24VDC in cab and roof) and it’s
outputs are used to activate 24VDC relays in the electrical load center mounted in the battery box. These relays in turn control all
the 12VDC exterior lighting.
The VIC(Vehicle Intelligence Center) is the main controller and communicator for the vehicle.
The EBS(Electronic Braking System) is the controller for the EoA(Electric over Air) braking system.
The OBD plug in the image above is the 16-pin style OBD connector typically found in passenger cars. It is 24VDC and is to be
used with the DAVIE Service Tool. Communication with the engine must be done through the 9-pin Diagnostic
connector(12VDC) located in the lower dash between the steering wheel and door aperture.
7-6
Section 7
Electrical
Dash Controls
1 Light switch
2 Instrument panel
3 Speedometer
4 Fuel level and DEF level gauges
5 Warning indicators
6 Master display
7 Warning indicators
8 Air pressure gauge
9 Tachometer
10 Speedometer display
11 Clock, outside temperature and
trip odometer display
12 Warning indicators
13 Gear display
14 N/A
15 Instrument lighting(ON/OFF)
16 N/A
17 N/A
Figure 7-5.1 Dash Contols-1
1 2
3 4 5
1 Instrument lighting dimmer
2 PTO switch (Optional)
3 Hazard lights
4 Air suspension dump switch position (if optioned)
5 Differential lock switch position (if optioned)
6 Diesel particulate filter Regen (DPF)
7 Radio and storage
7
6
Figure 7-5.2 Dash Contols-2
7-7
Section 7
Electrical
Power Distribution Center.
Figure 7.6.1 Pwer Distribution Center
Reference Figure 7.6.2
Pin
4C
4D
4F
4G
4B
3A
3F
3G
3H
3C
3B
Orange
Description
PDC Ground
PDC Ground
ECM Power (12V+)
ECM Power (12V+)
XMSN ECU (12V+)
Black
Heat Fuel Filter (12V+)
PDC Ground
PDC Ground
Converter Ignition
9-pin Diagnostic(12V+)
XMSN Actuator
Pin
1A
1B
1C
1D
1E
1F
1G
1H
12A
12B
12C
12D
12E
12F
12G
12H
Brown
Fog Lamp (12V+)
Fog Lamp Sw (24V+)
Chassis Ignition (12V+)
Ignition Signal (24V+)
NOX up (12V+)
NOX down (12V+)
Body Lamp (24V+)
Body Lamp (12V+)
Green
DCU Power (12V+)
11A
11B
Line heat (12V+)
11C
Starter sol (12V+)
11D
Start Signal (24V+)
11E
Ignition Signal (24V+)
11F
Engine Ignition (12V+)
11G
ECM w/u (12V+)
11H
DCU w/u (12V+)
The voltage converter provides 24V to cab systems. It is located inside the battery box. This voltage converter works with the Power
Distribution Center (PDC) with the following characteristics:
12V Input – 24V output
Input Current: 80 Amps
Output Current: 40
Amps
Temperature range: -40C to +85C
2C
2D
2E
2F
Red
Stop Lamp (12V+)
Stop Lamp (24V+)
Clearance (24V+)
Clearance (12V+)
Grey
Description
DIP HL (12V+)
DIP HL (24V+)
LH Turn (12V+)
LH Turn (24V+)
RH Turn (24V+)
RH Turn (12V+)
Main HL (24V+)
Main HL (12V+)
7-8
Section 7
Electrical
The output voltage from cab to chassis is 24V. The spare circuits in the PDC located in the battery box as described in
Table 7-1 are 12V.
Spare Circuit Powered
Through:
Minimum
Wire
Gauge
Pin
A
Pin
B
Circuit
PDC
Terminal
Capacity (Fuse
number/Amperes).
Install a fuse of
appropriate rating.
Numbered connector Location PDC
at battery box.
Spare 1
Spare 2
16
16
RG7
RG7
RH7
RH7
2B
2G
F20/10Amp
F20/10Amp
Red Connector (B068-7099-F)
Red Connector (B068-7099-F)
Table 7-1 Additional Spare Circuits for Wiring
On Power Distribution Center (chassis).
Figure 7-6.2 Power Distribution Center( Chassis)
7-9
Section 7
Electrical
Body Builder 9 pin connector
Figure 7-7 Body Builder 9 Pin Connector
The connector shown above is available for exterior lighting functions in addition to lighting circuits at the end of frame.
Table 7-2 Body Builder 9 Pin Connector
WIRE
DESCRIPTION
GND
Stop LP
FUNCTION
Ground
Stop lamp
Not Connected
Not Connected
Tails/Marker LP Tails / markers lamps
Turn RH rear
Turn signal right hand rear
Backup LP
Backup lamp
Turn LH rear
Turn signal left hand rear
Markers LP
Markers lamps
PIN
R
S
T
U
V
W
X
Y
Z
CIRCUIT
WHT2400
YEL2601
YEL2422
YEL2007
YEL2960
YEL2006
YEL2412
7-10
WIRE
COLOR
CAPACITY FUSE
(AMPERES
NUMBER)
White
Yellow
F18 / 25A
Not Connected
Not Connected
Yellow
F19 / 20A
Yellow
F15 / 15A
Yellow
TCU Relay
Yellow
F14 / 15A
Yellow
F19 / 20A
WIRE
GAUGE
6
8
12
12
12
12
12
Section 7
Electrical
Model 220 PTO Wiring Information
Wiring of the Current Model 220 is different from previous version of the Model 220. Please see the information below for basic
wiring and functionality.
1) If equipped, the factory PTO dash switch will tell the VIC to go to PTO mode.
2) J124 connector on the transmission needs 12V to tell the Allison TCM to enable PTO mode.
3) J125 connector on the transmission is a ground output signal from the Allison TCM for the PTO.
4) J126 connector on the transmission is a 24V output signal from the VIC when the PTO dash switch is on.
5) J128 connector on the transmission needs a ground to feedback to the VIC for PTO engaged status (must occur within 3-4
seconds after PTO switch). Option 1: Provide a ground from the PTO engaged switch to J128. Option 2: J128 & J125 can be
spliced together for the feedback ground to the VIC. Please note: J128 & J125 will not mate together, so connectors will have to
be cut off and spliced.
6) Pin 10 of the 12-pin Remote PTO connector (P124) on the engine harness –OR- pin B of the 3-pin connector (J144) on the
engine harness needs a ground to feedback to the VIC for PTO engaged status. This performs the same function as item 5 above.
This is primarily used for remote set-ups outside the cab.
As an example for setting up a PTO if using the factory PTO dash switch and one pre-set RPM:
(Refer Figure 7.9)
A) Use J126 to drive your PTO solenoid. This is 24V, so you may need to use a relay if the PTO requires 12V or a ground.
B) Send 12V to connector J124 for the Allison TCM when the PTO is engaged. This 12V can be “borrowed” from the relay used in
step A) above.
C) Provide a ground to J128 for feedback to the VIC when the PTO is engaged. This can be done by either splicing J125 & J128
together or by running a separate wire from the switch directly on the PTO (if equipped) to J128. This ground must be applied
within 3-4 seconds after the PTO switch is enabled.
D) Set your desired engine RPM for pre-set speed with DAVIE. This is found under Customer Parameters.
Please note: This information relates only to setting up the mechanical PTO for operation. This does not address the additional
function of ESC (Engine Speed Control), as this is a separate function. Engine Speed Control must be enabled in the VIC
programming and requires a modified PRS file. Instructions for use of ESC follow.
Engine Speed Control (ESC)
ESC can be fixed (pre-programmed) engine speed or variable engine speed. The Euro 6 only has two pre-programmed engine
speeds N2 and N3. N VAR is available using the “SET+” and “SET-“ to increase and decrease speed.
To activate these speeds the ESC must first be enabled by providing a high signal (12-24V) on pin 12 of the 12-pin connector on the
engine harness (P124).
•
•
The N2 and N3 can then be activated by providing a high signal on pins 7 and 6 respectively of the 12-pin
connector on the engine harness (P124).
N VAR can be activated by providing a high signal on pin 8 of the 12-pin connector on the engine harness (P124).
(N refers to a Speed Set point)
If N VAR variable control is desired with the steering wheel switches:
•
•
•
•
A high signal (12-24V) is provided to pin 12 of the 12pin connector on the engine harness (P124).
A high signal is provided to pin 8 of the 12pin connector (P124).
Use the “SET+” and “SET-“steering wheel switches to bump the throttle up and down.
The parking brake must be set for proper functionality.
7-11
Section 7
Electrical
Figure 7-8.1 Typical PTO Wiring for Euro 6 LFNA – 12V PTO Solenoid
7-12
Section 7
Electrical
Figure 7-8.2 Typical PTO Wiring for Euro 6 LFNA – 24V PTO Solenoid
7-13
Section 7
Electrical
Remote PTO / Throttle Harness
This option provides a connection from the engine ECU to the end of the frame to fit the engine throttle remote control and
PTOs. Controls are not provided. A 12-pin Deutsch connector (Deutsch P/N DT06-12SA-P012) is included.
Adding Electrical Options
WARNING!
Follow the engine manufacturer’s guidelines for use of these circuits. See your engine manufacturer to verify that the engine is
programmed correctly for the intended applications. Failure to properly program the engine or wire these circuits could cause an
accident.
Figure 7-9 A 12-pin Deutsch connector and remote PTO Control
7-14
Appendix A
Vehicle Identification
VEHICLE IDENTIFICATION NUMBER
A 17–character number (numeral and letter combination) forms the Vehicle Identification Number (VIN) which includes the
Chassis Number. It contains among other information, the model year (4), assembly plant (5), and vehicle serial number (6).
See Figure A–1
M
Serial Number
Chassis Number
Figure A-1. Vehicle Identification Number (VIN).
The model year (4) is designated by an alphanumeric code in the tenth character position in the VIN. See Table A-1 and
Figure A–1.
Code
C
D
E
F
G
H
Year
2012
2013
2014
2015
2016
2017
Table A-1. Model Year (Code) Designations.
VIN Location
The VIN is marked on the Incomplete Vehicle Certification Label (on trucks). It is located either on the driver’s door edge or
door frame. See Figure A–2.
Chassis Number Locations
The Chassis Number comprises the last six characters of the VIN.
•
•
•
•
•
•
The Model 220 chassis number is shown in multiple locations.
Right frame rail, bottom flange (underside), about 4 to 4.5 ft. from the front end: stamped.
Left frame rail, top of flange, about 4 to 4.5 feet from front end: stamped
Tire, Rim, and Weight Rating Data label.
Major Components and Weights label.
Paint Identification label.
A-1
Appendix A
Vehicle Identification
CERTIFICATION LABELS
Components and Weights Label
The Major Components and Weights Label is located on either the driver’s side door edge or on the door frame. See Figure A–2. It includes: chassis weight and gross weight; plus, model and serial numbers for the vehicle, engine, transmission, and axles.
Final Stage Manufacturer
Label to be Installed by
Final Stage Manufacturer
Tire, Rim and
Weight Rating
Data label
Chassis Serial
Number
Major Components and
Weights Label
Safety Mark (Canadian
Registry Only)
Incomplete Vehicle
Certification Label
Figure A-2. Locations of
Certification Labels - Driver’s Door
Figure A-2. Drivers Door and Door Frame Label
Tire/Rim and Weight Rating Data Label
The Tire/Rim and Weight Rating Data Label is located on the driver’s side door edge, above the door latch. See Figure
A–2. It contains the following information:
•
•
•
•
Note:
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
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 is located on the driver’s side door edge below the latch. See Figure A–
2. It contains the following information:
•
•
•
DATE OF MANUFACTURE
VIN — Vehicle Identification Number
LISTING OF APPLICABLE FEDERAL MOTOR VEHICLE SAFETY STANDARDS
A-2
Appendix A
Vehicle Identification
COMPONENT IDENTIFICATION
Each of the following components has their own identification label.
Engine Identification
The engine dataplate provides important facts about the engine. The engine serial number (ESN) and control parts list (CPL)
provide information for service and ordering parts. The engine dataplate must not be changed unless approved by PACCAR Inc.
The dataplate is located on rocker lever cover as illustrated.
Have the following engine data available when communicating with a PACCAR Authorized
Repair Location:
1.
2.
3.
4.
5.
Engine Serial Number (ESN)
Engine model information
Control Parts List (CPL)
Valve Lash
Horsepower and rpm rating
If the engine dataplate (1) is not readable, the ESN (2) can
be found on the engine block on top of the lubricating oil cooler housing. Additional engine information is on
the electronic control module (ECM) dataplate.
1.
2.
Dataplate
ESN
Figure A-3 Engine Identification Location
A-3
Appendix A
Vehicle Identification
Transmission Identification
The transmission identification number is stamped on a tag affixed to the right forward side of the transmission case. It
includes, among other specifications, the transmission model, serial and part number.
Front Axle Identification
The front axle has an identification tag located on the front axle beam. It includes the axle model, part number and serial
number.
Figure A-4 Front Axle Identification
Rear Axle Identification
The rear axle identification numbering system includes two labels or stamps.
1. Axle Housing Number Tag, located on the left forward side of the housing arm. This tag identifies the axle housing.
2. 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., Carrier Production Assembly No.,
Carrier Assembly Serial No., Gear Ratio, Axle Specifications Number and OEM part number and country
of origin.
2
1
Figure A-5 Rear Axle Identification 1
Note: Illustrated identification tag locations are typical. Actual locations may vary by axle manufacturer and with
single versus tandem axles.
A-4
Appendix B
Weight Distribution
INTRODUCTION
In the Medium Duty truck market, matching the wheelbase to the body specification is extremely important. Selection of the wrong wheelbase may lead to premature component failure, poor performance, and ultimately a
dissatisfied customer. Before selecting the proper wheelbase, it is important to have a basic understanding of
weight distribution.
Abbreviations
Throughout this section, abbreviations are used to describe certain features and requirements of the vehicle
(see the list below). Review this list frequently so you know what the abbreviations mean.
AF
BL
CA
Note:
=
=
=
The Model 220 CA figures are measured from the true back of cab to the centerline of the rear
axle. To obtain a usable CA the body builder must subtract any required space behind the cab,
which may be needed for other equipment.
CG
=
CGf
=
FA
=
GVWR =
L
=
Lf
Lr
RA
WB
Frame rail overhang length – behind the rear axle
Body Length
Back of cab to centerline of rear axle
=
=
=
=
Center of gravity: the balance point or center of a load. It is usually identified by a circle
with alternating black and white quarters.
Distance from the centerline of the front axle to the center of gravity of the load (L). The
load can be any load such as a fuel tank, a body, or the payload.
Front Axle
Gross Vehicle Weight Rating
Load: the weight that is carried. This could be the body, the payload or any item that has its
weight distributed between the two axles.
Portion of load (L) carried by front axle
Portion of load (L) carried by rear axle
Rear Axle
Wheelbase Length
B-1
Appendix B
Weight Distribution
CALCULATIONS
Weight Distribution without Body
There are two primary equations used in weight distribution calculations:
•
The first equation determines the portion of the load carried by the rear axle (Lr).
CGf
Lr = WB X L
Portion of Load Carried by the Rear Axle
Equation 1
•
The second determines the portion of the load carried by the front axle (Lf).
Lf =
Note:
L - Lr
Portion of Load Carried by the Front Axle Equation 2
For the purposes of calculation, the load (L) in these equations can be either actual revenue
producing load or it can be other weight that is carried such as the van body or an optional fuel
tank.
100 lbs
Front Axle
100 In.
214 In.
Figure B-1. Balanced Load: CGf 100 in. from front axle
Step 1. Figures B–1 and
B–2 show a representation of a 214 inch (5435.6 mm) wheelbase (WB) truck designed to carry a 100–lb. (45.3–kg) load. Figure B–1 represents a truck with the load placed an equal distance
between the two axles.
a.
For our balanced load example we need to establish the center of gravity location (CGf, as
shown in Figure B–1) by dividing the wheelbase by 2:
CGf =
b.
214
2
= 107 in (2717.8 mm)
Use equations 1 and 2 to determine the portions of the load carried by each axle.
•
The weight distribution is calculated as illustrated below:
CGf
107
Lr =
X
L
WB
214 (100) = 50 lbs (23 kg)
Lf =
•
L - Lr
100 - 50 = 50 lbs (23 kg)
Since the load is centered between both axles, 50 percent of the load is carried by each
axle: i.e., 50 lb. (22.6 kg) is distributed to each axle.
B-2
Appendix B
Weight Distribution
C.
In Figure B–2, the load (L) is located 133 in. (3378 mm) from the front axle. Moving the load
towards the rear axle changes the weight distribution. Use equations 1 and 2 to determine the
portion of the load carried by each axle.
100 lbs
Front Axle
133 In.
214 In.
Figure B-2. Unbalanced Load: CGf 133 In. From Front Axle
CGf
=
Lr =
CGf
WB
Lf =
L - Lr
•
133 in. (3378 mm)
XL
133
214 (100) = 62.14 lbs (28.18 kg)
100 – 62.14 = 38.86 lbs (17.6 kg)
The rear axle now carries a greater proportion
of the load than the front axle.
Although it is usually not important to know the CG of the chassis; it is important to know the CG location of truck
bodies, accessories, or loads that may be placed on the chassis. This example shows that the location of the CG
of an object relative to the front and rear axles (FA and RA) affects the load carried by each axle.
For most relatively uniform objects such as van bodies and fuel tanks, the CG is located close to the midpoint of
the object. For non–uniform objects such as liftgates and refrigeration units, obtain the CG from the equipment
manufacturer.
B-3
Appendix B
Weight Distribution
Weight Distribution with Body
Chassis Weights
Step 2. In the following example, a truck is modified to include a van body mounted to the chassis. This example is a
chassis, 214 inches (5435.6 mm) in WB, with a standard drivetrain and fuel tank. It is a 26,000 lb. GVWR with a 8,948 lb.
front axle and a 17,052 lb. rear axle.
When calculating weight distributions, start by determining chassis ground weights for each axle. The actual chassis
weight will vary with the wheelbase and the options installed. Listed in Tables B-1 and B-2 are the chassis tare weights
for the standard single rear axle vehicles and each wheelbase configuration.
We see that the 214-inch wheelbase, 2-axle has the following tare weights:
FA = 6263.4
RA = 9628.7
Model 220 with nominal weights and CGs. See your Peterbilt Dealer for more exact weights and CGs. It also lists
their added weight when installed on the chassis and the location (from the front axle) of the CG of this added
weight.
Wheelbase
Inches
214
Front
lb (kg)
6263.4 (2,841)
Rear
Total
lb (kg)
9628.7
(4367.5)
lb (kg)
15892.1 (7,208.5)
Table B-1 Model 220 Single Rear Axle “Bare” Chassis Tare Weights (no driver, no fuel)
Note:
The weight in Table B-1 represents an example of a standard chassis
B-4
Appendix B
Weight Distribution
Now we will calculate the distributed weight of van body that weighs 4825 pounds (2188.5 kg). Since an empty
van is very close to a uniform object, you can assume that the CG of the van body is at a point equal to half of the
BL.
Figure B-3. Balanced Body Unloaded: CGf 184.7 in. (4691.45 mm) from front axle.
When the body is mounted on the chassis, assume that the forward edge is positioned 4 inches (102 mm) behind the back of the cab. This is equivalent to 17. 3 i n c h e s ( 4 3 9 . 4 mm) behind the front axle. Therefore, the
CG of the body is located 72 inches plus half the body length from the front axle.
Use Equations 1 and 2 to calculate the distributed additional weight of the body:
Lr =
CGf
WB
Lf =
L - Lr
XL
184.7
214 (4825) = 4164.4 lbs (1888.9 kg)
4825 – 4164.4 = 660.5 lbs (299.6 kg)
Adding a liftgate to the van body will present some interesting weight distribution results. We will add a 1455
pound (659.9 kg) liftgate to the end of the van body. The CG location of non-uniform objects, such as a liftgate,
must be provided by the equipment manufacturer. For our example, the liftgate manufacturer has provided i n stallation information that indicates the liftgate CGf is located 322.2 in (8183.9 mm) behind the front axle.
Rear Liftgate Example
Figure B-4. Liftgate Example: CGf 322.2 in (8183.9 mm) from front axle.
B-5
Appendix B
Weight Distribution
Use CGf = 246 in equations 1 and 2 to determine how the liftgate weight is distributed to the axles.
Lr =
Lf =
CGf
WB
322.2
XL
L - Lr
214
X 1455 = 2190.6 lbs (993.6 kg)
1455 - 2190.6 = -735.6 lbs (-333.6 kg)
This negative weight on the front axle illustrates the difference between the distribution of weight (L) mounted
behind the rear axle versus in front of the rear axle.
•
The load carried by the rear axle is greater than the weight of the liftgate itself. Since the weight of
the liftgate (added to the vehicle) cannot be greater than 1,455 lb, the front axle loading is reduced
by a compensating amount (735.6 lb). The combined weight on the front and rear axles is equal to
that of the liftgate.
•
Weight added behind the rear axle has the effect of unloading the front axle. The amount of this
front axle load reduction is equal to the “extra” weight added to the rear axle.
•
By positioning equipment behind the rear axle, the effective load on the rear axle is more than the
weight of the equipment.
•
The farther behind the rear axle the load is mounted, the greater the load on the rear axle. However,
the combined weight, distributed to the front and rear axles (Lf plus Lr), does not exceed the weight
of the liftgate.
In order to get a realistic curb weight, we add weight for a driver and fuel. For purposes of calculation, we use a
standard of 200 lbs. (91 kg) for the driver. Of course, your driver weight will vary.
Using CGf = 10 in equations 1 and 2:
Lr =
CGf
WB
Lf =
L - Lr
XL
10
214
(200) = 9.34 lbs (4.2 kg)
200 - 9.34 = 190.6 lbs (86.4 kg)
We calculate the fuel load using 7 lbs per gallon as the weight for diesel fuel.
45 gal x (7 lbs/gal) = 315 lbs (142.8 kg)
Using CGf=73.9 and equations 1 and 2 for the standard tank:
Lr =
Lf =
CGf
WB
73.9
XL
L - Lr
214
(315) = 108.7 lbs (49.3 kg)
315 – 108.7 = 206.2 lbs (93.53 kg)
Appendix B W
B-6
Appendix B
Weight Distribution
Model 220 sample, Assume that the payload is evenly distributed. Freight that is distributed evenly is referred to as
a “water level” load. Our payload total is 14,500 lb. Since it is an evenly distributed “water level” load, its CG location will be the same as the CG location of the van body. See Figure B–5.
CGf =
1
1 BL + 72
2
(168) + 72 = 156 in.
2
Using CGf = 156 in equations 1 and 2:
Lr =
CGf
WB
Lf =
L - Lr
156
XL
214
(14,500) = 10,570 lbs (4794.5 kg)
14,500 – 10,570 = 3,929.9 lbs (1782.5 kg)
Figure B-5. Balanced Body Loaded: CGf 184.7 in (4691.45 mm) from front axle.
Item
Front Axle
(FA) lb (kg)
Chassis
Fuel 45 Gal Std, Tank
Tare Weight
Liftgate
Van Body
Driver
Curb Weight
Payload
Total Ground Weight
Chassis Axle Ratings
6845.3
206.2
7051.5
-735.6
660.7
190.65
7167.25
3929.9
11097.15
12000
Rear Axle
(RA) lb (kg)
3104.98
93.5307
3198.51
-333.66
299.688
86.4774
3251.01
1782.57
5033.58
5443.11
3439.2
108.7
3547.9
2490.6
4164.3
9.34
10212.14
10570
20782.14
21000
1559.995
49.30549
1609.3
1129.717
1888.895
4.236553
4632.149
4794.471
9426.62
9525.44
Total lb (kg)
10284.5
314.9
10599.4
1755
4825
199.99
17379.39
14499.9
31879.29
33000
4664.971
142.8362
4807.807
796.0546
2188.583
90.71394
7883.159
6577.044
14460.2
14968.55
Table B-2 Model 220 Weight Distribution and Chassis Rating Calculation (sample)
B-7
Appendix B
Weight Distribution
Weight Distribution Analysis
Step 3. The
final step is to total all of the front and rear axle weights to ensure that the axles are not overloaded. Table B-4 shows the assembled information in an easy to read format.
•
Compare the calculated axle ground totals against the axle weight ratings to be sure that the truck is
properly specified to haul this load.
•
From this, it is evident that the chassis is properly equipped for this job.
These calculations illustrate the importance of doing the weight distribution analysis. In some cases the addition of one component (for example, a liftgate) can produce a dramatic difference.
Body Length
Step 4. Your analysis may produce results that indicate an overloaded axle with a total loaded chassis weight
less than the GVW. This shows that you need to use a different body length for the truck. Each wheelbase
can accommodate several different body lengths. However, for each wheelbase and GVW one particular body
length will provide close to optimum weight distribution on both axles.
a.
Table B-3 lists Recommended Body Lengths for a particular wheelbase and
GVW. These body lengths provide the best weight distribution for the listed wheelbase.
Note:
These charts were generated assuming a plain van body with “water level”
loading. Any common additions such as lift gates or refrigeration units may
indicate a different wheelbase for a given body length. Also, different body
styles may require a different WB for a given size.
B-8
Appendix B
Weight Distribution
Table B-3 Available Model 220 Body Lengths
Wheelbase In. (mm)
142 (3606.8)
146 (3708.4)
154 (3911.6)
158 (4013.2)
166 (4216.4)
170 (4318)
178 (4521)
182 (4622.8)
190 (4826)
194 (4927.6)
202 (5130.8)
206 (5232.4)
214 (5435.6)
218 (5537.2)
226 (5740.4)
230 (5842)
238 (6045.2)
242 (6146.8)
Body Length (Ft)
33,000 GVW
26,000 GVW
16
16
17
17
18
18
20
20
22
22
24
24
26
26
27
27
28
28
*For trucks built before and including 6/22/2012
•
Remember that water level loading assumes that the load is arranged evenly in the body (as
water would be in a tank). If uneven load distribution is part of the vehicle layout, your weight
distribution analysis may indicate that a different body length, deviating from the recommended
length, will provide the best weight distribution.
Note: You should always perform
a weight distribution analysis to help ensure the vehicle performs
properly and meets your customer’s expectations.
B-9
Index
A
Abbreviations
vi
B
Body mount, rear
Body mounting
Body mounting with U-bolts
Brackets, body mounting
5-9
5-1
5-7
5-5
Frame, welding
Front axle serial number
Front View
Fuel tank locations
6-2
A-4
3-7
3-17
G
Ground clearance
3-8
I
Incomplete vehicle certification
Incomplete Vehicle Certification Label
2-2
A-2
M
Mounting holes, frame
5-6
N
Noise Requirements
Notes
2-3
2-1
O
Operating information
Options weights
1-1
B-4
C
Calculations
Cautions
Certification label
Chassis maintenance
Chassis Number
Chassis weight
Cab/Chassis Interface
Clearance, air lines and wiring
Critical clearances
Crossmember location
Crossmembers
B-2
2-1
a-2
1-1
A-1
B-4
7-3
5-8
5-4
3-14
6-2
D
Dimensions
Dimensions, air tanks
Dimensions, battery box
Dimensions, crew cab, conversion
Dimensions, overall
3-1
3-12
3-12
3-11
3-4
R
Rear axle identification
Rear suspension, changing
Rear View
Remote PTO/throttle harness
Repair information
A-4
6-1
3-7
7-14
1-1
E
Electrical circuits
Emissions requirements
Engine serial number
7-1
2-3
A-3
F
Federal Motor Vehicle Safety Standards
Final stage manufacturer
Fishplate bracket
Frame, drilling
2-2
2-2
5-9
5-7
S
Safety signals
Scope
Sill spacer
Spare Circuits
Step height
2-1
1-1
5-5
7-1
3-10
T
Transmission identification
Turning radius
A-4
3-2
V
Vehicle Identification Number
W
Warnings
Water level load
Weight distribution
Weight distribution analysis
Wheelbase, changing
A-1
2-1
B-9
B-1
B-8
6-1
A PACCAR COMPANY
Peterbilt Motors Company
P.O. Box 90208
Denton, Texas 76202
(800) FOR-PETERBILT
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