Peterbilt 220 Service Manual
2017 Body Builder Manual
Body Builder’s Manual
Contents
Figures .................................................................................................................................................................................................................................................................... iii
Tables ....................................................................................................................................................................................................................................................................... v
Abbreviations....................................................................................................................................................................................................................................................... vi
Section 1 Introduction
Section 2Safety&Compliance
SAFETY SIGNALS 2-1
FEDERAL MOTOR VEHICLE SAFETY STANDARDS COMPLIANCE 2-2
Incomplete Vehicle Certification ........................................................................................... 2-2
Noise and Emissions Requirements ...................................................................................... 2-3
Section 3 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
Section 4Exhaust & 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
Section 5 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
Section 6 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
Section7 Electrical
ELECTRICAL INTRODUCTION .................................................................................................................. 7-1
ELECTRICAL CIRCUITS .............................................................................................................................. 7-1
Capacity........................................................................................................................................... .7-1
Data Bus Communication ............................................................................................................... 7-2
CAB/CHASSIS INTERFACE
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
7-3
Body Builder’s Manual
Contents
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
Figure 4-6.2 Top view of Horizontal
Figure 4-6.3 Right view of Horizontal
Figure 4-6.4 Back view of Horizontal
Figure 4-7.1 Vertical
Figure 4-7.2 Top view of Vertical
Figure 4-7.3 Right view of Vertical
Figure 4-7.4 Back view of Vertical
iii
Exhaust Canister
Exhaust Canister
with Horizontal Tailpipe ....................................................................... 4-6
Exhaust Canister
Exhaust Canister
Exhaust Canister
with Horizontal Tailpipe ............................................................................ 4-8
Exhaust Canister
Exhaust Canister
Exhaust Canister
with Horizontal Tailpipe .................................................... 4-6
with Horizontal Tailpipe ................................................. 4-7
with Horizontal Tailpipe ................................................. 4-7
with Horizontal Tailpipe ........................................................ 4-8
with Horizontal Tailpipe ...................................................... 4-9
with Horizontal Tailpipe ...................................................... 4-9
Figures
Figure 5-1.1 Horizontal
BOC rectangular DEF tank and RH BOC battery box ........................................................................ 5-2
Figure 5-1.2 Horizontal
LH BOC rectangular DEF tank and RH BOC battery box .................................................................. 5-2
Figure 5-1.3 Vertical
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
Exhaust Canister
Exhaust Canister
Exhaust Canister
, RH horizontal tailpipe, LH BOC rectangular fuel tank, LH
, RH horizontal tailpipe, Duel BOC rectangular fuel tank,
, BOC Vertical tailpipe, LH BOC rectangular fuel tank, LH
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
AF
BFA
BOC BACK OF CAB
CA
CA
CBOC CLEAR BACK OF CAB
CGF CENTER GRAVITY OF LOAD FROM FRONT AXLE
CH
CLA CENTER LINE OF AXLE
CRP CLEAR RAIL PACKAGE
DEF DIESEL EXHAUST FLUID
DSOC DUAL SIDE OF CAB
EFF CA USEABLE CARGO AREA
EOF
FAX
FOC FRONT OF CAB
FOR FRONT OF RAIL
HA
AXLE TO END
FRAME RAIL OVERHANG LENGTH BEHIND REAR
FRONT BUMPER TO FRONT AXLE LENGTH
BACK OF CAB TO REAR AXLE LENGTH/CARGO AREA
CAB TO AXLE
CAB HEIGHT
END OF FRAME
FRONT AXLE
HEIGHT AXLE
L LOAD
LF LOAD FRONT
LHUC LEFT HAND UNDER CAB
LR LOAD REAR
OAL
R ROOF
RHUC RIGHT HAND UNDER CAB
SLR STATIC LOAD RADIUS
SOC SIDE OF CAB
TL
TOC TOP OF CLAMP
TOLC TOP OF LOWER CLAMP
TOR TOP OF RAIL
WB
OVERALL VEHICLE LENGTH
TOTAL LENGTH
WHEELBASE LENGTH
vi
Abbreviations
ACH-W AUXILIARY CAB HEATER WEBASTO
AEBS ADVANCED EMERGENCY BRELECTRONIC BRAKING SYSTEMAKING SYSTEM
AGC-A AUTOMATIC GEARBOX CONTROL ALLISON
ALS-S ALARM SYSTEM SCORPION
ASTRONIC LITE AUTOMATED GEARBOX CONTROL ZF
ASTE-MODULE ASTRONIC SELECTOR ECU
ASTMULTI-SPEED AUTOMATED 12-SPEED GEARBOX
AXM-F/AXM-R AXLE MODULATOR – FRONT/REAR
BBM BODYBUILDER MODULE
CDS-4 CENTRAL DOOR LOCKING
DIP-5 DIGITAL INSTRUMENT PACK
DNR DRIVE NEUTRAL REVERSE SWITCH
DTCO DIGITAL TECHNOGRAPH
E-MODULE AUTOMATED GEAR SELECTOR ZF
EAS 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 STEERING ANGLE SENSOR
SWA STEERING WHEEL SWITCHES
TI-2 TELEPHONE INTERFACE
VIC3 VEHICLE INTELLIGENCE CENTRE 3
VGT VARIABLE GEOMETRY TURBOCHARGER
VSC VEHICLE STABILITY CONTROL
SMART AIR CONTROL
vii
1-1
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.
2-1
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 spe cial attention to
comments prefaced by “WARNING”, “CAUTION”, and “ NOTE.” Please do not ignore a n y of these alerts.
Warnings, Cautions, and Notes
WARNING:
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.
When you see this word and s ymbo l , the message that follows is especially vital. It signals
a
potentially hazardous situation which, i f 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.
CAUTION:
Example:
CAUTION: Never use a torch to make a hole in the rail. Use the appropriate drill bit.
Signals a potentially hazardous situation which, if not avoided, could res u lt in minor
or moderate injury or damage to the v e h i c l e .
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 fu el 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 hazardo u s situation which, if not avoided, could result in minor or moderate
injury or damage to the vehic le.
NOTE
Useful information that is related to the topic being discussed.
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:
Figure 2-1. Incomplete Vehicle Certification
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
Or contact:
Transport Canada
Tower C, Place de Ville, 330 Sparks Street Ottawa,
Ontario K1A 0N5
(613) 990-2309
TTY: 1-888-675-6863
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.
Tire, Rim and
Weight Rating
Data label
Safety Mark (Canadian
Registry Only)
Incomplete Vehicle
Document
Certification Label
and
http://www.tc.gc.ca/eng/acts-regulations/menu.htm
- Driver’s Door and Frame
U.S. EPA Noise Label (U.S. registered vehicles only)
Figure 2-2. Locations of Certification Labels
Final Stage Manufacturer
Label to be Installed by
Final Stage Manufacturer
Chassis Serial
Number
Major Components and
Weights Label
or the regulations.
2-2
Section 2
Safety & Compliance
Noise and Emissions Requirements
NOTE:
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.
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 De-rated
Frame
Front Suspension
Laden 5.9” 5.9”
Rear Suspension
Unladen 8.5” 8.5”
Laden 8.3” 8.3”
79KB 21,000#
Unladen 9.18” 9.18”
Laden 6.75” 6.75”
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 22.5 G 25.8” 19.5” 35,710
10 ¼ inches 10 ¼ inches
Rating 12K 10K
Unladen
HAS 210/230
8.1” 8.1”
3-1
mm ft m ft m
206 5232.4
26.01
7.9 32.01
9.8
Section 3
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
Dimensions
Rear
Axles
Single
Wheelbase Range
Inch
121 3073.4 17.5 5.3 23.5 7.2
142 3606.8 18.4 5.6 24.4 7.5
146
156
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
3708.4 19.40 5.9 25.40 7.7
35162.4
Curb to Curb Est. Radius
20.1 6.1 26.1 4.0
Wall to Wall Radius Est.
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
Figure 3-1.1 Side View —Model 220 W/19.5 Tires Cab Tilt Height and Pivot
location Measurement
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)
Model 220 W/22.5 Tires
Behind CAB
Above FOF
Figure 3-1.2 Side View —Model 220 W/22.5 Tires Cab Tilt Height and Pivot
location Measurement
Table 3-4 Cab Pivot location
WL
CTR-CTR 978MM
Pivot location
44.5MM
209MM
3-3
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
Side View -
Model 220
Table 3-5 Overall Dimensions
Section 3
Dimensions
FAX to Back
Model
Wheelbase
(in)
FAX to
BOC
(in)
of Intake /
FAX to Back
of Exhaust
for 220**
(in)
146 11 25.3 120.7 72 192.7 16
158 11 25.3 132.7 72 204.7 17
164 11 25.3 138.7 72 210.7 18
168 11 25.3 142.7 72 214.7 18
170 11 25.3 144.7 72 216.7 18
220
Horizontal
Exhaust
178 11 25.3 152.7 88 240.7 18
182 11 25.3 156.7 84 240.7 20
194 11 25.3 168.7 96 264.7 22
206 11 25.3 180.7 108 288.7 24
218 11 25.3 192.7 120 312.7 26
230 11 25.3 204.7
242 11 25.3 216.7
274 11 25.3 248.7
121 11 31.3 89.7 72 155 10
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
220**
Vertical
Exhaust
*With 5 inch spacer.
142 11
146 11
156 11
158 11
164 11
168 11
170 11
178 11
182 11
194 11
206 11
218 11
230 11
242 11
274 11
Body
Builder
Useable
CA*
Overhang
(in)
Cab to
EOF
(in)
Recommended
Body Length (ft)
(in)
132
144
160
336.7
360.7
408.7
110.6 72 176 13
114.6 72 180 14
124.6 72 190 15
126.6 72 192 15
132.6 72 198 16
136.6 72 202 16
138.6 72 204 16
146.6 88 228 18
150.6 84 228 18
162.6 96 252 20
174.6 108 276 22
186.6 120 300 24
198.6 132 324 26
210.6 144 348 27
242.6 160 396 30
28
30
34
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
Front and Rear Views — Model 220
Inches (mm)
Section 3
)
Dimensions
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
275/22.5 17.6 7.7
295/22.5 18.8 8.9
11R/22.5 19.5 9.6
RADIATOR
GROUND
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 clearance W/19.5 Tire
TIRE SIZE SLR
TIRE SIZE SLR
245/19.5 15.5 7.5
245/19.5 15.5 7.5
265/19.5 15.9 7.9
265/19.5 15.9 7.9
RADIATOR
GROUND
RADIATOR
GROUND
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
Position
A
FUEL SUPPORT STEP
B
FIRST STEP
C
SECOND STEP
D
CAB FLOOR
Model 220 19.5 Tires
Unladen Laden
In
mm
10.5 269
16.6 421
27.2
690
38.6 977
In
7.5
13.2
23.8
35.2
mm
191
336
605
894
3-10
LOADED
inches
(mm)
*
UNLOADED
inches
(mm)
Front
Axle
Rear
Axle
Front
Axle
Rear
Axle
Section 3
3 Dimensions
Detail Views
Left side: Chassis Heights – Model220
3ions
ction
Dimensions
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
A
FUEL SUPPORT
B
FIRST STEP
C
SECOND STEP
D
CAB FLOOR
Table 3-8 Floor to Top of Frame Measurements
Frame Heights
Model 220 W/19.5
(15.6 SLR)
*Unladen Laden
In
15.8 401 14.3 363
18.4
32.7 830 31.2 794
41.4
31 (787) 32.5(825) 36 .1(916) 35.6 (905)
mm
In
467
16.9
1051
39.9
mm
430
1013
*
Unloaded Dimensions are estimated.
Model 220
W/ 11R-22.5
(19.4 SLR)
34.8 (884) 36.3 (922) 39.1(992) 38.6(980)
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
3 Dimensions
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
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