Peterbilt 220 2017 User Manual
Model: 220
AUGUST 2014 FORWARD
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
DPF & SCR 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
Section7 Electrical
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 Crossover DPF and SCR with Horizontal Tailpipe ......................................................... 4-6
Figure 4-6.2 Top view of Horizontal Crossover DPF and SCR with Horizontal Tailpipe ..................................... 4-6
Figure 4-6.3 Right view of Horizontal Crossover DPF and SCR with Horizontal Tailpipe ................................... 4-7
Figure 4-6.4 Back view of Horizontal Crossover DPF and SCR with Horizontal Tailpipe ................................... 4-7
Figure 4-7.1 Vertical Crossover DPF and SCR with Horizontal Tailpipe .............................................................. 4-8
Figure 4-7.2 Top view of Vertical Crossover DPF and SCR with Horizontal Tailpipe ......................................... 4-8
Figure 4-7.3 Right view of Vertical Crossover DPF and SCR with Horizontal Tailpipe ....................................... 4-9
Figure 4-7.4 Back view of Vertical Crossover DPF and SCR with Horizontal Tailpipe ....................................... 4-9
III
Figures
Figure 5-1.1 Horizontal Crossover DPF/SCR, LH horizontal tailpipe, RH BOC rectangular fuel tank, RH
BOC rectangular DEF tank and LH BOC battery box ........................................................................ 5-2
Figure 5-1.2 Horizontal Crossover DPF/SCR, LH horizontal tailpipe, RH BOC rectangular fuel tank, RH
BOC rectangular fuel tank, RH BOC rectangular DEF tank and LH BOC battery box ...................... 5-2
Figure 5-1.3 Vertical Crossover DPF/SCR, LH horizontal tailpipe, RH BOC rectangular fuel tank, RH
BOC rectangular DEF tank and LH 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
VI
AE
AXLE TO END
AF
FRAME RAIL OVERHANG LENGTH BEHIND REAR
BFA
FRONT BUMPER TO FRONT AXLE LENGTH
BOC
BACK OF CAB
CA
BACK OF CAB TO REAR AXLE LENGTH/CARGO AREA
CA
CAB TO AXLE
CBOC
CLEAR BACK OF CAB
CGF
CENTER GRAVITY OF LOAD FROM FRONT AXLE
CH
CAB HEIGHT
CLA
CENTER LINE OF AXLE
CRP
CLEAR RAIL PACKAGE
DEF
DIESEL EXHAUST FLUID
DSOC
DUAL SIDE OF CAB
EFF CA
USEABLE CARGO AREA
EOF
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
Abbreviations
VII
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
SMART AIR CONTROL
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
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.
This manual is not a maintenance manual or an operation manual.
•
For chassis maintenance and repair information consult the PACCAR Service Net 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 used 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 any of these alerts.
Warnings, Cautions, and Notes
WARNING:
When you see this word and symbol, the message that follows is especially vital. It signals
a
potentially hazardous situation which, if not avoided, could resul 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 vehicle .
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 hazardous situation which, if not avoided, could result in minor or moderate
injury or damage to the vehicle.
NOTE
Useful information that is related to the topic being discussed.
2-2
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.
Figure 2-1. Incomplete Vehicle Certification
Document
Tire, Rim and
Weight Rating
Data label
Safety Mark (Canadian
Registry Only)
Incomplete Vehicle
Certification Label
U.S. EPA Noise Label (U.S. registered vehicles only)
Final Stage Manufacturer
Label to be Installed by
Final Stage Manufacturer
Chassis Serial
Number
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 for 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
2-3
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.
3-1
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 10 ¼ inches 10 ¼ inches
Front Suspension
Rating 12K 10K
Unladen 8.1” 8.1”
Laden 5.9” 5.9”
Rear Suspension
HAS 210/230
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 19.5” 19.5” 35,710
3-2
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
Rear
Axles
Wheelbase Range
Curb to Curb Est. Radius
Wall to Wall Radius Est.
Inch
mm
ft m ft
m
Model 220
Single
121
3073.4
17.5
5.3
23.5
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
Section 3
Dimensions
3-3
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
Model 220 W/22.5 Tires
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
Behind CAB
Pivot location
Above FOF
44.5MM
WL
209MM
CTR-CTR
978MM
Table 3-3 Cab Tilt Height
CAB Tilt
Highest point inches (mm)
220 W/19.5
Tires
128 (3258.7)
220 W/22.5
Tires
132 (3355.2)
3-4
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 = 53”+WB+AF
3) Frame Length = OAL-49”
4) Effective CA = WB-34
3-5
Section 3
Dimensions
Side View -
Model 220
Table 3-5 Overall Dimensions
Model
Wheelbase
(in)
FAX to
BOC
(in)
FAX to Back
of Intake /
FAX to Back
of Exhaust
for 220
(in)
Body
Builder
Useable
CA
(in)
Overhang
(in)
Cab to
EOF
(in)
Recommended
Body Length (ft)
220
Horizontal
Exhaust
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
178
11
25.3
152.7
88
240.7
20
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
132
336.7
28
242
11
25.3
216.7
144
360.7
30
274
11
25.3
248.7
160
408.7
34
220
Vertical
Exhaust
121
11
38
83
72
155
10
142
11
38
104
72
176
13
146
11
38
108
72
180
14
156
11
38
118
72
190
15
158
11
38
120
72
192
15
164
11
38
126
72
198
16
168
11
38
130
72
202
16
170
11
38
132
72
204
16
178
11
38
140
88
228
18
182
11
38
144
84
228
18
194
11
38
156
96
252
20
206
11
38
168
108
276
22
218
11
38
180
120
300
24
230
11
38
192
132
324
26
242
11
38
204
144
348
26
274
11
38
236
160
396
32
3-6
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 = 53”+WB+AF
3) Frame Length = OAL-49”
4) Effective CA = WB-38”
3-7
)
Front and Rear Views — Model 220
Inches (mm)
Section 3
Dimensions
Figure 3-3.1 Front & Rear View —Model 220
3-8
Section 3
Dimensions
Front and Rear Views — Model 220
Table 3-6.1 Laden Ground
Clearance W/22.5 Tires
Figure 3-3.2 Model 220 Laden 22.5 Tires Front View: Width and Ground Clearance Measurements:
inches (mm).
Figure 3-3.3 Model 220 Laden 19.5 Tires Front View: Width and Ground Clearance Measurements:
inches (mm).
TIRE SIZE
SLR
RADIATOR
GROUND
275/22.5
17.6
7.7
295/22.5
18.8
8.9
11R/22.5
19.5
9.6
Table 3-6.2 Laden Ground clearance W/19.5 Tire
TIRE SIZE
SLR
RADIATOR
GROUND
245/19.5
15.5
7.5
265/19.5
15.9
7.9
Table 3-6.2 Laden Ground
Clearance W/19.5 Tire
TIRE SIZE
SLR
RADIATOR
GROUND
245/19.5
15.5
7.5
265/19.5
15.9
7.9
3-9
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).
3-10
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
Model 220 19.5 Tires
Unladen
Laden
In
mm
In
mm
A FUEL SUPPORT STEP
10.5
269
7.5
191
B FIRST STEP
16.6
421
13.2
336
C SECOND STEP FLOOR
27.2
690
23.8
605
D CABFLOOR
38.6
977
35.2
894
3-11
Section 3
Dimensions
3 Dimensions
Detail Views
Left side: Chassis Heights – Model220
ction
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
Position
Model 220 22.5 Tires
*Unladen
Laden
In
mm
In
mm
A FUEL SUPPORT
15.8
401
14.3
363
B FIRST STEP
18.4
467
16.9
430
C SECOND STEP FLOOR
32.7
830
31.2
794
D CABFLOOR
41.4
1051
39.9
1013
Table 3-8 Ground to Top of Frame Measurements
Frame Heights
LOADED inches (mm)
*UNLOADED inches (mm)
Front Axle
Rear Axle
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.
3-12
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, DEF Tank and Crossmember
Location Measured From Front Axle: inches (mm).
Figure 3-5.2 Model 220 22.5 Tires, Battery Box, Dual Fuel Tanks, Air Tank, DEF Tank, and Crossmember
Location Measured from Front Axle: inches (mm).
3-13
Section 3
Dimensions
3 Dimensions
Figure 3-5.3 Model 220 22.5 Tires, Short Wheelbase, Air Tanks on the RH Side, Battery Box, DEF Tank and
Crossmember Location Measured from Front Axle: inches (mm).
Figure 3-5.4 Model 220 22.5 Tires, Clear Rail Package, Air Tanks, Battery Box, DEF Tank and
Crossmember Location Measured from Front Axle: inches (mm).
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