March 2015
Rev A
BODY BUILDER MANUAL CONTENTS
SECTION 1: INTRODUCTION
SECTION 2: SAFETY AND COMPLIANCE
SAFETY SIGNALS vi
FEDERAL MOTOR VEHICLE SAFETY STANDARDS (FMVSS) AND
CANADIAN MOTOR VEHICLE SAFETY STANDARDS (CMVSS) COMPLIANCE vii
NOISE AND EMISSIONS REQUIREMENTS viii
SECTION 3: DIMENSIONS
INTRODUCTION 3-1
ABBREVIATIONS 3-1
OVERALL DIMENSIONS 3-2
Model 389-131 3-3
Model 389-123 3-4
Model 386 3-5
Model 384 3-6
Model 367 SFFA 3-7
Model 367 SBFA 3-8
Model 367 SBFA HH 3-9
Model 367 SBFA HH FEPTO 3-10
Model 365 SFFA 3-11
Model 365 SBFA 3-12
Model 365 SBFA FEPTO 3-13
Model 579-123 3-14
Model 579-117 3-15
Model 567-121 3-16
Model 567-115 3-17
UNIBILT SLEEPERS 3-18
CONVENTIONAL CAB 3-19
EXTENDED CAB 3-20
FRAME RAILS 3-21
FRAME HEIGHT CHARTS 3-22
FRONT DRIVE AXLE, PTO’S AND AUXILIARY TRANSMISSIONS 3-28
Examples 3-28
Guppy Outserts 3-31
EXHAUST HEIGHT CALCULATIONS 3-35
GROUND CLEARANCE CALCULATIONS 3-36
OVERALL CAB HEIGHT CALCULATIONS 3-37
FRAME COMPONENTS 3-38
Fuel Tanks 3-38
DEF Tanks 3-39
EXHAUST SYSTEMS 3-40
Exhaust Single RH Side of Cab DPF/SCR RH Under Cab 3-40
Exhaust Dual Side of Cab DPF/SCR RH Under Cab 3-41
Exhaust Single RH Back of Cab DPF/SCR RH Under Cab 3-42
Exhaust Single Horizontal DPF/SCR RH Under Cab 3-43
Exhaust Single RH Back of Sleeper DPF/SCR RH Under Cab 3-44
Exhaust Dual Back of Sleeper DPF/SCR RH Under Cab 3-45
Exhaust Single RH Back of Sleeper DPF/SCR Cross Over Under Cab 3-46
Exhaust Dual Back of Sleeper DPF/SCR Cross Over Under Cab 3-47
Exhaust Single Horizontal DPF/SCR Cross Over Under Cab 3-48
Exhaust Single LH Back of Sleeper DPF/SCR Vertical – Day Cab 3-49
Exhaust Single LH Back of Sleeper DPF/SCR Vertical – 36” Sleeper 3-50
Exhaust Single RH Side of Cab ISL-G Only 3-51
Exhaust Single RH Back of Cab ISL-G Only 3-52
Exhaust Single Horizontal ISL-G or ISL12-G Only 3-53
TABLE OF CONTENTS
Exhaust Single Vertical ISL-G or ISL12-G Only 3-54
PTO CLEARANCES 3-55
SECTION 4: BODY MOUNTING
INTRODUCTION 4-1
FRAME RAILS 4-1
CRITICAL CLEARANCES 4-2
BODY MOUNTING USING BRACKETS 4-3
Brackets 4-4
Mounting Holes 4-5
Frame Drilling 4-6
BODY MOUNTING USING U–BOLTS 4-7
Rear Body Mount 4-9
SECTION 5: FRAME MODIFICATIONS
INTRODUCTION 5-1
DRILLING RAILS 5-1
MODIFYING FRAME LENGTH 5-1
CHANGING WHEELBASE 5-1
CROSSMEMBERS 5-2
TORQUE REQUIREMENTS 5-3
WELDING 5-3
SECTION 6: ELECTRICAL 389 FAMILY
CONTROL UNIT IDENTIFICATION 6-1
Functional Description-Instrumentation Control Unit / 6-1
Cab Electronic Control Unit (ICU/CECU) 6-1
Electronic Service Agent (ESA) 6-2
Models–Build Dates Identification 6-2
Identification 6-2
HOW MULTIPLEXED INSTRUMENTS WORK 6-6
Introduction 6-6
Central Instrument Cluster 6-7
ICU/CECU Architecture 6-9
Power On Self-Test 6-10
Commercial Vehicle Smart Gauges (CVSG) 6-10
Instruments and Controls Operation 6-11
TRANSMISSION BACK UP SIGNALS 6-14
JUNCTION BOX 6-14
J1939 6-15
SECTION 7: ELECTRICAL 579 FAMILY
INTRODUCTION 7-1
BODY BUILDER CONNECTION POINTS 7-2
Harness Design 7-2
Remote Throttle and Remote PTO Control 7-2
Spare Power 7-2
Air Solenoid 7-2
Cab Switch Backlighting 7-2
Electric Engaged Equipment 7-3
Air Solenoid Bank and Chassis Node 7-3
Rear Axle Controls and Sensors 7-4
Location Diagrams for Various Connectors on the Frame 7-5
INSTALLING ADDITIONAL SWITCHES ONTO THE CHASSIS 7-10
INSTALLING ADDITIONAL GAUGES ON THE DASH 7-11
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TABLE OF CONTENTS
INSTALLING SENSORS ON THE CHASSIS FOR GAUGES 7-12
LIFT AXLES (PUSHERS & TAG) 7-14
Truck Lift Axles 7-14
Trailer Lift Axles 7-15
AIR SOLENOIDS 7-16
REMOTE THROTTLE 7-17
CAB ECU PARAMETER REFERENCE TABLE 7-19
INTERLOCK PROGRAMMING DETAILS 7-20
TRANSMISSION BACK UP SIGNALS 7-24
JUNCTION BOX 7-24
SNOW PLOW LIGHTING 7-25
J1939 7-26
HOW DO I... 7-28
Install a Multiplexed Instrument 7-28
Install and Air Operated External Device 7-28
Re-Program the CECU 7-28
Install New Telltale Icons into the Instrument Cluster 7-28
Access the Solenoid Bank and Chassis Node 7-29
Get the Air Bags to Deflate When the PTO is on 7-29
DASH 7-30
Gauge and Switch Installation 7-30
Telltale Icons Installation 7-33
SECTION 8: PTO SECTION
INTRODUCTION 8-1
TRANSMISSION MOUTED PTO – GENERAL 8-1
TRANSMISSION MOUNTED PTO – 579 FAMILY 8-3
TRANSMISSION CLEARANCE CHARTS – 579 FAMILY 8-4
HYDRAULIC CLUTCH ACTUATOR CONFIGURATIONS 8-6
FRONT ENGINE PTO 8-7
REAR ENGINE PTO 8-8
PTO INSTALLATIONS – 389 FAMILY 8-9
PTO INSTALLATIONS – 579 FAMILY 8-12
Peterbilt Motors Company iv
SECTION 1 INTRODUCTION
The Peterbilt Heavy Duty Body Builder Manual was designed to provide body builders with a comprehensive information
set to guide the body planning and installation process. Use this information when installing bodies or other associated
equipment.
In this manual you will find appropriate dimensional information, guidelines for mounting bodies, modifying frames,
electrical wiring configurations, as well as other information useful in the body installation process.
The Peterbilt Heavy Duty Body Builder Manual can be very useful when specifying a vehicle, particularly when the body
builder is involved in the vehicle selection and component ordering process. Information in this manual will help reduce
overall costs through optimized integration of the body installation with vehicle selection.
As products continually evolve, Peterbilt reserves the right to change specifications or products at any time without prior
notice. It is the responsibility of the user to ensure that he is working with the latest released information. If you require
additional information or reference materials, please contact your local Peterbilt dealer.
Peterbilt Motors Company v
2
SAFETY AND COMPLIANCE
SECTION 2 SAFETY AND COMPLIANCE
SAFETY SIGNALS
A number of alerting messages are shown in this book. Please read and follow them. They are there for your protection
and information. These alerting messages can help you avoid injury to yourself or others and help prevent costly damage
to the vehicle.
Key symbols and “signal words” are used to indicate what kind of message is going to follow. Pay special attention to
comments prefaced by “WARNING”, “CAUTION”, and “NOTE.” Please don't ignore any of these alerts.
WARNING
When you see this word and symbol, the message that follows is especially vital. It signals a potentially
hazardous situation which, if not avoided, could result in death or serious injury. This message will tell you what
the hazard is, what can happen if you don’t heed the warning, and how to avoid it.
Example:
WARNING! Be sure to use a circuit breaker designed to meet liftgate amperage requirements. An incorrectly
specified circuit breaker could result in 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.
Peterbilt Motors Company vi
2
SAFETY AND COMPLIANCE
FEDERAL MOTOR VEHICLE SAFETY STANDARDS (FMVSS) AND CANADIAN MOTOR
VEHICLE SAFETY STANDARDS (CMVSS) COMPLIANCE
As an Original Equipment Manufacturer (OEM), Peterbilt Motors Company ensures that our products comply with all
applicable Federal Motor Vehicle Safety Standards (FMVSS) and Canadian Motor Vehicle Safety Standards (CMVSS)
where applicable. However, the fact that this vehicle has no fifth–wheel and that a Body Builder (Final Stage
Manufacturer) will be doing additional modifications means that the vehicle was incomplete when it left the build plant.
Incomplete Vehicle Certification
An Incomplete Vehicle Document is shipped with the vehicle, certifying that the vehicle is not complete (see figure below).
In addition, affixed to the driver’s side door frame or edge is an Incomplete Vehicle Certification label.
NOTE: These documents list the FMVSS (or CMVSS) regulations that the vehicle complied with when it
left the build plant. You should be aware that if you modify or alter any of the components or systems
covered by these FMVSS (or CMVSS) regulations, it is your responsibility as the Final Stage
Manufacturer to ensure that the complete vehicle maintains compliance with the particular FMVSS (or
CMVSS) regulations when you complete your modifications.
Figure 2-1. Incomplete Vehicle Certification Document Figure 2-2. Location of Certification Labels -Driver’s Door Frame
As the Final Stage Manufacturer, you should retain the Incomplete Vehicle Document for your records. In addition, you
should record and retain the manufacturer and serial number of the tires on the vehicle. Upon completion of the vehicle
(installation of the body and any other modifications), you should affix your certification label to the vehicle as required by
Federal law. This tag identifies you as the “Final Stage Manufacturer” and certifies that the vehicle complies with Federal
Motor Vehicle Safety Standards.
Peterbilt Motors Company vii
2
SAFETY AND COMPLIANCE
Trucks equipped with a “Vehicle Emission Control Information” door label are certified to comply with United States
Greenhouse Gas (GHG) regulations. Original tires may be substituted provided the new tires possess an equal to or lower
Coefficient of rolling resistance (Crr).
The Emission Controls shown in Figure 2-3 may be indicated on the label.
Figure 2-3. Incomplete Vehicle Certification Document
Noise and Emissions Requirements
NOTE: This truck may be equipped with a Diesel Particulate Filter (DPF) muffler unit in order to meet
both noise and exhaust emissions requirements. Removal or tampering with the DPF muffler will not
improve engine performance. Also tampering with the exhaust system is against the rules that are
established by the U.S. Code of Federal Regulations and Environment Canada Regulations. The
DPF muffler may only be replaced with an approved part.
NOTE: 2007/10/13 emissions engines are integrated with particulate filters for 2007/10/13 EPA
certification. The particulate filter assembly may consist of one or more of the following components: a
diesel oxidation catalyst, a diesel particulate filter, temperature sensors, differential pressure sensor, and
exhaust silencing components integrated into a modular housing. Body Builders must not modify or
relocate this assembly or any components associated with it. It is also the case that there should not be
any modifications made to the exhaust piping from turbo outlet to aftertreatment inlet.
Peterbilt Motors Company viii
SECTION 3 DIMENSIONS
CA
Cab to axle. Measured from the back of the cab to the centerline of the rear axle(s).
EOF
Frame rail overhang behind rear axle--measured from the centerline of tandems
FS
Front suspension height
RS
Rear suspension height
WB
Wheelbase
SOC
Side of cab
BOC
Back of cab
INTRODUCTION
This section has been designed to provide enough information to successfully layout a chassis in the body planning
process. All dimensions are inches unless otherwise noted. Optional equipment may not be depicted. Please contact
your local Peterbilt dealer if more dimensional information is desired.
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.
TABLE 3-1. Abbreviations Used
3
DIMENSIONS
OVERALL DIMENSIONS
This section includes drawings and charts of the following Peterbilt Models: 389, 386, 384, 367 SFFA, 367 SBFA, 367 HH,
367 FEPTO, 365 SFFA, 365 SBFA, 365 FEPTO, 567 and 579. The Extended Rear Window, Extended Cab and Unibilt
sleepers are also included.
On the pages that follow, detail drawings show particular views of each vehicle; all dimensions are in inches (in). They
illustrate important measurements critical to designing bodies of all types. See the “Contents” at the beginning of the
manual to locate the drawing that you need.
All heights are given from the bottom of the frame rail.
Peterbilt also offers .dxf files and frame layouts of ordered chassis prior to build. Please speak with your local dealership
to request this feature when specifying your chassis.
Peterbilt Motors Company 3- 2
3
DIMENSIONS
MODEL 389-131
NOTES:
1) DIMENSIONS ARE FOR REFERENCE ONLY
2) DIMENSIONS ARE TO FRONT OF 0.25” THICK BUMPER
3) DIMENSION IS 16.1” WITH 11-5/8” RAIL
4) DIMENSION FRONT AXLE TO FRONT OF FRAME (FFA) IS 19.6”
5) DIMENSION FRONT OF BUMPER TO FRONT OF FRAME (BFF) IS 11.4”
FIGURE 3-1. Model 389-131 Top & LH View – Overall Dimensions
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3
DIMENSIONS
MODEL 388-123
NOTES:
1) DIMENSIONS ARE FOR REFERENCE ONLY
2) DIMENSIONS ARE TO FRONT OF 0.25” THICK BUMPER
3) DIMENSION FRONT AXLE TO FRONT OF FRAME (FFA) IS 19.6”
4) DIMENSION FRONT OF BUMPER TO FRONT OF FRAME (BFF) IS 11.4”
FIGURE 3-2. Model 389-123 Top & LH View – Overall Dimensions
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3
DIMENSIONS
MODEL 386
NOTES:
1) DIMENSIONS ARE FOR REFERENCE ONLY
2) DIMENSIONS ARE TO FRONT OF BUMPER
3) DIMENSION FRONT AXLE TO FRONT OF FRAME (FFA) IS 35.6”
4) DIMENSION FRONT OF BUMPER TO FRONT OF FRAME (BFF) IS 14.0”
FIGURE 3-3. Model 386 Top & LH View – Overall Dimensions
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3
DIMENSIONS
MODEL 384
NOTES:
1) DIMENSIONS ARE FOR REFERENCE ONLY
2) DIMENSIONS ARE TO FRONT OF BUMPER
3) DIMENSION FRONT AXLE TO FRONT OF FRAME (FFA) IS 35.6”
4) DIMENSION FRONT OF BUMPER TO FRONT OF FRAME (BFF) IS 12.0”
FIGURE 3-4. Model 384 Top & LH View – Overall Dimensions
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3
DIMENSIONS
Model 367SFFA
NOTES:
1) DIMENSIONS ARE FOR REFERENCE ONLY
2) DIMENSIONS ARE TO FRONT OF 0.25” THICK BUMPER
3) DIMENSION FRONT AXLE TO FRONT OF FRAME (FFA) IS 19.6”
4) DIMENSION FRONT OF BUMPER TO FRONT OF FRAME (BFF) IS 11.4”
FIGURE 3-5. Model 367 SFFA Top & LH View – Overall Dimensions
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3
DIMENSIONS
Model 367SBFA Sloped Hood
NOTES:
1) DIMENSIONS ARE FOR REFERENCE ONLY
2) DIMENSIONS ARE TO FRONT OF 0.25” THICK BUMPER
3) DIMENSION FRONT AXLE TO FRONT OF FRAME (FFA) IS 35.6”
4) DIMENSION FRONT OF BUMPER TO FRONT OF FRAME (BFF) IS 11.4”
FIGURE 3-6. Model 367 SBFA Sloped Hood Top & LH View – Overall Dimensions
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3
DIMENSIONS
Model 367SBFA HH
NOTES:
1) DIMENSIONS ARE FOR REFERENCE ONLY
2) DIMENSIONS ARE TO FRONT OF 0.25” THICK BUMPER
3) DIMENSION FRONT AXLE TO FRONT OF FRAME (FFA) IS 35.6”
4) DIMENSION FRONT OF BUMPER TO FRONT OF FRAME (BFF) IS 11.4”
FIGURE 3-7. Model 367 SBFA Heavy Haul Hood Top & LH View – Overall Dimensions
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3
DIMENSIONS
Model 367SBFA HH FEPTO
NOTES:
1) DIMENSIONS ARE FOR REFERENCE ONLY
2) DIMENSIONS ARE TO FRONT OF 0.25” THICK BUMPER
3) AVAILABLE IN 22.4” OR 31” FEPTO AND WITHOUT FEPTO (31” FEPTO SHOWN)
FIGURE 3-8. Model 367 SBFA FEPTO Heavy Haul Hood Top & LH View – Overall Dimensions
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3
DIMENSIONS
Model 365SFFA
NOTES:
1) DIMENSIONS ARE FOR REFERENCE ONLY
2) DIMENSIONS ARE TO FRONT OF 0.25” THICK BUMPER
3) DIMENSION FRONT AXLE TO FRONT OF FRAME (FFA) IS 17.6”
4) DIMENSION FRONT OF BUMPER TO FRONT OF FRAME (BFF) IS 11.4”
FIGURE 3-9. Model 365 SFFA Top & LH View – Overall Dimensions
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3
DIMENSIONS
Model 365SBFA
NOTES:
1) DIMENSIONS ARE FOR REFERENCE ONLY
2) DIMENSIONS ARE TO FRONT OF 0.25” THICK BUMPER
3) DIMENSION FRONT AXLE TO FRONT OF FRAME (FFA) IS 35.6”
4) DIMENSION FRONT OF BUMPER TO FRONT OF FRAME (BFF) IS 11.4”
FIGURE 3-10. Model 365 SBFA Top & LH View – Overall Dimensions
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3
DIMENSIONS
Model 365SBFA FEPTO
NOTES:
1) DIMENSIONS ARE FOR REFERENCE ONLY
2) DIMENSIONS ARE TO FRONT OF 0.25” THICK BUMPER
3) AVAILABLE IN 22.4” OR 31” FEPTO AND WITHOUT FEPTO (31” FEPTO SHOWN)
4) ADD 4” OVERALL CAB HEIGHT FOR FULL PROFILE HEIGHT FRAME RAILS (85.5”)
FIGURE 3-11. Model 365 SBFA FEPTO Hood Top & LH View – Overall Dimensions
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3
DIMENSIONS
Model 579-123
NOTES:
1) DIMENSIONS ARE FOR REFERENCE ONLY
2) DIMENSIONS ARE TO FRONT OF BUMPER
3) DIMENSION FRONT AXLE TO FRONT OF FRAME (FFA) IS 35.6”
4) DIMENSION FRONT OF BUMPER TO FRONT OF FRAME (BFF) IS 13.8”
FIGURE 3-12. Model 579-123 SBFA Top & LH View – Overall Dimensions
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3
DIMENSIONS
Model 579-117
NOTES:
1) DIMENSIONS ARE FOR REFERENCE ONLY
2) DIMENSIONS ARE TO FRONT OF BUMPER
3) DIMENSION FRONT AXLE TO FRONT OF FRAME (FFA) IS 35.6”
4) DIMENSION FRONT OF BUMPER TO FRONT OF FRAME (BFF) IS 13.8”
FIGURE 3-13. Model 579-117 SBFA Top & LH View – Overall Dimensions
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3
DIMENSIONS
Model 567-121
NOTES:
1) DIMENSIONS ARE FOR REFERENCE ONLY
2) DIMENSIONS ARE TO FRONT OF BUMPER
3) DIMENSION FRONT AXLE TO FRONT OF FRAME (FFA) IS 35.6”
4) DIMENSION FRONT OF BUMPER TO FRONT OF FRAME (BFF) IS 11.3”
FIGURE 3-14. Model 567-121 SBFA Top & LH View – Overall Dimensions
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3
DIMENSIONS
Model 567-115
NOTES:
1) DIMENSIONS ARE FOR REFERENCE ONLY
2) DIMENSIONS ARE TO FRONT OF BUMPER
3) DIMENSION FRONT AXLE TO FRONT OF FRAME (FFA) IS 35.6”
4) DIMENSION FRONT OF BUMPER TO FRONT OF FRAME (BFF) IS 11.3”
FIGURE 3-15. Model 567-115 SBFA Top & LH View – Overall Dimensions
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3
CAB TO SLEEPER
OPENING
SLEEPER DIMENSIONS
CAB TO
SLEEPER
GAP
STD CAB
ULTRACAB
D = DISTANCE FROM BTM OF FRAME RAIL TO TOP OF ROOF
MODEL
"A"
"B"
"A"
"B"
44"
58"
LOW
58"
HIGH
72"
LOW
72"
HIGH
78"
80"
"E"
389-131
49.0
59.0
59.0
59.0
81.7
83.5
99.3
83.3
99.4
101.6
N/A
2.3
389-123,
386, 384,
367, 365
49.0
59.0
59.0
59.0
83.7
85.5
101.4
85.3
101.5
103.7
N/A
2.3
579, 567
49.0
68.1
66.5
68.1
83.7
85.5
N/A
N/A
101.8
N/A
106.3
1.8
SLEEPER LENGTH "C" =
36.0
48.0
48.0
63.0
63.0
70.0
70.0
DIMENSIONS
SLEEPERS
TABLE 3-2. Sleeper Dimensions
FIGURE 3-16. Sleeper Dimensions – Front & LH View
Peterbilt Motors Company 3- 18
3
DIMENSIONS
CAB – 1.9 m CAB FAMILY
Models 389, 388, 386, 384, 367, 365
FIGURE 3-17. Cab Dimensions 1.9 m Cab Family
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3
DIMENSIONS
EXTENDED CAB – 1.9 m CAB FAMILY
Models 389, 388, 386, 384, 367, 365
FIGURE 3-18. Extended Cab
Peterbilt Motors Company 3- 20
3
DIMENSIONS
FRAME RAILS
Frame rail configurations are shown in FIGURE 3-19. Frame height, flange and structural values can be found in the
Body Mounting Section.
FIGURE 3-19. Frame Rail Configurations
NOTE: The outserted frame section does not extend through the rear suspension area.
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3
DIMENSIONS
FRAME HEIGHT CHARTS
FIGURE 3-20. Frame Height
Peterbilt Motors Company 3- 22
3
SFFA SUSPENSION
SPACER
(mm)
LIGHT
LOADED
12,000 lbs.3
TAPERLEAF
SFFA
10
9.3
8.9
20
9.7
9.3
30
10.1
9.7
40
10.5
10.1
50
10.9
10.5
60
11.3
10.9
70
11.7
11.2
80
12.1
11.6
13,200 lbs.3
TAPERLEAF
SFFA
10
9.3
8.9
20
9.7
9.3
30
10.1
9.7
40
10.5
10.1
50
10.9
10.5
60
11.3
10.9
70
11.7
11.3
80
12.1
11.5
14,600 lbs.
TAPERLEAF
SFFA
10
9.3
8.9
20
9.7
9.3
30
10.1
9.7
40
10.5
10.1
50
10.9
10.5
60
11.3
10.9
70
11.7
11.3
80
12.1
11.7
16,000 lbs.
TAPERLEAF
SFFA
10
10.5
10.0
20
10.9
10.3
30
11.3
10.7
40
11.7
11.1
50
12.1
11.5
60
12.5
11.9
70
12.9
12.3
80
13.3
12.7
18,000 - 20,000 lbs. 1
TAPERLEAF
SFFA
10
10.6
9.5
20
11.0
10.0
30
11.4
10.4
40
11.8
10.8
50
12.2
11.2
60
12.6
11.6
70
13.0
12.0
80
13.4
12.4
22,000 - 24,000 lbs. 2
TAPERLEAF
SFFA
10
12.4
10.9
20
12.8
11.3
30
13.2
11.7
40
13.6
12.1
50
14.0
12.5
60
14.3
12.9
70
14.7
13.3
80
15.1
13.6
DIMENSIONS
TABLE 3-3. Front Frame Height “A” - SFFA
NOTES:
1) Shown with 20K load for laden dim. Add 0.3" to laden dim. if 18K load.
2) Shown with 23K load for laden dim. Add 0.1" to laden dim. if 22K load. Subtract .01" from unladen dim if 24K load.
Note: Standard 3-1/2" drop axle heights shown, for 5" drop axles, subtract an additional 1-1/2".
Spacer blocks are used by Engineering to obtain level frame and are not options.
"A" dimension shown is to bottom of frame rail. Add frame rail height dimension for frame height.
Peterbilt Motors Company 3- 23
3
SBFA SUSPENSION
SPACER
(mm)
LIGHT (in.)
LOADED (in.)
12,000 lbs.
TAPERLEAF
SBFA
30
9.7
8.5
40
10.1
8.9
50
10.5
9.3
60
10.9
9.7
70
11.3
10.1
80
11.7
10.5
13,200 lbs.
TAPERLEAF
SBFA
30
9.8
8.5
40
10.2
8.9
50
10.6
9.3
60
11
9.7
70
11.4
10.1
80
11.8
10.5
14,600 lbs.
TAPERLEAF
SBFA
30
10.1
8.5
40
10.5
8.9
50
10.9
9.3
60
11.3
9.7
70
11.7
10.1
80
12.1
10.5
16,000 lbs.
TAPERLEAF
SBFA
30 3
11.4
9.5
40 3
11.8
9.9
50
12.2
10.3
60
12.6
10.7
70
13
11.1
80
13.4
11.5
18,000-20,000 1
TAPERLEAF
SBFA
50
11.9
10
60
12.3
10.4
70
12.7
10.8
80
13.1
11.2
22,000 - 24,000
lbs. 2
TAPERLEAF
SBFA
OMIT
12.3
9.4
30
13.4
10.5
40
13.8
10.9
50
14.2
11.3
60
14.6
11.7
70
15
12.1
80
15.4
12.5
DIMENSIONS
TABLE 3-4. Front Frame Height “A” - SBFA
NOTES:
1) Shown with 20K load for laden dim. Add 0.3" to laden dim. if 18K load. S
2) Shown with 23K load for laden dim. Add 0.1" to laden dim. if 22K load. Subtract 0.1" from laden dim. if 24K load.
3) 16K springs with 12K to 14.6K axle minimum spacer block is 30 mm. With 16K springs and 20K axle minimum
spacer block is 50 mm.
Note: Standard 3-1/2" drop axle heights shown, for 5" drop axles, subtract an additional 1-1/2".
Spacer Blocks are used by Engineering to obtain level frame and are not options.
"A" dimension shown is to bottom of frame rail. Add frame rail height for frame height.
Peterbilt Motors Company 3- 24
3
Suspension
Rating
Version
Light
Height
Laden
Height
AIR TRAC
20,000 lbs.
Standard
11.4
11.0
23,000 lbs.
Standard
11.4
11.0
REYCO 79KB
20,000 lbs.
Taperleaf (3.38" saddle)
9.4
11.8
21,000 lbs.
Taperleaf (1.38" saddle)
7.4
9.8
23,000 lbs.
Multileaf (1.38" saddle)
8.8
11.6
26,000 lbs.
Multileaf (1.38" saddle)
9.2
11.8
28,000 lbs.
Multileaf (1.38" saddle)
9.7
12.3
31,000 lbs.
Multileaf (1.38" saddle)
10.8
13.3
REYCO 102
23K-29K lbs.
4.38 saddle
12.1
10.2
23K-29K lbs.
4.63 saddle
12.2
10.4
29,000 lbs
3.50 saddle
11.7
10.0
31,000 lbs
3.50 saddle
12.2
10.5
31,000 lbs
4.38 saddle
12.5
10.7
31,000 lbs
4.63 saddle
12.7
10.9
REYCO 102AR (AIR)
17K -23K
Standard
9.3
9.3
Low
8.3
8.3
Suspension
Rating
Version
Light
Height
Laden
Height
AIR LEAF
38,000 lbs.
12.0
11.7
LOW AIR LEAF
40,000 lbs.
8.8
8.5
FLEX AIR
38,000 lbs.
8.7
8.5
LOW LOW AIR
LEAF
40,000 lbs.
6.8
6.5
AIR TRAC
40K-46K lbs
11.4
11.0
QUADRAFLEX
38,000 lbs.
Taperleaf
10.6
8.7
Suspension
Rating
Version
Light
Height
Laden
Height
NEWAY AD
52,000 lbs.
10.0
10.0
NEWAY ADZ
46K-52K lbs.
10.0
10.0
DIMENSIONS
REAR FRAME HEIGHTS "C"
TABLE 3-5. Single Drive Suspension Heights
TABLE 3-6. Tandem Peterbilt Suspension Heights
TABLE 3-7. Tandem Neway Suspension Heights
Peterbilt Motors Company 3- 25
3
Suspension
Rating
Version
Light
Height
Laden
Height
REYCO 102
MULTILEAF
40,000 lbs
1.75 saddle (STD)
11.7
9.9
1.38 saddle
10.2
8.3
3.38 saddle
13.4
11.5
44,000 lbs
1.75 saddle (STD)
11.7
9.8
1.38 saddle
11.5
9.7
REYCO 102AR (Air)
34K-40K
STD LOW
8.3
8.3
Suspension
Rating
Version
Light
Height
Laden
Height1
CHALMERS 854/860
40,000 lbs
LOW
11.2
8.9
HIGH
12.4
10.2
X-HIGH
14.5
12.2
XX-HIGH
17.2
14.9
CHALMERS 854/860
46,000 lbs
LOW
11.3
8.9
HIGH
12.5
10.1
X-HIGH
14.7
12.2
XX-HIGH
17.3
14.9
CHALMERS 854/860
50K-52K
LOW
11.3
8.9
HIGH
12.5
10.1
X-HIGH
14.7
12.1
XX-HIGH
17.3
14.8
CHALMERS 872
46,000 lbs
LOW
11.2
8.8
HIGH
12.5
10.3
X-HIGH
14.7
12.2
XX-HIGH
17.3
14.9
CHALMERS 872
50,000 lbs
LOW
11.2
8.8
HIGH
12.5
10.3
X-HIGH
14.7
12.1
XX-HIGH
17.3
14.8
DIMENSIONS
TABLE 3-8. Tandem Reyco Suspension Heights
TABLE 3-9. Tandem Chalmers Suspension Heights
NOTES:
1) Laden dimension shown with standard restrictor cans. Add 0.7” for #29 High Stability Restrictor Cans.
2) * With Meritor 70K axles frame height is 22.5" for R650.
Peterbilt Motors Company 3- 26
3
Suspension
Rating
Version
Light
Height
Laden
Height
RT-403
40,000 lbs
6.00 saddle
9.9
8.9
7.188 saddle (std)
11.2
10.1
RTE-403
40,000 lbs
6.00 saddle
9.9
8.4
7.188 saddle (std)
11.2
9.6
R-403
40,000 lbs
12.80 saddle
5.9
5.9
15.81 saddle (std)
8.9
8.9
17.60 saddle
10.6
10.6
RS-403
40,000 lbs
12.25 saddle
9.7
8.9
14.00 saddle (std)
11.5
10.6
15.25 saddle
12.7
11.9
HMX
40,000 lbs
16.5 saddle (low)
10.6
9.5
18.5 saddle (std)
12.6
11.5
HMX
46,000 lbs
16.5 saddle (low)
10.6
9.5
18.5 saddle (std)
12.6
11.5
HN462
46,000 lbs
20.25 saddle (high)
15
13.3
R-463
46,000 lbs
15.75 saddle (std)
8.8
8.8
20.50 saddle
13.5
13.5
RS-463
46,000 lbs
12.25 saddle
9.7
8.9
14.00 saddle (std)
11.5
10.6
15.25 saddle
12.7
11.9
RT-463
46,000 lbs
6.00 saddle
11.3
10.5
7.188 saddle (std)
13
11.4
11.00 saddle
16.3
15.2
RTE-463
46,000 lbs
7.188 saddle (std)
11.6
10.2
11.00 saddle
15.4
14
RS-503
50,000 lbs
14.00 saddle (std)
11.5
10.6
15.25 saddle
12.7
11.9
RT-503
50,000 lbs
7.188 saddle (std)
12.2
11.2
11.0
1
saddle
6.4
15.4
RTE-503
50,000 lbs
7.188 saddle (std)
11.6
10.2
11.00 saddle
15.4
14
RS-523
52,000 lbs
14.0 saddle (std)
11.5
10.6
RT-523 , RT-650
52K-65K
7.188 saddle (std)
12.2
11.2
11.00 saddle
16.4
15.4
HN522
52,000 lbs
18.50 saddle (std)
12.6
11.5
RS650
65,000 lbs
15.00 saddle (std)
12.0 1
11.0 2
19.00 saddle
16.0 2
15.1 2
R650 3
65,000 lbs
20.25 saddle (std)
12.5
12.5
R850 w/70K Meritor
85,000 lbs
20.25 saddle
12
12
R850 w/SISU 70K
20.25 saddle
12.1
12.1
RS850 w/SISU 70K
85,000 lbs
16.75 saddle
14.5
13.8
DIMENSIONS
TABLE 3-10. Tandem Hendrickson Suspension Heights
NOTES
1) With SISU 70K axle subtract .39" from light/laden.
2) With SISU 70K axle subtract .28 from light and.39 from laden.
3) With Meritor 70K axles frame height is 22.5" for R650.
Peterbilt Motors Company 3- 27
3
DIMENSIONS
FRONT DRIVE AXLE, PTO’S AND AUXILIARY TRANSMISSIONS
The front drive axle, PTO and auxiliary transmission layouts are provided as a tool to help layout bodies prior to arrival.
For information not detailed in these drawings, work with the local Peterbilt dealer to request that information.
EXAMPLES
FIGURE 3-20. Front Drive Axle with Spaghetti Drive Example
FIGURE 3-21. Front Drive Axle with Transfer Case Example
Peterbilt Motors Company 3- 28
3
DIMENSIONS
FIGURE 3-22. PTO with Transfer Case Example
Peterbilt Motors Company 3- 29
3
DIMENSIONS
FIGURE 3-23. PTO with Transfer Case Example
FIGURE 3-24. PTO with Transfer Case Example
Peterbilt Motors Company 3- 30
3
DIMENSIONS
GUPPY OUTSERTS
The rear suspension guppy outsert layouts are provided as a tool to help layout bodies prior to arrival. For information not
detailed in these drawings, work with the local Peterbilt dealer to request that information.
FIGURE 3-25. Peterbilt Air Trac Tandem Suspension Guppy
FIGURE 3-26. Peterbilt Air Trac Single Suspension Guppy
Peterbilt Motors Company 3- 31
3
DIMENSIONS
FIGURE 3-27. Chalmers Tandem Suspension Guppy
FIGURE 3-28. Hendrickson HN/HMX/R Tandem Suspension Guppy
Peterbilt Motors Company 3- 32
3
DIMENSIONS
FIGURE 3-29. Hendrickson RS Tandem Suspension Guppy
FIGURE 3-30. Hendrickson RT/RTE Tandem Suspension Guppy
Peterbilt Motors Company 3- 33
3
DIMENSIONS
FIGURE 3-31. Reyco 102 Single Drive Suspension Guppy
Peterbilt Motors Company 3- 34
3
Y = DISTANCE FROM BTM OF FRAME RAIL TO BTM OF STANDPIPE
Exhaust
Location
389-131
389-123, 386,
384, 367, 365
579, 567
587
388 w/ Low
Profile
Alum Hood
SOC Mounted
(Day Cab)
67.2
69.2
70.2
N/A
67.2
SOC Mounted
(Sleeper)
67.2
69.2
67.6
N/A
67.2
BOC Mounted
N/A
70.7
69.2
N/A
68.7
Frame
Mounted
N/A
84.9
86.0
84.9
N/A
Vertical-
Vertical
N/A
ISX/MX=77.3,
ISL=75
ISX/MX=78.3,
ISL=75.7
N/A
N/A
DIMENSIONS
EXHAUST HEIGHT CALCULATIONS
The exhaust height calculations are provided as a tool to help layout bodies prior to arrival as well as aid in exhaust
configuration selection.
Please work with the local Peterbilt Dealer to request additional information if required.
The overall exhaust height (EH) can be estimated based on the following formula: EH = Y + SPL + (A + B + C + D) / 2
TABLE 3-11. Exhaust Heights
NOTES:
1) For “A” and “C” values, reference the FRAME HEIGHTS section for front or rear suspension height.
2) For “B” and “D” values, reference the tire manufacturer’s website or catalog for static loaded radius (SLR).
3) For Stand Pipe Length (SPL) values, reference the truck sales order.
FIGURE 3-32. Exhaust Height Calculations
Peterbilt Motors Company 3- 35
3
Y = DISTANCE FROM BOTTOM OF
FRAME TO BOTTOM OF COMPONENT
Component
Y
RHUC DPF/SCR
16.7
Horizontal (Series or X-Over)
DPF/SCR
16.5
Battery/Tool Box
15.4
Space Saver Battery Box
(w/o Air Tanks or Step)
3.9
Space Saver Battery Box
(w/ Air Tanks or Step)
12.7
Frame Mounted Ladder Step
13.9
20" Diameter Fuel Tank
12.4
23" Diameter Fuel Tank
15.2
26" Diameter Fuel Tank
18.0
DEF Tank
15.4
FIGURE 3-33. Ground Clearance Calculations
DIMENSIONS
GROUND CLEARANCE CALCULATIONS
The ground clearance tables are provided as a tool as a tool to help layout bodies prior to arrival, not all optional
equipment is included.
The ground clearance (GC) can be estimated based on the following formula: GC = (A + B + C + D) / 2 - Y
TABLE 3-12. Ground Clearance
NOTES:
1) For “A” and “C” values, reference the FRAME HEIGHTS section for front suspension height or rear suspension
height.
2) For “B” and “D” values, reference the tire manufacturer’s website or catalog for overall diameter or static loaded
radius (SLR).
Peterbilt Motors Company 3- 36
3
Y = DISTANCE FROM BTM OF FRAME
TO TOP OF STANDARD CAB ROOF
Model
Y
389-131, 389-123 Low
Profile Hood
79.4
389-123, 386, 384, 367,
365
81.5
365 Full Profile Frame
Extensions
85.5
587 Day Cab
85.2
579/567
83.7
FIGURE 3-34. Overall Cab Height Calculations
DIMENSIONS
OVERALL CAB HEIGHT CALCULATIONS
The overall cab height tables are provided as a tool as a tool to help layout bodies prior to arrival, no roof mounted
equipment is included.
The overall cab height (CH) can be estimated based on the following formula: CH = (A + B + C + D) / 2 + Y
TABLE 3-13. Overall Cab Height
NOTES:
1) For “A” and “C” values, reference the FRAME HEIGHTS section for front suspension height or rear suspension
height.
2) For “B” and “D” values, reference the tire manufacturer’s website or catalog for overall diameter or static loaded
radius (SLR).
3) Roof mounted content such as horns and antennas are not included.
4) For extended day cab configurations, add 5.8” to overall cab height.
Peterbilt Motors Company 3- 37
3
DIMENSIONS
A B C D
20"
TANK
22.7
12.4
10.3
27.5
23"
TANK
24.5
15.2
10.5
31.0
26"
TANK
27.2
18.0
10.6
33.7
GALLONS
TANK LENGTH
USEABLE
TOTAL
20"
23"
26"
40
46
33.3
N/A
N/A
50
57
43.2
34.5
26.7
60
67
51.3
40.7
31.5
70
78
57.3
46.8
36.2
80
89
65.3
52.9
41.0
90
99
N/A
59.0
45.7
100
110
N/A
*65.1
50.5
110
121
N/A
N/A
55.2
120
131
N/A
77.3
60.0
135
147
N/A
N/A
66.8
150
163
N/A
N/A
*74.0
DIMENSIONS
FRAME COMPONENTS
This section includes drawings and charts related to common frame mounted components. Optional equipment may not
be depicted.
Please work with the local Peterbilt Dealer to request additional information if required. At the dealer’s request, Peterbilt
can provide frame layouts for individual vehicles prior to delivery.
FUEL TANKS
FIGURE 3-35. Fuel Tanks
TABLE 3-14. Fuel Tank Dimensions
TABLE 3-15. Fuel Tank Data
NOTES:
1) * Largest capacity without a weld seam.
Peterbilt Motors Company 3- 38
3
DESCRIPTION
LENGTH
STANDARD BOC BATTERY BOX
40.9
STANDARD BOC TOOL BOX
31.6
SPACE SAVER BATTERY BOX W/ STEP
28.2
SPACE SAVER BATTERY BOX W/O STEP
25.1
FRAME MOUNTED LADDER STEP
12.8
DESCRIPTION
GALLONS
A B C
SMALL DEF TANK
11.0
27.7
15.4
10.5
MEDIUM DEF TANK
20.7
27.7
15.4
10.5
LARGE DEF TANK
31.1
27.7
15.4
10.5
FIGURE 3-37. DEF Tank Isometric View
DIMENSIONS
DEF TANKS
FIGURE 3-36. DEF Tanks
TABLE 3-16. DEF Tank Dimensions and Data
OTHER FRAME COMPONENTS
TABLE 3-17. Other Frame Component Dimensions
Peterbilt Motors Company 3- 39
3
DIMENSIONS
EXHAUST SYSTEMS – 389 Family
EXHAUST SINGLE RH SIDE OF CAB DPF/SCR RH UNDER CAB
(Reference option code 3365040)
FIGURE 3-38. Exhaust Single RH Side of Cab DPF/SCR RH Under Cab
Peterbilt Motors Company 3- 40
3
DIMENSIONS
EXHAUST DUAL SIDE OF CAB DPF/SCR RH UNDER CAB
(Reference option code 3365090)
FIGURE 3-39. Exhaust Dual Side of Cab DPF/SCR RH Under Cab
Notes:
1) 11 5/8" frame rails or outserts are not available with dual side of cab exhaust configuration.
2) Dual side of cab exhaust is not available with Models 384 or 365 SBFA.
3) Dual side of cab exhaust is not available with an PX-9.
4) Dual side of cab exhaust on Model 389-131 will be low route configuration, not the high route shown above.
Peterbilt Motors Company 3- 41
3
DIMENSIONS
EXHAUST SINGLE RH BACK OF CAB DPF/SCR RH UNDER CAB
(Reference option code 3365020)
FIGURE 3-40. Exhaust Single RH Back of Cab DPF/SCR RH Under Cab
Peterbilt Motors Company 3- 42
3
DIMENSIONS
EXHAUST SINGLE HORIZONTAL DPF/SCR RH UNDER CAB
(Reference option code 3365050)
FIGURE 3-41. Exhaust Single Horizontal DPF/SCR RH Under Cab
Peterbilt Motors Company 3- 43
3
DIMENSIONS
EXHAUST SINGLE RH BACK OF SLEEPER DPF/SCR RH UNDER CAB
(Reference option code 3365030)
FIGURE 3-42. Exhaust Single RH Back of Sleeper DPF/SCR RH Under Cab
Peterbilt Motors Company 3- 44
3
DIMENSIONS
EXHAUST DUAL BACK OF SLEEPER DPF/SCR RH UNDER CAB
(Reference option code 3365100)
FIGURE 3-43. Exhaust Dual Back of Sleeper DPF/SCR RH Under Cab
Peterbilt Motors Company 3- 45
3
DIMENSIONS
EXHAUST SINGLE RH BACK OF SLEEPER DPF/SCR CROSS OVER UNDER FRAME
(Reference option code 3365000)
FIGURE 3-44. Exhaust Single RH Back of Sleeper DPF/SCR Cross Over Under Cab
Peterbilt Motors Company 3- 46
3
DIMENSIONS
EXHAUST DUAL BACK OF SLEEPER DPF/SCR CROSS OVER UNDER FRAME
(Reference option code 3365110)
FIGURE 3-45. Exhaust Dual Back of Sleeper DPF/SCR Cross Over Under Cab
Peterbilt Motors Company 3- 47
3
DIMENSIONS
EXHAUST SINGLE HORIZONTAL LH DPF/SCR CROSS OVER UNDER FRAME
(Reference option code 3365070)
FIGURE 3-46. Exhaust Single Horizontal DPF/SCR Cross Over Under Cab
Notes:
1) Day cabs require LH under cab battery box or in-cab battery box and omit hose tenna option.
DEF injector and coolant lines will be routed above the rails.
2) The piping between the DPF and SCR protrudes 1.2” above the 10-5/8” frame rail.
Peterbilt Motors Company 3- 48
3
DIMENSIONS
EXHAUST SINGLE LH BACK OF CAB/SLEEPER DPF/SCR VERTICAL – DAY CAB
(Reference option code 3365010)
FIGURE 3-47. Exhaust Single LH Back of Sleeper DPF/SCR Vertical – Day Cab
Notes:
1) With Model 365 or 384 and an MX engine, the piping will route below the frame rails similar to EXHAUST SINGLE
LH BACK OF SLEEPER DPF/SCR VERTICAL – 44” SLEEPER.
Peterbilt Motors Company 3- 49
3
DIMENSIONS
EXHAUST SINGLE LH BACK OF SLEEPER DPF/SCR VERTICAL – 44” SLEEPER
(Reference option code 3365010)
FIGURE 3-48. Exhaust Single LH Back of Sleeper DPF/SCR Vertical – 44” Sleeper
Peterbilt Motors Company 3- 50
3
DIMENSIONS
EXHAUST SGL RH SIDE OF CAB ISL-G ONLY
(Reference option code 3365130)
FIGURE 3-49. Exhaust Single RH Side of Cab ISL-G Only
Peterbilt Motors Company 3- 51
3
12.7”
DIMENSIONS
EXHAUST SINGLE RH BACK OF CAB ISL-G ONLY
(Reference option code 3365200)
FIGURE 3-50. Exhaust Single RH Back of Cab ISL-G Only
Peterbilt Motors Company 3- 52
3
29.0”
DIMENSIONS
EXHAUST SINGLE HORIZONTAL ISL-G OR ISX12-G ONLY
(Reference option code 3366650)
FIGURE 3-51. Exhaust Single Horizontal ISL-G or ISL12-G Only
Peterbilt Motors Company 3- 53
3
19.4”
DIMENSIONS
EXHAUST SINGLE RH FRAME MTD ISL-G OR X12-G ONLY
(Reference option code 3365140)
FIGURE 3-52. Exhaust Single Vertical ISL-G or ISL12-G Only
Peterbilt Motors Company 3- 54
3
DIMENSIONS
PTO CLEARANCES
This section includes visuals to aid in determining PTO locations and clearances.
Please work with the local Peterbilt Dealer to request additional information such as specific dimensions if required.
Reference transmission manufacturer literature for PTO locations for each transmission.
Bottom View from Right Rear Bottom View
Bottom View from Right Side Rear View
FIGURE 3-53. Automatic Transmission PTO Clearances
Peterbilt Motors Company 3- 55
3
DIMENSIONS
Bottom View from Right Rear Bottom View
Bottom View from Right Side Rear View
FIGURE 3-54. Manual Transmission PTO Clearances
Peterbilt Motors Company 3- 56
SECTION 4 BODY MOUNTING
Rail Height
(in.)
Flange Width
(in.)
Web Thickness
(in)
Section
Modulus
(cu. In.)
RBM (per rail)
(in.-lbs)
Weight (per rail)
(lbs/in.)
10 5/8
3.45
0.313
14.8
1,776,000
1.44
10 3/4
3.50
0.375
17.8
2,136,000
1.74
11 5/8
3.87
0.375
21.4
2,568,000
1.91
Main Rail
Height
(in.)
Insert
Outsert
Section
Modulus
(cu. In.)
RBM (per rail)
(in.-lbs)
Weight (per rail)
(lbs/in.)
10 5/8
9.875 x 2.87 x .250
None
23.6
2,832,000
2.48
10 3/4
9.875 x 2.87 x .250
None
28.9
3,468,000
2.78
10 3/4
9.875 x 2.87 x .250
11.63 x 3.87 x .375
45.7
5,484,000
4.67
(1)
11 5/8
10.75 x 3.50 x .375
None
37.7
4,524,000
3.65
INTRODUCTION
This section has been designed to provide guidelines to aid in body mounting. This is not intended as a complete guide,
rather as general information. Body mounting strategies are unique to each body type and body builder must determine
the appropriate method.
Please contact your local Peterbilt dealer if more information is desired.
FRAME RAILS
Frame rail information is provided per rail.
TABLE 4-1. Single Frame Rails
TABLE 4-2. Built-up Frame Rails
4
BODY MOUNTING
CRITICAL CLEARANCES
REAR TIRES AND CAB
CAUTION: Insufficient clearance between rear tires and body structure could cause damage to the body during
suspension movement.
Normal suspension movement could cause contact between the tires and the body. To prevent this, mount the body so
that the minimum clearance between the top of the tire and the bottom of the body is 8 inches (203 mm). This should be
measured with the body empty. See FIGURE 4-1.
FIGURE 4-1. Minimum Clearance Between Top of Rear Tires and Body Structure Overhang
CAUTION: Maintain adequate clearance between back of cab and the front (leading edge) of mounted body. It is
recommended the body leading edge be mounted 4 in. behind the cab. See FIGURE 4-2.
NOTE: Be sure to provide maintenance access to the battery box and fuel tank fill neck.
FIGURE 4-2. Minimum Back of Cab Clearance
Peterbilt Motors Company 4-2
4
BODY MOUNTING
BODY MOUNTING USING BRACKETS
CAUTION: Always install a spacer between the body subframe and the top flange of the frame rail. Installation of
a spacer between the body subframe and the top flange of the frame rail will help prevent premature wear of the
components due to chafing or corrosion.
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.
FRAME SILL
If the body is mounted to the frame with brackets, we recommend a frame sill spacer 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 4-3.
FIGURE 4-3. Spacer Between Frame Sill and Body Rail – Rubber or Plastic
Peterbilt Motors Company 4-3
4
BODY MOUNTING
BRACKETS
When mounting a body to the chassis with brackets, we recommend designs that offer limited relative movement, bolted
securely but not too rigid. Brackets should allow for slight movement between the body and the chassis. For instance,
FIGURE 4-4 shows a high compression spring between the bolt and the bracket and FIGURE 4-5 shows a rubber spacer
between the brackets. These designs will allow relative movement between the body and the chassis during extreme
frame racking situations. Mountings that are too rigid could cause damage to the body. This is particularly true with tanker
installations.
FIGURE 4-4. Mounting Brackets FIGURE 4-5. Mounting Brackets
Peterbilt Motors Company 4-4
4
BODY MOUNTING
MOUNTING HOLES
When installing brackets on the frame rails, the mounting holes in the chassis frame bracket and frame rail must comply
with the general spacing and location guidelines illustrated in FIGURE 4-6.
FIGURE 4-6. Hole Location Guidelines for Frame Rail and Bracket
FIGURE 4-7. Crossmember Gusset Hole Patterns (Additional Holes Available in 50 mm Horizontal Increments)
Peterbilt Motors Company 4-5
4
BODY MOUNTING
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.
FIGURE 4-8. Frame Rail Flange Drilling Prohibited
WARNING! DO NOT drill closely spaced holes in the frame rail. Hole centers of two adjacent holes should be
spaced no less than twice the diameter of the largest hole. Closer spacing could induce a failure between the
two holes.
CAUTION: An appropriately sized bolt and nut must be installed and torqued properly in all unused frame holes.
Failure to do so could result in a frame crack initiation around the hole.
CAUTION: 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.
CAUTION: Never use a torch to make holes in the rail. Use the appropriate diameter drill bit. Heat from a torch
will affect the material properties of the frame rail and could result in frame rail cracks.
CAUTION: The hole diameter should not exceed the bolt diameter by more than .060 inches (1.5mm).
Peterbilt Motors Company 4-6
4
BODY MOUNTING
BODY MOUNTING USING U–BOLTS
If the body is mounted to the frame with U–bolts, use a hardwood sill (minimum 1/2 inch (12.7 mm) thick) between the
frame rail and body frame to protect the top surface of the rail flange.
WARNING! Do not allow the frame rails or flanges to deform when tightening the U–bolts. It will weaken the
frame and could cause an accident. Use suitable spacers made of steel or hardwood on the inside of the frame
rail to prevent collapse of the frame flanges.
Use a hardwood spacer between the bottom flange and the U–bolt to prevent the U–bolt from notching the frame flange.
See FIGURE 4-9.
FIGURE 4-9. Acceptable U-Bolt Mounting with Wood and Fabricated Spacers
Peterbilt Motors Company 4-7
4
BODY MOUNTING
WARNING! Do not allow spacers and other body mounting parts to interfere with brake lines, fuel lines, or wiring
harnesses routed inside the frame rail. Crimped or damaged brake lines, fuel lines, or wiring could result in loss
of braking, fuel leaks, electrical overload or a fire. Carefully inspect the installation to ensure adequate
clearances for air brake lines, fuel lines, and wiring. See FIGURE 4-10.
FIGURE 4-10. Clearance Space for Air Lines and Cables
WARNING! Do not notch frame rail flanges to force a U–bolt fit. Notched or
damaged frame flanges could result in premature frame failure. Use a larger size U-bolt.
CAUTION: Mount U–bolts so they do not chafe on frame rail, air or electric lines.
Peterbilt Motors Company 4-8
4
BODY MOUNTING
REAR BODY MOUNT
When U–bolts are used to mount a body we recommend that the last body attachment be made with a “fishplate” bracket.
See FIGURE 4-11. This provides a firm attaching point and helps prevent any relative fore or aft movement between the
body and frame. For hole location guidelines, See FIGURE 4-7.
FIGURE 4-11. Fishplate Bracket at Rear End of Body
Peterbilt Motors Company 4-9
SECTION 5 FRAME MODIFICATIONS
FIGURE 5-1. Wheelbase Customization
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 5-1.
5
FRAME MODIFICATIONS
CROSSMEMBERS
After lengthening a wheelbase, an additional crossmember may be required to maintain the original frame strength. Contact Dealer for crossmember locations.
• The maximum allowable distance between the forward suspension crossmember and the next crossmember forward
is 47.2 inches (1200 mm). If the distance exceeds 47.2 inches (1200 mm) after the wheelbase is lengthened, add a
crossmember between them. See Figure 5-4. See Figure 4-7 on page 4-3 for crossmember hole patterns.
FIGURE 5-2. Crossmember Spacing Requirements
Peterbilt Motors Company 5-2
5
Fastener
Torque
Size
Nm
Lb.-Ft
5/16
22–30
16–22
3/8
41–54
30–40
7/16
75–88
55–65
1/2
109–122
80–90
9/16
156–190
115-140
5/8
224–265
165–195
3/4
394–462
290–340
7/8
517–626
380–460
1
952–1129
800–830
1-1/8
1346–1591
990–1170
1-1/4
1877–2217
1380–1630
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
FRAME MODIFICATIONS
TORQUE REQUIREMENTS
Torque values apply to fasteners with clean threads, lightly lubricated, with hardened steel washers, and nylon-insert nuts.
TABLE 5-1. Customary Grade 8 UNF or UNC.
TABLE 5-2. U.S. Customary - Grade 8 Metric Class 10.9
WELDING
The frame rails are heat treated; therefore, they are not weldable.
Peterbilt Motors Company 5-3
SECTION 6 ELECTRICAL 389 FAMILY
CONTROL UNIT IDENTIFICATION
This manual provides service information covering models equipped with the multiplexed instrumentation system. Before
attempting to make service repairs, the technician should be knowledgeable about the system design, components,
operation and troubleshooting procedures for diagnosing instrumentation problems.
Vehicle component inputs are sent to the ICU/CECU through the J1939 data bus or conventional wiring. The ICU/CECU
interprets the various inputs and monitors/controls the functions for each input through the ICU/CECU software. Output
signals from the ICU/CECU provide data for the gauges, warning lamps, audible alarms, and displays inside the cluster.
When used in conjunction with the Electronic Service Analyst (ESA) diagnostic software tool, the technician can review
fault codes stored in the ICU/CECU, verify whether the instrumentation is working properly and diagnose the root cause of
the problem more easily.
FUNCTIONAL DESCRIPTION-INSTURMENTATION CONTROL UNIT/CAB ELECTRONIC
CONTROL UNIT (ICU/CECU)
The heart of the multiplexed instrumentation system is the ICU/CECU. The ICU/CECU is located behind the radio at the
center of the dash. See FIGURE 6-1.
This manual provides service information covering trucks equipped with the multiplexed instrumentation system. Before
attempting to make service repairs, the technician should be knowledgeable about the system design, components,
operation and troubleshooting procedures for diagnosing multiplexed instrumentation problems.
6
Control
Module
Models
Production Build Dates
ICU
357, 378, 379,
385, 386
Vehicles built with new conventional interiors from April 2005 to
January 2007
CECU
365, 367, 384,
386, 387, 388,
389, 567, 579, 587
Vehicles built with EPA compliant engines beginning January
2007
Electrical 389 Family
Electronic Service Agent (ESA)
Introduced in 2005, the Electronic Service Analyst (ESA) is the diagnostic software tool that is used to simplify the
troubleshooting of the new multiplexed instrumentation.
CU or CECU?
Early multiplexing in Peterbilt trucks was for the instrumentation system only. The module was known as the
Instrumentation Control Unit (ICU).
Now, as multiplexing from this control module is being used for systems other than just the instrumentation, the module
has been renamed the Cab Electronic Control Unit (CECU).
The CECU is an updated ICU. It is still located behind the center console, but now includes a few more circuits to incorporate the new features. ESA 2.0 is the tool for both.
Identifying which control module is in the vehicle helps determine what features are present and also aids in
troubleshooting.
Models–Build Dates Identification
TABLE 6-1. Control Module
IDENTIFICATION
Control module identification can be made using a few methods:
Searching using the Electronic Catalog (ECAT)
Connecting using the Electronic Service Analyst (ESA) 2.0
Dome light function
ECAT IDENTIFICATION
Using ECAT or ESA 2.0 are the easiest and most exact ways of determining the type of control module in the truck.
ECAT provides a parts list “as built” and Bill of Materials in formation for each specific truck. The catalog is searchable,
and contains the part number and identification of the truck’s instrument panel control module.
ICU Part Number Q21-1029-X-XXX
CECU Part Number Q21-1055-X-XXX
Peterbilt Motors Company 6-2
6
Electrical 389 Family
ESA IDENTIFICATION
Connecting using ESA 2.0 brings up a control module information window. In this window, the fourth line item is the
Control Unit Type and identifies whether the truck has an ICU or CECU.
FIGURE 6-2. ESA Identification, Programming Date and Module Software Version
DOME LIGHT IDENTIFICATION
The CECU system has an updated feature that delays turning the dome light off when you close the door. The previous
ICU system did not have this function so the light turns off as soon as the door is shut. Therefore, if the dome light does
not turn off immediately after all doors are shut, then the vehicle has a CECU system. If the dome light does turn off
immediately, then the vehicle may be ICU OR CECU with this function disabled. In these cases, you will need to refer to
ECAT for verification.
Comparison Chart
The following charts show the differences between the ICU and CECU.
The first chart provides an alphabetical listing of the features available for either an ICU or CECU. Since the CECU is an
updated ICU, almost all of the features of an ICU are found in a CECU, except a few out dated options such as the
pyrometer.
The similarity of the modules is easily seen in the second chart as well. This chart is an abbreviated connector pinout of
each module. Since the same wiring connections are used for both modules, it’s easy to see that the CECU has more
circuits to handle the increase in multiplexed features.
Peterbilt Motors Company 6-3
6
Supported Features
ICU
CECU
Air filter restriction
x
x
Air pressure transducer
x
x
Ammeter
x
x
Axle temperature 1
x
x
Axle temperature 2
x
x
Axle temperature 3
x
x
Backlighting -auxiliary
x
x
Brakesaver oil temperature
x Cab dome lamp
x
Check engine telltale
x
x
Clutch switch
x
Courtesy lights - left door
x
x
Courtesy lights -right door
x
Cruise control
x
CVSG data/power
x
x
Dash buzzer
x
x
Dash/panel illumination
x
x
Dimmer input
x
x
Dome lamp
x
Editable telltale 1, position 4
x
x
Editable telltale 2, position 7
x
x
Editable telltale 3, position 8
x
x
Editable telltale 4, position 9
x
x
Editable telltale 5, position 10
x
Editable telltale 6, position 12
x
x
Editable telltale 7, position 13
x
Editable telltale 8, position 14
x
x
Editable telltale 9, position 16
x
x
Engine fan override
x
Fifth wheel lock telltale
x
x
Fuel filter restriction
x
x
Fuel level sensor 1
x
x
Fuel level sensor 2
x
x
General oil temperature
x
x
Hazard
x
x
Headlamps active
x
High beam active
x
x
I-CAN high
x
x
I-CAN low
x
x
Idle timer relay
x
Interaxle lock telltale
x
x
K-line
x
x
Left turn
x
x
Message display
x
Outside air temperature
x
x
Park brake active
x
x
Power -accessory
x
x
Power -battery
x
x
Power -ignition
x
x
Power supply +5V sensors
x
x
Pyrometer
x
Supported Features
ICU
CECU
Regeneration switch enable
x
Retarder select
x
Right turn
x
x
Seat belt telltale
x
Spare analog input 2R
x
Spare analog input 3V
x
Spare digital input 1H
x
Spare digital input 1L
x
Stop engine telltale
x
x
Tail & park lamps active
x
x
Tractor ABS telltale
x
x
Trailer ABS telltale
x
x
Transfer case oil temp
x
x
Transmission oil temp -aux
x
x
Transmission oil temp - main
x
x
V-CAN high
x
x
V-CAN low
x
x
Con
nector
Pin
Number
Circuit Function
ICU
CECU
A 1 CVSG power
x
x 2
Power - battery
x
x 3
Cab dome lamp
x
4 Menu control switch power
x 5
Ground
x
x
6 Menu control switch ground
x 7
Dash/panel illumination
x
x 8
Auxiliary backlighting
x
x 9
Power -battery
x
B 1 Menu control switch encode A
x 2
Menu control switch encode B
x 3
Menu control switch enter
x
4
Courtesy lights - right door jamb
switch
x
5 Spare digital input 1H
x 6
Dome lamp input
x 7
Seat belt telltale
x 8
Cruise set
x 9
Cruise resume
x 10
Spare digital input 1L
x 11
Retarder select 1
x 12
Retarder select 2
x 13
Clutch switch
x
14
Headlamps active
x
15
PTO set (future provision)
x
16
PTO resume (future provision)
x 17
Engine fan override
x 18
Regen enable
x 19
Spare digital input 3L (future prov)
x 20
Spare digital input 4L (future prov)
x 21
Spare digital input 5L (future prov)
x
22
Spare digital input 2H (future prov)
x
Electrical 389 Family
TABLE 6-2. Dome Light Identification
Peterbilt Motors Company 6-4
6
Con
nector
Pin
Number
Circuit Function
ICU
CECU
C 1 Power supply +5V sensors
x
x
2 Analog return
x
x
3
PTO oil temp (future
provision)
x 4
K-line
x
x 5
Dimmer input
x
x
6
Air pressure transducer - primary
x
x
7
Air pressure transducer secondary
x
x 8
Air pressure transducer application
x
x 9
Ammeter
x
x
10
Air filter restriction
x
x 11
Fuel filter restriction
x
x 12
Fuel level sensor 1
x
x 13
Fuel level sensor 2
x
x
14
CVSG data
x
x 15
CVSG return
x
x 16
Outside air temperature
x
x 17
Axle temperature 1
x
x 18
Axle temperature 2
x
x 19
Axle temperature 3
x
x 20
General oil temperature
x
x 21
Transmission oil temperature
- main
x
x 22
Transmission oil temperature
- aux
x
x 23
Pyrometer
x
24
Brakesaver oil temperature
x
25
Analog return
x
x
26
Transfer case oil
temperature
x
x 27
Remote throttle signal (future
provision)
x
28
Spare analog input 1V
(future provision)
x
29
Spare analog input 2V
(future provision)
x 30
Spare analog input 3V
x 31
Spare analog input 2R
x
32
Spare analog input 1R
(future provision)
x
39
Spare relay output 8 (future
provision)
x
D 1 Power - ignition
x
x 2
Courtesy lights -left door
jamb switch
x
x 3
Power - accessory
x
x
4 Hazard
x
x 5
Tail & park lamps active
x
x
6 High beam active
x
x
7 Park brake active
x
x
8 Left turn
x
x
Con
nector
Pin
Number
Circuit Function
IC
U
CECU
D
9
Right turn
x
x
(cont.)
10
Cruise on/off
x
11
Interaxle lock telltale
x
x
12
Fifth wheel lock telltale
x
x 13
Tractor ABS telltale
x
x 14
Trailer ABS telltale
x
x 15
Check engine telltale
x
x
16
Stop engine telltale
x
x
17
Spare digital input 6L (future
provision)
x
19
Editable telltale 1 - position 4
x
x 20
Editable telltale 2 - position 7
x
x
21
Editable telltale 3 - position 8
x
x
22
Editable telltale 4 - position 9
x
x 23
Editable telltale 5 - position 10
x
24
Editable telltale 6 - position 12
x
x 25
Editable telltale 7 - position 13
x
26
Editable telltale 8 - position 14
x
x
27
Editable telltale 9 - position 16
x
x
28
Dash buzzer 1A
x
x 29
Dash buzzer 1B
x
x 30
Dash buzzer 1C
x
x 31
Dash buzzer 2
x
x 32
M-CAN high (future provision)
x 33
M-CAN low (future provision)
x
34
I-CAN high
x
x
35
I-CAN low
x
x 37
V-CAN high
x
x 38
V-CAN low
x
x
E 1 Idle timer relay
x
2
Spare relay output 1 (future
provision)
x 3
Spare relay output 2 (future
provision)
x 4
Spare relay output 3 (future
provision)
x
5 Ground
x
6
Spare relay output 4 (future
provision)
x 7
Spare relay output 5 (future
provision)
x 8
Spare relay output 6 (future
provision)
x
9
Spare relay output 7 (future
provision)
x
Electrical 389 Family
Peterbilt Motors Company 6-5
6
Electrical 389 Family
HOW MULTIPLEXED INSTRUMENTS WORK
Multiplexed gauges receive signals through the Instrumentation Control Unit/Cab Electronic Control Unit (ICU/ CECU)
located behind the center console. The ICU/CECU receives sensor signals either through the J1939 data bus or via
conventional wiring sending signals from sensors that read actual pressures or temperatures. The ICU/CECU interprets
this data and monitors or controls vehicle operation through the ICU/CECU software. The ICU/CECU then sends data to
the gauges, warning lamps, audible alarms, and displays located inside the gauge clusters. The central instrument cluster
(Figure 6-3) includes the speedometer (including odometer and trip meter) and tachometer (including engine hour meter
and outside temperature display), plus pre-installed standard and/or editable warning light symbols called “telltale decals”
mounted on the “Icon Tray.”
The Icon Tray slides into the bottom of the cluster. The standard Icon Tray covers most warning light requirements;
editable icon lenses can be added for less common components that also require warning lights.
FIGURE 6-3. Central Instrument Cluster
Introduction
This section provides service information covering Peterbilt Conventional Models equipped with the multiplexed
instrumentation system. Before attempting to make service repairs, the technician should be knowledgeable about the
system design, components, operation and troubleshooting procedures for diagnosing instrumentation problems.
Vehicle component inputs are sent to the ICU/CECU through the J1939 data bus or conventional wiring. The ICU/CECU
interprets the various inputs and monitors/controls the functions for each input through the ICU/CECU software. Output
signals from the ICU/CECU provide data for the gauges, warning lamps, audible alarms, and displays inside the cluster.
See Figure 6-5.
When used in conjunction with the Electronic Service Analyst (ESA) diagnostic software tool, the technician can review
fault codes stored in the ICU/CECU, verify whether the instrumentation is working properly and diagnose the root cause of
the problem more easily.
Peterbilt Motors Company 6-6
6
Electrical 389 Family
Central Instrument Cluster
The central instrument cluster includes:
driver information display
speedometer (including odometer and trip meter)
tachometer (including engine hour meter and outside temperature display)
pre-installed standard and/or editable warning light symbols called “telltale decals” mounted on the “Icon Tray.”
The Icon Tray slides into the bottom of the cluster. The standard Icon Tray covers most warning light requirements;
editable icon lenses can be added for less common components that also require warning lights.
The Driver Information Display, located at the top of the instrument cluster, displays vehicle information and warnings
through a constant monitoring of the vehicle systems. The various functions may be accessed by navigating through
menu screens using the menu control switch (rotational knob).
FIGURE 6-4. ICU/CECU Access
Peterbilt Motors Company 6-7
6
Electrical 389 Family
Peterbilt Motors Company 6-8
6
Electrical 389 Family
ICU/CECU Architecture
The software programming of the control module can be grouped into three main types:
Run Time (RT) - which acts as the operating system where all communication takes place.
Programmable Logic Controller (PLC) Code - manufacturer specific programmed code and software that is
developed, accessible and editable.
Vendor Module - blocks of code that are developed for specific manufacturers to allow other features to be
implemented more efficiently.
See Multiplexed Instrumentation Block Diagram (Figure 6-6).
To better understand how Electronic Service Analyst (ESA) functions and why there are current limitations on some of the
multiplexed features, by explaining what ESA can see. Currently ESA can look at all information that is communicated
between the RT and PLC Code portions of the programming. Any signals, be they inputs, outputs, or dataline signals,
sent between the RT and PLC Code are visible to ESA. These are the signals that may be monitored and simulated using
ESA.
Limitations with the ESA program are found in the communications that go to the pre-developed Vendor Modules.
Currently this information is not available for ESA to look at. That is why some features that have Vendor Module
programming, such as the odometer and the message display, are not available to monitor and/or simulate through ESA.
FIGURE 6-6. CECU Block Diagram
Peterbilt Motors Company 6-9
6
Electrical 389 Family
The central instrument cluster receives input data from the ICU/CECU via the I-CAN data bus. When the ignition key
is first turned ON, the cluster performs a calibration power
on self-test.
Power On Self-Test
Ignition key turned ON.
The speedometer and tachometer gauge pointers move from pointing at zero, counter-clockwise to their
mechanical limit (approx. -8°), remain there for 1 second and return to pointing at zero.
At the same time, all LED indicators and telltales are switched on together, and then switched off together.
A warning sound sequence is also activated five times without a break.
The warning lamps in the cluster are all activated by the ICU/CECU, Three screens will sequentially display
warning icons on the Driver Information Dis¬play. The ICU/CECU receives direct wire inputs for all warning lamps
with the exception of the Low Cool¬ant Level warning and the Traction Control/Stability Control lamp. These lamp
inputs are received via the J1939 (vehicle CAN) data link. The ICU/CECU typi¬cally receives the Trailer ABS
warnings via the J1939 (Vehicle CAN) data link, however it can also be di¬rect wired to the ICU/CECU from the
ABS unit on the trailer, if required.
NOTE: Before replacing the ICU/CECU or any gauges, check the wiring and fuses, and perform the diagnostic tests using
ESA to verify that you are not replacing a good component.
Commercial Vehicle Smart Gauges (CVSG)
The right and left instrument panel gauges used with the multiplexed instrumentation are commonly referred to as
Commercial Vehicle Smart Gauges (CVSG). Like the central instrument cluster, the 2-inch gauges also receive input data
directly from the ICU/CECU. CVSG’s are electronic and mechanical. The electronic CVSG’s receive digi¬tal data from the
ICU/CECU via the CVSG data bus. The mechanical gauges (i.e. suspension air pressure, etc.) are driven directly from the
air pressure. Both types of gauges receive input signals from the ICU/CECU via a 4-wire “daisy chained” jumper harness
that links one gauge to another. When the ignition key is first turned ON, all the electronic 2-inch gauges will perform a
calibration “power on self-test.”
Power On Self-Test
Ignition key turned ON.
The gauge pointers move from pointing at zero, counterclockwise to their mechanical limit (approx. ¬5°), remain
there for 1 second and return to pointing at zero.
At the same time, all LED indicators are switched on together, and then switched off together.
Additional CVSG gauge information service technicians should be aware of:
2-inch electronic gauges receive their power from the ICU/CECU.
Yellow = Power wire (9-16 volts)
Green = Ground (Return) wire
The ICU/CECU sends 2-inch electronic gauges information over a data link (blue wire) between the ICU/ CECU
and the gauge.
4-way jumper harnesses link each 2-inch gauge together.
Yellow = Power wire
Green = Ground (Return)
Blue = Data link
Brown = Backlighting (used for mechanical gauges only)
Backlighting for 2-inch electronic gauges is sent from the ICU/CECU to the gauges via the data link (Blue wire).
If the headlamps are on and the dimmer is turned to bright, you can scan the panel and tell which elec¬tronic
gauges are wired and functioning correctly.
Peterbilt Motors Company 6-10
6
Electrical 389 Family
If part of the panel has gauges backlit and some of the gauges are not backlit, the jumper harness wire between
the gauges is probably not connected properly.
If a 2-inch electronic gauge has power (yellow wire) and ground (green wire) but is not receiving data (blue wire),
then the red indicator lamp at the 6 o’clock position of the gauge blinks after 30 seconds of waiting for data. This
indicates there is an open or short in the blue wire between the gauge and the ICU/CECU.
If the red indicator lamp is on but the gauge is operational, it indicates the value is out of normal range.
If a 2-inch electronic gauge has a short or open in the sensor wiring, the gauge needle moves 5° below the first
tick mark (approximately one needle thickness).
Optional mechanical gauge (such as air suspension) needles are driven mechanically with air pressure. There is
no red warning lamp and the backlighting is through the brown wire from the ICU/CECU (a PWM input). The 4way jumper harness is still used to pass all 4 circuits through the gauge to the next gauge in the chain.
Specialty CVSG gauges (such as the clock, PTO hour meter, and transmission display) are stand-alone gauges
and are independent of the ICU/CECU.
Instruments and Controls Operation
Before attempting to repair any instrumentation problems, the technician should have a complete understanding of how
the instruments and controls operate.
Speedometer The Speedometer indicates the vehicle speed in miles per hour (mph) and in kilometers per hour (km/h).
Tachometer The Tachometer measures the engine speed in revolutions per minute (rpm).
Air Filter Restriction Pressure The Air Filter Restriction Pressure gauge indicates the condition of the engine air cleaner
and is measured by inches of water (H2O). A clean filter should register 7 in. H2O (may vary with system design) and a
filter whose life is over registers approximately 25 in. H2O.
Air Starter Pressure The Air Starter Pressure Gauge indicates the amount of air pressure in the air start reservoir.
Ammeter The Ammeter monitors the vehicle’s electrical system and makes sure the system is in balance and operating
normally. If not, it may be drawing power from the alternator (positive reading) or from the batteries (negative reading).
Under normal conditions the ammeter will read nearly “zero.”
Axle, Drive Oil Temperature The Drive Axle Oil Temperature gauges (front, rear, and center) indicate the temperature of
the lubricant in the vehicle’s axles.
Axle, Pusher Air Pressure, #1, #2, #3 The Pusher Axle Air Pressure gauges indicate the air pressure in each of the
pusher axles suspension air bags.
Axle, Tag Air Pressure The Tag Axle Air Pressure gauge indicates the amount of air pressure in the tag axle suspension
air bags.
Brake, Application Air Pressure The Brake Application Air Pressure gauge indicates how much air pressure is being
applied from the foot brake valve or trailer brake hand valve to the air brakes.
BrakeSaver Application Air Pressure (Export vehicles only) The BrakeSaver Application Air Pressure gauge indicates
the amount of air pressure applied to the BrakeSaver hand control valve.
BrakeSaver Oil Temperature (Export vehicles only) The BrakeSaver Oil Temperature gauge indicates the temperature
in the BrakeSaver. If the oil temperature exceeds the maximum limits, a red warning lamp in the gauge turns on.
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Electrical 389 Family
Engine Coolant Temperature The Engine Coolant Temperature gauge indicates the temperature of the engine coolant.
If the coolant temperature exceeds the maximum limits, a red warning lamp in the gauge illuminates and an audible
warning sounds. If the coolant temperature continues to rise, the Check Engine and/or Stop Engine lights illuminate.
Under normal operating conditions the water temperature gauge should register between 165 and 205°F (74 and 90°C).
Under certain conditions, somewhat higher temperatures may be acceptable. The maximum allowable temperature is
220°F (104°C) with the cooling system pressurized, except for certain engines.
Engine, Oil Pressure If the oil pressure drops below the minimum pressure a red warning light in the gauge illuminates,
the Stop Engine light illuminates and an audible alarm tone sounds.
Engine Oil Temperature The Engine Oil Temperature gauge indicates the engine oil temperature. If the oil temperature
exceeds the maximum limits, a red warning light in the gauge illuminates.
Fuel Filter Restriction Pressure This gauge tells you the condition of the fuel filter by indicating the restriction from the
fuel filter to the fuel pump. The restriction is measured by inches of mercury (in-Hg).
Fuel Level, Primary/Secondary (if equipped) The Pri¬mary Fuel gauge and Secondary Fuel gauge (if equipped)
indicate the approximate amount of fuel in each fuel tank. In addition to indicating empty and full, the gauge(s) also
indicate the fuel level in graduated increments. When the fuel level for each tank is below 1/4 full, a red warning light in
the gauge illuminates.
General Air Pressure #1, #2 The General Air Pressure gauge(s) are used for customer installed component applications.
General Oil Temperature The General Oil Temperature gauge(s) are used for customer installed component
applications.
Manifold Pressure (Boost) The Manifold Pressure (Boost) gauge indicates the power the engine is putting out by
showing the amount of turbo boost. If the pressure indicated by the manifold pressure gauge goes down, there may be
something wrong with the engine
Primary and Secondary Air Pressure Gauge The Primary Air Pressure gauge indicates pressure in the rear braking
system. The Secondary gauge indicates pressure in the front braking system. Each gauge indicates the amount of air
pressure in each system in pounds per square inch (psi). On vehicles equipped with metric air pressure gauges, the
gauge faceplate includes a kPa (major) scale and psi (minor) scale. If the pressure in either or both circuits falls below 65
psi, a red warning light in the gauge illuminates and an audible alarm tone sounds when the engine is running.
Suspension Load Air Pressure, #1, #2 The Suspension Load Air Pressure gauge indicates the amount of air pressure in
the air suspension air bags. When the vehicle is equipped with a second Suspension Load Air pressure gauge, the #1
gauge indicates the air pressure in the driver’s side air bags. The #2 gauge indicates the air pressure in the passenger’s
side air bags.
Tractor Brake Application Air Pressure The Tractor Brake Application Air Pressure gauge indicates the amount of air
pressure applied to the tractor brakes.
Trailer Brake Application Air Pressure The Trailer Brake Application Air Pressure gauge indicates the amount of air
pressure applied to the trailer brakes during brake foot valve and/or hand brake control valve applications.
Trailer Reservoir Air Pressure The Trailer Reservoir Air Pressure gauge indicates the amount of air pressure in the trailer
brake reservoir.
Transfer Case Oil Temperature The Transfer Case Oil Temperature gauge indicates the temperature of the oil in the
transfer case. If the oil temperature exceeds maximum limits, a red warning light in the gauge illuminates.
Transmission Oil Temperature, Main The Main Transmission Oil Temperature Gauge indicates the temperature of the oil
in the transmission.
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Standard / Optional Input Source
Input Source
Sensor Type *
Air Filter Restriction Pressure
Sensor
Active
Air Starter Pressure
Mechanical
Ammeter
Sensor
Active
Auxiliary Transmission Oil Temperature
Sensor
Passive
Brake Application Pressure
Sensor
Active
Brake Saver Application Air Pressure
Mechanical
Brake Saver Oil Temperature (Not available with
CECU instrumentation)
Sensor
Passive
Drive Axle Oil Temperature
Sensor
Passive
Engine Coolant Temperature
V-CAN (J1939)
Engine Oil Pressure
V-CAN (J1939)
Engine Oil Temperature
V-CAN (J1939)
Fuel Filter Restriction Pressure
Sensor
Active
Fuel Level
Sensor
Passive
General Air Pressure
Mechanical
General Oil Temperature
Sensor
Passive
Main Transmission Oil Temperature
Sensor
Passive
Manifold Pressure (Boost)
V-CAN (J1939)
Primary & Secondary Air Pressure
Sensor
Active
Pusher Axle Air Pressure
Mechanical
Pyrometer (Exhaust Temperature) (Not available with
CECU instrumentation)
Sensor
Passive
Speedometer
V-CAN (J1939)
Suspension Load Air Pressure
Mechanical
Tachometer
V-CAN (J1939)
Tag Axle Air Pressure
Mechanical
Trailer Brake Application Air Pressure
Mechanical
Trailer Reservoir Air Pressure
Mechanical
Transfer Case Oil Temperature
Mechanical
Voltmeter
Battery Voltage
Electrical 389 Family
Transmission Oil Temperature, Auxiliary The Auxiliary Transmission Oil Temperature gauge indicates the temperature
of the oil in the auxiliary transmission.
Transmission Retarder Oil Temperature The Transmission Retarder Oil Temperature gauge indicates the temperature
of the oil in the transmission retarder.
Voltmeter The Voltmeter displays the battery voltage. Normally, it shows 12 to 14V (volts). A red warning light in the
gauge illuminates when an out of range condition exists.
TABLE 6-3. Gauge Input Sources
* Sensor Types:
Active - Has 3 wires and requires power to operate. Output is a linear voltage.
Passive - Has 2 wires and does not require power to operate. Output is a change in resistance.
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Electrical 389 Family
TRANSMISSION BACK UP SIGNALS
The back-up signal can be accessed from pin A of the 5-way tail light connector located at the end of frame.
The tail light connector is a 5-way connector located in the chassis harness at the end of frame. It will either be connected
to a tail light, a jumper harness, or tied up in the rail if no tail lights are provided.
FIGURE 6-7. Mating Connector: Packard PN 12186400
JUNCTION BOX
The junction box easy access to various signals as outlined in Figure 6-6.
FIGURE 6-8. Junction Box BOC or EOF
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Electrical 389 Family
J1939
Warning! The J1939 databus is the communication link between the engine and the Anti-Lock Braking System
(ABS). Only J1939 compatible devices should be added to the databus. Some J1939 compatible aftermarket devices may
disrupt the ability of the databus to communicate. If the databus is disrupted by an aftermarket device, it must be removed
from the databus.
Guidelines - J1939 Circuit Requirements
Circuits added must be a twisted pair consisting of a minimum of 1 twist per inch.
Individual breakout length of circuits added cannot exceed 118 inches.
Do not splice into existing J1939 circuits. Use the connection points provided.
J1939 circuits are for data transmission only and are not to be used for power or ground circuits.
Any modifications must conform to SAE J1939-15.
J1939 Access
All Peterbilt vehicles equipped with 2007 Emissions compliant engines include J1939-15 circuitry. The J1939 circuit can
be accessed in two locations. The first access is located inside the dash near the diagnostic connector. The second
access is at the driver side toward the rear of the engine.
1. Dash Access - Connector located in dash behind key switch panel approx 1 foot down the harness
FIGURE 6-9. Dash Access
2. Engine Access - Connector located on OEM engine harness on driver’s side of engine toward the rear of engine
FIGURE 6-10. Engine Access
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Electrical 389 Family
J1939 Access Procedures
1. Identify J1939 Access Connector (note long blue shell)
2. Disconnect connection (note terminating resistor from inside blue connector)
FIGURE 6-11. J1939 Access
3. Make connection in between original connection (tin).
4. Ensure terminating resistor is inserted in blue connector shell (arrow).
FIGURE 6-12. J1939 Access
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Electrical 579 Family
SECTION 7 ELECTRICAL 579 FAMILY
INTRODUCTION
This section is written to provide information to the body builder when installing equipment into vehicles built with
Multiplexed instrumentation. The new technology presented by NAMUX 4 level instrumentation integrates J-1939 CAN
data communications to various equipment on the vehicle. This book is intended to address how to work in aftermarket
equipment while still maintaining full functionality of the OEM vehicle.
The most important advancement of NAMUX 4 instrumentation is the implementation of the Cab ECU controlling air
operated aftermarket devices. While it is still possible to wire completely outside of the Cab ECU system, utilizing the
CECU functions will make a cleaner installation and will maintain OEM functionality. NAMUX 4 expands controls to air
operated devices by receiving input from dash switches, remote (aftermarket) switches, sensors mounted to the
aftermarket equipment and other vehicle parameters (engine speed, transmission status etc.) With the proper
programming, the CECU will then process the inputs and will create a J-1939 Data instruction which is communicated to
another controller outside the cab called the Chassis Node. This chassis node receives the instruction and connects 12V
power to an air solenoid. 12V power will open the solenoid and supply air pressure to that air circuit.
FIGURE 7-1. NAMUX 4 System Diagram
In addition to NAMUX 4 technology, the vehicle electrical harness has been redesigned to minimize weight and reduce
various connectors (which have been proven to increase the opportunity for electrical malfunctions which also increase
the amount of time to troubleshoot). What this means for the aftermarket installer is that there is a limitation to modifying
a vehicle with aftermarket equipment if the vehicle was not originally specified for those options from the factory. To the
aftermarket installer, more time will be spent installing pins and routing wires instead of simply installing jumper harnesses
if the vehicle was not specified with ‘customer installed’ equipment from the factory. For example, vehicles ordered with a
‘customer installed’ PTO will have connectors on the vehicle for aftermarket connectors. A vehicle specified with standard
radio will not have a pigtail for premium sound speakers.
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Electrical 579 Family
BODY BUILDER CONNECTION POINTS
Becoming familiar with the various connectors available to the aftermarket installer is important. This section contains
reference information for the connectors that are used to add equipment.
Harness Design
The 579 and the vocational 567 are designed and manufactured with a cab harness that is chassis specific. The new
design minimizes the number of connectors which improves routing, reduces electrical problems and reduces diagnostic
time when servicing. The new design, however, changes the way electrical components are added to the vehicle for final
use customers. The after-market installer will have several options available:
1. Ensure that the vehicle is ordered and specified with the equipment installed or at least have ‘furnish by owner’
provision.
2. Install electronic accessories outside of the CECU network, direct power from the power distribution center and no
splicing into the cab harness.
3. Route new wires and install pins to the designated pin location on all connectors.
It is imperative that the installer never splice into a cab harness for signal or power purposes.
Remote Throttle and Remote PTO Control
The body builder will need to find the 12-pin remote throttle connector, located in the engine compartment on the engine
harness. See the PTO Section for additional information
FIGURE 7-2. 12 Pin Connector
Spare Power
Spare power is located at the fuse panel or connector P001.
Air Solenoid Ground
Air solenoids are grounded to connectors P157 and P185 which are located behind the overbell between the air manifold
and the chassis node.
Cab Switch Backlighting
Splice blocks P011 and P013 provide power for switch lighting. These are located behind the panel to the right of the
steering column. In some instances, you may need to remove the instrument cluster.
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Electrical 579 Family
Electric Engaged Equipment (Opposed to Air Operated)
At the left hand forward cab mount, P198 is available for PTO controls that are electrically engaged via 12V DC power.
FIGURE 7-3. Electric Engaged Equipment Connector
Air Solenoid Bank and Chassis Node
The installer needs to identify where these two components are located.
FIGURE 7-4. Air Solenoid Bank and Chassis Node
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Electrical 579 Family
Rear Axle Controls and Sensors
Two connectors are located on the left hand frame rail forward of the forward rear drive axle. P046 is to install axle
temperature sensors and P047 is to connect differential lock mechanisms.
FIGURE 7-5. Rear Axle Controls and Sensors Connector
B-CAN Interface
One connector is located at the EOF for the BCAN interface.
FIGURE 7-6. B-CAN Connector
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Electrical 579 Family
Location Diagrams for Various Connectors on the Frame
FIGURE 7-7. Chassis Harness From Cab Mount to Front of Frame
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Electrical 579 Family
FIGURE 7-8. Chassis Harness From Cab Mount to BOC
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Electrical 579 Family
FIGURE 7-9. Connectors Near Front Cab Mount
FIGURE 7-10. Connector Near BOC
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Electrical 579 Family
FIGURE 7-11. VCAN Connectors
FIGURE 7-12. Firewall Connectors
Peterbilt Motors Company 7-8
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