Peterbilt Medium Duty Service Manuals

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Release Date 7/1/17

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BODY BUILDER MA NUAL CONTENTS

SECTION 1: INTRODUCTION SECTION 2: SAFETY AND COMPLIANCE

SAFETY SIGNAL S 2-1 FEDERAL MOT O R VEHI CLE SAFETY STANDA R DS AND CO MPLIANCE 2-2 NOISE AND EMISSIONS REQUIREMENTS 2-3 FUEL SYSTEM 2-4 COMPRESSED AIR SYSTEM 2-4 EXHAUST AND EXHAUST AFTER-TREATMENT SYSTEM 2-5 COOLING SYSTEM 2-6 AIR INTAKE SYSTEM 2-6 CHARGE AIR COOLER SYSTEM 2-6 ELECTRICAL SYSTEM 2-7

SECTION 3: DIMENSIONS

INTRODUCTION 3-1 ABBREVIATIONS 3-1 OVERALL DIMENSIONS 3-1

MODEL 348 (110” BBC) 3-2 MODEL 348, 337, 330, 325 (108” BBC) 3-3 MODEL 348 (110” BBC), 348 (108” BBC), 337 w/ 27.8” FEPTO Bumper Extension 3-4

MODEL 348 (110” BBC), 348 (108” BBC), 337 w/ 3.2” FEPTO Bumper Extension 3-5 CAB – 1.9m MEDIUM DUTY CAB FAMILY 3-6 ROOF FARING 3-7 REAR WINDOW 3-8 ROOF BOW STRUCTURE 3-9 CABMATE CAB SUSPENSION 3-10 CAB STEP HEIGHT 3-11 EXTENDED CAB – 1.9m MEDIUM DUTY CAB FAMILY 3-12 FRAME RAILS 3-13

RAME HEIGHT CHARTS 3-14

F REAR FRAME HEIGHTS "A" 3-15 REAR FRAME HEIGHTS "C" 3-16 FRAME SPACE REQUIREMENTS 3-18 FRAME SPACE DIMENSION "B" 3-19 FRAME SPACE DIMENSION "A" AND “C” 3-20 2017 MD EXHAUST CONFIGURATIONS 3-23

EXHAUST SINGLE RH SIDE OF CAB DPF/SCR RH UNDER CAB 3-23

EXHAUST SINGLE RH BACK OF CAB DPF/SCR RH UNDER CAB 3-24

EXHAUST SINGLE RH HORIZONTAL DPF/SCR RH UNDER CAB 3-25

EXHAUST SINGLE RH HORIZONTAL DPF/SCR RH UNDER FRAME 3-26 PTO LAYOUTS 3-27

SECTION 4: BODY MOUNTING

INTRODUCTION 4-1 FRAME RAILS 4-1 CRITICAL CLEARANCES 4-2 BODY MOUNTING USING BRACKETS 4-3 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 5-2

TABLE OF CONTENTS

CHANGING WHEELBASE 5-2 CROSSMEMBERS 5-3 TORQUE REQUIREMENTS 5-4 WELDING 5-4

PRECAUTIONS 5-5

SECTION 6: ELECTRICAL

INTRODUCTION 6-1 MULTIPLEX INSTRUMENTATION 6-1 INTERIOR IDENTIFICATION 6-2 DATA BUS COMMUNICATION 6-3 CAB ELECTRONIC CONTROL UNIT (CECU) AND OTHER ELECTRICAL MODULES 6-4 CENTRAL INSTRUMENT PANEL 6-5 CVSG GAUGES 6-5 POWER ON SELF-TEST 6-6 ACCESSING GAUGES, SWITCHES AND FUSES 6-7

IN CAB FUSE BOX LAYOUT 6-9 TELLTALE SYMBOLS 6-10 270 AMP ALTERNATOR (RECOMMENDED HOOKUP) 6-14 PTO WIRING 6-15

BASIC PTO SETUP WITHOUT PTO PROVISIONS 6-15

REMOTE PTO/THROTTLE HARNESS 6-15 ELECTRICAL WIRE NUMBER AND COLOR 6-17

GENERAL WIRE LABELS 6-17

DATA BUS WIRE COLORS 6-17

TRAILER CABLE CONNECTIONS 6-18

TRAILER/BODY BUILDER WIRE COLORS 6-19

BODY LIGHT CONNECTIONS 6-20

SECTION 7: POWER TAKE-OFF (PTO)

INTRODUCTION 7-1 TRANSMISSION MOUNTED PTO – GENERAL 7-1 AUTOMATIC TRANSMISSIONS 7-3

FRONT ENGINE PTO 7-4 REAR ENGINE PTO 7-5 PTO INSTALLATIONS 7-6

SECTION 8: AFTERTREAMENT

INTRODUCTION 8-1 DEF SYSTEM SCHEMATIC 8-1

GENERAL GUIDELINES FOR DEF SYSTEM 8-2 INSTALLATION REQUIREMENTS AND DIMENSIONS FOR DEF SYSTEM 8-3 ROUTING TO THE DOSING MODULE (INJECTOR) 8-3 DEF SUPPLY MODULE MOUNTING REQUIREMENTS 8-4

SECTION 9: ROUTING

INTRODUCTION 9-1 DEFINITIONS 9-1

ROUTING REQUIREMENTS 9-2 ROUTING OF WIRES AND HOSES NEAR EXHAUST SYSTEM 9-4

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SECTION 1

INTRODUCTION

The Peterbilt Medium Duty Body Build er Ma nu al was d esign ed t o pr o vi de body builders with a comprehensive inform at ion set to guide the body planning and instal lation process. Use this i nformation when instal ling bodies or other assoc iated equipment.

This manual contains appropriate dimensional information, g uidelines for mounting bodies, m odifying frames, electrical wiring information, and other information useful in the body installation process.

The Peterbilt Medium D uty Body Builder Man ual can be v er y useful when s pecif ying a veh icle, par tic ularl y when the bo dy builder is involved in the vehic le definition and order ing process. Inform ation in this manual will hel p reduce overall cos ts through optimized integration of the body installation with vehicle selection. Early in the process, professional body builders can often contribute valuable information that reduces the ultimate cost of the body installation.

In the interest of continuing product developm ent, Peterbilt reserves the r ight to change spec ifications 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. Check Peterbilt.com for the latest released version.

If you require additional information or reference materials, please contact your local Peterbilt dealer.

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SECTION 2 SAFETY AND COMPLIANCE

SAF ETY SIGNALS

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 don’t ignore any of these alerts.

Warnings, cautions, and notes

WARNING

Example:

WARNING! Be sure to use a circuit breaker designed to meet liftgate amperage requirements. An incorrectly specified circuit breaker could result in an electrical overload or fire situation. Follow the liftgate installation instructions and use a circuit breaker with the recommended capacity.

CAUTION

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 war ni ng,

and how to avoid it.

Signals a potentially hazardous situation which, if not avoided, could result in minor or

moderate injury or dam age to the vehicle.

NOTE

Example:

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

Provides general information: for example, the note cou ld 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.

SAFETY AND COMPLIANCE

FEDERAL MOTOR VEHICLE SAFETY STANDARDS AND COMPLIANCE

As an Original Equipment Manufacturer, Peterbilt Motors Company 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 Stag e 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 2–1. In addition, affixed to the driver’s side door frame or edge is an Incomplete Vehicle Certificati on la bel. See Figure 2–2.

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 complianc e wit h the particu lar 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

FIGURE 2-2. Locations of Certifica- tion Labels - Driver’s Door and Frame

U.S. EPA Noise Label (U.S. registered vehicles only)

Final Stage Manufacturer Label to be installed by Final Stage Manufacturer

Chassis Serial Number

Vehicle Emission Control Information Label

Major Components and Weights Label

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 Sta ge Manufacturer” and certifies that the vehicle complies with Federal Motor Vehicle Safety Standards. (See Figure 2–2.) Be advised that regulations affecting the intermediate and final stage manufacturer may change without notice. Ensure you are referencing the most updated copy of the regulation during the certification and documentation processes.

In part, if the final stage manufacturer can complete and certify the vehicle within the instruction in the incomplete vehicle document (IVD) the certification label would need a statement that reads, “This vehicle has been completed in accordance with the prior manufacturers‚ IVD where applicable. This vehicle conforms to all applicable Federal Motor Vehicle Safety Standards [and Bumper and Theft Prevention Standards if applicable] in effect in (month, year).”

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SAFETY AND COMPLIANCE

However, if the vehicle cannot be completed and certified with in the guidance provided in the IVD, the final stage manufacturer must ensure the vehicle conforms to all applicable Federal Motor Vehicle Safety Standards (FMVSS). The final stage manufactures certification label would need a statement that reads, “This vehicle conforms to all applicable Federal Motor Vehicle Safety Standards [and Bumper and Theft Prevention Standards if applicable] in effect in (month, year).

These statements are just part of the changes to the new certification regulation. Please refer to the Feb 15, 2005 final rule for all of the details related to this regulation. You can contact NTEA Technical Services Department at 1-800-441NTEA for a copy of the final rule (DocID 101760).

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

NOISE AND EMISSIONS REQUIREMENTS

NOTE

This truck may be equipped with specific emissions control components/systems in order to

meet applicable Federal and California noise and exhaust emissions requirements. Tampering

with these emissions control components/systems is against the rules that are established by the

U.S Code of Federal Regulations, Environment Canada Regul ati ons a nd California Air Resources

Board (CARB). These emissions control c omponents/ systems may only be replaced with origin al

equipment parts.

Additionally, most vehicles in North America will be equipped with a Greenhouse Gas (GHG)

“Vehicle Emission Control Information” door label indicating its certified configuration. The vehicle

components listed on this label are considered emission control devices.

Modifying (i.e. altering, substituting, relocating) any of the emissions control components/systems

defined above will affect the noise and emissions performance/certification. Modifications that

alter the overall s ha pe and aer odynamic performance of a tractor will also affect the emission

certification. If modifications are required, they must first be approved by the manufacturer.

Unapproved modifications could negatively affect emissions performance/certification. There is no

guarantee that proposed modifications will be approved.

Tires may be substituted provided the new tires possess a Coefficient of rolling resistance (Crr)

equal to or lower than Crr of the original tires. Consult with your tire supplier(s) for appropriate

• For Cummins Contact 1-800-DIESELS or your local Cummins distributor. Reference AEB 21.102.

It is possible to relocate the DEF tank; however the relocation requirements need to be followed. Any variances from the relocation requirements may cause the emissions control components/systems to operate improperly potentially resulting in engine de-rate.

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replacement tires.

Contact the engine manufacturer for any requirements and restrictions prior to any modifications.

SAFETY AND COMPLIANCE

NOTE

To ensure compliance to emissions regulations, the final configuration of certain features of the completed vehicle must meet specific requirements. This section describes requirements relevant for only the most common or critical modifications done by body builders. For a complete description of acceptable modifications, see the application guidance available from the manufacturer of the engine installed in the chassis.

All 2017 engine emissions certified vehicles will be equipped with an On-Board Diagnostics (OBD) system. The OBD system is desig ned to d etect m alfunctions of any engine or vehicle component that may increase exhaust em issions or interfere with the proper performance of the OBD system itself

All diesel engines will be equipped with an On-Board Diagnostics (OBD) system. The OBD sys tem consists of computer program on o ne or more of t he vehicle’s Electronic Control Units (ECUs). This program uses information from the control system and from additional sensors to detect malfunctions. When a malfunction is detected, information is stored in the ECU(s) for diagnostic purposes. A Malfunction Indicator Light (MIL) is illuminated in the dash to alert the driver of the need for service of an emission-related component or system.

FUEL SYSTEM

The following are highlights of some of the more common or critical aspects of this system. The overall system restriction may not exceed the restriction limitations set forth by the engine manufacturer for both supply and return.

• Ensure that fuel lines are not pinched or can potentially be damaged when installed between body

and frame

• Fuel lines must be routed and secured without dips or sags

• There must be easy access to filter(s) and fill cap

• The tank vent may not obstructed

• Added accessories (heaters, generators) cannot introduce air into system

• Fuel tank must be located so that the full level is not above cylinder head

• “Ultra-Low Sulfur Fuel Only” labels must be present on the dash and fuel fill

• Modification of the pressure side secondary filter and plumbing is not allowed without engine

manufacturer approval

• Body installation of fuel tank or routing of lines must not cause significant increase in fuel temperature

• Fuel hoses shall meet or exceed OEM supplied hose material construction specifications

COMPRESSED AIR SYSTEM

The following are highlights of some of the more common or critical aspects of this system.

• Air system modification must meet applicable FMVSS regulations

• Compressed Air tank may not be modified

• Added devices or bodywork may not interfere with or rub air lines

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SAFETY AND COMPLIANCE

• Air supply to the engine doser may not be restricted or disconnected

• Air lines should be routed, protected from heat, and properly secured to prevent damage from other components

• Care should be taken so that air lines do not rub against other components

• Care should be taken to protect the air system from heat sources

EXHAUST AND EXHAUST AFTER-TREATMENT SYSTEM

The following are highlights of some of the more common or critical aspects of this system.

• The following after-treatment and exhaust system components may not be modified:

• DPF assembly

• SCR Catalyst assembly

• Exhaust pipes between the engine and after-treatment devices (DPF, SCR Catalyst) and between after-treatment devices

• NO

• PM Sensor

• The following modifications may only be done within the guidelines of the “DEF System Relocation Guide.”

• All DEF and coolant lines should be routed, protected, and properly secured to prevent damage during

• If relocation of the DCU or ACM is necessary, use existing frame brackets and mount inside of frame

• The DPF, the SCR catalyst, or their mounting may not be modified

• The NOx sensor may not be relocated or altered in any way; this includes re-clocking the

• Exhaust pipes used for tailpipes/stacks must be properly sized, and must prevent water from entering

• Ensure ade quate clearance between the exhaust and body panels, hoses, and wire harnesses

• The body in the vicinity of the DPF must be able to withstand temperatures up to 400°C (750°F)

• Do not add thermal insulation to the external surface of the DPF

• The SCR water drain hole may not be blocked

Sensors

• Modifications to Diesel Exhaust Fluid (DEF) throttle, suction, or pressure lines

• Modification or relocation of the DEF tank

• Modification of coolant lines to and from the DEF tank

vehicle operation or other components

flanges where necessary. Do not extend the harnesses

aftertreatement canister or reorienting the sensor(s)

• Allow adequate clearance (25mm (1 inch)) for servicing the DPF sensors, wiring, and clamped joints

• Drainage may not come in contact with the DPF, SCR catalyst, sensors or wiring

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SAFETY AND COMPLIANCE

• Allow sufficient clearance for removing sensors from DPF. Thermistors require four inches. Other sensors require one inch

• Wiring should be routed, protected from heat, and properly secured to prevent damage from other components

• The exhaust system from an auxiliary power unit (APU) must not be connected to any part of the vehicle after-treatment system or vehicle tail pipe.

COOLING SYSTEM

The following are highlights of some of the more common or critical aspects of this system.

• Modifications to the design or locations of fill or vent lines, heater or defroster core, and surge tank are not recommended

• Additional accessories plumbed into the engine cooling system are not permitted, at the risk of voiding vehicle warranty

• Coolant level sensor tampering will void warranty

• When installing auxiliary equipment in front of the vehicle, or additional heat exchangers, ensure that adequate air flow is available to the vehicle cooling system. Refer to engine manufacturer application guide- lines for further detail

• When installing FEPTO drivelines, the lower radiator anti-recirculation seal must be retained with FEPTO driveline clearance modification only

• Changes made to cooling fan circuit and controls are not allowed, with the exception of AC minimum fan on time parameter

• See owner’s manual for appropriate winter front usage

AIR INTAKE SYSTEM

The following are highlights of some of the more common or critical aspects of this system.

• The air intake screen may not be blocked, either fully or partially

• Modification to the air intake system may not restrict airflow. For example, pipe diameter may not be reduced

• All sensors must be retained in existing locations

• To retain system seal, proper clamp torque must be used. Refer to service manual for proper clamp torque

CHARGE AIR COOLER SYSTEM

The following are highlights of some of the more common or critical aspects of this system.

• The Charge Air Cooler may not be modified

• The installation of engine overspeed shutdown devices must not introduce restriction in the intake system

• All plumbing associated with the charge air cooler may not be modified

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SAFETY AND COMPLIANCE

ELECTRICAL SYSTEM

The following are highlights of some of the more common or critical aspects of this system.

• Electr ic al harnes ses providing battery power and electronic control signals to engine and emissions control/ vehicle OBD components including datalinks may not be spliced. These emissions control/vehicle OBD components include the following:

• throttle pedal

• vehicle speed sensor

• after-treatment wiring

• 9-pin OBD Connector

• CAN Communication / OBD Diagnostic wiring

• If the alternator or battery is substituted, it must meet the requirements of the engine manufacture’s guidelines. This includes alternator ground voltage drop and alternator ground cable effectiveness. See the engine manufacture’s guidelines for recommended test procedure. Additionally the maximum voltage differential and the peak-peak voltage differential between the engine ECM block ground stud and battery negative terminal may not exceed 500 mV under any combination of loads or operating conditions.

• Only an OBD compliant battery disconnect switch may be installed on vehicles equipped EPA 2013 and beyond compliant diesel engines. An OBD compliant switch and harness, even in the off position, supply a small amount of power to the engine controller and enable certain emissions critical functions (e.g. DEF line purge). Any modifications to the electrical system which interrupt this power supply will cause OBD fault codes and illumination of the MIL. In addition, such a modification will render the engine non-compliant with certain emission regulations. As a general rule of thumb, you can remove and replace a battery disconnect switch on a truck equipped with a battery disconnect switch at the factory. However, if a battery disconnect switch was not installed in the factory a significant harness modification is required before a battery disconnect switch can be added.

• Installation of aftermarket transfer-cases must address the vehicle speed sensor position. The standard position of the speed sensor is at the transmission tail shaft. When a transfer-case is added it is best to relocate the sensor to the axle side output shaft of the transfer-case. This is typically accomplished by adding a tone wheel into the driveline yoke assembly.

• Wiring extensions for the after-treatment wiring are available for relocating the DEF tank from your dealer via Paccar Parts. For relocation of DEF tank, refer to the after-treatment section of this manual.

• The OBD/Diagnostic connector port is located below the dash to the left of the steering wheel. This connector and its location may not be changed.

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SECTION 3 DIMENSIONS

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

Rear suspension height

BOC

Back of cab

BFA

Bumper to front axle

Front engine PTO extension. Measured from the front of the grille to the front of the bumper

INTRODUCTION

This section has been designed to provide enough information to successfully layout a chassis in the body planning process. All dim ensions are inches un less o therwise noted. Opt ion al eq ui pment may not be depic ted . Ple as e contact your local Peterbilt dealer if more dimension al inf ormation is desired.

ABBREVIATIONS

Throughout this sectio n and in other sections as wel l, abbreviations are used t o describe certain character istics on your vehicle. The chart below lists the abbreviated terms used.

TABLE 3-1. Abbreviations Used

FS Front suspension height

SOC Side of cab

BBC Bumper to back of cab

FAB Front axle to back of cab FEPTO

OVERALL DIMENSIONS

This section includes dr awings and charts of the following Peterbilt Models: 348 (110” BBC), 348 ( 108” BBC), 337 (110” BBC), 337 (108” BBC), 330, and 325. Several optional configurations are also included.

On the pages that follow, deta il drawings show particular views of each vehic le; all dimensions are in inches (in). T hey illustrate important m easurem ents critical to des igning bodies of all types. See the “ Table of 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 la youts of ord ered chass is prior to bu ild. Please sp eak with your local dealer ship

to request this feature when specifying your chassis.

DIMENSIONS

MODEL 348, 337 (110” BBC)

NOTES:

1) DIMENSIONS ARE FOR REFERENCE ONLY

2) DIMENSIONS ARE TO FRONT OF 0.125” THICK BUMPER

3) DIMENSION FRONT AXLE TO FRONT OF FRAME (FFA) IS 36.2”

4) DIMENSION FRONT OF BUMPER TO FRONT OF FRAME (BFF) IS 2.1”

5) DIMEN SIO N S AR E WITH 11 5/8” RAIL

FIGURE 3-1. Model 348, 337 (110” BBC) Top, Front, & LH View – Overall Dimensions

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DIMENSIONS

MODEL 348, 337, 330, 325 (108” BBC)

FIGURE 3-2. Model 348, 337, 330, 325 (108” BBC) Top, Front & LH View – Overall Dimensions

NOTES:

1) DIMENSIONS ARE FOR REFERENCE ONLY

2) DIMENSIONS ARE TO FRONT OF 0.125” THICK BUMPER

3) DIMENSION FRONT AXLE TO FRONT OF FRAME (FFA) IS 34.9”

4) DIMENSION FRONT OF BUMPER TO FRONT OF FRAME (BFF) IS 1.3”

5) DIMESNIONS ARE WITH 10 5/8” RAIL

MODEL 348, 337 (110” BBC) and 348, 337 (108” BBC) w/ 27.8” FEPTO Bump er E xtension

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DIMENSIONS

NOTES:

1) DIMENSIONS ARE FOR REFERENCE ONLY

2) DIMENSIONS ARE TO FRONT OF 0.25” THICK BUMPER

3) DIMENSION FRONT OF BUMPER TO FRONT OF FRAME (BFF) IS 0.92”

FIGURE 3-3. 348, 337 (110” BBC) and 348, 337 (108” BBC) Top, Front & LH View – Overall Dimensions

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DIMENSIONS

MODEL 348, 337 (110” BBC) and 348, 337 (108” BBC) w/ 3.2” FEPTO Bumper Extension

NOTES:

1) DIMENSIONS ARE FOR REFERENCE ONLY

2) DIMENSIONS ARE TO FRONT OF 0.25” THICK BUMPER

3) DIMENSION FRONT OF BUMPER TO FRONT OF FRAME (BFF) IS 2.92”

FIGURE 3-4. Model 348, 337 (110” BBC) and 348, 337 (108” BBC) 337 Top, Front & LH View – Overall Dimensions

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DIMENSIONS

CAB – 1.9m MEDIUM DUTY CAB FAMILY

Models 348, 337 (110” BBC), 348 (108” BBC), 337, 330, 325

FIGURE 3-5. Cab Dimensions 1.9m Medium Duty Cab Family

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DIMENSIONS

ROOF FAIRING

FIGURE 3-6. Roof Fairing Dimensions

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DIMENSIONS

REAR WINDOW

FIGURE 3-7. Rear Window Dimensions

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DIMENSIONS

ROOF BOW STRUCTURE

FIGURE 3-8. Roof Bow Structure

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DIMENSIONS

CABMATE CAB SUSPENSION

FIGURE 3-9. Cabmate Cab Suspension Dimensions

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Description (2)

A (First Step)

B (Second Step)

C (Cab Floor) (1)

Aluminum Battery Box

13.4”

2.75”

18.2”

Steel Battery Box

10.7”

3.3”

18.2”

Model 325 Battery Box

1” - 18.2”

23” Fuel Tank

11.3”

6.7”

18.2”

26” Fuel Tank

11.5”

4.4”

18.2”

Rectangular Fuel Tank

8.6”

9.7”

18.2”

RH UCAB Aftertreatment Box (3)

10.5”

6”

18.2”

DIMENSIONS

CAB STEP HEIGHT

FIGURE 3-10. Cab Step Height Dimensions (Table 3-2)

Table 3-2. Cab Step Height

Notes

1.) Add 2.75” to the C Dimension for BBC 110” Hood or Raised Cab Option

2.) LH shown, RH Dimensions are equivalent

3.) Aftertreatment box is RH UCAB only

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DIMENSIONS

EXTENDED CAB – 1.9m MEDIUM DUTY CAB FAMILY

Models 348, 337 (110” BBC), 348 (108” BBC), 337, 330

FIGURE 3-11. Extended Cab

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DIMENSIONS

FRAME RAILS

Frame rail configurations are shown below. Frame height, flange and structural values can be found in the Body Mounting Section.

FIGURE 3-12. Frame Rail Configurations

NOTE: The outserted frame section does not extend through the rear suspension area.

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DIMENSIONS

FRAME HEIGHT CHARTS

FIGURE 3-13. Frame Height

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DIMENSIONS

FRONT FRAME HEIGHTS "A"

TABLE 3-3. Front Frame Height “A”

NOTES:

1) Spacers are used by Engineering to obtain a level frame and are not options.

2) LIGHT or UNLADEN heights are calculated on the below assumptions a. 12K or 14.6K springs assumes 8,000 lbs. load in LIGHT condition b. 16K springs assumes 8,500 lbs. load in LIGHT condition c. 18K - 20K springs assumes 9,000 lbs. load in LIGHT condition

3) "A" dimension shown is to bottom of frame rail. Add frame rail height dimension for frame height.

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Suspension

Rating

Version

Light

Height

Laden

Height

20,000 lbs.

Standard

11.4

11.0

23,000 lbs.

Standard

11.4

11.0

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

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

Standard

9.3

Low

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

Suspension

Rating

Version

Light

Height

Laden

Height

NEWAY ADZ

46K lbs.

10.0

DIMENSIONS

REAR FRAME HEIGHTS "C"

TABLE 3-4. Single Drive Rear Suspension Height “C”

AIR TRAC

REYCO 79KB

REYCO 102

REYCO 102AR (AIR) 17K -23K

TABLE 3-5. Tandem Peterbilt Rear Suspension Height “C”

TABLE 3-6. Tandem Neway Rear Suspension Height “C”

Peterbilt Motors Company 3- 16

Suspension

Rating

Version

Light

Height

Laden

Height

1.75 saddle (STD)

11.7

9.9

1.38 saddle

10.2

8.3

3.38 saddle

13.4

11.5

1.75 saddle (STD)

11.7

9.8

1.38 saddle

11.5

9.7

Suspension

Rating

Version

Light

Height

Laden

Height1

LOW

11.2

8.9

HIGH

12.4

10.2

X-HIGH

14.5

12.2

XXHIGH

17.2

14.9

LOW

11.3

8.9

HIGH

12.5

10.1

X-HIGH

14.7

12.2

XXHIGH

17.3

14.9

Suspension

Rating

Version

Light

Height

Laden

Height

6.00 saddle

9.9

8.9

7.19 saddle (std.)

11.2

10.1

16.5 saddle (low)

10.6

9.5

18.5 saddle (std.)

12.6

11.5

16.5 saddle (low)

10.6

9.5

18.5 saddle (std.)

12.6

11.5

12.25 saddle

9.7

8.9

14.00 saddle (std.)

11.5

10.6

15.25 saddle

12.7

11.9

6.00 saddle

11.3

10.5

7.2 saddle (std.)

11.4

11.00 saddle

16.3

15.2

DIMENSIONS

REYCO 102 MULTILEAF

TABLE 3-7. Tandem Reyco Rear Suspension Height “C”

40,000 lbs.

44,000 lbs.

TABLE 3-8. Tandem Chalmers Rear Suspension Height “C”

CHALMERS 854 40,000 lbs.

CHALMERS 854 46,000 lbs.

TABLE 3-9. Tandem Hendrickson Suspension Height “C”

RT-403 40,000 lbs.

HMX 40,000 lbs. HMX 46,000 lbs.

RS-463 46,000 lbs.

RT-463 46,000 lbs.

Peterbilt Motors Company 3- 17

DIMENSIONS

FRAME SPACE REQUIREMENTS

To ensure adequate space for fuel tanks, ladder steps, additional tool/battery boxes, pusher axles and other frame mounted components; the amount of available space must be calculated by using the formula below. Contact Applications Engineering for configurations not shown in this section. Examples are shown at the end of this section.

FIGURE 3-14. Frame Space

BASIC FORMULA: BOC Frame Space = Wheelba s e - Dimension A - Dimension C - Dimension B

Dimension "A" (shown in charts on following pages) is the minimum clearance measured from the centerline of the front axle to the back of the under cab component (DPF/SCR exhaust, fuel tank, battery box, tool box, etc). Dimension "C" is the amount of space from the rear of the under cab component to the back of the DEF tank (can be on LH or RH rail). Dimension "B" is the amount of required suspension and quarter fender clearance from the rear axle centerline to clear rail for a given suspension.

Peterbilt Motors Company 3- 18

REAR SUSPENSION

"B"

OVERHANG (1)

NOTES

AIR LEAF

53.0

LOW/ LOW LOW AIR LEAF

62.4

53.0

LOW AIR LEAF SINGLE

36.5

27.0

AIR TRAC SINGLE

27.0

AIR TRAC TANDEM

53.0

FLEX AIR

59.0

53.7

CHALMERS 800 (54" SPACING)

49.0

52.0

HENDRICKSON HLM / AL

26.6

N/A

HENDRICKSON HLR2

30.5

N/A

HENDRICKSON HMX, HN

53.0

54.0

HENDRICKSON R/RS/RT/RTE

53.0

HENDRICKSON SC20

25.6

15.0

HENDRICKSON SC8/10/13, FX, FXO, SCO

23.6

13.8

5, 6

NEWAY ADZ (54" SPACING)

61.0

58.3

REYCO 102 SINGLE

30.0

25.8

REYCO 102AR SINGLE

30.0

31.0

REYCO 102 TANDEM

56.0

52.7

REYCO 79KB

30.1

32.2

WATSON-CHALIN AL2200

26.6

22.2

WATSON-CHALIN SL0893SSR

27.6

11.8

5, 6

WATSON-CHALIN SL1093SSR

27.6

11.8

WATSON-CHALIN SL1190SSR

26.0

12.8

WATSON-CHALIN SL2065

27.6

14.4

DIMENSIONS

FRAME SPACE DIMENSION "B"

TABLE 3-10. Rear Suspension Dimension “B”

DIMENSION "B" IN INCHES (52" Axle Spacing on Tandems)

FRAME SPACE REQUIREMENTS

NOTES:

1) Overhang for Tractor Taper EOF and Standard Mud flap Hangers on Suspensions; Square EOF w/o

Crossmember for Lift Axles.

2) Add 2.0" to "C" dimension with quarter fenders .

3) Add 1.5" to "C" dimension with quarter fenders .

4) Add 0.6" to "C" dimension with quarter fenders.

5) Add 2.8" to "C" dimension with quarter fenders .

6) "C" dimension is from axle centerline (or bogie for tandem) to clear frame forward.

7) Extended Tractor Taper requires 58.0" overhang.

Peterbilt Motors Company 3- 19

DIMENSIONS

FRAME SPACE DIMENSION “A” AND “C”

Peterbilt Motors Company 3- 20

DIMENSIONS

CONTINUED FRAME SPACE DIMENSION “A” AND “C” FOR MODEL 325, 330, 337, 348-108”

Peterbilt Motors Company 3- 21

DIMENSIONS

Peterbilt Motors Company 3- 22

DIMENSIONS

2017 MD EXHAUST CONFIGURATIONS

EXHAUST SINGLE RH SIDE OF CAB DPF/SCR RH UNDER CAB

(Reference option code 3365270)

FIGURE 3-16. Exhaust Single RH Side of Cab DPF/SCR RH Under Cab

Peterbilt Motors Company 3- 23

DIMENSIONS

EXHAUST SINGLE RH BACK OF CAB DPF/SCR RH UNDER CAB

(Reference option code 3365250)

FIGURE 3-17. Exhaust Single RH Back of Cab DPF/SCR RH Under Cab

Peterbilt Motors Company 3- 24

DIMENSIONS

EXHAUST SINGLE RH HORIZONTAL DPF /SCR RH UNDER CAB

(Reference option code 3365280)

FIGURE 3-18. Exhaust Single RH Horizontal DPF/SCR RH Under Cab

Peterbilt Motors Company 3- 25

DIMENSIONS

EXHAUST SINGLE RH HORIZONTAL DPF /SCR RH UNDER FRAME

(Reference option code 3365290)

FIGURE 3-19. Exhaust Single RH Horizontal DPF/SCR RH Under Frame

Peterbilt Motors Company 3- 26

DIMENSIONS

PTO LAYOUTS

PTO LAYOUT MODEL 348-110” or 337-110”, PX-9, 4000 SERIES ALLISO N

Figure 3-20. Model 348-110” or 337-110”, PX -9 4000 Series Allison

Peterbilt Motors Company 3- 27

DIMENSIONS

PTO LAYOUT MODEL 348-110” OR 337-110” WITH PX-9 AND 4000 SERIES ALLISON

Figure 3-21. Model 348-110” or 337-110”, PX -9 4000 Series Allison

Peterbilt Motors Company 3- 28

DIMENSIONS

PTO LAYOUT MODEL 348-110” OR 337-110” WITH PX-9 AND 4000 SERIES ALLISON

Figure 3-22. Model 348-110” or 337-110”, PX -9 4000 Series Allison

Peterbilt Motors Company 3- 29

DIMENSIONS

PTO LAYOUT MODEL 348-110” OR 337-110” WITH PX-9 AND 4000 SERIES ALLISON

Figure 3-23. Model 348-110” or 337-110”, PX -9 4000 Series Allison

Peterbilt Motors Company 3- 30

DIMENSIONS

PTO LAYOUT MODEL 348-110” OR 337-110” WITH PX-9 AND 4000 SERIES ALLISON

Figure 3-24. Model 348-110” or 337-110”, PX-9 4000 Series Allison

Peterbilt Motors Company 3- 31

DIMENSIONS

PTO LAYOUT MODEL 348-110” OR 337-110” WITH PX-9 AND 3000 SERIES ALLISON

Figure 3-25. Model 348-110” or 337-110”, PX -9 3000 Series Allison

Peterbilt Motors Company 3- 32

DIMENSIONS

PTO LAYOUT MODEL 348-110” OR 337-110” WITH PX-9 AND 3000 SERIES ALLISON

Figure 3-26. Model 348-110” or 337-110”, PX-9 3000 Series Allison

Peterbilt Motors Company 3- 33

DIMENSIONS

PTO LAYOUT MODEL 348-110” OR 337-110” WITH PX-9 AND 3000 SERIES ALLISON

Figure 3-27. Model 348-110” or 337-110”, PX -9 3000 Series Allison

Peterbilt Motors Company 3- 34

DIMENSIONS

PTO LAYOUT MODEL 348-1 10” OR 337-110” WITH PX-9 AND 3000 SERIES ALLISON

Figure 3-28. Model 348-110” or 337-110”, PX -9 3000 Series Allison

Peterbilt Motors Company 3- 35

DIMENSIONS

PTO LAYOUT MODEL 348-1 10” OR 337-110” WITH PX-9 AND 3000 SERIES ALLISON

Figure 3-29. Model 348-110” or 337-110”, PX -9 3000 Series Allison

Peterbilt Motors Company 3- 36

DIMENSIONS

PTO LAYOUT MODEL 348-1 10” OR 337-110” WITH PX-9 AND 3000 SERIES ALLISON

Figure 3-30. Model 348-110” or 337-110”, PX -9 3000 Series Allison

Peterbilt Motors Company 3- 37

DIMENSIONS

PTO LAYOUT MODEL 348-1 10” OR 337-110” WITH PX-9 AND 3000 SERIES ALLISON

Figure 3-31. Model 348-110” or 337-110”, PX -9 3000 Series Allison

Peterbilt Motors Company 3- 38

DIMENSIONS

PTO LAYOUT MODEL 348-110” OR 337-110 ” WITH PX-9 AND 3000 SERIES ALLISON

Figure 3-32. Model 348-110” or 337-110”, PX -9 3000 Series Allison

Peterbilt Motors Company 3- 39

DIMENSIONS

PTO LAYOUT MODEL 348-1 10” OR 337-110” WITH PX-9 AND 3000 SERIES ALLISON

Figure 3-33. Model 348-110” or 337-110”, PX-9 3000 Series Allison

Peterbilt Motors Company 3- 40

SECTION 4 BODY MOUNTING

(in.)

(in)

Section (cu. In.)

(in.-lbs)

(lbs/in.)

9 7/8

3.50

0.250

10.5

1,250,000

1.06

10 1/4

3.50

0.250

11.7

1,400,000

1.15

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

Main Rail

(in.)

Insert

Outsert

Section

(cu. In.)

(in.-lbs)

(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

11.625 x 3.87 x .375

45.7

5,484,000

4.67

INTRODUCTION

This section has been desi gned to provide guid elines to aid in bod y mounting. This is not int ended as a complete guide, rather as general information. Body mounting s trategies are unique to each b ody type and body builder m ust determine the appropriate method.

Please contact your local Peterbilt dea ler if mor e information is desired.

FRAME RAILS

Frame rail information is provided per rail.

TABLE 4-1. Single Frame Rails

Rail Height

Height

Flange Width

Web Thickness

TABLE 4-2. Built-up Frame Rails

Modulus

RBM (per rail)

Weight (per rail)

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 m ovement could cause contact b etween the tires and the body. To prevent this, m ount the body so that the minimum clearance betwee n the top of the t ire and the bottom of the bod y is 8 inches (20 3 mm). This shou ld 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

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). Thes e materials will n ot undergo larg e dimensional cha nges during per iods of high or lo w humidity. The strip will be less likely to fall out during extreme relative motion between body and chas sis . See FIGURE 4-3.

FIGURE 4-3. Spacer Between Frame Sill and Body Rail – Rubber or Plastic

Peterbilt Motors Company 4-3

BODY MOUNTING

BRACKETS

When mounting a bod y to the chassis with brac kets, we recom mend designs that of fer limited relativ e movement, bolted securely but not too rigid. Brac kets should allow for slight movem ent between the body and the chassis . For instance, FIGURE 4-4 shows a high compression spring betwee n the bolt a nd the brac ket and FIGURE 4-5 shows a r ubber s pacer between the brackets. These designs will allow relative movement between the body and the chassis during extreme frame racking situatio ns. Mount ings th at are to o rigid c ould caus e dam age to the bod y. T his is partic ularl y true with t ank er installations.

FIGURE 4-4. Mounting Brackets FIGURE 4-5. Mounting Brackets

Peterbilt Motors Company 4-4

BODY MOUNTING

MOUNTING HOLES

When installing brac kets on the fr ame rails, the mount ing holes in the chas sis frame br acket and fram e rail must compl y 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

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.

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.

FIGURE 4-8. Frame Rail Flange Drilling Prohibited

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 appropriat e 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

BODY MOUNTING

BODY MOUNTING USING U–BOLTS

If the body is mounted to the frame with U–bolts, use a hardwood sill (m inimum 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 f lange and the U–bolt to prevent the U–bolt from notching the fr ame flange . See FIGURE 4-9.

FIGURE 4-9. Acceptable U-Bolt Mounting with Wood and Fabricated Spacers

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

clearances for air brake lines, fuel lines, and wiring. See FIGURE 4-10.

inspect the installation to ensure adequate

Peterbilt Motors Company 4-7

BODY MOUNTING

WARNING! Do not notch frame rail flanges to force a U–bolt fit. Notched or damaged frame flanges could result in premature frame failure. Use a larger size U-bolt.

CAUTION: Mount U–bolts so they do not chafe on frame rail, air or electric lines.

FIGURE 4-10. Clearance Space for Air Lines and Cables

Peterbilt Motors Company 4-8

BODY MOUNTING

REAR BODY MOUNT

When U–bolts are us e d t o mount a body we recommend that the las t b ody attachment be made with a “fishp late” br acket. See F IGURE 4-11. This provides a f irm attachin g point and he lps prevent any relati ve fore or af t movement b etween the body and frame. For hole location guidelines, See FIGURE 4-6.

FIGURE 4-11. Fishplate Bracket at Rear End of Body

Peterbilt Motors Company 4-9

This page is intentionally left blank.

SECTION 5 FRAME MODIFICATIONS

INTRODUCTION

Peterbilt offers cus tomer specified wheelbases and f rame overhangs. So, in most cas es 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 applicat ion. The modifications may be as simple as m odifying the frame cutoff, or as c om plex as modifying the wheelbase.

DRILLING RAILS

If frame holes need to be drilled in the rail, see SECTION 4 BODY MOUNTING for more information.

WARNING! Do not drill new holes any closer than 2 inches (50mm) to existing holes. Frame drilling affects the strength of the rails. If the holes are too close together, the rail could fail prematurely and cause an accident.

CAUTION: Use care when drilling the frame web so the wires and air lines routed inside the rail are not damaged.

•

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

Peterbilt Motors Company 5-1

FIGURE 5-1. Wheelbase Customization

FRAME MODIFICATIONS

MODIFYING FRAME LENGTH

The frame overhang af t er t he r ear axle can be shorte n ed to match a particular body length. Us ing a torch is acceptable; however, heat from a torch will af fect the mater ial characteristics of t he frame rail. The affected material will normally be confined to within 1 to 2 inches (25 to 50mm) of the flam e cut and may not adversely affec t the strength of the chassis or body installation.

CHANGING WHEELBASE

Changing a chassis’ wheel base is not recomm ended. 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 suspensio n is relocated, check the new location of the spring hanger brackets. The new holes for the spring hanger brackets must not ov erlap existing holes and shou ld 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 cu t to achieve the desire d fram e overhang. See FIGURE 5-1.

Peterbilt Motors Company 5-2

FRAME MODIFICATIONS

CROSSMEMBERS

After lengthening a wheelbase, an addition al crossmem ber may be required to m aintain the original fram e strength. The maximum allowable distan ce between the forward suspensio n crossmember and the next cr ossmember forward is 47.2 inches (1200 mm). If the dis tanc e ex ceeds 47.2 i nc he s ( 1200 mm ) af ter the whee lbas e is le ngt hen ed, ad d a c r ossmember between them.

FIGURE 5-2. Crossmember Spacing Requirements

Peterbilt Motors Company 5-3

Fastener

Torque

Size

lb-ft

5/16

22–30

16–22

7/16

75–88

55–65

5/8

224–265

165–195

952–1129

800–830

1-1/4

1877–2217

1380–1630

Fastener

Torque

Size

lb-ft

9–15

7–11

M10

33–43

24–32

M12

75–101

55–75

M20

352–460

260–340

FRAME MODIFICATIONS

TORQUE REQUIREMENTS

Torque values appl y to fasteners with clean thr ea ds , light l y lubric ate d, with har de ned ste el washer s , and n ylon-insert nuts.

TABLE 5-1. Customary Grade 8 UNF or UNC.

3/8 41–54 30–40

1/2 109–122 80–90

9/16 156–190 115-140

3/4 394–462 290–340 7/8 517–626 380–460

1-1/8 1346–1591 990–1170

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

M8 23–31

M14 134–164 M16 163–217

17–23

99–121 120–160

WELDING

The frame rails are heat treated and should not be welded. The high heat of welding nullifies the special heat treatment of the rails, greatly reducing the tensile strength of the frame rail. If a frame member becomes cracked from overloading, fatigue, surface damage or a collision, the only permanent repair is to replace the damaged frame member with a new part.

The following information is provided (for temporary emergency repair). Prior to welding a cracked frame rail, the area should be beveled (V’d out) to allow for a better weld. To prevent spreading of the crack, a 7 to 9 mm (1/4 in. to 3/8 in.) dia. hole should be drilled at the end of the crack. Widen the crack along its full length by using two hack saw blades together. When welding steel frames use the shielded arc method. When welding aluminum frames use either the tungsten inert gas (TIG) or consumable electrode method. Be sure to obtain full weld penetration along the entire length of the crack.

Peterbilt Motors Company 5-4

FRAME MODIFICATIONS

PRECAUTIONS

CAUTION:

WELDING PRECAUTIONS: ALL ELECTRONIC ENGINES

Before welding, disconnect the negative terminal battery cable.

Before welding, disconnect the alternator terminals. Failure to do so could result in damage to the voltage regulator and/or alternator.

To prevent damage to electrical equipment, disconnect battery cables before arc-welding on a truck, and be sure that the welding ground lead is connected to the frame. Bearings and other parts will be damaged if current must pass through them in order to complete the circuit.

Before welding on vehicles with electronic engines, the following precautions should be observed.

1. Disconnect all electrical connections to the vehicle batteries.

2. Disconnect all ECM connectors.

3. Do no use the ECM or engine ground stud for the ground of the welding probe.

4. Ensure that the ground connection for the welder is as close to the weld point as possible. This ensures

maximum weld current and minimum risk to damage electrical components on the vehicle.

5. Turn off key.

NOTE:

Bosch ABS and Wabco ABS: Disconnect ECU.

Peterbilt Motors Company 5-5

This page is intentionally left blank.

SECTION 6 ELECTRICAL

INTRODUCTION

This section has been designated to provide information to the body builder when installing equipment into vehicles built with Multiplexed instrumentation. The technology presented will show multiple access points for direct integration over body builder components. This section is intended to address how to work in aftermarket equipment while still maintaining full functionality of the OEM vehicle.

MULTIPLEX INSTRUMENTATION

Peterbilt utilizes Multiplex instrumentation and wiring to continuously improve our quality and the capability of our trucks. Multiplexing utilizes the industry standard Society of Automotive Engineering (SAE) J1939 data bus to send multiple signals over a single twisted pair of wires instead of individual wires for each function. The advantages are fewer wires, sensors, and connections that provide greater consistency, improved reliability and the ability to use ESA to troubleshoot the instrumentation. The following information is provided to increase your awareness about the Peterbilt product, it may be useful in installing telltales (warning lights) and gauges and coordination with other installed equipment. Data Bus

connector can be accessed on the LH side rear of engine

WARNING!

Don’t cut or tap into green/yellow twisted pairs. Only use approved J1939 components and connectors with validated software.

FIGURE 6-1. J1939 Data Link Wiring

ELECTRICAL

INTERIOR IDENTIFICATION

2013 is the first year that Peterbilt has used Multiplex Wiring in our 348, 337, 330 and 325 vehicles. Chassis with this new interior can be identified b y appearanc e sho wn be lo w. All dashes that resemble the following picture will utilize multiplex wiring.

FIGURE 6-2. Peterbilt B-Cab Dash

A model 2013 and later diesel engine chassis can be identified by the presence of the Diesel Exhaust Fluid “DEF” gauge.

FIGURE 6-3. Diesel Exhaust Fluid Gauge

Note:

The information contained in this manual is specific to chassis with 2013 engines. For pre-2013 engines

please work with your local Peterbilt dealer

Peterbilt Motors Company 6-2

CSVG BUS

FIREWALL

V-CAN

POWER TRAIN

CONTROLLERS

I-CAN

DWIM

CECU 3

ELECTRONIC

CVSGs

ELECTRIC SWITCHES

(SOME)

ELECTRICAL

DATA BUS COMMUNICATION

The multiplexed instrumentation system uses several different data links to transmit input/output data from other systems to the Cab Electronic Control Unit (CECU), and ultimately to the Central Instrument Cluster and CVSG Gauges

• V-CAN = Vehicle Controller Area Network The V-CAN, also referred to as the J1939, is used to transmit data between the transmission, ABS system, engine, etc. to the Cab Electronic Control Unit (CECU)

• I-CAN = Instrumentation Controller Area Net wor k The I-CAN provides data link communication from the Cab Electronic Control Unit (CECU) to the Central Instrument Cluster

• CVSG Bu s The CVSG bus is a private data bus used to transmit data from the Cab Electronic Control Unit (CECU) to the individual 2-inch gauges. A series of “daisy chained” jumper harnesses link each gauge to another.

FIGURE 6-4. Multiplexed Instrumentation Block Diagram

Peterbilt Motors Company 6-3

ELECTRICAL

CAB ELECTRONIC CONTROL UNIT (CECU) AND OTHER ELECTRICAL MODULES

The heart of the multiplexed instrumentation system is the Cab Electronic Control Unit (CECU). The CECU is located behind the center console. See Figure 6-5

FIGURE 6-5. CECU Location and Other Electrical Modules

Vehicle component inputs are sent to the CECU through the J1939 data bus or conventional wiring. The CECU interprets the various inputs and monitors/controls the functions for each input through the CECU software. Output signals from the CECU provide data for the gauges, warning lamps, audible alarms, and displays inside the cluster.

Peterbilt Motors Company 6-4

ELECTRICAL

CENTRAL INSTRUMENT PANEL

The central instrument panel includes the speedometer (including odometer and trip meter) and tachometer (including engine hour meter and outside temperature display), plus a Driver Warning and Indicator Module (DWIM) pre-installed standard and/or editable warning light symbols called “telltale” cards. Each “telltale” card slides into the left and right sides of the Driver Warning and Indicator Module (DWIM) from the bottom. The standard cards cover most warning light requirements; editable cards can be used for less common components that also require warning lights. The central instrument cluster receives input data from the CECU via the “I-CAN” data bus. When the ignition key is first turned ON, the cluster will perform a calibration “power on self-test”. The instrument panel is

installed with two screws.

FIGURE 6-6. Main Instrument Panel

CVSG GAUGES

The 2” gauges located to the left and right of the main instrument panel 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 CECU. CVSG’s are two types, electronic and mechanical. The electronic CVSG’s receive digital data from the 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 backlighting signals from the 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”.

Note:

The mechanical CVSG do not perform a power on self-test

Peterbilt Motors Company 6-5

ELECTRICAL

POWER ON SELF-TEST

• Ignition key turned ON

• The gauge pointers move from pointing at zero, counter-clockwise to their mechanical limit (approx. -5°), stay there for one second and go back to pointing at zero

• At the same time, all telltales in DWIM and main gauges are switched on together, and then switched off together

Additional CVSG gauge information body builders should be aware of:

• The CECU sends gauge information to CVSGs over a data link (blue wire) between the CECU and the gauge (called CVSG bus)

• CVSG gauges get their power from the CECU

• Yellow = Power w ire (9-16 volts)

• follows:

Pin # Color Function

1 Blue 2 Brown

3 White 4 Yellow

• Backlighting level for CVSG electronic gauges is sent from the CECU to the gauges via the data link (blue wire).

• Optional CVSG mechanical gauges (i.e. air suspension) are driven mec hanically with air pressure hosed to the fitting behind the gauge. There is no red warning lamp and the backlighting is powered through the brown wire from the CECU (a pulse-width modulated signal) circuits through the gauge to the next gauge in the chain

• Gauges can be relocated to any 2-inch open gauge position in the dash connector at the back and move it to the desired position. Plug the jumper wire in. (See “Accessing Gauges and Switches section below for instructions on physically moving the gauge). The connector will require a firm pull to remove it. When reinstalling the connector ensure that it is fully inserted. Both connector sockets on the rear of the gauge are the same, either one can be used

Data, backlighting for Electronic Gauges Backlighting for Mechanical Gauges

Return Power

The 4-way jumper harness is still used to pass all 4

To relocate a gauge unhook the

Peterbilt Motors Company 6-6

ELECTRICAL

ACCESSING GAUGES, SWITCHES AND FUSES

In order to access and install components described later on in the manual, you will need to know how to correctly remove the dash panels without causing damage.

The main dash panel installs by inserting on the left side and a snapping down on the right side. Removal is accomplished by gently prying the panel starting on the right as shown.

Peterbilt Motors Company 6-7

ELECTRICAL

To remove a switch push in the tabs on both sides of the switch and pull out the top section to disconnect the switch.

Pinch the bottom tabs to release the switch from the panel.

Peterbilt Motors Company 6-8

ELECTRICAL

The fuse box is located behind a corner cover in the left side foot well.

IN CAB FUSE BOX LAYOUT

FIGURE 6-11. Cab Load Center (mPDC)

Peterbilt Motors Company 6-9

ELECTRICAL

TELLTALE SYMBOLS

Peterbilt’s interior allows Body Builders to customize the dash telltale symbols (warning lights). The editable telltale symbols are located on removable cards inside the baseline cluster. This section will describe how to replace and insert editable cards, as well as how to activate the telltale lights.

Note the numbers 1 – 12 on Figure 6-12. These are how the positions are identified in Table 6-1 and on the instrument panel harness breakouts for the “editable” telltales behind the right hand cluster.

To remove the editable cards follow steps 1-3 in the instructions for accessing gauges and switches . The access cards have a positive lock. To remove the card push inwards on the lock with your thumb and pull the card

out with pliers. Figure 6-12 below details the cards. To reinstall a card slide it in either by hand or with pliers.

Note:

Peterbilt Motors Company 6-10

LEFT

FIGURE 6-12. Telltale Symbol Standard Card

The numbers 1–12 on Figure 6-12. These are how the positions are identified in Table 6-1 and on the instrument panel breakouts for the “editable” telltales behind the right hand cluster.

LOCK

RIGHT

Position

Standard Function

Use

Light Color

Editable or Fixed?

PTO

Illuminates to Indicate PTO is Engaged

Green

Editable

Illuminates to Indicate Left Turn Signal is Applied

Fasten Seat Belt

Used with Seatbelt Warning Option

Red

Fixed

Applied

ELECTRICAL

2 Check Transmission Illuminates During Transmission Fault Yellow Editable

TABLE 6-1. Telltales Position and Color

3 Left Turn Arrow

4 Wait To Start

5 Brake Fail

6 High Beam

9 Park Brake 10 Engine Brake Illuminates to Indicate Engine Brake Active Green Fixed 11 Hest

12 Right Turn Arrow

Note:

Malfunction Indicator

Lamp (MIL)

Only the positions labeled as “editable” in the chart above can be changed. You must apply the standard icons on the editable card on all the positions that read “fixed”.

Illuminates when Driver needs to Wait Before Starting Engine

Illuminates When the Hydraulic Brake ECU Determines Fault

Illuminates to Indicate High Beam Lights are Applied

Illuminates to Indicate a Malfunction in Emissions System (After 2013)

Illuminates to Indicate the Park Brake is

Indicates Exhaust After Treatment Filter Regeneration

Illuminates to Indicate Right Turn Signal is Applied

Green Fixed

Yellow Fixed

Red Editable

Blue Fixed

Yellow Fixed

Red Fixed

Yellow Fixed

Green Fixed

The wait to start and malfunction indicator lamp is part of the emission control system not be removed or altered.

They must

If a connector is already connected to the editable Position in the IP harness, that Position cannot

be used for another function

In order to activate the editable lights (either on the standard card or the editable card) locate the wiring connections on pigtail connectors behind the right hand side gauge panel

tagged with position numbers following text: “TELLTALE POS 1”. The color of the tag corresponds to the color of the light circuits are either grounded or powered the light in the dash will turn on

All cards come with standard editable telltale lights, even if the chassis you have was not ordered with related components.

For example for position 1 the breakout label will be green and have the

Peterbilt Motors Company 6-11

The wires will be labeled and

When these

ELECTRICAL

The standard trays are shown above (in Figure 6-12). Editable trays are also available from your local Peterbilt dealer. The left and right trays are s ho wn in belo w.

FIGURE 6-13. Blank Telltale Tray

Your local Peterbilt dealer will also sell a sheet of telltale light icons to install on the editable card. The symbols that are available are shown in below.

FIGURE 6-14. Telltale Icons

Peterbilt Motors Company 6-12

ELECTRICAL

FIGURE 6-14 CONTINUED. Telltale Icons

The telltales can then be peeled off of the sheet and applied directly to the card. The color of the telltale is controlled by the light, all of the icons are clear. Please see Table 6-1 to determine the position and color of the telltales.

Peterbilt Motors Company 6-13

ELECTRICAL

270 AMP ALTERNATOR (RECOMMENDED HOOKUP)

FIGURE 6-23: P27-6180 Fuse Holder

FIGURE 6-24: Battery Harness Jumper.

• Use three batteries

• Use P27-6180-150 Mega Fuse (Mount in Battery Box to provide Body Power).

• Use P92-2683-10000 to provide power from batteries to Mega Fuse.

• Tie Body Ground circuits to additional ground stud located on the lower outboard (driver side) of firewall at cover plate.

ENGINE CONNECTIONS

Electronic engines have the ability to send and receive control and warning signals from the components on

the chassis and body electronic control unit (ECU) or to other electronic engine components

Peterbilt Motors Company 6-14

Consult the appropriate body builder manual before making connections to the engine

ELECTRICAL

PTO WIRING

BASIC PTO SETUP WITHOUT PTO PROVISIONS

The cab harness has a pigtail connector in the dash coming off the engine harness firewall connector. When this connector P79 PTO is grounded the PTO functionality will be activated. See Figure 6-25

FIGURE 6-25. Basic PTO Connector

REMOTE PTO/THROTTLE HARNESS

This option provides a connection from the engine ECU for remote control of engine throttle and PTOs. Options that extend the wiring to the end of frame also exist, however controls are not provided. A 12-pin Deutsch connector (Deutsch P/N DT06-12SA-P012) is included. See Figure 6-26 below for wiring harness connector pin outs.

FIGURE 6-26. PACCAR PX-7 & PX-9.

Peterbilt Motors Company 6-15

Engine Harness – PACCAR PX-7 & PX-9

PB Harn Conn Pin Outs

Engine

Pin #

Starter Lockout

GRA3914

Gray

Max Speed SW

GRA3183

Gray

Remote Throttle Sensor Signal

BLU3144

Blue

Engine Ground

None

WHT1513

White

Remote Throttle On/Off

GRA3143

Gray

ELECTRICAL

TABLE 6-9. Multifunction Engine Connector

Circuit Function Name

Common Return #1 62 GRN3115 Green 18 3

PTO On/Off 94 GRA3511 Gray 18 5 Remote Throttle Enable None GRA3143 Gray 18 6 Power – Ignition None ORN1229 Orange 18 7

Torque Limit Switch 93 GRA3149 Gray 18 9 Remote Throttle Sensor Supply (+5V) 8 VIO3113 Violet 18 10

Remote Throttle Sensor Return 32 GRN3117 Green 18 11

ECM

PB Circuit

Number

Wire

Color

Wire

Gauge

Pin #

FIGURE 6-27: Wiring for Remote Throttle/PTO Control Switch EOF.

WARNING! To prevent emissions functions of the engine from modifying torque or speed during

PTO operation, be sure to connect the PTO sensor wire to the appropriate engine controller input.

Peterbilt Motors Company 6-16

ELECTRICAL

ELECTRICAL WIRE NUMBER AND COLOR

GENERAL WIRE LABELS

Peterbilt introduced a new electrical wire numbering system in 2007. This wire number system uses only 10 different colors and only one striped wire color. These colors determine a circuits FUNCTION as follows:

TABLE 6-10. Wire Number General Categories

R/W

Direct Batter y Power

RED

ORG

YEL

BRN

BLK

GRY

VIO

BLU GRN WHT

Each wire has at a minimum a 7 character label, the first three characters are the circuits color as listed above, and the remaining four are numerical which relate to the load the wire services. See Table 6-10 for the general categories.

To identify similarly labeled wires a suffix can be added. For example: YEL2950-1 would be a yellow wire indicating it is activated power. The 2950 indicates the load, in this case fog lamps, the -1 is a suffix used to differentiate similarly labeled circuit.

Sensor common not connected to GND

Protected Battery Power

IGN/ACC/Start Power

Activated Power

Indicator Illumination, Backlighting

Load Return

Control

Reference Voltage

Sensor Signal

Ground

DATA BUS WIRE COLORS

Data Bus wiring has its own color scheme as follows:

Data-bus high-side wires

– VIO – J1587 & J1708 – ORG – J1922 – YEL – J1939 – RED – OEM – GRY – CAN – BLU – Single-wire bus

Data-bus low-side wires

– GRN – All Data-bus low-side wires

Peterbilt Motors Company 6-17

SAE J560 Connector

Circuit

Ground

Marker Lamp Trailer

ISO 3731 Connector

Circuit

Ground

ELECTRICAL

TRAILER CABLE CONNECTIONS

Peterbilt offers may different trailer connection options. The SAE J560 connector is shown in Figure 6-28, the ISO 3731 connector is shown in Figure 6-29.

FIGURE 6-28: SAE J560 Trailer Connector FIGURE 6-29: ISO 3731 Trailer Connector

There are three basic configurations for trailer connections, they are detailed below. Work with your local Peterbilt dealer to identify which setup will be ideal for your intended application. Your local dealer can also identify and provide the wiring diagrams for any chassis that has been built for the configurations below the following circuits will be dedicated pin locations:

TABLE 6-12: SAE J560 Connector TABLE 6-13: ISO 3731 Connector

2 Clearance Lamp Trailer 3 Left Turn Trailer 4 Stop Lamp Trailer 5 Right Turn Trailer

Below is a description of how the cab ABS and trailer ABS control units interface to turn on the trailer ABS warning lamp. When there is no direct connection, the Power Line Carrier (PLC) is used to transmit the signal. PLC defines that the trailer and cab ABS controllers are communicating via signals transmitted on their power circuits.

Trailer ABS Power or

Trailer Hotline

2 3 Trailer ABS Warning Lamp 4 5 -

7 Trailer ABS Power

1. J560 with Full Truck &/or Tractor Kit (standard configuration):

Peterbilt Motors Company 6-18

• This option provides a single SAE J560 connector at the noted location(s).

• Trailer ABS power is received on pin 7 of the SAE J560 connector.

• Trailer ABS signal is on pin 7 of the SAE J560 via “PLC for trucks”

• Ground is on pin 1 of the SAE J560 connector

Color

Circuit

White

Ground

ELECTRICAL

2. J560 & ISO 3731 with Full Truck &/or Tractor Kit:

• This option provides two connectors: SAE J560 and ISO 3731 connector at the noted location(s): .

• Trailer ABS power is on pin 7 of the SAE J560 & ISO 3731 connectors

• Trailer ABS signal can be received on pin 7 of the SAE J560 & ISO 3731 via “PLC for trucks”

• Trailer ABS warning lamp circuit can be received on pin 3 of the ISO 3731 connector.

• Ground is on pin 1 of the SAE J560 & ISO 3731 connectors

J560 Hotline & ISO 3731 with Full Truck &/or Tractor Kit:

• This option provides two connectors: SAE J560 and an ISO 3731 connector at the noted location(s)

• Trailer ABS power is on pin 7 of the ISO 3731 connector

• Trailer ABS signal is on pin 7 of the ISO 3731 via “PLC for trucks”

• Trailer ABS warning lamp circuit is on pin 3 of the ISO 3731 connector.

• Trailer Hotline is provided on pin 7 of the SAE J560 connector. This may be either battery powered or switched.

• Ground is on pin 1 of both the SAE J560 & ISO 3731 connectors

TRAILER/BODY BUILDER WIRE COLORS

Trailer Wires have their own wiring scheme as follows:

TABLE 6-11. Trailer Wire Colors

Black Clearance ID Marker lamps

Yellow Left turn lamps

Red Stop lamps

Light green Right turn lamps

Brown Tail lamps

Light blue ABS power Auxiliary

To identify specific circuits contact your local Peterbilt Dealer.

Peterbilt Motors Company 6-19

ELECTRICAL

BODY LIGHT CONNECTIONS

In addition to these configurations an optional junction box is available mounted either behind the cab or at the end of frame. See Figure 6-30.

FIGURE 6-30. Junction Box

Circuits provided inside the junction box are:

• Ground

• Clearance Lamp Signal

• Marker Lamp Signal

• Left Turn Signal

• Brake Lights Signal

• Right Turn Signal:

These circuits are terminated with ring terminals attached to one side of a terminal strip. To connect to the circuits use a ring terminal for a #10 screw.

FIGURE 6-31. Junction Box Wiring

Peterbilt Motors Company 6-20

SECTION 7 POWER TAKE-OFF (PTO)

INTRODUCTION

A Power Take Off (PTO) provides a way to divert some or all of the trucks engine po wer to another component. T here are a wide variety of PTO options available on a Peterbilt that are described below.

FIGURE 7-1. Power Take-Off Locations

TRANSMISSION MOUNTED PTO – GENERAL

MANUAL TRANSMISSIONS

This is the most common type of PTO that is used. Figures 7-2 through 7-9 show all of the manual and automated transmissions available for Medium Duty. Reference Table 7-1 for transmission availability with the Peterbilt Medium Duty models. For mor e information go to www.roadranger .com and enter “PTO Installation Guid e” in the search bar in the upper right corner.

FIGURE 7-2. MD Manual Transmission FIGURE 7-3. HD Manual Transmission - RT

POWER TAKE-OFF (PTO)

FIGURE 7-4. HD Manual Transmission – RT Vocational FIGURE 7-5. HD Manual Transmission – RT Performance

FIGURE 7-6. HD Manual Transmission – Fuller Advantage FIGURE 7-7. HD Manual Transmission – FR Series

FIGURE 7-8. MD Automated FIGURE 7-9. HD Autom ated – Ultrashift Plus – VCS and VMS

Peterbilt Motors Company 7-2

POWER TAKE-OFF (PTO)

AUTOMATIC TRANSMISSIONS

On Allison transm issions th ere are t wo l ocations for PT O’s. T he Allison 400 0 ser ies has PT O locatio ns at 1 and 8 o’c lock viewed from the back of the transmission. See Figure 7-10. The 4000H S and 3000HS transmissions do not have a ny PTO locations. The 3000 series Allison transmissions have PTO locations at 4 and 8 o’clock ( Figure 7-11). For more information on using PTO’s with an Allison transmission go to www.allisontransmission.com and refer to the “Rugged Duty Series Brochure” and “PTO Request Flyer” which is available in a 1000/2000 version and a 3000/4000 version.

Some PTO configurations will have cleara nce issues with other components on t he truck. W ith manual transmiss ions, a 6-bolt PTO on the righ t will typicall y clear m ost com ponents when the DPF and S CR are und er the cab . Thi s is also tr ue when 30 and 45 degree adapters are used. The 8-bolt bottom mount PTO will not have any issues unless you are running a driveshaf t back to another com ponent and the truc k has a cross over style exhaust. In this case, the D PF and SCR would block any routing f or the driveshaft. If a wet kit is used in this scenario ther e is enough room to mount the PTO and the h ydraulic pum p without interfering with the exhaust. On Allison 4000 series transmis sions, most PT O’s will fit in the 1 o’clock position without in terfering with the cab. If a wet k it is used here, the dipstick housing will most likely need to be modif ied as it r uns o ver the to p of the t ransm ission to the driv er side of the ve hicle. T he PTO in the 8 o’clock position is typicall y ok. The same issue with cros sover exhaust would apply her e as well. There are some scenar ios where the PTO will be very c lose to or c ould inter fere with the rear s pring shack le on the front sus pension. This problem can occur on vehicles with a set-back front axle and the problem is amplified on the short hood models.

FIGURE 7-10. Allison 4000 Series FIGURE 7-11. Allison 3000 Series

Peterbilt Motors Company 7-3

POWER TAKE-OFF (PTO)

FRONT ENGINE PTO

Front engine PTO (FEPT O) is com monl y used in m ix er, sno w plow, an d cr ane ap plicatio ns. When a FEPTO is spec’d on a truck, the cooling m odule moves up to al low for a shaf t to be bolted to the f ront of the cr ankshaft and ex tend out to the front of the truck . The vehicle can be sp ec’d with a 13 50 flange adapter to simplify installing the F E PT O shaft . T he f r am e rails will be extended ou t to mount a hydraulic pum p, snow plow or outrigg ers. There are options f or either a 27.8” or a

3.2” frame extension. See Figures 7-12 through 7-14 for frame extension dimensions.

FIGURE 7-12. Frame Extension Top View FIGURE 7-13. Frame Extension Left Hand View

FIGURE 7-14. Frame Extension

Peterbilt Motors Company 7-4

POWER TAKE-OFF (PTO)

REAR ENGINE PTO

Rear Engine PTO ( REPTO) is commonl y used in cement mixer and fee d lot applications. T he REPTO is driven of f the rear gear train on the engine. There is a 1350/1410 flange on the bell housing in the 1 o’clock position that can be used to attach a hydraulic pum p or driveshaf t. See Figure 7-15 for an ex ample. The R EPTO flange w ill always b e turning wh en the engine is running and t he output rot ation is t he sam e as the engine. T he Cumm ins ISL9 and PX -9 REP TO turns at a rate of 1.15:1.

FIGURE 7-15. REPTO Flywheel Housing

Peterbilt Motors Company 7-5

POWER TAKE-OFF (PTO)

PTO INSTALLATIONS

STANDARD PTO OPERATION

Cab PTO switch can be setup by the operator to a pre-programmed engine set speed(s) and the engine speed can be ramped up and down with the set/resume switch. To control the PTO there are various dash switches that we offer. Standard with every vehicle is the Cruise Control/PTO on off switch and the Set/Resume switch. There are also several additional PTO control switches that can be used. The PTO control switch will be plumbed with air lines that will be plugged at the firewall bulkhead. See Section 6 for PTO dash switch plumbing and firewall bulkhead locations. On PACCAR engines, when the cruise control switch is activated and all parameters set in the ECM for PTO mode are met, the engine will go into PTO mode. In this mode, the engine will respond to all PTO mode parameters that have been programmed into the software. These parameters can be changed with INSITE on all PACCAR engines. There is a PTO light on the dash that should be wired to the PTO to inform the operator when the PTO has engaged or disengaged. This should be wired to the PTO output, not just a dash switch or PTO enable circuit. The wire can be found in the right hand rail in the area of the transmission. The wire is labeled WHT1513 PTO Circuit.

ALlISON TRANSMISSION PTO

The PTO’s will require an electric signal. We do not currently offer an electric PTO switch for the medium duty family, but there are several options available. The most common method of getting an electric signal for the PTO is to get a factory air switch and install a pressure switch on the air line. It is recommended to provide a 12 volt signal to the transmission control module (TCM) and have the TCM programmed to check for specific requirements such as engine speed, gear selection, output speed etc. before engaging the PTO. If the TCM logic is bypassed and the PTO is engaged directly it could cause damage to the PTO and the transmission. Contact your local Allison rep for more information.

PTO ENABLE RELAY CONNECTION WITH ALLISON TRANSMISSION

A 3-wire pigtail is available in Allison chassis harness. The connector is labeled “J105-PTO Enable” and the pigtail is connected to the PTO Enable Relay. The relay is energized by an output from the TCM (PTO Enable Output, AT130). The PTO Enable Input to TCM is J109 – PTO (AT143) which requires 12V+. When relay is energized, pins B & C are “connected”. When relay is not energized, pins B & A are “connected”.

RANGE INDICATOR RELAY CONNECTI ON WITH AN ALLISON TRANSMISSION

A 3-wire pigtail is always available in Allison chassis harness. The connector is labeled “J104-Range Indicator” and the pigtail is connected to the Range Indicator Relay. The relay is energized by an output from the TCM (for Neutral Indicator) When relay is energized, pins C & B are “connected”. When relay is not energized, pins C & A are “connected”.

Peterbilt Motors Company 7-6

SECTION 8 AFTERTREAMENT

INTRODUCTION

The following section is designed to give you information regarding the aftertreatment systems on Peterbilt chassis. All Peterbilt’s equipped with 2017 emission level engines will utilize Selective Catalyst Reduction (SCR). SCR is a process

in which Diesel Exhaust Fluid (DEF) is injected into the exhaust downstream of the engine. DEF is converted to ammonia by the heat of the exhaust system. Inside of the SCR canister a catalyst causes a chemical reaction to occur between the ammonia and NOx, turning it into water and nitrogen. For more information on the specific details of how SCR works, please contact your local Peterbilt dealer.

DEF SYSTEM SCHEMATIC

On most Peterbilt chassis the DEF Supply Module (or pump) is integrated into the DEF tank. Peterbilt does not allow relocation of this pump. The following schematic details how the DEF lines route to the after-treatment system.

FIGURE 8-1. DEF System Schematic

FUEL VOLUME ALLOWED (USABLE GALLONS)

Ratio (1:1), No Derates

EXHAUST & AFTERTREATMENT

DEF will freeze at approximately 11° F. In order to keep DEF from freezing all tanks will be heated with engine coolant. The following schematic shows the routing of these lines. It is critical that the system is not compromised in any manner. Below, numbers denote the order of the component in the flow.

FIGURE 8-2. DEF Coolant Routing Schematic

GENERAL GUIDELINES FOR DEF SYSTEM

The installation of the DEF tank is a critical component of the aftertreatment system. While Peterbilt does not recommend relocating the DEF tank, there are applications and body installations that will require it. The guidelines below must be strictly followed by any entity relocating the tank. Failure to follow the guidelines completely and accurately may result in engine shut-down situations.

PACCAR-approved DEF hoses are required when retrofitting for system to function properly. The use of unapproved hoses for DEF line s will void warranty and may cause engine shut-down situations. The DEF pump (or Supply Module) cannot be relocated from the DEF tank.

Peterbilt offers a variety of DEF tank sizes to meet every application. The DEF tank volume is regulated by the E.P.A. Peterbilt advises against modifying the tank volume after the truck has been delivered from the factory. These are estimated nominal (published) maximum fuel capacities for various DEF tanks, engines, and fill ratios. Dosing rates for these calculations are also shown.

TABLE 8-1. DEF Fuel Ratios

DEF Tank

Standard DEF-Fuel Ratio

PX-7/

ISX15

(2:1)

ISX12

MX-11/

MX-13

PX-9

Minimum Recommended DEF-Fuel

PX-7/

ISX15

ISX12

MX-11/

MX-13

PX-9

SMALL MEDIUM LARGE MEDIUM AERO LARGE AERO

Rectangular

153 162 113 189 193 204 152 238 286 303 212 353 387 409 286 477 431 455 318 531 581 614 430 717 291 307 215 358 393 416 308 485 368 389 272 454 538 569 419 664 103 109 76 128 148 157 110 183

Peterbilt Motors Company 8-2

EXHAUST & AFTERTREATMENT

INSTALLATION REQUIREMENTS AND DIMENSIONS FOR DEF SYSTEM

When relocating any DEF system components, the locations must meet the guidelines below. Failure to comply may result in non-conformance to EPA standards and engine shutdown.

With all relocating procedures, general clearances and routing guidelines must be followed. See section 10 of this manual for general routing guidelines.

When relocating the components the maximum pressure DEF hose length, from Supply module to Dosing Module, is 5.5 meters (216.5").

Maintain a minimum of 3" clearance to shielded exhaust components when routing DEF lines to prevent possible melting. If the DEF tank is relocated the coolant lines will need to be modified. During this process if the tank is moved forward on

the chassis (closer to the engine) it is necessary to remove excess coolant lines and maintain the original routing path. If the tank is moved rearward on the chassis the additional length of cooling line required to complete the installation must be installed in a straight section of the existing coolant routing lines. This process minimizes the change in coolant flow by mitigating changes in restrictions. Changes in restriction are added with excessive line length and bends. Work with your local Peterbilt dealer if you are unsure about the coolant line modifications.

ROUTING TO THE DOSING MODULE (INJECTOR)

A DEF pressure line “trap” is no longer required after EPA 2013 emissions level engine. The dosing module (injector) no longer needs to be purged and relative heights of components are no longer critical. See Figure 8-3 below for typical routing with RHUC exhaust and LH DEF tank shown. Figure below shows a typical coolant line routing.

FIGURE 8-3. Routing for DEF and Coolant Lines

Peterbilt Motors Company 8-3

EXHAUST & AFTERTREATMENT

DEF SUPPLY MODULE MOUNTING REQUIREMENTS

The Supply Module (or Pump) standard mounting location is on the DEF tank assembly. Body builders may need to relocate this component, and should follow the location and length restrictions above. Additionally the mounting and the orientation of the Supply Module must not exceed 45° from vertical in any direction.

FIGURE 8-4. Supply Module Allowed Clocking Angle Limit Scribes a 90° Inverted Cone.

Peterbilt Motors Company 8-4

Peterbilt Medium Duty Service Manuals

Specifications and Main Features

Frequently Asked Questions

User Manual