Peterbilt MD Body Builder

Medium Duty
Body Builder Manual
Model 325
Model 330
Model 337
Model 348
Table of Contents
MEDIUM DUTY BODY BUILDERS MANUAL

CONTENT
SECTION 1 INTRODUCTION
SCOPE.....................................................................................................................................1-1
SECTION 2 SAFETY AND COMPLIANCE

SAFETY SIGNALS.......................................................................................................................2-1
Warnings, cautions, and notes.........................................................................................2-1
FEDERAL MOTOR VEHICLE SAFETY STANDARDS (FMVSS) & CANADIAN MOTOR VEHICLE SAFETY
STANDARDS (CMVSS) COMPLIANCE.............................................................................................2-1
Incomplete Vehicle Certification.......................................................................................2-2
Noise and Emissions Requirements..................................................................................2-2
SECTION 3 DIMENSIONS
DIMENSIONS.............................................................................................................................3-1
ABBREVIATIONS........................................................................................................................3-1
TURNING RADIUS......................................................................................................................3-1
OVERALL DIMENSIONS
Side View - Single Rear Axle Model 330,337,348.............................................................3-2
Side View - Single Rear Axle Model................................................................................3-3
Side View - Tandem Rear Axle Model 348.......................................................................3-4
Front and Rear Views ....................................................................................................3-5
Rear Window.................................................................................................................3-6
Cab and Hood - Standard Cab.........................................................................................3-7
Cab and Hood - Crew Cab...............................................................................................3-8
Battery Box - Location - Model 330,337,348......................................................................3-9
Battery Box - Location - Model 325.................................................................................3-10
Battery Box - Step Height - Model 330,337,348...............................................................3-11
Battery Box - Step Height - Model 325............................................................................3-12
Fuel Tank Location - Model 330,337,348.......................................................................3-13
Fuel Tank Location - Model 325...................................................................................3-14
Fuel Tank Location - Model 325...................................................................................3-15
Fuel Tank - Step Height - Model 325...............................................................................3-16
Fuel Tank - Step Height - Model 330,335,348..................................................................3-17
DEF Tank System Overview........................................................................................3-18
DEF Tank Tank Measurements....................................................................................3-19
DEF Tank Ground Clearance Rectangular...................................................................3-20
DEF Tank Ground Clearance Round...........................................................................3-21
Exhaust Location 2007 Horizontal DPF w/Horizontal Diffuser...........................................3-22
Exhaust Location 2007 Horizontal DPF w/ Vertical Stack Model 330,337,348...................3-23
Exhaust Location 2007 Under Cab DPF w/side of Cab Stack Model 330,337,348..............3-24
Exhaust Location 2010 Horizontal In-series DPF/SCR w/Horizontal Tailpipe.......................3-25
Exhaust Location 2010 Horizontal Crossover DPF/SCR w/Horizontal Tailpipe......................3-26
Exhaust Location 2010 RH Under Cab DPF/SCR w/Side of Cab.........................................3-27
PTO Layouts 2010 Manual Transmission with PX6..........................................................3-28
PTO Layouts 2010 Automatic Transmission with PX6......................................................3-29
PTO Layouts 2010 Manual Transmission with PX8..........................................................3-30
PTO Layouts 2010 Automatic Transmission with PX8......................................................3-31
FEPTO Extension and Bumper - Model 337,348................................................................3-32
Air Horn - Model 330,337,348........................................................................................3-33
Rear Frame Height - Single Rear Axle.............................................................................3-34
Rear Frame Height - Tandem Rear Axles - Model 348........................................................3-35
Rear Suspension and Tire Clearance - Single Rear Axle.....................................................3-36
Rear Suspension & Tire Clearance - Tandem Rear Axles - Model 348...................................3-37
Frame Rail Sections......................................................................................................3-38
Crossmember Drillings..................................................................................................3-39
SECTION 4 BODY MOUNTING

CRITICAL CLEARANCES...............................................................................................................4-1
Rear Wheels and Cab.....................................................................................................4-1
BODY MOUNTING USING BRACKETS.............................................................................................4-1
Frame Sill.....................................................................................................................4-1
ii Medium Duty Body Builder Manual 1/2010

Table of Contents
Brackets.......................................................................................................................4-2
Mounting Holes..............................................................................................................4-2
Frame Drilling...............................................................................................................4-3
BODY MOUNTING USING UBOLTS...............................................................................................4-4
Spacers........................................................................................................................4-4
Rear Body Mount...........................................................................................................4-5
SECTION 5 FRAME MODIFICATIONS

INTRODUCTION.........................................................................................................................5-1
DRILLING RAILS........................................................................................................................5-1
Location and Hole..........................................................................................................5-1
MODIFYING FRAME LENGTH........................................................................................................5-1
Frame Insert.................................................................................................................5-1
Changing Wheelbase......................................................................................................5-2
Crossmembers..............................................................................................................5-4
WELDING..................................................................................................................................5-4
Precautions...................................................................................................................5-4
TORQUE REQUIREMENTS............................................................................................................5-5
SECTION 6 ELECTRICAL
INTRODUCTION.........................................................................................................................6-1
BODY LIGHTS JUNCTION BOX......................................................................................................6-1
REMOTE PTO HARNESS...............................................................................................................6-2
THIRD BATTERY.........................................................................................................................6-2
ENGINE CONNECTIONS...............................................................................................................6-2
SECTION 7 HYBRID
HYBRID - Model 330, Model 337...................................................................................................7-1
Power Electric Carrier Placement (PEC).............................................................................7-1
General Notes and Cautions............................................................................................7-1
HYBRID UTILITY APPLICATION.....................................................................................................7-2
EPTO Functionality.........................................................................................................7-2
EPTO Connection...........................................................................................................7-2
Body Builder Connection.................................................................................................7-3
Sections of the MD Hybrid Electrical Schematics on Body Builder Connections....................................7-4
HYBRID BATTERY BOX ACCESS....................................................................................................7-5
APPENDIX A VEHICLE IDENTIFICATION

VEHICLE IDENTIFICATION NUMBER .............................................................................................A-1
VIN Location.................................................................................................................A-1
Chassis Number Locations..............................................................................................A-1
CERTIFICATION LABELS..............................................................................................................A-2
Components and Weights Label.......................................................................................A-2
Tire and Rim Data Label.................................................................................................A-2
Incomplete Vehicle Certification Label...............................................................................A-2
Noise Emission Label......................................................................................................A-2
Paint Identification Label................................................................................................A-2
COMPONENT IDENTIFICATION.....................................................................................................A-3
Engine Identification......................................................................................................A-3
Transmission Identification.............................................................................................A-3
Front Axle Identification.................................................................................................A-3
Rear Axle Identification..................................................................................................A-3
APPENDIX B WEIGHT DISTRIBUTION

INTRODUCTION.........................................................................................................................B-1
BODY BUILDERS RESPONSIBILITIES ..........................................................................................B-1
APPENDIX C ROUTING
INTRODUCTION.........................................................................................................................C-1
ELECTRICAL CIRCUITS...............................................................................................................C-1
Capacity.......................................................................................................................C-1
ROUTING..................................................................................................................................C-1
Definitions....................................................................................................................C-1
ROUTING REQUIREMENTS...........................................................................................................C-2
Wiring..........................................................................................................................C-2
iii Medium Duty Body Builder Manual 1/2010

Table of Contents
Wires in Bundles............................................................................................................C-2
Exceptions....................................................................................................................C-2
Wires Crossing other Components....................................................................................C-3
Piping..........................................................................................................................C-3
Hoses Crossing Components...........................................................................................C-3
Air Compressor Discharge Hoses......................................................................................C-3
Bundles........................................................................................................................C-3
Routing of Wires & Hoses near Moving Components...........................................................C-3
Routing of Wires & Hoses near Exhaust System.................................................................C-4
iv Medium Duty Body Builder Manual 1/2010

SECTION 1 INTRODUCTION
SCOPE
This manual was created to provide body builders with and ordering process. Early in the process, profes-
appropriate information and guidelines useful in the sional body builders can often contribute valuable
body planning and installation process. This information information that reduces the ultimate cost of the body
will be helpful when installing bodies or other associ- installation. This manual is not a maintenance
ated equipment. manual or an operation manual.
For chassis maintenance and repair information
This manual contains appropriate dimensional informa-
consult the model-appropriate Maintenance Manual
tion, guidelines for mounting bodies, guidelines for
available in the Service Department of the selling
modifying frames, electrical wiring information, and
dealer or you can order your own copy of the
other information useful in the body installation process.
maintenance manual from your local dealer.
The intended primary users of this manual are body For chassis operating information consult the Oper-
builders who install bodies and associated equipment ators Manual, included with each vehicle. It also
on Peterbilt Medium Duty vehicles. Dealers who sell and can be ordered from your local dealer.
service the vehicle will also find this information useful.
This Medium Duty Body Builder Manual can be very

useful when specifying a vehicle, particularly when
the body builder is involved in the vehicle definition
1-1 Medium Duty Body Builder Manual 10/2009

Page Intentionally Left Blank.
Peterbilt Motors Co.

SECTION 2 SAFETY AND COMPLIANCE
SAFETY SIGNALS NOTE
Provides general information: for example, the
A number of alerting messages are shown in this book. note could warn you on how to avoid damaging
Please read and follow them. They are there for your your vehicle or how to drive the vehicle more effi-
protection and information. These alerting messages can
ciently.
help you avoid injury to yourself or others and help
prevent costly damage to the vehicle.
Example:
Key symbols and signal words are used to indicate what NOTE: Be sure to provide maintenance access
kind of message is going to follow. Pay special attention to to the battery box and fuel tank fill neck.
comments prefaced by WARNING, CAUTION, and
NOTE. Please don't ignore any of these alerts.
Please take the time to read these mes-

sages when you see them, and remember:
Warnings, cautions, and notes
WARNING WARNING
When you see this word and symbol, the mes- Indicates a potentially hazardous situation
sage that follows is especially vital. It signals a which, if not avoided, could result in death or
serious injury.
potentially hazardous situation which, if not
avoided, could result in death or serious injury. CAUTION
This message will tell you what the hazard is, Signals a potentially hazardous situation which,
what can happen if you dont heed the warning, if not avoided, could result in minor or moderate
and how to avoid it. injury or damage to the vehicle.
Example: NOTE
Useful information that is related to the topic
WARNING! Be sure to use a circuit breaker being discussed.
designed to meet liftgate amperage require-
ments. An incorrectly specified circuit
breaker could result in a electrical overload
or fire situation. Follow the liftgate installa-
tion instructions and use a circuit breaker
with the recommeded capacity. FEDERAL MOTOR VEHICLE SAFETY
CAUTION STANDARDS (FMVSS) AND
S ignals a potentially hazardous situation
CANADIAN MOTOR VEHICLE
which, if not avoided, could result in minor or mod- SAFETY STANDARDS (CMVSS)
erate injury or damage to the vehicle. COMPLIANCE
Example:
As an Original Equipment Manufacturer (OEM), Peter-
CAUTION: Never use a torch to make a hole bilt Motors Company ensures that our products comply
in the rail. Use the appropriate drill bit. with all applicable Federal Motor Vehicle Safety Stan-
dards (FMVSS) and Canadian Motor Vehicle Safety
Standards (CMVSS) where applicable. However, the
fact that this vehicle has no fifthwheel and that a Body

SAFETY AND COMPLIANCE 2
Builder (Final Stage Manufacturer) will be doing addi- As the Final Stage Manufacturer, you should retain the
tional modifications means that the vehicle was incom- Incomplete Vehicle Document for your records. In addi-
plete when it left the build plant. tion, you should record and retain the manufacturer and
serial number of the tires on the vehicle. Upon comple-
tion of the vehicle (installation of the body and any other
Incomplete Vehicle Certification modifications), you should affix your certification label
to the vehicle as required by Federal law. This tag iden-
An Incomplete Vehicle Document is shipped with the
tifies you as the Final Stage Manufacturer and certi-
vehicle, certifying that the vehicle is not complete (see
fies that the vehicle complies with Federal Motor
figure below). In addition, affixed to the drivers side
Vehicle Safety Standards.
door frame or edge is an Incomplete Vehicle Certifica-
tion label.
Figure 2-2.
NOTE: These documents list the FMVSS (or Location of Certification
CMVSS) regulations that the vehicle complied Labels - Drivers Door
with when it left the build plant. You should be Frame
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.
Noise and Emissions Requirements

NOTE: This truck may be equipped with a Diesel
Particulate Filter (DPF) mufer unit in order to
meet both noise and exhaust emissions require-
ments. Removal or tampering with the DPF
mufer 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 mufer may only be
replaced with an approved part.
NOTE: 2007/10 emissions engines are integrated

with particulate lters for 2007/10 EPA certication.
The particulate lter 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 compon-
ents associated with it. It is also the case that
there should not be any modications made to the
Figure 2-1. Incomplete Vehicle Certification Document exhaust piping from turbo outlet to aftertreatment
inlet.
Peterbilt Motors Co. 2-2

SECTION 3 DIMENSIONS
DIMENSIONS TURNING RADIUS
This section includes dimensions for a standard The curb-to-curb turning radius is the minimum radius
Medium Duty configuration, plus several optional configu- the outermost portion of the outboard front tire would
rations. See the CONTENTS section at the beginning of follow in a turn.
the manual to locate the information you need.
The wall-to-wall turning radius is the minimum radius
the outermost tip of the front bumper would follow in a
ABBREVIATIONS turn.
Both the curb-to-curb and wall-to-wall turning radius

Throughout this manual, we use the following abbrevia- depend on the wheelbase, front axle, front tire and
tions for various critical dimensions: wheel sizes, and many other factors. Approximate turn-
ing radius figures are listed in Table 3-1. Optional
BBC Bumper to back of cab. components may result in different figures.
BFA Bumper to front axle.
The figures in Table 3-1 are based on the following
CA Cab to axle. Measured from the back of the components (for all models except Model 325):
cab to the centerline of the rear axle(s). Eaton Spicer E1002I and E1202I front axles
TRW TAS 65 steering gear
FAB Front axle to back of cab.
PHP-10 iron hubs/cast drums
FEPTO Front engine PTO extension. Measured from Bridgestone R250F295/75R22.5 14-ply front
the front of the grille to the front of the tires
bumper. Accuride 28408E 22.5 x 8.25 steel front wheels
OAL Overall vehicle length. Measured from the
No FEPTO
bumper to the end of frame. Without tandem drive
Model 325 components:
OH Frame overhang. Measured from the center-
Dana Spicer D800F front axle
line of the rear axle(s) to the end of frame.
TRW TAS 40 steering gear
WB Wheelbase. Hydraulic disc brakes
Bridgestone R250F 225/70R19.5 12-ply front tires
Accuride 28680 19.5 x 6.75 steel front wheels
To obtain the turning circle diameter, multiply the
radius by 2.
TABLE 3-1. Turning Radius
Left-Hand Turn Right-Hand Turn

Models 330,337,348 Model 325 Models 330,337,348 Model 325
WHEELBASE CURB TO CURB WALL TO WALL CURB TO CURB WALL TO WALL CURB TO CURB WALL TO WALL CURB TO CURB WALL TO WALL
[IN. (mm)] [FT. (m)] [FT. (m)] [FT. (m)] [FT. (m)] [FT. (m)] [FT. (m)] [FT. (m)] [FT. (m)]
150 (3810) 22.6 (6.9) 24.9 (7.6) 16.3 (5.0) 18.5 (5.6) 23.2 (7.1) 25.3 (7.7) 16.3 (5.0) 18.5 (5.6)
154 (3912) 23.2 (7.1) 25.4 (7.7) 16.8 (5.1) 19 (5.8) 23.8 (7.3) 25.9 (7.9) 16.8 (5.1) 19 (5.8)
164 (4166) n/a n/a 17.8 (5.4) 20 (6.1) n/a n/a 17.8 (5.4) 20 (6.1)
178 (4521) 26.7 (8.1) 28.9 (8.8) 19.4 (5.9) 21.6 (6.6) 27.4 (8.4) 29.5 (9.0) 19.4 (5.9) 21.6 (6.6)
190 (4826) 28.5 (8.7) 30.7 (9.4) 20.7 (6.3) 22.9 (7.0) 29.2 (8.9) 31.3 (9.5) 20.7 (6.3) 22.9 (7.0)
208 (5283) 31.1 (9.5) 33.3 (10.1) 22.6 (6.9) 24.8 (7.6) 31.8 (9.7) 34.0 (10.4) 22.6 (6.9) 24.8 (7.6)
220 (5588) 32.8 (10.0) 35.0 (10.7) 23.9 (7.3) 26.1 (8.0) 33.6 (10.2) 35.8 (10.9) 23.9 (7.3) 26.1 (8.0)
238 (6045) 35.4 (10.8) 37.7 (11.5) 25.9 (7.9) 28.1 (8.6) 36.3 (11.1) 38.5 (11.7) 25.9 (7.9) 28.1 (8.6)
256 (6502) 38.0 (11.6) 40.3 (12.3) n/a n/a 39.0 (11.9) 41.1 (12.5) n/a n/a
274 (6960) 40.7 (12.4 42.9 (13.1) n/a n/a 41.7 (12.7) 43.8 (13.4) n/a n/a
* 50 degree wheel cut L/R

DIMENSIONS 3
Side View Single Rear Axle - Overall Dimensions - Model 330, Model 337, Model 348
Figure 3-1. Side View w/ Single Rear Axle: Overall Dimensions.
TABLE 3-2. Side view with single rear axle - overall dimensions - lengths [inches (mm)]
WB OAL OH CA*
150 (3810) 234 (5944) 45.8 (1163) 80.2 (2037)
154 (3912) 238 (6045) 45.8 (1163) 84.2 (2139)
178 (4521) 279 (7087) 62.8 (1595) 108.2 (2748)
190 (4826) 301 (7645) 74.8 (1900) 120.2 (3053)
208 (5283) 328 (8331) 81.8 (2078) 138.2 (3510)
220 (5588) 352 (8941) 93.8 (2383) 150.2 (3815)
238 (6045) 376 (9550) 99.8 (2535) 168.2 (4272)
256 (6502) 419 (10643) 124.8 (3170) 186.2 (4729)
274 (6960) 419 (10643) 106.8 (2713) 204.2 (5187)
* Measured from the back of cab to the centerline of the rear axle as shown.
TABLE 3-3. Side view with single rear axle - overall dimensions - height [inches (mm)]
WB H EIGHT**
REYCO 79KB REYCO 79KB PETERBILT LOW AIR
21,000 LB. 23,000 AND 26,000 LB. LEAF 21,000 LB.
150 (3810) 105.3 (2675) 105.9 (2690) 105.3 (2675)
154 (3912) 105.3 (2675) 105.9 (2690) 105.3 (2675)
Greater than 157 103.9 (2639) 105.9 (2690) 105.3 (2675)
(3988)
** Measured in the light (unloaded) condition with an Eaton Spicer E1002I or E1202I front axle, required front axle spacer
blocks, 10,000 lb or 12,000 lb taperleaf front suspension, 10- or 10-5/8 inch frame rails, and Bridgestone R250F
295/75R22.5 front tires. Does not include height of optional roof-mounted air horn or optional vertical exhaust stack.

3 DIMENSIONS
Side View Single Rear Axle - Overall Dimensions - Model 325
Figure 3-1. Side View w/ Single Rear Axle: Overall Dimensions.
TABLE 3-4. Side view with single rear axle - overall dimensions - lengths [inches (mm)] - Model 325
WB OAL OH CA*
150 (3810) 234 (5943) 45.8 (1163) 80.2 (2037)
154 (3912) 240.2 (6101) 48 (1219.4) 84.2 (2138.6)
164 (4166) 257 (6528) 54.8 (1392.4) 94.2 (2392.6)
178 (4521) 279 (7086) 62.8 (1594.8) 108.2 (2748.2)
190 (4826) 303 (7696) 74.8 (1900) 120.2 (3053)
208 (5283) 328 (8331) 81.8 (2077.8) 138.2 (3510.2)
220 (5588) 352 (8941) 93.8 (2383) 150.2 (3815)
238 (6045) 376 (9550) 99.8 (2534.8) 168.2 (4272.2)
* Measured from the back of cab to the centerline of the rear axle as shown. Rev. 6-07
TABLE 3-5. Side view with single rear axle - overall dimensions - height [inches (mm)] - Model 325
WB HEIGHT**
REYCO 79KB
11,500 LB.
ALL 99 (2515)
**Measured in the laden (loaded) condition with a Dana D800F front axle, required front axle spacer blocks,
8,000 lb taperleaf spring, 9 7/8 inch frame rails, and Bridgestone R250F 225/70 R19.5 front tires.

DIMENSIONS 3
Side View Tandem Rear Axle - Overall Dimensions - Model 348
Figure 3-2. Side View w/ Tandem Rear Axle - Overall Dimensions.
TABLE 3-6. Side view with tandem rear axle - overall dimensions - lengths [inches (mm)]
WB OAL OH CA*
150 (3810) 234 (5944) 45.8 (1163) 80.2 (2037)
154 (3912) 238 (6045) 45.8 (1163) 84.2 (2139)
178 (4521) 279 (7087) 62.8 (1595) 108.2 (2748)
190 (4826) 301 (7645) 74.8 (1900) 120.2 (3053)
208 (5283) 328 (8331) 81.8 (2078) 138.2 (3510)
220 (5588) 352 (8941) 93.8 (2383) 150.2 (3815)
238 (6045) 376 (9550) 99.8 (2535) 168.2 (4272)
256 (6502) 419 (10643) 124.8 (3170) 186.2 (4729)
274 (6960) 419 (10643) 106.8 (2713) 204.2 (5187)
* Measured from the back of cab to the centerline of the rear tandem as shown.
TABLE 3-7. Side view with tandem rear axle - overall dimensions - height [inches (mm)]
WB H EIGHT**
REYCO 102 HENDRICKSON PETERBILT LOW AIR
38,000 LB. RT2-400 LEAF 38,000 LB.
40,000 LB.
ALL 106.9 (2715) 106.9 (2715) 105.3 (2675)
** Measured in the light (unloaded) condition with an Eaton Spicer E1202I front axle, required front axle spacer
blocks, 12,000 lb taperleaf front suspension, 10-5/8 inch frame rails, and Bridgestone R250F
295/75R22.5 front tires. Does not include height of optional roof-mounted air horn or optional vertical exhaust stack.

3 DIMENSIONS
Front and Rear Views Overall Dimensions
Figure 3-3. Front View - Overall Dimensions
* with 10 5/8 inch rails.

A dd 0 .1 inc h (3 mm)
when measuring from top.
Add 0.7 inch (17.8 mm)
when measuring from top
on 9 7/8 inch rails. Sub-
tract 0.27 inch (6.8 mm)
when measuring from top
of 10 3/4 inch rails.
** with Bridgestone
R250F 295/75R22.5 tires
a nd Ac cu rid e 2 84 08 E
22.5 X 8.25 steel wheels.
Figure 3-4. Rear View - Overall Dimensions

DIMENSIONS 3
Rear Window
* with 1 0 5/8 in ch rails. A dd

0 .1 inch (3 mm) when measur-
ing from top of 10 1/2 inch rails.
A dd 0.7 inch (17.8 mm) when
measuring from top of 9 7/8 inch
rails. Subtract 0.27 inch (6.8
mm) when measuring from top
of 10 3/4 inch rails.
Figure 3-5. Rear Window
Contact Dealer for loadlight locations.

3 DIMENSIONS
Cab and Hood - Standard Cab
AREA OF
CONTACT
WITH ROOF
SKIN
DETAIL A
ROOF SKIN
2.0 (51)
SECTION A-A
Figure 3-6. Cab and Hood - Standard cab

DIMENSIONS 3
Cab and Hood - Crew Cab
* WITH 10 5/8 INCH RAILS
Figure 3-7. Cab and Hood - Crew cab
NOTE: This configuration is not available from the factory.

3 DIMENSIONS
Battery Box - Location - Model 330, Model 337, Model 348
(STEEL BATTERY
BOX SHOWN)
Figure 3-8. Battery Box - Location
TABLE 3-8. Battery box location [inches (mm)]
DIMENSION* STEEL BATTERY BOX ALUMINUM BATTERY

BOX
X 25.6 (650) 30.2 (767)
Y ** 8.4 (213) 0.9 (22)
Z 30.5 (775) 30.4 (772)
* Dimensions are for battery boxes located left-hand under-cab. The loca-
tion of battery boxes located back of cab varies according to the location of
other frame-mounted components.
** A minimum clearance of 4.0 in. (101 mm) is required to the rear of the
battery box to allow the release of the cover latches and to access the air
tank drain valve.

DIMENSIONS 3
Battery Box - Location - Model 325
Figure 3-9. Battery Box - Location - Model 325
TABLE 3-9. Battery box location [inches (mm)]
Dimension
X 30.1 (765)
Y 6.3 (159)
Z 27.7 (703)

3 DIMENSIONS
Battery Box - Step Height - Model 330, Model 337, Model 348
Figure 3-10. Battery Box - Step Height
TABLE 3-10. Battery box - step height [inches (mm)]
STEEL ALUMINUM
BATTERY BOX BATTERY BOX
STEP HEIGHT* STD CROSSMEMBER HD CROSSMEMBER HD CROSSMEMBER
A** (ground to first 18.7 (475) 17.2 (437) 14.5 (368)
step)
B (first step to second 14.0 (356) 14.0 (356) 16.1 (409)
step)
C (second step to cab 12.0 (305) 13.5 (343) 15.0 (381)
floor)
*Measured in the light (unloaded) condition with a left-hand under-cab battery box, Eaton Spicer E1002I or
E1202I front axle, required front axle spacer blocks, 10,000 lb or 12,000 lb taperleaf front suspension, 10-1/2 or
10-5/8 inch frame rails, Bridgestone R250F or R299PFE 295/75R22.5 front tires, wheelbases less than 157 inch,
and a Reyco 79KB 21,000 lb rear suspension. Other components may result in different "A" step heights.
**Make the following corrections to step height "A" for the conditions listed above with these optional wheelbases
and rear suspensions:
Wheelbases greater than 157 inch with Reyco 79KB 21,000 lb suspension - subtract 1.4 inch (36 mm)
All wheelbases with Reyco 79KB 23,000 or 26,000 lb suspensions - add .6 inch (15 mm)
All wheelbases with Peterbilt Low Air Leaf 21,000 lb suspension - subtract 1.4 inch (35 mm)
All wheelbases with Reyco 102 38,000 lb suspension - add 1.6 inch (41 mm)
All wheelbases with Hendrickson RT2-400 40,000 lb suspension - add 1.6 inch (41 mm)
All wheelbases with Peterbilt Low Air Leaf 38,000 lb suspension - no correction required
NOTE: Vehicles designed for use as fire apparatus must have an "A" step height of no more than 24.0
inches (610 mm) to comply with NFPA 1901 Standard for Automotive Fire Apparatus, 1999 Edition.

DIMENSIONS 3
Battery Box - Step Height - Model 325
Figure 3-11. Battery Box - Step Height - Model 325
TABLE 3-11. Battery box - step height [inches (mm)]
Step Height
A (ground to first step) 21.7 (550)
B (first step to cab floor) 19.7 (500)

3 DIMENSIONS
Fuel Tank - Location - Model 330, Model 337, Model 348
Rectangular 50-gal steel

fuel tank shown
Figure 3-12. Fuel Tank - Location
TABLE 3-12. Fuel tank location [inches (mm)]
STEEL FUEL TANK ALUMINUM FUEL TANK
STD HD
DIMENSION* CROSSMEMBER CROSSMEMBER HD CROSSMEMBER
RECT RECT 23 IN. RND 23 IN. RND 23 IN. RND
50 GAL 50 GAL 50 GAL 70 GAL 100 GAL
X 33.5 (851) 33.5 (851) 34.5 (876) 46.8 (1189) 65.1 (1654)
Y** + 2.5 (64) - 1.9 (48) - 1.5 (38) + 10.8 (275) + 28.0 (711)
Z 25 (634)*** 25 (634)*** 30.7 (779)**** 30.7 (779)**** 30.7 (779)****
*Dimensions are for fuel tanks located right-hand under-cab. The location of fuel tanks located back of cab varies
according to the location of other frame-mounted components.
**Positive numbers for the Y dimension indicate distance rearward from the back of cab. Negative numbers indicate
distance forward from the back of cab.
***The fuel filler neck on steel rectangular fuel tanks protrudes an additional 1.4 inch (36 mm) outboard from the out-
board edge of the fuel tank.
****This dimension includes 6.2 inch (157 mm) for the fuel tank steps. The outboard edge of the fuel tank itself is 24.5
inch (622 mm) outboard from the frame rail.

DIMENSIONS 3
Fuel Tank - Location - Model 325
TABLE 3-13. Fuel tank location [inches (mm)]
STEEL FUEL TANK

DIMENSION* RECT 30 GAL
X 37.7 (958)
Y ** 1.4 (35.2)
Z 27.5 (698)
*Dimensions are for fuel tanks located right-hand under-cab.
**Positive numbers for the Y dimension indicate distance

rearward from the back of cab.
Right hand under cab tank shown, dual tanks similar

3 DIMENSIONS
Fuel Tank - Location - Model 325
TABLE 3-14. Fuel tank location [inches (mm)] - Model 325
RECTANGULAR 35 GAL
WB X Y Z
150 (3810) 43.7 (1110) 3.4 (86.5) 21.6 (548)
154 (3912) 43.7 (1110) 3.4 (86.5) 21.6 (548)
164 (4166) 43.7 (1110) 18.4 (466.7) 21.6 (548)
178 (4521) 43.7 (1110) 23.9 (606.7) 21.6 (548)
190 (4826) 43.7 (1110) 23.9 (606.7) 21.6 (548)
208 (5283) 43.7 (1110) 57.0 (1446.7) 21.6 (548)
220 (5588) 43.7 (1110) 68.0 (1726.7) 21.6 (548)
238 (6045) 43.7 (1110) 79.0 (2006.7) 21.6 (548)

DIMENSIONS 3
Fuel Tank - Step Height - Model 325

fuel tank shown
Figure 3-15. Fuel Tank - Step Height
TABLE 3-15. Fuel tank - step height [inches (mm)]
STEP HEIGHT STEEL FUEL TANK

A** (ground to step) 19.5 (495)
B (step to cab floor) 20.4 (517)
Measured in the light (unloaded) condition with a right-hand under-cab fuel tank, Dana D800F front
axle, required front axle spacer blocks, 8,000 lb taperleaf front suspension, 9 7/8 inch frame rails,
Bridgestone R250F 245/70R19.5 front tires, wheel base less than 157 inch, and a Reyco 79KB
11,500 lb rear suspension. Other components may result in different "A" step heights.

3 DIMENSIONS
Fuel Tank - Step Height - Model 330, Model 337, Model 348

fuel tank shown
Figure 3-16. Fuel Tank - Step Height
TABLE 3-16. Fuel tank - step height [inches (mm)]
STEP HEIGHT* STEEL FUEL TANK ALUMINUM FUEL TANK

A** (ground to first step) 23.3 (592) 17.4 (442)
B (first step to second step) 14.8 (376) 15.2 (386)
C (second step to cab floor) 6.5 (165) 12.1 (308)
*Measured in the light (unloaded) condition with a right-hand under-cab fuel tank, Eaton Spicer E1002I or E1202I
front axle, required front axle spacer blocks, 10,000 lb or 12,000 lb taperleaf front suspension, 10-1/2 or 10-5/8 inch
frame rails, Bridgestone R250F or R299PFE 295/75R22.5 front tires, wheelbases less than 157 inch, and a Reyco
79KB 21,000 lb rear suspension. Other components may result in different "A" step heights.
**Make the following corrections to step height "A" for the conditions listed above with these optional wheelbases and
rear suspensions:
Wheelbases greater than 157 inch with Reyco 79KB 21,000 lb suspension - subtract 1.4 inch (36 mm)
All wheelbases with Reyco 79KB 23,000 or 26,000 lb suspensions - add .6 inch (15 mm)
All wheelbases with Peterbilt Low Air Leaf 21,000 lb suspension - subtract 1.4 inch (35 mm)
All wheelbases with Reyco 102 38,000 lb suspension - add 1.6 inch (41 mm)
All wheelbases with Hendrickson RT2-400 40,000 lb suspension - add 1.6 inch (41 mm)
All wheelbases with Peterbilt Low Air Leaf 38,000 lb suspension - no correction required
NOTE: Vehicles designed for use as fire apparatus must have an "A" step height of no more than 24.0
inches (610 mm) to comply with NFPA 1901 Standard for Automotive Fire Apparatus, 1999 Edition.

3 DIMENSIONS
2010 DEF TANK and AFTERTREATMENT SYSTEM
SCR System Overview

(Cross-Over System Shown)

3 DIMENSIONS
2010 DEF TANK MEASUREMENTS
DEF Tank Information

Tank Shape Round Round Rectangular
DEF Tank Size D-Tank: Small D-Tank: Medium Class 5, 6 & 7
Useable Capacity Gallons 9 18 6.6
Width (x) mm (in) 265 (10.4) 480.4 (18.9) 250 (9.8)
Length (y) mm (in) 586 (23.0) 580 (22.8) 386 (15.2)
Height (z) mm (in) 609 (23.9) 609 (23.9) 496 (19.5)
Assembly Weight lbs 53 75 74
Assy Weight w/Urea lbs 160 270 150
Max Fuel Capacity Gallons 150 300 110
Note: Rectangular DEF tanks are only available with rectangular fuel tanks on Medium Duty
Models

3 DIMENSIONS
2010 DEF TANK GROUND CLEARANCE - RECTANGULAR
TOPOFSENDING
UNITBOOT
C=245.3mm(9.7in)
BOTTOMOFRAIL
B=312.5mm(12.3in)
BOTTOMOF
PUMPPLATE
A=636.1mm(25.0in)
D=657.4mm(25.9in)

3 DIMENSIONS
2010 DEF TANK GROUND CLEARANCE - ROUND
TOPOFSENDING
UNITBOOT
C=267.7mm(10.5in)
BOTTOMOFRAIL
B=391.7mm(15.4in)
BOTTOMOF
PUMPPLATE
A=673.9mm(26.5in)
D=702.8mm(27.7in)

DIMENSIONS 3
Exhaust Location - 2007 Horizontal DPF with Horizontal Diffuser
** Dimension shown is for 10 5/8

inch rails. Add 0.125 inch (3.2
mm) for 10 3/4 inch rail. Add 0.7
inch (17.8 mm) when measuring
from top of 9 7/8 inch rail.
Figure 3-17. Exhaust Location - Horizontal DPF with Horizontal Diffuser
TABLE 3-17. Exhaust Location - Horizontal DPF with Horizontal Diffuser

Engine Transmission DPF Location* X
All manual
PX-6 2275 15.8 (402)
Allison 2000 series
Allison 3000 HS
PX-6 Allison 3000 RDS 2475 21.7 (552)
Allison 3500 RDS
Fuller FS series
Fuller FR series
PX-8 2375 23.2 (590)
Allison 2000 series
Allison 3000 HS
Fuller RT series
Allison 3000 RDS-P
PX-8 Allison 3500 RDS-P 2513 28.7 (728)
Allison 3000 EVS-P
Allison 3500 EVS-P
* DPF LOCATION IS MEASURED FRONT OF FRAME TO FRONT MOUNTING BRACKET.

3 DIMENSIONS
Exhaust Location - 2007 Horizontal DPF with Vertical Stack - Model 330, 337, 348

Figure 3-18. Exhaust Location - Horizontal DPF with Vertical Stack
TABLE 3-18 Exhaust Location - Horizontal DPF with Vertical Stack

Engine Transmission DPF Location* X Y
All manual
PX-6 2275 21.4 (543) 16.8 (426)
Allison 2000 series
Allison 3000 HS
PX-6 Allison 3000 RDS 2475 27.4 (695) 22.6 (575)
Allison 3500 RDS
Fuller FS series
Fuller FR series
PX-8 2375 25.3 (643) 19.6 (499)
Allison 2000 series
Allison 3000 HS
Fuller RT series
Allison 3000 RDS-P
PX-8 Allison 3500 RDS-P 2513 30.9 (784) 26.3 (668)
Allison 3000 EVS-P
Allison 3500 EVS-P
* DPF LOCATION IS MEASURED FRONT OF FRAME TO FRONT MOUNTING BRACKET.

DIMENSIONS 3
Exhaust Location - 2007 Under Cab DPF w/Side of Cab Stack - Model 330, 337, 348

Figure 3-19. Exhaust Location - Under Cab DPF w/Side of Cab Stack
TABLE 3-19. Exhaust Location - Under Cab DPF w/Side of Cab Stack
Engine DPF Location* X Y
PX-6 2063 4.5 (115) 2.8 (70)
PX-8 2063 4.5 (115) 2.8 (70)
PX-8 2163 8.5 (215) 6.7 (170)
* DPF LOCATION IS MEASURED FRONT OF FRAME TO
FRONT MOUNTING BRACKET.

3 DIMENSIONS
2010 UNDER FRAME IN-SERIES DPF/SCR with HORIZONTAL EXHAUST
14.3
12.4
105
Reference option code 3365060

3 DIMENSIONS
2010 UNDER FRAME CROSSOVER DPF/SCR with HORIZONTAL EXHAUST
14.3
12.4
51
Reference option code 3365070

3 DIMENSIONS
2010 RIGHT HAND UNDER CAB DPF/SCR with SIDE OF CAB EXHAUST
15.9 A
31.5
A = Lower step to upper step = 14.2

B = Upper step to cab floor = 15.5
Reference option 3365040

3 DIMENSIONS
2010 MANUAL TRANSMISSION PX6 PTO FRAME CLEARANCE
Bottom view from right rear Rear view
Bottom view from forward side Bottom view from side

3 DIMENSIONS
2010 ALLISON TRANSMISSION PX6 PTO FRAME CLEARANCE
Bottom view from right rear Bottom view
Bottom view from right side Rear view

3 DIMENSIONS
2010 MANUAL TRANSMISSION PX8 PTO FRAME CLEARANCE
Bottom view from right rear Rear view
Bottom view from forward side Bottom view from side

3 DIMENSIONS
2010 ALLISON TRANSMISSION PX8 PTO FRAME CLEARANCE
Bottom view from right rear Bottom view
Bottom view from right side Rear view

3 DIMENSIONS
FEPTO Extension and Bumper - Model 337, Model 348
* FEPTO extension is measured from the front of the

grille to the front of the bumper. 2007=25.5, 2010=27.8
** 6.0 in X 3.45 in (152 mm X 88 mm) L section
Figure 3-20. FEPTO Extension and Bumper

DIMENSIONS 3
Air Horn - Model 330, Model 337, Model 348
* Single air horn shown. Second air horn would be

mounted symmetrically opposite on the right side.
** with 10 5/8 inch rails. Add 0.1 inch (3 mm) when
measuring from top of 10 1/2 inch rails.
Subtract 0.27 inch (6.8 mm) when measuring from
top of 10 3/4 inch rails.
Figure 3-21. Air Horn

3 DIMENSIONS
Rear Frame Height - Single Rear Axle
Rear Frame Height = RSH + RTH

Figure 3-22. Rear Frame Height - Single Rear Axle
TABLE 3-20. Rear Suspension Height (RSH*) - single rear axle [inches(mm)] Models 330, 337, 348
REAR SUSPENSION HEIGHT (RSH*)
CROSSMEMBER REYCO 79KB REYCO 79KB REYCO 79KB PB LOW AIR LEAF PB AIR TRAC
21,000 LB. 23,000 LB. 26,000 LB. 21,000 LB. 23,000 LB.
STD 19.8 (503) 21.6 (549) N/A 17.4 (441) N/A
HD 20.4 (518) 22.2 (564) 22.6 (574) 17.4 (441) 22.1 (561)
*Same as "C" height in Peterbilt Engineering Data Book. Measured in the light (unloaded) condition with 10-5/8 inch frame rails. Add 0.125 inch (3.2
mm) for 10 3/4 inch rail.
TABLE 3-21. Rear Suspension Height (RSH) - single rear axle [inches(mm)] - Model 325
REYCO 79 KB
11,500 LB
15.8 (401)
TABLE 3-22. Rear Tire Height (RTH**) - single rear axle [inches(mm)] Models 330, 337, 348
REAR TIRE HEIGHT (RTH**)
BRIDGESTONE BRIDGESTONE BRIDGESTONE BRIDGESTONE MICHELIN
R250F 14-PLY M711 14-PLY M711 16-PLY R250F 16-PLY XDHT 14-PLY
295/75R22.5 11R22.5 11R22.5 12R22.5 11R22.5
18.8 (478) 19.7 (500) 19.7 (500) 19.8 (503) 19.5 (495)
** Same as "D" height in Peterbilt Engineering Data Book. Measured in the static (non-rolling) condition.
TABLE 3-23. Rear Tire Height (RTH) - single rear axle [inches(mm)] - Model 325
REAR TIRE HEIGHT (RTH)
BRIDGESTONE BRIDGESTONE BRIDGESTONE BRIDGESTONE
R250 F 12-PLY R250F 12-PLY M724F 12-PLY M724F 12-PLY
225/70 R19.5 245/70 R19.5 225/70 R19.5 245/70 R19.5
15 (381) 15.5 (394) 15.3 (389) 15.6 (396)

DIMENSIONS 3
Rear Frame Height - Tandem Rear Axles - Model 348
Rear Frame Height = RSH + RTH
Figure 3-23. Rear Frame Height - Tandem Rear Axle
TABLE 3-24. Rear Suspension Height (RSH*) - tandem rear axle [inches(mm)]
REAR SUSPENSION HEIGHT (RSH*)
REYCO 102 HENDRICKSON RT2-400 PB LOW AIR LEAF PB AIR TRAC
38,000 LB. 40,000 LB. 40,000 LB. 40,000 LB.
22.3 (566) 21.8 (554) 19.4 (441) 22.0 (559)
*Same as "C" height in Peterbilt Engineering Data Book. Measured in the light (unloaded) condition with 10-5/8 inch frame rails.
TABLE 3-25. Rear Tire Height (RTH**) - tandem rear axle [inches(mm)]
REAR TIRE HEIGHT (RTH**)
BRIDGESTONE BRIDGESTONE BRIDGESTONE BRIDGESTONE MICHELIN
R250F 14-PLY M711 14-PLY M711 16-PLY R250F 16-PLY XDHT 14-PLY
295/75R22.5 11R22.5 11R22.5 12R22.5 11R22.5
18.8 (478) 19.7 (500) 19.7 (500) 19.8 (503) 19.5 (495)
** Same as "D" height in Peterbilt Engineering Data Book. Measured in the static (non-rolling) condition.

3 DIMENSIONS
Rear Suspension and Tire Clearance - Single Rear Axle
Figure 3-24. Rear Suspension and Tire Clearance - Single Rear Axle
Rear Suspension Clearance (RSC) determines the minimum distance to frame-mounted components without
interference with the rear suspension.
Rear Tire Clearance (RTC) may be used to determine the distance from the end of frame to the rear tire; for
example, for an asphalt dump truck. RTC also determines the minimum height of the body above the frame rail.
Minimum body height above frame rail = RTC + 8.0 inches (203 mm) - RSH (from Table 3-18 and Table 3-19).
TABLE 3-26. Rear Suspension Clearance (RSC) - Single Rear Axle [inches(mm)] - Models 330, 337, 348
REAR SUSPENSION CLEARANCE (RSC)

REYCO 79KB PETERBILT LOW AIR LEAF PB AIR TRAC
21,000 to 26,000 LB. 21,000 LB. 23,000 LB.
27.7 (704) 36.5 (926) 27.0 (686)
TABLE 3-27. Rear Suspension Clearance (RSC) - Single Rear Axle [inches(mm)] - Model 325
REAR SUSPENSION CLEARANCE
REYCO 79KB
11,500 LB
29.8 (757)
TABLE 3-28. Rear Tire Clearance (RTC) - Single Rear Axle [inches(mm)] - Models 330, 337, 348
REAR TIRE CLEARANCE (RTC) *
BRIDGESTONE BRIDGESTONE BRIDGESTONE BRIDGESTONE BRIDGESTONE BRIDGESTONE
M843 M725 M844F R294 M724F M729F
12R24.5 285/75R24.5 425/65R22.5 255/70R22.5 245/70R19.5 285/70R19.5
22.7 (576.6) 21.1 (536) 23.0 (584.2) 18.4 (467.4) 16.8 (426.7) 17.7 (449.6)
*Largest and smallest tires offered in the three basic tire diameters: 24.5, 22.5 and 19.5
TABLE 3-29. Rear Tire Clearance (RTC) - Single Rear Axle [inches(mm)] - Model 325
REAR TIRE CLEARANCE (RTC)
BRIDGESTONE
R250F
225/75R19.5
16.1 (408.9)

DIMENSIONS 3
Rear Suspension and Tire Clearance - Tandem Rear Axles - Model 348
Figure 3-25. Rear Suspension and Tire Clearance - Tandem Rear Axle
* Based on 52 inch axle spacing.

Rear Suspension Clearance (RSC) determines the minimum distance to frame-mounted components with-
out interference with the rear suspension.
Rear Tire Clearance (RTC) may be used to determine the distance from the end of frame to the rear tire; for
example, for an asphalt dump truck. RTC also determines the minimum height of the body above the frame
rail.
Minimum body height above frame rail = RTC + 8.0 inches (203 mm) - RSH (from Table 3-22).
TABLE 3-30. Rear Suspension Clearance (RSC)** - Tandem Rear Axles [inches(mm)]
REAR SUSPENSION CLEARANCE (RSC)**
REYCO 102 HENDRICKSON RT2-400 PB LOW AIR LEAF PB AIR TRAC
38,000 LB. 40,000 LB. 38,000 LB. 40,000 LB.
55.0 (1397) 53.0 (1346) 57.5 (1460) 53.0 (1346)
TABLE 3-31. Rear Tire Clearance (RTC)** - Tandem Rear Axles [inches(mm)
REAR TIRE CLEARANCE (RTC)**
BRIDGESTONE BRIDGESTONE BRIDGESTONE BRIDGESTONE
M843 M725 M844F R294
12R24.5 285/75R24.5 425/65R22.5 255/70R22.5
22.7 (576.6) 21.1 (536) 23.0 (584.2) 18.4 (467.4)
**Largest and smallest tires offered in the two basic tire diameters: 24.5 and 22.5

3 DIMENSIONS
Frame Rail Sections
9 7/8INCH RAIL 10 1/2INCH RAIL

YIELD: 120,000 psi YIELD: 120,000 psi
SECTION MODULUS: SECTION MODULUS:
10 cu in. 11.8 cu in.
RBM: 1,200,000 lb. in. RBM: 1,416,000 lb. in.
3.5
.25 (88.9)
(6)
10.5 10
9.4 9.88 (267) (254)
(239) (251)
.25
(6) 3.5
(89)
10 5/8INCH RAIL 10 5/8INCH RAIL WITH LINER 10 3/4INCH RAIL

HEAT TREATED HEAT TREATED HEAT TREATED
YIELD: 120,000 psi YIELD: 120,000 psi YIELD: 120,000 psi
SECTION MODULUS: SECTION MODULUS: SECTION MODULUS:
14.8 cu in. 23.6 cu in. 17.8 cu in.
RBM: 1,776,000 lb. in. RBM: 2,832,000 lb. in. RBM: 2,136,000 lb. in.
3.45
.31 (88)
(8) 3.45 .38 3.50
(88) (10) (89)
.31
(8)
10.62 10 10.75
10 10.62 9.38
(254) (270) (270) (254) (273)
(238)
.25
(6)
2.87
(73)
Figure 3-26. Frame Rail Sections

DIMENSIONS 3
Crossmember Drillings
6 HOLES 5 HOLES
0.53 IN. DIA 0.66 IN DIA
(13.5 MM) (16.7 MM)
6.30 IN
5.63 IN (160 MM)
(143 MM)
2.0 IN
(50 MM)
2.5 IN 5.5 IN 3.94 IN

(63 MM) (140 MM) (100 MM)
11.0 IN 7.87 IN
(280 MM) (200 MM)
STANDARD CROSSMEMBER THREE-PIECE CROSSMEMBER
01022-01
Figure 3-27. Crossmember Drillings

SECTION 4 BODY MOUNTING
CRITICAL CLEARANCES
Rear Wheels and Cab

CAUTION: Insufficient clearance between
rear tires and body structure could cause
damage to the body during suspension
movement. Allow at least 8 inches clear-
ance (See Figure 4-1.)
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 4-2. Minimum BackofCab Clearance.
The true distance from the centerline of the front axle to

the back of the cab is 69.8 inches (1773 mm). It is rec-
ommended that the leading edge of the body be
mounted 4 inches (102 mm) behind the cab. The result
8 in.
(203 mm) is a minimum dimension of 73.8 inches (1875 mm) from
the front axle to the leading edge of the body.
NOTE: The distance from the back of cab to

the front of the body may vary depending on
the location of vehicle components. See SEC-
TION 3 DIMENSIONS for further details on
dimensions and clearances.
BODY MOUNTING USING

02866 BRACKETS
Figure 4-1. Minimum Clearance Between Top of Rear
Tires and Body Structure Overhang. CAUTION: Always install a spacer between
the body subframe and the top flange of
CAUTION: Maintain adequate clearance the frame rail.
between back of cab and the front (leading
Installation of a spacer between the body subframe and
edge) of mounted body. See Figure 4-2.
the top flange of the frame rail will help prevent prema-
NOTE: Be sure to provide maintenance ture wear of the components due to chafing or
access to battery box and fuel tank fill neck. corrosion.
Frame Sill
If the body is mounted to the frame with brackets, we
recommend that the frame sill spacer be made from a

BODY MOUNTING 4
strip of rubber or plastic (delrin or nylon). These materi-
als 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.
BODY RUBBER
SUBFRAME SPACER
(RAIL)
SPACER 01445
CHASSIS FRAME Figure 4-5. Rubber Spacer Between Brackets.

(RAIL) SILL
Another possibility is mounting a rubber spacer
between the brackets. See Figure 4-5. These designs
will allow relative movement between the body and the
01016
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 4-3. Spacer Between Frame Sill and Body Rail
Rubber or Plastic.
Mounting Holes
When installing brackets on the frame rails, the mount-
Brackets ing holes in the chassis frame bracket and frame rail
must comply with the general spacing and location
When mounting a body to the chassis with brackets, we guidelines illustrated in Figure 4-6. The hole diameter
recommend designs that offer limited amount of relative should not exceed the bolt diameter by more than .060
movement, bolted securely but not too rigid. Brackets inches (1.5mm).
should allow for slight movement between the body and
the chassis. For instance, Figure 4-4 shows a high com-
pression spring between the bolt and the bracket. A MUST BE EQUAL TO OR
GREATER THAN 2 IN. (50mm)
UPPER FRAME
FLANGE A
A
A
SPRING
LOWER FRAME
FLANGE A
01023
01446
Figure 4-6. Hole Location Guidelines for Frame Rail and

Figure 4-4. High Compression Spring Between the Bracket.
Mounting Bolt and Upper Bracket.

4 BODY MOUNTING
6 HOLES 5 HOLES
0.53 IN. DIA 0.66 IN DIA
(13.5 MM) (16.7 MM)
6.30 IN
5.63 IN (160 MM)
(143 MM)
2.0 IN
(50 MM)
2.5 IN 5.5 IN 3.94 IN

(63 MM) (140 MM) (100 MM)
11.0 IN 7.87 IN
(280 MM) (200 MM)
STANDARD CROSSMEMBER THREE-PIECE CROSSMEMBER
01022-01
Figure 4-7. Crossmember - Gusset Hole Patterns.
Frame Drilling WARNING! Do not drill new holes any

closer than 2 inches (50mm) to existing
holes. Frame drilling affects the strength of
WARNING! When mounting a body to the
the rails. If the holes are too close together,
chassis, DO NOT drill holes in the upper or
the rail could fail prematurely and cause an
lower flange of the frame rail. If the frame
accident. See Figure 4-6.
rail flanges are modified or damaged, the
rail could fail prematurely and cause an
Hole Location Guidelines
accident. Mount the body using body
mounting brackets or Ubolts. Holes must be located at least two inches (50 mm) from
the flange as indicated in Figure 4-6. They must be no
closer than 2 inches (50mm) to each other.
NOTE: If your design permits placement of

body mounting brackets at crossmember loca-
tions, you can use the crossmember gusset
bolt holes for body mounting. See Figure 4-7.
CAUTION: Use care when drilling the

frame web so the wires and air lines routed
inside the rail are not damaged.

BODY MOUNTING 4
BODY MOUNTING USING UBOLTS inspect the installation to ensure adequate clear-
ances for air brake lines, fuel lines, and wiring. See
Figure 4-9.
Spacers
If the body is mounted to the frame with Ubolts, use a
hardwood sill (minimum 1/2 inch (12.7 mm) thick)
between the frame rail and body frame to protect the FRAME UBOLT
RAIL
top surface of the rail flange.
WARNING! Do not allow the frame rails or

flanges to deform when tightening the FRAME RAIL
Ubolts. It will weaken the frame and could AIR LINES SPACER
AND WIRING (HARDWOOD
cause an accident. Use suitable spacers
HARNESSES OR STEEL)
made of steel or hardwood on the inside of
the frame rail to prevent collapse of the
frame flanges. CHECK
CLEARANCE
Use a hardwood spacer between the bottom SPACE FOR AIR
flange and the Ubolt to prevent the Ubolt LINES AND UBOLT
from notching the frame flange. See Figure 4-8. WIRING SPACER
01027
BODY
STRUCTURE
UBOLT
Figure 4-9. Clearance Space for Air Lines and Cables.
WARNING! Do not notch frame rail flanges

WOOD SILL to force a Ubolt fit. Notched or damaged
in. (12.7 mm) frame flanges could result in premature
MINIMUM
frame failure. Use a larger size Ubolt.
TRUCK FRAME
FRAME RAIL
SPACER UBOLT
(FABRICATED SPACER
STEEL OR (HARDWOOD)
HARDWOOD) 01018
Figure 4-8. Acceptable UBolt Mounting with Wood and CAUTION: Mount Ubolts so they do not
Fabricated Spacers.
chafe on frame rail, air or electric lines.
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

4 BODY MOUNTING
Rear Body Mount

When Ubolts are used to mount a body we recom-
mend that the last body attachment be made with a
fishplate bracket. See Figure 4-10. 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 4-6.
01021
Figure 4-10. Example of Fishplate Bracket at Rear End of

Body, used with UBolts.


SECTION 5 FRAME MODIFICATIONS
INTRODUCTION WARNING! Do not drill new holes any

There are several standard wheelbase choices for holes. Frame drilling affects the strength of
single and tandem rear axles. In addition, customer- the rails. If the holes are too close together,
specified wheelbases are available. So, in most cases the rail could fail prematurely and cause an
frame modifications to produce a certain wheelbase accident.
should not be necessary.
CAUTION: Use care when drilling the
However, some installations may require slight modifi- frame web so the wires and air lines routed
cations, while other installations will require extensive inside the rail are not damaged.
modifications. Sometimes an existing dealer stock Never use a torch to make a hole in the rail. Use
chassis may need to have the wheelbase changed to the appropriate diameter drill bit.
better fit a customers application. The modifications
may be as simple as shortening or lengthening the Hole pattern dimensions for crossmember designs are
frame overhang, or they may be as complex as chang- illustrated on Page 4-3, Figure 4-7.
ing the wheelbase.
Hole diameter should not exceed the bolt diameter by
more than .060 inches (1.5 mm).
DRILLING RAILS
MODIFYING FRAME LENGTH
Location and Hole Pattern
The frame overhang after the rear axle can be short-
If holes need to be drilled to attach anything to the rail,
ened to match a particular body length. Using a torch is
see SECTION 4 BODY MOUNTING for more informa-
acceptable; however, heat from a torch will affect the
tion. Follow the general spacing and hole location
material characteristics of the frame rail. The affected
guidelines on Page 42, Figure 4-6.
material will normally be confined to within 1 to 2 inches
(25 to 50mm) of the flame cut and may not adversely
WARNING! When mounting a body to the affect the strength of the chassis or body installation.
chassis, DO NOT drill holes in the upper or
lower flange of the frame rail. If the frame The frame overhang on the 10.5-inch rail can be length-
rail flanges are modified or damaged, the ened by adding frame extenders.
rail could fail prematurely and cause an
accident. Mount the body using body When extending the 10.5-inch rails, the additional sec-
mounting brackets or Ubolts. tions can typically be welded to the existing rails. The
joint should be welded and reinforced as illustrated in
Figure 5-1.
NOTE: See page 54 for more information on

welding frames.
Frame Insert
A frame insert must be added after welding a 10.5-inch
frame rail to compensate for lost strength. The insert
should be of the same material as the frame member
and at least equal to the frame rail in thickness.

FRAME MODIFICATIONS 5
Attachment of the insert to the frame should be made Where possible, use existing bolt holes to attach the
with Ream-Fit Class 8 5/8 in. dia. or Class 10.9 16 mm insert to the frame. Bolt holes must not be located
dia. bolts or the next larger size. Both the reinforce- closer to the frame flanges than the present bolt pattern.
ment and frame holes should be reamed to provide a fit
of from .001 in. to .003 in. (.025 to .076 mm) clearance.
Do not weld the insert. The insert must be a full C- If the insert is placed in a section of the main frame
channel, not a fishplate or L channel, and should where few bolts are located, additional bolts are
span a distance of at least 24 in. (610 mm) on either required. Use the following guideline for locating addi-
side of the joint to insure an even distribution of tional bolt holes.
stresses. Cut the ends of the insert at 45 as shown
in Figure 5-2 unless the insert extends to the end of the
frame.
8.1 in
(205 mm)
2.4 in
7.9 in (62 mm)
(200 mm)
.15 IN (4 mm)
45
WELD FRAME RAILS ON
THE OUTSIDE ONLY
01019
Figure 5-1. Detail of Frame Extensions and Joint Welding.
Changing Wheelbase
We do not recommend modifying the wheelbase. Occa-
sionally, 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 manufac-
WELDED
turers recommendations for driveline
JOINT length or angle changes. Incorrectly modi-
min
in. m) fied drivelines can fail prematurely due to
24 10 m
(6 excessive vibration. This can cause an
accident and severe personal injury.
210003
Figure 5-2. Frame Insert

5 FRAME MODIFICATIONS
Before changing the wheelbase the driveline angles of Before the rear suspension is relocated, check the new
the proposed wheelbase need to be examined to location of the spring hanger brackets. The new holes
ensure that no harmful vibrations are created. Consult for the spring hanger brackets must not overlap existing
the driveline manufacturer for appropriate recommen- holes and should not come any closer than 2 inches
dations. (50mm) to existing holes.
WARNING! Do not drill new holes any

holes. Frame drilling affects the strength of
the rails. If the holes are too close together,
the rail could fail prematurely and cause an MOUNT THE SUSPENSION
BRACKETS ON THE
accident. ORIGINAL RAIL
10 IN (254 mm) Minimum
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 not come any closer than 2 inches LENGTHENED WHEELBASE
(50mm) to existing holes in the frame. DO NOT MOUNT THE
SUSPENSION BRACKET ON
WARNING! When relocating a suspension THE ADDED FRAME RAIL
bracket, do not mount it on the extended
(added) section of a frame rail. The sus-
pension loading could result in premature
failure of the added section splice. This
could cause an accident. Use care when
planning the wheelbase so that the rear
suspension bracket is always mounted on
the original rail section. See Figure 5-3.
If you are lengthening the wheelbase, you may also ORIGINAL WHEELBASE
have to extend the frame length to accommodate a
body. When you reposition the rear suspension spring
hangers, do not mount them on the added extended
portion of the rail. The relocated rear suspension
bracket should be located on the original frame rails
RELOCATED REAR
with a miniumum of 10 inches (254 mm) between the SUSPENSION
suspension bracket and the spliced section.
See Figure 5-3.
When shortening the wheelbase, we recommend that

the suspension be moved forward and relocated on the
original rail. The rail behind the suspension can then be
SHORTENED WHEELBASE
cut to achieve the desired frame overhang.
See Figure 5-3. CUT FRAME AT REAR TO
OBTAIN DESIRED CUTOFF
Figure 5-3. Comparison of Original, Shortened,

and Lengthened Wheelbases.

FRAME MODIFICATIONS 5
Crossmembers WELDING
After lengthening a wheelbase, an additional crossmember The 9.88 (9 7/8), 10.5 (10 1/2), 10.62 (10 5/8),
may be required to maintain the original frame strength. Con- 10.75 (10 3/4), 11.625 (11 5/8) inch rails are heat
tact Dealer for crossmember locations. treated and are not weldable.
The maximum allowable distance between the for-
ward suspension crossmember and the next cross-
member forward is 47.2 inches (1200 mm). If the Precautions
distance exceeds 47.2 inches (1200 mm) after the
wheelbase is lengthened, add a crossmember CAUTION: The 9.88 (9 7/8), 10.5 (10 1/2)
between them. See Figure 5-4. See Figure 4-7 on 10.62 (10 5/8), 10.75 (10 3/4), and 11.625
page 4-3 for crossmember hole patterns. (11 5/8) inch rails are heat treated;
therefore, they are not weldable.
LESS THAN
47.2 IN.
(1200 mm)
BEFORE WHEELBASE IS LENGTHENED
GREATER
THAN 47.2 IN.
ADDITIONAL CROSSMEMBER REQUIRED
AFTER WHEELBASE IS LENGTHENED

00627B
Figure 5-4. Additional Crossmember Required When

Distance Exceeds 47.2 Inches (1200 mm).

5 FRAME MODIFICATIONS
TORQUE REQUIREMENTS
TORQUE REQUIREMENTS
TABLE
TABLE 5-1.
5-1. Customary
Customary GradeGrade
8 UNF 8
or UNF
UNC or UNC.
Fastener Torque
Size Nm Lb.-Ft
5/16 2230 1622
3/8 4154 3040
7/16 7588 5565
1/2 109122 8090
9/16 156190 115-140
5/8 224265 165195
3/4 394462 290340
7/8 517626 380460
1 9521129 800830
1-1/8 13461591 9901170
1-1/4 18772217 13801630
Torque values apply to fasteners with clean threads, lightly lubricated,
with hardened steel washers, and nylon-insert nuts.
TABLE5-2.
TABLE 5-2.U.S.
U.S. Customary
Customary Grade
- Grade 8 Metric 8. Metric
Class 10.9 Class 10.9
Torque
Fastener Nm Lb-Ft
M6 915 711
M8 2331 1723
M10 3343 2432
M12 75101 5575
M14 134164 99121
M16 163217 120160
M20 352460 260340

SECTION 6 ELECTRICAL
INTRODUCTION BODY LIGHTS JUNCTION BOX

Peterbilt offers several options to provide power and The body lights junction box option provides a wiring
electrical connections between the chassis electrical harness from the firewall to a junction box located at the
system and the electrical components on the body. back of cab. The box is strapped to the back-of-cab- or
These options include: intermediate-crossmember for shipping and is designed
to be permanently mounted by the body builder.
a junction box to provide power and ground for
body lights
The harness is sufficiently long to allow a certain flexi-
an engine harness to install a remote PTO control bility in installation. It provides power and ground cir-
cuits for clearance lights, marker lights, brake lights,
a third battery to provide power for lift gates and
and rear turn signals.
other high-amperage electrical devices
By specifying these options, the body can often be WARNING! This option is intended for
installed in less time and with fewer possibilities of lighting circuits only. It is not intended to
maintenance problems. provide power to any other electrical com-
ponent. Using a circuit for any other pur-
NOTE: These options should be specified at pose may result in an electrical overload,
the time the truck is ordered to ensure proper which could cause a fire.
installation. Consult the current pricebook for
appropriate option codes, prices, and The circuits terminate with ring terminals in the junction
restrictions. box. See Figure 6-1 for circuit identification.
5 CLEARANCE LIGHTS
8 MARKER LIGHTS
66 GROUND
227 RIGHT TURN SIGNAL

228 LEFT TURN SIGNAL
279 BRAKE LIGHTS

BODY CONNECTION
AT FIREWALL
66 GROUNDED TO
CAB FIREWALL
Figure 6-1. Body Lights Junction Box Circuits.

ELECTRICAL 6
REMOTE PTO HARNESS THIRD BATTERY
This option provides wiring from the engine to end of frame This option provides a third battery installed in the battery
for remote control of engine throttle and a customer installed box. It includes three batteries as specified in the price-
PTO. Controls are not provided with this option. Included is book, a battery holddown designed for three batteries, and
a 354.3 inch (9000 mm) wiring harness with a 7-pin connec- the appropriate inter-connecting battery cables.
tor that is routed to the end of frame. Any excess is coiled
and secured there. See Table 6-1 for wiring harness connec-
NOTE: This option does not include the
tor pin outs and Figure 6-2 for end of frame connector
cables or circuit breakers required to connect
conguration.
the batteries to the auxiliary electrical devices.
WARNING! Follow the engine manufacturers
guidelines for use of these circuits. See your This option is required when auxiliary high-amperage
engine manufacturer to verify that the engine is electrical devices such as electric winches, lift gates,
programed correctly for the intended applica- and electromechanical sirens are to be installed by the
tions. Failure to properly program the engine or body builder.
wire these circuits could cause an accident.
WARNING! Follow the manufacturers
installation instructions when installing
high-amperage electrical devices such as
electric winches, lift gates, and electrome-
chanical sirens. Failure to properly install
these devices could result in an electrical
overload and fire.
ENGINE CONNECTIONS
Electronic engines have the ability to send and receive
control and warning signals from other components on
the chassis and body. Consult the appropriate engine
manufacturers application or body builder manuals
before making connections to the engine electronic
Figure 62. Remote PTO/Throttle Control Wiring Harness
control unit (ECU) or to other electronic engine
Connector Pinouts.
components.
TABLE 6-1. Remote PTO/Throttle Wiring Harness.
Remote PTO/Throttle Connection

Engine PB Circuit Wire Connector
Circurt Function Name ECU Pin Number Wire Color Gauge Pinout
NOT USED NONE NONE NONE NONE 1
NOT USED NONE NONE NONE NONE 2
COMMON RETURN #1 (SWITCH) 41 EE03 BLK/WHT 18 3
REMOTE THROTTLE SIGNAL 37 EE39 BRN/YEL 18 4
PTO ON/OFF 18 EE18 GRN/WHT 18 5
REMOTE THROTTLE ENABLE NONE EE11 BLK/WHT 18 6
SWITCH POWER NONE 242 RED 14 7
GROUND NONE 239 BLK 14 8
TORQUE LIMIT SWITCH 17 EE64 LT BLU 18 9
5V SUPPLY 26 EE58 GRN/BLU 18 10
COMMON RETURN #3(SENSOR) 22 EE02 BLK/WHT 18 11
REMOTE THROTTLE ON/OFF 8 EE63 WHT/BLK 18 12

SECTION 7 HYBRID
Hybrid - Model 330, Model 337
Figure 7-1. Hybrid Model 337 shown General Notes:

All guidelines outlined in the Eaton Installation Guide
TABLE 7-1. Power Electric Carrier (PEC) Placement -
must be followed and are available at
www.roadranger.com.
Model 330, Model 337
The high voltage cables and hybrid electric
Power Electric Carrier Placement harnesses must have at least 6 inches of clearance
to any vehicle exhaust system component or any
Configuration "A" Dimension
heat source exceeding 150 degrees Celsius.
Pick up & delivery 5 (127) All high voltage cables and hybrid electric harnesses
Utility W/O outrigger 5 (127) must have sufficient clearance to any other compo-
Utility with outrigger 15 (381) nent to prevent abrasion, chaffing or other damage.
The Power Electric Carrier (PEC) can be remote
mounted. Peterbilt offers a 9 ft. long high voltage
CAUTION: Do not weld chassis. cable and extended electrical harnesses so that the
PEC can be relocated per the Eaton Installation
Guide. Service switch must be accessible.
CAUTION: Do not paint the orange high Do not install components on or adjacent to the
voltage cables. under cab battery box. This area needs to remain
unobstructed for proper function of the hybrid
cooling system.

HYBRID 7
HYBRID UTILITY APPLICATION
EPTO Functionality
In order to make the EPTO functional on the Hybrid Utility
Application trucks, the Body Builder must install a J1939
compatible Body controller capable of transmitting the CAN
AuxIO messages listed on the EPTO installation require-
ments section of the Eaton Installation Guide TRIG1000 to
the Hybrid Control Module (HCM).
TRIG1000 also provides an engagement flowchart of the

EPTO requirements.
EPTO Connection
Locate connector labeled J5-EPTO on the hybrid power
train harness attached and zip tied at the bottom of the trans-
mission (see Figure 7-2 and Figure 7-3).
Figure 72. J5-EPTO Connector
This connector provides two signals coming from the HCM
on the transmission to the body builder interconnection and
receives a PTO engaged confirmation signal from the body
builder to the HCM.
Terminal B: provides a negative signal (GND) intended
for the EPTO solenoid.
Terminal C: provides a positive signal (12 VDC)
intended for the EPTO solenoid.
Terminal A: provides the PTO status analog signal to
the HCM under EPTO operation.
Figure 73. Transmission for EPTO Connection

7 HYBRID
Body Builder Connection

The body builder connector labeled P7-BODY CONNEC-
TION is located attached to the left side chassis rail. This
connector has a 1000 mm break out which is left zip tied
from factory behind the BOC cross member junction (see
Figure 7-4 and Figure 7-5).
This connector provides and receives the following signals:

Terminal 2: (inserted by Body Builder) a safety interlock
ground signal which first goes throughout the Park
Brake interlock and returns through the Hood tilt switch
back to terminal 1 to the body controller.
Terminal 1: returns to the body controller a safety
interlock ground signal inserted through terminal 2.
Terminal 3: provides a 12VDC, 10Amps ignition power
signal.
Terminal 5: provide a chassis ground signal.
Terminal 7: interfaces the J1939 Data Link Minus Figure 74. P7 Body Connector
Terminal 8: interfaces the J1939 Data Link Plus
Terminals 4 and 6: Not used.
Figure 75. Location on Frame Rail of Body Builder Connection

HYBRID 7
Sections of the MD Hybrid Electrical Sche-
matics on Body Builder connections
Figure 7.6 and Figure 7.7, shown below, refer to the MD Reference Drawings:
Hybrid Electrical Schematic P94-6069.
a) P94-6069 SCHEMATIC MD HYBRID SYSTEM
b) P97-6250 INSTL HYBRID XMSN AND POWER-
TRAIN HARN
c) P95-6269 ROUTING CHASSIS, HYBRID
Figure 76. EPTO Section - Medium Duty Hybrid Electrical Schematic P94-6069
Figure 77. Body Connection Section - Medium Duty Hybrid Electrical Schematic P94-6069

7 HYBRID
HYBRID SYSTEM BATTERY BOX ACCESS
To prevent damage from the box lid, additional routing of cables to the batteries should
utilize feature located in the back wall of the box and secured using the provided hole.

APPENDIX A VEHICLE IDENTIFICATION
VEHICLE IDENTIFICATION NUMBER VIN Location
A 17character number (numeral and letter combina-
The VIN is marked on the Incomplete Vehicle Certifica-
tion) forms the Vehicle Identification Number (VIN) and
tion Label (on trucks) or on the Tire, Rim, and Weight
Chassis Number. It contains among other information,
Rating Data Label (on tractors). Both labels are located
the model year (4), assembly plant (5), and vehicle
on the drivers door frame. See Figure A2.
serial number (6). See Figure A1.
Chassis Number Locations

SAMPLE VIN
The Chassis Number (comprising the last seven char-
2NP NHD 8 X X YM 5 6 7 8 9 0 acters of the VIN) includes an assembly plant designa-
tor (5) and a sixdigit serial number (6). See Figure
1 2 3 4 5 6 A1.
The chassis number is shown in six places:

1 - Manufacturer Identifier
Right frame rail, top flange, about 3 ft. from the
2 - Vehicle Attributes
front end: stamped.
3 - Check Digit
4 - Model Year Left side back of cab, stamped plate.
5 - Assembly Plant
Tire, Rim, and Weight Rating Data label (truck).
6 - Serial/Chassis Number
Components and Weights label.
Figure A1. Vehicle Identification Number (VIN). Noise Emission label.
The model year (4) is designated by a letter or numeric Paint Identification label.
code in the tenth character position in the VIN. See
Table A-1 and Figure A1.
TABLE A-1. Model Year Letter (CODE) Designations.
CODE YEAR
5 2005
6 2006
7 2007
8 2008
9 2009
A-1 Medium Duty Body Builder Manual 10/2009

VEHICLE IDENTIFICATION A
CERTIFICATION LABELS Tire and Rim Data Label
The Tire and Rim Data Label is located on the drivers
Components and Weights Label side door frame, below the door latch. See Figure A2.
It contains the following information:
The Components and Weights Label is located on
either the drivers side door edge for truck/tractors, or GVWR Gross Vehicle Weight Rating
on the door frame for trucks. See Figure A2. It GAWR FRONT and REAR Gross Axle
includes: chassis weight and gross weight; plus, model Weight Ratings for Front and Rear Axle
and serial numbers for the vehicle, engine, transmis- TIRE/RIM SIZES AND INFLATION PRES-
sion, and axles. SURES Tire/Rim Sizes and Cold Pressure
Minimums
Chassis (Serial) Number
FINAL STAGE MANUFACTURER
LABEL (TO BE INSTALLED BY NOTE: GVWR is the TOTAL WEIGHT the
FINAL STAGE MANUFACTURER) vehicle is designed to carry. This includes the
weight of the empty vehicle, loading platform,
occupants, fuel, and any load. Axle weight rat-
ings are listed on the edge of the drivers door.
Incomplete Vehicle Certification Label

The Incomplete Vehicle Certification Label (for trucks)
is located on the drivers side door edge. See Figure
A2. It contains the following information:
DATE OF MANUFACTURE
VIN Vehicle Identification Number
LISTING OF APPLICABLE FEDERAL MOTOR
VEHICLE SAFETY STANDARDS
Noise Emission Label

The Noise Emission Label is located in the map com-
partment. It contains information regarding U.S. noise
emission regulations, chassis number, and date of
manufacture.
TIRE, RIM, AND WEIGHT RATING
DATA LABEL (TRUCK)
Paint Identification Label
TIRE, RIM, CERTIFICATION AND
WEIGHT LABEL (TRACTOR) OR
INCOMPLETE VEHICLE CERTIFI- The Paint Identification Label contains the paint colors
CATION LABEL used by the factory to paint your truck/tractor. It lists
frame, wheels, cab interior and exterior colors. This
FMVSS 121 BRAKE CAUTION
label is located in the map compartment.
LABEL (TRUCK)
MAJOR COMPONENTS AND

WEIGHTS LABEL (TRUCK OR
TRACTOR)
Figure A2. Drivers Door Frame
Peterbilt Motors Co. A-2

A VEHICLE IDENTIFICATION
COMPONENT IDENTIFICATION
Each of the following components has their own identifi-
cation label.
Engine Identification
The PACCAR engine serial number is stamped on a
plate located on the front driver side of the engine. For
further information, please refer to the Engine Opera-
tion and Maintenance Manual (included in the glove
compartment of each vehicle).
Figure A4. Front Axle Identification.
1. Axle Specification Number, stamped on the right

rear side of the axle housing. This number identifies
the complete axle.
2. Axle Housing Number Tag, located on the left for-
ward side of the housing arm. This tag identifies the
axle housing.
Engine Identification
Location 3. Axle Differential Carrier Identification, located on
(PX-8 Shown) the top side of the differential carrier. The following
information is either stamped, or marked with a
metal tag: Model No., Production Assembly No.,
Serial No., Gear Ratio, and Part Number.
Figure A3. Engine Identification Location and Label (PX-8 Shown) 3
Transmission Identification 2
The transmission identification number is stamped on a
tag affixed to the right rear side of the transmission
case. It includes among other specifications the trans-
mission model number, serial number, and part number.
1
Front Axle Identification 01053
The front axle serial number is stamped on a plate Figure A5. Rear Axle Identification Labels.
located on the front axle beam. See Figure A4.
NOTE: Illustrated identification tags are typi-

Rear Axle Identification cal. Actual locations may vary by axle manu-
facturer.
The rear axle identification numbering system includes
three labels or stamps. See Figure A5.
A-3 Medium Duty Body Builder Manual 10/2009


APPENDIX B WEIGHT DISTRIBUTION
INTRODUCTION BODY BUILDERS
RESPONSIBILITIES
As the final stage manufacturer of a vehicle, the body
builder is responsible for ensuring and certifying that The body builder is responsible for designing and
the weight distribution of the completed truck with the installing the body such that the weight distribution of
body and intended payload does not exceed the the bare chassis, body, and intended payload does not
Gross Axle Weight Rating (GAWR) for each axle. To exceed the GAWR for each axle. Each body builder
help the body builder in that process, Peterbilt can needs to develop a system for calculating weight distri-
supply the GAWR for each axle based on the bution. This would include tabulation of the weight and
published ratings of the tires, wheels, axles, and location of every body component, as well as an under-
suspensions. Peterbilt can also supply the distributed standing of the weights and locations (point load versus
weight of the bare chassis on the front and rear axles. distributed load) of various payloads. See Table B-1. for
the weights of various common payloads.
NOTE: The distributed weight should be
requested at the time the vehicle is ordered. WARNING! Incorrect calculation of the
It can be automatically calculated as part of weight distribution on the front and rear
the electronic ordering process. axles may result in poor vehicle perfor-
mance, component failure, or loss of
vehicle control with the resulting possi-
bility of serious personal injury or
death.
TABLE B-1. Weights of common payloads [lb(kg)]
Pay l o ad Wei g h t /Un i t o f Meas u r e
Construction Materials
Asphalt 2399 (1045) /cubic yard
Concrete 4150 (1886) /cubic yard
Earth, Dry 2000 (909) /cubic yard
Earth, Wet 3000 (1364) /cubic yard
Gravel, Dry 3100 (1409) /cubic yard
Gravel, Wet 3400 (1545) /cubic yard
Sand, Dry 2700 (1227) /cubic yard
Sand, Wet 3400 (1545) /cubic yard
Liquids
Asphalt Oil 10 (4.5) /gallon
Butane/LNG 4 (1.8) /gallon
Diesel Fuel 7 (3.2) /gallon
Gasoline 6 (2.7) /gallon
Milk 9 (4.1) /gallon
Water 8 (3.6) /gallon
B-1 Medium Duty Body Builder Manual 10/2009


APPENDIX C ROUTING
INTRODUCTION current to the circuit must be equal to or greater than the
demand of the added circuit otherwise these components
Electrical wiring can sometimes be very frustrating. This is may not work properly.
especially true when adding circuits to an existing setup.
Through the use of a optional body harness and additional
spare circuits, we have tried to reduce the complexity asso- ROUTING
ciated with adding common circuits to a body installation.
This section species the general requirements for secur-
Note: The most common circuits that body build- ing hoses and electrical wires to present an orderly
ers may need are pre-connected to this optional appearance; facilitate inspection and maintenance; and to
wiring harness. prevent potential damage to these lines.
The new body related circuits can be added by connecting

the added circuit wires to the appropriate wires in this Denitions
harness.
Bundle: Two or more air, electrical, fuel, or other lines tied
together to form a unitized assembly.
ELECTRICAL CIRCUITS
Clamp: A cushioned rigid or semi-rigid, anti-chang device
Capacity for containing the bundle and securing it to the frame or
other structural support. Standard clamps have a black
WARNING! Do not install an electrical circuit that elastomer lining. High temperature clamps (e.g., those
requires more amperage (electrical capacity) than used with compressor discharge hose) have a white or red
what is available in the specic chassis circuit. An elastomer lining (most applications for these are called out
overloaded circuit could cause a re. Compare in the bills of material). An assembly of two clamps fastened
the amperage requirements of the new circuit to together to separate components is referred to as a
the electrical current capacity of the existing chas- buttery clamp. Note: the metal portion of clamps shall be
sis circuit before adding the body or other stainless steel or otherwise made capable, through plating
equipment. or other means, of passing a 200 hour salt spray test per
ASTM B117 without rusting.
When adding an electrical circuit, you must know the current
capacity (amperes) of each circuit.
The capacity of the existing system in the chassis must be

enough to power the additional circuit. The new circuit will
require a certain amount of power to operate; so, the existing
(battery or alternator) power source must have the capacity
to provide additional power or the new circuit will not function
properly.
Figure C-1 Clamp and Buttery Clamp
Check the current (ampere) demand of the circuit to be
added. Compare it to the current capacity of the circuit you
are connecting into. The current carrying capacity of the
wires, controls, switches, and circuit breakers that provide
C-1 Medium Duty Body Builder Manual 10/2009

ROUTING C
Buttery Tie: A tough plastic (nylon or equivalent) locking Excess of material: More than 3 inches of slack for every
Dual Clamp Tie strap used to separate bundles or single 14 inch section of hose routing, except for air conditioner
lines, hoses, etc. These straps must be UV stable. (Tyton hoses.
DCT11)
Shortness of material: Less than 1 inch of slack on a 14

inch section of hose routing.
Figure C-2 Buttery Tie

ROUTING REQUIREMENTS
Tie Strap: A tough plastic (nylon, or equivalent) locking
strap used to tie the lines in a bundle together between Wiring
clamps or to otherwise secure hoses and wires as noted
below. These straps must be UV stable. Electrical ground wire terminals must be securely attached
and the complete terminal surface must contact a clean
bare metal surface. Apply electrical contact corrosion
inhibitor Nyogel 759G grease (made by William F. Nye, Inc.,
New Bedford, MA) .
Dont bend wires or use tie straps within 75 mm of

(connected) wire connectors or plugs.
Figure C-3 Tie Strap
Heavy Duty (HD) Mount: A black rigid device used for Wires in Bundles
securing a tie strap to the frame or other structural support.
Mounts are made of impact modied, heat stabilized UV Electrical wires (other than the exceptions covered below)
resistant nylon capable of continuous operation between running parallel with air or coolant hose bundles, may be in-
temperatures 220F (150) and -40F (-40). cluded in the bundle if they are isolated from the hoses with
a covering of convoluted plastic tubing.
NOTE: Heavy duty tie straps 0.50 in (12.7mm)
wide (Tyton T255ROHIR or similar) shall be used
whenever HD mounts are specied. Although Exceptions
0.25 in (6.4mm) tie straps may be used in some
specied applications.
Battery cables (including jump start cables) may be
bundled with or tied to the charging wire harness. They
shall not be bundled with or tied directly to any other
components, including hoses, wires, or bundles. They
shall be separated from other routed components using
buttery ties at intervals not exceeding 356 mm (14 in).
Battery strap tie down shall be used without exception to
secure battery cables to frame mounted or other major
component (e.g. engine, tmsn, etc.) mounted standoffs at
intervals not exceeding 356 mm (14 in). The (positive)
Figure C-4 Heavy Duty (HD) Mount battery cable shall be covered with convoluted plastic
tubing from terminal to terminal.
Peterbilt Motors Co. C-2

C ROUTING
110/220 volt wires for engine heaters, oil pan heaters, trans- Air Compressor Discharge Hoses
mission oil heaters and battery pad warmers, shall not be
included in any hose/wire bundle with a fuel hose. Individual Wires or hoses shall not be tied to the high temperature air
heater wires not in a bundle shall be separated from other compressor discharge hose. Hoses and wires may be
components by using buttery clamps or buttery ties at routed across the air compressor discharge hose at a
intervals not exceeding 356 mm (14 in). Heater wires with a distance of 457 mm (18 in) or greater from the compressor
secondary covering shall be covered with convoluted tubing discharge port. In this case the crossing hoses and wires
whether they are in bundles or not. shall be buttery clamped to the air compressor
discharge hose and covered with convoluted tubing at the
clamp point (use high temperature clamps on the
compressor hose).
Wires Crossing other Components
Electrical wires crossing over other components, such as Bundles

lines, bolt heads, ttings, engine components lifting eyes,
engine block, cylinder head, etc., close enough to rub shall HD mount and tie strap, or clamp shall be located at
be isolated with a covering of convoluted tubing and sepa- intervals not to exceed 356 mm (14 in) along the bundle.
rated from the component by using buttery clamps, buttery
ties, or plastic sheathing. 110/220 volt engine heater wiring Regular tie straps shall be located at intervals not to
shall be installed with buttery ties or buttery clamps exceed 178 mm (7 in) between HD mount or clamps. Extra
tie straps may be used as needed to contain the hoses and
wires in the bundle.
Piping
Use no street elbows in air brake, water, fuel, or hydraulic
systems unless specied on the piping diagram and the Routing of Wires and Hoses near Moving
build instructions. Components
Use no elbows in the air brake system unless specied on
Wires and Hoses shall be routed away from moving
the air piping diagram and the build instructions.
components, such as fans, shackle links, drivelines, steer-
ing linkages, etc. so that there is at least 12.7 mm (0.5 in)
clearance when the component is operating at its maxi-
Hoses Crossing Components mum travel limits.
Hoses crossing over other components close enough to rub A minimum clearance of 25.4 mm (1.0 in) shall be main-
shall be protected with a secured covering of convoluted tained between steering axle tires (and associated rotating
plastic tubing, another section of hose, or plastic sheathing. parts) in all positions and routed components, such as
The usage of buttery ties, or buttery clamps are also hoses, oil lines, wires, pipes, etc.
recommended.
C-3 Medium Duty Body Builder Manual 10/2009

ROUTING C
Routing of Wires and Hoses near Exhaust System
Table C-1 Exhaust System Clearance
Description Shielded Unshielded

Coolant hoses, HVAC hoses and tubing, and electrical wires
within 15 of the turbo and/or over 15 from the turbo 2 minimum 3 minimum
Fuel hoses
within 15 of the turbo n/a 4 minimum
over 15 from the turbo 2 minimum 3 minimum
Fuel tanks and hydraulic tanks
crossing tank n/a 2 minimum
parallel to tank n/a 2 minimum
end of tank n/a 1 minimum
aluminum/ceramic-coated exhaust pipe crossing ttank n/a 1.5 minimum
Air hose
nylon 3 minimum 8 minimum
wire braid 2 minimum 3 minimum
Peterbilt Motors Co. C-4

Peterbilt Motors Company
P.O. Box 90208
Denton, Texas 76202
A DIVISION OF
-/-
Rev. 1/10 dpt

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Medium Duty

Body Builder Manual

MEDIUM DUTY BODY BUILDERS MANUAL

SECTION 2 SAFETY AND COMPLIANCE

SECTION 4 BODY MOUNTING

ii Medium Duty Body Builder Manual 1/2010

SECTION 5 FRAME MODIFICATIONS

APPENDIX A VEHICLE IDENTIFICATION

APPENDIX B WEIGHT DISTRIBUTION

iii Medium Duty Body Builder Manual 1/2010

iv Medium Duty Body Builder Manual 1/2010

This Medium Duty Body Builder Manual can be very

1-1 Medium Duty Body Builder Manual 10/2009

Peterbilt Motors Co.

Please take the time to read these mes-

2-1 Medium Duty Body Builder Manual 10/2009

Noise and Emissions Requirements

NOTE: 2007/10 emissions engines are integrated

Peterbilt Motors Co. 2-2

Both the curb-to-curb and wall-to-wall turning radius

Left-Hand Turn Right-Hand Turn

* 50 degree wheel cut L/R

3-1 Medium Duty Body Builder Manual 10/2009

Figure 3-1. Side View w/ Single Rear Axle: Overall Dimensions.

Peterbilt Motors Co. 3-2

Side View Single Rear Axle - Overall Dimensions - Model 325

Figure 3-1. Side View w/ Single Rear Axle: Overall Dimensions.

3-3 Medium Duty Body Builder Manual 10/2009

Figure 3-2. Side View w/ Tandem Rear Axle - Overall Dimensions.

Peterbilt Motors Co. 3-4

Front and Rear Views Overall Dimensions

Figure 3-3. Front View - Overall Dimensions

* with 10 5/8 inch rails.

Figure 3-4. Rear View - Overall Dimensions

3-5 Medium Duty Body Builder Manual 10/2009

* with 1 0 5/8 in ch rails. A dd

Figure 3-5. Rear Window

Contact Dealer for loadlight locations.

Peterbilt Motors Co. 3-6

Cab and Hood - Standard Cab

Figure 3-6. Cab and Hood - Standard cab

3-7 Medium Duty Body Builder Manual 10/2009

* WITH 10 5/8 INCH RAILS

Figure 3-7. Cab and Hood - Crew cab

NOTE: This configuration is not available from the factory.

Peterbilt Motors Co. 3-8

Battery Box - Location - Model 330, Model 337, Model 348

Figure 3-8. Battery Box - Location

TABLE 3-8. Battery box location [inches (mm)]

DIMENSION* STEEL BATTERY BOX ALUMINUM BATTERY

3-9 Medium Duty Body Builder Manual 10/2009

Figure 3-9. Battery Box - Location - Model 325

TABLE 3-9. Battery box location [inches (mm)]

Peterbilt Motors Co. 3-10

Figure 3-10. Battery Box - Step Height

TABLE 3-10. Battery box - step height [inches (mm)]

3-11 Medium Duty Body Builder Manual 10/2009

Figure 3-11. Battery Box - Step Height - Model 325

TABLE 3-11. Battery box - step height [inches (mm)]