Free Peterbilt Model 548 Truck Body Builder Operator’s Manual PDF | Manualsnet (2024)

Release Date 5/3/2021

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BODY BUILDER MANUAL CONTENTS SECTION 1: INTRODUCTION SECTION 2: SAFETY AND COMPLIANCE

SAFETY SIGNALS 2-1 FEDERAL MOTOR VEHICLE SAFETY STANDARDS AND COMPLIANCE 2-2

NOISE AND EMISSIONS REQUIREMENTS 2-3 FUEL SYSTEM 2-4 COMPRESSED AIR SYSTEM 2-4 EXHAUST AND EXHAUST AFTERTREATMENT SYSTEM 2-5 COOLING SYSTEM 2-6 AIR INTAKE SYSTEM 2-6 CHARGE AIR COOLER SYSTEM 2-6 ELECTRICAL SYSTEM 2-7 GENERAL WIRE ROUTING 2-8 SAFETY RELATED COMPONENTS AND SYSTEMS 2-8

SECTION 3: DIMENSIONS

INTRODUCTION 3-1 ABBREVIATIONS 3-1 OVERALL DIMENSIONS 3-1 MODELS 535, 536, 537, & 548 107 BBC AERO HOOD 3-2 MODELS 536, 537, & 548 109 BBC AERO HOOD 3-3 MODELS 537 & 548 109 VOC HOOD 3-4 MODELS 537 & 548 VOC HOOD W/ 24 FEPTO BUMPER EXTENSION 3-5

CAB 2.1m MEDIUM DUTY CAB FAMILY 3-6 REAR WINDOW 3-7 CAB SUSPENSION 3-8 CAB STEP HEIGHT 3-9 FRAME RAILS 3-10 FRAME HEIGHT CHARTS 3-11 FRONT FRAME HEIGHTS "A" 3-12 REAR FRAME HEIGHTS "C" 3-13 FRAME MOUNTED COMPONENT GROUND CLEARANCE 3-15

FRAME SPACE REQUIREMENTS 3-16 FRAME SPACE DIMENSION "B" 3-17 FRAME SPACE DIMENSION "A" 3-18 FRAME SPACE DIMENSION C 3-20 2021 MD EXHAUST CONFIGURATIONS 3-24

TURN RADIUS ANALYSIS 3-34

SECTION 4: BODY MOUNTING INTRODUCTION 4-1 FRAME RAILS 4-1 CRITICAL CLEARANCES 4-2 BODY MOUNTING USING BRACKETS 4-3 FRAME SILL 4-3 BRACKETS 4-4 MOUNTING HOLES 4-5

FRAME DRILLING 4-6 BODY MOUNTING USING UBOLTS 4-7 REAR BODY MOUNT 4-9

TABLE OF CONTENTS

Peterbilt Motors Company ii

SECTION 5: FRAME MODIFICATIONS INTRODUCTION 5-1 DRILLING RAILS 5-1 MODIFYING FRAME LENGTH 5-2 CHANGING WHEELBASE 5-2 CROSSMEMBERS 5-3 TORQUE REQUIREMENTS 5-4 WELDING 5-4 PRECAUTIONS 5-5

SECTION 6: CAN COMMUNICATIONS

INTRODUCTION 6-1 CAN COMMUNICATIONS ACRONYM LIBRARY 6-1 SAE J1939 6-2 PARAMETER GROUP NUMBER 6-2 SUSPECT PARAMETER NUMBER 6-2 CAN MESSAGES AVAILABLE ON BODY CONNECTIONS 6-3

SECTION 7: ELECTRICAL

INTRODUCTION 7-1 ELECTRICAL ACRONYM LIBRARY 7-1 ELECTRICAL WIRING CIRCUIT CODES 7-2 MULTIPLEX SYSTEM 7-3 CAN BUS SYSTEM OVERVIEW 7-3 CAN BUS SPEEDS AND CIRCUIT DESIGNATION 7-3 ELECTRICAL COMPONENT OVERVIEW 7-4 ELECTRICAL HARNESS OVERVIEW 7-5 IN CAB CAN BASED MESSAGING CONNECTOR RP1226 7-6 BODY CONNECTION POINTS MAIN CHASSIS HARNESS 7-7 ELECTRIC ENGAGED EQUIPMENT 7-11 RP170 CONNECTOR 7-11 ENGINE HARNESS 12 PIN CONNECTOR 7-12 POWER DISTRIBUTION CENTER 7-15 ENGINE SIDE FUSE BOX FULL COMPONENT POPULATION 7-17 DASH SIDE FUSE BOX FULL COMPONENT POPULATION 7-18 CHASSIS MODULE 7-19 CHASSIS MODULE FUNCTION DESIGNATIONS 7-20 FUSE GROUPS 7-21 ELECTRIC OVER AIR SOLENOIDS 7-23 SOLENOID BANK DIAGRAM 7-23 SOLENOID OVERVIEW LAYOUT 7-24 MUX SOLENOID BANK FRAME MOUNTING 7-25 SWITCHES 7-26 SWITCH RELEARN PROCESS 7-27 GROUNDING 7-29 SPARE POWER 7-30 JUNCTION BOX 7-34 TRANSMISSION BACKUP SIGNALS 7-35 SNOW PLOW LIGHTING 7-35 LIFT AXLES (PUSHERS & TAGS) 7-36 LIFT AXLE DIAGRAM 7-36 LIFT AXLE LOGIC 7-36 TRAILER LIFT AXLE 7-37 DIGITAL DISPLAY 7-37 TELLTALE ICONS 7-38

TABLE OF CONTENTS

Peterbilt Motors Company iii

SECTION 8: POWER TAKE-OFF (PTO) INTRODUCTION 8-1 PTO ACRONYM LIBRARY 8-1 TRANSMISSION MOUNTED PTO 8-2 MANUAL TRANSMISSIONS 8-2

AUTOMATIC TRANSMISSIONS - ALLISON 8-3 AUTOMATIC TRANSMISSIONS PACCAR 8-SPEED 8-4

FRONT ENGINE PTO 8-5 PTO MOUNTING CLEARANCE 8-6 ALLISON PTO MOUNTING CLEARANCE 8-6 PACCAR PTO MOUNTING CLEARANCE 8-10

EATON PTO MOUNTING CLEARANCE 8-11 HYDRAULIC CLUTCH ACTUATOR CONFIGURATIONS 8-13 REAR ENGINE PTO 8-13 REMOTE PMC CONNECTIONS 8-14

SECTION 9: AFTERTREATMENT

INTRODUCTION 9-1 GENERAL GUIDELINES FOR DEF SYSTEM 9-1 DEF SYSTEM SCHEMATICS 9-2 INSTALLATION REQUIREMENTS AND DIMENSIONS FOR DEF SYSTEM 9-3 DEF ASSEMBLY RELOCATION - SUPPLY MODULE REQUIREMENTS 9-3 ROUTING TO THE DOSING MODULE (INJECTOR) 9-4

SECTION 10: ROUTING

INTRODUCTION 10-1 DEFINITIONS 10-1 ROUTING REQUIREMENTS 10-3 ROUTING OF WIRES AND HOSES NEAR EXHAUST SYSTEM 10-5

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SECTION 1 INTRODUCTION

The Peterbilt Medium Duty Body Builder Manual was designed to provide body builders with a comprehensive information set to guide the body planning and installation process. Use this information when installing bodies or other associated equipment.

This manual contains appropriate dimensional information, guidelines for mounting bodies, modifying frames, electrical wiring information, and other information useful in the body installation process.

The Peterbilt Medium Duty Body Builder Manual can be very useful when specifying a vehicle, particularly when the body builder is involved in the vehicle definition and ordering process. Information in this manual will help reduce overall costs 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 development, Peterbilt reserves the right to change specifications or products at any time without prior notice. It is the responsibility of the user to ensure that he is working with the latest released information. 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 SAFETY SIGNALS

There are a number of alerting messages in this book. Please read and follow them. They are there for your

protection and informational reference. These alerting messages can help you avoid injury to yourself or others

and help prevent costly damage to the vehicle.

Key symbols and signal words are used to indicate what kind of message is going to follow. Pay special attention

to comments prefaced by WARNING, CAUTION, and NOTE. Please do not ignore any of these alerts.

Warnings, Cautions, and Notes

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 do

not heed the warning, and how to avoid it.

Example:

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

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

moderate injury or damage to the vehicle.

Example:

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

Provides general information: for example, the note could warn you on how to avoid

damaging your vehicle or how to drive the vehicle more efficiently.

Example:

NOTE: Be sure to provide maintenance access to the battery box and fuel tank fill neck.

Please take the time to read these messages when you see them, and remember: WARNING

Indicates a potentially hazardous situation, which, if not avoided, could result in death or serious injury. CAUTION

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

moderate injury or damage to the vehicle. NOTE

Useful information that is related to the topic being discussed.

SAFETY AND COMPLIANCE

Peterbilt Motors Company 2-2

2 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 Stage Manufacturer) will be doing additional modifications means that the vehicle was incomplete when it left the build plant.

INCOMPLETE VEHICLE CERTIFICATION An Incomplete Vehicle Document is shipped with the vehicle, certifying that the vehicle is not complete. See Figure 21. In addition, affixed to the drivers side door frame or edge is an Incomplete Vehicle Information label. See Figure 22.

These documents list the U.S. or Canadian Federal Motor Vehicle Safety Standard regulations that the vehicle complied with when it left the build plant. You should be aware that if you add, modify or alter any of the components or systems covered by these regulations, it is your responsibility as the Intermediate or Final Stage Manufacturer to ensure that the complete vehicle is in compliance with the particular regulations upon completion of the modifications.

FIGURE 2-1. Incomplete Vehicle

Document (IVD)

FIGURE 2-2. Locations of Information Labels - Drivers

Door and Frame

As the Intermediate or Final Stage Manufacturer, you must retain the Incomplete Vehicle Document for your records. In addition, you must 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 must affix your certification label to the vehicle as required by Federal law. This label identifies you as the Intermediate or Final Stage Manufacturer and certifies that the vehicle complies with Federal Motor Vehicle Safety Standards. (See Figure 22.) 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.

SAFETY AND COMPLIANCE

Peterbilt Motors Company 2-3

2 In part, if the final stage manufacturer completes and can certify the vehicle with guidance provided in the incomplete vehicle document, 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).

However, if the vehicle cannot be completed and certified within 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 manufacturers 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 certification regulation. Please refer to NHTSA/DOT Title 49 CFR part 567 - certification for all of the details related to this regulation.

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

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

meet applicable Federal and California noise and exhaust emissions regulations established

by the U.S. Code of Federal Regulations, Environment Canada, and the California Air

Resources Board. These emissions control components/systems may only be replaced with

original 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 shape and aerodynamic

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 replacement tires.

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

For Cummins, contact 1-800-DIESELS or your local Cummins distributor. Reference AEB 21.102.

SAFETY AND COMPLIANCE

Peterbilt Motors Company 2-4

2 It is possible to relocate the DEF tank; however, the relocation requirements in section 9 of this manual 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.

All engine emissions certified vehicles will be equipped with an On-Board Diagnostics

(OBD) system. The OBD system is designed to detect malfunctions of any engine or vehicle

component that may increase exhaust emissions 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

system consists of computer program on one or more of the vehicles 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.

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.

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, and properly secured to prevent damage.

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 fuel 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

Care must be taken that fuel lines do not route against other components.

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

SAFETY AND COMPLIANCE

Peterbilt Motors Company 2-5

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

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 AFTERTREATMENT SYSTEM

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

The following aftertreatment and exhaust system components may not be modified: DPF/SCR assembly Exhaust pipes between the engine and aftertreatment devices (DPF, SCR Catalyst) and

between aftertreatment devices

NOx Sensors PM Sensor

The following modifications may only be done within the guidelines outlined in section 9 of this manual: 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

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

vehicle operation or other components

The DPF/SCR or its mounting may not be modified

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

canister or reorienting the sensor(s)

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

Ensure adequate clearance between the exhaust and body panels, hoses, and wire harnesses (see routing section of this manual for more details)

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

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

The SCR water drain hole may not be blocked

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, sensors, or wiring

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 aftertreatment system or vehicle tail pipe.

SAFETY AND COMPLIANCE

Peterbilt Motors Company 2-6

2 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 guidelines 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 operators 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

SAFETY AND COMPLIANCE

Peterbilt Motors Company 2-7

2 ELECTRICAL SYSTEM

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

Electrical harnesses providing battery power and electronic control signals to engine and emissions

control devices/vehicle OBD components including datalinks may not be spliced. These emissions

control devices/vehicle OBD components include the following:

throttle pedal

vehicle speed sensor

aftertreatment 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 manufacturers

guidelines. This includes alternator ground voltage drop and alternator ground cable effectiveness.

See the engine manufacturers 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 with 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 aftertreatment wiring are available for relocating the DEF tank from your

dealer via PACCAR Parts. For relocation of DEF tank, refer to the aftertreatment 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.

WARNING: When jump starting using a battery charger/booster, verify that the battery charger/booster is

set to the same jump start voltage and amperage specifications as the vehicle electrical

system and batteries (i.e. if the vehicle electrical system is a 12 volt system, the jump start

voltage on the battery charger/booster shall be set at no higher than a 12 volt setting).

Failure to comply may cause an explosion and/or fire resulting in death, personal injury, equipment or property damage.

See additional general wire routing statements on next page

SAFETY AND COMPLIANCE

Peterbilt Motors Company 2-8

2 GENERAL WIRE ROUTING

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

Whenever possible, battery cables, electrical wires, and wire harnesses should be secured by

clamps attached to rigid components (for example, the engine, frame, bracket, etc.), or secured by

tie straps fastened to other restrained lines at intervals not exceeding 460mm (18 in.).

Battery cables, alternator cables, electrical wires, and wires harnesses routed on the chassis and

engine should be covered by braided loom or convoluted tubing.

At the clamping or tie points, battery cables, electrical wires, and wire harnesses should be covered

by braided loom or convoluted tubing.

SAFETY RELATED COMPONENTS AND SYSTEMS

Upfitting and other modifications may change the compliance of an as-built vehicle. As such, Peterbilt will not

support any modifications that affect the as-built compliance of a vehicle. These may include modifications to

the following:

Stability Control Systems for vehicles with factory-installed Stability Control Systems,

modifications to the following are not supported:

Wheelbase (reducing or increasing wheelbase)

Lift Axles (removal or addition)

Conversion of a truck to a tractor

Factory installed Safety Systems (Factory installed Safety Systems will not be removed or

inactivated)

Green House Gas Requirements

SECTION 3 DIMENSIONS

INTRODUCTION This section has been designed to provide enough information to successfully layout a chassis in the body planning process. All dimensions are inches unless otherwise noted. Optional equipment may not be depicted. Please contact your local Peterbilt dealer if more dimensional information is desired.

ABBREVIATIONS Throughout this section and in other sections as well, abbreviations are used to describe certain characteristics on your vehicle. The chart below lists the abbreviated terms used.

TABLE 3-1. Abbreviations Used

AF After Frame Frame rail overhang behind rear axle(s)

CA Cab to Axle Dimension from back of the cab to the centerline of the rear axle(s)

WB Wheelbase Measured from front axle to the centerline of the rear axle(s)

FS Front suspension height

RS Rear suspension height

SLR Tire Static Loaded Radius

SOC Side of cab

BOC Back of cab

UC Under cab

BBC Bumper to back of cab

BFA Bumper to front axle

FAB Front axle to back of cab

FDA Front drive axle

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

SH Short aero hood (107)

MH Medium aero hood (109)

VH Vocational hood (109)

OVERALL DIMENSIONS This section includes drawings and charts of the following Peterbilt Models: 535, 536, 537, & 548. Several optional configurations are also included. On the pages that follow, detailed drawings show particular views of each vehicle. They illustrate important measurements critical to integrating 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 layouts of ordered chassis prior to build. Please speak with your local dealership to request this feature when specifying your chassis.

DIMENSIONS

Peterbilt Motors Company 3-2

3 MODELS 535, 536, 537, & 548 107 BBC AERO HOOD

FIGURE 3-1. Short Aero Hood (107 BBC) Overall Dimensions

NOTES: 1) DIMENSIONS ARE FOR REFERENCE ONLY 2) DIMENSIONS REFERENCE FRONT OF BUMPER 3) DIMENSION FRONT AXLE TO FRONT OF FRAME (FFA) IS 26.8 4) DIMENSION FRONT OF BUMPER TO FRONT OF FRAME (BFF) IS 13.2 5) FLAT ROOF SHOWN, CURVED ROOF 4 TALLER 6) 36 EXHAUST STANDPIPE SHOWN, OTHER HEIGHT OPTIONS ARE AVAILABLE

DIMENSIONS

Peterbilt Motors Company 3-3

3 MODELS 536, 537, & 548 109 BBC AERO HOOD

FIGURE 3-2. Medium Aero Hood (109 BBC) Overall Dimensions

NOTES: 1) DIMENSIONS ARE FOR REFERENCE ONLY 2) DIMENSIONS REFERENCE FRONT OF BUMPER 3) DIMENSION FRONT AXLE TO FRONT OF FRAME (FFA) IS 26.8 4) DIMENSION FRONT OF BUMPER TO FRONT OF FRAME (BFF) IS 13.2 5) FLAT ROOF SHOWN, CURVED ROOF 4 TALLER 6) 36 EXHAUST STANDPIPE SHOWN, OTHER HEIGHT OPTIONS ARE AVAILABLE

DIMENSIONS

Peterbilt Motors Company 3-4

3 MODELS 537 & 548 109 VOC HOOD

FIGURE 3-3. Vocational Hood (109 BBC) Overall Dimensions

NOTES: 1) DIMENSIONS ARE FOR REFERENCE ONLY 2) DIMENSIONS REFERENCE FRONT OF BUMPER 3) DIMENSION FRONT AXLE TO FRONT OF FRAME (FFA) IS 38.5 4) DIMENSION FRONT OF BUMPER TO FRONT OF FRAME (BFF) IS 1.5 5) FLAT ROOF SHOWN, CURVED ROOF 4 TALLER 6) 48 EXHAUST STANDPIPE SHOWN, OTHER HEIGHT OPTIONS ARE AVAILABLE

DIMENSIONS

Peterbilt Motors Company 3-5

3 MODELS 537 & 548 VOC HOOD W/ 24 FEPTO BUMPER EXTENSION

FIGURE 3-4. Vocational Hood 24 FEPTO Extension Top, Front & LH View Overall Dimensions

NOTES: 1) DIMENSIONS ARE FOR REFERENCE ONLY 2) DIMENSIONS ARE TO FRONT OF BUMPER 3) DIMENSION FRONT OF BUMPER TO FRONT OF FRAME (BFF) IS 1.5

DIMENSIONS

Peterbilt Motors Company 3-6

3 CAB 2.1m MEDIUM DUTY FAMILY

FIGURE 3-5. Cab Dimensions 2.1m Medium Duty

NOTE: 1) FLAT ROOF SHOWN, CURVED ROOF 4 TALLER

DIMENSIONS

Peterbilt Motors Company 3-7

3 REAR WINDOW

FIGURE 3-6. Rear Window Dimensions

DIMENSIONS

Peterbilt Motors Company 3-8

3 CAB SUSPENSION

FIGURE 3-7. Cab Suspension Dimensions

Note:

1) Rigid Cab Suspension does not protrude BOC

DIMENSIONS

Peterbilt Motors Company 3-9

3 CAB STEP HEIGHT

FIGURE 3-8. Cab Step Height Dimensions (Table 3-2)

Table 3-2. Cab Step Height

Notes:

1) Dimension C: SH = 15.0, MH = 16.1, VH = 20.8 2) LH shown, RH Dimensions are equivalent 3) Aftertreatment box is RH UCAB only

DIMENSIONS

Peterbilt Motors Company 3-10

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

FIGURE 3-9. Frame Rail Configurations

DIMENSIONS

Peterbilt Motors Company 3-11

3 FRAME HEIGHT CHARTS

FIGURE 3-10. Frame Height

DIMENSIONS

Peterbilt Motors Company 3-12

3 FRONT FRAME HEIGHTS "A"

TABLE 3-3. Front Frame Ride Height A

NOTES: 1) Spacers are used by Engineering to obtain a level frame and are not optional. 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. 4) All suspension heights are with standard 3.5" drop axles.

DIMENSIONS

Peterbilt Motors Company 3-13

3 REAR FRAME HEIGHTS "C"

TABLE 3-4. Single Drive Rear Suspension Height C

DIMENSIONS

Peterbilt Motors Company 3-14

3

TABLE 3-5. Tandem Rear Suspension Height C

Suspension Rating Version C (in)

Light Height Laden Height

AIR LEAF 38,000 lbs. Standard 12.0 11.7

LOW AIR LEAF 40,000 lbs. Standard 8.8 8.5

FLEX AIR 38,000 lbs. Standard 8.7 8.5

LOW LOW AIR LEAF 40,000 lbs. Standard 6.8 6.5

AIR TRAC 40K-46K lbs. Standard 11.4 11.0

NEWAY ADZ 46K lbs. Standard 10.0 10.0

REYCO 102

MULTILEAF

40,000 lbs.

1.75 saddle (STD) 11.7 9.9

1.38 saddle 10.2 8.3

3.38 saddle 13.4 11.5

44,000 lbs. 1.75 saddle (STD) 11.7 9.8

1.38 saddle 11.5 9.7

CHALMERS 8541 40,000 lbs.

LOW 11.2 8.9

HIGH 12.4 10.2

X-HIGH 14.5 12.2

XX-HIGH 17.2 14.9

CHALMERS 8541 46,000 lbs.

LOW 11.3 8.9

HIGH 12.5 10.1

X-HIGH 14.7 12.2

XX-HIGH 17.3 14.9

RT-403 40,000 lbs. 6.00 saddle 9.9 8.9

7.19 saddle (std.) 11.2 10.1

HMX EX

40,000 lbs.

16.5 11.6 9.5

17.5 12.6 10.5

18.5 13.6 11.5

46,000 lbs.

16.5 11.6 9.5

17.5 12.6 10.5

18.5 13.6 11.5

RS-463 46,000 lbs.

12.25 saddle 9.7 8.9

14.00 saddle (std.) 11.5 10.6

15.25 saddle 12.7 11.9

RT-463 46,000 lbs.

6.00 saddle 11.3 10.5

7.2 saddle (std.) 13.0 11.4

11.00 saddle 16.3 15.2

NOTES: 1) Laden dimension shown with standard restrictor cans. Add 0.7 for #29 High Stability Restrictor Cans.

DIMENSIONS

Peterbilt Motors Company 3-15

3

FRAME MOUNTED COMPONENT GROUND CLEARANCE To calculate estimated ground clearance for frame mounted components, using the underside of the frame rail as a reference, do the following:

1) Find the front and rear tire SLR data from the manufacturers literature, as described on page 3-11 2) Determine front and rear suspension ride heights from the tables on the previous few pages 3) Add the tires SLR to its respective suspension ride height to calculate frame height 4) Find the bottom of rail to bottom of component dimension Y for the desired component in table 3-6 below. 5) Ground clearance = lowest frame height component dimension Y

TABLE 3-6. Bottom of Frame to Bottom of Component Dimension Y

Ground clearances, like height calculations, are affected by numerous factors including, but not limited to, front and rear axle loading and tire pressure. Placement of frame components, such as fuel tanks, will affect loads on the front axle and rear axle, as well as distribution to the left and right side of the vehicle. Ground clearances calculated from this information are estimates only.

DIMENSIONS

Peterbilt Motors Company 3-16

3 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 3-11. Frame Space BASIC FORMULA: BOC Frame Space = Wheelbase - 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.

DIMENSIONS

Peterbilt Motors Company 3-17

3 FRAME SPACE DIMENSION "B"

TABLE 3-7. Rear Suspension Dimension B

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 "B" dimension with quarter fenders. 3) Add 1.5" to "B" dimension with quarter fenders. 4) Add 0.6" to "B" dimension with quarter fenders. 5) Add 2.8" to "B" dimension with quarter fenders. 6) "B" dimension is from axle centerline (or bogie for tandem) to clear frame forward. 7) Extended Tractor Taper requires 58.0" overhang.

DIMENSIONS

Peterbilt Motors Company 3-18

3 FRAME SPACE DIMENSION A

TABLE 3-8. LH Under Cab DEF Dimension A

TABLE 3-9. Under Cab Battery/Tool Box Dimension A

TABLE 3-10. Under Cab DPF/SCR Dimension A

DIMENSIONS

Peterbilt Motors Company 3-19

3 TABLE 3-11. Under Cab Fuel Tank Dimension A

DIMENSIONS

Peterbilt Motors Company 3-20

3 FRAME SPACE DIMENSION C

TABLE 3-12. BOC DEF Dimension C

TABLE 3-13. BOC Battery/Tool Box Dimension C

DIMENSIONS

Peterbilt Motors Company 3-21

3 TABLE 3-14. BOC Fuel Tank Dimension C

DIMENSIONS

Peterbilt Motors Company 3-22

3 TABLE 3-14. BOC Fuel Tank Dimension C Continued

DIMENSIONS

Peterbilt Motors Company 3-23

3 TABLE 3-14. BOC Fuel Tank Dimension C Continued

DIMENSIONS

Peterbilt Motors Company 3-24

3 2021 MD EXHAUST CONFIGURATIONS

EXHAUST RH SOC - DPF/SCR RH UNDER CAB (Reference option code 3365270)

FIGURE 3-12. Exhaust RH Side of Cab DPF/SCR RH under Cab

DIMENSIONS

Peterbilt Motors Company 3-25

3 EXHAUST RH BOC - DPF/SCR RH UNDER CAB (Reference option code 3365250)

FIGURE 3-13. Exhaust RH Back of Cab DPF/SCR RH under Cab

NOTES: 1) BOC exhaust only available with vocational hood.

DIMENSIONS

Peterbilt Motors Company 3-26

3 EXHAUST RH HORIZONTAL - DPF/SCR RH UNDER CAB (STANDARD) (Reference option code 3365280)

FIGURE 3-14. Exhaust RH Horizontal DPF/SCR RH under Cab (Standard)

DIMENSIONS

Peterbilt Motors Company 3-27

3 EXHAUST RH HORIZONTAL - DPF/SCR RH UNDER CAB (W/ RH DEF) (Reference option code 3365280)

FIGURE 3-15. Exhaust RH Horizontal DPF/SCR RH under Cab (RH DEF)

DIMENSIONS

Peterbilt Motors Company 3-28

3 EXHAUST RH HORIZONTAL - DPF/SCR RH UNDER CAB (W/ FDA) (Reference option code 3365280)

FIGURE 3-16. Exhaust RH Horizontal DPF/SCR RH under Cab (FDA)

DIMENSIONS

Peterbilt Motors Company 3-29

3 EXHAUST RH HORIZONTAL - DPF/SCR RH UNDER FRAME (Reference option code 3365290)

FIGURE 3-17. Exhaust RH Horizontal DPF/SCR RH under Frame

DIMENSIONS

Peterbilt Motors Company 3-30

3 EXHAUST RH SOC - NATURAL GAS CATALYST RH UNDER CAB (Reference option code 3365420)

FIGURE 3-18. Exhaust Single RH Side of Cab DPF/SCR RH under Cab

DIMENSIONS

Peterbilt Motors Company 3-31

3 EXHAUST RH BOC - NATURAL GAS CATALYST RH UNDER CAB (Reference option code 3365440)

FIGURE 3-19. Exhaust RH Back of Cab DPF/SCR RH under Cab

DIMENSIONS

Peterbilt Motors Company 3-32

3 EXHAUST RH HORIZONTAL - NATURAL GAS CATALYST RH UNDER FRAME (L9N) (Reference option code 3365460)

FIGURE 3-20. Exhaust RH Horizontal Natural Gas Catalyst RH under Frame (L9N)

DIMENSIONS

Peterbilt Motors Company 3-33

3 EXHAUST RH HORIZONTAL - NATURAL GAS CATALYST RH UNDER FRAME (B6.7N) (Reference option code 3365460)

FIGURE 3-21. Exhaust RH Horizontal Natural Gas Catalyst RH under Frame (B6.7N)

DIMENSIONS

Peterbilt Motors Company 3-34

3 TURN RADIUS ANALYSIS Figure 3-22 is an example of turn radius estimates available through SmartSpec. Please contact your local Peterbilt dealer for chassis specific turn information.

FIGURE 3-22. Turn Radius Estimate Available from Dealership

Peterbilt Motors Company 4-1

SECTION 4 BODY MOUNTING

INTRODUCTION

This section has been designed to provide guidelines to aid in body mounting. This is not intended as a complete guide, rather as general information. Body mounting strategies are unique to each body type, and body builders must determine the appropriate method. Please note, an alignment adjustment is required after body installation. Front alignment and rear alignment must be performed prior to putting the vehicle into service. Please contact your local Peterbilt dealer if more information is desired.

FRAME RAILS

Frame rail information is provided per rail.

TABLE 4-1. Single Frame Rails

Rail Height (in.)

Flange Width (in.)

Web Thickness (in)

Section Modulus (cu. In.)

RBM (per rail) (in.-lbs)

Weight (per rail) (lbs/in.)

9 7/8 3.50 0.250 10.5 1,250,000 1.06

10 5/8 3.45 0.313 14.8 1,776,000 1.44

10 11/16 3.5 0.5 22.35 2,683,000 2.35

10 3/4 3.50 0.375 17.8 2,136,000 1.74

11 5/8 3.874 0.375 21.4 2,568,000 1.91

TABLE 4-2. Built-up Frame Rails

Main Rail Height

(in.) Insert Outsert

Section Modulus (cu. In.)

RBM (per rail) (in.-lbs)

Weight (per rail) (lbs/in.)

10 5/8 9.875 x 2.87 x .25 None 23.6 2,832,000 2.48

10 3/4 9.875 x 2.87 x .25 None 28.9 3,468,000 2.78

11 5/8 10.75 x 3.5 x 0.375 None 37.7 4,524,000 3.65

BODY MOUNTING

Peterbilt Motors Company 4-2

4 CRITICAL CLEARANCES

REAR TIRES AND CAB

CAUTION: Insufficient clearance between rear tires and body structure could cause damage to the body during suspension movement.

Normal suspension movement could cause contact between the tires and the body. To prevent this, mount the body so that the minimum clearance between the top of the tire and the bottom of the body is 8 inches (203 mm). This should be measured with the body empty. See FIGURE 4-1.

FIGURE 4-1. Minimum Clearance between Top of Rear Tires and Body Structure Overhang

CAUTION: Maintain adequate clearance between back of cab and the front (leading edge) of mounted body. It is recommended the body leading edge be mounted 4 in. behind the cab. See FIGURE 4-2.

NOTE: Be sure to provide maintenance access to the battery box and fuel tank fill neck.

FIGURE 4-2. Minimum Back of Cab Clearance

BODY MOUNTING

Peterbilt Motors Company 4-3

4 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 Ubolts.

FRAME SILL If the body is mounted to the frame with brackets, we recommend a frame sill spacer made from a strip of rubber or plastic (delrin or nylon). These materials will not undergo large dimensional changes during periods of high or low humidity. The strip will be less likely to fall out during extreme relative motion between body and chassis. See FIGURE 4-3.

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

BODY MOUNTING

Peterbilt Motors Company 4-4

4 BRACKETS

When mounting a body to the chassis with brackets, we recommend designs that offer limited relative movement, bolted securely but not too rigid. Brackets should allow for slight movement between the body and the chassis. For instance, FIGURE 4-4 shows a high compression spring between the bolt and the bracket, and FIGURE 4-5 shows a rubber spacer between the brackets. These designs will allow relative movement between the body and the chassis during extreme frame racking situations. Mountings that are too rigid could cause damage to the body. This is particularly true with tanker installations.

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

BODY MOUNTING

Peterbilt Motors Company 4-5

4 MOUNTING HOLES

When installing brackets on the frame rails, the mounting holes in the chassis frame bracket and frame rail must comply with the general spacing and location guidelines illustrated in FIGURE 4-6.

FIGURE 4-6. Frame Hole Location Guidelines for Frame Rail and Bracket

FIGURE 4-7. Fill-In Crossmember Gusset Hole Patterns (Additional Holes Available in 50 mm Horizontal Increments)

BODY MOUNTING

Peterbilt Motors Company 4-6

4 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 Ubolts.

FIGURE 4-8. Frame Rail Flange Drilling Prohibited

WARNING! DO NOT drill closely spaced holes in the frame rail. Frame hole centers of two adjacent holes should

be spaced no less than twice the diameter of the largest hole. Closer spacing could induce a failure between the two holes.

CAUTION: An appropriately sized bolt and nut must be installed and torqued properly in all unused frame holes. Failure to do so could result in a frame crack initiation around the hole.

CAUTION: Use care when drilling the frame web so the wires and air lines routed inside the rail are not damaged. Failure to do so could cause an inoperable electrical or air system circuit.

CAUTION: Never use a torch to make holes in the rail. Use the appropriate diameter drill bit. Heat from a torch will affect the material properties of the frame rail and could result in frame rail cracks.

CAUTION: The frame hole diameter should not exceed the bolt diameter by more than .060 inches (1.5mm).

BODY MOUNTING

Peterbilt Motors Company 4-7

4 BODY MOUNTING USING UBOLTS If the body is mounted to the frame with Ubolts, use a hardwood sill (minimum 1/2 inch 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 Ubolts. It will weaken the frame and could cause an accident. Use suitable spacers made of steel or hardwood on the inside of the frame rail to prevent collapse of the frame flanges.

Use a hardwood spacer between the bottom flange and the Ubolt to prevent the Ubolt from notching the frame flange. See FIGURE 4-9.

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

BODY MOUNTING

Peterbilt Motors Company 4-8

4 WARNING! Do not allow spacers and other body mounting parts to interfere with brake lines, fuel lines, or wiring harnesses routed inside the frame rail. Crimped or damaged brake lines, fuel lines, or wiring could result in loss of braking, fuel leaks, electrical overload or a fire. Carefully inspect the installation to ensure adequate

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

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

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

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

BODY MOUNTING

Peterbilt Motors Company 4-9

4 REAR BODY MOUNT When Ubolts are used to mount a body, we recommend that the last body attachment be made with a fishplate bracket. See FIGURE 4-11. This provides a firm attaching point and helps prevent any relative fore or aft movement between the body and frame. For frame hole location guidelines, see FIGURE 4-6.

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

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Peterbilt Motors Company 5-1

SECTION 5 FRAME MODIFICATIONS INTRODUCTION Peterbilt offers customer specified wheelbases and frame overhangs. So, in most cases, frame modifications should not be necessary. However, some body installations may require slight modifications, while other installations will require extensive modifications. Sometimes an existing dealer stock chassis may need to have the wheelbase changed to better fit a customers application. The modifications may be as simple as modifying the frame cutoff, or as complex as modifying the wheelbase.

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

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 Ubolts.

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.

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

FRAME MODIFICATIONS

Peterbilt Motors Company 5-2

5 MODIFYING FRAME LENGTH The frame overhang after the rear axle can be shortened to match a particular body length. Using a torch is acceptable; however, heat from a torch will affect the material characteristics of the frame rail. The affected material will normally be confined to within 1 to 2 inches (25 to 50mm) of the flame cut and may not adversely affect the strength of the chassis or body installation.

CHANGING WHEELBASE Changing a chassis wheelbase is not recommended. Occasionally, however, a chassis wheelbase will need to be shortened or lengthened. Before this is done, there are a few guidelines that should to be considered.

WARNING! When changing the wheelbase, be sure to follow the driveline manufacturers 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.

WARNING! When changing the wheelbase, contact your local Peterbilt dealership for support. It is important to verify that these changes do not compromise vehicle frame strength.

Before changing the wheelbase, the driveline angles of the proposed wheelbase need to be examined to ensure no harmful vibrations are created. Consult with the driveline manufacturer for appropriate recommendations. Before the rear suspension is relocated, check the new location of the spring hanger brackets. The new holes for the spring hanger brackets must not overlap existing holes and should adhere to the guidelines in the FRAME DRILLING section of this manual. When shortening the wheelbase, the suspension should be moved forward and relocated on the original rail. The rail behind the suspension can then be cut to achieve the desired frame overhang. See FIGURE 5-1.

FIGURE 5-1. Wheelbase Customization

FRAME MODIFICATIONS

Peterbilt Motors Company 5-3

5 CROSSMEMBERS

After lengthening a wheelbase, an additional crossmember may be required to maintain the original frame strength. The maximum allowable distance between the forward suspension crossmember and the next crossmember forward is 47.2 inches (1200 mm). If the distance exceeds 47.2 inches (1200 mm) after the wheelbase is lengthened, add a crossmember between them.

FIGURE 5-2. Crossmember Spacing Requirements

FRAME MODIFICATIONS

Peterbilt Motors Company 5-4

5 TORQUE REQUIREMENTS

Torque values apply to fasteners with clean threads, lightly lubricated, with hardened steel washers, and nylon-insert nuts.

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

Fastener Torque

Size Nm lb-ft

5/16 2734 2025

3/8 4760 3544

7/16 7696 5671

1/2 117148 86109

9/16 167214 123-158

5/8 235296 173218

3/4 411523 303386

7/8 654846 482624

1 9731268 718935

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

Fastener Torque

Size Nm lb-ft

M6 911 78

M8 2427 1820

M10 4754 3540

M12 8395 6170

M14 132150 97111

M16 206235 152173

M20 403458 297338

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 (Vd 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.) diameter 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. Be sure to obtain full weld penetration along the entire length of the crack.

FRAME MODIFICATIONS

Peterbilt Motors Company 5-5

5 PRECAUTIONS

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.

WELDING PRECAUTIONS: ALL ELECTRONIC ENGINES

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, TCM, and VECU connectors.

3. Do not use the ECM, TCM, VECU, 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: Bendix ABS and Wabco ABS: Disconnect ECU, TCM, & VECU.

This page is intentionally left blank.

Peterbilt Motors Company 6-1

SECTION 6 CAN COMMUNICATIONS INTRODUCTION Controller Area Network (CAN) is a serial network technology that was originally designed for the automotive industry but has also become popular in the commercial trucking industry. The CAN bus is primarily used in the embedded systems and network technology that provides fast communication among controllers up to real-time requirements, eliminating the need for the much more expensive and complex technology. CAN is a two-wire high-speed network system, that is far superior to conventional hardwired technologies functionality and reliability. CAN implementations are more cost effective. CAN is designed for real-time requirements which can easily beat hardwire connections when it comes to short reaction times, timely error detection, quick error recovery, and error repair. Characteristics of the Controller Area Network

A serial networking technology for embedded solutions

Needs only two wires to communicate messages

Operates at data rates of 250K and 500K

Supports a maximum of 8 bytes per message frame

One application can support multiple message IDs

Supports message priority, i.e. the lower the message ID the higher its priority

CAN COMMUNICATIONS ACRONYM LIBRARY

Acronym Definition

CAN Controller Area Network

J-1939 SAE CAN Communication Standard

PGN Parameter Group Number

PTO Power Take Off

SPN Suspect Parameter Number

SCR Selective Catalytic Reduction

DPF Diesel Particulate Filter

Regen Aftertreatment Regeneration

TSC1 Torque Speed Commands

CAN COMMUNICATIONS

Peterbilt Motors Company 6-2

6 SAE J1939 The Society of Automotive Engineers (SAE) Communications Subcommittee for Truck and Bus Controls has developed a family of standards concerning the design and use of devices that transmit electronic signals and control information among vehicle components. SAE J1939 and its companion documents are the accepted industry standard for the vehicle network of choice for commercial truck applications. SAE J1939 is used in the commercial vehicle area for communication in the embedded systems of the commercial vehicle. SAE J1939 uses CAN as physical layer. It is a recommended practice that defines which and how the data is communicated between the Electronic Control Units within a vehicle network. Typical controllers are the Engine, Brake, Transmission, etc. The messages exchanged between these units can be data such as vehicle road speed, torque control message from the transmission to the engine, oil temperature, and many more. Characteristics of J1939

Extended CAN identifier (29 bit) Peer-to-peer and broadcast communication Network management Definition of parameter groups for commercial vehicles and others Manufacturer specific parameter groups are supported Diagnostics features A standard developed by the Society of Automotive Engineers Defines communication for vehicle networks A Higher-Layer Protocol using CAN as the physical layer Uses unshielded twisted pair wire Applies a maximum network length of 120 ft. Applies a standard baud rate of 500 Kbit/sec Supports peer-to-peer and broadcast communication Supports message lengths up to 1785 bytes Defines a set of Parameter Group Numbers Supports network management

PARAMETER GROUP NUMBER

Parameter Groups contain information on parameter assignments within the 8-byte CAN data field of each message as well as repetition rate and priority. Parameters groups are, for instance, engine temperature, which includes coolant temperature, fuel temperature, oil temperature, etc. Parameter Groups and their numbers are listed in SAE J1939 and defined in SAE J1939/71, a document containing parameter group definitions plus suspect parameter numbers.

SUSPECT PARAMETER NUMBER A Suspect Parameter Number is a number assigned by the SAE to a specific parameter within a parameter group. It describes the parameter in detail by providing the following information: Data Length in bytes Data Type Resolution Offset Range Reference Tag (Label) SPNs that share common characteristics are grouped into Parameter Groups, and they will be transmitted throughout the network using the Parameter Group Number.

CAN COMMUNICATIONS

Peterbilt Motors Company 6-3

6 CAN MESSAGES AVAILABLE ON BODY CONNECTIONS

SPN CAN Signal Name PGN, Message Tx SA Rx SA CAN Bus

38 Fuel Level 2 65276, DD1 39 Broadcast KCAN, SCAN, BCAN

46 Pneumatic Supply Pressure 65198, AIR1 48 Broadcast KCAN, SCAN, BCAN

51 Engine Throttle Valve 1 Position 1 65266, LFE1 00 Broadcast KCAN, SCAN, BCAN

52 Engine Intercooler Temperature 65262, ET1 00 Broadcast KCAN, SCAN, BCAN

69 Two Speed Axle Switch 65265, CCVS1 00 Broadcast KCAN, SCAN, BCAN

70 Parking Brake Switch 65265, CCVS1 39 Broadcast KCAN, SCAN, BCAN

74 Maximum Vehicle Speed Limit 65261, CCSS 39 Broadcast KCAN, SCAN

81 Aftertreatment 1 Diesel Particulate Filter

Intake Pressure 65270, IC1 00 Broadcast KCAN, SCAN, BCAN

84 Wheel-Based Vehicle Speed 65265, CCVS1 00 Broadcast KCAN, SCAN, BCAN

86 Cruise Control Set Speed 65265, CCVS1 00 Broadcast KCAN, SCAN, BCAN

86 Cruise Control Set Speed 65265, CCVS1 39 Broadcast KCAN, SCAN

90 Power Takeoff Oil Temperature 65264, PTO 7, 33 Broadcast KCAN, SCAN, BCAN

91 Accelerator Pedal Position 1 61443, EEC2 00 Broadcast KCAN, SCAN, BCAN

92 Engine Percent Load At Current Speed 61443, EEC2 00 Broadcast KCAN, SCAN, BCAN

94 Engine Fuel Delivery Pressure 65263, EFL/P1 00 Broadcast KCAN, SCAN, BCAN

96 Fuel Level 1 65276, DD1 39 Broadcast KCAN, SCAN, BCAN

97 Water In Fuel Indicator 1 65279, OI 00 Broadcast KCAN, SCAN, BCAN

98 Engine Oil Level 65263, EFLP1 00 Broadcast KCAN, SCAN, BCAN

100 Engine Oil Pressure 1 65263, EFL/P1 00 Broadcast KCAN, SCAN, BCAN

101 Engine Crankcase Pressure 1 65263, EFL/P1 00 Broadcast KCAN, SCAN, BCAN

102 Engine Intake Manifold #1 Pressure 65270, IC1 00 Broadcast KCAN, SCAN, BCAN

105 Engine Intake Manifold 1 Temperature 65270, IC1 00 Broadcast KCAN, SCAN, BCAN

106 Engine Intake Air Pressure 65270, IC1 00 Broadcast KCAN, SCAN, BCAN

108 Barometric Pressure 65269, AMB 00 Broadcast KCAN, SCAN, BCAN

110 Engine Coolant Temperature 65262, ET1 00 Broadcast KCAN, SCAN, BCAN

111 Engine Coolant Level 1 65263, EFL/P1 00 Broadcast KCAN, SCAN, BCAN

117 Brake Primary Pressure 65274, B1 39 Broadcast KCAN, SCAN, BCAN

118 Brake Secondary Pressure 65274, B1 39 Broadcast KCAN, SCAN, BCAN

158 Key Switch Battery Potential 65271, VEP1 39 Broadcast KCAN, SCAN

161 Transmission 1 Input Shaft Speed 61442, ETC1 03 Broadcast KCAN, SCAN, BCAN

162 Transmission Requested Range 61445, ETC2 03 Broadcast KCAN, SCAN, BCAN

163 Transmission Current Range 61445, ETC2 03 Broadcast KCAN, SCAN, BCAN

168 Battery Potential / Power Input 1 65271, VEP1 39 Broadcast KCAN, SCAN, BCAN

168 Battery Potential / Power Input 1 65271, VEP1 00 Broadcast KCAN, SCAN, BCAN

171 Ambient Air Temperature 65269, AMB 00 Broadcast KCAN, SCAN, BCAN

173 Engine Exhaust Temperature 65270, IC1 00 Broadcast KCAN, SCAN, BCAN

174 Engine Fuel Temperature 1 65262, ET1 00 Broadcast KCAN, SCAN, BCAN

175 Engine Oil Temperature 1 65262, ET1 00 Broadcast KCAN, SCAN, BCAN

177 Transmission Oil Temperature 1 65272, TRF1 03 Broadcast KCAN, SCAN, BCAN

CAN COMMUNICATIONS

Peterbilt Motors Company 6-4

6 SPN CAN Signal Name PGN, Message Tx SA Rx SA CAN Bus

182 Engine Trip Fuel 65257, LFC1 00 Broadcast KCAN, SCAN, BCAN

183 Engine Fuel Rate 65266, LFE1 00 Broadcast KCAN, SCAN, BCAN

184 Engine Instantaneous Fuel Economy 65266, LFE1 00 Broadcast KCAN, SCAN, BCAN

185 Engine Average Fuel Economy 65266, LFE1 23 Broadcast KCAN, SCAN, BCAN

187 Power Takeoff Set Speed 65264, PTO 39 Broadcast KCAN, SCAN, BCAN

187 Power Take Off Set Speed 65264, PTO 00 Broadcast KCAN, SCAN, BCAN

190 Engine Speed 61444, EEC1 00 Broadcast KCAN, SCAN, BCAN

191 Transmission 1 Output Shaft Speed 61442, ETC1 03 Broadcast KCAN, SCAN, BCAN

235 Engine Total Idle Hours 65244, IO 00 Broadcast KCAN, SCAN, BCAN

236 Engine Total Idle Fuel Used 65244, IO 00 Broadcast KCAN, SCAN, BCAN

237 Vehicle Identification Number 65260, VI 00 Broadcast KCAN, SCAN, BCAN

244 Trip Distance 65248, VD 00 Broadcast KCAN, SCAN, BCAN

245 Total Vehicle Distance 65248, VD 00 Broadcast KCAN, SCAN, BCAN

247 Engine Total Hours of Operation 65253, HOURS 00 Broadcast KCAN, SCAN, BCAN

248 Total Power Takeoff Hours 65255, VH 00 Broadcast KCAN, SCAN, BCAN

249 Engine Total Revolutions 65253, HOURS 00 Broadcast KCAN, SCAN, BCAN

250 Engine Total Fuel Used 65257, LFC1 00 Broadcast KCAN, SCAN, BCAN

512 Driver's Demand Engine - Percent Torque 61444, EEC1 00 Broadcast KCAN, SCAN, BCAN

513 Actual Engine - Percent Torque 61444, EEC1 00 Broadcast KCAN, SCAN, BCAN

518 Engine Requested Torque/Torque Limit

0, TSC1 39 249 (DA

specific) KCAN, SCAN, BCAN

518 Engine Requested Torque/Torque Limit

0, TSC1 7, 33 00 (DA

specific) KCAN, SCAN, BCAN

523 Transmission Current Gear 61445, ETC2 03 Broadcast KCAN, SCAN, BCAN

524 Transmission Selected Gear 61445, ETC2 03 Broadcast KCAN, SCAN, BCAN

525 Transmission Requested Gear

256, TC1 03 255 (DA

specific) KCAN, SCAN, BCAN

525 Trans Requested Gear

256, TC1 7, 33 03 (DA

specific) KCAN, SCAN, BCAN

526 Transmission Actual Gear Ratio 61445, ETC2 03 Broadcast KCAN, SCAN, BCAN

527 Cruise Control States 65265, CCVS1 39 Broadcast KCAN, SCAN, BCAN

527 Cruise Control States 65265, CCVS1 00 Broadcast KCAN, SCAN

558 Accelerator Pedal1 Low Idle Switch EEC2, 61443 00 Broadcast KCAN, SCAN, BCAN

559 Accelerator Pedal Kick down Switch 61443, EEC2 00 Broadcast KCAN, SCAN, BCAN

560 Transmission Driveline Engaged 61442, ETC1 03 Broadcast KCAN, SCAN, BCAN

561 ASR Engine Control Active 61441, EBC1 39 Broadcast KCAN, SCAN, BCAN

562 ASR Brake Control Active 61441, EBC1 39 Broadcast KCAN, SCAN, BCAN

563 Anti-Lock Braking (ABS) Active 61441, EBC1 39 Broadcast KCAN, SCAN, BCAN

573 Transmission Torque Converter Lockup

Engaged 61442, ETC1 03 Broadcast KCAN, SCAN, BCAN

574 Transmission Shift In Process 61442, ETC1 03 Broadcast KCAN, SCAN, BCAN

590 Engine Idle Shutdown Timer State 65252, SHUTDN 00 Broadcast KCAN, SCAN, BCAN

590 Engine Idle Shutdown Timer State 65252, SHUTDN 39 Broadcast KCAN, SCAN, BCAN

CAN COMMUNICATIONS

Peterbilt Motors Company 6-5

6 SPN CAN Signal Name PGN, Message Tx SA Rx SA CAN Bus

591 Engine Idle Shutdown Timer Function 65252, SHUTDN 00 Broadcast KCAN, SCAN, BCAN

591 Engine Idle Shutdown Timer Function 65252, SHUTDN 39 Broadcast KCAN, SCAN, BCAN

592 Engine Idle Shutdown Timer Override 65252, SHUTDN 00 Broadcast KCAN, SCAN, BCAN

593 Engine Idle Shutdown has Shutdown Engine 65252, SHUTDN 00 Broadcast KCAN, SCAN, BCAN

594 Engine Idle Shutdown Driver Alert Mode 65252, SHUTDN 00 Broadcast KCAN, SCAN, BCAN

595 Cruise Control Active 65265, CCVS1 39 Broadcast KCAN, SCAN, BCAN

595 Cruise Control Active 65265, CCVS1 00 Broadcast KCAN, SCAN, BCAN

596 Cruise Control Enable Switch 65265, CCVS1 39 Broadcast KCAN, SCAN, BCAN

597 Brake Switch 65265, CCVS1 39 Broadcast KCAN, SCAN, BCAN

598 Clutch Switch 65265, CCVS1 39 Broadcast KCAN, SCAN, BCAN

599 Cruise Control Set Switch 65265, CCVS1 39 Broadcast KCAN, SCAN, BCAN

600 Cruise Control Coast (Decelerate) Switch 65265, CCVS1 39 Broadcast KCAN, SCAN, BCAN

601 Cruise Control Resume Switch 65265, CCVS1 39 Broadcast KCAN, SCAN, BCAN

602 Cruise Control Accelerate Switch 65265, CCVS1 39 Broadcast KCAN, SCAN, BCAN

606 Engine Momentary Overspeed Enable 61442, ETC1 03 Broadcast KCAN, SCAN, BCAN

607 Progressive Shift Disable 61442, ETC1 03 Broadcast KCAN, SCAN, BCAN

684 Requested % Clutch Slip

256, TC1 7, 33 03 (DA

specific) KCAN, SCAN, BCAN

695 Engine Override Control Mode

0, TSC1 7, 33 00 (DA

specific) KCAN, SCAN, BCAN

696 Engine Requested Speed Control Conditions

0, TSC1 7, 33 00 (DA

specific) KCAN, SCAN, BCAN

897 Override Control Mode Priority

0, TSC1 7, 33 00 (DA

specific) KCAN, SCAN, BCAN

898 Engine Requested Speed/Speed Limit

0, TSC1 7, 33 00 (DA

specific) KCAN, SCAN, BCAN

899 Engine Torque Mode 61444, EEC1 00 Broadcast KCAN, SCAN, BCAN

917 Total Vehicle Distance (High Resolution) 65217, VDHR 39 Broadcast KCAN, SCAN, BCAN

969 Remote Accelerator Enable Switch 61441, EBC1 00 Broadcast KCAN, SCAN, BCAN

970 Engine Auxiliary Shutdown Switch

61441, EBC1 7, 33,

160 Broadcast KCAN, SCAN, BCAN

974 Remote Accelerator Pedal Position 61443, EEC2 7, 33 Broadcast KCAN, SCAN, BCAN

974 Remote Accelerator Pedal Position 61443, EEC2 00 Broadcast KCAN, SCAN, BCAN

975 Engine Fan 1 Estimated Percent Speed 65213, FD1 00 Broadcast KCAN, SCAN, BCAN

976 PTO Governor State 65265, CCVS1 39 Broadcast KCAN, SCAN, BCAN

976 PTO Governor State 65265, CCVS1 00 Broadcast KCAN, SCAN, BCAN

976 PTO Governor State 65265, CCVS1 7, 33 Broadcast KCAN, SCAN, BCAN

977 Fan Drive State 65213, FD1 00 Broadcast KCAN, SCAN, BCAN

979 Engine Remote PTO Governor

Preprogrammed Speed Control Switch 65264, PTO 7, 33 Broadcast KCAN, SCAN, BCAN

979 Engine Remote PTO Governor

Preprogrammed Speed Control Switch 65264, PTO 00 Broadcast KCAN, SCAN, BCAN

980 Engine PTO Governor Enable Switch 65264, PTO 7, 33 Broadcast KCAN, SCAN, BCAN

980 Engine PTO Governor Enable Switch 65264, PTO 00 Broadcast KCAN, SCAN, BCAN

CAN COMMUNICATIONS

Peterbilt Motors Company 6-6

6 SPN CAN Signal Name PGN, Message Tx SA Rx SA CAN Bus

982 Engine PTO Governor Resume Switch 65264, PTO 7, 33 Broadcast KCAN, SCAN, BCAN

984 Engine PTO Governor Set Switch 65264, PTO 7, 33 Broadcast KCAN, SCAN, BCAN

985 A/C High Pressure Fan Switch 65252, SHUTDN 00 Broadcast KCAN, SCAN, BCAN

1028 Total Engine PTO Governor Fuel Used 65203, LFI1 00 Broadcast KCAN, SCAN, BCAN

1040 Total Fuel Used (Gaseous) 65199, GFC 00 Broadcast KCAN, SCAN, BCAN

1081 Engine Wait to Start Lamp 65252, SHUTDN 00 Broadcast KCAN, SCAN, BCAN

1087 Service Brake Circuit 1 Air Pressure 65198, AIR1 39 Broadcast KCAN, SCAN, BCAN

1087 Service Brake Circuit1 Air Pressure 65198, AIR1 11 Broadcast KCAN, SCAN, BCAN

1087 Service Brake Circuit1 Air Pressure 65198, AIR1 48 Broadcast KCAN, SCAN, BCAN

1088 Service Brake Circuit 2 Air Pressure 65198, AIR1 39 Broadcast KCAN, SCAN, BCAN

1090 Air Suspension Supply Pressure 1 65198, AIR1 23 Broadcast KCAN, SCAN, BCAN

1107 Engine Protection System Timer State 65252, SHUTDN 00 Broadcast KCAN, SCAN, BCAN

1108 Engine Protection System Timer Override 65252, SHUTDN 00 Broadcast KCAN, SCAN, BCAN

1109 Engine Protection System Approaching

Shutdown 65252, SHUTDN 00 Broadcast KCAN, SCAN, BCAN

1110 Engine Protection System Approaching

Shutdown 65252, SHUTDN 00 Broadcast KCAN, SCAN, BCAN

1111 Engine Protection System Configuration 65252, SHUTDN 00 Broadcast KCAN, SCAN, BCAN

1172 Engine Turbocharger1 Compressor Intake

Temperature 65178, TCI2 00 Broadcast KCAN, SCAN, BCAN

1184 Engine Turbocharger1 Turbine Outlet

Temperature TCI5, 65175 00 Broadcast KCAN, SCAN, BCAN

1214 Suspect Parameter Number 65226, DM1 39 Broadcast KCAN, SCAN

1215 Failure Mode Identifier 65226, DM1 39 Broadcast KCAN, SCAN

1216 Occurrence Count 65226, DM1 39 Broadcast KCAN, SCAN

1437 Road Speed Limit Status 61443, EEC2 00 Broadcast KCAN, SCAN, BCAN

1482 Source Address of Controlling Device for

Transmission Control 61442, ETC1 03 Broadcast KCAN, SCAN, BCAN

1483 Source Address of Controlling Device for

Engine Control 61444, EEC1 00 Broadcast KCAN, SCAN, BCAN

1487 Illumination Brightness Percent

53248, CL 39 74 (DA

specific) KCAN, SCAN

1639 Fan Speed 65213, FD1 00 Broadcast KCAN, SCAN, BCAN

1675 Engine Starter Mode 61444, EEC1 00 Broadcast KCAN, SCAN, BCAN

1706 SPN Conversion Method 65226, DM1 39 Broadcast KCAN, SCAN

1761 Aftertreatment 1 Diesel Exhaust Fluid Tank

Volume 65110, AT1T1I1 00 Broadcast KCAN, SCAN, BCAN

1807 Steering Wheel Angle 61449, VDC2 11, 62 Broadcast KCAN, SCAN, BCAN

1854 TransMode3

256, TC1 7, 33 03 (DA

specific) KCAN, SCAN, BCAN

1856 Seat Belt Switch

57344, CM1 39 255 (DA

specific) KCAN, SCAN

2347 High Beam Head Light Command 65089, LCMD 39 Broadcast KCAN, SCAN, BCAN

2347 High Beam Head Light Command

65089, LCMD 7, 33,

160 Broadcast KCAN, SCAN, BCAN

CAN COMMUNICATIONS

Peterbilt Motors Company 6-7

6 SPN CAN Signal Name PGN, Message Tx SA Rx SA CAN Bus

2349 Low Beam Head Light Command 65089, LCMD 39 Broadcast KCAN, SCAN, BCAN

2349 Low Beam Head Light Command

65089, LCMD 7, 33,

160 Broadcast KCAN, SCAN, BCAN

2367 Left Turn Signal Lights Command 65089, LCMD 39 Broadcast KCAN, SCAN, BCAN

2367 Left Turn Signal Lights Command

65089, LCMD 7, 33,

160 Broadcast KCAN, SCAN, BCAN

2369 Right Turn Signal Lights Command 65089, LCMD 39 Broadcast KCAN, SCAN, BCAN

2369 Right Turn Signal Lights Command

65089, LCMD 7, 33,

160 Broadcast KCAN, SCAN, BCAN

2371 Left Stop Light Command 65089, LCMD 39 Broadcast KCAN, SCAN, BCAN

2371 Left Stop Light Command

65089, LCMD 7, 33,

160 Broadcast KCAN, SCAN, BCAN

2373 Right Stop Light Command 65089, LCMD 39 Broadcast KCAN, SCAN, BCAN

2373 Right Stop Light Command

65089, LCMD 7, 33,

160 Broadcast KCAN, SCAN, BCAN

2385 Rotating Beacon Light Command 65089, LCMD 39 Broadcast KCAN, SCAN, BCAN

2385 Rotating Beacon Light Command

65089, LCMD 7, 33,

160 Broadcast KCAN, SCAN, BCAN

2387 Tractor Front Fog Lights Command 65089, LCMD 39 Broadcast KCAN, SCAN, BCAN

2387 Tractor Front Fog Lights Command

65089, LCMD 7, 33,

160 Broadcast KCAN, SCAN, BCAN

2391 Back Up Light and Alarm Horn Command 65089, LCMD 39 Broadcast KCAN, SCAN, BCAN

2391 Back Up Light and Alarm Horn Command

65089, LCMD 7, 33,

160 Broadcast KCAN, SCAN, BCAN

2403 Running Light Command 65089, LCMD 39 Broadcast KCAN, SCAN, BCAN

2403 Running Light Command

65089, LCMD 7, 33,

160 Broadcast KCAN, SCAN, BCAN

2432 Engine Demand Percent Torque 61444, EEC1 00 Broadcast KCAN, SCAN, BCAN

2538 TransMode3Indicator 65098, ETC7 03 Broadcast KCAN, SCAN, BCAN

2540 Parameter Group Number (RQST)

59904, RQST 251 255 (DA

specific) KCAN, SCAN

2540 Parameter Group Number (RQST)

59904, RQST 7, 33,

160

00 (DA

specific) KCAN, SCAN, BCAN

2609 Cab A/C Refrigerant Compressor Outlet

Pressure 64993, CACI 25 Broadcast KCAN, SCAN, BCAN

2641 Horn Switch

64980, CM3 7, 33,

160 Broadcast KCAN, SCAN, BCAN

2863 Front Operator Wiper Switch 64973, OWW 39 Broadcast KCAN, SCAN, BCAN

2873 Work Light Switch 64972, OEL 39 Broadcast KCAN, SCAN, BCAN

2873 Work Light Switch

64972, OEL 7, 33,

160 Broadcast KCAN, SCAN, BCAN

2875 Hazard Light Switch

64972, OEL 7, 33,

160 Broadcast KCAN, SCAN, BCAN

2876 Turn Signal Switch 64972, OEL 39 Broadcast KCAN, SCAN

2979 Vehicle Acceleration Rate Limit Status 61443, EEC2 39 Broadcast KCAN, SCAN, BCAN

2979 Vehicle Acceleration Rate Limit Status 61443, EEC2 00 Broadcast KCAN, SCAN, BCAN

CAN COMMUNICATIONS

Peterbilt Motors Company 6-8

6

SPN CAN Signal Name PGN, Message Tx SA Rx SA CAN Bus

3026 Transmission Oil Level 1 Measurement

Status 65272, TRF1 03 Broadcast KCAN, SCAN, BCAN

3027 Transmission Oil Level 1 High / Low 65272, TRF1 03 Broadcast KCAN, SCAN, BCAN

3028 Transmission Oil Level 1 Countdown Timer 65272, TRF1 03 Broadcast KCAN, SCAN, BCAN

3031 Aftertreatment 1 Diesel Exhaust Fluid Tank

Temperature 1 65110, AT1T1I1 00 Broadcast KCAN, SCAN, BCAN

3246 Aftertreatment 1 Diesel Particulate Filter

Outlet Temperature 64947, AT1OG2 00 Broadcast KCAN, SCAN, BCAN

3349 TSC1 Transmission Rate

0, TSC1 7, 33 00 (DA

specific) KCAN, SCAN, BCAN

3350 TSC1 Control Purpose

0, TSC1 7, 33 00 (DA

specific) KCAN, SCAN, BCAN

3357 Actual Maximum Available Engine - Percent

Torque 61443, EEC2 00 Broadcast KCAN, SCAN, BCAN

3363 Aftertreatment 1 Diesel Exhaust Fluid Tank

Heater 65110, AT1T1I1 00 Broadcast KCAN, SCAN, BCAN

3447 Remote PTO Governor Preprogrammed

Speed Control Switch #2 65264, PTO 7, 33 Broadcast KCAN, SCAN, BCAN

3462 Engagement Status 64932, PTODE 7, 33 Broadcast KCAN

3462 Engagement Status

64932, PTODE 7, 33 03 (DA

specific) SCAN, BCAN

3543 Engine Operating State 64914, EOI 00 Broadcast KCAN, SCAN, BCAN

3606 Engine Controlled Shutdown Request 64914, EOI 00 Broadcast KCAN, SCAN, BCAN

3607 Engine Emergency (Immediate) Shutdown

Indication 64914, EOI 00 Broadcast KCAN, SCAN, BCAN

3609 Aftertreatment 1 Diesel Particulate Filter

Intake Pressure 64908, AT1GP 00

Broadcast

(255) KCAN, SCAN, BCAN

3610 Aftertreatment 1 Diesel Particulate Filter

Outlet Pressure 64908, AT1GP 00 Broadcast KCAN, SCAN, BCAN

3673 Engine Throttle Valve2 Position 65266, LFE1 00 Broadcast KCAN, SCAN, BCAN

3695 Aftertreatment Regeneration Inhibit Switch

57344, CM1 7, 33,

160

255 (DA

specific) KCAN, SCAN, BCAN

3695 Aftertreatment Regeneration Inhibit Switch

57344, CM1 39 255 (DA

specific) KCAN, SCAN, BCAN

3696 Aftertreatment Regeneration Force Switch

57344, CM1 7, 33,

160

255 (DA

specific) KCAN, SCAN, BCAN

3696 Aftertreatment Regeneration Force Switch

57344, CM1 00 255 (DA

specific) KCAN, SCAN, BCAN

3696 Force Regen

57344, CM1 39 255 (DA

specific) KCAN, SCAN, BCAN

3697 Diesel Particulate Filter Lamp Command 64892, DPFC1 00 Broadcast KCAN, SCAN, BCAN

3698 Exhaust System High Temperature Lamp

Command 64892, DPFC1 00 Broadcast KCAN, SCAN, BCAN

3700 Aftertreatment Diesel Particulate Filter

Active Regeneration Status 64892, DPFC1 00 Broadcast KCAN, SCAN, BCAN

3701

Aftertreatment Diesel Particulate Filter

Status

64892, DPFC1 00 Broadcast KCAN, SCAN, BCAN

CAN COMMUNICATIONS

Peterbilt Motors Company 6-9

6 SPN CAN Signal Name PGN, Message Tx SA Rx SA CAN Bus

3702 Diesel Particulate Filter Active Regeneration

Inhibited Status 64892, DPFC1 00 Broadcast KCAN, SCAN, BCAN

3703 Diesel Particulate Filter Active Regeneration

Inhibited Due to Inhibit Switch 64892, DPFC1 00 Broadcast KCAN, SCAN, BCAN

3704 Diesel Particulate Filter Active Regeneration

Inhibited Due to Clutch Disengaged 64892, DPFC1 00 Broadcast KCAN, SCAN, BCAN

3705 Diesel Particulate Filter Active Regeneration

Inhibited Due to Service Brake Active 64892, DPFC1 00 Broadcast KCAN, SCAN, BCAN

3706 Diesel Particulate Filter Active Regeneration

Inhibited Due to PTO Active 64892, DPFC1 00 Broadcast KCAN, SCAN, BCAN

3707 Diesel Particulate Filter Active Regeneration

Inhibited Due to Accelerator Pedal Off Idle 64892, DPFC1 00 Broadcast KCAN, SCAN, BCAN

3708 Diesel Particulate Filter Active Regeneration

Inhibited Due to Out of Neutral 64892, DPFC1 00 Broadcast KCAN, SCAN, BCAN

3709 Diesel Particulate Filter Active Regeneration

Inhibited Due to Vehicle Speed Above

Allowed Speed

64892, DPFC1 00 Broadcast KCAN, SCAN, BCAN

3710 Diesel Particulate Filter Active Regeneration

Inhibited Due to Parking Brake Not Set 64892, DPFC1 00 Broadcast KCAN, SCAN, BCAN

3711 Diesel Particulate Filter Active Regeneration

Inhibited Due to Low Exhaust Temperature 64892, DPFC1 00 Broadcast KCAN, SCAN, BCAN

3712 Diesel Particulate Filter Active Regeneration

Inhibited Due to System Fault Active 64892, DPFC1 00 Broadcast KCAN, SCAN, BCAN

3713 Diesel Particulate Filter Active Regeneration

Inhibited Due to System Timeout 64892, DPFC1 00 Broadcast KCAN, SCAN, BCAN

3716 Diesel Particulate Filter Active Regeneration

Inhibited Due to Engine Not Warmed Up 64892, DPFC1 00 Broadcast KCAN, SCAN, BCAN

3717 Diesel Particulate Filter Active Regeneration

Inhibited Due to Vehicle Speed Below

Allowed Speed

64892, DPFC1 00 Broadcast KCAN, SCAN, BCAN

3718 Diesel Particulate Filter Automatic Active

Regeneration Initiation Configuration 64892, DPFC1 00 Broadcast KCAN, SCAN, BCAN

3719 Aftertreatment 1 Diesel Particulate Filter

Soot Load Percent 64891, AT1S1 00 Broadcast KCAN, SCAN, BCAN

3721 Aftertreatment 1 Diesel Particulate Filter

Time Since Last Active Regeneration 64891, AT1S1 00 Broadcast KCAN, SCAN, BCAN

3948 At least one PTO engaged 64932, PTODE 39 Broadcast KCAN, SCAN, BCAN

4154 Actual Engine - Percent Torque (Fractional) 61444, EEC1 00 Broadcast KCAN, SCAN, BCAN

4175 Diesel Particulate Filter Active Regeneration

Forced Status 64892, DPFC1 00 Broadcast KCAN, SCAN, BCAN

4191 Engine Requested Torque (Fractional)

0, TSC1 7, 33 00 (DA

specific) KCAN, SCAN, BCAN

4206 Message Counter

0, TSC1 7, 33 00 (DA

specific) KCAN, SCAN, BCAN

4207 Message Checksum

0, TSC1 7, 33 00 (DA

specific) KCAN, SCAN, BCAN

4765 Aftertreatment 1 Diesel Oxidation Catalyst

Intake Temperature 64800, A1DOC1 00 Broadcast KCAN, SCAN, BCAN

CAN COMMUNICATIONS

Peterbilt Motors Company 6-10

6 SPN CAN Signal Name PGN, Message Tx SA Rx SA CAN Bus

4816 Transmission Torque Converter Lockup

Transition in Process 61442, ETC1 03 Broadcast KCAN, SCAN, BCAN

5078 Engine Amber Warning Lamp Command 64775, DLCC1 00 Broadcast KCAN, SCAN, BCAN

5079 Engine Red Stop Lamp Command 64775, DLCC1 00 Broadcast KCAN, SCAN, BCAN

5082 Engine Oil Pressure Low Lamp Command 64775, DLCC1 00 Broadcast KCAN, SCAN, BCAN

5083 Engine Coolant Temperature High Lamp

Command 64775, DLCC1 00 Broadcast KCAN, SCAN, BCAN

5084 Engine Coolant Level Low Lamp Command 64775, DLCC1 00 Broadcast KCAN, SCAN, BCAN

5086 Engine Air Filter Restriction Lamp Command 64775, DLCC1 23 Broadcast KCAN, SCAN, BCAN

5087 Vehicle Battery Voltage Low Lamp

Command 64774, DLCC2 23 Broadcast KCAN, SCAN, BCAN

5088 Vehicle Fuel Level Low Lamp Command 64774, DLCC2 23 Broadcast KCAN, SCAN, BCAN

5245 Aftertreatment Diesel Exhaust Fluid Tank

Low Level Indicator 65110, AT1T1I1 00 Broadcast KCAN, SCAN, BCAN

5246 Aftertreatment SCR Operator Inducement

Severity 65110, AT1T1I1 00 Broadcast KCAN, SCAN, BCAN

5398 Estimated Pumping - Percent Torque 61443, EEC2 00 Broadcast KCAN, SCAN, BCAN

5399 DPF Thermal Management Active 61443, EEC2 00 Broadcast KCAN, SCAN, BCAN

5400 SCR Thermal Management Active 61443, EEC2 00 Broadcast KCAN, SCAN, BCAN

5466 Aftertreatment 1 Diesel Particulate Filter

Soot Load Regeneration Threshold 64891, AT1S1 00 Broadcast KCAN, SCAN, BCAN

5676 Forward Collision Advanced Emergency

Braking System State 61487, AEBS1 42 Broadcast KCAN, SCAN

5825 Driver Warning System Indicator Status 65279, OI 00 Broadcast KCAN, SCAN, BCAN

8484 Demanded Brake Application Pressure 61712, B2 39 Broadcast KCAN, SCAN, BCAN

12308 Headlamp Emergency Flash Switch 64972, OEL 7, 33 Broadcast SCAN

12308 Headlamp Emergency Flash Switch 64972, OEL 7, 33 Broadcast KCAN

12308 Headlamp Emergency Flash Switch 64972, OEL 7, 33 Broadcast BCAN

12964 Auxiliary Lamp Group Switch 64972, OEL 39 Broadcast KCAN, SCAN, BCAN

12964 Auxiliary Lamp Group Switch

64872, OEL 7, 33,

160 Broadcast KCAN, SCAN, BCAN

13105 Engine Oil Temperature High Lamp

Command 64775, DLCC1 23 Broadcast KCAN, SCAN, BCAN

13108 Primary Air Pressure Low Lamp Command 64774, DLCC2 23 Broadcast KCAN, SCAN, BCAN

13109 Secondary Air Pressure Low Lamp Command 64774, DLCC2 23 Broadcast KCAN, SCAN, BCAN

13116 Transmission Oil Temperature High Lamp

Command 64775, DLCC1 23 Broadcast KCAN, SCAN, BCAN

13132 Air Suspension Supply Pressure 2 64195, AIR3 23 Broadcast KCAN, SCAN, BCAN

Peterbilt Motors Company 7-1

SECTION 7 ELECTRICAL INTRODUCTION This section is written to provide information to the body builder when installing equipment into vehicles built with multiplexed instrumentation. The technology presented by VECU level instrumentation integrates J-1939 CAN data communications between controllers and equipment on the vehicle. This section is intended to address how to work in aftermarket equipment while still maintaining full functionality of the OEM vehicle. These topics apply to 2.1M medium duty chassis built with a Vehicle Electronic Control Unit (VECU). The electrical architecture for these trucks will be named VMUX, which replaces NAMUX3. This system integrates a parallel control unit to manage outbound messages via a faster baud rate 500kbps and FCAN signals for the chassis module(s). Since the F- CAN has moved to the VECU, the VCAN is divided into VCAN1 and VCAN2. The second CAN is dedicated to OBD communication. The most important advancement of electrical instrumentation is the implementation of the VECU controller. While it is still possible to wire completely outside of the VECU system, utilizing the VECU functions will make a cleaner installation and will maintain OEM functionality. VECU expands controls to air operated devices by receiving input from dash switches, remote (aftermarket) switches, sensors mounted to the aftermarket equipment and other vehicle parameters (engine speed, transmission status etc.) With the proper programming, the VECU will then process the inputs and will create a J- 1939 Data instruction, which is communicated to another controller outside the cab called the Chassis Module. This chassis module receives the instruction and communicates the information to the air solenoid bank. Then 12V power will open the solenoid and supply air pressure to the specified air circuit. The chassis module can also supply voltage to other systems on the chassis.

ELECTRICAL ACRONYM LIBRARY

Acronym Definition

CAN Controller Area Network

DTC Diagnostics Trouble Code

ECM Engine Control Module

ECU Electrical Control Unit

EOA Electric Over Air

EOH Electric Over Hydraulic

J-1939 SAE CAN Communication Standard

LIN Local Interconnect Network

MSB Master Solenoid Bank

MSM Master Switch Module

MUX Multiplex Switch

OBD On Board Diagnostics

OEM Original Equipment Manufacturer

PCC Predictive Cruise Control

PDC Power Distribution Center

PGN Parameter Group Number

PTO Power Take Off

RP1226 TMS Messaging Standard

SPN Suspect Parameter Number

TCM Transmission Control Module

VECU Vehicle Electronic Control Unit

ELECTRICAL

Peterbilt Motors Company 7-2

7 ELECTRICAL WIRING CIRCUIT CODES The wire system uses 10 different colors and only one striped wire color. Each wire has a minimum of seven characters, with the first three characters as the wire color. The remaining four characters are related to the wire services. The colors determine the circuits function as follows:

ELECTRICAL WIRE CIRCUIT CODE TABLES

Number Category

XXX0000 through XXX0999 General

XXX1000 through XXX1999 Power Supply

XXX2000 through XXX2999 Lighting

XXX3000 through XXX3999 Powertrain

XXX4000 through XXX4999 Instrumentation

XXX5000 through XXX5999 Safety systems

XXX6000 through XXX6999 Convenience, Security

XXX7000 through XXX7999 HVAC

XXX8000 through XXX8999 Undefined

XXX9000 through XXX9999 Trailer/Body Connections

ELECTRICAL

Peterbilt Motors Company 7-3

7 MULTIPLEX SYSTEM The VECU electrical architecture uses a multiplexing system. Multiplexing can be defined as the process of sending multiple digital signals on the same shared medium at the same time. These signals are introduced into the multiplexing system through data connection points, which are defined by J1939 backbone.

CAN BUS SYSTEM OVERVIEW

CAN BUS SPEEDS AND CIRCUIT DESIGNATION

J1939-14 (500KBPS): J1939-15 (250KBPS):

B-CAN 0813 Body Builder T-CAN 0828 Transmission

C-CAN 0821 Cab K-CAN 0829 Telematics and Remote PTO

D-CAN 0822 Diagnostics

F-CAN 0819 Frame

G-CAN 0825 Bendix ACB Antenna S-CAN 0827 Radio and PACCAR Display V-CAN1 0812 Vehicle1 V-CAN2 0823 Vehicle2

ELECTRICAL

Peterbilt Motors Company 7-4

7 ELECTRICAL COMPONENT OVERVIEW

ELECTRICAL

Peterbilt Motors Company 7-5

7

ELECTRICAL HARNESS OVERVIEW

ELECTRICAL

Peterbilt Motors Company 7-6

7

IN CAB CAN BASED MESSAGING CONNECTOR

RP1226 CONNECTOR

The RP1226 connector is located on the left hand side of the steering wheel behind the dash near the OBD connector. The RP1226 connector can be used for after-market telematics, ELD, body controls, and PTO controls. There will be multiple bus speeds available, K-CAN for 250kbps and S-CAN for 500 kbps. The RP1226 provides defined messages and major telematics supplier data for customer use.

Pin Description

1 PROTECTED POWER

2 J1939 S-CAN (+)

4 J1939 K-CAN (+)

7 IGNITION POWER

8 GROUND

9 J1939 S-CAN (-)

11 J1939 K-CAN (-)

ELECTRICAL

Peterbilt Motors Company 7-7

7 BODY CONNECTION POINTS MAIN CHASSIS HARNESS

ISOMETRIC VIEW

SIDE VIEW

ELECTRICAL

Peterbilt Motors Company 7-8

7 FRONT PORTION VIEW

DETAIL VIEW OF ENGINE COMPARTMENT BODY CONNECTORS

ELECTRICAL

Peterbilt Motors Company 7-9

7 DETAIL VIEW OF ENGINE COMPARTMENT BODY CONNECTORS CONTINUED

REAR PORTION VIEW

ELECTRICAL

Peterbilt Motors Company 7-10

7 DETAIL VIEW OF BOC AND EOF BODY CONNECTORS

DETAIL VIEW OF BOC AND EOF BODY CONNECTORS CONTINUED

ELECTRICAL

Peterbilt Motors Company 7-11

7

ELECTRIC ENGAGED EQUIPMENT At the left hand forward cab mount, P198 is available for PTO controls that are electrically engaged via ground.

RP170 CONNECTOR

The RP170 connector provides various pins for vehicle and trailer lamps. The connector will be located in the frame rail right behind the BOC crossmember.

Pin Description

1 FIREWALL GROUND

2 BACKUP LIGHTS

3 LH TURN/STOP

4 TRAILER LH TURN

5 TRAILER MARKER LAMP RELAY

6 PARK LAMPS

7 TRAILER STOP LAMPS

8 NOT USED

9 NOT USED

10 NOT USED

11 NOT USED

12 NOT USED

13 RH TURN/STOP

14 TRAILER RH TURN

Pin Description

1 VEHICLE GROUND

2 #1 PTO ON/OFF

3 PTO PUMP MODE SIGNAL

4 #2 PTO ON/OFF

ELECTRICAL

Peterbilt Motors Company 7-12

7 ENGINE HARNESS 12 PIN CONNECTOR Chassis must be ordered with the appropriate option to have a 12 pin connector on the engine harness. The Body IGN signal was moved off the engine harness connector, so the Chassis Harness will include the PTO layer to insert the Body IGN signal back into the 12-way connector. Signals that feed directly to the engine ECM typically will be active low signals. Connect pins 3 and 5 for simple PTO ON/OFF signal. For Remote throttle bump, you must connect pins 3 & 6. Having a momentary switch to signal ground on pins 2 and 1 will then increase/decrease engine speed. Engine speed will depend on how engine is programmed. Unless otherwise specified, engine is set by default for incremental speed increase. Full remote throttle control can be achieved with a twisted triple to pin 4, 10, and 11.

Pin Description

1 INPUT FOR REMOTE PTO RESUME (Active Low)

2 INPUT FOR REMOTE PTO SET (Active Low)

3 SWITCH RETURN FOR CUMMINS ENGINE

4 INPUT FOR REMOTE THROTTLE SENSOR CIRCUIT (TWISTED TRIPLE)

5 PTO ENGAGED SIGNAL (LOW = ENGAGED)

6 CRUISE ON/OFF (Active Low)

7 +12V 10A BODY IGN FUSE C_A6

8 VEHICLE GROUND

9 TORQUE LIMIT INPUT (Active Low)

10 PWR SUPPLY +5V (TWISTED TRIPLE)

11 ANALOG RETURN (TWISTED TRIPLE)

12 REMOTE ACCELERATOR ENABLE

ELECTRICAL

Peterbilt Motors Company 7-13

7 ENGINE HARNESS CONNECTION LOCATIONS

PX7 Connection location

PX9 Connection location

ELECTRICAL

Peterbilt Motors Company 7-14

7

B6.7N Connection location

L9N Connection location

ELECTRICAL

Peterbilt Motors Company 7-15

7

POWER DISTRIBUTION CENTER

ENGINE SIDE

ELECTRICAL

Peterbilt Motors Company 7-16

7

DASH SIDE

ELECTRICAL

Peterbilt Motors Company 7-17

7 ENGINE SIDE FUSE BOX FULL CONTENT POPULATION

ELECTRICAL

Peterbilt Motors Company 7-18

7

DASH SIDE FUSE BOX FULL CONTENT POPULATION

ELECTRICAL

Peterbilt Motors Company 7-19

7 CHASSIS MODULE Chassis modules are replacing the legacy NAMUX3 chassis node. Chassis modules are slave I/O drivers controlled by the VECU. Chassis modules have expanded functionality and option platform growth in comparison to the previous chassis node. Chassis modules have built-in protections to prevent internal damage, are capable of detecting faults, and storing DTCs. Chassis modules can also be diagnosed through the DAVIE service tool.

There are three variants of chassis module: the Primary (CMP), Primary LITE (CMLITE), and Secondary (CMS). Depending on how the truck is ordered, a CMP or CMLITE will be installed. Like the heavy duty variant, certain options would require medium duty trucks to have a CMS installed in addition to a CMP or CMLITE. MD trucks will have a maximum of two chassis modules installed, depending on order configuration. The primary chassis module will be mounted under the back of the cab on the top left hand side of the back of cab cross-member. The secondary optional chassis module will be bracket mounted inside the LH frame rail a few feet behind BOC.

CHASSIS MODULE LOCATIONS

TOP VIEW OF CHASSIS MODULE LOCATIONS

Primary Secondary

ELECTRICAL

Peterbilt Motors Company 7-20

7 CHASSIS MODULE FUNCTION DESIGNATIONS

PRIMARY AND PRIMARY LITE CHASSIS MODULE

Exterior Lighting: Headlamps, Park/Tail, Turn, Brake, DRL, Fog Lights*, Reverse etc.

Axle Temperature Sensor Inputs* Front Rear and Rear

Ammeter Sensor Input

Secondary Kingpin Release Solenoid Control

Primary/Secondary Fuel Level Sensors

Lift Axle Air Solenoid Controls 1st, 2nd

Primary Transmission Neutral Position Switch

Remote PTO/Throttle Control Inputs

J-CAN Multiplexed EOA Solenoid Bank Control

Fuel Filter Gauges

Main Transmission Oil Temp

* = Functionality is depopulated on CMLITE Module

SECONDARY CHASSIS MODULE

External Notification of DPF Regeneration

AT1202 Aux Trans Neutral Switch

Axle Temperature Gauges Center Rear

Lift Axle Air Solenoid Controls 3rd , Tag (Rocker Panel Controls)

NAMCO/FABCO Split shaft PTO/Transfer Case Sensors

Aux Transmission Temperature Sensor

Split Shaft PTO Temperature Sensor

Fuel Temp Sensor (Auto Start)

Chicken/Panel Lamps, Snow Plow Lamp

ISO 3731 Spare Outputs

B-CAN

Auto Start/Stop Hood Tilt Switch

City Horn

ELECTRICAL

Peterbilt Motors Company 7-21

7 FUSE GROUPS

PRIMARY CHASSIS MODULE

Fuse Group Function

F1

Electric Over Air Solenoid Kingpin Release

Main Beam (aka High Beam) - LH

Tractor Direction Indication and Hazard Lights - RH Rear (Brake Lamps Also)

F2

Tractor Direction Indication/Hazard/DRL Lights - LH Front

Front Tractor Position lights (Park Lamps)

Tractor Direction Indication Hazard Side Turn Indicator LH Front

Dipped Beam (aka Low Beam) - LH

F3

Lift Axle #2 Solenoid

Daytime Running Lights (DRL) Peterbilt - LH

Tractor Direction Indication/Hazard/DRL Lights - RH Front

Tractor Direction Indication Hazard Side Turn Indicator RH Front

Dipped Beam (aka Low Beam) - RH

F4

Daytime Running Lights (DRL) Peterbilt - RH

Main Beam (aka High Beam) - RH

Fog/Driving Lights (Front) 1st Set

F5 Reverse Warning (aka Backup Alarm)

(Rear) Direction Indication and Hazard Lights - LH Trailer

F6

Rear Tractor Position lights (Park Lamps)

Reverse Lamps

Tractor Direction Indication and Hazard Lights LH Rear (Brake Lamps Also)

F7

LVD Bipolar Output 1

LVD Bipolar Output 2

Lift Axle #1 Solenoid

(Rear) Direction Indication and Hazard Lights - RH Trailer

SECONDARY CHASSIS MODULE

Fuse Group Function

F1 Work Lights 1st Set (Frame mounted Flood Light Options without pass-through grommet)

F2 Aftertreatment External Notification

F3 Sky/Auxiliary lights

Snowplow Lamps OR Dual Station

F4 Lift Axle #3 Solenoid

Trailer Options - ISO 3731/Spare OR Additional 4/6/7-Way Trailer Connections OR Berg Box

F5 Lift Axle #4 (Tag) Solenoid

Trailer Options - ISO 3731/Spare OR Additional 4/6/7-Way Trailer Connections OR Berg Box

F6 Trailer Options - Trailer Dump Gate Coiled BOC OR Configurable Output

Trailer Options - ISO 3731/Spare OR Additional 4/6/7-Way Trailer Connections OR Berg Box

ELECTRICAL

Peterbilt Motors Company 7-22

7 VECU

Fuse Group Function

G1

Peterbilt Driving Lights

Inside/Outside Air Filter Control

Starter Interrupt / Start Enable Relay Control

Mirror Heat Relay

Cab Dome Lamp

Sleeper Dome Lamp

Trailer Marker/Clearance Lamps

G2

Recirculating Header Fan - Low Speed

Trailer Hotline Relay

Work Lights (Flood Lamps) 2

Work Lights (Flood Lamps) 3

Allison MTD PTO Controls - PTO 2

Allison MTD PTO Controls - PTO 1

Passenger Spot Lamp

Work Lights (Flood Lamps) 1

Beacon/Strobe

Trailer Brake Lamps

Trailer/Cab Park Lamps

Recirculating Header Fan - High Speed

Digital Vision System Mirrors (DVS-M)

Start Signal

Right Hand Steer

LED Headlamps Heater

PTO Engaged Output for PTO Hour Meter and PTO Telltale

Footwell Lamp

G3

Cab Marker/Clearance Lamps Relay Output

Washer Pump Control

Auxiliary Lamps/ Chicken Panel Lamps

MCS (Power)

G4 Dash PWM Backlighting

Dash Illumination 2

ELECTRICAL

Peterbilt Motors Company 7-23

7

ELECTRIC OVER AIR SOLENOIDS Air solenoids are devices that translate the electrical signal into physical functions that controls the air pressure in various circuits. The air solenoids are mounted to a bracket outside the cab. The solenoids are designed to stack on each other so that they share a common air supply which reduces the amount of air lines on the vehicle. The aftermarket installer/final vehicle manufacturer needs to decide what type of valve to install and ensure that the documentation to the operator provides them with enough understanding of how the customized switches work.

SOLENOID BANK DIAGRAM

ELECTRICAL

Peterbilt Motors Company 7-24

7

SOLENOID OVERVIEW LAYOUT

MUX Solenoid Bank LITE MUX Solenoid Bank

ELECTRICAL

Peterbilt Motors Company 7-25

7

MUX SOLENOID BANK LITE FRAME MOUNTING LOCATION

MUX SOLENOID BANK FRAME MOUNTING LOCATION

Note: If the chassis has both a lite and full solenoid bank they will be mounted side-by-side in the RH rail.

ELECTRICAL

Peterbilt Motors Company 7-26

7 SWITCHES SWITCH OVERVIEW LAYOUT

Multiplexing = shorter wire bundles, improved diagnostics, and greater driver feedback. Safety critical switches use hybrid switch with hardwire for redundancy. The switches are less expensive with fewer wires behind the dash and on chassis. The switches are self-diagnosable to improve troubleshooting with DAVIE. Master Switch Module (MSM) LIN Communication to/from Switches CAN Communication to/from VECU

SPARE SWITCHES

Spare switches offer customers and body builders a convenient way to control power and air to various sources, like a body or trailer. They should be flexible and easily configurable to meet the vast and unique needs of body builders. The spare switches, along with all hybrid switch variants, are rated to 15 A of current.

ELECTRICAL

Peterbilt Motors Company 7-27

7 SWITCH RELEARN PROCESS

Switch replacement installation instructions:

1. Turn off the engine and all switches 2. Remove dash panel 3. Unplug LIN jumpers from the original existing switch 4. Remove original switch 5. Replace the old switch with the new switch 6. Reconnect LIN jumpers into the replacement switch 7. Reinstall the dash panel 8. Open DAVIE application 9. Select the Repair Support tab. 10. Select the Driver Environment tab 11. Select the Learn Dash Switches 12. Run Quick Check 13. Clear Inactive DTCs (Diagnostics trouble code) from MSM 14. Finished

New switch installation instructions:

1. Turn off the engine and put all switches into the off position 2. Remove the dash panels 3. Remove the switch blank 4. Add the new switch into the dash panel 5. Connect the LIN jumper between the last open switch to the newly installed switch

a. Part Number S92-1127-0125 6. Reinstall the dash panel 7. Open DAVIE application 8. Select the Repair Support tab. 9. Select the Driver Environment tab 10. Select the Learn Dash Switches 11. Run Quick Check 12. Clear Inactive DTCs (Diagnostics trouble code) on the MSM 13. Finished

ELECTRICAL

Peterbilt Motors Company 7-28

7

DAVIE Switch Relearn Screen View

SWITCH LOCATION Switches on the same LIN bus can be reordered in any configuration without the need to run a relearn process with DAVIE tool. Unlike the heavy duty dash, all MUX switches for 2.1M medium duty product are on B-Panel, which operates on LIN bus 2. Therefore, a switch relearn process is not required when moving previously learned switches amongst B- Panel. However, a relearn process is required when adding a new MUX switch that has not previously been learned. Push button switches on A-Panel operate on LIN bus 1 and are not compatible with Lin bus 2 (B-Panel) dash positions.

DASH LAYOUT

ELECTRICAL

Peterbilt Motors Company 7-29

7 GROUNDING

Grounding any post-OEM component/device/apparatus/etc. to the metal cab structure or frame is not acceptable. Failure to properly ground add-on components can result in vehicle damage and possibly bodily injury. Ground all post-OEM component/device/apparatus/etc. with combined current draw of less than 30A to the firewall ground buss bar with appropriately sized wire/cable for the load required.

Grounding Buss Bar Design

Grounding Point - Cab Interior Behind Drivers Side Kick Panel

Grounding Point - Cab Exterior LH Side of Firewall

Post OEM components/devices/apparatus/etc. with combined current draw in excess of 30A, ground must be attained from vehicle batteries directly with appropriately sized wire/cable for the load required.

ELECTRICAL

Peterbilt Motors Company 7-30

7 SPARE POWER Spare power connector P096 is located on lower left side of dash behind key switch or kick panel. The mating harness is available from PACCAR parts with pre-labeled pigtails, P92-8916-000000001. Any spare power requiring more than 20 amps must go directly to the battery box, not this spare circuit.

SPARE CIRCUIT CONNECTOR

Pin Spare Circuit No. Designation Fuse Max Rating

F ORN0731-9 Spare Ignition #2 Cab Side - 20A

C ORN0752-4 Spare Accessory #1 Cab Side - 20A

E ORN0731-8 Spare Ignition #1 Cab Side - 20A

B RED0712-5 Spare Battery #1 Cab Side - 20A

G ORN0791-4 Spare LVD #1 Cab Side - 20A

A RED0711-1 Spare Battery #2 Engine Side - 20A

ELECTRICAL

Peterbilt Motors Company 7-31

7 SPARE CIRCUIT LOCATION UNDER DASH P096

Spare circuit location on Power Distribution Center (Dash-Side, P001)

ELECTRICAL

Peterbilt Motors Company 7-32

7

Spare Circuits A & B Diagram (P096)

ELECTRICAL

Peterbilt Motors Company 7-33

7

Spare Circuits C, D, & E Diagram Note: For additional schematic information, please contact your local Peterbilt dealership for assistance.

ELECTRICAL

Peterbilt Motors Company 7-34

7 JUNCTION BOX The junction box provides access to lighting signals.

Junction Box BOC or EOF

ELECTRICAL

Peterbilt Motors Company 7-35

7 TRANSMISSION BACKUP SIGNALS The back-up signal can be accessed from pin D of the 6-way tail light connector located at the end of frame. The tail light connector is a 6-way connector located in the chassis harness at the end of frame. It will either be connected to a tail light, a jumper harness, or tied up in the rail if no tail lights are provided. Note: Back-up signal will also be available in the RP170 connection.

Mating Connector: Packard PN 12020786

SNOW PLOW LIGHTING When the optional switch and wiring for snowplow lights are ordered, the truck will include a switch on the dash to control the snowplow lights and a body builder connection at the front of the chassis, J168.

Pin Description

1 LOW BEAM LH

2 LOW BEAM RH

3 HIGH BEAM LH

4 HIGH BEAM LH

5 TURN INDICATOR LH

6 TURN INDICATOR RH

7 MARKER LAMPS

8 NOT USED

9 SNOWPLOW GROUND

10 SNOWPLOW GROUND

11 TURN INDICATOR, LH DRL

12 TURN INDICATOR, RH DRL

ELECTRICAL

Peterbilt Motors Company 7-36

7 LIFT AXLES (PUSHERS & TAG) All truck lift axles (pushers and tag), are direct wire Electric-Only. The wiring comes from the Primary Chassis Module or Secondary Chassis Module, and goes direct to the axle mounted solenoid. This is not from the EoA Solenoid Bank. The activation signal comes from either a dash mounted MUX switch, or a hardwired switch that is mounted outside of the cab. There are a total of four lift axle controls available; 3 pushers and 1 tag axle, or 4 pushers and no tag. These are controlled with separate switches by default, but it is possible to have a single switch control all axles if they are the same type. The customer can order the following configurations; steerable, non-steerable, with auto-reverse, and with park brake interlock. A lift axle comes with a control switch (single or separate), a gauge, and a regulator valve.

LIFT AXLE DIAGRAM

TRUCK LIFT AXLE LOGIC

Lift Axle Type Raise Condition Logic Lower Condition Logic

Steerable Lift Axle w/o Auto-Reverse - Lift Switch is Inactive OR - Park Brake Active OR - Trans in Reverse

- Lift Switch is Active AND - Park Brake Inactive AND - Trans Not in Reverse

Steerable Lift Axle with Auto-Reverse OR Non-Steerable Lift Axle w/o Park Brake

- Lift Switch is Inactive OR - Park Brake Active

- Lift Switch is Active AND - Park Brake Inactive

Non-Steerable Lift Axle with Park Brake - Lift Switch is Inactive AND - Park Brake Inactive

- Lift Switch is Active OR - Park Brake Active

ELECTRICAL

Peterbilt Motors Company 7-37

7 TRAILER LIFT AXLE Trailer lift axles can be either EoA or Electric-Only type. There are a total of two available EoA trailer lift axle controls using latching solenoids. If one axle is ordered, the customer will receive a switch labeled Trailer Lift Axle. If two axles are ordered, the customer can have a single switch that controls both axles or two switches. If two switches are present, they are labeled Forward Trailer Lift Axle and Rear Trailer Lift Axle.

DIGITAL DISPLAY

The standard display comes with a set of gauges. A limited number of additional gauges can be configured on the 7 digital display after the initial truck build using Paccar Vehicle Pro (PVP). Please contact your local Peterbilt dealership for assistance.

Gauges on the 7 Digital Display

ELECTRICAL

Peterbilt Motors Company 7-38

7 TELLTALE ICONS

Custom Telltales will no longer be available with a physical card inserted into the dash cluster. Instead, the body builder telltales will populate on the digital portion of the display from a limited list and can be reconfigured using PVP at your local Peterbilt dealership. The location of the telltale will be dependent on the configuration of the vehicle and what other telltales are present on the digital display.

Body Builder Telltale Positions The Digital Display is capable of receiving up to 5 hardwire inputs to trigger the body builder (editable) telltales on the 2.1 Medium Duty product with one editable telltale associated with an analog signal in the IP harness behind the cluster.

Body Builder Telltale Connections

Peterbilt Motors Company 8-1

SECTION 8 POWER TAKE-OFF (PTO)

INTRODUCTION A Power Take-Off (PTO) provides a way to divert some or all of the trucks engine power to another component. There are a wide variety of PTO options available.

PTO ACRONYM LIBRARY

Acronym Definition Acronym Definition

ABS Anti-Lock Braking System PCC Predictive Cruise Control

CAN Controller Area Network PDC Power Distribution Center

CC Cruise Control PGN Parameter Group Number

DEF Diesel Exhaust Fluid PMC PTO Mode Control

DTC Diagnostics Trouble Code PSC PTO Speed Control

ECM Engine Control Module PTO Power Take Off

ECU Electrical Control Unit PVP PACCAR Vehicle Pro

EIST Engine Idle Shutdown Timer RP1226 TMS Messaging Standard

EOA Electric Over Air SCM Standard Control Module

EOH Electric Over Hydraulic SCR Selective Catalyst Reduction

FIC Fast Idle Control SPN Suspect Parameter Number

J-1939 SAE CAN Communication Standard

TCM Transmission Control Module

LIN Local Interconnect Network TSC1 Torque Speed Control (request)

MSB Master Solenoid Bank VECU Vehicle Electrical Control Unit

MSM Master Switch Module

MUX Multiplex

OBD On Board Diagnostics

OCM Optional Control Module

OEM Original Equipment Manufacture

POWER TAKE-OFF (PTO)

Peterbilt Motors Company 8-2

8 TRANSMISSION MOUNTED PTO

MANUAL TRANSMISSIONS This is the most common type of PTO that is used. On a manual transmission, there are two locations for PTOs. On medium duty, transmissions there are 6 bolt PTO locations on the right and left. On heavy duty manual transmissions there is a 6 bolt PTO on the right and an 8 bolt PTO on the bottom left. There are also some options for a thru shaft or extended countershaft PTO. On a thru shaft PTO, the counter shaft extends out through the back of the transmission, which can be used to power a PTO. When using a thru shaft PTO the vehicle must be specd with the correct option, as not all transmissions will be set up for use with thru shaft PTOs. For more information go to www.roadranger.com and enter PTO Installation Guide in the search bar in the upper right corner.

MD Manual Transmission

MD Automated (10-Speed)

POWER TAKE-OFF (PTO)

Peterbilt Motors Company 8-3

8 AUTOMATIC TRANSMISSIONS - ALLISON On Allison transmissions there are two locations for PTOs. The Allison 4000 series has PTO locations at 1 and 8 oclock viewed from the back of the transmission. The 4000HS transmissions do not have any PTO locations. The 3000 series Allison transmissions have PTO locations at 4 and 8 oclock. For more information on using PTOs 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 clearance issues with other components on the truck. With manual transmissions, a 6- bolt PTO on the right will typically clear most components when the DPF and SCR are under the cab. This is also true when 30 and 45 degree adapters are used. On Allison 4000 series transmissions, most PTOs will fit in the 1 oclock position without interfering with the cab. If a wet kit is used here, the dipstick housing will most likely need to be modified as it runs over the top of the transmission to the driver side of the vehicle. The PTO in the 8 oclock position is typically ok. There are some scenarios where the PTO will be very close to or could interfere with the rear spring shackle on the front suspension. This problem can occur on vehicles with a set-back front axle and the problem is amplified on the short hood models.

Allison 4000 Series Allison 3000 Series

POWER TAKE-OFF (PTO)

Peterbilt Motors Company 8-4

8

AUTOMATIC TRANSMISSIONS PACCAR 8-SPEED There are two locations for PTOs on the PACCAR 8-speed transmission: 9 o'clock and 3 o'clock from the back of the transmission. The PACCAR 8-speed automatic transmission is relatively wide at the PTO mounting locations. For this reason, it is important to be aware of potential PTO packaging issues. Frame rails and frame mounted hose bundles can present a challenge, depending on the specific configuration. If the PTO is using an elongated driveshaft it is advised to be aware of the location of the back of cab crossmember in relation to the driveshaft. PTOs mounted in the 9 o'clock position on the PACCAR 8-speed may need a spacer to clear the transmission shift actuator.

PACCAR 8-Speed Automatic Transmission

POWER TAKE-OFF (PTO)

Peterbilt Motors Company 8-5

8

FRONT ENGINE PTO Front engine PTO (FEPTO) is commonly used in mixer, snowplow, and crane applications. When a FEPTO is specd on a truck, the cooling module moves up to allow for a shaft to be bolted to the front of the crankshaft and extend out to the front of the truck. The vehicle can be specd with a 1350 flange adapter to simplify installing the FEPTO shaft. The frame rails will be extended out to mount a hydraulic pump, snowplow, or outriggers. The frame extension is 24 long and a full rail profile, see Figure 7-12.

FIGURE 7-12. FEPTO 24 Full Profile Frame Extension

POWER TAKE-OFF (PTO)

Peterbilt Motors Company 8-6

8 PTO MOUNTING CLEARANCE

This application guide indicates if a PTO has sufficient clearance to truck components in various mounting configurations. The truck components investigated in this guide include frame rails, Set Back Front Axle (SBFA) rear shackle, SBFA Front Air Suspension (FAS) rear shackle, over-bell frame brace, coolant return manifold, transmission clutch actuator, and exhaust system components. Usage Notes:

1. This application guide is only applicable to 2.1M trucks. 2. Only the specified PTO configurations have been analyzed. 3. Horizontal aftertreatment limits access behind PTO's for shaft drives and other PTO attachments. 4. Eaton FR transmissions require the use of a 30 adapter when installing Chelsea or Muncie transmission PTOs in

the right hand position. 5. Eaton RT & UltraShift Plus transmissions require the use of a 45 adapter when installing Chelsea transmission

PTOs in the right hand position. 6. Eaton RT & UltraShift Plus transmissions require the use of a 55 adapter when installing Muncie transmission

PTOs in the right hand position. 7. Eaton transmissions require the use of a 6 to 8 Bolt adapter when installing a 6 bolt PTO in the bottom position.

PTO MOUNTING CLEARANCE CHARTS ALLISON TRANSMISSIONS

Series Type 4 8 4 8 4 8

E3 x ok x ok ok ok

E5 x x ok x ok ok x Will not package in truck

V3 x ok ok ok Will package in truck

V5 ok ok ok Requires "RH PTO" exhaust

H1 x x ok

H3 x x ok

FA6B H3 x ok ok

H1 x ok ok

H3 ok ok ok

442

CS6

Clocking Position on Transmssion

6 -B

o lt

4 o'clock &

8 o'clock

PTO's for 1000/2000

Allison Transmissions

-7L Only-

TG6

Chelsea

PTO

Muncie

Brand

VocMHSH

272

POWER TAKE-OFF (PTO)

Peterbilt Motors Company 8-7

8

Series Type 4 8 4 8 4 8 4 8 4 8 4 8 4 8 4 8

M3 x ok ok x ok ok ok ok

M5 ok ok ok ok ok ok ok ok

E3 x ok ok x ok ok ok ok

E5 ok ok ok ok ok ok ok ok

M3 x ok ok x ok ok ok ok

M5 ok ok ok ok ok ok ok ok

E3 x x ok x x ok ok ok

E5 x x ok x x ok ok ok

M3 x x ok x x ok ok ok

M5 x x ok x x ok ok ok

R-B5 x x ok x x ok ok ok

L-B5 x x ok x x ok ok ok

T-B5

E-B5

U-B5

H-B5

R-M5 x x ok x x ok ok ok

L-M5 x x ok x x ok ok ok

T-M5

E-M5

U-M5

H-M5

CD05 M3 ok ok ok ok ok ok ok ok

M1 x ok ok x ok ok ok ok

M3 ok ok ok x x ok ok ok

M1 x x ok x x ok x ok

M3 x x ok x x ok x ok

H1 x x ok x x ok x x

H3 x x ok x x ok x x

H1

H3

H1 x x ok x x ok x ok

H3 x x ok x x ok x ok

H1 x ok ok x ok ok ok ok

H3 ok ok ok ok ok ok ok ok

HX1 x ok ok x ok ok ok ok

HX3 ok ok ok ok ok ok ok ok

HX5

3000 - 4 o'clock & 8 o'clock Positions

Voc

7L 9L 9L REPTO

SH MH Voc

Chelsea

Muncie

HS24

CD10

SH MH MH Voc

Allison Transmissions

-7L & 9L-

280

CS24

CS41

267

287

870

877

1 0

-B o

lt

A20

890

897

PTO

CD40

CS10

Brand

POWER TAKE-OFF (PTO)

Peterbilt Motors Company 8-8

8

Series Type 1 8 1 8 1 8 1 8 1 8 1 8 1 8 1 8

M3 x x x x ok ok x x

M5 x x ok x x ok ok ok

E3 x x x x ok x x x

E5 x x ok x x ok ok ok

M3 x x x x ok x x x

M5 x x ok x x ok ok ok

E3 x x x x ok x x x

E5 x x ok x x ok x ok

M3 x x x x ok x x x

M5 x x ok x x ok x ok

R-B5

L-B5

T-B5 x x x x x ok x x

E-B5 x x ok x x ok x ok

U-B5

H-B5

R-M5

L-M5

T-M5 x x x x x ok x x

E-M5 x x ok x x ok x ok

U-M5

H-M5

CD05 M3 ok ok ok ok ok ok ok ok

M1 x x x ok ok x x x

M3 x x ok x x ok x ok

M1 x x x ok ok x x x

M3 x x ok x x x x ok

H1 x x x ok ok x x x

H3 x x x x x x x x

H1

H3

H1 x x x ok ok x x x

H3 x x ok x x x x ok

H1

H3 x x x x ok ok ok x ok x ok ok x ok x ok

HX1

HX3 x x ok x x ok ok ok

HX5 x x x ok ok x x x

3000 - 1 o'clock & 8 o'clock Positions

7L 9L REPTO

Chelsea

Muncie

SH Voc MH

HS24

9L

CD10

MH VocSHMH Voc

280

CS24

CS41

267

287

870

877

1 0

-B o

lt

A20

890

897

PTO

CD40

CS10

Brand

POWER TAKE-OFF (PTO)

Peterbilt Motors Company 8-9

8

Series Type 1 8 1 8 1 8 1 8

M3 ok ok x x

M5 ok ok ok ok

E3

E5 ok x ok ok x ok x ok

M3

M5 ok x ok ok x ok x ok

E3 ok ok x x

E5 x x ok ok

M3 ok ok x x

M5 x x ok ok

R-B5

L-B5

T-B5

E-B5

U-B5 x x x x

H-B5 x x ok ok

R-M5

L-M5

T-M5

E-M5

U-M5 x x x x

H-M5 x x ok ok

CD05 M3

M1 ok ok x x

M3 x x ok ok

M1 ok ok x x

M3 x x x x

H1 ok ok x x

H3 ok x x x

H1

H3

H1 ok ok x x

H3 x x x ok

H1

H3 ok ok ok ok x ok x ok

HX1

HX3 x ok ok ok

HX5 ok ok x x

4000

Chelsea

Muncie

9L

HS24

9L REPTO

CD10

VocMH Voc MH

280

CS24

CS41

267

287

870

877

1 0

-B o

lt

A20

890

897

PTO

CD40

CS10

Brand

POWER TAKE-OFF (PTO)

Peterbilt Motors Company 8-10

8 PTO MOUNTING CLEARANCE CHARTS PACCAR 8-SPEED TRANSMISSION

POWER TAKE-OFF (PTO)

Peterbilt Motors Company 8-11

8 PTO MOUNTING CLEARANCE CHARTS EATON TRANSMISSIONS

Left Right Bottom Right Bottom Right Bottom Right Bottom Right Bottom Right Bottom

V3 s s s s s s

V5 s

340 V5 s s s s s s s

V3 s s s s s s

V5 s

660 V3 s s s s s

282 V3 s s s s s

348 V5 s s s s s

489 V5 s s s s s s

680 V3 s s s s s

823 V3 s s s s s

880 V3 o o o o s s

885 V3 o o o o s

P1 s x x s s s

P3 s

RL6 A3 s s x s s s s

P1 s x x s s s

P3 s

P1 s x x s s s

P3 s

828 P1 s s s s s s

CS8 P1 s s s s s

RL8 A3 s s s s s

SH8 P1 s s s s s s

TG8 P1 s s s s s s

M u

n ci

e

8 -B

o lt

SH6

C h

e ls

e a

8 -B

o lt

6 -B

o lt

272

6 -B

o lt

TG6

442

CS6

Single PTO's for Eaton Transmissions LH, RH or Bottom Mounted

PTO

SAE #2 SAE #1

FR/FROFS/FSO

Endurant

PACCAR AMT

RT/RTO/RTLO

Adv Manual

Ultrashift +

Adv AMTFR/FRO RT/RTO/RTLO

x = Will not package for this configuration

ok = Will package for this configuration

o = Will package for this configuration w/

Optional Hydraulic Clutch Actuator

s = Will package for this configuration w/

Standard Hydraulic Clutch Actuator

POWER TAKE-OFF (PTO)

Peterbilt Motors Company 8-12

8

x = Will not package for this configuration

ok = Will package for this configuration

o = Will package for this configuration w/

Optional Hydraulic Clutch Actuator

s = Will package for this configuration w/

Standard Hydraulic Clutch Actuator

POWER TAKE-OFF (PTO)

Peterbilt Motors Company 8-13

8

HYDRAULIC CLUTCH ACTUATOR CONFIGURATIONS (Only used with 2.1M models with Eaton transmissions)

Notes:

1. The actuator should never be flipped upside-down to achieve PTO clearance. 2. The bleed nipple must always be above the centerline. 3. The drain valve should always be below the centerline.

REAR ENGINE PTO

Rear Engine PTO (REPTO) is commonly used in cement mixer and feed lot applications. The REPTO is driven off the rear gear train on the engine. There is a 1350/1410 flange on the bell housing in the 1 oclock position that can be used to attach a hydraulic pump or driveshaft. The REPTO flange will always be turning when the engine is running and the output rotation is the same as the engine. The Cummins ISL9 and PX-9 REPTO turns at a rate of 1.15:1.

POWER TAKE-OFF (PTO)

Peterbilt Motors Company 8-14

8 REMOTE PMC CONNECTIONS There are options to control PTO functionality from the following locations.

Engine Bay Hardwired option only

RP1226 Connection in the Cab CAN bus connection only

BOC/BOS Hardwired and CAN bus connections

EOF Hardwired and CAN bus connections There are options available for the body builder to specify controller speeds of 250 kbps or 500 kbps.

PTO CAN functionality may be accessed in the cab through the RP1226 connector and remotely through the body connectors K-CAN (E-3375-021) and B-CAN (DTM06-2S-EP10) Connectors. PTO hardwired functionality may be accessed in the engine bay or on the frame through optional the 12-Way connector.

Pin-out information for the PTO connectors can be found in the Electrical Section

12-Way Deutsch

Connector

RP1226 Delphi

Connector

Peterbilt Motors Company 9-1

SECTION 9 AFTERTREATMENT

INTRODUCTION

The following section is designed to give you information regarding the aftertreatment systems on Peterbilt chassis. All Peterbilts equipped with 2021 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.

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 lines 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

EPA 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.

TABLE 9-1. DEF Fuel Ratios

AFTERTREATMENT

Peterbilt Motors Company 9-2

9 DEF SYSTEM SCHEMATICS On most Peterbilt chassis, the DEF Supply Module (or pump) is integrated into the DEF tank assembly. See page 9-3 for assembly relocation requirements.

FIGURE 9-1. DEF System Schematic 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.

FIGURE 9-2. DEF Coolant Routing Schematic

AFTERTREATMENT

Peterbilt Motors Company 9-3

9 INSTALLATION REQUIREMENTS AND DIMENSIONS FOR DEF SYSTEM When relocating any DEF system component, the locations must meet all guidelines described below. Failure to comply may result in non-conformance to EPA standards and engine shutdown. General clearances, routing guidelines, and installation requirements must be followed. See section 10 of this manual for general routing guidelines and clearances. The maximum DEF hose line length is 5.5 meters (216.5"). 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 and mitigates the risk of increased flow restriction. Changes in flow restriction are added with excessive line length and hose bends. Work with your local Peterbilt dealer if you are unsure about coolant line modifications.

DEF ASSEMBLY RELOCATION - SUPPLY MODULE REQUIREMENTS The Supply Module (or Pump) standard mounting location is on the DEF tank assembly. The pump cannot be removed from the DEF tank assembly. However, the assembly as a whole may be relocated. Body builders should follow the location and length restrictions above. Additionally the supply module must be mounted with the filter cap oriented downwards within +/-45 of vertical (or a 90 inverted cone as shown in figure 9-3). The supply module should be located in a space that will minimize its vulnerability to road debris. Serviceability of the supply module filter should be considered, and adequate space for filter access and removal should be given (at least 5).

FIGURE 9-3. Supply Module Mounting Angle Limits

AFTERTREATMENT

Peterbilt Motors Company 9-4

9 ROUTING TO THE DOSING MODULE (INJECTOR) A DEF pressure line trap is not required for EPA 2017 and later emissions level engines. The dosing module (injector) no longer needs to be purged and relative heights of components are no longer critical. See Figure 9-4 below for typical routing with RHUC exhaust and LH DEF tank shown. Figure below shows a typical coolant line routing.

FIGURE 9-4. Routing for DEF and Coolant Lines

Peterbilt Motors Company 10-1

SECTION 10 ROUTING INTRODUCTION This section specifies the general requirements for securing hoses and electrical wires to present an orderly appearance, facilitate inspection and maintenance, and prevent potential damage to these lines.

DEFINITIONS Bundle: Two or more air, electrical, fuel, or other lines tied together to form a unitized assembly. Clamp: A cushioned rigid or semi-rigid, anti-chafing device for containing the bundle and securing it to the frame or other structural support. Standard clamps have a black elastomer lining. High temperature clamps (e.g., those used with compressor discharge hose) have a white or red elastomer lining (most applications for these are called out in the bills of material). An assembly of two clamps fastened together to separate components is referred to as a butterfly clamp. Note: the metal portion of clamps shall be stainless steel or otherwise made capable, through plating or other means, of passing a 200 hour salt spray test per ASTM B117 without rusting.

FIGURE 10-1. Clamp and Butterfly Clamp

Butterfly Tie: A tough plastic (nylon or equivalent) locking dual clamp tie strap used to separate bundles or single lines, hoses, etc. These straps must be UV stable. (Tyton DCT11)

FIGURE 10-2. Butterfly Tie

Tie Strap: A tough plastic (nylon, or equivalent) locking strap used to tie the lines in a bundle together between clamps or to otherwise secure hoses and wires as noted below. Straps must be UV stable.

FIGURE 10-3. Tie Strap

ROUTING

Peterbilt Motors Company 10-2

10 Button Tie Strap: A tough plastic (nylon or equivalent) locking strap used to secure lines to the frame or other structural support. Straps must be UV stable.

FIGURE 10-4. Button Tie Mount.

Fir Tree Mount: A tough plastic mount, inserted into a bracket or other intended support structure, used for securing routed bundles via a tie strap. Mounts must be UV stable

FIGURE 10-5. Fir Tree Mount

Heavy Duty (HD) Mount: A black rigid device used for securing a tie strap to the frame or other structural support. Mounts are made of impact modified, heat stabilized UV resistant nylon capable of continuous operation between temperatures 220F (150) and -40F (-40).

FIGURE 10-6. Heavy Duty (HD) Mount.

NOTE: Heavy duty tie straps 0.50in (12.7mm) wide (Tyton T255ROHIR or similar) shall be used whenever HD mounts are specified, although 0.25in (6.4mm) tie straps may be used in some specified applications.

Excess of material: More than 3 inches of slack for every 18 inch section of hose routing, except for air conditioner hoses. Shortness of material: Less than 1 inch of slack on an 18 inch section of hose routing.

ROUTING

Peterbilt Motors Company 10-3

10

ROUTING REQUIREMENTS

ELECTRICAL WIRING Electrical ground wire terminals must be securely attached, and the complete terminal surface must contact a

clean bare metal surface. See R414-558 for grounding wire connection practice. Apply electrical contact corrosion

inhibitor Nyogel 759G grease (made by William F. Nye, Inc., New Bedford, MA) per R414-558.

Dont bend wires or use tie straps within 75 mm (3 inches) of (connected) wire connectors or plugs

Electrical wiring must be routed so that other components do not interfere with it

Electrical wiring must be routed away from moving components so that at least 13.0 mm (0.5 in.) of clearance

exists when the component is in operation and at maximum limits of the components travel

Electrical wiring must be protected in the locations they are routed

Electrical wiring must be routed to avoid heat sources

Electrical wiring must be secured to a crossmember when going from one frame rail to the other

When crossing other components, electrical wiring must have a covering of convoluted tubing, PSA tape, or must

be separated from the component with a standoff or butterfly clamp

Electrical wiring must not be routed directly over a sharp edge unless separated from the edge by a clip, standoff

bracket, or similar spacing feature that prevents any risk of chafing or cutting

o Alternatively, the installation of windlace applied to the edge along with PSA tape or convoluted tubing on

the harness is acceptable

Electrical wiring must be routed in a way that will not place strain on connectors.

WIRES IN BUNDLES Electrical wires (other than the exceptions covered below) running parallel with air or coolant hose bundles, may be included in the bundle if they are isolated from the hoses with a covering of convoluted plastic tubing.

EXCEPTIONS: 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 butterfly ties at intervals not exceeding 18 inches (356 mm). Battery strap (W84-1000) tie down shall be used without exception to secure battery cables to frame mounted or other major component (e.g. engine, transmission, etc.) mounted standoffs at intervals not exceeding 18 inches (356 mm). The (positive) battery cable shall be covered with convoluted plastic tubing from terminal to terminal.

110/220 volt wires for engine heaters, oil pan heaters, transmission oil heaters, and battery pad warmers shall not be included in any hose/wire bundle with a fuel hose. Individual heater wires not in a bundle shall be separated from other components by using butterfly clamps or butterfly ties at intervals not exceeding 18 inches (356 mm). Heater wires with a secondary covering shall be covered with convoluted tubing whether they are in bundles or not.

ROUTING

Peterbilt Motors Company 10-4

10

WIRES CROSSING OTHER COMPONENTS Electrical wires crossing over other components, such as lines, bolt heads, fittings, engine components lifting eyes, engine block, cylinder head, etc., close enough to rub shall be isolated with a covering of convoluted tubing and separated from the component by using butterfly clamps, butterfly ties, or plastic sheathing. 110/220 volt engine heater wiring shall be installed with butterfly ties or butterfly clamps

PIPING Use no street elbows in air brake, water, fuel, or hydraulic systems unless specified on the piping diagram and the build instructions. Use no elbows in the air brake system unless specified on the air piping diagram and the build instructions.

HOSES CROSSING COMPONENTS Hoses crossing over other components close enough to rub shall be protected with a secured covering of convoluted plastic tubing (part number K344-813), another section of hose, or plastic sheathing (part number K213-1312). The usage of butterfly ties or butterfly clamps are also recommended.

AIR COMPRESSOR DISCHARGE HOSES Wires or hoses shall not be tied to the high temperature air compressor discharge hose. Hoses and wires may be routed across the air compressor discharge hose at a distance of 18 inches (457 mm) or greater from the compressor discharge port. In this case, the crossing hoses and wires shall be butterfly clamped to the air compressor discharge hose and covered with convoluted tubing at the clamp point (use high temperature clamps on the compressor hose).

BUNDLES HD mount and tie strap or clamp shall be located at intervals not to exceed 18 inches (356 mm) along the bundle. Regular tie straps shall be located at intervals not to exceed 7 inches (178 mm) between HD mount or clamps. Extra tie straps may be used as needed to contain the hoses and wires in the bundle.

ROUTING OF WIRES AND HOSES NEAR MOVING COMPONENTS Wires and hoses shall be routed away from moving components, such as fans, shackle links, drivelines, steering linkages, etc. so that there is at least 0.5 inches (12.7 mm) clearance when the component is operating at its maximum travel limits. A minimum clearance of 1.0 inch (25.4 mm) shall be maintained between steering axle tires (and associated rotating parts) in all positions and routed components, such as hoses, oil lines, wires, pipes, etc.

ROUTING

Peterbilt Motors Company 10-5

10

ROUTING OF WIRES AND HOSES NEAR EXHAUST SYSTEM

TABLE 10-1. Exhaust System Clearance

Description Shielded Unshielded

Coolant hoses (Silicone, colored) 1 minimum 2 minimum

DEF hose (EPDM) 6 minimum 7 minimum

HVAC hoses, tubing, and hard lines 5 minimum 7 minimum

Electrical wires 6 minimum 8 minimum

Fuel hoses within 15 of the turbo over 15 from the turbo

n/a

2 minimum

4 minimum

3 minimum

Fuel tanks and hydraulic tanks crossing tank

parallel to tank end of tank

aluminum/ceramic-coated exhaust pipe crossing tank

n/a n/a

n/a n/a

2 minimum 2 minimum

1 minimum 1.5 minimum

Air hose nylon

wire braid

6 minimum

6 minimum

8 minimum

7 minimum

FIGURE 10-7. Definition of measurements.

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Peterbilt Motors Company APPENDIC