# HEAVY DUTY VOCATIONAL VEHICLE INDUSTRY CHARACTERIZATION

September 30 , 2013

EPA Contract No. EP

- C

- 12

- 011 Work Assignment No. 1

- 13 Final Report

# INDUSTRY CHARACTERIZATION OF HEAVY DUTY VOCATIONAL VEHICLES

TABLE OF CONTENTS

1. Introduction

................................ ................................ ................................ ................................ .. 1
2. Industry Structure

................................ ................................ ................................ ......................... 3

3. Vocat ional Vehicle Chassis Manufacturers

................................ ................................ .................. 4
Chassis Manufacturer Detail By Model

................................ ................................ ............................ 9
4. Vocational Body Manufacturers

................................ ................................ ................................ . 15

5. Vocational Vehicl e Pricing

................................ ................................ ................................ .......... 19
Glossary

................................ ................................ ................................ ................................ .......... 20

Additional Sources

................................ ................................ ................................ .......................... 21

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# 1. Introduct ion

“ The U.S. Environmental Protection Agency (EPA) and the Department of Transportation’s National Highway Traffic Safety Administration (NHTSA) issued the first

- ever program to reduce greenhouse has (GHG) emissions and improve fuel efficiency of heavy

- duty trucks and buses in 2011. This program was the first phase of a multi

- stage GHG reduction approach. The first phase includes regulations for vocational vehicles, which are defined in this report as all heavy

- duty vehicles that are not heavy

- du ty pickup trucks, vans, or combination tractors. The agencies divided the vocational vehicle segments into three categories which align with the existing criteria pollutant standards for heavy

- duty engines. The three categories are: light

- heavy, medium

- h eavy, and heavy

- heavy duty vehicles. Light

- heavy duty vehicles are defined as Class 2b

– 5, medium

- heavy vehicles are Class 6

– 7, and heavy

- heavy are Class 8 vehicles based on gross vehicle weight rating. ” Class 2b in this report only includes vehicles that are used for commercial purposes. This excludes pickup trucks, large SUVs, Vans, and other vehicles that could be dual

- purposed commercial/non

- commercial.

A classification matrix was created to group each vocational truck type into a vocational categ ory. The initial matrix is in Table 1.1. During our research, the matrix was revised into Table 1.2 separating Truck Rental and School Bus truck types into two more truck categories, Truck Rental and School Bus. Rental trucks are used by an individual oth er than the owner of record ; lessees include but are not limited to those involved in freight delivery and housing services

. Since these vehicles are utilized on an as needed basis, the irregular usage pattern sets this category apart from other truck cate gories . School buses are different from other vocational vehicles in that they are used locally and seasonally and general ly accumulate lower annual mileage. Due to these differences, it was determined they did not properly fit in an existing category and were given their own individually

. Table 1.1 Preliminary Classification Table 1.2 Final Classification

Truck Category Truck Type Truck Category Truck Type

Freight Delivery Delivery Walk

- in & Conventional Vans

Freight Delivery Delivery Walk

- in & Conventional Vans

Delivery Box Trucks Delivery Box Trucks Beverage and Food Trucks Beverage and Food Trucks Tankers Tankers Armored Vehicles Armored Vehicles Car Haulers Car Haulers

Housing Construction Concrete Mixers

Housing Construction Concrete Mixers Dump Trucks Dump Trucks Logging Trucks Logging Trucks Stake Bed/Landscape Trucks Stake Bed/Landscape Trucks
Truck Rentals Truck Rentals Truck Rentals

Municipal Services Refuse & Recycling School Buses School Buses School Buses

Municipal Services Refuse & Recycling Utility Trucks Utility Trucks Tree Trimmers Tree Trimmers Plow Trucks Plow Trucks Street Sweepers Street Sweepers Transit, Para transit, and Shuttle Buses Transit, Para transit, and Shuttle Buses

Emergency Services Fire Trucks Emergency Services Fire Trucks Ambulances Ambulances Tow/Recovery Vehicles Tow/Recovery Vehicles

Recreational Travel Recreational Vehicles Recreational Travel Recreational Vehicles Motor Coaches Motor Coaches
Tow Vehicles Tow Vehicles

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## | 2 Throughout this report, small businesses will be designated by an asterisk (*). Table 1.3 outlines the SBA standard for each component group examined in this report. The number of employees for each business was obtained through the manufacturer website, internet research, manta.com, or findthecompany.com.

Table 1.3 SBA Small Business Size Criteria. 1



### Component NAICS

Code NAICS Industry Description Size Standard in Number of Employees Size

Standard in Revenue Chassis 336120 Heavy Duty Truck Manufacturing 1,000 Body 336211 Motor Vehicle Body Manufacturing 1,000 Engine, Transmission, Axles 336350 Motor Vehicle Transmission and Power Train Parts Manufacturing 750

1 U.S. Small Business Administration. (n.d.). sba.gov. Retrieved from

http://www.sba.gov/sites/default/files/files/size_table_07222013.pdf

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# 2. Industry Structure

A new vocational vehicle is comprised of products from many suppliers. The primary two suppliers are the chassis and body builders . Secondary suppliers provide major components to the primary suppliers; examples include engine s and engine parts, transmission s , suspension s, axles and brakes. S econdary suppli ers include companies such as Allison, Meritor, Bendix, Dana, Eaton, Hendrickson, TRW and ZF. They provide the same assembly o r components to multiple OEMs (Original Equipment Manufacturer) as well as supplying aftermarket parts to both OEMs and parts dist ributors

.
Table 2.1 Major OEM Component Suppliers

Transmission Axle Brake Clutch Drive Line Suspension

OEMs X X X X X X

Allison X

Meritor X X X X X X

Bendix X

Dana X X X X

Eaton X X

Hendrickson X X

TRW X X

ZF X X X X



### The major OEM heavy

- duty truck manufacturers have slowly evolved in to offering proprietary components and integrated vehicles despite opposition from major fleet customers and major suppliers. Truck Manufacturers are attempting to minimize fleets’ options when speci fyi ng new truck s by limiting choices of component suppliers ultimately reduc ing the cost of producing a truck. By limiting choices, specifically engines, fleets are forced to return to the OEM when aftermarket p arts are needed . Mack has done th is for years and other OEMs are moving in this direction starting with engines and drivetrain components.
In the U.S. heavy

- duty market, most new vocational vehicles are produced in two stages. Stage one is cab chassis production at a truck or chassis man ufacturer. A typical c ab chassis configuration will have a finished cab and engine compartment, but blank frame rails behind the cab to accept a number of different vocational body types. In some cases, particularly Class A RV s and Step Vans, the vocation al body dictates that only a chassis i s needed. These are fully functioning rolling chassis with a complete drive train, firewall with a steering wheel and some dashboard components. For the purposes of this report, when the word ‘chassis’ is used, it is understood to mean both cab chassis and chassis . Stage two is the application of the body to the chassis. This application is completed either at the body company or at an outlet designated by the body company. Some manufacturers produce an integrated bo d y and chassis together; some buses are manufactured in this manner

.

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# 3. Vocational Vehicle Chassis Manufacturers

Section 3 details v ocational v ehicles ’ primary chassis manufacturers. Table 3 .1 contains manufacturers that currently prod uce light

- heavy and medium

- heavy truck chassis and the primary powertrain component manufacturers. Table 3 .2 contains medium

- heavy and heavy

- heavy chassis manufacturers and the primary powertrain component manufacturers. Table 3 .3 contains bus chassis ma nufacturers and the primary powertrain component manufacturers. This information was gathered us ing the 2013 Diesel Truck Index 2 

### and the respective manufacturer s ’ web

- sites 3 

### . These tables represent approximately 95% of the primary vocational chassis produced and sold annually.

Table 3.1 Summa ry of Primary Light

- Heavy and Medium

- Heavy (Class 2 b

– 5)

Chassis and Component Manufacturers

Vocational Vehicle Component

Chassis Engine Transmission Axle
Ram (Chrysler) Cummins Aisin AT Dana

Ford Ford Ford AT Ford, Dana Spicer

Mitsubishi Fuso Mitsubishi Fuso Mitsubishi Fuso AT not specified

Isuzu Isuzu Aisin AT not specified
Freightliner Custom Chassis Mercedes

- Benz, Cummins Allison AT Axle Alliance Co, Detroit

Hino Hino Aisin AT Meritor

International Maxxforce Allison A T Dana Spicer

Freightliner Cummins, Cummins Westport (Nat Gas) Eaton MT,AMT, Hybrid; Allison A T; Mercedes

- Benz MT Meritor, Detroit

Kenworth Paccar Eaton MT; Allison A T Dana Spicer

Peterbilt Paccar Eaton MT, AMT; Allison A T Dana Spicer

General Motors DMAX (GM/Isuzu) Allison AT not specified

Spartan Chassis DMAX (GM/Isuzu) not specified not specified
Note: MT= manual transmission; AMT = automated manual transmission; AT = automatic transmission

2 Diese l Truck Index, Published by Truck Index Inc., Santa Ana, CA 2013

3 See sources section

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## | 5 Table 3.2 Summary of Primary Medium

- Heavy and Heavy

- Heavy (Class 6

– 8)

Chassis and Component Manufacturers

Vocational Vehicle Component

Chassis Engine Transmission Axle

Kenworth Paccar, Cummins, Cummins Westport (Nat Gas)
, Westport Innovations Eaton MT, AMT, Hybrid; Allison AT Watson

- Chalin*, Dana Spicer, Meritor

Peterbilt Paccar, Cummins, Cummins Westport (Nat Gas)
, Westport Innovations Eaton MT, AMT; Allison AT; Eaton Hybrid Fabco*, Dana Spicer, Meritor, Marmon

Herrington

Mack Mack, Cummins, Cummins Westport (Nat Gas) Mack MT; Eaton MT, Hybrid; Allison AT Mack, Dana Spicer, Meritor, Hendrickson

Volvo Volvo, Cummins, Cummins Westport (Nat Gas) Eaton MT and AMT; Allison AT; Volvo AMT Volvo, Dana Spicer, Meritor, Hendrickson

International Cummins, Maxxforce, Cummins Westport (Nat Gas) Eaton MT, AMT, Hybrid; Allison A T Fabco*, AxleTech * , Dana Spicer, Hen d rickson, Meritor

Western Star Cummins, Detroit Eaton MT and AMT; Allison A T Axle T ech * , Dana Spicer, Hendrickson, Meritor, Detroit, Sisu

Freightliner Cummins, Detroit, Cummins Westport (Nat Gas) Eaton MT, AMT, Hybrid; Allison A T; Detroit AT; Mercedes

- Benz MT Watson

- Chalin*, Dana Spicer, Meritor, Detroit, Hendrickson

Freightliner Custom Chassis Cummins, Detroit, Mercedes

- Benz Allison AT ZF, Meritor, Ingersoll, Axle Alliance Company, Detroit

Spartan Chassis Cummins Allison AT Meritor, Hendrickson

Ford Cummins; Ford (Nat Gas, Propane) Eaton MT; Allison AT ; Dana AT Dana Spicer, Meritor

Hino Hino Allison AT Meritor Note: MT= manual transmission; AMT = automated manual transmission; AT = automatic transmission *Indicates company is considered a small business as defined by the SBA.

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## | 6 Table 3.3 Summary of Primary
Bus Manufacturers and Component Manufacturers (Class 2b

– 8)

Vocational Vehicle Component

Chassis Engine Transmission Axle

Gillig Cummins Allison AT, hybrid drive; Voith AT; ZF AT Not specified

Nova Bus Cummins, Cummins Westport Allison AT, hybrid drive; Voith AT; ZF AT ZF

New Flyer Cummins, Cummins Westport Allison AT, hybrid drive; BAE HybriDrive(R); Voith AT; ZF AT Dana, MAN

NABI (recently acquired by New Flyer) Cummins, Cummins Westport Allison AT, hybrid drive; ZF AT Meritor

Thomas Cummins , Cummins Westport, Powertrain Integration (Propane) Allison AT not specified

Freightliner Custom Chassis Cummins Allison AT Axle Alliance Company, Meritor

Blue Bird Cummins, Ford (Propane) Ford AT; Allison AT not specified

IC Bus Maxxforce, Cummins Allison AT not specified

Spartan Chassis Cummins Allison AT not specified

General Motors DMAX (GM/Isuzu) Allison AT not specified
Note: MT= manual transmission; AMT = automated manual transmission; AT = automatic transmission

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## | 7 Table 3.4 outlines the specifications of each engine model available on at least one make and model ; many of these engines are available across multiple makes and models. Only diesel and alternative fuel engines are listed as they are the most representative of the heavy

- duty vocational vehicle market.

Table 3.4 2 013 Cl ass 2b

– 8 Engine Manufacturers

Make Model HP Range Torque Range ( lb

- ft ) Configuration Displacement (L) Fuel

Cummins ISB 200

- 375 520

- 750 Inline

- 6 6.7 Diesel

ISC 260

- 380 660

- 1050 Inline

- 6 8.3 Diesel

ISL 260

- 380 720

- 1250 Inline

- 6 8.9 Diesel

ISM 280

- 330 925

- 1150 Inline

- 6 10.8 Diesel

ISX12 310

- 425 1150

- 1650 Inline

- 6 11.9 Diesel

ISX15 400

- 600 1450

- 2050 Inline

- 6 14.9 Diesel

Cummins Westport ISL G 250

- 320 730

- 1100 Inline

- 6 8.9 CNG, LNG, Biomethane

ISX12 G 320

- 400 1150

- 1450 Inline

- 6 11.9 CNG, LNG, Biomethane
Westport Innovations HD15 400

- 475 1450

- 1750 Inline

- 6 15 LNG

Daimler 8.0 LPG 350 500 V8 8 Propane DMAX (Isuzu/GM) Duramax 300 520 V8 6.6 Diesel

Detroit Diesel DD13 350

- 470 1350

- 1650 Inline

- 6 12.8 Diesel

DD15/15TC 455

- 5 05 1550

- 1 7 50 Inline

- 6 14.8 Diesel

DD16 475

- 600 1750

- 2050 Inline

- 6 15.6 Diesel

Ford Power Stroke 300 660 V8 6.7 Diesel

Triton V10 362 457 V10 6.8 CNG, LNG, Propane

Hino J05E 210 440 Inline

- 4 5 .0 Diesel

J08E 220

- 260 520

- 660 Inline

- 6 8 .0 Diesel

Powertrain Integration N/A 350 500 V8 8.0 Propane

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## | 8 Table 3.4 (continued) 2013 Class 2 b

– 8 Engine Manufacturers.

Make Model HP Range Torque Range ( lb

- ft ) Configuration Displacement (L) Fuel

Isuzu 4JJ1

- TC 150 282 Inline

- 4 3 Diesel

4HK1

- TC 215 452 Inline

- 4 5.2 Diesel

Mack MP7 325

- 405 1200

- 1560 Inline

- 6 11 Diesel

MP8 415

- 505 1460

- 1760 Inline

- 6 12.78 Diesel

MP10 515

- 605 1860

- 2060 Inline

- 6 16 Diesel

Maxxforce (Navistar) 7 220

- 300 560

- 660 V8 6.4 Diesel

DT 215

- 300 560

- 860 Inline

- 6 7.6 Diesel

9 300

- 330 860

- 950 Inline

- 6 9.3 Diesel

10 310

- 350 1050

- 1150 Inline

- 6 9.3 Diesel

11 330

- 390 1250

- 1450 Inline

- 6 10.5 Diesel

13 410

- 475 1450

- 1700 Inline

- 6 12.4 Diesel

Mercedes

- Benz V6

- CDI 188 325 V6 3 Diesel

MBE926 250

- 330 800

- 1000 Inline

- 6 7.2 Diesel

Mitsubishi 4P10(T5) 161 295 Inline

- 4 3 Diesel

Paccar PX

- 7 200

- 360 520

- 800 Inline

- 6 6.7 Diesel

PX

- 9 260

- 450 720

- 1250 Inline

- 6 8.9 Diesel

MX

- 13 380

- 500 1450

- 1850 Inline

- 6 12.9 Diesel

Volvo D11 325

- 405 1250

- 1450 Inline

- 6 10.8 Diesel

D13 375

- 500 1450

- 1750 Inline

- 6 12.8 Diesel

D13

- LNG 455 1750 Inline

- 6 12.8 LNG

D13

- DME 460 1750 Inline

- 6 12.8 Dimethyl Ether

D15 500

- 550 1850 Inline

- 6 16.1 Diesel

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# Chassis Manufacturer Detail By Model

Chassis manufacturer specifications were gathered us ing the 2013 Diesel Truck Index 2 

### and the respective manufactu rer s ’ web

- sites 3 

### . Table 3

. 5 contains manufacturers that currently produce light

- heavy and medium

- heavy truck chassis and the primary powertrain component manufacturers. Table 3

. 6 contains medium

- heavy and heavy

- heavy chassis manufacturers and the primary powertrain component manufacturers. Table 3

. 7 contains bus chassis manufacturers and the primary powertrain component manufacturers. V ocation classification for each chassis model w as established through online research, predominantly through dealer and manufacturer websites.

Table 3.5 Light

- Heavy and Medium

- Heavy Chassis Manufacturer Detail

Note: MT= manual transmission; AMT = automated manual transmission; AT = automatic transmission

2 Diesel Truck Index, Published by Truck Index Inc., Santa Ana, CA 2013

3 See Sources page

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## | 10 Table 3.6 Medium

- Heavy and Heavy

- Heavy Chassis Manufacturer Detail

Note: MT= manual transmission; AMT = automated manual transmission; AT = automatic transmissio n *Indicates company is considered a small business as defined by the SBA.

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## | 11 Table 3.6 (continued) Medium

- Heavy and Heavy

- Heavy Chassis Manufacturer Detail

Note: MT= manual transmission; AMT = automated manual transmission; AT = automatic transmission *Ind icates company is considered a small business as defined by the SBA.

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## | 12 Table 3.6 (continued) Medium

- Heavy and Heavy

- Heavy Chassis Manufacturer Detail

Note 1 : MT= manual transmission; AMT = automated manual transmission; AT = automatic transmission Note2: Class A under Spartan Chassis references a motor home classification . Class A is the largest motorhome resembling a bus

. *Indicates company is considered a small business as defined by the SBA.

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## | 13 Table 3.6 (continued) Medium

- Heavy and Heavy

- Heavy Chas sis Manufacturer Detail

Note: MT= manual transmission; AMT = automated manual transmission; AT = automatic transmission *Indicates company is considered a small business as defined by the SBA.

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## | 14 Table 3.7 Bus Chassis Manufacturer Detail

Note: MT= manu al transmission; AMT = automated manual transmission; AT = automatic transmission

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# 4. Vocational Body Manufacturers

Table 4.1 lists primary vocational body builders, designated vocations and truck types produce d . This list
is not all

- inclusive and lists primary body builders that were identified through our industry knowledge and online research. Online research was also conducted utilizing the Trailer

- Body Builder magazine website

- specifically the Truck Body news section 4 

### and the Buyer’s guide section 5



### . Once manufacturer s

w ere identified, further online research was conducted via the manufacturer s ’ website s to determine the vehicle truck types produced. Subsequent searches were conducted to identify whether or not the manufac turer was a small business as outlined in Table 1. 3

. Businesses listed in Table 4.1 fall under NAICS code 336211 and are categorized as a small business if they have fewer than 1,000 employees. Those that are small businesses are noted with an asterisk (* ).

Table 4.1 Primary Vocational Bod y Builder

*Indicates company is considered a small business as defined by the SBA.

4 http://directory.trailer

- bodybuilders.com/Main/DirectoryHome.aspx

5 http://trailer

- bodybuilders.com/truck

- bodies

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## | 16 Table 4.1 (continued) Primary Vocational Body Builders

*Indicates company is considered a small business as defined by the SBA.

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## | 17 Table 4.1 (continued) Primary Vocational Body Builders

* Indicates company is considered a small business as defined by the SBA.

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## | 18 Table 4.1 (continued) Primary Vocational Body Builders

*Indicates company is considered a small business as defined by the SBA.

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## 5. Vocational Vehicle Pricing

The primary sources utilized to obtain pricing for Table 5.1 were dealer websites. New truck searches to obtain pricing for specific vocational trucks were also made online, within Truckpaper.com and Commercialtrucktrader.com 6



### . Pricing for the School Buses, Delivery Box Truck, and Dump Truck were obtained from a prior EPA report and is in 2009 dollars. Additionally, t hree truck dealers and two body companies were contacted to obtain pricing on four vehicle types not available through public sources. Vehicles in the category of Recreational Travel were excluded from the pricing analysis. All pricing except those obtained from the prior EPA report is in 2013 dollars.

Table 5.1 Vocational Vehicle Pricing

6 http://www.bluebagmedia.com/2013/06/garrison

- and

- fire

- dept

- ask

- for

- 1.html http://www.l eaderherald.com/page/content.detail/id/556690.html http://www.ci.hillsborough.nc.us/content/new

- fire

- truck

- improve

- safety

- hillsborough http://www.flagstaff. az.gov/DocumentCenter/Home/View/38710 http://www.truckpaper.com/Default.aspx http://www.commercialtrucktrader.com/

7 US EPA, Investigation of Costs for Strategies to Reduce Greenhouse Gas Emissions for Heavy

- Duty On

- Road Vehicles , 2010

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## | 20 

# Glossary

OEMs

- Original Equipment Manufacturer

Chassis

- both cab chassis and chassis

.

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# Additional Sources

Manufacturer websites and online brochures

a. http://www.macktrucks.com/default.aspx?pageid=9111 b. http://www.freightlinertrucks.com/Trucks/

c. http://www.internationaltrucks.com/trucks/ d. http://www.icbus.com/ICBus/

e. http://freightlinerchassis.com/ f. http://cumminsengines.com/on

- highway
g. http://www.hino.com/trucks/ h. http://www.isuzucv.com/
i. http://www.mitfuso.com/en

- US/Canter

- Work

- Truck

- Models j. http://www.kenworth.com/trucks.aspx k. http://www.peterbilt.com/products/trucks/ l. http://www. westernstartrucks.com/Trucks/default.aspx

m. http://www.demanddetroit.com/engines/default.aspx

n. http://www.spartanchassis.com/er/er.asp

o. http://www.spartanchassis.com/rv/walkaround.asp

p. http://lionbuses.com/en/

q. http://www.volvotrucks.com/trucks/na/en

- us/products/Pages/trucklanding.aspx

r. http://www.gillig.com/New%20GILLIG%20WEB/product.htm

s. http://www.novabus.com/transit

- solutions/vehicles.html

t. http://www.newflyer.com/

u. http://www.nabusind.com/NABI/index.asp

v. http://www.thomasbus.com/bus

- models/school/

w. http://www.thomasbus.com/bus

- models/commercial/

x. http://www.ford.com/commercial

- trucks/

y. http://www.ramtrucks.com/en/ram_chassis_cab/#3500_tradesman/bright_white_clear _coat/mono