Superstructure Instructions Chassis
Superstructure Instructions Chassis
Date Revised
Contents 5.0
Wheelbase alterations 5.10 10.00 x
Introduction
Restrictions
Permitted wheelbase (RIGID) – Outside South America
Permitted wheelbase – South American market
Permitted overhang (RIGID) – Outside South America
Permitted overhang (TRACTOR)
Permitted overhang (TRACTOR/RIGID) – South American market
Crossmembers (RIGID)
Crossmembers (TRACTOR)
Shortening of wheelbase on vehicles with rear air suspension
Material
Design
Work procedure (RIGID)
Work procedure (TRACTOR)
Propeller shafts – Outside South America 5.20 10.00 x
Propeller shafts
Installation
Propeller shaft – South American market 5.30 10.00 x
Propeller shaft variants explanation
Measurements for the propeller shaft installation (South American market)
Painting 5.40
TSP146867
ENG08921 English
Printed in Sweden
Superstructure instructions
Volvo Truck Corporation
Göteborg, Sweden Chassis
Vehicle type Date Section Page
Wheelbase alterations FM, FH, NH 10.00 5.10 1(28)
Wheelbase alterations
Introduction
The instructions for alterations to the chassis length refer
to FM, FH and NH Rigid trucks (RIGID) and Tractors
(TRACTOR) 4x2.
Restrictions
• TRACTORS with bogies must not have the wheel-
base altered without authorisation from Volvo Truck
Corporation.
T9006095
Volvo Truck Corporation
Superstructure instructions Chassis
Vehicle type Date Section Page
Wheelbase alterations FM, FH, NH 10.00 5.10 3(28)
Vehicle Rear axle in- FAL1 (ton) RAL2 (ton) Frame Permitted wheelbase (mm)
stallation
min. max.
FRAME66
RAD-A4 7,1/8,0 13 FRAME77 3700
FRAMEHIGH
RAD-A4 FRAME88
7,1 11,5 5200
CHH850 FRAMELOW
4x2 FRAME66 6000
RAD-A4
FRAME77 5600
CHH900
FRAMELOW
7,1/8,0 13
FRAME66
RAD-L90 FRAME77 3400
FRAME HIGH
FRAME88
4x4 RAD-L90 8,0/9,0 13 FRAME88P 3500 4800
FRAMEHIGH
FRAME77
RADT-AR 7,1/8,0/8,6 19/21 FRAME77P 3400
FRAMEHIGH
FRAME88
RADT-LA 3900 6000
FRAMEHIGH
7,1/8,0 19 FRAME77
RADT-A6 FRAME77P 3700
FRAMEHIGH
RADT-A6 FRAME77
7,1 18 4300 4900
6x2 CHH900 FRAMEMED
FRAME88
RADT-A6S 3900 6000
FRAMEHIGH
FRAME77
RAPD-A6 4300 5200
7,1/8,0 FRAMEHIGH
19 FRAME77
RADT-A8 FRAME77P 3700 6000
FRAMEHIGH
RADT-A8 FRAME88
7,1 4600 5600
CHH850 FRAMELOW
1
Axle pressure on front axle/axles
2
Rear axle pressure/bogie pressure
Page 4
Vehicle Rear axle in- FAL1 (ton) RAL2 (ton) Frame Permitted wheelbase (mm)
stallation
min. max.
FRAME77P
RADD-BR 20/21
FRAMEHIGH
6,7/7,1/8,0/8,6 5600
FRAME88P
RADD-TR 23/26/32 3200
FRAMEHIGH
6x4
RADD-TR FRAME88P
9,0 26 3900
TRHT-HIG FRAMEHIGH
FRAME77P
RADD-A8 8,0 21 3900 5600
FRAMEHIGH
FRAME88P
6x6 RADD-TR 8,0/9,0 13/26/32 3500 3900
FRAMEHIGH
FRAME88
RADT-AR 19/21 5100 5600
FRAMEHIGH
8x2 16
FRAME88
RADT-A6 19 4600 6000
FRAMEHIGH
FRAME88
RADD-A8 16/17,4 21 6000
FRAMEHIGH
FRAME88
RADD-BR 16 20/21 6400
FRAMEHIGH
8x4 4300
FRAME88P
RADD-TR 16/17,4 26/32 6200
FRAMEHIGH
RADD-TR FRAME88P
16 26 5100
TRHT-HIG FRAMEHIGH
Volvo Truck Corporation
Superstructure instructions Chassis
Vehicle type Date Section Page
Wheelbase alterations FM, FH, NH 10.00 5.10 5(28)
T9006988
T9006988
4x2
RAD-L90 FRAME77 • 55% of the wheelbase up to
RAD-A4 FRAMEHIG wheelbase 6000 mm.
RADD-BR (RAL20)
FRAME77P • 55% of the wheelbase up to
FRAMEHIG wheelbase 4900 mm.
Tractor vehicle
The overhang on tractor vehicle (with trailer) may be only
extended after approval by Volvo do Brasil Design Engi-
neering Department.
Page 10
Crossmembers (RIGID)
The distance between two adjacent crossmembers must
not exceed 1500 mm. This applies both within the
wheelbase and to the overhang.
Crossmembers (TRACTOR)
Crossmembers should be positioned as per the chassis
drawing.
If the rear axle has lost contact with the ground the air
suspension system must be reprogrammed to ensure
that the axle resumes contact with the ground. Contact
Technical Service at Volvo Truck Corporation for assis-
tance with reprogramming and to order new data kits for
the air suspension control unit.
Gearbox crossmember
The gearbox crossmember on a tractor vehicle (TRAC-
TOR) is subjected a higher degree of stress than on a
rigid vehicle (RIGID). If a truck which was originally a 3-
axle rigid vehicle is to be used as a tractor unit, the
gearbox crossmember must accordingly be changed.
Material
Extension profile
The correct extension profile must be used when extend- Extension profile Part no.
ing the frame. It should have the same material quality
and the same cross-section as the frame profile on the FRAME66 1625100
particular vehicle.
FRAMELOW FRAME77 1625200
The extension profile is sold in lengths of 2,4 m from FRAME88 1625300
Volvo Parts Corporation.
FRAMEMED FRAME77 1615771
FRAME66 1625400
FRAMEHIG FRAME77 1625500
FRAME88 1625600
Inner liner FRAME55 1625000
T9007008
Volvo Truck Corporation
Superstructure instructions Chassis
Vehicle type Date Section Page
Wheelbase alterations FM, FH, NH 10.00 5.10 13(28)
Reinforcement profile
RIGID
Reinforcement profile 3094843 is used for rigid vehicles
(RIGID) with 300 mm high frame profile, FRAMEHIG, to
reinforce the joint where the chassis frame has been cut.
T9007009
T9006336
TRACTOR
The inner liner FRAME55, with cut upper flange as
reinforcement profile, is used as inner liner on tractor ve-
hicles (TRACTOR 4x2).
Page 14
Design
Welded joint
See section 1.40 ”Attachment”.
Bolt unions
See section 1.40 ”Attachment”.
Driven bolted joints are used on TRACTORS to join the
reinforcement profile with the chassis frame.
Frame joint
Cutting point
Rigid
On a rigid vehicle (RIGID) with 300 mm high frame pro-
file (FRAMEHIG) or 275 mm high profile (FRAMEMED)
the frame should be cut 1650 mm in front of the leading
drive axle.
T9006162
T9006997
T9006996
TRACTOR
On a 4x2 TRACTOR the frame should be cut in the mid-
dle of the centre point of the gearbox member’s jointing
plate.
T9006995
Reinforcement
RIGID
The frame joint should always be reinforced with a rein-
forcement profile. This should extend 400 mm on each
side of the joint(s).
T9006099
T9006098
T9006991
T9006989
Page 18
TRACTOR 4x2
The frame joint should always be reinforced with a
bolted reinforcement piece. If the vehicle is built with
FRAMELOW frame, the upper flange on inner liner
FRAME55 is cut as below.
T9006990
Shortening 850
Extension 100 950
Extension 200 1050
Extension 300 1150
Extension 400 1250
T9006998
T9007001
Volvo Truck Corporation
Superstructure instructions Chassis
Vehicle type Date Section Page
Wheelbase alterations FM, FH, NH 10.00 5.10 19(28)
T9006999
T9007002
T9007000
Page 20
Chassis components
After length alterations to the chassis the removed chas-
sis components should be positioned:
T9006992
Framelow
T9006993
Framemed
T9006994
Framehig
Volvo Truck Corporation
Superstructure instructions Chassis
Vehicle type Date Section Page
Wheelbase alterations FM, FH, NH 10.00 5.10 21(28)
T9006328
T9006329
T9006331
Page 22
C9000108
T9006322
T9006334
Volvo Truck Corporation
Superstructure instructions Chassis
Vehicle type Date Section Page
Wheelbase alterations FM, FH, NH 10.00 5.10 23(28)
• Grind the weld bead on the top and root sides and
remove ignition marks and spatter. The grinding
should be conducted so that any grinding marks run
parallel to the frame and at right angles to the weld.
The joint should hardly be visible on completion of
the grinding.
T9007157
T9006272
Extension - overhang
Extension of the overhang should be conducted in the
same way as the extension of the wheelbase.
Page 24
T9006325
T9006331
Volvo Truck Corporation
Superstructure instructions Chassis
Vehicle type Date Section Page
Wheelbase alterations FM, FH, NH 10.00 5.10 25(28)
C9000109
T9006322
T9006324
• Grind the weld bead on the top and root sides and
remove ignition marks and spatter. The grinding
should be conducted so that any grinding marks run
parallel to the frame and at right angles to the weld.
The joint should hardly be visible on completion of
the grinding.
T9007157
Volvo Truck Corporation
Superstructure instructions Chassis
Vehicle type Date Section Page
Wheelbase alterations FM, FH, NH 10.00 5.10 27(28)
T9006128
Propeller shafts
Shaft in vehicle
The propeller shafts used are C2045, C2055 and
C2060. They are provided with cross-toothed companion
flanges that can only be fitted together in one position.
The following tables indicate which type of propeller
shaft should be used.
A stronger propeller shaft must be selected if the engine
torque or gross train weight is exceeded.
Driving on site
Propeller shaft Max. engine GCW (ton)
torque (Nm)
C2045 1190 35
C2055 1710 35
C2060 2550 60
Page 2
Dimensions
With support bearings
Pro- D T L (mm) Part number1
peller
shaft (mm) (mm) max. min.
1
Propeller shafts are available in length increments of 25 mm
from minimum length to maximum length. The part number gives
the lengths of the shortest and longest propeller shafts. All num-
bers in between are shafts of the same type, but different
lengths. For example, part no 1067505 is a C2055 with support
bearing and 475 mm long. The part number is marked on the
propeller shaft tube adjacent to one of the edges.
1
Propeller shafts are available in length increments of 25 mm
from minimum length to maximum length. The part number gives
the lengths of the shortest and longest propeller shafts. All num-
bers in between are shafts of the same type, but different
lengths. For example, part no 1067715 is a C2055 with spline
coupling and 725 mm long. The part number is marked on the
propeller shaft tube adjacent to one of the edges.
Propeller shafts with spined joints can be lengthened a
further 110 mm over and above the stated length by dis-
placing the bar union.
Volvo Truck Corporation
Superstructure instructions Chassis
Vehicle type Date Section Page
Propeller shafts – Outside South America FM, FH, NH 10.00 5.20 3(7)
Critical speed
To avoid reaching the propeller shaft’s critical speed the
propeller shafts must not exceed certain lengths, please
refer to the table below.
Installation
Selection of shaft
Select the same propeller shaft as the one fitted to a fac-
tory built vehicle with the corresponding driveline and
wheelbase. A shaft with standard length should always
be selected. The length is limited by the max. and min.
length for the propeller shaft in question.
T9006130
T9007338
Structure of shaft
Propeller shafts are normally supplied in parts with tubu-
lar sections and companion flanges.
T9007439
Assembly
Lubrication
The universal joints are maintenance-free. They already
contain sealed-in grease.
Joint displacement
On a propeller shaft with sliding bearings, the front and
rear yokes should be in phase with each other, i.e. with
a relative displacement of 0 . This is the case with a sin-
gle propeller shaft and a rear propeller shaft on a
multiple propeller shaft.
T9006131
Page 6
Companion flanges
Fix the flanges together with M14 screws, grade 10.9.
Tightening torque must be 190 ± 15 Nm. Screws and
nuts can be ordered from Volvo Parts AB, part nos
1672273 and 979020.
Joint angles
The joint angle is the angle between the input and out-
put shaft on a propeller shaft.
The gearbox shaft is the input in the first joint. In the last
joint the joint angle is the one between the last propeller
shaft and rear axle inclination.
The joint angle should be between 0.5 and 8.0 . If it is
less than 0.5 the bearing races on the spider’s needle
bearings can be damaged. If the joint angle is greater
than 8.0 the flexural torque in the spider will be so
excessive that the service life of the driveline will be re-
duced.
T9006167
Volvo Truck Corporation
Superstructure instructions Chassis
Vehicle type Date Section Page
Propeller shafts – Outside South America FM, FH, NH 10.00 5.20 7(7)
T9006284
T9006286
T9006285
Superstructure instructions
Volvo Truck Corporation
Göteborg, Sweden Chassis
Vehicle type Date Section Page
Propeller shaft – South American market FM, FH, NH 10.00 5.30 1(11)
C4001456
C9000140
V Vertical support
H Horizontal support
C4001457
A Support number
B Drilling position
Page 4
2 Drilling position
C4001460
Page 6
Example 2
The vehicle with the chassis number 670785 contains
the following variants:
C4001341
Unloaded vehicle
ZT1816
WB3500 8129152 1648 1456 3087 71 52 267 4.0 7.9 4.0
RAEV91
SR1900
WB3500 8129151 1621 1482 3087 71 54 267 4.0 8.0 4.0
RAEV91
ZT1816
WB3700 8129160 1846 1456 3287 71 52 267 4.0 7.0 4.0
RAEV91
SR1900
WB3700 8129159 1819 1482 3287 71 54 267 4.0 7.0 4.0
RAEV91
ZT1816
WB3500 8129154 1682 1456 3127 22 52 240 4.0 6.7 4.0
RAN471
SR1900
WB3500 8129153 1655 1482 3127 22 54 240 4.0 6.8 4.0
RAN471
Volvo Truck Corporation
Superstructure instructions Chassis
Vehicle type Date Section Page
Propeller shaft – South American market FM, FH, NH 10.00 5.30 9(11)
L1
x1 (mm) x2 (mm) y2 (mm) z1 (mm) z2 (mm)
1 (de- 2 (de- 3 (de-
Length grees) grees) grees)
P/N
(mm)
ZT1816
WB3700 8129162 1881 1456 3327 22 52 240 4.0 5.9 4.0
RAN471
SR1900
WB3700 8129161 1854 1482 3327 22 54 240 4.0 5.9 4.0
RAN471
WB = wheelbase
ZT1816
WB3500 8129151 1623 1481 3087 71 54 267 4.0 8.0 4.0
RAEV91
SR1900
WB3500 8129150 1596 1507 3087 71 56 267 4.0 8.1 4.0
RAEV91
ZT1816
WB3700 8129159 1821 1481 3287 71 54 267 4.0 7.0 4.0
RAEV91
SR1900
WB3700 8129158 1794 1507 3287 71 56 267 4.0 7.1 4.0
RAEV91
ZT1816
WB3500 8129153 1657 1481 3127 22 54 240 4.0 6.7 4.0
RAN471
SR1900
WB3500 8129152 1630 1507 3127 22 56 240 4.0 6.8 4.0
RAN471
ZT1816
WB3700 8129161 1856 1481 3327 22 54 240 4.0 5.9 4.0
RAN471
SR1900
WB3700 8129160 1829 1507 3327 22 56 240 4.0 6.0 4.0
RAN471
WB = wheelbase
Page 10
NH
C4001340
Unloaded vehicle
L1 L2
Variants
x1
(mm)
x2
(mm)
x3
(mm)
y2
(mm)
y3
(mm)
z1
(mm)
z2
(mm)
z3
(mm)
1 2 3 4
P/N (mm) P/N (mm)
ZT1816
WB4300 8129040 1300 8129131 1119 1481 2772 3887 24 71 54 134 267 4.0 3.5 7.4 4.0
RAEV91
ZT1816
WB4300 8129040 1300 8129133 1154 1481 2773 3927 12 22 54 123 240 4.0 3.0 6.2 4.0
RAN471
SR1900
WB4300 8129039 1275 8129131 1117 1507 2772 3887 24 71 56 134 267 4.0 3.5 7.4 4.0
RAEV91
SR1900
WB4300 8129039 1275 8129132 1152 1507 2773 3927 12 22 56 123 240 4.0 3.0 6.2 4.0
RAN471
C1 C1
Variants Installation posi- Variants Installation posi-
(mm) (mm)
tion tion
ZT1816 SR1900
A A
WB4300 2738 WB4300 2738
9-12 9-12
RAEV91 RAEV91
ZT1816 SR1900
B B
WB4300 2738 WB4300 2738
8-11 8-11
RAN471 RAN471
= angle WB = wheelbase
Volvo Truck Corporation
Superstructure instructions Chassis
Vehicle type Date Section Page
Propeller shaft – South American market FM, FH, NH 10.00 5.30 11(11)
L1 L2
Variants
x1
(mm)
x2
(mm)
x3
(mm)
y2
(mm)
y3
(mm)
z1
(mm)
z2
(mm)
z3
(mm)
1 2 3 4
P/N (mm) P/N (mm)
ZT1816
WB4600 8129040 1300 8129143 1417 1481 2772 4187 12 71 54 134 267 4.0 3.5 5.6 4.0
RAEV91
ZT1816
WB4600 8129040 1300 8129144 1453 1481 2773 4227 0 22 54 123 240 4.0 3.0 4.7 4.0
RAN471
SR1900
WB4600 8129039 1275 8129143 1415 1507 2772 4187 12 71 56 134 267 4.0 3.5 5.6 4.0
RAEV91
SR1900
WB4600 8129039 1275 8129144 1451 1507 2773 4227 0 22 56 123 240 4.0 3.0 4.8 4.0
RAN471
ZT1816
WB4300 8129036 1200 8129135 1218 1481 2672 3887 24 71 54 124 267 4.0 3.3 7.3 4.0
RAEV91
SR1900
WB4300 8129035 1175 8129135 1216 1507 2672 3887 24 71 56 124 267 4.0 3.3 7.3 4.0
RAEV91
SR1900
WB4300 8129035 1175 8129136 1252 1507 2672 3927 0 22 56 124 240 4.0 3.3 5.6 4.0
RAN471
ZT1816
WB4300 8129036 1200 8129137 1254 1481 2672 3927 0 22 54 124 240 4.0 3.3 5.6 4.0
RAN471
C1 C1
Variants Installation posi- Variants Installation posi-
mm mm
tion tion
ZT1816 ZT1816
B A
WB4600 2738 WB4300 2638
9-12 8-11
RAEV91 RAEV91
ZT1816 SR1900
C A
WB4600 2738 WB4300 2638
8-11 8-11
RAN471 RAEV91
SR1900 SR1900
B C
WB4600 2738 WB4300 2638
9-12 8-11
RAEV91 RAN471
SR1900 ZT1816
C C
WB4600 2738 WB4300 2638
8-11 8-11
RAN471 RAN471
= angle
WB = wheelbase
Superstructure instructions
Volvo Truck Corporation
Göteborg, Sweden Chassis
Vehicle type Date Section Page
Painting FM, FH, NH 10.00 5.40 1(1)
Painting
You are often exposed to solvents and other chemical
products when painting. Use suitable protective equip-
ment, make sure that there is good ventilation, and avoid
inhaling and skin contact. Always follow the instructions
on the packaging.