Chassis Training VOLVO

Body builder instructions
Volvo Truck Corporation
D
Gteborg, Sweden
Date Group Release Page

Supersedes VBI Release 09 from 3.09.
Changes are marked with a bar (|) in the margin. 6.09 95 10 1(24)
Chassis
Wheelbase alterations
FM, FH, NH, VERSION2
FE, FL
Contents
Introduction page 2
Restrictions page 3
Permitted wheelbase (RIGID) page 4
FM, FH, NH page 4
FE page 5
FL page 5
Permitted rear frame length (RIGID) page 8
Permitted overhang (TRACTOR) page 8
Cross members (RIGID) page 8
Shortening the wheelbase on vehicles with rear air suspension page 9
FM, FH, NH, FE page 10
FL page 10
Material page 10
Design page 12
Work procedure (RIGID) page 18
Work procedure (TRACTOR) page 21
Wheelbase alteration for vehicles with innerliner page 24
88928593
ENG36476.ihval English
Printed in Sweden
Volvo Truck Corporation Date Group Release Page
Body builder instructions 6.09 95 10 2(24)
Wheelbase alterations
Introduction
The instructions for alterations to the chassis length refer
to FM, FH, NH, FE, FL Rigid trucks (RIGID) and FM, FH,
NH and FE Tractors (TRACTOR).
The Volvo warranty ceases to be valid if the restrictions

below are not complied with, or the instructions are
otherwise not followed.
Modifications can only be made to trucks having different

chassis lengths and values to those shown in the tables,
after first obtaining special permission from the Volvo
D
Note: Since illustrations are reused for different
variants, certain details may differ from the variant in
question. The essential information in the illustrations
is however always accurate.
Truck Corporation.
Electrical cables must be jointed as described in Service T9007983

Manual, Group 37, Cable repairs. The Service Manual
can be ordered from Volvo Parts AB.
Propeller shafts must be installed and fitted as described

in Body builder instructions Propeller shafts and the
Service information, group 45, Propeller shafts.
After wheelbase modification, a Volvo dealer should be

contacted to update the VDA database and to download
the updated vehicle parameters.
Frames should be installed and fitted as described in

this section.
Restrictions
TRACTORS with bogies must not have the wheelbase

altered without authorisation from the Volvo Truck
Corporation.
RIGID vehicles must not be changed to TRACTORS,
without authorisation from the Volvo Truck Corporation,
since TRACTORS have a longer inner liner than RIGID
vehicles and another crossmember configuration.
TRACTORS with a low chassis frame (266 mm), and

regardless of frame thickness, must not be changed to
RIGID vehicles without authorisation from the Volvo
Truck Corporation.
D
RIGID vehicles with 6 mm thick and 300 mm high
chassis frames must not be changed to TRACTORS.
Rebuilt trucks must have the same dimensions and

measurements on the frames and inner liners as
a similar standard variant. This applies to both
wheelbase and rear frame length.
Making any type of modification to the crossmembers

is not permitted.
Moving any crossmembers that affect the suspension

or the gearbox crossmember is not permitted.
It is strictly forbidden to dismantle riveted joints

that attach and align the suspension and axles on
the chassis for the purpose of using these joints
elsewhere, such as fitting the lower parts of brackets to
the bodywork, etc.
Note: Always follow the legal requirements applicable

to your market.
Permitted wheelbase (RIGID)

The shortest possible wheelbase (WB) is limited by the
drive-line installation. The longest possible wheelbase is
limited by the frame strength and rigidity, which includes
the dynamic characteristics of the truck. The table below
indicates the shortest and longest permitted wheelbases
for RIGID trucks.
Note: The correct frame profile must be used for

respective wheelbases. Standard wheelbases and frame
profiles are shown in the chassis drawing.
FM, FH, NH
D
Permitted
Rear axle wheelbase (mm)
Vehicle
installation
Min Max
RAD-A4 6700
4x 2 3400
RAD-L90 6000
4x 4 RAD-L90 3500 4900
RADT-AR 3400
6x 2 RAPD-A6 4300 6000
RADT-A8 3500
RADD-BR
5600
RADD-TR
6x 4 RADD-TR 3200 3900
RSH-HIG 1
RADD-A8 5600
RADD-TR
6x 6 3500 4600
RADD-BR
RADT-AR 5100
8x 2 6000
RADT-A8 4300
RADD-A8 4600
6400
RADD-BR
RADD-TR 6200
8x 4 4300
RADD-TR
RSH-HIG 1 5100
RADDT12 3600
1
RSH-HIG: Rear Suspension Height High
D
FE
The permitted wheelbase for FE depends on the rear
axle installation.
Permitted
Rear wheelbase (mm)
Vehicle
suspension
Min Max
RADA2R 3500 6800
4 x2
RADL90 3495 6795
6 x2 RADTA4 3500 6450
6 x4 RADDBR 3195 5495
FL
The permitted wheelbases for FL depend on the vehicle
weight (12/14/16/18 T), rear suspension (leaf/air) and
chassis type (GVWR-L/M/H) and steel used.
GVWR-L = 12/14/16T
GVWR-M = 14/16T
GVWR-H = 18 T
The following tables show the permitted wheelbase

extensions. Frame strength can limit the extension.
GVWR-L and GVWRM (12T)

RSS-LEAF RSS-AIR
Wheelbase
GVWR-L GVWR-M GVWR-L GVWR-M
3070
3250
3500 4400 4400 3800
3800 Not allowed
4100
4400 Not allowed 5000
Not allowed
4700 5000
5000 Not allowed Not allowed
5300
5600
6500 6500
5900
6200
GVWR-L and GVWRM (14T)
Wheelbase
3070
3250
3500
3800
4100
4400
GVWR-L
3800
RSS-LEAF
Not allowed
5000
D
GVWR-M
3800
Not allowed
4700
GVWR-L
4400
Not allowed
RSS-AIR
GVWR-M
4700 Not allowed

5000 Not allowed
5300
6500
5600
6500
5900
6200
GVWR-L and GVWR-M (16T)

RSS-LEAF RSS-AIR
Wheelbase
GVWR-L GVWR-M GVWR-L GVWR-M
3070
3250
3500 4400 4700
3800 4400
4100
4700 Not allowed
5000
5300
6500 6500
5600
5900
6200
GVWR-H (18T)
Wheelbase
3070
3250
3500
3800
4100
4400
4700
RSS-LEAF
5000
RSS-AIR
5000
D
5300
5600
5900 6800 6800
6200
6500
Permitted rear frame length (RIGID)

Restriction
Rear frame length (RFL) is measured from the first driven
axle to the frame end, this is also shown in the geometry
parameter section in the order information. The correct
frame profile, inner liner and cross member must be used
for the respective wheelbases and truck variants. The
longest possible rear frame length is limited by the frame
strength, and the beam deflection.
Please see Chassis Drawings on the VBI site for the

longest permitted rear frame length.
D
WB = Wheelbase
T9008218
RFL = Rear frame length
Permitted overhang (TRACTOR)

The tractor overhang may only be changed with the
approval of Volvo.
Cross members (RIGID)

The distance between two adjacent crossmembers must
not exceed:
1500 mm (FM, FH, NH, FE)

1100 mm (FL)
This applies to both the wheelbase and the overhang.

Cross members should be positioned as shown in the
chassis drawing. The reinforcement, at inside of rails,
causes the frame side thickness to increase inwards,
requiring the crossmember to shortened by 10 mm. In
this case a shorter crossmember should be ordered from
Volvo Parts Corporation. T9006263
Alternatively, for vehicles built without innerliner, cut the

cross member in half and shorten each section by 5 mm.
Cross member for vehicles built with innerliner and extra
reinforcement should be cut and shortened 5 mm per
section (please refer to section Wheelbase alteration for
vehicles with innerliner. Weld the crossmember together
again. Grind off the weld bead and remove ignition marks,
spatter and slag. Follow the instructions for welding of
the sides of the frame as described in this section, rigid
or tractor.
Note: The welded cross member does not need a

reinforcement profile.
Shortening the wheelbase on vehicles with rear air suspension

Changing the wheelbase is considered a critical job
demanding high quality results and where it is the
body builders responsibility to ensure correct vehicle
performance.
Installation of extra axles on an air suspended vehicle

should not be carried out without first contacting Volvo or
a Volvo recommended company.
To ensure that the bogie does not lose contact with the
ground after shortening the wheelbase, ensure that the
slope of the vehicle falls within the values shown below.
This shall be done before shortening the wheelbase.
D
Maximum permitted frame slope
Rigid: 1 degree towards the front and 1 degree to the rear.
Tractor: 2 degrees towards the front and 1 degree to the
rear.
If the rear axle subsequently loses contact with the ground

it will hang on its shock absorbers and be pressed down
under full pressure. There will then be a risk of damaging
the air suspension system and, in particular, the shock
absorbers and reaction rod.
If the rear axle loses 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
assistance with reprogramming and to order new data kits
for the air suspension control unit.
Gearbox crossmember
The gearbox crossmember is used for tractors that are
exposed to high load levels. If a truck (which was originally
a 3-axle rigid vehicle) is to be used as a tractor unit, the
gearbox crossmember must be changed accordingly.
The gearbox crossmember on the 3-axle tractor has a

thicker plate on both the crossmember and the tie plate
in comparison with a similar rigid vehicle. In the tractor
variants the gearbox crossmember is joined to each side
of the frame by 6 bolts. On some variants, two of the bolts
are replaced by rivets.
Gearbox crossmembers for tractors can be ordered from

the Volvo Parts Corporation.
T9008068
1 Bolt
2 Rivet
Material
Extension profile
The correct extension profile must be used when
extending the frame. It should be of the same material
quality and have the same cross-section as the frame
profile of the particular vehicle.
FM, FH, NH, FE

The extension profile is sold in lengths of 2,4 m and can
be obtained from the Volvo Parts Corporation.
D
Extension profile Part no.
1
FRAME66 1625100
FRAMELOW FRAME77 1625200
FRAME88 1625300
FRAME66 1 1625400
FRAMEHIG FRAME77 1625500
FRAME88 1625600
Inner liner FRAME55 1625000 T9008566
1
Extension
Not available for FE LF = 2400 mm (FM, FH, NH, FE)
LF = 2400 mm, except for FRAME220,
FL FRAME66, FMAT-HT = 1200 mm (FL)
The extension profile is sold in lengths of 2,4 m and can
be obtained from the Volvo Parts Corporation.
Extension Part no
profile
FMAT- FMAT
BAS -HT
FRAME55 20934191
FRAME66 20934197 20934200
FRAME220
FRAME77 20934198 20934202
FRAME88 20934199 20934203
FRAME244 FRAME77 20934204
FRAME88 20934206
Reinforcement profile
RIGID
FM, FH, NH, FE
Reinforcement profile 3094843 is used for rigid vehicles
(RIGID) with a 300 mm high frame profile, FRAMEHIG, to
reinforce the joint where the chassis frame has been cut.
The same reinforcement profile can be used for rigid

vehicles with FRAMELOW, if the upper flange on the
reinforcement is cut.
Reinforcement
profile
Part no.
D
FRAMEHIG FRAME55 3094843
FL
(RIGID) with a 220 mm high frame profile, FRAME220, to

T9008567
(RIGID) with a 244 mm high frame profile, FRAME244, to
Reinforcement Part no
profile
FMAT- FMAT
BAS -HT
FRAME220 FRAME55 82050007 82050007
FRAME224 FRAME55 - 82050062
TRACTOR
The inner liner 1625000 is used for tractor vehicles.
The same reinforcement profile can be used for rigid

vehicles with FRAMELOW, if the upper flange on the
reinforcement is cut. This is described in the section
"Reinforcement".
T9007008
Design
Welded joint
Please refer to Body builder instructions Attachments.
Bolt unions
Please refer to Body builder instructions Fasteners.
Driven bolted joints should be used on TRACTORS to join
the reinforcement profile to the chassis frame. Co-drill the
bolted joint on TRACTORS with the reinforcement profile
and the chassis frame. The hole diameter should be
13,8 mm for co-drilled M14 joints.
D
Note: Driven joints must be tightened at the nut.
Tightening torque M14:
FM, FH, NH: 140 Nm 20 Nm
FE, FL: 155 31 Nm
For bolt part numbers, please refer to Body builder
instructions Fasteners.
Frame joint
Cutting point
RIGID
FM, FH, NH
On a rigid FM, FH, NH vehicle, the frame should be cut

1650 mm in front of the leading drive axle.
T9007986
Cutting point FM,, FH, NH

23 mm = reference hole in chassis frame
FE, FL
On a rigid FE, FL vehicle, the frame should be cut

1550 mm (D) in front of the leading drive axle.
T9008578
Cutting point FE, FL
TRACTOR
If a tractor is to be used as a rigid vehicle after altering
the wheelbase, the frame joint should be positioned as for
a rigid truck. (This assumes that the tractor unit frame
profile corresponds to the rigid truck). Instructions for
changing the wheelbase of the rigid truck must then be
followed.
D
On a 4x2 TRACTOR, the frame should be cut in the
middle of the centre point of the gearbox members joint
plate (L).
T9006995
D
Reinforcement
RIGID
The frame joint should always be reinforced with a
reinforcement profile. This should extend by 400 mm on
each side of the joint(s).
The reinforcement profiles can be shortened by being cut

into 800 mm pieces.
In extensions of up to 800 mm, the reinforcement profile T9006099
should cover both joints by being cut to the correct length.
Two reinforcement profiles of 800 mm each are used for T9006098
extensions over 800 mm.
For FRAMELOW, the reinforcement profile (3094843) T9006991
should be cut 39 mm under the upper edge of the upper

flange. (There will not be enough room on the frame for
the upper flange on the reinforcement profile.)
T9006989
D
TRACTOR 4x2
The frame joint should always be reinforced with a
bolted reinforcement piece. If the vehicle is built with a
FRAMELOW frame, the upper flange on the inner liner
FRAME55 is cut as illustrated below.
Cut the upper flange on the reinforcement pieces (A) mm
under the upper edge of the upper flange.
FRAME66 FRAMELOW A = 35 mm
Cut the reinforcement pieces to the correct length. T9006990
4x2T
Wheelbase alterations Length of reinforcement
piece (mm)
Shortening 850
Extension = L L + 850
Example: L=100
Length of reinforcement piece =100+850=950 mm (see
illustration).
Drill 6 mm holes in the reinforcement pieces as shown

in the diagram. These holes should later be co-drilled
with the chassis frame up to 13.8 mm for M14 joints or
15.7 mm for M16 joints.
T9008193
T9008194
L=100 mm
D
Tractor 4x2
T9008195
L=200 mm
T9008196
L=300 mm
T9007000
L=400 mm
Chassis components on FH/FM/NH/FE

After alterations to the length of the chassis, the previously
removed components should be re-fitted as follows:
By measuring the chassis.
According to the chassis drawing.

According to the adjacent hole pattern.
D
T9006992
Framelow
T9006994
FRAMEHIGH
Work procedure (RIGID)
Position the vehicle on a flat surface.
Remove the propeller shafts, brake liners, electrical

cables and other components at the cutting area.
Punch mark the position of the rear measuring points

(RM), on the frame members. A line through RM1
& RM2 should be perpendicular to the frame profile
length.
D
T9006328
Select the front measuring points (FM) so that the

distance to the rear measuring points (RM) after the
wheelbase alteration is at least 1200 mm.
T9006329
Mark out the cutting points with a dotted line. For

shortening, mark out two cutting point(s).
Mark the measuring points (B) on the frame members

so that the centre punch marks are just off centre from
the cutting point.
Carefully measure and note the distance (C) between
the centre punch marks.
T9006331
Support the chassis members with axle stands so that

it is adequately supported. Use a spirit level to check
that the chassis members are horizontal.
Cut the frame members at right angles. Cut any

extension profiles to the correct length. Even off and
chamfer the welded surfaces to an external V-joint,
forming the V-joint according to the welding method
used (A) or (B).
D T9008069
T9006330
A = Metal arc welding

B = Gas-metal arc welding (MAG)
T9006322
Adjust the frame to the correct distance between the Check that the distance between (FM) and (RM) is the
front and rear measuring points (FM) and (RM). Fit same on both sides.
any extension profiles in position. The root gap for the
welding joint should be as shown by either alternative Check that the diagonal measurements between (FM)
(A) or (B) in the adjacent illustration. and (RM) do not differ by more than 2 mm.
T9006334
D
Check that the surfaces of the frame members are
level with each other. When they are level the frame
members should be tack-welded together.
Re-check the measurement.
If the measurements are correct, weld the frame

together. Re-weld the root. The weld root should be
made according to the welding sequence shown in
the adjacent illustration.
Grind the weld bead on the top and sides of the root
and remove ignition marks and spatter. Grinding
should be done so that any grinding marks run parallel
to the frame and at right angles to the weld. After
grinding, the joint should hardly be visible.
T9007157
Cut the reinforcement profiles (midway between

the holes) to the correct length. Please refer to the
illustration and remove any burrs.
Place the reinforcement profiles in the correct position

and plug weld the pre-punched holes.
Note: Only the pre-punched holes should be

plug-welded.
For painting please refer to Body builder instructions

General about bodywork
T9006272
Work procedure (TRACTOR)
Position the vehicle on a flat surface.
Remove the propeller shafts, brake lines, electrical

cables and other components at the cutting area.
Remove the required number of rivets on the L-profiles.
Release the gearbox crossmember.
Mark out the cutting point(s).

D
T9006995
Mark out the position for the rear measuring points

(RM) on the frame members with centre punch marks.
They should be at right angles to the frame web.
T9006325
Mark out the cutting points with a dotted line. For

shortening, mark out two cutting points.
Mark the front and rear measuring points (B) just off
centre from the cutting point(s).
Measure and note the distance (C) between the centre

punch marks.
T9006331
Support the chassis members on axle stands, so that

the chassis is adequately supported. Use a spirit level
to check that the chassis members are horizontal.
T9008070
D
Cut the frame members at right angles. Cut any
extension profiles to the correct length. Even off and
chamfer the welded surfaces to an external V-joint,
forming the V-joint according to the welding method
used (A) or (B).
T9006322
A = Metal arc welding

B = Gas-metal arc welding (MAG)
Place the new, shorter gearbox crossmember inside

the chassis frame as far to the rear as possible.
Adjust the frame to the correct distance between the

front and rear measuring points FM and RM and
position any extension profiles. The root gap for the
weld joint should be as shown in either alternative (A) T9006330
or (B) in the adjacent illustration.
Check that the distance between FM and RM is the

same on both sides.
Check that the diagonal measurements between FM

and RM do not differ by more than 2 mm diagonally.
T9008257
Check that the surfaces of the crossmembers are

level with each other. When they are level the
crossmembers and reinforcement profiles should be
tack-welded together.
Re-check the measurement.
If the measurement is correct, complete the welding.

Re-weld the root. The weld root should be made
using the welding sequence shown in the adjacent
illustration.
Grind the weld bead on the top and sides of the root
and remove ignition marks and spatter. Grinding
should be done so that any marks run parallel to the
frame and at right angles to the weld. After grinding,
the joint should hardly be visible.
For painting please refer to Body builder instructions

General about bodywork
T9007157
D
Centre the reinforcement pieces over the joint so that
the pre-drilled 6 mm holes correspond with the
frames hole location system.
Drill 2 6 mm holes in the chassis frame to coincide

with the reinforcement profiles 6 mm holes and
secure the reinforcement profile with two M6 bolts.
Drill 6 mm hole from the inside in the chassis frame

using the reinforcement piece as a template.
Install the new, shorter gearbox crossmember in the

correct position. Please refer to the chassis drawing.
The screw holes used in the gearbox crossmember

before the chassis length was made should be re-used
after the alteration, together with new holes made in
the reinforcement piece.
Fit any support members in the correct position.
Co-drill all 6 mm holes to 13,8 mm (through

the reinforcement piece, frame side, and where
appropriate the L-profile).
Bolt with M14 driven bolts as described in Body builder

instructionsFasteners.
Re-fit chassis components with the existing bolts.
Note: Solvents must not be allowed to come in contact

with the plastic glass on lamps when cleaning.
Wheelbase alteration for vehicles with innerliner

To lengthen or shorten a chassis frame where innerliner is
used, for tractors and rigid vehicles, the work procedure is
basically the same as tractor and rigid without innerliner.
Cut the frame and the innerliner to the right length at

straight angles. The best result is achieved if frame
and innerliner are cut together. Even off the surfaces
and chamfer the surfaces that are to be welded to
an external v-joint, according to either (A) or (B)
depending on the welding method used.
To avoid damage from ignition or spatter to inner sides

of frame and innerliner when welding, insulate between
D
The following instructions complete the procedure for
vehicles with innerliner.
T9006330
frame and innerliner using ceramic backing, or ceramic

fabric or equivalent insulation.
Proceed by welding the chassis frame parts together

from outside, and continue by welding the innerliner
parts together from inside, observing welding
sequence and weld roots in the adjacent illustration.
Grind the weld bead on top and sides of the root and
remove ignition marks and spatter. Grinding should be
done so that any marks run in parallel with the frame
and at a right angle to the weld. After grinding, the joint
should hardly be visible.
T9008770
A reinforcement profile to strengthen the welded

joint should be manufactured by the bodybuilder, an
example could look like as the sketch below. Use the
same material as for the chassis frame or innerliner or
equivalent, with the same surface treatment for the
chassis frame (please refer to Body builder instruction
Chassis painting). The thickness of the manufactured
reinforcement should be 5 mm. (It is recommended
to use bolted joints as shown in the illustration below
with at least 2 driven M16 at the edge and 8 M14 on
each side of the weld joint.)
T9008771
Items in illustrations:
1 Chassis frame
2 Innerliner
3 Extra reinforcement
T9008818 T9008817
FRAMEHIGH FRAMELOW

Chassis Training VOLVO

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Body builder instructions

Volvo Truck Corporation

Date Group Release Page

The Volvo warranty ceases to be valid if the restrictions

Modifications can only be made to trucks having different

Electrical cables must be jointed as described in Service T9007983

Propeller shafts must be installed and fitted as described

After wheelbase modification, a Volvo dealer should be

Frames should be installed and fitted as described in

TRACTORS with bogies must not have the wheelbase

TRACTORS with a low chassis frame (266 mm), and

Rebuilt trucks must have the same dimensions and

Making any type of modification to the crossmembers

Moving any crossmembers that affect the suspension

It is strictly forbidden to dismantle riveted joints

Note: Always follow the legal requirements applicable

Permitted wheelbase (RIGID)

Note: The correct frame profile must be used for

The following tables show the permitted wheelbase

GVWR-L and GVWRM (12T)

GVWR-L and GVWRM (14T)

4700 Not allowed

GVWR-L and GVWR-M (16T)

4700 Not allowed

Permitted rear frame length (RIGID)

Please see Chassis Drawings on the VBI site for the

RFL = Rear frame length

Permitted overhang (TRACTOR)

Cross members (RIGID)

1500 mm (FM, FH, NH, FE)

This applies to both the wheelbase and the overhang.

Alternatively, for vehicles built without innerliner, cut the

Note: The welded cross member does not need a

Shortening the wheelbase on vehicles with rear air suspension

Installation of extra axles on an air suspended vehicle

If the rear axle subsequently loses contact with the ground

The gearbox crossmember on the 3-axle tractor has a

Gearbox crossmembers for tractors can be ordered from

FM, FH, NH, FE

The same reinforcement profile can be used for rigid

Reinforcement profile 82050062 is used for rigid vehicles

The same reinforcement profile can be used for rigid

On a rigid FM, FH, NH vehicle, the frame should be cut

Cutting point FM,, FH, NH

On a rigid FE, FL vehicle, the frame should be cut

Cutting point FE, FL

The reinforcement profiles can be shortened by being cut

In extensions of up to 800 mm, the reinforcement profile T9006099

should cover both joints by being cut to the correct length.

Two reinforcement profiles of 800 mm each are used for T9006098

extensions over 800 mm.

For FRAMELOW, the reinforcement profile (3094843) T9006991

should be cut 39 mm under the upper edge of the upper

Cut the reinforcement pieces to the correct length. T9006990

Drill 6 mm holes in the reinforcement pieces as shown

Chassis components on FH/FM/NH/FE

By measuring the chassis.

According to the chassis drawing.

Work procedure (RIGID)

Position the vehicle on a flat surface.

Remove the propeller shafts, brake liners, electrical

Punch mark the position of the rear measuring points

Select the front measuring points (FM) so that the