Body Builder Instructions Volvo Trucks North America Body Builder, General Guidelines and Certification VN, VHD, VAH Section 0 Introduction The information in this document was developed to assist our customers throughout the body planning and installation process. This information will assist with the required specifications and guidelines for completion for your specific applications. The information in this document does not include each and every unique situation that you may encounter when working on Volvo vehicles. Volvo Trucks North America cannot possibly know, evaluate, or advise someone on all the types of work that can be done on a Volvo vehicle and all the appropriate ways to do such work. This includes all of the possible consequences of performing such work in a certain manner. Therefore, any situations or methods of working on a Volvo vehicle that are not addressed in this document are not necessarily approved by Volvo Trucks North America. In the event that you require additional assistance, please contact Volvo Body Builder Support at 877-770-7575. Unless otherwise stated, following the recommendations listed in this document does not automatically guarantee compliance with applicable government regulations. Compliance with applicable government regulations is your responsibility as the party making the additions/modifications. Please be advised that the Volvo Trucks North America vehicle warranty does not apply to any Volvo vehicle that has been modified in any way, which in Volvo’s judgment might affect the vehicles stability or reliability. The information, specifications, and illustrations in this document are based on information that was current at the time of publication. Please note that illustrations are typical and may not reflect the exact arrangement of every component installed on a specific vehicle. No part of this publication may be reproduced, stored in a retrieval system, or transmitted by any means including (but not limited to) electronically. Note: The model VN includes VNM, VNL, and VNX. The VNM model is replaced with the new VNR model, which will start production in late August or early September 2017. The VNM model and the new VNR model share the same cab, chassis, and fuel tank dimensions. Contents: • • • • “Introduction”, page 1 “Glossary”, page 3 “Conversion Chart”, page 4 “Safety Regulations and Standards General”, page 7 Volvo Body Builder Instructions USA159041959 VN, VHD, VAH, Section 0 Date 11.2021 Page 1 (104) All Rights Reserved • • • • • • • • • • • • • • • • • “Certification Label”, page 14 “Center of Gravity”, page 15 “Brake Modification Guidelines”, page 16 “Air-operated Accessories”, page 17 “Welding”, page 18 “Battery Charging and Jump Starting”, page 19 “Data Link Wiring”, page 20 “Towing Procedure”, page 22 “Weight Distribution”, page 27 “Conversion Factors”, page 36 “Chassis Diagrams, VHD”, page 38 “Chassis Diagrams, VAH”, page 54 “Chassis Diagrams, VNM / VNR”, page 56 “Chassis Configurations, VHD”, page 64 “Chassis Configurations, VN”, page 72 “Fuel Tank Position, VHD ”, page 78 “Fuel Tank Position, VN ”, page 92 VN, VHD, VAH, Section 0 USA159041959 Date 11.2021 Release Page 2 (104) Glossary Gross Axle Weight Rating (GAWR) The maximum rated capacity measured at the ground for a given axle system consisting of the axle, springs, wheels, and tires. May also be influenced by the frame capacity. GAWR is determined by the least rated component in the system. Gross Vehicle Weight (GVW) The in-service vehicle weight, including chassis, body, add-on equipment, and cargo. Gross Vehicle Weight Rating (GVWR) The manufacturer’s maximum rated GVW for any given vehicle. GVWR is frequently the sum of the GAWRs. However, it may be downrated for braking or handling considerations. Payload Weight The actual weight of the cargo carried by a vehicle. Tare Weight The weight of a truck fully equipped and ready for service, minus any payload. Also called curb weight or empty weight. All trucks begin with a tare weight for the standard chassis, to which weights are added for optional equipment, fuel, body and equipment, plus driver and passengers. Notes Volvo Body Builder Instructions USA159041959 VN, VHD, VAH, Section 0 Date 11.2021 Body Builder, General Guidelines and Certification Page 3 (104) All Rights Reserved General Guidelines Conversion Chart Conversion Units Multiply By Length Calculations Inches (in) to Millimeters (mm) 25.40 Inches (in) to Centimeters (cm) 2.540 Feet (ft) to Centimeters (cm) 30.48 Feet (ft) to Meters (m) 0.3048 Yards (yd) to Centimeters (cm) 91.44 Yards (yd) to Meters (m) 0.9144 Miles (mi) to Kilometers (km) 1.609 Millimeters (mm) to Inches (in) 0.03937 Centimeters (cm) to Inches (in) 0.3937 Centimeters (cm) to Feet (ft) 0.0328 Centimeters (cm) to Yards (yd) 0.0109 Meters (m) to Feet (ft) 3.281 Meters (m) to Yards (yd) 1.094 Kilometers (km) to Miles (mi) 0.6214 Area Calculations Square Inches (sq-in) to Square Millimeters (sq-mm) 645.2 Square Inches (sq-in) to Square Centimeters (sq-cm) 6.452 Square Feet (sq-ft) to Square Centimeters (sq-cm) 929.0 Square Feet (sq-ft) to Square Meters (sq-m) 0.0929 Square Yards (sq-yd) to Square Meters (sq-m) 0.8361 Square Miles (sq-mi) to Square Kilometers (sq-km) 2.590 Square Millimeters (sq-mm) to Square Inches (sq-in) 0.00155 Square Centimeters (sq-cm) to Square Inches (sq-in) 0.155 Square Centimeters (sq-cm) to Square Feet (sq-ft) 0.001076 Square Meters (sq-m) to Square Feet (sq-ft) 10.76 Square Meters (sq-m) to Square Yards (sq-yd) 1.196 Square Kilometers (sq-km) to Square Miles (sq-mi) 0.3861 Volume Calculations Cubic Inches (cu-in) to Cubic Centimeters (cu-cm) 16.387 Cubic Inches (cu-in) to Liters (L) 0.01639 Quarts (qt) to Liters (L) 0.9464 Volvo Body Builder Instructions USA159041959 VN, VHD, VAH, Section 0 Date 11.2021 Body Builder, General Guidelines and Certification Page 4 (104) All Rights Reserved Conversion Units Multiply By Gallons (gal) to Liters (L) 3.7854 Cubic Yards (cu-yd) to Cubic Meters (cu-m) 0.7646 Cubic Centimeters (cu-cm) to Cubic Inches (cu-in) 0.06102 Liters (L) to Cubic Inches (cu-in) 61.024 Liters (L) to Quarts (qt) 1.0567 Liters (L) to Gallons (gal) 0.2642 Cubic Meters (cu-m) to Cubic Yards (cu-yd) 1.308 Weight Calculations Ounces (oz) to Grams (g) 28.5714 Pounds (lb) to Kilograms (kg) 0.4536 Pounds (lb) to Short Tons (US tons) 0.0005 Pounds (lb) to Metric Tons (t) 0.00045 Short Tons (US tons) to Pounds (lb) 2000 Short Tons (US tons) to Kilograms (kg) 907.18486 Short Tons (US tons) to Metric Tons (t) 0.90718 Grams (g) to Ounces (oz) 0.035 Kilograms (kg) to Pounds (lb) 2.205 Kilograms (kg) to Short Tons (US tons) 0.001102 Kilograms (kg) to Metric Tons (t) 0.001 Metric Tons (t) to Pounds (lb) 2205 Metric Tons (t) to Short Tons (US tons) 1.1023 Metric Tons (t) to Kilograms (kg) 1000 Force Calculations Ounces Force (ozf) to Newtons (N) 0.2780 Pounds Force (lbf) to Newtons (N) 4.448 Pounds Force (lbf) to Kilograms Force (kgf) 0.456 Kilograms Force (kgf) to Pounds Force (lbf) 2.2046 Kilograms Force (kgf) to Newtons (N) 9.807 Newtons (N) to Kilograms Force (kgf) 0.10196 Newtons (N) to Ounces Force (ozf) 3.597 Newtons (N) to Pounds Force (lbf) 0.2248 Newton Meters (Nm) 0.11298 Torque Calculations Pound Inches (lb-in) Volvo Body Builder Instructions USA159041959 to VN, VHD, VAH, Section 0 Date 11.2021 Body Builder, General Guidelines and Certification Page 5 (104) All Rights Reserved Conversion Units Multiply By Pound Feet (lb-ft) to Newton Meters (Nm) 1.3558 Pound Feet (lb-ft) to Kilograms Force per Meter (kgfm) 0.13825 Newton Meters (Nm) to Pound Inches (lb-in) 8.851 Newton Meters (Nm) to Pound Feet (lb-ft) 0.7376 Newton Meters (Nm) to Kilograms Force per Meter (kgfm) 0.10197 Kilograms Force per Meter (kgfm) to Pound Feet (lb-ft) 7.233 Kilograms Force per Meter (kgfm) to Newton Meters (Nm) 9.807 Radiator Specific Heat Dissipation Calculations British Thermal Unit per Hour (BTU/hr) to Kilowatt per Degree Celsius (kW/C) to 0.000293 Kilowatt per Degree Celsius (kW/ C) British Thermal Unit per Hour (BTU/hr) 3414.43 Temperature Calculations Degrees Fahrenheit (F) to Degrees Celsius (C) (F 32) x 0.556 Degrees Celsius (C) to Degrees Fahrenheit (F) (1.8 x C) + 32 Pressure Calculations Atmospheres (atm) to Bars (bar) 1.01325 Atmospheres (atm) to Kilopascals (kPa) 101.325 Bars (bar) to Atmospheres (atm) 0.98692 Bars (bar) to Kilopascals (kPa) 100 Bar (bar) to Pounds per Square Inch (psi) 14.5037 Inches of Mercury (in Hg) to Kilopascals (kPa) 3.377 Inches of Water (in H2O) to Kilopascals (kPa) 0.2491 Pounds per Square Inch (psi) to Kilopascals (kPa) 6.895 Pounds per Square Inch (psi) to Bar (bar) 0.06895 Kilopascals (kPa) to Atmospheres (atm) 0.00987 Kilopascals (kPa) to Inches of Mercury (in Hg) 0.29612 Kilopascals (kPa) to Inches of Water (in H2O) 4.01445 Kilopascals (kPa) to Pounds per Square Inch (psi) 0.145 Power Calculations Horsepower (hp) to Kilowatts (kW) 0.74627 Kilowatts (kW) to Horsepower (hp) 1.34 Volvo Body Builder Instructions USA159041959 VN, VHD, VAH, Section 0 Date 11.2021 Body Builder, General Guidelines and Certification Page 6 (104) All Rights Reserved Conversion Units Multiply By Fuel Performance Calculations Miles per Gallon (mi/gal) to Kilometers per Liter (km/L) 0.4251 Kilometers per Liter (km/L) to Miles per Gallon (mi/gal) 2.352 Velocity Calculations Miles per Hour (mi/hr) to Kilometers per Hour (km/hr) 1.609 Kilometers per Hour (km/hr) to Miles per Hour (mi/hr) 0.6214 Volume Flow Calculations Cubic Feet per Minute (cu-ft/min) to Liters per Minute (L/min) 28.32 Liters per Minute (L/min) to Cubic Feet per Minute (cu-ft/min) 0.03531 Safety Regulations and Standards General All motor vehicles must conform to the motor vehicle safety standards (MVSS) mandated by the U.S. and Canadian Governments. MVSS address the manufacture and sale of a new motor vehicle, not its use. U.S. Federal MVSS and safety regulations are issued and enforced by the National Highway Traffic Safety Administration (NHTSA) of the U.S. Department of Transportation (USDOT). In Canada, motor vehicle safety regulations/standards are issued and enforced by the Ministry of Transport (Transport Canada). Standards and regulations apply to newly manufactured motor vehicles and certain motor vehicle equipment offered for sale, or placed into operation in the United States, its territories (which include the District of Columbia, the Northern Mariana Islands, Puerto Rico, Guam, the Virgin Islands and American Samoa) and Canada. These safety standards and regulations are applicable to motor vehicles and motor vehicle equipment manufactured on and after the effective date of each standard/regulation. Specific vehicle certification label(s) must be affixed to motor vehicles to certify that the vehicle conforms to all applicable U. S. Federal or Canada Motor Vehicle Safety Standards (FMVSS and CMVSS) at the time of manufacture. For a vehicle manufactured in two or more stages, the party that completes an incomplete vehicle, e.g., by the addition of a load-carrying body, is the final-stage manufacturer and is responsible for certifying (by labeling) that the completed vehicle complies with all applicable FMVSS or CMVSS. Additionally, if a new vehicle that has been certified as a completed vehicle is altered in such a manner that its compliance with any FMVSS or CMVSS is affected, or its weight ratings are changed before its first purchase by a customer, the party performing the alteration must re-certify (re-label) the vehicles compliance with applicable FMVSS or CMVSS. For more information on vehicle certification, refer to this guide. Notes Volvo Body Builder Instructions USA159041959 VN, VHD, VAH, Section 0 Date 11.2021 Body Builder, General Guidelines and Certification Page 7 (104) All Rights Reserved Safety Regulations and Standards Penalties for Violation Penalties for noncompliance with U.S. Federal and Canada Motor Vehicle Safety Standards and Regulations are severe. Penalties for U.S. noncompliance can be found in U.S. Code of the Federal Regulations 49CFR§578.Penalties for Canadian noncompliance can be found in Transport Canada’s Motor Vehicle Safety Act SC1993, c.16, section 17. The above penalties may apply to any party that: • Manufactures a vehicle for sale that does not comply with all applicable MVSS in effect at the time the vehicle was manufactured. • • • • Offers a vehicle for sale that does not comply with all applicable MVSS in effect at the time the vehicle was manufactured. Sells a vehicle that does not comply with all applicable MVSS in effect at the time the vehicle was manufactured. Fails to provide the proper certification labels and documents for a vehicle in the manner required. Provides the required certification labels and documents in spite of knowing that the vehicle does not comply with all applicable (MVSS). Both the National Highway Traffic Safety Administration (NHTSA) and Transport Canada may periodically inspect new vehicles subject to the standards and regulations in order to find vehicles that do not comply with the requirements. It is mandatory that all personnel involved with the following know the requirements of the standards and regulations. • • • • • • Sales Modification or conversion Installation of bodies and/or equipment Intermediate/final manufacture Preparation for delivery Maintenance and/or repair Many public libraries keep a complete, up-to-date copy of the U.S. Code of the Federal Regulations. In Canada, the Motor Vehicle Safety Standards/Regulations may be obtained at Federal government bookstores and many law libraries. The regulations/standards of both countries are also publicly available on the Internet. The FMVSS can be found in Title 49CFR§571 (e.g., FMVSS 101 is Section 571.101). The CMVSS, Canadian Motor Vehicle Safety Regulations (CMVSR), Motor Vehicle Tire Safety Regulations (CMVTSR), Technical Standards Documents (TSD) and Test Methods (TM) can be found in C.R.C., c.1038. https://www.ecfr.gov/current/title-49/subtitle-B/chapter-V/part-571/subpart-B?toc=1 https://tc.canada.ca/en/corporate-services/acts-regulations/list-regulations/motor-vehicle-safety-regulations-crc-c-1038? pedisable=false https://laws-lois.justice.gc.ca/eng/regulations/SOR-2013-198/ Volvo Body Builder Instructions USA159041959 VN, VHD, VAH, Section 0 Date 11.2021 Body Builder, General Guidelines and Certification Page 8 (104) All Rights Reserved Safety Standards Lists and Tables The following table lists U.S. Federal and Canada Motor Vehicle Safety Standards applicable to all Class 6, 7 and 8 trucks and truck tractors, or related equipment, sold in the United States and Canada. U.S/Federal and Canada Motor Vehicle Safety Standards, National Safety Code Standard U.S. Standard No. (1) Canada Standard No. (2) Title of Standard FMVSS 101 CMVSS 101 Location and Identification of Controls and Displays FMVSS 102 CMVSS 102 Transmission Shift Lever Sequence, Starter Interlock and Transmission Braking Effect FMVSS 103 CMVSS 103 Windshield Defrosting and Defogging Systems FMVSS 104 CMVSS 104 Windshield Wiping and Washing Systems FMVSS 106 CMVSS 106 Brake Hoses FMVSS 108 CMVSS 108 Lamps, Reflective Devices, and Associated Equipment/Lighting System and Retroreflective Devices FMVSS 111 CMVSS 111 Rear-View Mirrors FMVSS 113 CMVSS 113 Hood Latch System (3) CMVSS 115 Vehicle Identification Number FMVSS 119 (4) New Pneumatic Tires for Vehicles Other Than Passenger Cars FMVSS 120 CMVSS 120 Tire and Rim Selection for Motor Vehicles Other Than Passenger Cars FMVSS 121 CMVSS 121 Air Brake Systems FMVSS 124 CMVSS 124 Accelerator Control Systems FMVSS 125 NSCS 11, Section 5 (National Safety Code Standard 11, Section 5) (10) Warning Devices FMVSS 136 (9) CMVSS 136 (9) Electronic Stability Control Systems for Heavy Vehicles FMVSS 205 CMVSS 205 Glazing Materials FMVSS 206 CMVSS 206 Door Locks and Door Retention Components FMVSS 207 CMVSS 207 Seating and Seat Anchorage Systems FMVSS 208 CMVSS 208 Occupant Crash Protection FMVSS 209 CMVSS 209 Seat Belt Assemblies FMVSS 210 CMVSS 210 Seat Belt Assembly Anchorages N/A CMVSS 301.2 CNG Fuel System Integrity FMVSS 302 CMVSS 302 Flammability of Interior Materials FMVSS 304 N/A CNG Fuel Container Integrity Volvo Body Builder Instructions USA159041959 VN, VHD, VAH, Section 0 Date 11.2021 Body Builder, General Guidelines and Certification Page 9 (104) All Rights Reserved (7) CMVSS 1100 Vehicle Emissions (8) (5) CMVSS 1106 Noise Emissions (6) (1) Found in Title 49, Code of Federal Regulations, Part 571, i.e., FMVSS 101 is 49 CFR 571.101. In addition to the definitions found in the individual Safety Standards, definitions can also be found in 49 CFR 571.3. (2) Found in Part II of Schedule IV of the Canadian Motor Vehicle Safety Regulations. In addition to the definitions found in the individual Safety Standards, definitions can also be found in Section 2 and Part I of Schedule IV (CMVSS100) of the Canadian Motor Vehicle Safety Regulations. (3) See 49 CFR Part 565 found on next page. (4) See MVTSR found on next page. (5) See EPA Noise Emissions Regulations. (6) Found in Section 5 of Schedule V.1 of the Canadian Motor Vehicle Safety Regulations. (7) See EPA Gaseous and Smoke Regulations. (8) Administered by Environment Canada. (9) Applies to truck tractor only. (10) https://www.ccmta.ca/en/national-safety-code Safety Standards Lamps and Reflective Devices U.S. Federal and Canada Motor Vehicle Safety Standards (FMVSS 108 and CMVSS 108) specify requirements for lamps and reflective devices on new vehicles. Lamps and reflective devices installed on Volvo vehicles at the assembly plant are installed in compliance with applicable requirements of these standards. The installation of a body or other equipment must not cause these lamps and/or reflective devices to no longer comply with the angular visibility requirements of these standards. Also, an increase in the height of a vehicle must not cause the lamps and/or reflective devices to exceed the height limitations of these standards. Intermediate manufacturers, final-stage manufacturers and vehicle alterer must ensure that equipment installed by the incomplete vehicle manufacturer continues to meet the applicable requirements of these standards. To maintain compliance, lamps and/or reflective devices may have to be relocated. Reorienting a lamp from its installed position, however, may result in the lamp no longer conforming to Standard 108. Safety Standards Trailer ABS Indicator Lamp Requirements U.S. Federal and Canada Motor Vehicle Safety Standards (FMVSS 121 and CMVSS 121) require that combination vehicles (any vehicle pulling an air brake-equipped trailer) must have an ABS indicator lamp mounted on the instrument panel to alert the operator of a trailer anti-lock brake system (ABS) malfunction. This requirement includes all straight trucks having full trailer connections. To comply with this requirement, communication between the towing vehicle and trailer anti-lock brake system is necessary. Communication between these two systems has been accomplished with power line carrier (PLC) technology. This technology allows data to be transmitted over the same line that supplies power. With this technology, the center pin of the standard 7-pin trailer electrical connector has become the standardized source of uninterrupted power as well as data transmission for the trailer ABS. This pin cannot be used to power any other trailer auxiliary equipment. Any straight truck intended to pull an air brake-equipped trailer should be ordered from the factory with a full trailer package to ensure that the vehicle electrical system is PLC compatible and complies with applicable requirements. If the vehicle is not PLC compatible, modification of the electrical system for PLC compatibility, along with installation of a trailer ABS indicator lamp on the dashboard will be necessary. In many instances, however, converting a non-PLC compatible vehicle may not be feasible. Contact Customer Service/Product Support for information concerning converting a vehicle to be PLC compatible. Volvo Body Builder Instructions USA159041959 VN, VHD, VAH, Section 0 Date 11.2021 Body Builder, General Guidelines and Certification Page 10 (104) All Rights Reserved Functional Safety Standards ISO 26262 is the functional safety standard for road vehicles. Functional safety addresses safety related functionality implemented in electronics and software. Volvo Trucks follows the standard for new product development after the standard became applicable to trucks, buses and trailers. This standard replaces Volvo Trucks internal processes addressing functional safety. The functionality, supporting body building activities, developed according to ISO 26262 will increase continuously. This support is described in the Functional Safety Manual included in the Electrical/Electronics section of the Body Builder Instructions. Safety Regulations Lists and Tables Parts 501 through 595 of Title 49 of the Code of Federal Regulations (CFR) contain various additional vehicle safety regulations addressing such subjects as procedural rules, petitions for rulemaking, defect and noncompliance orders, standards enforcement and defects investigation, exemption for inconsequential defect or noncompliance, manufacturer identification, defect and noncompliance reports, definitions, record retention, defect and noncompliance responsibility, etc., some of which are listed below. Sections 1 through 17, Schedules I, II, III and VII of the Canada Motor Vehicle Safety Regulations address additional subjects such as definitions, national safety mark, classes of vehicles, records, test methods and technical standards documents, etc., some of which are listed below. The Canada Motor Vehicle Tire Safety Regulations (MVTSR) address tire requirements. Motor Vehicle Safety Regulations U.S. Regulation CFR Title 49 Canada Regulation Title of Regulation Part 565 (See CMVSS 115) Vehicle Identification Number Requirements Part 566 N/A Manufacturer Identification Part 567 Certification MVSR 6 Compliance Label Part 568 Vehicles Manufactured in Two or More Stages MVSR9 Altered Vehicles Part 571.3 MVSR 2 Definitions/Interpretation Part 576 MVSR 10 Record Retention/Records Part 577 Defect and Noncompliance Notification Part 579.26 (See FMVSS 119) MVSR 15 Notice of Defect N/A Reporting of Information and Communications About Potential Defects MVTSR Reporting Requirements for Manufacturers of Tires Notes Volvo Body Builder Instructions USA159041959 VN, VHD, VAH, Section 0 Date 11.2021 Body Builder, General Guidelines and Certification Page 11 (104) All Rights Reserved Safety Regulations In-Use Motor Vehicles Sold in U.S. The Federal Motor Carrier Safety Administration (FMCSA) of the U.S. Department of Transportation establishes and enforces the Federal Motor Carrier Safety Regulations (FMCSR) found in Title 49, Code of Federal Regulations, Parts 350 through 399. While generally applicable to motor carriers, some of these regulations (Parts 393 and 399 in particular) do address design aspects of a vehicle, and, therefore, manufacturers must be aware that compliance with these regulations may be affected by their designs. Most, if not all, of the States have adopted and enforce at least some of these regulations. A list of the titles of the subparts of Parts 393 and 399 follows. Part 393 Subpart A, General Subpart B, Lighting Devices, Reflectors, and Electrical Equipment Subpart C, Brakes Subpart D, Glazing and Window Construction Subpart E, Fuel Systems Subpart F, Coupling Devices and Towing Methods Subpart G, Miscellaneous Parts (includes sleeper berths, exhaust systems, rear end protection, interior noise levels, and other items) Subpart H, Emergency Equipment Subpart I, Protection Against Shifting or Falling Cargo Subpart J, Frames, Cab and Body Components, Wheels, Steering and Suspension Systems Part 399 Subpart L, Step, Handhold and Deck Requirements for Commercial Motor Vehicles The Federal Motor Carrier Safety Regulations can be found on the FMCSR website at: https://www.ecfr.gov/current/title-49/subtitle-B/chapter-III/subchapter-B Notes Volvo Body Builder Instructions USA159041959 VN, VHD, VAH, Section 0 Date 11.2021 Body Builder, General Guidelines and Certification Page 12 (104) All Rights Reserved Weight Regulations Bridge Gross Weight Formula U.S. The U.S. Federal Bridge Gross Weight Formula was established to provide a standard for controlling the spacing of axles on trucks that use highway bridges. The purpose is to spread the load over a greater area of the highway surface by spacing the axles over a longer length of the vehicle, or combination vehicle. This prevents highway damage caused by high concentrations of load. The U.S. Federal Government established the following formula for determining the allowable weight limits and axle spacings for trucks: https://ops.fhwa.dot.gov/freight/sw/regulations/index.htm No state shall impose a width limitation of more or less than 102 in, or its approximate metric equivalent, 2.6 m (102.36 in) on a vehicle operating on the National Network (NN), except the State of Hawaii, which is allowed to keep the States 2.7 m (108 in) width maximum. • • Maximum Width 2.6 m (102 in) Length Limitations on length for straight trucks are regulated by states. The above applies to truck tractors and trailers operating on the National Network, i.e., the Interstate Highway System and designated Federal-aid highways. Some states have more restrictive width limitations applicable to state highways. Overall width of straight trucks is regulated by individual states. To ensure that the most current regulatory information is available, a subscription to a service that provides updated information on a regular basis should be considered. J. J. Keller Associates, Inc., is the preferred supplier of safety compliance publications, training videos and software, forms, supplies, and training workshops. Contact Keller at 800-327-6868, or visit its web site at: www.jjkeller.com. Size Regulations Maximum overall vehicle width is regulated by the Federal Highway Administration (FHWA) in Title 23, Code of Federal Regulations (CFR), Part 658 can be found at: https://www.ecfr.gov/current/title-23/chapter-I/subchapter-G/part-658?toc=1 Truck Tractor Conspicuity To make a truck tractor more conspicuous when approached from the rear at nighttime when being operated without a semitrailer, federal regulations require reflective devices be applied to the rear of the cab and to the mudflaps or mudflap hanger brackets if mudflaps or mudflap hanger brackets were supplied by the vehicle assembly plant. If mudflaps or mudflap hanger brackets were not supplied from the vehicle assembly plant, reflective devices must be applied to the rear, lower portion of the cab. Refer to the illustration. Locations of these reflective devices may vary from this illustration, depending on the cab model and/or equipment at the rear of the cab. Detailed requirements can be found in U.S. Federal Motor Vehicle Safety Standards (FMVSS) 108. If installed equipment obstructs the view of any installed reflectors, the reflectors must be relocated, in accordance with FMVSS 108, to a location where they will be visible. Volvo Body Builder Instructions USA159041959 VN, VHD, VAH, Section 0 Date 11.2021 Body Builder, General Guidelines and Certification Page 13 (104) All Rights Reserved Certification Label The “Certification Label” must be part of the vehicle at all times. It shows the vehicle's serial number, the gross vehicle weight rating (GVWR), and the front and rear gross axle weight ratings (GAWR). Gross vehicle weight (GVW) is the weight of the original equipped vehicle and all items added to it after it has left the factory. This includes bodies, winches, booms, the driver and all occupants, plus the load the vehicle is carrying. The GVW must not exceed the total of the front and rear axle weight ratings. The vehicle certification label also shows the tire size and recommended tire inflation pressures for the tires originally supplied with the vehicle. The tires on the vehicle must be of the proper size and must be properly inflated for the load being carried. Incomplete Vehicle Document The “Incomplete Vehicle Document” is issued with a temporary certification label, in place of the final certification label, when the vehicle is sent to a body builder for completion. If several manufacturers are involved in the process of completing the vehicle, each manufacturer must issue a temporary certification label that shows to what legal standard the vehicle currently conforms. The final manufacturer must issue the permanent certification label certifying that the vehicle conforms to FMVSS standards (as required by 49 CFR Part 567) that are in effect at the time of final manufacture of the incomplete vehicle. If the vehicle is altered from its original build specifications, the certification label must be updated to reflect the changes (also see Service Bulletin, “Electrical Guidelines”, “Brake Modification Guidelines”, page 16 , “Air-braked Vehicles”, page 16 , and “Air-operated Accessories”, page 17 ). W0117794 Fig. 1 Typical Vehicle Certification Label (USA) Volvo Body Builder Instructions USA159041959 VN, VHD, VAH, Section 0 Date 11.2021 Body Builder, General Guidelines and Certification Page 14 (104) All Rights Reserved W0117795 Fig. 2 Typical Complete Vehicle Label W0117796 Fig. 3 Typical Incomplete Vehicle Label Center of Gravity The vertical center of gravity of the completed vehicle has a direct effect on the vehicle's stopping distance capability. As the vertical center of gravity increases or the wheelbase decreases, additional weight is transferred to the front axle during a stop, adversely affecting the stopping distance. VTNA requires that trucks built shall have a center of gravity height/wheelbase ratio of 0.50 or less when loaded to a weight not exceeding GVWR* distributed proportionately to, but not exceeding GWVR,* and a center of gravity height not exceeding 1778 mm (70 in.) on single rear axle vehicle or 1905 mm (75 in.) on tandem rear axle vehicles. As a guide, the vertical center of gravity height of the incomplete vehicle, as manufactured by VTNA, may be assumed to be the distance from the ground to the top of the frame side rail measured at the longitudinal midpoint of the vehicle in the unladen condition for single axle vehicles and laden condition for tandem axle vehicles. Volvo Body Builder Instructions USA159041959 VN, VHD, VAH, Section 0 Date 11.2021 Body Builder, General Guidelines and Certification Page 15 (104) All Rights Reserved The frame rail height may be calculated from the chassis diagrams in this document. Also, if you are measuring an unloaded chassis, you may assume the loaded frame rail height to be approximately two inches lower than the bare chassis. Vehicles completed as trucks could require a vertical center of gravity lower than the recommendations above based on the stability considerations of certain vocational body and/or usage situations. The above recommendations consider only vehicle brake performance. If higher vertical center-of-gravity limitations are required for a specific vocational body or application, contact VTNA or submit all chassis specifications along with body and payload information in a request for advice to: Product Information Dept./Sales Engineering. *GVWR and GAWR are indicated on the cover of the Incomplete Vehicle Document. Vehicle GVWR and GAWRs The representation as to conformity of the complete vehicle to FMVSS-121 provided in the Incomplete Vehicle Document has a condition that the GVWR and the GAWR of the completed vehicle shall be identical to the ratings designated on the front cover of the Incomplete Vehicle Document for the vehicle. The brake system on each incomplete vehicle manufactured by Volvo Trucks North America (VTNA) is designed to comply with FMVSS-121 when loaded to a specific completed vehicle GVWR distributed proportionate to specific GAWR. Revised vehicle GVWR or GAWR, or the addition of axles to the vehicle will change loading conditions and can adversely affect compliance to FMVSS-121. Brake Modification Guidelines Final stage manufacturers should note that in order to rely on the representations as to conformity to “FMVSS-121, Brake Systems” (as provided in the “Incomplete Vehicle Document” which accompanies each Volvo incomplete vehicle), each of the conditions and instructions of applicable FMVSS-121 statements in the Incomplete Vehicle Document must be followed. If the final stage manufacturer chooses not to follow each of these instructions and conditions listed in the Incomplete Vehicle Document, he must assume full responsibility for conformity of the vehicle to FMVSS-121. Final stage manufacturers should also note that instructions provided are for the assistance of final stage manufacturers who choose to certify the completed vehicle to FMVSS-121 independently of and without reliance on the conformity representations provided in the Incomplete Vehicle Document. Air-braked Vehicles DANGER Pneumatic components store compressed air and can separate violently during disassembly or removal. Before servicing any part of the pneumatic (air) system, completely release the air pressure. Failure to do so can result in serious personal injury or death. Volvo air-brake equipped incomplete vehicle products, to the extent completed, comply with Federal Motor Vehicle Safety Standard 121, Air Brake Systems (specific completed vehicles exempt from the Standard or portions of the Standard are discussed below). At the time of writing, FMVSS-121 is applicable to all current production air–brake equipped trucks with specific exceptions. The statements contained in this section regarding FMVSS-121 compliance are accurate at the time of printing. However, these statements are not intended to replace the statements regarding FMVSS-121 in the Incomplete Vehicle Document. Therefore, that manual should be consulted for compliance conditions. The following are components and characteristics of the completed vehicle which are critical to overall performance of airbraked vehicles. These items should be carefully considered in ordering a vehicle as well as planning vehicle completion by subsequent stage manufacturers to ensure compliance (final certification) of the completed vehicle to FMVSS-121 as well as completed vehicle integrity. Volvo Body Builder Instructions USA159041959 VN, VHD, VAH, Section 0 Date 11.2021 Body Builder, General Guidelines and Certification Page 16 (104) All Rights Reserved Air-operated Accessories FMVSS-121 has a pressure build-up requirement which states that the system pressure must build up from 586 to 689 kPa (85 to 100 PSI) in a specific time period under certain conditions. Therefore, the addition of any accessory or its associated plumbing which increases the volume of air subject to the build-up requirement will increase the build-up time and may affect compliance with FMVSS-121. The representation as to conformity of the completed vehicle to FMVSS-121 provided in the Incomplete Vehicle Document has the following conditions for air operated accessories and its associated plumbing added to a vehicle by a subsequent stage manufacturer. DANGER Pneumatic components store compressed air and can separate violently during disassembly or removal. Before removing or replacing any part of the pneumatic (air) system, completely release the air pressure. Failure to do so can result in serious personal injury or death. • No connections are made into (1) the air line tubing or fittings for the parking brake system; (2) the rear axle system (modulated spring brake system); (3) the air supply and signal lines to the rear chassis relay valve(s); or (4) the air delivery lines to the front axle brakes and quick release valve. • • No connections are made between the check valve and the reservoir port for air supply. • Each added reservoir shall be capable of withstanding an internal hydrostatic pressure of five times the compressor cutout pressure — or 3,447 kPa (500 psi), whichever is greater — for 10 minutes. Additional reservoir volume must be added with pusher and tag axles, Jifflox, etc. Added volume must be equal to 12 times the added brake chambers rated volume. Air for pneumatic accessories should be sourced directly from an air reservoir. If an unused reservoir tap is not available, fittings added to the system at the reservoir must not restrict air flow to any existing air lines. The following are to be observed when adding air accessories. Electronic Control Units (ECUs) ECUs are connected through the Databus. These ECUs consist of sophisticated electronics that can be permanently damaged if not treated properly (such as exposure to high temperatures). To prevent serious damage to ECUs, please follow these important guidelines: CAUTION Possible damage to electronic components. Turn the vehicle ignition switch OFF before disconnecting or connecting any electrical components. Failure to de-energize circuits may result in electronic equipment damage. Volvo Body Builder Instructions USA159041959 VN, VHD, VAH, Section 0 Date 11.2021 Body Builder, General Guidelines and Certification Page 17 (104) All Rights Reserved Welding Welding anywhere on the truck chassis requires that certain precautionary measures be taken. This is required to prevent damage to electrical, as well as electronic systems, wiring harness and components. CAUTION Welding on trucks can permanently damage the vehicle electrical system/components, due to the voltage and current spikes that normally occur when welding. It is preferable to avoid welding; however, if welding must be done on any structure on or in contact with the vehicle, disconnect the electrical connectors at the rear of the instrument cluster and follow the recommendations below: Before welding on the vehicle: 1 Disconnect the power to the vehicle. 2 Disconnect both the positive (+) and negative (-) battery cables. Disconnect the negative cable first. (When reconnecting, connect the positive cable first.) Note: Disconnect the other ECU grounds from the battery before disconnecting the main ground (to avoid damage to the ECUs). 3 Disconnect the engine/starter ground from the chassis. 4 Disconnect the power harness and vehicle interface harness at the Engine Electronic Control Unit (EECU). 5 Disconnect all electronically controlled modules and devices, including: • • • • • • • • Governor Controls Shutdown/Warning Electronics Starter and Ignition Controls Engine and Vehicle ECUs Transmission ECU Anti-lock Brake (ABS) ECU Chassis ECU Electronic Speedometer/Tachometer (This prevents the possibility of alternate paths for induced voltage and currents being created and damaging those components.) 6 Disconnect the electrical connectors at the rear of the instrument cluster. 7 Attach the welder ground cable as close as possible to the weld (no more than 60 cm (24 in.) from the part being welded). 8 Do not connect the welder ground cable to the engine ECU or the ECU cooling plate. CAUTION DO NOT WELD on the engine or engine components. Welding on the engine or components mounted on the engine can cause serious damage to the Engine ECU and other electrical components. Volvo Body Builder Instructions USA159041959 VN, VHD, VAH, Section 0 Date 11.2021 Body Builder, General Guidelines and Certification Page 18 (104) All Rights Reserved There are certain basic common sense rules also to be followed when welding, including (but not limited to): • Welding cables should not be allowed to lie on/near or cross over any electrical wiring or electronic component during the welding procedure. • After the welding process has been completed and the welded parts have cooled, inspect wiring and components for possible shorts or damage which would allow the possibility of drawing excessive currents or cause short circuits when the batteries are reconnected. DANGER Before working on a vehicle, set the parking brakes, place the transmission in neutral, and block the wheels. Failure to do so can result in unexpected vehicle movement and can cause serious personal injury or death. WARNING Fuel leaked or spilled onto hot surfaces or electrical components can cause a fire. Clean up fuel spills immediately. DANGER Exhaust gases contain deadly poison. When testing a vehicle with the engine running, conduct the test outdoors or use a properly vented exhaust hose. WARNING Keep yourself and your test equipment clear of all moving or hot engine parts. A hot engine can cause serious burns or can permanently damage test equipment. DANGER Pneumatic components store compressed air and can separate violently during disassembly or removal. Before servicing any part of the pneumatic (air) system, completely release the air pressure. Failure to do so can result in serious personal injury or death. Battery Charging and Jump Starting Jump Starting It is preferable NOT to jump start vehicles which are electronically controlled. The electronic control units can be damaged by voltage spikes and current surges created by jump starting. When jump starting, use only extra batteries from another truck or from a battery tray. The nominal voltage of the extra batteries must not exceed the system voltage of the truck (i.e. 12 V). DO NOT connect the extra batteries in series with the truck batteries. Volvo Body Builder Instructions USA159041959 VN, VHD, VAH, Section 0 Date 11.2021 Body Builder, General Guidelines and Certification Page 19 (104) All Rights Reserved CAUTION Do not connect battery charging or jump starting cables to any part of an engine electronic system. This can damage sensitive electrical devices. CAUTION DO NOT use a “Hot Shot” type starting cart or a battery charger, as most use extremely high voltages. Use of a “Hot Shot” device or battery charger to jump-start the vehicle will seriously damage the ECUs and other electronic equipment. DANGER DO NOT use ether when starting an engine with electric or “flame start” intake air heater. Use of ether can cause an explosion and can seriously damage the engine and components and cause serious personal injury or death. Battery Charging Before charging, remove the battery box fuse for the Engine Electronic Control Unit (EECU) and Vehicle Electronic Control Unit (VECU). Next, remove any ECU power supply wires that are directly connected to the batteries. This will ensure that these components will not be affected by any transient voltages that may occur during charging. This precaution is necessary due to the extensive variety of manufacturers of battery charging devices and the wide variance in outputs from these devices. When charging batteries, ALWAYS disconnect the battery cables and charge each battery separately. This will prevent the voltage coming into the battery from damaging other system circuits. Adding Electrical Equipment Carefully determine the proper wire sizing and fuse requirements for each circuit to be added. Relays may be required for circuits with higher current flow. Wire connections must not disturb or interfere with any existing system(s) or component(s) within the vehicle. For example, the 400-409 wires MUST NOT be cut or spliced for any connections. These wires must not be tampered with. Data Link Wiring J1708/J1587 Information Link If a connection is required to the J1708/J1587 Information Link (i.e. for the Road Relay), use the connector already supplied in the vehicle harness. This circuit is identified by wires 400 and 401; these will always be a twisted pair of black wires. Note: Wires 400 and 401 are used for the transmission of data for diagnostic messages and gauges. Modifying this circuit can cause these functions to fail. If a circuit being added will carry high currents or frequencies, route it in a location AWAY from wires 400 and 401 to prevent mutual inductance from interfering with Data Link functions. Volvo Body Builder Instructions USA159041959 VN, VHD, VAH, Section 0 Date 11.2021 Body Builder, General Guidelines and Certification Page 20 (104) All Rights Reserved J1939/J1922 Control Link Note: Vehicles with Volvo engines use the J1939 Control Link. Follow the same guidelines and precautions for the J1939/J1922 Control Link wiring. No connections may be made to wires 406 (yellow), 407 (green), and 408 (shield). These circuits are used for control of the vehicle. Accelerator pedal, engine brake, and traction control are examples of functions controlled by these circuits. Note: Wires 406 and 407 carry the high-speed communications between the electronic systems in the vehicle. Wire 408 is an uninsulated wire that wraps around 406 and 407. It absorbs RFI that is produced from the communication circuits 406 and 407. A “terminating resistor” is wired into the Data Link at the end of the Data Link harness. This has a resistance of 120 Ω and must remain connected for the systems to function properly. For Volvo engines, a similar terminating resistor is designed into the Engine Electronic Control Unit (EECU) and defines the other end of the Data Link. For non-Volvo engines, the second terminating resistor is external to the EECU. Note: These two resistors are in parallel, so the total resistance value measured across the Data Link should be 60 Ω. CAUTION Do not modify or make connections to wires 406 (yellow), 407 (green), or 408 (shield). Any modifications, connections, or damage to these wires can result in the failure of the vehicle's electronic systems. Notes Volvo Body Builder Instructions USA159041959 VN, VHD, VAH, Section 0 Date 11.2021 Body Builder, General Guidelines and Certification Page 21 (104) All Rights Reserved Towing Procedure General CAUTION The driveshaft must be removed before towing the vehicle. Failure to remove the driveshaft may result in damage to the transmission. Remove the driveshaft from the rear axle before moving the vehicle. When the transmission is driven from the rear wheels without the engine running, there is no lubrication in the transmission. Axle shafts must be removed if the vehicle is to be towed at speeds over 40 km/h (25 mph) or for a long distance. Openings should be covered to prevent loss of oil and entry of dirt and grit. Where oil-lubricated bearings are used, openings should be thoroughly sealed with metal discs and new gaskets before towing. WARNING If a vehicle with air suspension is lifted by the rear frame member, there is a risk that the air springs will separate from the spring plates. When towing has been completed, never use your hands to reposition the air springs. There is a great risk that your hand will be caught between spring and plate causing personal injury. T0006670 WARNING Do not tow a vehicle backwards when equipped with roof air fairings. The fairings act as an air scoop and may break off. Failure to follow this warning may lead vehicle damage and personal injury. WARNING Vehicles with air fairings or large superstructures are tall. Make sure that the total height of the vehicle, when it is raised up behind the wrecker, does not exceed the maximum allowed height for local underpasses. Failure to follow this instruction may lead to vehicle damage and personal injury. The vehicle may now be towed. It is recommended that a wrecker with a lift bar is used since the service brakes will not function. The system must be filled with air to release the parking brake. Note: The power steering does not function when towing a vehicle with a disabled engine. Volvo Body Builder Instructions USA159041959 VN, VHD, VAH, Section 0 Date 11.2021 Body Builder, General Guidelines and Certification Page 22 (104) All Rights Reserved Towing Instructions CAUTION If the vehicle becomes disabled, it is very important to tow it properly. Failure to do so can cause damage to the frame and body parts. Follow the instructions below to avoid damage. In the event that the vehicle is not accessible to place the wrecker lift bar under the front axle, use the tow hooks in the front of the vehicle. The front tow hooks are used as a point at the front of the vehicle where the vehicle can be pulled. W9000939 When the vehicle is situated properly, lift the front and position the lift bar under the front axle and secure. Using the front axle for towing minimizes the risk of damage to the vehicle body, frame, and suspension. If necessary, the driveshaft and axle shaft can be removed for towing. Note: When the driveshaft or axle shafts are reinstalled, make sure the nuts are tightened to the correct torques. Also make sure the axle shafts are installed in the proper sides, with the left shaft in the left side and the right shaft in the right side. W1000227 Volvo Body Builder Instructions USA159041959 VN, VHD, VAH, Section 0 Date 11.2021 Body Builder, General Guidelines and Certification Page 23 (104) All Rights Reserved CAUTION If the vehicle becomes disabled, it is very important to tow it properly. Failure to do so can cause damage to the frame and body parts. Follow the instructions below to avoid damage. DANGER Do not use the tow eyes for raising the front of the vehicle; the tow eyes can break. Do not crawl under a vehicle suspended by tow eyes. Failure to follow these instructions can result in serious personal injury or death. W9000940 On day cab models, the tow eyes are stored bolted to the back of the cab wall. W9000941 Volvo Body Builder Instructions USA159041959 VN, VHD, VAH, Section 0 Date 11.2021 Body Builder, General Guidelines and Certification Page 24 (104) All Rights Reserved On sleeper cab models, the tow eyes are stored bolted to the back wall of the luggage compartment wall. W9000942 The tow eyes are held in place when mounted on the front of the vehicle by tractor pins. These pins are stored in the tow eye mounting holes when not being used. W9000943 Volvo Body Builder Instructions USA159041959 VN, VHD, VAH, Section 0 Date 11.2021 Body Builder, General Guidelines and Certification Page 25 (104) All Rights Reserved The vehicle may now be towed. It is recommended that a wrecker with a lift bar is used since the service brakes will not function. The system must be filled with air to release the parking brake. Note: The power steering does not function when towing a vehicle with a disabled engine. CAUTION It is recommended that the front bumper be removed when lifting with the front tow eyes/hooks. Failure to remove the front bumper can cause possible component damage. Acceptable loads per hook: • • • Straight pull: Less than or equal to 18,143 kg/hook (40,000 lb). Vertical pull: Less than or equal to 5170 kg/hook (11,400 lb). 45° cone (combination loads): Less than or equal to 7239 kg (15,960 lb). Towing a Vehicle Equipped with an I-Shift Transmission CAUTION You must tow a vehicle equipped with an I-Shift transmission according to the guidelines below. Failure to do so can result in damage to transmission components. When towing the vehicle, the output shaft of the transmission must not be allowed to spin or turn. If the vehicle is towed with the drive wheels still in contact with the road surface, the vehicle axle shafts or driveline must be removed or disconnected. Notes Volvo Body Builder Instructions USA159041959 VN, VHD, VAH, Section 0 Date 11.2021 Body Builder, General Guidelines and Certification Page 26 (104) All Rights Reserved Design and Function Weight Distribution Determining the weight distribution of a truck is an important calculation. It can indicate whether a truck is legally loaded, and can show whether any dangerous overloading might occur. Weight distribution calculations are not difficult to perform; an understanding of the theory involved will make it easier to perform the calculations and correctly analyze each application. Theory The theory of weight distribution can be illustrated as follows: Two men are painting a house. To get all of the material to the job in one trip, they put the paint and brushes in a box, set it on a ladder, and each pick up an end. W9000362 Fig. 4 Weight Distribution Theory 1 Load 2 Total length 3 Distance from center of load to “B” The ladder is 10 feet long. The box of supplies weighs 50 lb. The center of the box is located 3 feet from the man at position B. Intuitively, we know that man “B” is carrying more of the load because he is closer to it than man “A.” The amount of weight being carried by man “A” can be determined using the following formula: Weight at man "A" = Total weight x Distance from weight to man "B" Distance from man "A" to man "B" 50 lb x 3 feet Weight at man "A" = 10 feet Volvo Body Builder Instructions USA159041959 VN, VHD, VAH, Section 0 Date 11.2021 Body Builder, General Guidelines and Certification Page 27 (104) All Rights Reserved Weight at man “A” = 15 lb. The weight carried by man “B” is obtained by subtracting the weight at man “A” from the total weight. Weight at man “B” = Total weight – weight at man “A” Weight at man “B” = 50 lb – 15 lb Weight at man “B” = 35 lb The percentage of weight transferred to each man can also be calculated. % of weight at man “A” = 3/10 x 100% = 30% The percentage of weight transferred to man “B” is found by subtracting the % weight at man “A” from 100%: 100% – 30% = 70%. Distance from weight to man "B" % of Weight at man "A" = x 100 Distance from man "A" to man "B" Weight Distribution Formulas W9000364 W9000365 AC Front axle to back-of-cab L Body length G Gap between cab and body or trailer WB Wheelbase CG Center of gravity of body and payload W Weight of body plus payload, or kingpin load C Front of body to CG, or front of trailer to kingpin WF Portion of W transferred to front axle D Distance CG or fifth wheel is ahead of rear axle WR Portion of W transferred to rear axle F Distance CG or fifth wheel is behind front axle Basic Formulas a W x D = WF x WB b WB = F + D = AC + G + C + D c W = WF + WR d Percent of W transferred to front axle = e Percent of W transferred to rear axle = Volvo Body Builder Instructions USA159041959 or D WB F WB x 100 x 100 VN, VHD, VAH, Section 0 Date 11.2021 Body Builder, General Guidelines and Certification Page 28 (104) All Rights Reserved Sample Calculations WxD WF = WxF WR = WB WB or WR = W – WF WF W – WR Weight Distribution Formulas (Text Descriptions) (Total Weight) x (Distance CG is ahead of Rear Axle) Weight transferred to Front Axle = Wheelbase) (Weight transferred to Front Axle) x (Wheelbase) Distance CG must be placed ahead of Rear Axle = (Total Weight) (Total Weight) x (Distance CG is ahead of Rear Axle) Wheelbase = (Weight to be transferred to Front Axle) (Weight to be transferred to Front Axle) x (Wheelbase) Total Weight = (Distance CG is ahead of Rear Axle) (Total Weight) x (Distance CG is behind Front Axle) Weight transferred to Rear Axle = (Wheelbase) (Weight transferred to Rear Axle) x (Wheelbase) Distance CG must be placed behind Front Axle = (Total Weight) (Total Weight) x (Distance CG is behind Rear Axle) Wheelbase = (Wheelbase) (Weight to be transferred to Rear Axle) x (Wheelbase) Total Weight = (Distance CG is behind Front Axle) Note: Total Weight must always equal Weight transferred to Rear Axle plus Weight transferred to Front Axle. Volvo Body Builder Instructions USA159041959 VN, VHD, VAH, Section 0 Date 11.2021 Body Builder, General Guidelines and Certification Page 29 (104) All Rights Reserved Formulas for Lift Axles Pusher Axles Pusher Up DIS WFA = x Pusher Tare Weight WB WRA = Tare Weight - WFA Pusher Down – (DIS) x Pusher Pressure WFA = WB - (WB - DIS) x Pusher Pressure WRA = WB W9000387 Fig. 5 Pusher Axle Notes Volvo Body Builder Instructions USA159041959 VN, VHD, VAH, Section 0 Date 11.2021 Body Builder, General Guidelines and Certification Page 30 (104) All Rights Reserved Tag Axles Tag Up WB + DIS) x Tare Weight WRA = WB WFA = Tare Weight - WFA (will be Negative Number) Tag Down - (WB + DIS) WRA = x Tag Pressure (Negative Pressure) WB DIS WFA = x Tag Pressure (Positive Number) WB W9000389 Fig. 6 Tag Axle Notes Volvo Body Builder Instructions USA159041959 VN, VHD, VAH, Section 0 Date 11.2021 Body Builder, General Guidelines and Certification Page 31 (104) All Rights Reserved Boost-A-Load Axles Boost Up (WB + DIS#1) x Tare Weight WRA = WB WFA = Tare Weight - WFA (will be Negative Number) Boost Down - (WB + DIS#2) x Boost Axle Pressure (Negative Number) WRA = WB (DIS#2) x Boost Axle Pressure (Positive Number WFA = WB W9000389 Fig. 7 Boost Axle W9000390 Volvo Body Builder Instructions USA159041959 VN, VHD, VAH, Section 0 Date 11.2021 Body Builder, General Guidelines and Certification Page 32 (104) All Rights Reserved Customer Information Worksheet CUSTOMER BRANCH OR DEALER ADDRESS QUANTITY DATE MODEL ORDER NO. STRAIGHT TRUCKS Body Make:___________________ Body Type: Model:____________________ Length:___________________ […] Dump …… […] Flat …… […] Van …… […] Tank …… […] Mixer …… […] Block …… […] Specialty______________ […] Rear Refuse Loader …… […] Front Refuse Loader …… […] Side Refuse Loader …… […] Rolloff Body Weight: ____________________lb Additional Equipment: […] Snow Plow ……… […] Tailgate ……… […] Boom ……… […] Frame-mounted Water Tank Equipment Weight: Center of Gravity Location:______________________ […] PTO ……… […] Tag/Pusher Axle ……… […] Wet (Hydraulic) Kit ____________________lb Center of Gravity Location*:______________________ Body Height: *Center of Gravity 1___________________ Body (B 2____________________ Payload (A) 3_____________________ Overhang Required 4_____________________ W9000385 Volvo Body Builder Instructions USA159041959 VN, VHD, VAH, Section 0 Date 11.2021 Body Builder, General Guidelines and Certification Page 33 (104) All Rights Reserved ALL TRUCKS Commodity Hauled: ________________________________________ Operating Conditions: […] Increasing Loads …………… […] Decreasing Loads Road Surface/ Grades: Payload Weight :__________________lb […] One Way ………… […] Both Ways ………… […] Fully Loaded______________ Average Trip: ______________miles Number Round-trips Per Day: ___________ Average Number of Stops: ______________ Average Idling Time: ______________ […] Concrete ………… […] Asphalt ………… […] Packed Dirt ………… […] Gravel […] Sand …………… […] Mud …………… […] Loose Dirt Maximum Starting Grade ____________% Maximum Highway Grade ___________% Speed: Cruise Speed Desired on Highway _________mph Top Speed (Unloaded) ____________mph Operating Area: […] Interstate ……………… […] Primary Roads ……………… […] Other Roads States Operating _____________________________________________ Length Restrictions ___________________________________________ Climate: Outside High Temp ___________ Low___________ Altitude ___________ft Weight Limits: Front ___________lb Rear __________lb Tag/Pusher ____________lb Total ____________lb GVW/GCW Requested ____________lb Other Restrictions / Conditions Volvo Body Builder Instructions USA159041959 VN, VHD, VAH, Section 0 Date 11.2021 Body Builder, General Guidelines and Certification Page 34 (104) All Rights Reserved TRACTORS Type of Service: […] Tractor Semi/Trailer ………… […] Tractor Double Trailers ………… […] Tractor Triple Trailers […] Straight Truck/PUP Trailer Trailer: Make ___________ Model ___________ Length ___________ft […] Dry Van ……… […] Refrigerated ……… […] Flatbed ……… […] Tank ……… […] Dump Capacity__________________[…] Gallons …… […] Cu. Yards Height ___________in. Width ___________in. Kingpin Location __________in. (front) Weight ___________lb Landing Gear Location __________in. (front) Rear Trailer Axles __________in. (rear) Trailer Height 1____________ Overall Height 2____________ Trailer Axle Setting 3____________ Trailer Axle Spacing 4____________ W9000386 Notes Volvo Body Builder Instructions USA159041959 VN, VHD, VAH, Section 0 Date 11.2021 Body Builder, General Guidelines and Certification Page 35 (104) All Rights Reserved Conversion Factors Convert From: To: Multiply By: Area Square Inch in² Square millimeter mm² 645.16 Square foot ft² Square meter m² 0.0929 Square millimeter mm² Square Inch in² 0.0016 Square meter m² Square foot ft² 10.7643 Flow (Volume Per Unit Time) Gallon (U.S.) per minute gpm Cubic meter per second m³/s 0.00006 Gallon (U.S.) per minute gpm Liter per minute L/min 3.7854 Cubic meter per second m³/s Gallon (U.S.) per minute gpm 15850.3 Liter per minute L/min Gallon (U.S.) per minute gpm 0.26417 Millimeter mm 25.4 0.3048 Length Inch in. Foot ft Meter m Yard yd Meter m 0.09144 Millimeter mm Inch in 0.0394 Meter m Foot ft 3.2808 Meter m Yard yd 1.0936 Kilogram kg 0.4536 Mass Pound lb Ton (U.S.) Ton (metric, 2,204.6 lbs) Kilogram kg Pound Ton (metric) 0.9072 lb Ton (U.S.) 2.2046 1.1023 Power Horsepower (550 ft-lb f/sec) hp Kilowatt kW 0.7457 Kilowatt kW Horsepower (550 ft-lb f/sec) hp 1.3910 Pressure Pound-Force per square inch psi Kilopascal kPa 6.8948 Kilopascal kPa Pound-Force per square inch psi 0.145 Temperature Degree Fahrenheit °F Degree Celsius °C 5/9 (°F - 32) Degree Celsius °C Degree Fahrenheit °F (9/5 °C) + 32 Velocity Miles per hour (U.S.) mph Kilometer per hour km/h 1.6093 Kilometer per hour km/h Miles per hour (U.S.) mph 0.6214 Volvo Body Builder Instructions USA159041959 VN, VHD, VAH, Section 0 Date 11.2021 Body Builder, General Guidelines and Certification Page 36 (104) All Rights Reserved Convert From: To: Multiply By: Volume Cubic inch in³ Cubic millimeter mm³ 16387.06 Cubic inch in³ Cubic centimeter cm³ 16.3871 Cubic foot ft³ Cubic meter m³ 0.0283 Cubic yard yd³ Cubic meter m³ 0.7646 Quart (U.S. liquid) qt Liter L 0.9464 Gallon (U.S. liquid) gal Liter L 3.7854 Liter L Quart (U.S. liquid) qt 1.0566 Liter L Gallon (U.S. liquid) gal 0.2642 Gallon (U.S. liquid) gal Cubic meter m³ 0.0038 Cubic millimeter mm³ Cubic inch in³ 0.00006 Cubic centimeter cm³ Cubic inch in³ 0.061 Cubic meter m³ Cubic foot ft³ 35.3357 Cubic meter m³ Cubic yard yd³ 1.3079 Cubic meter m³ Gallon (U.S. liquid) gal 263.1579 Notes Volvo Body Builder Instructions USA159041959 VN, VHD, VAH, Section 0 Date 11.2021 Body Builder, General Guidelines and Certification Page 37 (104) All Rights Reserved Chassis Diagrams Chassis Diagrams, VHD VHD 200, Truck, Axle Forward, 4 x 2 W9031950 Fig. 8 VHD 200, Truck, Axle Forward, 4 x 2 Volvo Body Builder Instructions USA159041959 VN, VHD, VAH, Section 0 Date 11.2021 Body Builder, General Guidelines and Certification Page 38 (104) All Rights Reserved See Fig. 8 Dimensions Description Drawing Reference Dimension Front Frame Extension FE 0 in (0 mm) Bumper to Front Axle BA 29.10 in (739 mm) Wheelbase WB 199 in (5055 mm) Overhang OH 84 in (2134 mm) Overall Length OA 312.10 in (7927 mm) Bumper to Back of Cab BBC 113.60 in (2885 mm) Effective Bumper to Back of Cab EBBC See table below. Cab to Rear Axle CA 114.50 (2908 mm) Effective Cab to Rear Axle ECA See table below. Front Axle to Back of Cab AC 84.50 in (2146 mm) Effective Front Axle to Back of Cab EAC See table below. Cab to End of Frame CE 198.50 in (5042 mm) Effective Cab to End of Frame ECE See table below. Unladen Frame Height FH 43.49 in (1105 mm) Cab Height CH 74.30 in (1887 mm) Overall Height OVH 117.55 in (2986 mm) Driver CG DCG 64.50 in (1638 mm) Width of Rear of Cab WROC 89 in (2261 mm) Mirror Width MW 117.45 in (2983 mm) Cab Width W 95 in (2413 mm) EAC ECA EBBC ECE Single Stack 97.95 in (2488 mm) 101.05 in (2567 mm) 127.05 in (3227 mm) 185.05 in (4700 mm) Dual Stack 101.81 in (2586 mm) 97.19 in (2469 mm) 130.91 in (3325 mm) 181.19 in (4602 mm) Vertical SCR 106.06 in (2694 mm) 92.94 in (2361 mm) 135.16 in (3433 mm) 176.94 in (4494 mm) Volvo Body Builder Instructions USA159041959 VN, VHD, VAH, Section 0 Date 11.2021 Body Builder, General Guidelines and Certification Page 39 (104) All Rights Reserved VHD 200, Truck, Axle Forward, 6 x 4 W9034070 Fig. 9 VHD 200, Truck, Axle Forward, 6 x 4 Volvo Body Builder Instructions USA159041959 VN, VHD, VAH, Section 0 Date 11.2021 Body Builder, General Guidelines and Certification Page 40 (104) All Rights Reserved See Fig. 9 Dimensions Description Drawing Reference Dimension Front Frame Extension FE 0 in (0 mm) Bumper to Front Axle BA 29.10 in (739 mm) Wheelbase WB 232 in (5893 mm) Overhang OVH 55 in (1397 mm) Overall Length OA 316.10 in (8029 mm) Bumper to Back of Cab BBC 113.60 in (2885 mm) Effective Bumper to Back of Cab EBBC See table below. Cab to Rear Axle CA 147.50 in (3747 mm) Effective Cab to Rear Axle ECA See table below. Cab to Rear of Axle AC 84.50 in (2146 mm) Effective Front Axle to Back of Cab EAC See table below. Cab to End of Frame CE 202.50 in (5144 mm) Effective Cab to End of Frame ECE See table below. Unladen Frame Height FH 42.31 in (1075 mm) Cab Height CH 74.30 in (1887 mm) Overall Height OVH 116.61 in (2962 mm) Driver CG DCG 64.50 in (1638 mm) Width of Rear of Cab WROC 89 in (2261 mm) Mirror Width MW 117.45 in (2983 mm) Cab Width W 95 in (2413 mm) EAC ECA EBBC ECE Single Stack 97.95 in (2488 mm) 134.05 in (3405 mm) 127.05 in (3227 mm) 189.05 in (4802 mm) Dual Stack 101.81 in (2586 mm) 130.19 in (3307 mm) 130.91 in (3325 mm) 185.19 in (4704 mm) Vertical SCR 106.06 in (2694 mm) 125.94 in (3199 mm) 135.16 in (3433 mm) 180.94 in (4596 mm) Volvo Body Builder Instructions USA159041959 VN, VHD, VAH, Section 0 Date 11.2021 Body Builder, General Guidelines and Certification Page 41 (104) All Rights Reserved VHD 200, Truck, Axle Forward, 8 x 4 W9031949 Fig. 10 VHD 200, Truck, Axle Forward, 8 x 4 Volvo Body Builder Instructions USA159041959 VN, VHD, VAH, Section 0 Date 11.2021 Body Builder, General Guidelines and Certification Page 42 (104) All Rights Reserved See Fig. 10 Dimensions Description Drawing Reference Dimension Front Frame Extension FE 0 in (0 mm) Bumper to Front Axle BA 29.10 in (739 mm) Wheelbase WB 232 in (5893 mm) Overhang OH 55 in (1397 mm) Overall Length OA 316.10 in (8029 mm) Bumper to Back of Cab BBC 113.60 in (2885 mm) Effective Bumper to Back of Cab EBBC See table below. Cab to Rear Axle CA 147.50 in (3747 mm) Effective Cab to Rear Axle ECA See table below. Front Axle to Back of Cab AC 84.50 in (2146 mm) Effective Front Axle to Back of Cab EAC See table below. Cab to End of Frame CE 202.50 in (5144 mm) Effective Cab to End of Frame ECE See table below. Bogie Spread BS 54 in (1372 mm) Unladen Frame Height FH 42.31 in (1075 mm) Cab Height CH 74.30 in (1887 mm) Overall Height OVH 116.61 in (2962 mm) Driver CG DCG 64.50 in (1638 mm) Width of Rear of Cab WROC 89 in (2261 mm) Mirror Width MW 117.45 in (2983 mm) Cab Width W 95 in (2413 mm) Pusher PP 75 in (1905 mm) EAC ECA EBBC ECE Single Stack 97.95 in (2488 mm) 134.05 in (3405 mm) 127.05 in (3227 mm) 189.05 in (4802 mm) Dual Stack 101.81 in (2586 mm) 130.19 in (3307 mm) 130.91 in (3325 mm) 185.19 in (4704 mm) Vertical SCR 106.06 in (2694 mm) 125.94 in (3199 mm) 135.16 in (3433 mm) 180.94 in (4596 mm) Volvo Body Builder Instructions USA159041959 VN, VHD, VAH, Section 0 Date 11.2021 Body Builder, General Guidelines and Certification Page 43 (104) All Rights Reserved VHD 200, Truck, Axle Forward, 8 x 6 W9034068 Fig. 11 VHD 200, Truck, Axle Forward, 8 x 6 Volvo Body Builder Instructions USA159041959 VN, VHD, VAH, Section 0 Date 11.2021 Body Builder, General Guidelines and Certification Page 44 (104) All Rights Reserved See Fig. 11 Dimensions Description Drawing Reference Dimension (mm/in) Front Frame Extension FE 0 in (0 mm) Bumper to Front Axle BA 29.10 in (739 mm) Wheelbase WB 230 in (5842 mm) Overhang OH 84 in (2134 mm) Overall Length OA 343.10 in (8715 mm) Bumper to Back of Cab BBC 113.60 in (2885 mm) Effective Bumper to Back of Cab EBBC See table below. Cab to Rear Axle CA 137.50 in (3493 mm) Effective Cab to Rear Axle ECA See table below. Front Axle to Back of Cab AC 84.50 in (2146 mm) Effective Front Axle to Back of Cab EAC See table below. Cab to End of Frame CE 229.50 in (5829 mm) Effective Cab to End of Frame ECE See table below. Bogie Spread BS 108 in (2743 mm) Unladen Frame Height FH 42.31 in (1075 mm) Cab Height CH 74.30 in (1887 mm) Overall Height OVH 115.31 in (2929 mm) Driver CG DCG 64.50 in (1638 mm) Width of Rear of Cab WROC 89 in (2261 mm) Mirror Width MW 117.45 in (2983 mm) Cab Width W 95 in (2413 mm) EAC ECA EBBC ECE Single Stack 97.95 in (2488 mm) 132.05 in (3354 mm) 127.05 in (3227 mm) 216.05 in (5488 mm) Dual Stack 101.81 in (2586 mm) 128.19 in (3256 mm) 130.91 in (3325 mm) 212.19 in (5390 mm) Vertical SCR 106.06 in (2694 mm) 123.94 in (3148 mm) 135.16 in (3433 mm) 207.94 in (5282 mm) Volvo Body Builder Instructions USA159041959 VN, VHD, VAH, Section 0 Date 11.2021 Body Builder, General Guidelines and Certification Page 45 (104) All Rights Reserved VHD 200, Truck, Axle Back, 4 x 2 W9031954 Fig. 12 VHD 200, Truck, Axle Back, 4 x 2 Volvo Body Builder Instructions USA159041959 VN, VHD, VAH, Section 0 Date 11.2021 Body Builder, General Guidelines and Certification Page 46 (104) All Rights Reserved See Fig. 12 Dimensions Description Drawing Reference Dimension Front Frame Extension FE 0 in (0 mm) Bumper to Front Axle BA 51.2 in (1300 mm) Wheelbase WB 177 in (4496 mm) Overhang OH 84 in (2134 mm) Overall Length OA 261 in (6629 mm) Bumper to Back of Cab BBC 113.60 in (2885 mm) Effective Bumper to Back of Cab EBBC See table below. Cab to Rear Axle CA 114.60 in (2911 mm) Effective Cab to Rear Axle ECA See table below. Axle to Back of Cab AC 62.40 in (1585 mm) Effective Front Axle to Back of Cab EAC See table below. Cab to End of Frame CE 198.60 in (5044 mm) Effective Cab to End of Frame ECE See table below. Unladen Frame Height FH 43.25 in (1099 mm) Cab Height CH 74.30 in (1887 mm) Overall Height OVH 117.55 in (2985 mm) Driver CG DCG 42 in (1067 mm) Width of Rear of Cab WROC 89 in (2261 mm) Mirror Width MW 116 in (2946 mm) Cab Width W 95 in (2413 mm) EAC ECA EBBC ECE Single Stack 75.90 in (1928 mm) 101.10 in (2568 mm) 127.10 in (3228 mm) 185.10 in (4702 mm) Dual Stack 79.76 in (2026 mm) 97.24 in (2470 mm) 130.96 in (3326 mm) 183.24 in (4654 mm) Vertical SCR 84.01 in (2134 mm) 92.99 in (2362 mm) 135.21 in (3434 mm) 176.99 in (4496 mm) Volvo Body Builder Instructions USA159041959 VN, VHD, VAH, Section 0 Date 11.2021 Body Builder, General Guidelines and Certification Page 47 (104) All Rights Reserved VHD 200, Truck, Axle Back, 6 x 4 W9033935 Fig. 13 VHD 200, Truck, Axle Back, 6 x 4 Volvo Body Builder Instructions USA159041959 VN, VHD, VAH, Section 0 Date 11.2021 Body Builder, General Guidelines and Certification Page 48 (104) All Rights Reserved See Fig. 13 Dimensions Description Drawing Reference Dimension Front Frame Extension FE 0 in (0 mm) Bumper to Front Axle BA 51.2 in (1300 mm) Wheelbase WB 208 in (5283 mm) Overhang OH 55 in (1397 mm) Overall Length OA 314.20 in (7981 mm) Bumper to Back of Cab BBC 113.60 in (2885 mm) Effective Bumper to Back of Cab EBBC See table below. Cab to Rear Axle CA 145.60 in (3698 mm) Effective Cab to Rear Axle ECA See table below. Front Axle to Back of Cab AC 62.40 in (1585 mm) Effective Front Axle to Back of Cab EAC See table below. Cab to End of Frame CE 200.60 in (5095 mm) Effective Cab to End of Frame ECE See table below. Bogie Spread BS 54 in (1372 mm) Unladen Frame Height FH 42.31 in (1075 mm) Cab Height CH 74.30 in (1887 mm) Overall Height OVH 116.61 in (2962 mm) Driver CG DCG 42 in (1067 mm) Width of Rear of Cab WROC 89 in (2261 mm) Mirror Width MW 117.45 in (2983 mm) Cab Width W 95 in (2413 mm) EAC ECA EBBC ECE Single Stack 75.90 in (1928 mm) 132.10 in (3355 mm) 127.10 in (3228 mm) 187.10 in (4752 mm) Dual Stack 79.76 in (2026 mm) 128.24 in (3257 mm) 130.96 in (3326 mm) 183.24 in (4654 mm) Vertical SCR 84.01 in (2134 mm) 123.99 in (3149 mm) 135.21 in (3434 mm) 178.99 in (4546 mm) Volvo Body Builder Instructions USA159041959 VN, VHD, VAH, Section 0 Date 11.2021 Body Builder, General Guidelines and Certification Page 49 (104) All Rights Reserved VHD 200, Truck, Axle Back, 8 x 4 W9054803 Fig. 14 VHD 200, Truck, Axle Back, 8 x 4 Volvo Body Builder Instructions USA159041959 VN, VHD, VAH, Section 0 Date 11.2021 Body Builder, General Guidelines and Certification Page 50 (104) All Rights Reserved See Fig. 14 Dimensions Description Drawing Reference Dimension Front Frame Extension FE 0 in (0 mm) Bumper to Front Axle BA 51.2 in (1300 mm) Wheelbase WB 208 in (5283 mm) Overhang OH 55 in (1397 mm) Overall Length OA 277.20 in (7041 mm) Bumper to Back of Cab BBC 113.60 in (2885 mm) Effective Bumper to Back of Cab EBBC See table below. Cab to Rear Axle CA 145.60 in (3698 mm) Effective Cab to Rear Axle ECA See table below. Front Axle to Back of Cab AC 62.40 (1585) Effective Front Axle to Back of Cab EAC See table below. Cab to End of Frame CE 200.60 in (5095 mm) Effective Cab to End of Frame ECE See table below. Bogie Spread BS 54 in (1372 mm) Unladen Frame Height FH 42.31 in (1075 mm) Cab Height CH 74.30 in (1887 mm) Overall Height OVH 116.61 in (2962 mm) Driver CG DCG 42 in (1067 mm) Width of Rear of Cab WROC 89 in (2261 mm) Mirror Width MW 117.45 in (2983 mm) Cab Width W 95 in (2413 mm) Pusher PP 75 in (1905 mm) EAC ECA EBBC ECE Single Stack 75.90 in (1928 mm) 132.10 in (3355 mm) 127.10 in (3228 mm) 150.10 in (3813 mm) Dual Stack 79.76 in (2026 mm) 128.24 in (3257) 130.96 in (3326 mm) 146.24 in (3715 mm) Vertical SCR 84.01 in (2134 mm) 123.99 in (3149 mm) 135.21 in (3434 mm) 141.99 in (3607 mm) Volvo Body Builder Instructions USA159041959 VN, VHD, VAH, Section 0 Date 11.2021 Body Builder, General Guidelines and Certification Page 51 (104) All Rights Reserved VHD 200, Truck, Axle Back, 8 x 6 W9054805 Fig. 15 VHD 200, Truck, Axle Back, 8 x 6 Volvo Body Builder Instructions USA159041959 VN, VHD, VAH, Section 0 Date 11.2021 Body Builder, General Guidelines and Certification Page 52 (104) All Rights Reserved See Fig. 15 Dimensions Description Drawing Reference Dimension Front Frame Extension FE 0 in (0 mm) Bumper to Front Axle BA 51.2 in (1300 mm) Wheelbase WB 208 in (5283 mm) Overhang OH 84 in (2134 mm) Overall Length OA 343.20 in (8717 mm) Bumper to Back of Cab BBC 113.60 in (2885 mm) Effective Bumper to Back of Cab EBBC See table below. Cab to Rear Axle CA 145.60 (3698) Effective Cab to Rear Axle ECA See table below. Front Axle to Back of Cab AC 62.40 in (1585 mm) Effective Front Axle to Back of Cab EAC See table below. Cab to End of Frame CE 229.60 in (5832 mm) Effective Cab to End of Frame ECE See table below. Bogie Spread BS 108 in (2743 mm) Unladen Fifth Wheel Height FWH 50.50 in (1283 mm) Unladen Frame Height FH 41.01 in (1042 mm) Cab Height CH 74.30 in (1887 mm) Overall Height OVH 115.31 in (2929 mm) Driver CG DCG 42 in (1067 mm) Width of Rear of Cab WROC 89 in (2261 mm) Mirror Width MW 117.45 in (2983 mm) Cab Width W 95 in (2413 mm) EAC ECA EBBC ECE Single Stack 75.90 in (1928 mm) 132.10 in (3355 mm) 127.10 in (3228 mm) 216.10 in (5489 mm) Dual Stack 79.76 in (2026 mm) 128.24 in (3257 mm) 130.96 in (3326 mm) 212.24 in (5391 mm) Vertical SCR 84.01 in (2134 mm) 123.99 in (3149 mm) 135.21 in (3434 mm) 207.99 in (5283 mm) Volvo Body Builder Instructions USA159041959 VN, VHD, VAH, Section 0 Date 11.2021 Body Builder, General Guidelines and Certification Page 53 (104) All Rights Reserved Chassis Diagrams, VAH VAH 200, Truck, Axle Forward, 6 x 4 W9057063 Fig. 16 VAH 200, Truck, Axle Forward, 6 x 4 Volvo Body Builder Instructions USA159041959 VN, VHD, VAH, Section 0 Date 11.2021 Body Builder, General Guidelines and Certification Page 54 (104) All Rights Reserved See Fig. 16 Dimensions Description Drawing Reference Dimension Front Frame Extension FE 0 in (0 mm) Bumper to Front Axle BA 29.10 in (739 mm) Wheelbase WB 237 in (6020 mm) Overhang OH 62 in (1575 mm) Overall Length OA 328.10 in (8334 mm) Bumper to Back of Cab BBC 113.60 in (2885 mm) Cab to Rear Axle CA 152.50 in (3874 mm) Front Axle to Back of Cab AC 84.50 in (2146 mm) Cab to End of Frame CE 214.50 in (5448 mm) Bogie Spread BS 52 in (1321 mm) Unladen Frame Height FH 35.70 in (907 mm) Cab Height CH 74.30 in (1887 mm) Overall Height OVH 110 in (2794 mm) Driver CG DCG 64.50 in (1638 mm) Width of Rear of Cab WROC 89 in (2261 mm) Mirror Width MW 117.45 in (2983 mm) Cab Width W 95 in (2413 mm) Notes Volvo Body Builder Instructions USA159041959 VN, VHD, VAH, Section 0 Date 11.2021 Body Builder, General Guidelines and Certification Page 55 (104) All Rights Reserved Chassis Diagrams, VNM / VNR VNM 200 / VNR 200, Truck, Axle Back, 4 x 2 W9056682 Fig. 17 VNM 200 / VNR 200, Truck, Axle Back, 4 x 2 Volvo Body Builder Instructions USA159041959 VN, VHD, VAH, Section 0 Date 11.2021 Body Builder, General Guidelines and Certification Page 56 (104) All Rights Reserved See Fig. 17 Dimensions Description Drawing Reference Dimension Front Frame Extension FE 0 in (0 mm) Bumper to Front Axle BA 51.10 in (1298 mm) Wheelbase WB 152 in (3861 mm) Overhang OH 33 in (838 mm) Overall Length OA 236.10 in (5997 mm) Bumper to Back of Cab BBC 113.50 in (2883 mm) Effective Bumper to Back of Cab EBBC See table below. Cab to Rear Axle CA 89.60 in (2276 mm) Effective Cab to Rear Axle ECA See table below. Axle to Back of Cab AC 62.40 in (1585 mm) Effective Front Axle to Back of Cab EAC See table below. Cab to End of Frame CE 122.60 in (3114 mm) Effective Cab to End of Frame ECE See table below. Unladen Fifth Wheel Height FWH 47.50 in (1207 mm) Unladen Frame Height FH 38.60 in (980 mm) Cab Height CH 75 in (1905 mm) Overall Height OVH 113.60 in (2885 mm) Driver CG DCG 42 in (1067 mm) Width of Rear of Cab WROC 89 in (2261 mm) Mirror Width MW 116 in (2946 mm) Cab Width W 95 in (2413 mm) EAC ECA EBBC ECE Single Stack 75.91 in (1928 mm) 76.09 in (1933 mm) 127.01 in (3226 mm) 109.09 in (2771 mm) Dual Stack N/A N/A N/A N/A Vertical SCR 84.01 in (2134 mm) 67.99 in (1727 mm) 135.11 in (3432 mm) 100.99 in (2565 mm) Volvo Body Builder Instructions USA159041959 VN, VHD, VAH, Section 0 Date 11.2021 Body Builder, General Guidelines and Certification Page 57 (104) All Rights Reserved VNM 200 / VNR 200, Truck, 6 x 4 W9056680 Fig. 18 VNM 200 / VNR 200, Truck, 6 x 4 Volvo Body Builder Instructions USA159041959 VN, VHD, VAH, Section 0 Date 11.2021 Body Builder, General Guidelines and Certification Page 58 (104) All Rights Reserved See Fig. 18 Dimensions Description Drawing Reference Dimension Front Frame Extension FE 0 in (0 mm) Bumper to Front Axle BA 51.10 in (1298 mm) Wheelbase WB 170 in (4318 mm) Overhang OH 55 in (1397 mm) Overall Length OA 276.10 in (7013 mm) Bumper to Back of Cab BBC 113.60 in (2885 mm) Effective Bumper to Back of Cab EBBC See table below. Cab to Rear Axle CA 107.60 in (2733 mm) Effective Cab to Rear Axle ECA See table below. Axle to Back of Cab AC 62.40 in (1585 mm) Effective Front Axle to Back of Cab EAC See table below. Cab to End of Frame CE 162.50 in (4128 mm) Effective Cab to End of Frame ECE See table below. Bogie Spread BS 52 in (1321 mm) Unladen Frame Height FH 38.60 in (980 mm) Cab Height CH 75 in (1905 mm) Overall Height OVH 113.60 in (2885 mm) Driver CG DCG 42 in (1067 mm) Width of Rear of Cab WROC 89 in (2261 mm) Mirror Width MW 117.45 in (2983 mm) Cab Width W 95 in (2413 mm) EAC ECA EBBC ECE Single Stack 75.91 in (1928 mm) 94.09 in (2390 mm) 127.01 in (3226 mm) 149.09 in (3787 mm) Dual Stack N/A N/A N/A N/A Vertical SCR 84.02 in (2134 mm) 85.98 in (2184 mm) 135.12 in (3432 mm) 140.98 in (3581 mm) Volvo Body Builder Instructions USA159041959 VN, VHD, VAH, Section 0 Date 11.2021 Body Builder, General Guidelines and Certification Page 59 (104) All Rights Reserved Chassis Diagrams, VNL VNL 300, Truck, Axle Back, 4 x 2 W9034901 Fig. 19 VNL 300, Truck, Axle Back, 4 x 2 Volvo Body Builder Instructions USA159041959 VN, VHD, VAH, Section 0 Date 11.2021 Body Builder, General Guidelines and Certification Page 60 (104) All Rights Reserved See Fig. 19 Dimensions Description Drawing Reference Dimension (in/mm) Front Frame Extension FE 0 in (0 mm) Bumper to Front Axle BA 52.20 in (1326 mm) Wheelbase WB 152 in (3861 mm) Overhang OH 33 in (838 mm) Overall Length OA 237.20 in (6025 mm) Bumper to Back of Cab BBC 122.40 in (3109 mm) Effective Bumper to Back of Cab EBBC See table below. Cab to Rear Axle CA 81.80 in (2078 mm) Effective Cab to Rear Axle ECA See table below. Axle to Back of Cab AC 70.20 in (1783 mm) Effective Front Axle to Back of Cab EAC See table below. Cab to End of Frame CE 114.80 in (2916 mm) Effective Cab to End of Frame ECE See table below. Unladen Frame Height FH 38.60 in (980 mm) Cab Height CH 75 in (1905 mm) Overall Height OVH 113.60 in (2885 mm) Driver CG DCG 42 in (1067 mm) Width of Rear of Cab WROC 89 in (2261 mm) Mirror Width MW 116 in (2946 mm) Cab Width W 95 in (2413 mm) EAC ECA EBBC ECE Single Stack 80.75 in (2051 mm) 71.25 in (1810 mm) 132.95 in (3377 mm) 104.25 in (2648 mm) Dual Stack N/A N/A N/A N/A Vertical SCR 91.89 in (2334 mm) 60.11 in (1527 mm) 144.09 in (3660 mm) 93.11 in (2365 mm) Volvo Body Builder Instructions USA159041959 VN, VHD, VAH, Section 0 Date 11.2021 Body Builder, General Guidelines and Certification Page 61 (104) All Rights Reserved VNL 300, Truck, 6 x 4 W9034915 Fig. 20 VNL 300, Truck, 6 x 4 Volvo Body Builder Instructions USA159041959 VN, VHD, VAH, Section 0 Date 11.2021 Body Builder, General Guidelines and Certification Page 62 (104) All Rights Reserved See Fig. 20 Dimensions Description Drawing Reference Dimension (in/mm) Front Frame Extension FE 0 in (0 mm) Bumper to Front Axle BA 52.20 in (1326 mm) Wheelbase WB 170 in (4318 mm) Overhang OH 55 in (1397 mm) Overall Length OA 277.20 in (7041 mm) Bumper to Back of Cab BBC 122.40 in (3109 mm) Effective Bumper to Back of Cab EBBC See table below. Cab to Rear Axle CA 99.80 in (2535 mm) Effective Cab to Rear Axle ECA See table below. Front Axle to Back of Cab AC 70.20 in (1783 mm) Effective Front Axle to Back of Cab EAC See table below. Cab to End of Frame CE 154.80 in (3932 mm) Effective Cab to End of Frame ECE See table below. Bogie Spread BS 52 in (1321 mm) Unladen Frame Height FH 38.60 in (980 mm) Cab Height CH 75 in (1905 mm) Overall Height OVH 113.60 in (2885 mm) Driver CG DCG 50 in (1270 mm) Width of Rear of Cab WROC 89 in (2261 mm) Mirror Width MW 116 in (2946 mm) Cab Width W 95 in (2413 mm) EAC ECA EBBC ECE Single Stack 80.75 in (2051 mm) 89.25 in (2267 mm) 132.95 in (3377 mm) 144.25 in (3664 mm) Dual Stack N/A N/A N/A N/A Vertical SCR 91.89 in (2334 mm) 78.11 in (1984 mm) 144.09 in (3660 mm) 133.11 in (3381 mm) Volvo Body Builder Instructions USA159041959 VN, VHD, VAH, Section 0 Date 11.2021 Body Builder, General Guidelines and Certification Page 63 (104) All Rights Reserved Chassis Configurations, VHD VHD Axle Forward, Left-Hand Chassis Configuration W0118134 Three battery capacity battery box W0118135 Four battery capacity battery box W0118136 Clean Back of Cab w/75 gal fuel tank (920012) Volvo Body Builder Instructions USA159041959 W0118137 Clean Back of Cab w/100 gal fuel tank (920013) VN, VHD, VAH, Section 0 Date 11.2021 Body Builder, General Guidelines and Certification Page 64 (104) All Rights Reserved VHD Axle Forward, Right-Hand Chassis Configuration, GHG 2017 W0118138 W0118139 Integrated DPF/SCR with three battery box driver side and frame mounted air tanks (also used on VAH) Integrated DPF/SCR with four battery box driver side W0118140 W0118141 Clean Back of Cab Package, 75 or 100 Gallon D-Shaped fuel tank with Integrated DEF tank Volvo Body Builder Instructions USA159041959 Integrated DPF/SCR four battery box driver side VN, VHD, VAH, Section 0 Date 11.2021 Body Builder, General Guidelines and Certification Page 65 (104) All Rights Reserved W0118142 Integrated DPF/SCR four battery box driver side Notes Volvo Body Builder Instructions USA159041959 VN, VHD, VAH, Section 0 Date 11.2021 Body Builder, General Guidelines and Certification Page 66 (104) All Rights Reserved VHD Axle Forward, Right-Hand Chassis Configuration, US 2010 W0118143 W0118144 Frame mounted SCR Vertical mounted SCR Notes Volvo Body Builder Instructions USA159041959 VN, VHD, VAH, Section 0 Date 11.2021 Body Builder, General Guidelines and Certification Page 67 (104) All Rights Reserved VHD Day Cab Axle Back, Left-Hand Chassis Configuration W0118119 W0118120 Three battery capacity battery box Four battery capacity battery box W0118122 W0118121 Battery box mounted on right side Volvo Body Builder Instructions USA159041959 Narrow stacked three capacity battery box VN, VHD, VAH, Section 0 Date 11.2021 Body Builder, General Guidelines and Certification Page 68 (104) All Rights Reserved VHD Axle Back, Right-Hand Chassis Configuration, GHG 2017 W0118123 W0118124 Integrated DPF/SCR with three battery box passenger side Integrated DPF/SCR with three battery box driver side and frame mounted air tanks W0118125 Integrated DPF/SCR with four battery box driver side Volvo Body Builder Instructions USA159041959 W0118126 Integrated DPF/SCR with three battery box driver side VN, VHD, VAH, Section 0 Date 11.2021 Body Builder, General Guidelines and Certification Page 69 (104) All Rights Reserved W0118127 Integrated DPF/SCR with four battery box driver side W0118128 Integrated DPF/SCR with four battery box driver side Notes Volvo Body Builder Instructions USA159041959 VN, VHD, VAH, Section 0 Date 11.2021 Body Builder, General Guidelines and Certification Page 70 (104) All Rights Reserved VHD Axle Back, Right-Hand Chassis Configuration, US 2010 W0118129 W0118130 Frame mounted SCR with Air Tank Arrangement, Basic Frame mounted SCR with In Frame Air Tanks W0118131 W0118132 Frame mounted SCR Volvo Body Builder Instructions USA159041959 Vertical mounted SCR VN, VHD, VAH, Section 0 Date 11.2021 Body Builder, General Guidelines and Certification Page 71 (104) All Rights Reserved Chassis Configurations, VN VN Day Cabs, Left-Hand Chassis Configuration W0118215 VNM / VNR – Three battery capacity battery box W0118216 VNL – Four battery capacity battery box Notes Volvo Body Builder Instructions USA159041959 VN, VHD, VAH, Section 0 Date 11.2021 Body Builder, General Guidelines and Certification Page 72 (104) All Rights Reserved VN Day Cabs, Right-Hand Chassis Configuration, GHG 2017 VNM / VNR Day Cabs The VNM / VNR day cabs with Volvo D11 or D13 engines. W0118217 Volvo D11 or D13 engine, Integrated DPF/SCR W0118218 Volvo D11 or D13 engine, Integrated DPF/SCR with B-pillar exhaust Notes Volvo Body Builder Instructions USA159041959 VN, VHD, VAH, Section 0 Date 11.2021 Body Builder, General Guidelines and Certification Page 73 (104) All Rights Reserved VNL Day Cabs VNL day cabs with Volvo D11 or D13 engines. W0118220 Volvo D11 or D13 engine, Integrated DPF/SCR W0118221 Volvo D11 or D13 engine, Integrated DPF/SCR with B-Pillar exhaust W0118222 D11, D13, or D16 engine, Frame mounted DPF with vertical SCR Volvo Body Builder Instructions USA159041959 VN, VHD, VAH, Section 0 Date 11.2021 Body Builder, General Guidelines and Certification Page 74 (104) All Rights Reserved VNM / VNR Day Cabs, Right-Hand Chassis Configuration, US 2010 W0118219 Volvo 11 and 13-liter engine, Frame mounted SCR Notes Volvo Body Builder Instructions USA159041959 VN, VHD, VAH, Section 0 Date 11.2021 Body Builder, General Guidelines and Certification Page 75 (104) All Rights Reserved VN Day Cabs, Right-Hand Chassis Configuration, GHG 2017 VNL or VNX day cabs with Volvo D16 engines. W0118223 Volvo D16 engine, Frame mounted SCR W0118224 Volvo D16 engine, Frame mounted SCR W0118225 Volvo D16 engine, Frame mounted DPF with vertical SCR Volvo Body Builder Instructions USA159041959 VN, VHD, VAH, Section 0 Date 11.2021 Body Builder, General Guidelines and Certification Page 76 (104) All Rights Reserved VNL or VNX day cabs with Cummins’ engines. W0118226 Cummins 15-liter engine, Frame mounted SCR Notes Volvo Body Builder Instructions USA159041959 VN, VHD, VAH, Section 0 Date 11.2021 Body Builder, General Guidelines and Certification Page 77 (104) All Rights Reserved Fuel Tank Position, VHD Fuel Tank Position (FTP) indicates the distance the fuel tanks are located from the front axle. The VHD has multiple battery mounting options available and two SCR locations on the passenger side. This chassis configuration section will help in determining the optimum chassis configurations. The fuel tank configurations are offered in single driver side or dual tank options. Dual fuel tanks may not always be symmetrical, depending on chassis configurations. However, different size fuel tanks on the driver side and passenger side may be chosen to make the chassis look symmetrical. In addition, new “D-shaped” tanks are available to shorten wheelbases with the same capacity fuel tank. The D-shaped tanks provide approximately a 10% shorter fuel tank, which reduces overall fuel tank length approximately three to seven inches. The fuel tank lengths are shown in the table below. Fuel Tank Lengths for VHD Models Fuel Tank Length Round Capacity D-shaped 26" dia. 22" dia. 26" dia. Gal. Liters Inches mm Inches mm Inches mm 50 190 25.2 640 22.5 572 30.9 786 70 265 N/A N/A N/A N/A 40.6 1032 75 285 36.0 914 32.2 817 N/A N/A 90 340 N/A N/A N/A N/A 54.0 1372 100 380 46.0 1168 41.1 1044 N/A N/A 125 475 58.0 1473 51.9 1317 70.5 1791 150 570 70.0 1778 62.6 1590 84.6 2148 VHD Axle Forward, Left-Hand Fuel Tank Position The left-hand fuel tank position is dependent on the battery box configuration, three or four battery capacity battery boxes. The fuel tanks are mounted in the same location regardless of the DEF tank size, i.e., 11.9 gallons (45.0 L) or 18.5 gallons (70.0 L), because they are the same width. Notes Volvo Body Builder Instructions USA159041959 VN, VHD, VAH, Section 0 Date 11.2021 Body Builder, General Guidelines and Certification Page 78 (104) All Rights Reserved See Fig. 21 Three (3) Battery Capacity Battery Box VHD Axle Forward Distance to Front Axle, in. (mm) Capacity gals (L) Fuel Tank Dia A B 75 (285) 76 (1930) 112 (2845) 100 (380) 76 (1930) 122 (3098) 125 (475) 76 (1930) 134 (3404) Round Fuel Tanks 26’ D-shaped Fuel Tanks 22’ 26’ 50 (190) 76 (1930) 107 (2722) 70 (265) 76 (1930) 117 (2967) 90 (340) 76 (1930) 130 (3307) 75 (285) 76 (1930) 108 (2752) 100 (380) 76 (1930) 117 (2979) 125 (475) 76 (1930) 128 (3252) W0118238 Fig. 21 VHD Axle Forward, Three Battery Capacity Battery Box Volvo Body Builder Instructions USA159041959 VN, VHD, VAH, Section 0 Date 11.2021 Body Builder, General Guidelines and Certification Page 79 (104) All Rights Reserved See Fig. 22 Four (4) Battery Capacity Battery Box VHD Axle Forward Fuel Tank Dia. Distance to Front Axle, in. (mm) Capacity gals (L) A B 75 (285) 92 (2337) 128 (3251) 100 (380) 92 (2337) 138 (3505) 125 (475) 92 (2337) 150 (3810) Round Fuel Tanks 26’ D-shaped Fuel Tanks 22’ 26’ 50 (190) 92 (2337) 123 (3124) 70 (265) 92 (2337) 132 (3353) 90 (340) 92 (2337) 146 (3708) 75 (285) 92 (2337) 124 (3150) 100 (380) 92 (2337) 133 (3379) 125 (475) 92 (2337) 144 (3658) W0118239 Fig. 22 VHD Axle Forward, Four Battery Capacity Battery Box Volvo Body Builder Instructions USA159041959 VN, VHD, VAH, Section 0 Date 11.2021 Body Builder, General Guidelines and Certification Page 80 (104) All Rights Reserved VHD Axle Forward, Right-Hand Fuel Tank Position On the VHD axle forward model, the right-hand fuel tank position is dependent on the SCR configuration, frame mounted or vertical SCR. See Fig. 23 Frame Mounted SCR US 2010 VHD Axle Forward Distance to Front Axle, in. (mm) Capacity gals (L) Fuel Tank Dia. C D 75 (285) 110 (2794) 146 (3708) 100 (380) 110 (2794) 156 (3962) 125 (475) 110 (2794) 168 (4267) Round Fuel Tanks 26’ D-shaped Fuel Tanks 22’ 26’ 50 (190) 110 (2794) 141 (3581) 70 (265) 110 (2794) 150 (3810) 90 (340) 110 (2794) 164 (4166) 75 (285) 110 (2794) 142 (3607) 100 (380) 110 (2794) 151 (3836) 125 (475) 110 (2794) 162 (4115) W0118240 Fig. 23 VHD Axle Forward, Frame Mounted SCR US 2010 Volvo Body Builder Instructions USA159041959 VN, VHD, VAH, Section 0 Date 11.2021 Body Builder, General Guidelines and Certification Page 81 (104) All Rights Reserved See Fig. 24 Vertical Mounted SCR US 2010 VHD Axle Forward Fuel Tank Dia. Distance to Front Axle, in. (mm) Capacity gals (L) C D 75 (285) 86 (2185) 122 (3099) 100 (380) 86 (2185) 132 (3353) 125 (475) 86 (2185) 144 (3658) Round Fuel Tanks 26’ D-shaped Fuel Tanks 22’ 26’ 50 (190) 86 (2185) 117 (2972) 70 (265) 86 (2185) 127 (3226) 90 (340) 86 (2185) 140 (3557) 75 (285) 86 (2185) 118 (2997) 100 (380) 86 (2185) 127 (3226) 125 (475) 86 (2185) 138 (3505) W0118241 Fig. 24 VHD Axle Forward, Vertical Mounted SCR US 2010 Volvo Body Builder Instructions USA159041959 VN, VHD, VAH, Section 0 Date 11.2021 Body Builder, General Guidelines and Certification Page 82 (104) All Rights Reserved See Fig. 25 Integrated DPF/SCR GHG 2017 VHD Axle Forward Distance to Front Axle, in. (mm) Capacity gals (L) Fuel Tank Dia. C D 75 (285) 90 (2286) 126 (3200) 100 (380) 90 (2286) 136 (3454) 125 (475) 90 (2286) 148 (3759) Round Fuel Tanks 26’ D-shaped Fuel Tanks 22’ 26’ 50 (190) 90 (2286) 113 (2870) 70 (265) 90 (2286) 150 (3810) 90 (340) 90 (2286) 144 (3658) 75 (285) 90 (2286) 122 (3099) 100 (380) 90 (2286) 131 (3327) 125 (475) 90 (2286) 142 (3607) W0118323 Fig. 25 VHD Axle Forward, Integrated DPF/SCR GHG 2017 Volvo Body Builder Instructions USA159041959 VN, VHD, VAH, Section 0 Date 11.2021 Body Builder, General Guidelines and Certification Page 83 (104) All Rights Reserved See Fig. 26 Integrated DPF/SCR GHG 2017 Clean BOC VHD Axle Forward Fuel Tank Dia. Distance to Front Axle, in. (mm) Capacity gals (L) C D 75 (285) 85 (2159) 121 (3073) 100 (380) 85 (2159) 131 (3327) 125 (475) 85 (2159) 143 (3632) Round Fuel Tanks 26’ D-shaped Fuel Tanks 22’ 26’ 50 (190) 85 (2159) 116 (2946) 70 (265) 85 (2159) 126 (3200) 90 (340) 85 (2159) 139 (3531) 75 (285) 85 (2159) 117 (2972) 100 (380) 85 (2159) 126 (3200) 125 (475) 85 (2159) 137 (3480) W0118324 Fig. 26 VHD Axle Forward, Integrated DPF/SCR GHG 2017 Clean BOC Volvo Body Builder Instructions USA159041959 VN, VHD, VAH, Section 0 Date 11.2021 Body Builder, General Guidelines and Certification Page 84 (104) All Rights Reserved See Fig. 27 Integrated DPF/SCR GHG 2017 VHD Axle Forward Distance to Front Axle, in. (mm) Capacity gals (L) Fuel Tank Dia. C D 75 (285) 85 (2159) 121 (3073) 100 (380) 85 (2159) 131 (3327) 125 (475) 85 (2159) 143 (3632) Round Fuel Tanks 26’ D-shaped Fuel Tanks 22’ 26’ 50 (190) 85 (2159) 116 (2946) 70 (265) 85 (2159) 126 (3200) 90 (340) 85 (2159) 139 (3531) 75 (285) 85 (2159) 117 (2972) 100 (380) 85 (2159) 126 (3200) 125 (475) 85 (2159) 137 (3480) W0118325 Fig. 27 VHD Axle Forward, Integrated DPF/SCR GHG 2017 Volvo Body Builder Instructions USA159041959 VN, VHD, VAH, Section 0 Date 11.2021 Body Builder, General Guidelines and Certification Page 85 (104) All Rights Reserved VHD Axle Back, Left-Hand Fuel Tank Position The left-hand fuel tank position is dependent on the battery box configuration, three or four battery capacity battery boxes. The fuel tanks are mounted in the same location regardless of the DEF tank size, i.e., 11.9 gallons (45.0 L) or 18.5 gallons (70.0 L), because they are the same width. See Fig. 28 Three (3) Battery Capacity Battery Box VHD Axle Back Fuel Tank Dia. Distance to Front Axle, in. (mm) Capacity gals (L) A B 75 (285) 62 (1575) 98 (2489) 100 (380) 62 (1575) 108 (2743) 125 (475) 62 (1575) 120 (3048) Round Fuel Tanks 26’ D-shaped Fuel Tanks 22’ 26’ 50 (190) 62 (1575) 93 (2262) 70 (265) 62 (1575) 103 (2616) 90 (340) 62 (1575) 116 (2946) 75 (285) 62 (1575) 94 (2388) 100 (380) 62 (1575) 103 (2616) 125 (475) 62 (1575) 114 (2896) W0118242 Fig. 28 VHD Axle Back, Three Battery Capacity Battery Box Volvo Body Builder Instructions USA159041959 VN, VHD, VAH, Section 0 Date 11.2021 Body Builder, General Guidelines and Certification Page 86 (104) All Rights Reserved See Fig. 29 and Fig. 30 Four (4) Battery Capacity Battery Box VHD Axle Back Distance to Front Axle, in. (mm) Capacity gals (L) Fuel Tank Dia. A B 75 (285) 77 (1956) 113 (2870) 100 (380) 77 (1956) 123 (3124) 125 (475) 77 (1956) 135 (3429) Round Fuel Tanks 26’ D-shaped Fuel Tanks 22’ 26’ 50 (190) 77 (1956) 108 (2743) 70 (265) 77 (1956) 118 (2997) 90 (340) 77 (1956) 131 (3327) 75 (285) 77 (1956) 109 (2769) 100 (380) 77 (1956) 118 (2997) 125 (475) 77 (1956) 129 (3277) W0118243 Fig. 29 VHD Axle Back, Four Battery Capacity Battery Box Volvo Body Builder Instructions USA159041959 W0118244 Fig. 30 VHD Axle Back, Four Battery Capacity Battery Box VN, VHD, VAH, Section 0 Date 11.2021 Body Builder, General Guidelines and Certification Page 87 (104) All Rights Reserved VHD Axle Back, Right-Hand Fuel Tank Position On the VHD Axle Back model, the right-hand fuel tank position is dependent on the SCR configuration, frame mounted or vertical SCR and the air tank arrangement. See Fig. 31 and Fig. 32 Frame Mounted SCR US 2010 VHD Axle Back Fuel Tank Dia. Distance to Front Axle, in. (mm) Capacity gals (L) C D 75 (285) 88 (2235) 124 (3150) 100 (380) 88 (2235) 134 (3404) 125 (475) 88 (2235) 146 (3708) Round Fuel Tanks 26’ D-shaped Fuel Tanks 22’ 26’ 50 (190) 88 (2235) 119 (3023) 70 (265) 88 (2235) 128 (3251) 90 (340) 88 (2235) 142 (3607) 75 (285) 88 (2235) 120 (3048) 100 (380) 88 (2235) 129 (3277) 125 (475) 88 (2235) 140 (3556) W0118245 W0118246 Fig. 31 VHD Axle Back, Frame Mounted SCR US 2010 Fig. 32 VHD Axle Back, Frame Mounted SCR US 2010 Volvo Body Builder Instructions VN, VHD, VAH, Section 0 USA159041959 Date 11.2021 Body Builder, General Guidelines and Certification Page 88 (104) All Rights Reserved See Fig. 33 Vertical Mounted SCR US 2010 VHD Axle Back Distance to Front Axle, in. (mm) Capacity gals (L) Fuel Tank Dia. C D 75 (285) 64 (1625) 100 (2540) 100 (380) 64 (1625) 110 (2794) 125 (475) 64 (1625) 116 (2946) Round Fuel Tanks 26’ D-shaped Fuel Tanks 22’ 26’ 50 (190) 64 (1625) 95 (2413) 70 (265) 64 (1625) 105 (2667) 90 (340) 64 (1625) 118 (2997) 75 (285) 64 (1625) 96 (2438) 100 (380) 64 (1625) 105 (2667) 125 (475) 64 (1625) 116 (2946) W0118247 Fig. 33 VHD Axle Back, Vertical Mounted SCR US 2010 Volvo Body Builder Instructions USA159041959 VN, VHD, VAH, Section 0 Date 11.2021 Body Builder, General Guidelines and Certification Page 89 (104) All Rights Reserved See Fig. 34 Integrated DPF/SCR GHG 2017 VHD Axle Back Fuel Tank Dia. Distance to Front Axle, in. (mm) Capacity gals (L) C D 75 (285) 83 (2108) 119 (3023) 100 (380) 83 (2108) 129 (3277) 125 (475) 83 (2108) 141 (3581) Round Fuel Tanks 26’ D-shaped Fuel Tanks 22’ 26’ 50 (190) 83 (2108) 114 (2896) 70 (265) 83 (2108) 124 (3150) 90 (340) 83 (2108) 137 (3480) 75 (285) 83 (2108) 115 (2921) 100 (380) 83 (2108) 124 (3150) 125 (475) 83 (2108) 135 (3429) W0118575 Fig. 34 VHD Axle Back, Integrated DPF/SCR GHG 2017 Volvo Body Builder Instructions USA159041959 VN, VHD, VAH, Section 0 Date 11.2021 Body Builder, General Guidelines and Certification Page 90 (104) All Rights Reserved See Fig. 35 Integrated DPF/SCR GHG 2017 VHD Axle Back Distance to Front Axle, in. (mm) Capacity gals (L) Fuel Tank Dia. C D 75 (285) 74 (1880) 110 (2794) 100 (380) 74 (1880) 120 (3048) 125 (475) 74 (1880) 132 (3353) Round Fuel Tanks 26’ D-shaped Fuel Tanks 22’ 26’ 50 (190) 74 (1880) 105 (2667) 70 (265) 74 (1880) 115 (2921) 90 (340) 74 (1880) 128 (3251) 75 (285) 74 (1880) 106 (2692) 100 (380) 74 (1880) 115 (2921) 125 (475) 74 (1880) 126 (3200) W0118576 Fig. 35 VHD Axle Back, Integrated DPF/SCR GHG 2017 Volvo Body Builder Instructions USA159041959 VN, VHD, VAH, Section 0 Date 11.2021 Body Builder, General Guidelines and Certification Page 91 (104) All Rights Reserved Fuel Tank Position, VN Fuel Tank Position (FTP) indicates the distance the fuel tanks are located from the front axle. There are multiple battery mounting options available on the driver’s side and multiple SCR combinations provided on the passenger side. This chassis configuration section will help in determining the optimum chassis configurations. The fuel tank configurations are offered in single driver side, single passenger side or dual tank options. Dual fuel tanks may not always be symmetrical, depending on chassis configurations. However, different size fuel tanks on the driver side and passenger side may be chosen to make the chassis look symmetrical. In addition, “D-shaped” tanks are available to shorten wheelbases with the same capacity fuel tank. The D-shaped tanks provide approximately a 10% shorter fuel tank, which reduces overall fuel tank length approximately three to seven inches. The fuel tank lengths are shown in the table below. Fuel Tank Lengths for VN Models Fuel Tank Length Capacity Round D-shaped 26" dia. 26" dia. Gal. Liters Inches mm Inches mm 50 190 25.2 640 22.5 572 75 285 36 914 32.2 817 100 380 46 1168 41.1 1044 125 475 58 1473 51.9 1317 150 570 70 1778 62.6 1590 Notes Volvo Body Builder Instructions USA159041959 VN, VHD, VAH, Section 0 Date 11.2021 Body Builder, General Guidelines and Certification Page 92 (104) All Rights Reserved Left-Hand Fuel Tank Position for VN Models The left-hand fuel tank position is dependent on the battery box configuration, three or four battery capacity battery boxes. See Fig. 36 Three (3) Battery Capacity Battery Box Capacity gals (L) Distance to Front Axle, in. (mm) A B Round Fuel Tanks VNL300 / VNM200 / VNR200 75(285) 64 (1626) 100 (2540) 100 (380) 64 (1626) 110 (2794) 125 (475) 64 (1626) 122 (3099) 150 (570) 64 (1626) 134 (3404) D-shaped Fuel Tanks 75(285) 64 (1626) 96 (2438) 100 (380) 64 (1626) 105 (2667) 125 (475) 64 (1626) 116 (2946) 150 (570) 64 (1626) 127 (3226) W0118314 Fig. 36 Three Battery Capacity Battery Box Volvo Body Builder Instructions USA159041959 VN, VHD, VAH, Section 0 Date 11.2021 Body Builder, General Guidelines and Certification Page 93 (104) All Rights Reserved See Fig. 37 and Fig. 38 Four (4) Battery Capacity Battery Box Model Cab Distance to Front Axle, in. (mm) Capacity gals (L) A B 75 (285) 79 (2007) 115.3 (2929) 100 (380) 79 (2007) 125.3 (3183) 125 (475) 79 (2007) 137.3 (3488) 150 (570) 79 (2007) 149.3 (3793) 75 (285) 79 (2007) 111.9 (2842) 100 (380) 79 (2007) 120.8 (3069) 125 (475) 79 (2007) 131.6 (3342) 150 (570) 79 (2007) 142.3 (3615) 75 (285) 79 (2007) 113.5 (2882) 100 (380) 79 (2007) 120.4 (3059) 125 (475) 79 (2007) 131.2 (3332) 150 (570) 79 (2007) 141.9 (3605) Round Fuel Tanks VNL300 / VNM200 / VNR200 D-shaped Fuel Tanks VNL VNM / VNR 300 200 W0118315 W0118316 Fig. 37 Four Battery Capacity Battery Box Fig. 38 Four Battery Capacity Battery Box Volvo Body Builder Instructions VN, VHD, VAH, Section 0 USA159041959 Date 11.2021 Body Builder, General Guidelines and Certification Page 94 (104) All Rights Reserved Right-Hand Fuel Tank Position for VN Models The right-hand fuel tank position is dependent on the engine selection (SCR unit size) and SCR configuration. See Fig. 39 Volvo D11 or Volvo D13 Engine Frame Mounted SCR US 2010 Model Cab Capacity gals (L) Distance to Front Axle, in. (mm) C D 50 (190) 88 (2235) 113 (2870) 75 (285) 88 (2235) 124 (3150) 100 (380) 88 (2235) 134 (3404) 125 (475) 88 (2235) 146 (3708) 150 (570) 88 (2235) 158 (4013) 50 (190) 88 (2235) 110 (2794) 75 (285) 88 (2235) 120 (3048) 100 (380) 88 (2235) 129 (3277) 125 (475) 88 (2235) 140 (3556) 150 (570) 88 (2235) 150 (3810) Round Fuel Tanks VNL / VNM / VNR ALL D-shaped Fuel Tanks VNL 300 W0118317 Fig. 39 Volvo D11 or Volvo D13 Engine, Frame Mounted SCR US 2010 Volvo Body Builder Instructions USA159041959 VN, VHD, VAH, Section 0 Date 11.2021 Body Builder, General Guidelines and Certification Page 95 (104) All Rights Reserved See Fig. 40 Volvo D11 or Volvo D13 Engine Frame Mounted SCR US 2010 Model Cab Distance to Front Axle, in. (mm) Capacity gals (L) C D 50 (190) 88 (2235) 110 (2794) 75 (285) 88 (2235) 120 (3048) 100 (380) 88 (2235) 129 (3277) 125 (475) 88 (2235) 140 (3556) 150 (570) 88 (2235) 150 (3810) D-shaped Fuel Tanks VNM / VNR 200 W0118317 Fig. 40 Volvo D11 or Volvo D13 Engine, Frame Mounted SCR US 2010 Volvo Body Builder Instructions USA159041959 VN, VHD, VAH, Section 0 Date 11.2021 Body Builder, General Guidelines and Certification Page 96 (104) All Rights Reserved See Fig. 41 Volvo D16 Engine Frame Mounted SCR US 2010 Model Cab Capacity gals (L) Distance to Front Axle, in. (mm) C D 50 (190) 92 (2337) 117 (2972) 75 (285) 92 (2337) 128 (3251) 100 (380) 92 (2337) 138 (3505) 125 (475) 92 (2337) 150 (3810) 150 (570) 92 (2337) 162 (4115) 50 (190) 92 (2337) 115 (2337) 75 (285) 92 (2337) 124 (3150) 100 (380) 92 (2337) 133 (3378) 125 (475) 92 (2337) 144 (3658) 150 (570) 92 (2337) 155 (3937) Round Fuel Tanks VNL 300 D-shaped Fuel Tanks VNL 300 W0118319 Fig. 41 Volvo D16 Engine, Frame Mounted SCR US 2010 Volvo Body Builder Instructions USA159041959 VN, VHD, VAH, Section 0 Date 11.2021 Body Builder, General Guidelines and Certification Page 97 (104) All Rights Reserved See Fig. 42 Volvo D11 / D13 / D16 Engine Vertical SCR US 2010 Model Cab Distance to Front Axle, in. (mm) Capacity gals (L) C D 50 (190) 64 (1626) 89 (2261) 75 (285) 64 (1626) 100 (2540) 100 (380) 64 (1626) 110 (2794) 125 (475) 64 (1626) 122 (3099) 150 (570) 64 (1626) 134 (3404) 50 (190) 64 (1626) 87 (2297) 75 (285) 64 (1626) 96 (2492) 100 (380) 64 (1626) 105 (2669) 125 (475) 64 (1626) 116 (2942) 150 (570) 64 (1626) 127 (3215) Round Fuel Tanks VNM / VNR / VNL ALL D-shaped Fuel Tanks VNM / VNR / VNL ALL W0118318 Fig. 42 Volvo D11 / D13 / D16 Engine, Vertical SCR US 2010 Volvo Body Builder Instructions USA159041959 VN, VHD, VAH, Section 0 Date 11.2021 Body Builder, General Guidelines and Certification Page 98 (104) All Rights Reserved See Fig. 43 Cummins ISX 15.0 L Engine Switchback Frame Mounted SCR Model Cab Capacity gals (L) Distance to Front Axle, in. (mm) C D 50 (190) 74 (1880) 99 (2515) 75 (285) 74 (1880) 110 (2794) 100 (380) 74 (1880) 120 (3048) 125 (475) 74 (1880) 132 (3353) 150 (570) 74 (1880) 144 (3658) 50 (190) 74 (1880) 100.3 (2547) 75 (285) 74 (1880) 106.0 (2692) 100 (380) 74 (1880) 114.9 (2919) 125 (475) 74 (1880) 125.7 (3192) 150 (570) 74 (1880) 136.4 (3465) Round Fuel Tanks VNL ALL D-shaped Fuel Tanks VNL 300 W0118320 Fig. 43 Cummins ISX 15.0 L Engine, Switchback Frame Mounted SCR Volvo Body Builder Instructions USA159041959 VN, VHD, VAH, Section 0 Date 11.2021 Body Builder, General Guidelines and Certification Page 99 (104) All Rights Reserved See Fig. 44 Volvo D11 or Volvo D13 Engine Integrated DPF/SCR GHG 2017 Model Cab Distance to Front Axle, in. (mm) Capacity gals (L) C D 50 (190) 83 (2108) 108 (2743) 75 (285) 83 (2108) 119 (3023) 100 (380) 83 (2108) 129 (3277) 125 (475) 83 (2108) 141 (3581) 150 (570) 83 (2108) 153 (3886) 50 (190) 83 (2108) 106 (2692) 75 (285) 83 (2108) 115 (2921) 100 (380) 83 (2108) 124 (3150) 125 (475) 83 (2108) 135 (3429) 150 (570) 83 (2108) 146 (3708) Round Fuel Tanks VNM / VNR 200 D-shaped Fuel Tanks VNM / VNR 200 W0118326 Fig. 44 Volvo D11 or Volvo D13 Engine, Integrated DPF/SCR GHG 2017 Volvo Body Builder Instructions USA159041959 VN, VHD, VAH, Section 0 Date 11.2021 Body Builder, General Guidelines and Certification Page 100 (104) All Rights Reserved See Fig. 45 and Fig. 46 Volvo D11 or Volvo D13 Engine Integrated DPF/SCR GHG 2017 Model Cab Distance to Front Axle, in. (mm) Capacity gals (L) C D 50 (190) 73 (1854) 98 (2489) 75 (285) 73 (1854) 109 (2769) 100 (380) 73 (1854) 119 (3023) 125 (475) 73 (1854) 131 (3327) 150 (570) 73 (1854) 143 (3632) 50 (190) 73 (1854) 96 (2438) 75 (285) 73 (1854) 105 (2667) 100 (380) 73 (1854) 114 (2896) 125 (475) 73 (1854) 131 (3327) 150 (570) 73 (1854) 136 (3454) Round Fuel Tanks VNL300 / VNM200 / VNR200 D-shaped Fuel Tanks VNL300 / VNM200 / VNR200 W0118329 Fig. 45 Volvo D11 or Volvo D13 Engine, Integrated DPF/ SCR GHG 2017 Volvo Body Builder Instructions USA159041959 W0118327 Fig. 46 Volvo D11 or Volvo D13 Engine, Integrated DPF/ SCR GHG 2017 VN, VHD, VAH, Section 0 Date 11.2021 Body Builder, General Guidelines and Certification Page 101 (104) All Rights Reserved See Fig. 47 Volvo D11/ D13 Integrated DPF/SCR GHG 2017 Model Distance to Front Axle, in. (mm) Capacity gals (L) C D 50 (190) 81 (2057) 106 (2694) 75 (285) 81 (2057) 117 (2972) 100 (380) 81 (2057) 127 (3226) 125 (475) 81 (2057) 139 (3531) 150 (570) 81 (2057) 151 (3835) Round Fuel Tanks VNL D-shaped Fuel Tanks VNL 50 (190) 81 (2057) 104 (2642) 75 (285) 81 (2057) 113 (2870) 100 (380) 81 (2057) 122 (3099) 125 (475) 81 (2057) 133 (3378) 150 (570) 81 (2057) 144 (3658) W0118328 Fig. 47 Volvo D11/ D13, Integrated DPF/SCR GHG 2017 Volvo Body Builder Instructions USA159041959 VN, VHD, VAH, Section 0 Date 11.2021 Body Builder, General Guidelines and Certification Page 102 (104) All Rights Reserved Volvo Body Builder Instructions USA159041959 VN, VHD, VAH, Section 0 Date 11.2021 Body Builder, General Guidelines and Certification Page 103 (104) All Rights Reserved English 11.2021, 159041959 Last page Volvo Trucks North America http://www.volvotrucks.com