Body builder instructions
Volvo Truck Corporation
Supersedes VBI Release 15 from 09.20
Changes are marked with a bar (|) in the margin. Chapter 1, General
Calculations and loads
FM (4), FH (4)
FL (3), FE (3)
Contents
“Bodywork calculations”, page 2
“Input data”, page 2
“Payload”, page 6
“Positioning the fifth wheel”, page 6
“Bodywork length”, page 8
“Load distribution”, page 10
“Static loads”, page 10
“Dynamic loads”, page 11
Calculations and loads FM (4), FH (4), FL (3), FE (3)
ENG159753800 Date 11.2021 Release 16 Page 1 (12)
All Rights Reserved
Calculations and loads
Bodywork calculations
The length and position of the bodywork must be calculated to obtain an optimum vehicle. Correct axle loads are ob-
tained by calculation.
When calculating the maximum axle loads on a rigid vehicle, for example, a van body, it must be taken into account that
the centre of gravity will move forwards as the vehicle is unloaded from the rear end, which will increase the load on the
front axle.
Note: Since illustrations are reused for different variants, certain details may differ from the variant in question. The es-
sential information in the illustrations is however always accurate.
Input data
Basic data for the calculations can be found in the binders product Information, “Model Range” and “Fact Sheet”. Basic
data can also be found in national or local data sheets.
Note: Always check that the final dimensions of the design, such as overhang and total length, comply with national and
local requirements.
Note: The space between the cab and bodywork must allow space for the cab suspension movement. The cab length
and the cab movement when tipping, can be seen on the chassis drawing or on the data sheets in product information.
See also “Space between cab and bodywork”, page 3 .
Calculations and loads FM (4), FH (4), FL (3), FE (3)
ENG159753800 Date 11.2021 Release 16 Page 2 (12)
Space between cab and bodywork
FM (4), FH (4)
The space between the cab and bodywork must be at least
50 mm.
T9162589
FM (4) trucks with CAB-DAY
Depending on the bodywork, it may be necessary to re-
move a portion of the fender extension so that they do not
touch the bodywork when tilting the cab.
T9162590
Cut the rear portion of the fender extension as per the
marking lines available inside the fender extension.
T9163588
Remove the protection film from the rubber cap.
T9163589
Install the rubber cap to the fender extension.
Part name Variant Part number
Rubber cap FMUDE-B,
82678390
(for RH fender FMUDE-TH
extension)
FMUDE-TW 82695268
Rubber cap FMUDE-B,
82678388
(for LH fender FMUDE-TH
extension) T9163590
FMUDE-TW 82695266
Calculations and loads FM (4), FH (4), FL (3), FE (3)
ENG159753800 Date 11.2021 Release 16 Page 3 (12)
FE (3)
The space (D) between the cab and the bodywork de-
pends on the type of cab.
Cab Space (D)
CAB-DAY (L1H1) 74 mm
CAB-SSLP (L2H1) 74 mm
CAB-SLP (L3H1) 42 mm
FL (3)
Cab Space (D)
CAB-DAY (L1H1)
50 mm
CAB-SSLP (L2H1)
T9008545
CAB-CRW (L4H1C) 25 mm
Air deflector
Top of spoiler should be adjusted to the start of radius of ex. Van box. For more information about air deflector, refer body
builder instructions “Roof-mounted equipment”.
C9139344
Calculations and loads FM (4), FH (4), FL (3), FE (3)
ENG159753800 Date 11.2021 Release 16 Page 4 (12)
Data necessary for calculations
The truck kerb weights front and rear (Kerb FAL and RAL).
The bodywork and any extra equipment, such as a crane,
are included in the kerb weights.
Permitted axle loads front and rear (Permitted FAL and
RAL) are limited by national or local legislation, and by
the axle loads (FAL and RAL) permitted by Volvo.
Note: Select the lowest of the two alternatives in the
calculations.
T9162591
WB (Wheelbase) and TWB (Theoretical Wheelbase) can
be found on the internet site http://vbi.truck.volvo.com.
Select Order Information.
T9162592
T9162593
T9162594
T9162595
T9162596
Calculations and loads FM (4), FH (4), FL (3), FE (3)
ENG159753800 Date 11.2021 Release 16 Page 5 (12)
Payload
The maximum permitted payload per axle is equivalent to the difference between the permitted FAL and RAL and the
Kerb FAL and RAL.
The payload on the front axle (Payload FA) and rear axle(s) (Payload RA) and the total permissible payload (L) then
becomes:
Payload FA = Permitted FAL - Kerb FAL
Payload RA = Permitted RAL - Kerb RAL
Total Pay- = Payload FA + Payload RA
load, L
Positioning the fifth wheel
To be able to utilise the permitted axle load on a tractor unit, it is important to position the fifth wheel at a suitable distance
S from the rear axle/theoretical rear axle.
It is assumed that the load is equal to the total permitted load L according to the definition given on the previous page.
The load applied by the trailer to the king pin is then equal to L.
Calculate S with an equilibrium equation around the rear axle, on a two axle truck or the centre of the bogie on a three or
more axle trucks.
This calculated value of S gives a location of the fifth wheel, which loads the front axle with the permissible front axle load
(permitted FAL) and the rear axle(s) with the permissible rear axle load (permitted RAL). (The value of S can also be cal-
culated from Payload RA. Use the formula for S under “Bodywork length”, page 8 .)
If an axle load tolerance is required for FA and RA, take half the difference between the two values of (S) obtained in the
two calculations.
Note: National and local requirements must be taken into account when specifying overall length, cab clearance, swing
area, etc.
Calculations and loads FM (4), FH (4), FL (3), FE (3)
ENG159753800 Date 11.2021 Release 16 Page 6 (12)
Two axle trucks
T9162597
Three and four axle trucks
T9162598
T9162599
Calculations and loads FM (4), FH (4), FL (3), FE (3)
ENG159753800 Date 11.2021 Release 16 Page 7 (12)
Bodywork length
For a rigid type vehicle, it is essential to determine the length of the bodywork B.
First decide the permitted load and the distance between the front axle and the front edge of the bodywork.
It is assumed that the load is equal to the total permitted load L and that it is evenly distributed.
The centre of gravity of the load lies B/2 behind the front edge of the bodywork and at a distance of S in front of the rear
axle(s).
S is decided by an equilibrium equation around the rear axle/theoretical rear axle.
Half the length of the body B/2 is:
B/2 = WB - A - S 2 axle trucks
B/2 = TWB - A - S 3 axle and 4 axle trucks
The calculated length B should be rounded off to the nearest 100 mm.
Note: National and local requirements must be taken into account when specifying overhang, overall length, cab clear-
ance, etc.
Two axle trucks
T9162600
Calculations and loads FM (4), FH (4), FL (3), FE (3)
ENG159753800 Date 11.2021 Release 16 Page 8 (12)
Three, four and five axle trucks
T9162601
T9162602
T9162603
Calculations and loads FM (4), FH (4), FL (3), FE (3)
ENG159753800 Date 11.2021 Release 16 Page 9 (12)
Load distribution
Static loads
The loads on the chassis frame depend on the type of
body fitted. The load is evenly distributed, concentrated
over a limited length or spread over several points.
A correctly attached rigid platform, generally distributes
the load evenly over the chassis frame. The moment dia-
gram shows the maximum values at the middle of the
wheelbase and at the rear axle/bogie.
T9162604
When a crane is mounted behind the cab on a truck with
a rigid platform, a concentrated load is introduced just be-
hind the cab. The moment diagram shows a maximum
value close to the crane.
T9162605
Calculations and loads FM (4), FH (4), FL (3), FE (3)
ENG159753800 Date 11.2021 Release 16 Page 10 (12)
A correctly attached tank exerts point loads on the chassis
frame at the attachment points.
T9162606
Dynamic loads
When the truck is being driven, the chassis frame is af-
fected both by dynamic loads from the road/ground sur-
face and by manoeuvring. The moment diagram is altered
and the maximum values are increased. In addition, the
chassis is also influenced by side loads and torsional
loads. The dynamic loading constantly.
T9006237
Calculations and loads FM (4), FH (4), FL (3), FE (3)
ENG159753800 Date 11.2021 Release 16 Page 11 (12)
English 11.2021, 159753800
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