Frame Rails and Crossmembers - VN,VHD
Contents
1. 49 HUCK FIT Fastener Removal 56 HUCK FIT Fastener Installation ss 57 Frame Rail Replacement 2 622 oko oor doo ee x om vrs ee 37 Frame Alignment Adjustment llle les 44 Frame Length Adjustment a a 51 Frame Alignment Checking 2 2 eel 43 Body Bound Bolt Installation a x arsos amor ek ome ho ERR RR E IER E a 56 VOLVO Volvo Trucks North America Inc P O Box 26115 Greensboro NC 27402 6115 Volvo Trucks Canada Ltd 6490 Vipond Drive Mississauga Ontario L5T 1W8 http Avww volvotrucks volvo com PV776 TSP143123 1000 8 2000 O Volvo Trucks North America Inc 20002. 24 W7001185 1 Jack Stand Install the radiator support bracket and the lower radiator isolator mount 41 Group 71 25 Install the fasteners to the front spring hanger and reinstall the bumper sup port bracket 26 Install the fasteners to the front closing crossmember and the fasteners to the tow hook on the side of the vehicle be ing worked on 27 Install the inner fender splash shield and the lower splash shield support bracket to the frame rail 28 Install the battery tray mounting fas teners and install the battery and air tank support brackets 29 Once this step is complete go back 200 33 Nm and tighten fasteners that have been 148 24 ft lb installed from steps 8 through 26 as 275 45 Nm follows M14 tighten to a torque of 204 34 ft lb 200 33 Nm 148 24 ft lb M16 540 90 Nm 275 45 Nm 204 34 ft lb and M20 540 90 Nm 400 67 ft lb 400 67 ft lb 30 Install the air tank straps and the air tanks 31 Reconnect the supply and return lines to the wind shield washer reservoir Reinstall the clamp that secures the drain valve pull cords to the air tanks 32 Install the battery cable hold down bracket to the frame rail and reconnect the windshield wiper fluid pump 33 Install the battery hold down strap and remove the batteries 34 Install the battery box cover and re connect the batteries 35 Reconnect the fuel supply and return line Instal
3. The result will usually be twisted or cracked frame rails Localized stress concentration failures may be the result of exceeding allowable bending moment however bend ing moment levels encountered during normal operation would not be high enough to cause a failure Incidental to the failure is the condition of localized stress concen tration Possible causes for exceeding allowable bending moment could be high bending loads concurrent with se vere torsional loads as may be found in off road service Points of localized stress concentration may also be the result of one or several of the following Poor body or fifth wheel mounting Improper special equipment or accessory installation Improper reinforcements Loose bolts Defective material Special equipment or accessory installation can cause high stress concentration due to the method of attach ment or the weight of the equipment Holes should never be drilled through the flanges Rapid changes of Section Modulus which could occur during operations such as adding a large mounting plate for supporting special equipment should be avoided Heavy equipment mounted across the flanges or on the web of a side rail may produce enough stress concentration to cause fail ure at the nearest crossmember bracket or other frame stiffener or through a nearby hole in the frame flange Design and Function 27 Group 71 Improper reinforcement or attachment of the reinforce ment may ca
4. the Volvo T Ride Tighten the V torque rod nuts axle housing to a torque of 310 50 Nm 228 37 ft lb Tighten the V torque rod bolts chassis bracket to a torque of 320 50 Nm 236 37 ft lb 11 Install all the harness and airlines mounting brackets 12 Install the light bar and mud flaps 200 33 Nm 148 24 ft lb 275 45 Nm 204 34 ft Ib 500 75 Nm 369 55 ft Ib 200 33 Nm 148 24 ft lb 310 50 Nm 228 37 ft lb 320 50 Nm 236 37 ft lb Group 71 13 Install the closing crossmember See Closing Crossmember Replacement page 47 14 Remove any supports for the frame rails and the drive axle 7113 05 02 04 Frame Length Adjustment AN 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 in jury or death Always wear appropriate eye protection to prevent the risk of eye injury due to contact with debris or fluids Note Total wheel vehicle alignment may be necessary after completing this procedure Refer to the appropriate service information Note The only approved alteration to the frame is short ening of the vehicle wheelbase by moving the rear axle s forward and cutting the excess frame from the end Frame rails are not to be spliced or extended Before beginning any service work on any part of
5. tighten to a torque of 200 33 Nm 148 24 ft lb M16 275 45 Nm 204 34 ft lb 204 34 ft lb 9 Install the fuel cooler and or fuel water separator 10 Install the air dryer and or purge tank 11 Install the transmission mount bracket and the transmission crossmember mounting bracket on the frame rail be ing replaced 12 Install the rear spring hanger on the front axle 13 Install the lower spring pin on the rear spring hanger to the front axle using 9996791 9996791 14 Install the front cab support 15 Install any air valves wiring and or air line brackets under the cab inside and outside of the frame rail 16 Install the ground wire and the ground stud located on the frame rail forward of the front cab support 17 Connect the hood release cable and install the hood tube mount bracket Service Procedures 18 Install the rear A C line support bracket and remove the bulkhead fit ting and wheel speed sensor from the front brake 19 Install the steering shaft carrier bear ing bracket and or the power steering reservoir bracket 20 Install the A C line support bracket inside the frame rail and install the up per shock absorber bolt 21 Install the front axle bump stop to the frame rail on the side of the vehicle being worked on 22 Stabilize the steering gear and install the fasteners that mount the steering gear 23 Install the pitman arm to the steering gear
6. 23 Y A 2 W7001172 1 Desired end of frame 2 Rough cut Cut out the wedge 24 W7000390 Bevel the outer edges of the cuts to 45 54 Service Procedures 25 W7000408 Bend the upper flange down until it makes contact with the web Note lt may be necessary to heat the flange in order to bend it 26 Verify the proper fit up of the tapered crossmember before welding 27 W7000413 N WARNING Eye injury hazard Wear eye protection during weld ing Failure to wear eye protection could result in Severe eye injury and blindness Weld the cut edges of the web to gether Group 71 28 W7000414 Cut off the end of the frame rail at the desired end frame mark 29 Repeat the cutting and welding process for the other frame rail 30 51 5 9 mm W7000391 Measure mark and drill holes in the frame to accommodate the closing crossmember 31 Grind the end of the frame and the welded areas smooth and paint all bare metal frame surfaces Service Procedures 32 W7000378 W7000379 275 45 Nm 203 33 ft lb Slide the closing crossmember into place Tighten tapered crossmember bolts to 275 45 Nm 203 33 ft lb 33 Mark and drill holes for the fifth wheel angle irons Bolt the fifth wheel as sembly to the frame and tighten bolts to 275 45 Nm 203 33 ft lb 275 45 Nm 203 33 ft lb 34 Install and tighten an appropriate siz
7. 56 HUCK FIT Fastener Installation een 57 Feedback Operation Numbers Group 71 General General Frame Rails and Crossmembers The information in this manual covers specifications tools designs function and ser vice procedures for VN VHD Frame Rails and Crossmembers This information is essential for maintenance and proper serviceability of the Frame Rails and Crossmem bers Group 71 Specifications Specifications Frame Rails Material 5 5 0 cti ri 758 4 MPa 110 000 psi yield heat treated steel Distance between rails FROIN T E E 1080 2 mm outside editur teo e UNI E 836 27 mm Frame rail end taper 52 edt seid de tae ee db gif de ud e a O pb Da Sa 27 Available Frame Heights and Thicknesses Frame height Frame thickness Eu MeL 6 mm 7 mm 8 mm So ue TEE 7 mm 8 mm 300mm MED 9 tii et Einen 7 mm 8 mm 11 1 mm Group 71 Specifications Bolt Hole Patterns Hole spacing with Volvo T Ride suspension sese eee eee ee eee 60 mm 2 26 in vert x 50 mm 1 97 in horiz applicable only from 1685 mm 65 2 in from front edge of the rail and rearward Note Hole size for this spacing must be 15 5 mm 0 61 in long W7001187 A 60 mm 2 36 in B 60 mm 2 36 in C 60 mm 2 36 in D 60 mm 2 36 in E 60 mm 2 36 in F 50 mm 1 97 in G 43 mm 1 69 in H 60 mm 2 36 in 160 mm 2 36 in J 60 mm 2 36 in K 43 mm 1 69
8. 940 POWERIG hydraulic unit This portable 110V electric power unit provides hydraulic fluid under pressure to the model 585 hydraulic in stallation tool This tool is also available in 220V Group 71 Tools The Digital Angle Gauge The Anglemaster is a digital inclinometer available from Dana Spicer telephone 419 535 4300 Oli el S ES 8 Sg Drill with Magnetic base W0001876 Plumb Bob W0001877 Threaded rods 1 2 in diameter 1200 mm 48 in long 2 required with 12 nut W0001878 12 Group 71 Design and Function Design and Function Frame Rails and Crossmembers The frame for the VN VHD series has frame sidemember designs for vehicles produced by Volvo Trucks North America The designs include two sidemember heights three sidemember thicknesses and a flared shape The frame height is constant for the entire length of the rail The rail height is either 266 mm called the Low Pro file frame or 300 mm called the High Profile frame The low profile frame may have a thickness of either 6 mm 7 mm 8 mm or 11 1 mm The high profile height frame may a have thickness of 7 mm 8 mm or 11 1 mm VHD The rails of the frame are separated at the front edge a distance of 1080 mm outside edges From a position just rearward of the front engine crossmember to a position just forward of the rear engine crossmem ber
9. Function Closing Crossmember The closing crossmember keeps the separation of the frame rail ends fixed at 836 mm The frame rail ends are either tapered at a 27 degree angle or are cut straight There is a crossmember designed for each of these conditions W7001010 Fig 4 Closing Crossmember with tow hook 23 Group 71 Mountings and Brackets The engine mounting system consists of brackets con structed of ductile iron castings and rubber cushion isolators With Volvo transmissions the rear mount at taches to the engine flywheel housing The rear mounts attach to the clutch housing on all vendor transmissions Various brackets have been designed to adapt the Volvo engine front isolators and cushions to vendor engines The rubber cushions on the engine mounts are tuned to a precise vertical longitudinal and lateral stiffness The fine tuning of the mount cushions enhances truck perfor mance by isolating engine vibrations and noise from the chassis cab These cushions have the ability to dampen forces caused by frame distortion when driving off road or on poor roads The front and rear cushions are de signed differently to allow a higher degree of movement The engine mounts minimize the motion of the engine In addition they provide for easy service to the engine These advantages apply to all of the engines available with the VN VHD series models The fuel tank mountings are J brackets that support and attach the fu
10. Nm 667 111 ft lb Proper frame bolt thread engagement sess Max 13 mm past nut min two 2 threads Group 71 Tools Tools Standard Tools and Equipment All listed tools and equipment are not required for each service procedure Review the service procedure to be performed to determine which tools and equipment will be re quired Torque wrench Tape measure C clamps Drift pins Hammer Metal saw Gas cutting torch Metal grinder Welding machine Reamer 0 652 inch Group 71 Special Tools The J 38460 A is a digital protractor available from Kent Moore telephone 800 328 6657 The J 44771 Frame Rail Guide Support is available from Kent Moore telephone 800 328 6657 10 Tools NI W7000708 W7001140 Group 71 Special Equipment The following special equipment may be required for work on the frame rails and crossmembers This equip ment can be ordered from your manufacturer Ay The HUCK Manufacturing 940INTRKTV tool kit is avail able from your local HUCK distributor and consists of 1 Nose assembly 99 1481 This nose assembly is designed for use with the 16 mm 5 8 fastener and attaches to the model 585 hydraulic installation tool Model 585 hydraulic installation tool This hand held tool has a 3 5 m 12 ft hose assembly that is ZZ AM j a E Tools W0000397 attached to the model 940 POWERIG hydraulic unit Model
11. between the minimum and maximum shank length 9 Install the body bound bolts in each hole that was reamed Place a hard ened steel washer and a stop nut on each bolt 10 Tighten the nuts to 225 37 5 Nm 225 37 5 166 28 ft lb Hit the bolt with a Nm brass hammer several times during torquing to insure proper seating 166 28 ft lb 7113 01 02 01 HUCK FIT Fastener Removal 1 An air impact wrench can generally be used to remove the fasteners Always try to remove the collar with an air im pact wrench first If you encounter difficulty increase air pressure to the maximum for your equipment to obtain best results If the air impact wrench fails to remove a fastener the collar must be split or cut Group 71 W7001135 Fig 11 Huck Fit Fastener 1 Cut through collar and pin at this location 2 Swaged area Note Use this method of removal only if the fastener cannot be removed with an air impact wrench or hydraulic split ter A hydraulic collar splitter is available from HUCK If the splitter is available to you it should be used Make the cut just above the collar s hex flange To help avoid damage to other compo nents use an 1 8 metal shield with a hole that fits around the hex portion of the collar 7113 02 02 01 HUCK FIT Fastener Installa tion To install the fasteners select the correct grip range pin To ensure flush pin seating the hole size for 16 mm 5 8 pins m
12. in L 50 mm 1 97 in Group 71 Hole Spacing With All Suspensions Except Volvo T Ride Front axle crossmember and forward Rear of front axle crossmember Specifications aims 60 mm 2 26 in vert x 50 mm horiz 76 3 mm 3 in vert x 50 8mm 2 in horiz Note Hole size for this spacing must be 17 mm 0 66 in long A 74 1 mm 2 92 in B 50 8 mm 2 00 in C 50 8 mm 2 00 in D 50 8 mm 2 00 in E 74 1 mm 2 92 in F 76 0 mm 3 00 in G 56 8 mm 2 24 in H 50 8 mm 2 00 in 150 8 mm 2 00 in J 50 8 mm 2 00 in K 56 8 mm 2 24 in L 76 0 mm 3 00 in W7001188 Group 71 Specifications Tightening Torques Frame Rail Bolts for property class 10 9 bolts and property class 10 nuts Bolt Size Torque MO xit OR UR EEG RU OU EUG HU RS EO ORE ORE UG BU Rd 12 2 Nm 9 x 1 5 ft lb Myr iun p cu eL IM M Lum D M tA 22 3 Nm 16 3 ft lb n ma 30 5 Nm 22 4 ft lb M10 iiie cited pei aide ad eL pei iL pe e RR re PR HR eed NR RAR 60 10 Nm 44 7 ft lb M12 bolts crossmembers together 105 20 Nm 78 13 ft Ib M14 bolts crossmembers to frame 200 33 Nm 148 24 ft lb M16 bolts crossmembers to frame 275 45 Nm 204 34 ft lb up tia RR RN RR 360 55 Nm 267 44 ft lb M20 bolts cab mounts to frame sse 540 90 Nm 400 67 ft lb N aag hatin een treed deena ee teat eed ered E eet 730 120 Nm 541 90 ft lb Me e ettet unit 900 140
13. in 12 mm threaded rod approximately 48 in 1200 mm long through the uppermost front cross member mounting bracket hole in one frame rail 5 Run four nuts onto the rod so that they are between the frame rails 6 Insert the rod through the uppermost hole in the other frame rail 7 Run a single nut onto the rod on the outside of both rails 8 Repeat the steps for inserting a threaded rod in the lowest front cross member mounting bracket hole Group 71 W7001183 X 1080 mm 42 5 in Y 836 mm 32 9 in Adjust the position of the inner and outer nuts to set the distance between the front outer edges of the frame rails to 1080 2 mm 10 Tighten the nuts while ensuring the distance between the rails remains at 1080 2 mm 11 Refer to Frame Alignment Adjust ment page 44 Adjust the position of one of the rails until the crosswise di mension is the same both ways A B 12 Adjust the distance between the rear end of the rails until the distance be tween the inside edges is 836 74 iim 13 Re verify all dimensions Readjust if necessary 14 Tighten the mounting fasteners on all crossmembers See Tightening Torques Frame Rail Bolts page 8 Service Procedures 7112 03 02 02 Intermediate Crossmember Re placement Rivets Under the Flame Flange AN DANGER Before working on a vehicle set the parking brakes place the transmission in neutral and block the
14. material used and is measured in MPa or psi It is the maximum amount of force that can be applied to the material to stretch or twist it and still have it return to its original shape These two factors are mul tiplied to produce the measure of strength known as Resisting Bending Moment RBM Generally when the allowable level of RBM is exceeded the frame will likely experience failure The degree of failure is related to how much the RBM was exceeded and the method by which it was exceeded The frame is designed to absorb the energy associated with stresses produced by normal operation of the vehi cle including the higher stresses involved in off road use The frame is unlikely to experience failure as long as the conditions assumed in design are not exceeded The failures usually occur in situations when either the maximum allowable stress levels are exceeded or the maximum levels have been reduced The cause of frame failures are placed into one of three classifications 1 Collisions 2 Excessive bending moment 3 Localized stress concentration 26 Design and Function Group 71 Frame Failure Frame failure resulting from collision can be in the form of cracks bends twists or broken rails or crossmembers Excessive bending moment failures are caused by over load improper weight distribution or misapplication of the vehicle Excessive bending moment failure will occur at different areas on various types of vehicles
15. models remove the fasteners that mount the spring hang ers to the frame rail For the VHD axle forward remove the frame bracket on one side to assist in the removal of the front engine crossmember For the VHD axle back remove the front en gine mount isolator from the engine to assist with the removal of the front en gine crossmember 9 Remove the front engine crossmem ber 48 Service Procedures Installation Install the front engine crossmember 2 Install the front engine mount isolator 105 20 Nm on the VHD axle back Tighten fasten 78 13 ft lb ers to a torque of 105 20 Nm 78 200 33 Nm 13 ft lb Install the frame bracket on 148 24 ft lb the VHD axle forward or install the spring hanger fasteners to the frame rail on the VNM and VNL models Tighten fasteners to a torque of 200 33 Nm 148 24 ft lb 3 Lower the engine and install the front engine mount isolator to the front en gine crossmember 4 Connect the lower radiator hose and the air cooler hose on the VNM and VNL models Fill the radiator with coolant 5 Install the front spring pins on the 851 15 Nm VNM and VNL models Tighten fasten 63 11 ft lb ers to a torque of 851 15 Nm 63 11 ft lb 6 Install the front ABS modulator valves 60 10 Nm Tighten fasteners as follows M10 44 7 ft lb tighten to a torque of 60 10 Nm 44 7 ft lb Group 71 7112 03 02 06 Rear Suspension Crossmem ber
16. on the frame rails 51 Group 71 10 Mark and drill the new holes neces sary to accommodate the rear axle crossmember at its new position Holes must be placed in accordance with the specifications given in Bolt Hole Patterns page 6 11 Unbolt the rear axle crossmember end plates from the frame and move the crossmember to its new position 12 Bolt up the suspension and crossmem bers Tighten the fasteners as follows M14 200 33 Nm 148 24 ft lb M16 275 45 Nm 204 34 ft lb 13 Remove the jack stands from under the frame 14 Determine the appropriate overhang from the table below Overhang Axle Straight Tapered Tapered Type End end end 4x2 838mm 813mm 889 mm 6x4 1371 1346 1422 mm mm mm for bar type mud flap brackets for spring type mud flap brackets 52 Service Procedures 15 200 33 Nm 148 24 ft lb 275 45 Nm 204 34 ft lb W7001167 1 Desired end of frame 2 Current end of frame Measure rearward from the new cen terline of the rear axle 4x2 or from the new centerline of the bogie 6x4 the overhang amount Mark that point on the frame rails as the desired end of frame DO NOT CUT THE FRAME 16 W7001168 1 Desired end of frame 2 Rough cut 3 28 5 mm 266 mm frame 36 0 mm 300 mm frame For tapered rail ends only mark the frame rail at a point 28 5 mm 266 mm frame height or 36 mm 300 mm fr
17. spilled onto hot surfaces or electrical components can cause a fire Clean up coolant spills immediately Use a hoist or get assistance when lifting components that weight 23 kg 50 Ib or more Make sure all lifting devices such as chains hooks or slings are in good condition and are of the correct capacity Make sure hooks are positioned correctly Always use a spreader bar when necessary The lifting hooks MUST NOT be side loaded Failure to follow these warnings may re sult in personal injury 47 Group 71 Removal 1 Park the vehicle on a level surface with the transmission in neutral and the front wheels chocked 2 Remove the ABS modulator valves from the front engine crossmember and or the frame rails on both sides of the front engine crossmember 3 Support the frame rail on both sides of the front engine crossmember and re move the front spring pins This step is for VNM and VNL models only 4 Support the front of the engine with a hoist 5 Drain the coolant into a suitable con tainer Disconnect the lower radiator hose and air cooler hose This step is for VNM and VNL models only 6 Remove the fasteners that hold the front engine isolator mount to the front engine crossmember 7 Slowly raise the engine with the hoist to separate the isolator from the cross member 8 Remove the fasteners that mount the front engine crossmember to the spring hangers on the VHD For the VNM and VNL
18. the rails are tapered closer together From that point V 1080 mm 42 5 in W 836 mm 32 9 in X 266 mm 10 48 in Y 300 mm 11 82 in to the rear edge the distance is 836 mm inside edges Note Frame dimensions are specified in millimeters due to design To obtain the approximate dimension in inches multiply mm by 0 03937 Because the frame rails are made of a high strength heat treated steel only the frame modifications detailed in this information are permitted in order to ensure that the structural integrity of the rails is maintained In conjunction with the new frame design the allowable bolt hole patterns in the frame web are specified and must be strictly followed W7001181 Group 71 The frame consists of two steel side rails joined by sev VN VHD Frame rails with crossmembers Axle Forward with extension VHD Axle Back with extension VHD VN Axle Forward VHD Axle Back VHD Qn E GM eral crossmembers The frame for the VN VHD series models is made in a variety of configurations to allow flexibility in adapting the frame for different transport re quirements See the following design information Side Members page 15 Crossmembers page 17 Mountings and Brackets page 24 Fasteners page 25 Frame Material Behavior page 26 Design and Function W7001180 Group 71 Side Members The side members or frame rails are constructed of 760 MPA 110 000 psi yiel
19. wheels Failure to do so can result in unexpected vehicle movement and can cause serious personal in jury or death Removal 1 Park the vehicle on a level surface with the transmission in neutral and the front wheels chocked 2 Remove the closing crossmember 3 Remove the harness supports be tween the closing and the intermediate crossmembers 4 Remove the rear light bar 5 Remove the intermediate crossmem ber from the vehicle by sliding it out of the frame rail Note For intermediate crossmembers with riveted beams located forward of the rear suspension crossmembers must be removed See Rear Suspen sion Crossmember Bogie Replacement page 49 45 Group 71 Installation 1 Install the intermediate crossmember Tighten fasteners to a torque of 200 33 Nm 148 24 ft lb 2 Install the harness supports between the intermediate and the closing cross member Tighten fasteners to a torque of 200 33 Nm 148 24 ft lb 3 Install the closing crossmember Tighten fasteners to a torque of 200 33 Nm 148 24 ft lb 4 Install the light bar Tighten fasteners to a torque of 200 33 Nm 148 24 ft lb 46 200 33 Nm 148 24 ft lb 200 33 Nm 148 24 ft lb 200 33 Nm 148 24 ft lb 200 33 Nm 148 24 ft lb Service Procedures 7112 03 02 03 Intermediate Crossmember Replacement Bolted and Ex posed Rivets AN DANGER Before working on a ve
20. 60 Feedback One of our objectives is that workshop personnel should have access to correct and appropriate service manuals where it concerns fault tracing repairs and maintenance of Volvo trucks In order to maintain the high standards of our literature your opinions and experience when using this manual would be greatly appreciated If you have any comments or suggestions make a copy of this page write down your comments and send them to us either via telefax or mailing directly to the address listed below To From Volvo Trucks North America INC eesssssee IIIImmemeeeennnehhhenehyennn Dept 516 Service Publications 2222622 7825 National Service Road n 11 22e emere RO Box20115 Ro a eaea eaa ariari iaei Greensboro NC 27402 6115 1 222 5 eene nennen nennen nnne USA Fax 336 393 3170 Comments proposals 7112 03 02 02 7112 03 02 03 7112 03 02 04 7112 03 02 05 7112 03 02 06 7113 01 02 01 7113 02 02 01 7113 03 02 01 7113 05 02 03 7113 05 02 04 7113 06 02 01 7119 02 02 01 Operation Numbers Intermediate Crossmember Replacement Rivets Under the Flame Flange 45 Intermediate Crossmember Replacement Bolted and Exposed Rivets 46 Closing Crossmember Replacement lll ln 47 Engine Crossmember Replacement lll ls 47 Rear Suspension Crossmember Bogie Replacement
21. 696 D max 24 1mm 948 Should A or B dimensions exceed the given values the fastener is out of grip A C dimension less than the given value indicates an incomplete swage A D dimension greater than the given values indicates an incorrect or worn anvil on the installation tool If any of these conditions are present the fastener is installed incorrectly and must be replaced Group 71 s s ES ME Y IA LC I E MA G a T N q e INS Ly LIME AN eK a KE W7000301 Fig 17 Bolt turned inboard HUCK bolts can be turned in or out ward as tool limitations may require an Z UU ISSS CS SS 17 ZOLL RSS W7000302 Fig 18 Less than a flush break Bolt pin break to be flush or greater than the collar length A recessed pin break less than flush with the collar is unacceptable Service Procedures ZA SES gt ES I 4 E C ZUZI mn ES OUUU 177 ae Cs W7000303 Fig 19 Flange bolts and bolts Do not mix bolts and flange bolts within a hole pattern unless a specific exception is documented U 7 gt ERIC dE MANN ES E L7 ZU UU Wa XS SY SN ES E T aee C CAY LC Sf W7000304 Fig 20 Scored collar If the collar is scored the tool anvil is worn and should be replaced 59
22. Bogie Replacement AN 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 in jury or death Removal 1 Park the vehicle on a level surface with the transmission in neutral and the front wheels chocked 2 Remove the rear light bar and mud flaps 3 Remove the closing crossmember See Closing Crossmember Replace ment page 47 4 Remove the harness support brackets that are located between the rear sus pension crossmember and the closing crossmembers 5 Remove the airline support brackets located under the rear suspension crossmember Before beginning any service work on any part of the air system be certain that the air pressure has been released Failure to do so may cause a component to violently separate which can result in serious per sonal injury Service Procedures Remove the brake valves and brake hoses that are mounted to or located at the rear suspension Also remove the Traction Control Valve TCS mounted to the frame rail if the vehicle is equipped with TCS W0000411 Using jack stands support the nose of the first and second drive axles and the rear section of the frame rails 8 Remove the bump stops and the upper shock brackets for the rear drive axle 9 Remove the intermediate crossmem ber See Int
23. Flange bolt to bolt crossover 1 Pin Tail 2 Pin Tail Break Area 3 Oollar 4 Huck Bolt 33 34 Group 71 Troubleshooting Troubleshooting HUCK FIT Fastener Troubleshooting Tool fails to operate Inoperative POWERIG Check power source Loose or disconnected control cord Check and tighten securely Loose or faulty hydraulic hose couplings Check and tighten securely or replace faulty couplings Tool operates in reverse Reversed hose connections between Check and correct hose connections POWERIG and tool Tool leaks hydraulic oil Depending on where leak occurs defective Check and replace O rings and back or worn O rings loose hydraulic hose con up rings or tighten hydraulic hose nection at tool Hydraulic oil overheats POWERIG not operating properly Pump See POWERIG instruction manual motor rotation reversed Restriction in hydraulic line Check and tighten couplings and re place if necessary Tool operates erratically and Low or erratic hydraulic pressure supply See POWERIG instruction manual fails to install fastener properly Defective or excessively worn piston O ring Replace O ring and back up rings in tool Excessive wear or scoring of sliding sur Check and replace defective parts faces of tool parts Pull grooves on fastener pin Operator not sliding nose completely onto Instruct operator in proper installation tail stripped during pull stroke fastener pin tail methods Incorr
24. Service Manual Trucks Group 710 500 Frame Rails and Crossmembers VN VHD PV776 TSP143123 VOLVO Foreword The descriptions and service procedures contained in this manual are based on de signs and methods studies carried out up to August 2000 The products are under continuous development Vehicles and components produced after the above date may therefore have different specifications and repair methods When this is believed to have a significant bearing on this manual supplementary ser vice bulletins will be issued to cover the changes The new edition of this manual will update the changes In service procedures where the title incorporates an operation number this is a refer ence to an S R T Standard Repair Time Service procedures which do not include an operation number in the title are for gen eral information and no reference is made to an S R T The following levels of observations cautions and warnings are used in this Service Documentation Note Indicates a procedure practice or condition that must be followed in order to have the vehicle or component function in the manner intended Caution Indicates an unsafe practice where damage to the product could occur Warning Indicates an unsafe practice where personal injury or severe damage to the product could occur Danger Indicates an unsafe practice where serious personal injury or death could oc cur Volvo Trucks North America Inc Greens
25. allation enables these fasteners to consistently retain more than 95 of their initial clamp force providing as much as 10 20 higher clamp force and tensile strength than conventional threaded fasteners The swaged collar design resists vibration eliminating the back off problem encountered with threaded nuts and bolts The installation tooling allows easy operation and elimi nates the need for specialized welding or tighten training Once the fastener is installed visual inspection of the full swage is sufficient to verify correct installation This is in sharp contrast to traditional threaded fasteners for which installation accuracy and inspection depend on the cali bration of tighten equipment The fasteners are removable which makes them both ex ceptional and practical The unique swaging action of the lockbolt collar provides very high break loose and back off resistance However with enough applied force the collar can be removed without cutting Standard impact type tighten tooling can be used to remove the collar 30 Design and Function W7001149 Fig 5 Huck Fit bolt 1 Pull Grooves 2 Pin Helix 3 Breakneck Groove 4 Pintail N p W7001150 Fig 6 Head Markings 1 Grip Markings 2 Huck Symbol 3 Property class Group 71 W7001151 Fig 7 Hex Base Flange Collar W7001152 Fig 8 Collar Markings 1 Huck Symbol 2 Property class Design and Function 31 Group 71 Identificati
26. ame height past the mark for de sired end of frame This is the rough cut mark Group 71 17 V W7001169 1 Desired end of frame 2 Rough cut For straight rails cut the excess frame off at the mark for desired end of frame For tapered rails cut the ex cess frame off at the mark for rough cut 18 If the frame ends will be straight bolt two splay crossmembers back to back using M12 bolts and nuts tighten the bolt to 105 20 Nm 142 27 ft lb 105 20 Nm 142 27 ft lb Note Splay crossmembers must be painted prior to installation 19 Insert the closing crossmember be tween the frame rails and slide it as far forward as possible Note Steps 20 through 29 for cutting beveling and welding the frame web apply only to vehicles that require a ta pered closing crossmember Service Procedures 20 W7001170 1 Desired end of frame 2 Rough cut 3 See table for dimensions Mark a wedge shape on the frame web for cutting Refer to the table be low for dimensions Frame Frame Thickness Height 6 mm 7 mm 8 mm 266 236 4 232 6 228 7 mm 2 mm 2 mm 2 mm 300 N A 299 3 295 4 mm 2 mm 2 mm 21 W7001171 1 Drill hole here 2 See table for dimensions Drill a 24 mm diameter hole with cen ter at the upper corner of the wedge 12 mm below the bottom of the upper flange 53 Group 71 22 Verify the angle of the wedge is 27 0 25
27. art of the air system be certain that the air pressure has been released Failure to do so may cause a component to violently separate which can result in serious per sonal injury For air suspension disconnect and re move air line for left side rear air bag and remove left side upper shock ab sorber bracket Also remove leveling valve assembly on 4x2 tractor 4 Remove closing crossmember Installation 1 Place new closing crossmember be tween the frame rails 2 Install and tighten the crossmember fasteners Tighten fasteners to a torque of 200 33 Nm 148 24 ft lb 200 33 Nm 148 24 ft lb Service Procedures 3 For air suspension install upper shock absorber bracket and air line for left side rear air bag On 4x2 tractor in stall leveling valve assembly 4 Install taillight assemblies and wiring harness clamps 7112 03 02 05 Engine Crossmember Replace ment AN 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 in jury or death Do not remove the coolant fill cap or cap on the ex pansion tank if the coolant is hot wait until coolant temperature is less than 50 C 120 F Otherwise scalding steam or fluid may escape under pressure which can cause serious injury Coolant may be combustible Coolant leaked or
28. boro NC USA Order number PV776 TSP143123 2000 Volvo Trucks North America Inc Greensboro NC USA All rights reserved No part of this publication may be reproduced stored in retrieval system or transmitted in any forms by any means electronic me chanical photocopying recording or otherwise without the prior written permission of Volvo Trucks North America Inc Contents cru ee 3 Frame Rails and Crossmembers scscceeseeescennnsseeessncenteseneennescnaenees 3 POPC MIGRATIONS seriinin e a i eu ex D a E kc E a 5 FaMo AS E E 5 TOONS aora dit 9 Standard Tools and EQUIP MSM rn 9 Specii A T T 10 ect 11 Design and Functio c ta Frame Rails and Crossinienibets 2 lec ee oraya 13 Less e ci 35 HUCK FIT Fastener Troubleshooting 35 Lileiedup i A 37 Frame Rail Replacement sisas rr ta 37 Frame Aligniment Checking sms nne tipi acini Mosa Papin baie ad 43 Frame Alignment Adjustment ssssssss sees rea 44 Intermediate Crossmember Replacement Rivets Under the Flame xi sc MR NH 45 Intermediate Crossmember Replacement Bolted and Exposed GC C NR D DO 46 Closing Crossmember Replacement sees 47 Engine Crossmember Replacement esee 47 Rear Suspension Crossmember Bogie Replacement 49 Frame Leni AdjuSimMeni sn 57 Bod Boung Bel Inea aha acia 56 HUCK FIT Fastener Removal esee
29. d together after the end plates have been mounted to the frame rails The front engine crossmember is an excep tion to this in which case the rivets are replaced by body bound bolts Note The numbers in the crossmember descriptions that follow refer to the numbers on the frame and cross member diagram at the beginning of the Crossmembers subsection Front Crossmember The front crossmember connects the front ends of the side rails It is 4 mm thick and has large holes to allow maximum air flow to the radiator and charge air cooler It is physically bolted to the front crossmember and bumper mounting brackets which are bolted to the side rails Fig 1 VN W7000376 19 Group 71 Front Engine Crossmember The second crossmember is the front engine crossmem ber It is riveted to the front spring hangers which are bolted to the side members It is designed to support the forward end of the front suspension and the front engine mount which is a single point suspension at the center of the crossmember The crossmember is universal in that it can accommodate engines made by Volvo or by other manufacturers This crossmember is simply rotated 180 from the Volvo engine position to adapt to other vendor engines Unique brackets have been designed for fitting each vendor engine to the VN VHD series engine mounts Be cause the second crossmember coincides with the spring hangers it provides support against side bending f
30. d heat treated steel There are several combinations of side member height and thick nesses The smaller height referred to as the Low Profile frame has a web height of 266 mm and may be either 6 mm 7 mm 8 mm or 11 1 mm VHD thick The larger height referred to as the High Profile frame has a height of 300 mm and may be either 7 mm or 8 mm thick These combinations of height and thickness provide for the variety of load and usage characteristics necessary to meet the hauling requirements of nearly any tractor The flange width is a constant 90 mm for all combina tions of web height and thickness Unlike previous frame designs the side members are not an equal distance apart for their entire length When viewed from the side the side members appear straight Viewed from above the frame rails are flared outward from a point just forward of the rear engine crossmem ber This design provides for increased lateral vertical and torsional stiffness The result is improved vehicle integrity handling accident avoidance and collision en ergy absorption Widening the frame at the front also minimizes the need for cut outs in the frame flange to adapt the side members to various vendor engines Regardless of the frame rail height thickness and length the basic frame design and dimensions are the same The front rail separation is 1080 mm as mea sured from the outside of the frame rails because the front crossmember bolts to the o
31. e metric flange bolt into each frame rail web hole that is not used 35 Measure distance from transmission pinion to axle pinion and record the distance Have a certified driveline shop alter the drive shaft for this dis tance 36 Install the drive shaft 37 Check the pinion angles and ride height and make corrections if neces sary 55 Group 71 7119 02 02 01 Body Bound Bolt Installation 1 Always wear appropriate eye protection to prevent the risk of any eye injury due to the contact with debris or fluids Only use a reamer with clockwise rotation Do not re verse rotation to remove the reamer Use a drill with a maximum 350 rpm no load speed Always use cutting oil Failure to follow these precautions will result in damage to the reamer Ream the holes in the crossmember and end plates or bracket to 16 56 mm 0 652 in 2 Clean out any metal chips that remain in the holes 3 W7000383 1 Body bound bolt 2 Crossmember 3 Elastic stopnut 4 Hardened flat washer 5 End plate or spring bracket Measure the thickness of the end plate or spring bracket 4 Multiply the thickness from Step 3 by 66 56 Service Procedures 5 Measure the thickness of the cross member 6 Add the thickness values from Steps 3 and 5 This is maximum bolt shank length 7 Add the thickness values from Steps 4 and 5 This is minimum bolt shank length 8 Select a body bound bolt with a shank length
32. e end plates from the frame Instal lation requires cutting the new crossmember in half bolting the halves in place and welding them together Possible material failure The quality of the weld on a replacement crossmember is important to the struc tural strength of the crossmember All crossmember welding must be performed by a certified welder to guarantee the integrity of the crossmember Failure to properly perform the weld could result in failure of the crossmember Front of Axle Crossmember The front of axle crossmember exists mainly to provide support for the suspension system This particular cross member is used on vehicles equipped with the Volvo Optimized Air Suspension VOAS and the four spring leaf spring suspension An aluminum front axle cross member is available for reduced weight W7000374 Design and Function 21 Group 71 Rear Suspension Crossmember There are a variety of rear suspension crossmembers designed to accompany the axle suspension systems they support Because of the higher stresses and load ing taken up at the rear suspension this crossmember has larger flanges than the other crossmembers The rear suspension crossmembers shown at right are for 4x2 tractor with leaf springs or air ride top 6x4 trac tor with leaf springs or Volvo Optimized Air Suspension middle and 6x4 tractor with T Ride bottom 22 Design and Function W0001880 W7000419 Group 71 Design and
33. e of each frame rail and one directly beneath the rear lower edge of each rail Service Procedures 5 Move the vehicle away from the marks 6 Refer to Frame Alignment Adjust ment page 44 Measure from the mark for the front of the right frame rail to the rear of the left frame rail this is dimension A 7 Measure from the mark for the front of the left frame rail to the rear of the right frame rail this is dimension B This dimension must be the same as dimension A 8 If any of the dimensions noted are not within tolerance align the vehicle frame 43 Group 71 7113 05 02 03 Frame Alignment Adjustment AN 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 in jury or death Total wheel vehicle alignment may be necessary For proper specifications for wheel vehicle alignment refer to Service 601 06 Bulletin Wheel Alignment Steer and Drive Axles VN VHD IMPACT Function Group 601 Information Type Bulletin Alignment Specifications and Proce dures 1 Ensure all crossmember mounting bolts are loose 2 Remove the front bumper and any other obstructions to the front cross member 3 Remove the front crossmember and the bumper mounting brackets 44 Service Procedures W7001184 X 1080 mm 42 5 in Insert a 1 2
34. ect fastener length Use correct length fastener Worn or damaged jaw segments Check and replace jaw set Metal chips accumulated in pull grooves of Clean jaw segments jaw segments Excessive sheet gap Eliminate excessive gap Collar of fastener not com Improper tool operation See fault Tool operates erratically and pletely swaged fails to install fastener properly Scored anvil in nose Check and replace anvil Tool hangs up on swaged Improper tool operation See fault Tool operates erratically and collar fails to install fastener properly 35 Group 71 Troubleshooting Pin tail of fastener fails to Pull grooves on fastener stripped See faults Tool operates erratically and break fails to install fastener properly and Pull grooves on fastener pin tail stripped during pull stroke Jaw segments do not main Improper operation of jaw follower Check spring and install correct number tain proper position in collet of follower O rings Clean before re assembling Hydraulic couplers leak oil Defective or worn O ring in coupler body Replace O ring and back up ring Pin tail fails to eject from nose Bent or broken pin tail ejector Replace pin tail ejector assembly 36 Group 71 Service Procedures Service Procedures 7113 03 02 01 Frame Rail Replacement AN DANGER Before working on a vehicle set the parking brakes place the transmission in neutral and block the wheels Failure to do so can re
35. el tank s to the chassis Dual fuel tanks are stabilized by an additional crossover brace They also support the steps up to the cab 24 Design and Function Group 71 Design and Function Fasteners The crossmembers are connected to the frame rails us ing metric flange bolts The beams and end plates of individual crossmembers are either bolted to one an other using metric flange bolts or are riveted Whenever replacement of metric flange bolts is necessary they must be replaced with identical hardware In cases where rivets are used to connect beams and end plates they must not be disturbed because this will affect the structural integrity of the crossmember Some crossmember beams are riveted to the end plates In cases where the rivets are accessible and must be re moved they should be replaced with a 16 mm body bound bolt These special bolts are manufactured with a shank diameter that is slightly larger than the outer di ameter of the thread so that the load is not placed on the threaded portion of the bolts To make proper use of body bound bolts the holes that 7000383 will be used must be reamed to a diameter of 0 79 mm Body bound bolt 0 031 in larger than the thread diameter Proper join Crossmember ing of the crossmember and end plates or brackets is Elastic stopnut accomplished when the shank of the body bound bolt is Hardened flat washer in complete contact with the crossmember and inserts at End plate or
36. emoved 40 Service Procedures 41 W7001179 1 Frame Rail Guide Support 2 Air Jack Stand Slide and push the frame rail back ward while simultaneously moving the jack stands one after the other to the rear of the frame rail This will ade quately support the frame rail while it is being removed Installation Note Do not tighten fasteners until they have been properly installed This will help maintain proper frame alignment and will assist in obtaining proper height be tween the frame rails 1 Slide and push the frame rail forward while simultaneously moving the jack stands one after the other to the front of the frame rail This will adequately support the frame rail while it is being replaced 2 Install all fasteners and crossmembers on the frame rail being replaced 3 Install fasteners from the rear suspen sion on the frame rail that is being replaced 4 Install the upper shock brackets and the bump stops to the rear suspension 5 Support the vertical exhaust pipe in place then install the support bracket for the exhaust Group 71 6 Install the air valves to the inside and outside of the frame rail 7 Install all clipping brackets for the wiring or air line harnesses to the in side and outside of the frame rail 8 Once this step is complete go back 200 33 Nm and tighten fasteners that have been 148 24 ft lb installed from steps 1 through 7 as fol 275 45 Nm lows M14
37. ermediate Crossmember Replacement Bolted and Exposed Rivets page 46 10 This step only applies to trucks with the Volvo Optimized Air Suspension For proper information on removing fasteners for the spring hangers refer to 710 500 Volvo Optimized Air Suspension from 5 99 Service Manual IMPACT Function Group 7114 Information Type Re pair Spring Hanger Re placement Remove the fasteners for the spring hangers on the rear drive axle on trucks equipped with the Volvo Opti mized Air Suspension 11 Remove the V torque rod on trucks equipped with the Volvo T Ride 49 Group 71 12 Remove the leaf spring assembly on each side of the suspension on trucks equipped with the Volvo T Ride 13 Support the saddle bracket on each side of the suspension on trucks equipped with the Volvo T Ride 14 Remove the fasteners to the saddle bracket on each side of the rear sus pension on trucks equipped with the Volvo T Ride 15 Remove the fasteners to the V torque rod on the first drive axle at the frame bracket if the truck is equipped with the Volvo T Ride 16 Remove the remaining fasteners to the rear suspension Bogie crossmember and remove the rear suspension Bo gie crossmember Installation 1 Once this step is complete go back and tighten fasteners that have been installed from steps 1 through 7 as fol lows 2 Install the rear suspension Bogie crossmember Install and tigh
38. es of the bumper and re move the bumper 4 Disconnect the headlamp and foglamp connectors and remove the hood spring 5 Remove the hood splash shields on the left and right sides of the hood Disconnect the hood restraint cylin ders 6 Remove the fasteners to the hood pivot and remove the hood 37 Group 71 W7001177 1 Hoist 2 Transmission Jack 3 Jack stand Support the engine and transmission jack with a hoist and transmission jack 8 Remove the battery box cover and dis connect the batteries 9 Remove the battery hold down strap and remove the batteries 10 Remove the battery cable hold down bracket to the frame rail and discon nect the windshield wiper fluid pump 11 Disconnect the supply and return lines to the windshield washer reservoir Remove the clamp that secures the drain valve pull cords to the air tanks 12 Remove the air tank straps and the air tanks 38 Service Procedures W7001186 1 Frame Rail Guide Support 2 Air Jack Stand Remove the battery tray mounting bolts Remove the battery and air tank support brackets Note Some applications may require supporting the rear cab suspension 14 Using tool J 44771 support the frame J 44771 rail being removed with jack stands and frame rail guide supports which are distributed equally throughout the length of the frame rail Note A minimum of three jack stands and frame rail guide supports of ade quate ra
39. hicle 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 in jury or death Removal 1 Remove any equipment which ob structs crossmember replacement 2 Remove fasteners or rivets from the installed crossmember beam Remove the beam from the end plates 3 If required unbolt and remove the end plates from the frame rails Installation 1 If required bolt the new end plates to the frame rails Do NOT tighten 2 For bolted beams bolt the new beam to the end plates For riveted beams bolt the beam to the end plates using body bound bolts Perform body bound bolt installation in accordance with the procedure in this manual 3 Tighten the end plate to the frame rail fasteners Tighten the beam to end plate fasteners Tighten both fasteners as follows M14 tighten to a torque of 200 33 Nm 148 24 ft lb 200 33 Nm 148 24 ft lb Group 71 7112 03 02 04 Closing Crossmember Re placement AN 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 in jury or death Removal 1 Remove taillight assemblies and wiring harness clamps 2 Remove closing crossmember fasten ers Before beginning any service work on any p
40. ket 27 Remove the ground wire and the ground stud located on the frame rail forward of the front cab support 28 Remove any air valves wiring and or air line brackets under the cab inside and outside of the frame rail 29 W7001177 1 Hoist 2 Transmission Jack 3 Jack Stand Support the front of the cab with a jack stand and remove the front cab support 30 Remove the lower spring pin on the 9996791 rear spring hanger to the front axle us ing tool 9996791 31 Remove the rear spring hanger on the front axle 32 Remove the transmission mount bracket and the transmission cross member mounting bracket on the frame rail being removed 39 Group 71 33 Remove the fuel cooler and or fuel wa ter separator 34 Remove the air dryer and or purge tank 35 Remove all the remaining clipping brackets from the wiring or air line har nesses located inside and outside of the frame rail 36 Remove any remaining air valves that are mounted inside or outside the frame rail 37 Support the vertical exhaust pipe in place then remove the support bracket for the exhaust 38 Support the rear suspension cross member with a jackstand then remove the upper shock brackets and the bump stops from the rear suspension 39 Remove all existing fasteners from the rear suspension on the frame rail that is being removed 40 Remove all existing fasteners to the crossmembers on the frame rail being r
41. l the fuel tank and the fuel tank J brackets 42 Service Procedures 36 Reinstall the engine and transmission jack Reinstall the hoist and transmis sion jack 37 Check the frame alignment and make sure everything is installed and prop erly tightened to specifications 38 Install the fasteners to the hood pivot blocks and install the hood 39 Install the hood splash shields on the left and right sides of the hood Con nect the hood restraint cylinders 40 Connect the headlamp and foglamp connectors and install the hood spring 41 Install the support rods from the left and right sides of the bumper and in stall the bumper 42 Install the mounting screws from the top and bottom of the bumper Group 71 7113 06 02 01 Frame Alignment Checking AN 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 in jury or death W7001183 X 1080 mm 42 5 in Y 836 mm 32 9 in Measure the distance between the outside edges of the front edge of the frame rails The dimension must be 1080 2 mm 2 Measure the distance between the in side edges of the rear end of the frame rails The dimension must be 836 44 3 Ensure the vehicle is on a level area of the shop floor 4 Make a mark on the floor directly be neath the front lower edg
42. on 1 S34X6227 8397081 2 S343X6225 8397060 3 S343X622 839709 4 S343X6220 8397078 5 S343X6217 8397077 6 5343X6215 839706 7 8343X6212 8397075 8 S344X6200 8397202 NUT 32 Design and Function W7001147 Fig 9 Typical Flange Bolt to Huck Bolt Crossover Reference Grade 8 Flange 9 10 11 12 13 14 15 MHCH R16U 8075532 COLLAR HUCK P N VTNA P N MHFF DT16 15 8075528 MHFF DT16 25 8075529 MHFF DT16 35 8075530 MHFF DT16 45 8075531 GRIP NO Group 71 Volvo vehicles currently use 16 mm 5 8 fasteners Fas tener selection is based on the thickness of material to be clamped The fasteners have a grip number The grip number is stamped into the head of each pin and represents the midpoint of the grip range expressed in millimeters for that particular pin The 16 mm pin is available with a grip marking of 17 This pin has a grip range of 10 24 mm The 16 mm pin can also be identi fied by the raised nipple at the center of the pin head Grip No mm Range min Decimal Range min max max 10 5 15 0 19 0 59 15 10 20 0 39 0 78 20 15 25 0 59 0 98 25 20 30 0 78 1 18 30 25 35 0 98 1 37 35 30 40 1 18 1 57 40 35 45 1 37 1 77 45 40 50 1 57 1 96 50 45 55 1 77 2 16 55 50 60 2 96 2 56 65 60 70 2 36 2 75 70 65 75 2 55 2 95 75 70 80 2 75 3 15 Design and Function W7001148 Fig 10 VTNA
43. orces generated by driving in curves Rear Engine Crossmember The next crossmember is the rear engine crossmember It is supported by the rear engine support brackets and provides support against side loads that occur during ve hicle turning This crossmember is attached to the rear engine mounting brackets If the vehicle is equipped with a Volvo transmission the brackets are bolted to the en gine flywheel housing For vendor transmissions the brackets are bolted to the clutch housing Transmission Crossmember The transmission crossmember is the first crossmember rear of the transmission The stiffness of this crossmem ber is improved over earlier models due to wider end plate attachment flanges Its higher placement on the frame provides greater structural strength It is posi tioned so that there is sufficient prop shaft clearance without having to bend the crossmember The rivets that connect the beam to the end plates on this crossmember are covered by the frame flange and are not accessible 20 Design and Function W0001879 Group 71 Intermediate Crossmember The intermediate crossmember functions as the anchor age for the prop shaft center bearing mounting in addition to its normal function Longer wheelbase vehi cles may have one or two additional intermediate crossmembers installed Note Removal of the transmission and intermediate crossmembers requires cutting the old crossmember in half and unbolting th
44. rloading Dump trucks should never be used to spread loads 2 3 4 Tank trucks should have baffles 5 Avoid excessive fifth wheel positions 6 Avoid vehicle operation on extremely rough terrain Note Only the following repairs modifications are per mitted on the VN VHD series frame e Drilling holes for the attachment of equipment in ac cordance with the specified hole pattern e Cutting the frame to shorten it never attempt to lengthen the frame e Welding is only permitted on the riveted type cross members for replacement and on the frame rail ends to shorten them Observe the following recommendations when altering a frame rail 1 Avoid abrupt changes in section modulus 2 Never drill holes in frame rail flanges 3 Ensure holes drilled in the frame rail web are spaced according to the hole pattern specifications 4 Use existing holes whenever possible 5 Do not cut holes with a torch 6 Do not cut notches in the rails 7 Do not use rivets for attaching equipment through holes in the frame Always use a proper size Class 10 9 tighten flange bolts and Class 10 nut 8 Welding should only be performed by a certified welder Design and Function 29 Group 71 Huck Fit Fasteners The HUCK FIT fastening system which consists of the fastener and installation tooling was designed to meet today s high strength industrial fastening needs The unique tension tension method of the Lockbolt in st
45. rossmembers 12 Design and Function VN Frame and Crossmember O ON OO WO M 10 11 12 13 Front Crossmember Front Engine Crossmember Rear Engine Crossmember Transmission Crossmember Intermediate Crossmember Front of Axle Crossmember Rear Suspension Crossmembers Closing Crossmember Rear Engine Support Brackets Front Spring Hanger Bumper Mounting Bracket W7001043 Group 71 Design and Function 8 W7001008 VHD Frame and Crossmember Front Crossmember Front Engine Crossmember Rear Engine Crossmember Transmission Crossmember Intermediate Crossmember Front of Axle Crossmember Rear Suspension Crossmembers Closing Crossmember OO JO Qm DB WO NM Rear Engine Support Brackets 10 11 Front Spring Hanger 12 13 Bumper Mounting Bracket 18 Group 71 Design and Function The crossmembers provide a high degree of torsional stiffness to the frame They allow the vehicle to handle the side forces caused by turns and uneven road condi tions Improved crossmember design and positioning for the VN VHD series models has resulted in reduced weight enhanced frame stability improved truck han dling and reduced noise and vibration The crossmember components are to be treated as a unit Each consists of a beam and end plates Where beams and end plates are riveted together they must not be separated If replacement is necessary the re placement beams must be cut in the center and welde
46. spring bracket least 2 3 of the way into the hole in the component on the nut side but does not extend out of the hole Qn E GM Some components are fastened to the frame using HUCK Spin fasteners If these fasteners must be re placed metric flange bolts of the same size should be used Huck fasteners can usually be removed by using an air impact wrench Rai I For Description information see Huck Fit Fasteners HUCK Spin bolt and collar page 30 For Troubleshooting and Diagnostics information see HUCK FIT Fastener Troubleshooting page 35 For Service Procedure information see HUCK FIT Fastener Removal page 56and HUCK FIT Fastener Installation page 57 HUCK FIT Fastener Installation page 57 Possible component damage Never mix HUCK Spin fasteners and flange fasteners within a hole pattern Mixing fastener types could cause the flange bolts to come loose 25 Group 71 Frame Material Behavior Frame Strength The amount of stress that a frame rail can withstand is a function of several factors The most important of these are the Section Modulus and the Yield Strength Sec tion Modulus is a measure of the strength of a frame member cross section It is based on the height thick ness and shape of the cross section as well as the width of the flange It does not account for the material used in that side rail Yield Strength is a measure of the strength of the
47. sult in unexpected vehicle movement and can cause serious personal in jury or death AN DANGER Never work under or around a vehicle unless it is sup ported on jack stands of adequate rating Failure to use adequate jack stands can result in the vehicle falling which can cause serious injury or death to anyone under the vehicle Fuel leaked or spilled onto hot surfaces or electrical components can cause a fire Clean up fuel spills im mediately Always wear appropriate eye protection to prevent the risk of eye injury due to contact with debris or fluids Use a hoist or get assistance when lifting components that weight 23 kg 50 lb or more Make sure all lifting devices such as chains hooks or slings are in good condition and are of the correct capacity Make sure hooks are positioned correctly Always use a spreader bar when necessary The lifting hooks MUST NOT be side loaded Failure to follow these warnings may re sult in personal injury Before beginning any service work on any part of the air system be certain that the air pressure has been released Failure to do so may cause a component to violently separate which can result in serious per sonal injury Removal 1 Park the vehicle on a level surface with transmission in neutral and the front wheels chocked Raise the hood 2 Remove the mounting screws from the top and bottom of the bumper 3 Remove the support rods from the left and right sid
48. ten fas teners as follows M14 tighten to a torque of 200 33 Nm 148 24 ft Ib M16 275 45 Nm 204 34 ft lb 3 Install the fasteners between the V torque rod and the frame bracket and apply the proper torque to trucks equipped with the Volvo T Ride M14 tighten to a torque of 200 33 Nm 148 24 ft lb M16 275 45 Nm 204 34 ft lb 50 200 33 Nm 148 24 ft lb 275 45 Nm 204 34 ft lb 200 33 Nm 148 24 ft lb 275 45 Nm 204 34 ft lb Service Procedures 4 Install the fasteners to the saddle brackets and apply the proper torque on trucks equipped with the Volvo T Ride M14 tighten to a torque of 200 33 Nm 148 24 ft lb M16 275 45 Nm 204 34 ft lb 5 Install the leaf spring assembly on each side and tighten the U bolts to the saddle caps on trucks equipped with the Volvo T Ride Tighten the U bolts to a torque of 500 75 Nm 369 55 ft Ib 6 Install the fasteners to the spring hang ers on the rear drive axle and apply proper tighten on trucks equipped with the Volvo Optimized Air Suspension 7 Install the intermediate crossmember and tighten the fasteners to a torque of 200 33 Nm 148 24 ft lb 8 Install the upper shock brackets and the bump stops and the tighten fasten ers 9 Install the brake valves and hoses lo cated near the rear suspension crossmember 10 Install and properly tighten the V torque rod on trucks equipped with
49. the air system be certain that the air pressure has been released Failure to do so may cause a component to violently separate which can result in serious per sonal injury Use a hoist or get assistance when lifting components that weight 23 kg 50 Ib or more Make sure all lifting devices such as chains hooks or slings are in good condition and are of the correct capacity Make sure hooks are positioned correctly Always use a spreader bar when necessary The lifting hooks MUST NOT be side loaded Failure to follow these warnings may re sult in personal injury Service Procedures W0000411 Place the vehicle on jack stands at the normal ride height Do not jack the ve hicle up 2 Remove the driveshaft 3 Unbolt the fifth wheel angle irons from the frame and remove the fifth wheel and the angle irons as an assembly 4 Mark the frame at the existing wheel base centerline of the rear axle for single axle and center between axles for a tandem axle 5 Unbolt the existing suspension brack ets hardware and crossmembers 6 Unbolt and remove any other brackets hoses or electrical wiring that obstruct the area of the frame to be altered 7 Remove any intermediate crossmem ber that will no longer be needed 8 Make a template of the hole pattern for the rear suspension using the ex isting wheelbase and hole pattern as reference points 9 Determine the new wheelbase for the vehicle and mark
50. ting should be used for this procedure 15 Disconnect the fuel supply and return line Remove the fuel tank and fuel tank J brackets 16 Remove the inner fender splash shield and the lower bracket on the side of the vehicle being worked on 17 Remove the fasteners to the front closing crossmember and the fasten ers to the tow hook on the side of the vehicle being worked on 18 Remove the fasteners to the front spring hanger and remove the bumper support bracket Note Support the front engine sup port crossmember Group 71 19 D AA EA W7001185 1 Jack Stand Support the radiator with a jack stand Remove the radiator support bracket and the lower radiator isolator mount on the side of the vehicle being worked on 20 Remove the pitman arm from the steering gear 21 Stabilize the steering gear and remove the fasteners that mount the steering gear 22 Remove the front axle bump stop from the frame rail on the side of the vehi cle being worked on 23 Remove the Air Conditioning line sup port brackets inside the frame rail and remove the upper shock absorber bolt 24 Remove the steering shaft carrier bearing bracket and or the power steering reservoir bracket Service Procedures 25 Remove the rear A C line support bracket the bulkhead fitting and the wheel speed sensor from the front brake 26 Disconnect the hood release cable and remove the hood tube mount brac
51. use more difficulty than the original problem Creation of localized stress concentrations may reduce the frame s load carrying capacity below its value prior to adding reinforcements Frame failure may be complete failure breakage of the frame or partial failure frame misalignment The list be low describes several of the possible frame misalignment conditions that could be caused by exceeding bending moment Sag Refers to a frame or side rail that is bent DOWN from its proper position Bow Refers to a frame of side rail that is bent UP from its proper position Diamond Refers to a condition in which one entire side rail is moved forward or rearward of its correct alignment in relation to the other side rail Twist Refers to a condition where the entire frame has been twisted One rail appears to slope upward and the other appears to slope down Sidesway Refers to a side rail that is bent inward or outward of its proper position from the other rail 28 Design and Function Group 71 Minimizing Frame Failure The potential for frame failures can be reduced or elimi nated by operating the vehicle within the design limits and not creating areas of local stress concentration Ob servance of the following guidelines will greatly minimize the chances of frame failure Vehicles should only be used for the purposes for which they were designed 1 Avoid overloading vehicles Load vehicles evenly avoid localized ove
52. ust be 17 1 17 5 mm use an 11 16 drill bit Holes as small 16 mm can be used but the holes have to be chamfered on the head side to ensure proper head pin seating Note Never reuse fasteners Huck Fit fasteners are not serviceable or reusable Service Procedures W7000306 Fig 12 Threading the collar onto the bolt Insert pin bolt through prepared hole 2 Slide the collar over the pin tail and hand tighten W7000307 Fig 13 Swaging of the collar Place hydraulic tool nose assembly over pin tail and squeeze the trigger 4 The nose assembly pulls on the pin tail drawing the work pieces together The anvil pushes on the collar 57 Group 71 W7000308 Fig 14 Completing the swage of the collar The tool continues pulling on the pin tail moving the anvil forward and swaging the collar into the locking grooves of the pin bolt thereby achieving clamp W7000309 Fig 15 Pin tail breaking off When the tool completes the swage the pin tail breaks off the bolt 7 The tool automatically ejects itself off the collar 58 Service Procedures Inspection 1 W7000310 Fig 16 Dimensional limitations Visually inspect the installed fastener as follows e Check for a complete swage D dimension e Check for proper pin protrusion B dimension Diameter 16mm 5 8 A max 0 6mm 023 B max 10 6mm 417 C max 17 7mm
53. utside of the rails The separation at the rear end is 836 mm as measured from the inside because the closing crossmember is bolted between the rails The separation is a constant 836 mm at a point 1635 mm from the front Design and Function CL X 266 mm 10 48 in Y 300 mm 11 82 in X 1080 mm 42 5 in Y 836 mm 32 9 in W7001182 W7001183 Group 71 A standard hole pattern is designated for the frame rail web For vehicles with a complete Volvo T Ride suspen sion the hole pattern is 60 mm vertically between holes and 50 mm horizontally These dimensions apply to the web behind the rear bend and forward of the rearmost suspension component for the rear axles For vehicles with other than Volvo T Ride suspension the pattern is 60 mm vertically and 50 mm horizontally from behind the forward spring hanger to the intermediate crossmember and 3 in vertically by 2 in horizontally from the front axle crossmember to the rearmost suspension compo nent for the rear axles See Bolt Hole Patterns page 6 The rear end of the frame is either cut straight or is ta pered at a 27 degree angle There are three different closing crossmembers to accompany the style of frame termination 16 Design and Function W7000378 Tapered frame end with tapered closing crossmem ber W7000379 Straight frame end with splay closing crossmember W7001005 VHD frame with closing crossmember Group 71 C
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