Section J - Overview 2 Modification Code J2 - Truck-Bus Body Fitting 13
Section J - Overview 2 Modification Code J2 - Truck-Bus Body Fitting 13
5. Design requirements
Advanced braking systems
Advanced braking systems are an important safety feature fitted
to many new vehicles.
Advanced braking systems are programmed by the vehicle
manufacturer and are specific to the vehicle to which they are
fitted. Changes made to the vehicle, such as engine, tyre size,
steering control, suspension characteristics, vehicle mass and its
distribution, may impact the performance of the advanced
braking system.
Exercise extra caution when modifying vehicles fitted with
advanced braking systems. Electric braking systems may be
known as:
• electronic stability control (ESC)
• electronic stability program (ESP)
• vehicle stability control (VSC)
• dynamic stability control (DSC)
• vehicle stability assist (VSA)
• roll stability control (RSC)
• roll control system (RCS)
• electronic braking system (EBS)
• trailer electronic braking system (TEBS).
− where the body modifications require GVM re-rating, ensure • Avoid using U-bolts for body/sub-frame attachments as outlined
the modifications are certified in accordance with VSB6 below in ‘6. Body mount installation requirements’.
Section S — Vehicle rating • Do not locate body mounting attachments within the shaded
− the overall dimensions of the modified vehicle. areas of Figures 3 and 4, unless the manufacturer’s
• Do not let the body project beyond the end of the chassis by recommendations state otherwise.
more than 1.5 times final chassis depth unless the body structure • Ensure the design and installation of the body does not
is self-supporting at full load. negatively impact on vehicle functions access for maintenance
• Ensure the modification achieves optimal centre of gravity of (see purposes.
Figure 1).
Recommended:
• Ensure that the body sub-frame extends for the entire length of
the body without breaks or joins.
• Use standard manufacturer mountings and attachment methods.
• Where point load situations occur, (e.g. vehicles fitted with
cells/scales), install the body in accordance with manufacturer
guidelines.
Figure 3: Attachment front end of sub- frame
• Ensure the front end of the sub-frame offers progressive load
bearing transition to the chassis (see Figure 2 for two methods of
preventing stress concentration).
Recommended:
• Ensure the lower attachment hole on all body mountings is below
the neutral axis of the chassis.
• Ensure the bottom edge of the body mount is as near as possible
to the web of the chassis to prevent frame cracking.
• Locate the body mountings so that:
− stress concentrations are kept to a minimum in relation to
changes in chassis section, suspension mountings and chassis
attachments
− regular inspection and maintenance can be carried out on
mountings and adjacent vehicle parts
− sufficient clearance of mountings between moving parts such
as tail shafts, suspension links, etc.
U-bolt mounting
Where U-bolts are used as the method of fixing the body to the
chassis there is no positive location. This means friction and high
clamping forces are relied on to prevent movement.
Ensure the manufacturer guidelines are referred to as the use of U-
bolts may not be endorsed, particularly for use in conjunction with
heat treated chassis rails.
Avoid using a U-bolt to attach a body to the chassis for the
following reasons:
• U-bolts work loose over time.
• Runner shrinkage and wear over time can occur, resulting in body
movement and damage.
• The load is carried on the top and bottom of the flange of the
chassis, rather than the web.
• The body longitudinals stiffen the frame thus reducing the
flexibility along part of the frame length.
• U-bolts holding body longitudinals are often over tightened
causing:
− buckling of the frame flange
− reduced chassis strength Figure 5: Typical U-bolt body mountings
− frame distortion.
• Locate the body on the chassis to prevent it from moving during
• Positioning metal spacers between top and bottom flanges
violent braking by using at least four (4) outrigger mounts or fish
prevents the flange being buckled, causing localised: plates.
− loss of flexibility • Locate a bracket or fish plate at the front and rear of the body on
− stiffening both sides of the vehicle.
− increased stress.
Flexible bodies — platform bodies • Where attached using bolts, use bolts with a minimum ISO Grade
When a body that is relatively flexible under beaming and torsional 8.8 (or SAE Class 5) and appropriate grade nuts (see AS 1110.1).
loads is fitted to a conventional ladder-type chassis for operation The use of vibration-proof fasteners of equivalent strength such
on normal road surfaces, mountings that firmly attach the body to as Huck bolts are an acceptable alternative.
the chassis can be used. • If using alternative fasteners, check the bolt manufacturer’s
specifications to ensure that they are of equivalent strength and
The two preferred mounting systems are outrigger mount and fish
toughness.
plate systems, with the best option for flexible bodies being
outrigger mounting brackets (see examples in Figure 6). Recommended:
• To facilitate body fitting, enable one pair of mounts to have plain
holes to provide fore and aft body location. The remaining
mounts may have slotted holes.
• Bolt mounts to the chassis at intervals of 900 mm (this may be
altered to suit the installation).
• Provide a clearance space between the frame and the body
longitudinals and cross-members.
• If necessary, place a spacer between the chassis and body.
Required:
• Attach fish plate mounts securely to the web of the chassis.
• Prevent flexing of the web by extending the bracket at least half-
Figure 8: Typical support bracket
way down the web of the frame.
Vehicle Standards Bulletin 6 — Version 3.1
Section J — Body 7 of 18
Modification Code J1
Required:
Tipper bodies that have a form of hoist and as such must meet the
following requirements, including:
• Ensure tipper bodies fitted to motor vehicles and trailers comply
with all the relevant requirements of AS1418.8 including the ‘tip
truck hoisting systems’ section.
The NHVR has introduced a moratorium on the above requirement
for more information refer to Vehicle Standards Guide 17 (VSG17)
Required:
• Ensure hoist systems also include an independent mechanism to
retain the hoist in the raised position in accordance with and
meeting the requirements of AS 1418.8 (i.e. body props).
Recommended:
• Where a body prop is installed, ensure its design and installation
is validated by a competent and suitably experienced engineer.
• Ensure that the design of impact locations are considered,
including ensuring that it is not possible to mistakenly place the
prop in a location at which it is not effective.
• Ensure that the body prop is permanently connected to the
vehicle and readily accessible.
• Ensure that body props can be operated independently and
without special skill, strength, protective equipment or protective
clothing, or tools.
Long and rigid bodies — road tank vehicles Figure 11: Details of a typical front mounting bracket
Long and rigid bodies, such as road tank vehicles, may need greater
relative movement between body and frame while retaining chassis
flexibility. A mounting system with three or five point resilience is
preferred (see Figure 10).
Vehicle Standards Bulletin 6 — Version 3.1
Section J — Body 8 of 18
Modification Code J1
Required:
• If a road tank vehicle is to carry liquid dangerous goods, ensure it
satisfies the special requirements outlined in the Australian Code
for the Transport of Dangerous Goods by Road and Rail.
Recommended:
• Consult officers of the relevant state or territory authority
Figure 13: Details of a typical chassis mounting bracket controlling transport of the particular dangerous goods.
Alternative mounting for road tank vehicles Semi-rigid bodies
Rigid type mounting systems may be used, provided that the
attachments are sufficiently flexible and suitably located to allow Required:
the chassis to flex. If these mountings are arranged in a three-point • Ensure vertical compliance allowances are provided in the body
layout (see Figure 14, Typical three-point mounting) or a four-point mountings of vehicles where rigidity limits the ability of the frame
diamond plan (see Figure 15, Typical four-point mounting), the to resist beaming and twisting. This can be achieved by fitting
chassis is free to deflect torsionally with no undue stress resilient mountings or mountings with slotted holes and friction
concentrations in either the chassis or the body. inserts. Resilient mountings may comprise a steel spring or a
rubber bush and are usually used in conjunction with outrigger
Required: brackets (see Figure 16).
Due to the large concentrated loads that result from these
mounting methods, use substantial load bearing cross-members.
1. Scope
3. Certification procedure
A truck-bus is a composite vehicle consisting of truck cab-chassis
fitted with a specifically constructed bus-body for carrying The certification procedure for this modification code is as
passengers. The composite vehicle must therefore meet the follows:
safety standards (including ADRs) that also apply to an omnibus.
1. Modifier Determine if the modification is within
Modifications covered under this code: manufacturer specifications.
Covered • If yes, the modification will need to be done in
• fitting of a bus body (i.e. a passenger carrying pod) onto a accordance with manufacturer specifications.
truck cab-chassis, with change of GVM, seating capacity and • If no, the modification will need to be done in
of ride height accordance with this modification code.
• mounting a compliant bus body on a compliant rolling chassis. 2. Modifier Consult with an accredited J2 AVE for guidance on
Not covered how to perform the modification.
• certification of an omnibus body 3. Modifier Perform modification in accordance with AVE
advice and this code.
• certification of a body fitted to a rolling chassis based on a
bus chassis sub-assembly registration number (BC-SARN) 4. Modifier Organise approval inspection by an accredited J2
(carry out using the second stage of manufacture (SSM) AVE.
approval process). 5. J2 AVE Perform inspection, complete J2 checklist and
If a SSM identification plate approval (IPA) holder retrofits a determine if compliance has been achieved:
bus body to an in-service truck for which the fitting would be • If yes, proceed to step 6.
covered by the IPA at the SSM, only perform the modification • If no, do not proceed, advise modifier rework is
in accordance with this code if it is also performed in required to ensure compliance. Return to step 2.
accordance with that SSM IPA. 6. J2 AVE Issue modification certificate, affix modification
plate, and submit paperwork as required by the
relevant AVE registration scheme.
2. Related standards
AVEs must be satisfied that the vehicle modification
Modified vehicles must comply with all ADRs, Australian requirements are being met. It is advised that before
Standards, acts and regulations. Below are some but not all of modifications are carried out they are discussed with the
the areas that may be affected by the modifications in this code certifying AVE.
and require certification testing or evidence to demonstrate
compliance. 4. Certification requirements
The certifier must ensure that the modified vehicle continues to If the manufacturer’s installation instructions are not available
comply with all related Australian Design Rules. or no longer applicable, apply the following:
Truck-chassis
Required:
This… Must comply with…
• Ensure the body installation meets the requirements of, and is
Installation of lighting and light-signalling 13/.. certified in accordance with VSB6 modification codes J1 and
devices on other than L-group vehicles J2.
Commercial vehicle brake systems 35/.. • Ensure the modified vehicle complies with all relevant ADR
Maximum road speed limiting for heavy 65/.. requirements, this may require compliance with an additional
goods vehicles and heavy omnibuses vehicle category, such as MD or ME (see ADR applicability
Emission control for heavy vehicles 80/.. tables for guidance).
• If a bus body is re-used, do not remove SSM approval plate or
External noise 83/..
manufacturer’s plate from the bus body. Certify the
Bus body attachment of the bus body to the replacement truck-chassis
This… Must comply with… in accordance with this modification code.
Seatbelts 4/.. • Where the base vehicle used has not been tested and certified
Anchorages for seatbelts 5/.. at the new category’s requirements, ensure that all applicable
braking requirements are validated. For example, an NC
Installation of lighting and light-signalling 13/..
category vehicle fitted with a truck bus body must meet ME
devices on other than L-group vehicles
requirements and therefore the higher braking requirement of
Child restraint anchorages and child 34/.. ME vehicles.
restraint anchor fittings • Ensure the modified vehicle complies with the emergency exit
General safety requirements 42/.. requirements of either ADR58/.. or ADR44/.. (as applicable).
Specific purpose vehicle requirements 44/.. • Ensure a report or other evidence of compliance with ADRs,
Requirements for omnibuses designed for 58/.. Australian Standards and public transport requirements is
hire and reward provided to the owner/operator of the vehicle for
presentation at registration or vehicle inspection.
Standards for omnibus rollover strength 59/..
• Ensure compliance with ADRs relating to additional vehicle
Seat strength, seat anchorage strength 66/.. categories such as MD or ME (as applicable).
and padding in omnibuses
• Retain evidence of compliance with all related ADRs.
Occupant protection in buses 68/.. Statements of assurance are not acceptable.
Vehicle Standards Bulletin 6 — Version 3.1
Section J — Body 13 of 18
Modification Code J2
1. Scope Truck-chassis
This… Must comply with…
This modification code provides the standards that must be met Installation of lighting and light-signalling 13/..
when installing a roll-over protection system (ROPS) or a falling devices on other than L-group vehicles
object protection system (FOPS) on an in-service vehicle. It Rear vision mirrors 14/..
advises the precautions needed to provide a distributed load
General safety requirements 42/..
over the vehicle chassis in order to protect the chassis from
Vehicle configuration and dimensions 43/..
point loading and fatigue stresses.
Note that where the vehicle manufacturer has guidelines on It is recommended that the certifier ensure the ROPS/FOPS
the installation of ROPS/FOPS, these guidelines take device be constructed so it is fit for purpose.
precedence over and above this section of VSB6. Where the Some work sites such as building or mining sites may require the
vehicle manufacturer’s guidelines do not cover the installation ROPS/FOPS to be built and certified in accordance with
of ROPS/FOPS, the requirements of this section of VSB6 recognised standards such as the following:
prevail.
• AS 2294
Warning: Ensure that only ROPS/FOPS suitable for use in • ISO3471
automotive applications are fitted. • ISO3449
Poorly designed ROPS/FOPS are unlikely to provide the desired • ADR 59/..
protection of a ROPS/FOPS and may increase the risk of injury • an equivalent international standard.
and/or death in the event of an incident.
The installation of poorly designed ROPS/FOPS to a vehicle 3. Certification procedure
chassis is likely to increase the stress on the chassis and may The certification procedure for this modification code is as
induce fatigue cracking. This fatigue cracking is likely to be more follows:
prevalent in vehicles which are used off-road or on unsealed
roads. The design of the ROPS/FOPS mountings should take into 1 Modifier Obtain the installation instructions and evidence of
consideration the inputs likely to occur in off-road use when design calculations/testing from the ROPS/FOPS
conducting fatigue calculations on the ROPS/FOPS and vehicle manufacturer.
chassis. 2 Modifier Consult with an accredited J3 AVE for guidance on
Unless explicitly permitted by the vehicle manufacturer’s how any modifications are required to be
guidelines, under no circumstances should ROPS/FOPS be welded performed, and if the installation and design
directly to the chassis. calculations/testing supplied by the ROPS/FOPS
manufacturer to cover any chassis stresses or
Modifications covered under this code: fatigue are adequate.
4 Modifier Perform modifications in accordance with AVE
Covered
advice and this code.
• installation of an external ROPS/FOPS on a motor vehicle in
accordance with the ROPS/FOPS manufacturer’s instructions 5 Modifier Organise approval inspection by an accredited J3
AVE.
where these instructions meet the requirements of this
modification code. 6 J3 AVE Perform inspection, complete J3 checklist and
determine if compliance has been achieved:
Not covered
• If yes, proceed to step 7.
• installation of a ROPS/FOPS internal to the cabin compartment
• If no, do not proceed, advise modifier rework is
• certification of a ROPS/FOPS
required to ensure compliance. Return to step 2.
• installation of ROPS/FOPS where the manufacturer
instructions are unavailable or do not meet requirements of 7 J3 AVE J3 AVE issues modification certificate, affixes
this modification code. modification plate, and submits paperwork as
required by the relevant AVE registration scheme.
AVEs must be satisfied that the vehicle modification
2. Related standards requirements are being met. It is advised that before
Modified vehicles must comply with all ADRs, Australian modifications are carried out they are discussed with the
Standards, acts and regulations. Below are some but not all of certifying AVE.
the areas that may be affected by the modifications in this code
and require certification testing or evidence to demonstrate
compliance.
The certifier must ensure that the modified vehicle continues to
comply with all related Australian Design Rules.
Recommended:
• Ensure bolts are no greater than 19 mm in diameter.
• Ensure ROPS/FOPS to sub-frame/chassis mounting bolts or
studs are at least ISO Grade 10.9 (SAE Class 8), unless a lower
grade is specified by the ROPS/FOPS manufacturer.
• Use fish plates which are bolted or welded to the ROPS/FOPS
sub-frame to attach the vehicle chassis (see Figure 22).
Recommended:
• Consider using a square hollow section (SHS) or rectangular
(RHS) sub-frame design in preference to any other.
• Ensue that the ROPS/FOPS device does not cause the modified
vehicle to exceed GVM requirements when in operation.
• Consider the overall load carrying capacity and weight
distribution of the vehicle with the ROPS/FOPS attached.