DAF Superstructures BodyBuilders.guide

7/25/2019 DAF Superstructures BodyBuilders.guide

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Superstructures

BODYBUILDERS' GUIDELINES

4

Superstructures

SUPERSTRUCTURES

Page Date

4.1 Fixed body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109 201222

4.2 Body with tail lift. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111 2012224.3 Vehicle loading cranes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114 201222

4.4 Tipper bodies. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120 201222

4.5 Tankers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124 201222

4.6 Concrete mixers and concrete pumps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130 201222

4.7 Public utility vehicles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131 201222

4.8 Front mounted equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134 201222

4.9 TRACTORS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136 201222
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4. SUPERSTRUCTURES

4.1 FIXED BODY

For all the superstructures described in thissection, also see section 3: "Generalinformation on superstructures".

Body attachment method BAM 1is generallysufficient for the mounting of a fixed body ordemountable body with sub-frame.

The tie rods must be attached to the chassis sidemembers, if possible near or against the crossmembers. At least one attachment plate mustalways be fitted between the front and rear springbrackets of the rear axle(s).

A sub-frame is not necessary but can befitted, in order to obtain the required wheelclearance. Also see the sections2.10: "Chassis and cabine relateddimensions"and 2.14: "Wheel clearance".

Minimum requirement is the fitting on the chassisof a strip or angle brace, to which the crossmembers of the body can be welded. For themounting of box bodies without a sub-frameDAF recommends the fitting of a number of extracross members in the floor of the body above oras close as possible to the vehicle axles. As a

result of chassis flexing, additional pulling andpushing forces are exerted on the floor of thebody. However, the bodybuilder remains at alltimes responsible for the soundness of aconstruction and the strength of the self-supporting bodywork.

(High-)volume body

For (high-)volume applications DAF has various'Low-Deck' rigid truck chassis in its range with alow frame (260 mm with continuous innerreinforcement flitches). If required, some of thesevehicles - for instance, FA/S/R Low-Deck - can bespecified with lower suspension, in combinationwith speed-dependent height control and tyrecompression compensation. These chassisrequire additional strength and/or stiffness of thesuperstructure.

Fixed body with sub-frame, BAM 1

Tie rod mounting, body without sub-frame (withmounting strip)

Attachment plate, body without sub-frame (withmounting strip)

G000276

96120404-404

96120404-405

Fixed volume body with a sub-frame, BAM 3a

G000277
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A (semi-)self-supporting fixed or demountablebody, with or without a sub-frame, can bemounted on these chassis. The superstructureshould be attached in accordance with body

attachment method BAM 1 or BAM 3a. Thechoice is determined by the moment of inertia ofthe sub-frame or the floor of the fixed body. Thesame applies to the minimum required moment ofinertia of the floor of demountable bodies. For subframe dimensions see table.

Attachment according to BAM 1

(1) FA LF45/55 and CF65 chassis. 260 mm high chassis longitudinal with continuous inner reinforcement profile up to first springhanger bracket of the rear axle.

(2) FA LF45

Attachment according to BAM 3a

(1) FA LF45/55 and CF65 chassis. 260 mm high chassis longitudinal with continuous inner reinforcement profile up to first springhanger bracket of the rear axle.

(2) FA LF45

Min. required body/sub-frame dimensions for chassis with 192 mm and 260 mmhigh side members with continuous inner reinforcement flitches

Wheelbase[m]

Chassis rearoverhang (AE)

[m]

Side membersection

(A)

Sub frame profile dimensions; st52 [mm]

FA (4x2) FAR/S (6x2)

WB >5.40 - 6.00 (2)

AE 0.5 x WB 192x66.5x4.5+ 180x47/62x4

U 180x60x6 not applicable

WB 5.00 AE 0.6 x WB260x75x6 +245x65x5

- U 200x70x7

WB 5.40 (1) AE 0.5 x WB260x75x6 +246x60x5


WB 5.90 AE 0.6 x WB260x75x7 +245x65x5

U 80x50x6 U 220x80x8

WB 7.30 (1)AE 0.5 x WB

260x75x6 +246x60x5

U 180x60x6not applicable

Min. required body/sub-frame dimensions for chassis with 192 mm and 260 mmhigh side members with continuous inner reinforcement flitches

Wheelbase[m]

Chassis rearoverhang (AE)

[m]

Side membersection

(A)

Sub frame profile dimensions; st52 [mm]

FA (4x2) FAR/S (6x2)

WB >5.40 - 6.00 (2)

AE 0.6 x WB192x66.5x4.5

+ 180x47/62x4U 80x50x6 not applicable

WB 5.00 AE 0.6 x WB 260x75x7 +245x65x5

- U 100x65x6

WB 5.40(1) AE 0.6 x WB

260x75x6 +246x60x5


WB 5.90 AE 0.6 x WB260x75x7 +245x65x5

U 80x50x6 U 120x60x6

WB 7.30(1) AE 0.6 x WB

260x75x6 +246x60x5

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Wheel clearance at the rear

On versions with speed-dependent height controland tyre compression compensation, theminimum clearance required above the tyres of

the driven axle has been reduced to 10 mm withthe springs bottoming (metal to metal). Also seesection 2.14: "Wheel clearance".

Body with twist-locks

When mounting (demountable) bodies withoutsub-frame, with twist-locks, directly to the vehiclechassis, fit the twist-locks to the side of thechassis frame, using at least 6 M16 flange boltsfor each of them.

For (self-supporting) demountable bodies whichbear evenly on the chassis over its entire length,there are no specific requirements with respect to

the position of the twist-locks, and the dimensionsgiven below may be departed from.

The twist-lock bracket should be fitted near achassis cross member. If this is impossible, youare referred to section 2.6: "Attachment ofcomponents to the chassis".

However, if a demountable body is supported atonly a few points, the twist-lock positions givenbelow must be adhered to. If the support pointsare in other positions, e.g. as in the case of ISOcontainers, DAF should be contacted.

Position of the twist locks:

For the mounting of (demountable) bodies withsub-framein which the twist-locks are included,BAM 1is specified in most cases (without tail lift).

Make sure that demountable bodies rest onthe sub-frame or the chassis members, but inno case directly on the twist-locks!

4.2 BODY WITH TAIL LIFT

Body with tail lift

The next table gives the minimum dimensions tobe adhered to for sub-frames of bodies with taillifts with capacities up to 2000 kg, dependingon the type of vehicle, the wheelbase, the chassisdimensions and the rear overhang length. Fortail lifts with a higher capacity than specifiedin the table, DAF should be contacted.Tail liftswith a capacity higher than 2500 kg alwaysrequire the fitting of vehicle support legs to beused during loading and unloading.

Attachment of twist locks

Position of the twist locks

96120404-406

max.A

max.105022032802-012

max.A

max.1300

22032802-023

A: 1000 (LF)

1400 (CF - XF)

G000278
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For the mounting of the sub-frame for asuperstructure with tail lift, BAM 3b (CF75-85)or BAM3 (LF / CF65) is specified in mostcases.

If according to DAF a sub-frame is not requiredfor structural strength or because of deflection(see note 5)), a sub-frame in accordance withBAM 1 may still be fitted, for example because ofthe desired wheel clearance.

Take note of the effect of the tail lift on the vehicleweight distribution in fully laden and partly ladenconditions. If necessary, refer to the TOPECcalculations for axle load distribution of the partlyladen vehicle.

Attachment of the tail lift

With this type of superstructure, the tail liftattachment can also be used to attach the sub-frame to the chassis. In that case, the tail lift isbolted to the chassis frame and bolted or weldedto the sub-frame.

Superstructure with post type tail lift

A post type tail lift must always be fitted to thebody. Consult the supplier of the post type tail liftfor the correct mounting instructions.

Sub-frame dimensions

The following table gives an overview of theminimum dimensions required for sub-frames.

Attachment of the tail lift in accordance with BAM

3b

96120404-409


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(1) Consult DAF for tail lifts with a higher capacity, and for other combinations not mentioned in this overview.(2) The determination of the sub-frame dimensions is based on the use of Steel 37 (Fe 360 B according to EN10025).

(3) Tail lift capacity

1000 kg.(4) Tail lift capacity 1500 kg.(5) Body length and AE to be determined on the basis of axle load calculation; consult TOPEC.

Minimum sub-frame dimensions for tail lifts with capacities up to 2000 kg (1)

Vehicle type WB[m]

Chassis sectionsin rear overhang

Maximum AE (5)

(value 3 %)Sub-frame (2)

sections

FA LF45 (3) 4,30

192x66.5 x4.5

0.50xWB

U 120x60x6

5,40 U 140x60x6

FA LF45 (4)

12 tonnes GVM 4,30

192x66.5x4.5+180x62x4U 120x60x6

5,40 U 140x60x6

FA LF55FA CF65

4,20

260x75x6

U 80x60x6

5,35 U 120x60x6

6,30 U 160x60x6

7,30 U 180x60x6

FAN LF55 4,20260x75x6 0.55xWB

U 180x60x6

5,35 U 200x60x6

FA CF75-85FA XF

4,90260x75x7

0.50xWB

U 160x60x6

310x75x7 U 80x60x6

5,70

260x75x7 U 160x60x6

310x75x7 U 100x65x6

260x75x7 + 245x65x5 U 100x65x6

6,90 310x75x7 U 120x60x6

FAG CF75-85 5,35 310x75x7 + 295x65x5

0.40xWBU 80x60x6

6,60 310x75x7 + 295x65x5 U 140x60x6

FAS/R CF75FAS/R CF85FAS/R XFFAN CF75-85FAN XF

3,80260x75x7 + 245x65x5

0.55xWB

U 100x60x6

310x75x7 U 160x60x6

5,50 310x75x7 U 200x60x6

4,20 310x75x7 + 295x65x5 U 100x65x6

4,80 260x75x7 + 245x65x5 U 180x60x6

5,30 310x75x7 + 295x65x5 U 160x60x6

5,90 260x75x7 + 245x65x5 U 200x60x6

6,10 310x75x7 + 295x65x5 U 200x60x6
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WARNING! Vehicle stability duringoperation of any superstructuresystem is the responsibility of thebodybuilder and the user. The user

should at all times make sure thatvehicle stability is guaranteed. It istherefore important that clearinstructions for use of thesuperstructure should be providedby the bodybuilder on or suppliedwith the vehicle.For more information see:1.3: "Verificaton of superstructure"

4.3 VEHICLE LOADING CRANES

The attachment method for a vehicle loadingcrane depends upon the position of the crane:

- crane immediately behind cab: BAM 2, or- crane at rear end of chassis: BAM 3a. or

BAM 3(LF and CF65 series)- crane in combination with more than 2 crane

supports: BAM 4.

Consult DAF for any position other than thetwo above-mentioned crane positions, forinstance for cranes mounted amidships.

(1) Position of the crane; crane behind the cab, see Graph A, and crane at the rear overhang, see Graph B.(2) Dependent of vehicle layout, see chassis drawing.

Vehicle series Side mem-

ber dimen-sions[mm]

Flitch dimen-

sions[mm]

Max. crane capacity Number of

crane sup-ports

Crane behindcab. (1)[kNm]

Crane at rearoverhang

(1)[kNm]

FA LF45 192x66x4,5 (180x62x4,0)(2)

100 75

2

FA CF65FA / FAN LF55

260x75x6,0 (245x60x5,0)(2)

150 100

FA CF75-85FA XF

260x75x7,0 -

310x75x7,0 (295x65x5,0)(2)

200 150

FAS/R FAG

FAN CF75-85XF

260x75x7,0 245x65x5,0 250 170

2 / 4310x75x7,0 -

300 200310x75x7,0 295x65x5,0

310x75x8,5 292x65x8,5

FAC FADFAK FAQ FAXCF85XF

310x75x6,0 295x65x5,0

400 250 4310x75x7,0 295x65x5,0

310x75x8,5 292x65x8,5
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Attachment of the crane base

The number of attachment bolts under the cranebase depends on the attachment method and themaximum capacity of the crane. It should always

be determined by and under the responsibility ofthe supplier of the crane. In any case, the part ofthe sub-frame on which the vehicle loading craneis to be mounted, must be attached to the chassisframe of the vehicle with large attachment platesand flange bolts.


Always use a sub-frame when mounting a cranesuperstructure on a chassis frame. For thedimensions of the required sub-frame, refer toone of the two graphs shown below. Thefollowing information will help you to choose theapplicable graph:

The 2 graphs (A and B) can be used to determinethe sub-frame dimensions as follows. Graph A:from a crane capacity of, for instance, 140 kNm,draw an imaginary horizontal line to the right untilit crosses the vertical line of the side member, forinstance 260x75x6 (LF55). The reading for the

sub-frame dimensions is box section 160x80x8.The dimensions of the chassis members(possibly with flitches) in the indicated criticalzones (*; see figure) of the chassis can now beread from the bodybuilders' drawings.

These drawings are available on the internet(www.dafBBI.com).

Torsional stability

If a vehicle loading crane is fitted at the rear endof the chassis, a torsional stiffener must beprovided in the rear overhang. The torsionalstiffening may be provided by the superstructureitself or by a sub-frame stiffener; also see'Torsional stability of the sub-frame' in section3.1: "Superstructure with sub-frame". Thestability is determined by the vehicle, the load, theposition of the support legs and the structure of

Attachment of the crane base

96120404-411

Critical zones for mounting of cranes

20061604-4121700*max.

20061604-413 1700*AE

Graph A: Crane immediately behind cab

Sub-frame material Fe 510 D, accord-ing to EN 10025 (St 52-3 according toDIN 17100).

Graph B: Crane at rear end of chassisSub-frame material Fe 510 D, accord-ing to EN 10025 (St 52-3 according toDIN 17100).
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the surface under the support legs. Vehicleswith front leaf / rear air-suspension or full air-suspension.During crane operation; deflatingthe suspension of the vehicle and than lifting the

chassis using the crane support legs can lead todamage to the air bellows. Therefore the ECASair-suspension should be equipped with thefunction to deflate the air-suspension to lowresidual pressure to protect the air-bellows. Forinstallation of this function, please contact DAFSales Engineering.

Vehicle stability during operation of anysuperstructure system is the responsibility ofthe bodybuilder and the user. The user shouldat all times make sure that vehicle stability isguaranteed. It is therefore important that clearinstructions for use of the superstructure

should be provided on or supplied with thevehicle.

Graph A

Minimum sub-frame dimensions for:

- crane immediately behind the cab,- sub-frame material Fe 510 D.


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Graph B

Minimum sub-frame dimensions for:

- crane at rear end of chassis,- sub-frame material Fe 510 D.

240

220

200

180

160

140

120

100

80

60

40

250x100x8

220x120x8

200x80x8

180x80x8

160x80x8

140x70x6

120x60x6

100x60x680x60x5

260x140x8

Wx

400

380

360

340

320

300

280

260

G000304

L (m)

G (kN)

310x75

x8,5

+29

3x65

x8,5

3

10x75

x7

+29

6x65

x5

310x75

x6+296

x65

x5

260x75

x7+245

x65

x5

310x75

x7+245

x65

x5

310x75

x6

310x75

x7

260x75

x7

260x75

x6

192x66

,5x4,5

192x66

,5x4,5

+180

x47/

62x4

Box profile

GxL (kNm)

2)

1)

L

G

3)

1. Vehicle loading cranes, see section 4.3.

2. Chassis dimensions, see section2.10: "Chassis and cabine relateddimensions".

3. Superstructure with sub-frame, seesection 3.1: "Superstructure with sub-frame".
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250

225

200

175

150

125

100

75

50

250x100x8

220x120x8

200x80x8

180x80x8

160x80x8

140x70x6

120x60x6100x60x6

80x60x5

Wx

L (m)

G (kN)

310x

75

x8,5

+29

3x65

x8,5

310x75

x7

+29

6x65

x5

310

x75

x6

+29

6x65

x5

26

0x75

x7+245

x65

x5

31

0x75

x7+245

x65

x5

310x75

x6

310x75

x7

260x75

x7

260x75

x6

192x

66,5x4

,5

GxL (kNm)

2)

1)

3)

L

G

G000303

1

92x66,5

x4,5

+18

0x47

/62x4

Box profile

1. Vehicle loading cranes, see section 4.3.

2. Chassis dimensions, see section2.10: "Chassis and cabine relateddimensions".

3. Superstructure with sub-frame, seesection 3.1: "Superstructure with sub-frame".


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Recovery vehicles and hydraulic platforms

The superstructure should always be attached tothe chassis with a sub-frame or a self-supporting("pontoon-type") sub-frame construction. If the

latter type is used, it is generally not possible toprovide a rigid attachment because of theunequal distribution of strength and stiffnessbetween the chassis and sub-frame andconsequently the location of the neutral line of theassembly. If the vehicle chassis frame has tocontribute to the strength of the superstructure,DAF should be contacted.

Vehicles with front leaf / rear air-suspension

or full air-suspension

During crane operation; deflating the suspensionof the vehicle and than lifting the chassis usingthe crane support legs can lead to damage to theair bellows. Therefore the ECAS air-suspensionshould be equipped with the function to deflatethe air-suspension to low residual pressure toprotect the air-bellows. For installation of thisfunction, please contact DAF Sales Engineering.

WARNING! Vehicle stability duringoperation of any superstructuresystem is the responsibility of thebodybuilder and the user. The user

should at all times make sure thatvehicle stability is guaranteed. It istherefore important that clearinstructions for use of thesuperstructure should be providedby the bodybuilder on or suppliedwith the vehicle.For more information see:1.3: "Verificaton of superstructure"

Recovery vehicle, BAM 4

Hydraulic platform with 'pontoon-type' sub-frame,BAM 1

20061604-418

20061604-419
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4.4 TIPPER BODIES

For the mounting of tipper bodies, the followinggeneral guidelines always apply:

- Tipper bodies should preferably be fitted tochassis with 310 mm high side members.Depending on the application, tipper bodiesmay, however, be fitted to chassis with 192or 260 mm high side members; however, insuch cases the sub-frame will have to be ofa heavier design than when a chassis with310 mm high side members is used.

- Vehicles with front leaf / rear air-suspension or full air-suspension.Duringtipping or body swop for demountables, theair suspension should be lowered to bump-stop. This option can be activatedautomatically or manual, please contact DAFSales Engineering.

- It is not permitted to mount tipper bodies onthe FAN LF55, FAR chassis (6x2 vehicles

with single wheels on the trailing axle) andFAX / FAQ chassis (8x2 vehicles with singlewheels on the trailing axle), because thesevehicle types were not developed for thisapplication. If, for a certain application, atipper body mustbe used on such chassis,consultation with DAF is required, on the onehand for verification and on the other to becertain that the conditions set can be met.

In the table you will find the sub-frame data forvarious tipper versions and also the maximumdistance (B) from pivot point to rear axle.

Attachment methods for tipper bodies

Tipper with front-end ram Version 1 BAM 3a

Tipper with central ram Version 2 BAM 3a

Three-way tipper Version 3 BAM 4 or BAM3a

Tipping demountable body Version 4 BAM 4

Tipper with front-end ram

Tipper with central ram

Three-way tipper

Tipping demountable body

BA

1

G000300

2

G000299

B

BA

3

G000298

B

4

G000297


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(1) Minimum required moment of resistance of one sub-frame side member.(2) A sub-frame is not required for chassis strength or because of deflection, but can be mounted, for instance, to obtain sufficient

wheel clearance.(3) Rear axles airsuspension B Max. is 1000 mm.(4) FAS rear axles airsuspension B Max. is 1000 mm.(5) Rear axles airsuspension.(6) Independent chassis support in the rear overhang is recommended for increased stability during tipping operation.

Data for tipper bodies and sub-frames

Vehicle

type

GVM

max.[tonne]

WB

[m]

Chassis section

near rear axle[mm]

Tipper

type

A

Max.[mm]

B

Max.[mm]

Wx,min(1)

[cm

3

]

FA LF45 7.5-12 3.65 192x66,5x4.5 1,-,-,- 1000 1050 (2)

-,2,3,4 1000 1050 41.0

FA LF55 13-18 4.30 260x75x6 1,-,-,- 1000 1200 (2)

-,2,3,4 1000 1200 41.0

FA CF65 19 4.45 260x75x6 1,-,-,- 1200 1050 61.0

-,2-3-4 1200 1050 86.0

FA CF65FA CF75-85FA XF

20.5 4.90 310x75x7 1,2,3,4 1200 1050 26.5

1,2,-,- 1200 1300 41.0

FA CF65FA CF75-85FA XF

20.5 4.90 260x75x7 1,2,3,4 1200 1050 61.0

1,2,-,- 1200 1300 86.0

FAG CF75-85 28 5.90 310x75x7+295x65x5

1,2,3,4 1200 1050 85.0

1,2,-,-, 1200 1300 115.0

FAS CF75-85FAS XFFAN CF75-85

28 4.20 310x75x7 1,2,3,4 1200 650 116.0

1,2,-,- 1200 800 (4) 150.0

FAS CF75-85FAS XFFAN CF75-85

28 4.80 310x75x7 +295x65x5

1,2,3,4 1200 650 26.5

1,2,-,- 1200 800 (4) 41.0

FAT CF75-85FAT XF

28 5.55 310x75x7 +295x65x5

1,2,3,4 1200 650 85.0

1,2,-,- 1200 800 (3) 115.0

FAT CF85FAT XF

33 5.55 310x75x8.5 +292x65x8.5

1,2,3,4 1200 650 85.0

1,2,-,- 1200 800 (3) 115.0

FAC CF85 34 (6) 5.70 310x75x7 +295x65x5

1,2,3,4 1200 650 85.0

1,2,-,- 1200 800 (3) 115.0

FAC CF85 37 (6) 6.20 310x75x8.5 +292x65x8.5

1,2,3,4 1200 650 85.0

1,2,-,- 1200 800 (3) 115.0

FAD CF85

FAD XF

34 (6) 6.40 310x75x7 +

295x65x5

1,2,3,4 1200 650 85.0

1,2,-,- 1200 800 (3) 115.0

FAD CF85FAD XF

37 (6) 6.40 310x75x8.5 +292x65x8.5

1,2,3,4 1200 650 85.0

1,2,-,- 1200 800 (3) 115.0

FAD CF85FAD XF

44 (6) 6.40 310x75x8.5 +292x65x8.5

1,2,3,4 1200 650 250

1,2,-,- 1200 800 (3) 285

FAK CF85 XFFAQ CF85

35.5 (6) 5.30 310x75x7 +295x65x5

1,2,3,4 1200 1000 (5) 160
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Attachment of ram and tipping pivot

Both the front-end ram and the central ramshould be attached in the sub-frame. Allowanceshould be made for the space required for

driveline movements. The tipping pivot at the rearof the tipper body should be attached to the sub-frame.

Attachment of guide plate

The sub-frame should be provided with guideplates at the front end of the tipper body toprevent lateral movement of the body. To preventtorsion in the sub-frame, it is recommended to fita cross member in the sub-frame here, too.

Attachment of the front-end ram

Tipper with front-end ram

96120404-424

20061604-425

Guide plate

Tipper with central ram

96120404-426

20061604-427


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Attachment of ball pivot (three-way tipper)

The tipper body pivot should be attached to thesub-frame. Braces can be bolted into positionand, if they are attached to the sub-frame, they

will also serve as retainer plates.

Attachment of the demounting system

Irrespective of the type of system, thedemounting system should be attached to thesub-frame. If the sub-frame of the demountingsystem is wider than the vehicle chassis frame,consoles can be used to mount the demountingsystem. The top of the consoles must be flush

with the top of the chassis frame. If DAF consolesare used for this purpose, the locating edge at thetop of their rear wall should be removed. Theconsoles can be welded to the sub-frame andattached to the chassis with flange bolts; also seesection 3.2: "BAM's - body attachment methods".

Stability by torsional stiffeners

In all cases, torsional stiffeners should be fitted inthe sub-frame rear overhang; see: 'Stability bytorsional stiffening of the sub-frame' in section3.1: "Superstructure with sub-frame". Stabilityduring tipping depends on a number of factorsand is positively influenced by:

- greater rigidity in the chassis (rear overhang)and body,

- ram(s) positioned as far as possible to thefront (front-end ram),

Attachment of ball pivot

Three-way tipper

96120404-428

20061604-429

Attachment of sub-frame with console

Tipping demountable body

96120404-430

20061604-431
http://-/?-http://-/?-http://-/?-http://-/?-


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- shortest possible rear overhang andfavourable position of tipping pivot,

- Independent chassis support in the rearoverhang. This chassis support can be fitted

at the rearmost axle, however the axle loadmust not exceed twice the maximumtechnical axle load. Alternative the chassissupport can be fitted at the end off thechassis and supporting on ground level.

- tipping stabiliser (scissors construction)between body and chassis,

- skilled operation and firm level surface forthe vehicle to stand on.

Vehicle stability during operation of anysuperstructure system is the responsibility ofthe bodybuilder and the user. The user shouldat all times make sure that vehicle stability is

guaranteed. It is therefore important that clearinstructions for use of the superstructureshould be provided by the bodybuilder on orsupplied with the vehicle.For more information see: 1.3: "Verificaton ofsuperstructure"

4.5 TANKERS

General

For torsionally rigid (self-supporting) bodyconstructions, including tanker superstructures,console attachment can be opted for. However,at certain vehicle speeds and under certainconditions, such an attachment may lead toannoying bending vibrations in the frame, whichmay have a highly adverse effect on the drivingcomfort. It is therefore important not to exceedthe indicated maximum positions of attachmentpoints on the frame.

In chapter 3 is shown how many consoles pervehicle type and chassis segment are required. Inthe event that less consoles per segment areused, these consoles must be lengthened to have

a longer contact surface with the longitudinal. Thechassis load by the tanker support must be inrelation with the console dimension andattachment.

The console attachment introduces a localvertical point load which results in localstresslevel in the chassis. Therefore the chassislongitudinal must be reinforced with an innerliner,in case there is no innerliner reinforcement asubframe must be mounted.

The centre of gravity of the tanker body must beas low as possible, in order to decrease the risc

for vehicle overturning.


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On trucks with tanker superstructures which areto transport liquid goods, the need for lengthwaysand crossways baffles must be considered.

The bodybuilder is free to make a choice fromthe undermentioned body attachments,depending on which construction (accordingto his own insights and experience) is mostsuitable for the superstructure in question. Inall cases, the bodybuilder remainsresponsible for ensuring that the tankconstruction is sufficiently strong for theselected attachment and/or mounting methodof the tanker body.

Tanker body with sub-frame

Body attachment method BAM 1should beused for a tanker body with sub-frame. Take care

that the load is evenly distributed over the sub-frame, by using sufficient tank brackets. Also seethe figure opposite.

Tanker body on consoles (with or without

onboard weighing system)

The console attachment introduces a localvertical point load which results in local stress inthe chassis. Therefore the chassis longitudinalmust be reinforced with an innerliner, in case

there is no innerliner reinforcement a subframemust be mounted. The console attachment mightalso introduce lateral torsion to the chassislongitudinal. To eliminate this lateral torsion across member must be present. Check sectionconsoles in 3.2: "BAM's - body attachmentmethods".

Body with sub-frame

Positions of superstructure attachment points

20061604-432

22032802-015

max.A

max.600

A: 1000 (LF)

1400 (CF - XF)


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Console attachment, fixed

Body attachment method BAM 5is used forthis. Fixed attachment of the tankersuperstructure is particularly suitable for two-axle

vehicles. Spacer bushes with a length of at least30 mm should be used (see section 3.4: "Type ofsuperstructure/BAM matrix").

Console attachment, semi-flexible

Bodyattachment method BAM 5is used for this.Consoles with pressure springs are used at thefront. Spring pre-tension should be 3 kN perspring. In relation with a vertical static consoleload of 20 kN two pressure springs should be

used,the pre-tension of each spring should be 3kN.The minimum spring rate per spring is 225 N/mm. Fixed superstructure-to- console-attachment is used at the rear. For this, usespacer bushes with a length of at least 30 mm(see section 3.4: "Type of superstructure/BAMmatrix").

Console attachment

Positions of consoles on two-axle vehicles

20061604-434

22032802-014

max.A

max.1050

max.1050

A: 1000 (LF)

1400 (CF - XF)

Console with pressure springs

Console with fixed attachment

96120404-436

96120404-437


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Console attachment, all-flexible

Body attachment method BAM 5is used forthis. Consoles with pressure springs are used atboth front and rear. At the rear, rubbers are

added. These rubbers must always rest directlyon the console and may never be placed on, forexample, spacers. The rubbers used must not becompressed more than 1 mm under a static load.

The tank brackets on consoles with pressuresprings and rubber must have a provision forfixation of the superstructure in the longitudinaland transverse directions.

Console with springs and rubber

Position of consoles on multi-axle vehicles

96120404-438

22032802-013

max.A

max.1050

max.1050

A: 1000 (LF)

1400 (CF - XF)


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Console attachment, three-point

(two-axle vehicles)

Body attachment method BAM 5is used for this.

The front mounting point of the tank is a spring-loaded swinging unit. In relation with a verticalstatic console load of 20 kN per side aspecifiedspring tension can be seen from the graph. Witha given dimension 'a', representing the distancebetween the console springs, the spring tensionshould be 'P'.The consoles placed in front of the rear axle havepressure springs. Those placed behind the rearaxle have fixed attachment.

Three-point attachment on two-axle vehicles

Position of consoles

Oscillating unit

Graph

20061604-440

22032802-014

max.A

max.1050

max.1050

a

P

96120404-441

0

200

200

400 800

600

640

360240

1000

400

600

800

P N/mm

a mm

96120404-442

A: 1000 (LF)

1400 (CF - XF)


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Console attachment, three-point

(multi-axle vehicles)

Body attachment method BAM 5is used for

this. The front mounting point is a tank bracketattached with rubbers and springs to a crossmember resting on consoles.

The spring force of the machine rubbers usedshould be:

- vertical: 6 + 0.5 kN/mm,- horizontal: 7 + 0.5 kN/mm.

The consoles placed in front of the rear axlecentre have pressure springs. Those placedbehind the rear axle have fixed attachment.

WARNING! Operation of anysuperstructure system is theresponsibility of the bodybuilder andthe user. It is therefore importantthat clear instructions for use of thesuperstructure should be providedby the bodybuilder on or suppliedwith the vehicle.For more information see:1.3: "Verificaton of superstructure"

Three-point attachment on multi-axle vehicles

Positions of consoles on multi-axle vehicles

Front mounting

Mounting of machine rubber

20061604-443

22032802-013

max.A

max.1050

max.1050

96120404-444

400 - 650 mm

96120404-445

A: 1000 (LF)

1400 (CF - XF)
http://-/?-http://-/?-


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4.6 CONCRETE MIXERS ANDCONCRETE PUMPS

A sub-frame should always be used for concretemixers, concrete pumps and combined concretemixer/pump superstructures. BAM 4 (fully rigidattachment) should be used for the mounting ofthis sub-frame.

Consult DAF for the selection of the sub-framesection.

Torsional stability

In all casestorsional stiffeners should be fitted inthe rear overhang of the vehicle, in accordancewith 'Torsional stability of the sub-frame' in

section 3.1: "Superstructure with sub-frame".

WARNING! Vehicle stability duringoperation of any superstructuresystem is the responsibility of thebodybuilder and the user. The usershould at all times make sure thatvehicle stability is guaranteed. It istherefore important that clearinstructions for use of thesuperstructure should be providedby the bodybuilder on or suppliedwith the vehicle.For more information see:

1.3: "Verificaton of superstructure"

Concrete mixer superstructure

Combined concrete mixer/ concrete pumpsuperstructure

Concrete pump superstructure

20061604-446

20061604-448

20061604-447


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4.7 PUBLIC UTILITY VEHICLES

There is a wide range of public utility vehicles ofadvanced designs, often regarded as a machinerather than a piece of transport equipment. Thecustomary attachment methods for the mostcommon superstructures are given below. Incase of doubt and/or if you have any technicalquestions about necessary vehicle adaptations,you should contact DAF.Refuse collector bodies with a compactor at therear cause extreme high local load (more than7500 kg) on the rear overhang of the chassisframe. To support this high load in lateraldirection and for torsion, the rear end of thechassis frame must be reinforced with a torsionalcruciform type stiffening. See an example of the

torsional cruciform stiffening in paragraph'stability by torsional stiffening of the sub frame' inchapter 3.1: "Superstructure with sub-frame".

NOTE: On special request, analternative preparation for the FAGrefuse collector chassis can be orderedat DAF. This FAG frame, with short rearoverhang of 740, 920 or 1000 mm, hasa 310x75x7 mm frame with full chassisinner reinforcement profile (295x75x5mm) and is equipped with a heavy dutycross member at the location of the rearaxle. For this alternative chassis is no

extra subframe or torsional stiffeningrequired.

Refuse collector with sub-frame

20061604-449

Heavy duty cross member

G000517
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Refuse collector with sub-frame

Body attachment method BAM 1is used for arefuse collector superstructure with sub-frame.Contact DAF if extremely torsionally rigid

constructions are used.

Refuse collector on consoles (with or without

onboard weighing system)

The console attachment (BAM5) introduces alocal vertical point load which results in localstress in the chassis. Therefore the chassis

longitudinal must be reinforced with an innerlinerand on multi-axle vehicles with rear compacteralso a heavy duty cross member is required, incase that there are no inner reinforcements asubframe must be mounted. The consoleattachment might also introduce lateral torsion tothe chassis longitudinal. To eliminate this lateraltorsion a cross member must be fitted, on thespot of the console, if not present. Check sectionconsoles in 3.2: "BAM's - body attachmentmethods".

Console attachment

Positions of consoles

20061604-450

22032802-024

max.1050

max.1050

max.A

A: 1000 (LF)

1400 (CF - XF)


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Body attachment method BAM 5is used forthis. In relation with a vertical static console loadof 20 kN two pressure springs should be used,the pre-tension of each spring should be 3 kN.

The minimum spring rate per spring is 225 N/mm.Consoles with pressure springs are used at thefront. Spring pre-tension should be 3 kN perspring. Fixed superstructure-to-console-attachment is used at the rear. For this, usespacer bushes with a length of at least 30 mm(see section 3.4: "Type of superstructure/BAMmatrix").

Refuse collector with rotating drum

Always use a sub-frame and sufficientattachment plates to mount the superstructure tothe chassis, in accordance with bodyattachment method BAM 4.

Road sweeper

The superstructure should always be fitted with asub-frame and in accordance with bodyattachment method BAM 1. However, use BAM3afor a tipping road sweeper superstructure. See

section 4.4: "Tipper bodies"for the required sub-frame dimensions.

Console with pressure springs

Console with fixed attachment

96120404-452

96120404-453

Refuse collector with rotating drum

20061604-455

Road sweeper with sub-frame

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(Tipping) gully emptier

The superstructure should always be fitted with asub-frame and in accordance with bodyattachment method BAM 1.Use BAM 3afor

tipping superstructure. See section 4.4: "Tipperbodies"for the required sub-frame dimensions.Torsional stiffening must be provided in thechassis rear overhang (in accordance with:'Torsional stability of the sub-frame' in section3.1: "Superstructure with sub-frame".

WARNING! Vehicle stability duringoperation of any superstructuresystem is the responsibility of thebodybuilder and the user. The usershould at all times make sure thatvehicle stability is guaranteed. It istherefore important that clear

instructions for use of thesuperstructure should be providedby the bodybuilder on or suppliedwith the vehicle.For more information see:1.3: "Verificaton of superstructure"

4.8 FRONT MOUNTED EQUIPMENT

The front mounting equipment is commonly fittedto a mounting plate according DIN 76060. Thevehicle front mounting area has two attachmentpoints on each chassis side member. Theattachment points at the chassis are:

- Upper part mounted to the towing lugs (oneon each side).

- Lower part mounted to two areas on theFUP (Front Underrun Protection) beamfrontal surface.

For the upper part; LF and CF65 series, it isadvice to make the fixation with the towing eyes,

there must be no play due to the attachment pins.CF75-85 and XF, It is advice to take the diameterdimensions of the fixation pen towing lug, assupplied in the toolbox, to ensure a rigid andclose tolerance fit. For the lower part of the frontmounting construction, the reinforced sections onthe FUP beam must be used. These are the greymarked areas (see illustration) directly in front ofthe left and right hand leaf spring (or airsuspension) hanger bracket. Welding brackets orstuds onto the FUP is not allowed. Due to pullingforces (i.e. towing) the fixation brackets shouldpreferably (partly) enclose the FUP beam at theappointed fixation points.

(Tipping) gully emptier

Position of tipper pivot point

20061604-456

G000296

B

Example of installation of front mountingequipment.

G001192


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The maximum load and distance allowed for aconstruction suspended as illustrated in theimage are:

Snow plough equipment must be equipped with afeature to reduce the transmission of shockloadings in to the vehicle frame from strikingobstructions (sprung blades).

NOTE: The front mounting equipmentmust comply with regulation ECE R61and/or directive EC 92/114 externalprotection of cabs. For equipmentsupporting DIN brackets that have anintegrated towing lug construction themaximum permitted weight of a towedvehicle (including load) is 40 tons.Towing may not take place at an anglelarger than 20 with the vehicle centreline.

NOTE: All information applies to CF 75

- 85 and XF series produced fromrespectively 2009 wk 49 and 2009 wk21 onwards. Chassis produced beforethese dates require a reinforcedsupport at the front (replacing thestandard) and an extra at the rear of theFUP beam reaching towards thechassis main longitudinal. Contact DAFif in doubt.

G001266

a

G

Vehicle series Maximum load [kN] Maximum distance [mm]

LF 45 5 1200

LF 55 15 tonnes 7.5 1200

LF55 and CF65 18/19 tonnes 11.5 1200

CF75 - 85 and XF 15 1200


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WARNING! Operation of anysuperstructure system is theresponsibility of the bodybuilder andthe user. It is therefore important

that clear instructions for use of thesuperstructure should be providedby the bodybuilder on or suppliedwith the vehicle.For more information see:1.3: "Verificaton of superstructure"

4.9 TRACTORS

DAF offers a wide range of tractor models, seechapter 1.9: "DAF vehicle range"for more detail.These tractor models are specifically designed tocope with the characteristics, load conditions,brake forces and road holding performancerelated to pulling a semi-trailer. Therefore, onlythe dedicated production released tractors areallowed for this application. A truck chassismodification into a tractor chassis is onlypermitted with a Letter Of No Objection issued byDAF Trucks.

WARNING! Tractor chassis used in atractor/truck application (e.g. cartransporter chassis) are not allowedin combination with a Vehicle

Stability Control system.

Fifth wheel

DAF tractor chassis are provided with anglesections for simple fifth wheel mounting. Foroptimum utilisation of tractor/semi-trailercombinations, it is highly important that thetechnical specifications of tractor chassis andsemi-trailer should be carefully matched. Onlythen will it be possible to determine the correctposition of the fifth wheel (KAdimension) and thecorrect fifth wheel mounting height (HKdimension).

To ensure quality and durability of the entireconstruction, only fifth wheels and baseplates released by DAF must be mounted.

Mounting height and freedom of movement

Because of the required freedom of movementfor the semi-trailer, the fifth wheelmountingheight is determined by a number of factors:

- A semi-trailer coupled to a tractor should, inthe straight-ahead position, have enoughfreedom of movement to move 6 forwards,7 backwards and 3 to each side (takenfrom ISO standard R 1726).


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- When turning, the front corners of the semi-trailer must not touch the rear wall of the cab.Swing clearance should be at least 200 mm.This minimum clearance is highly dependent

on components on the rear wall of the cab,such as the air intake system, the exhaustand accessories that have been fitted. Tomeet the minimum requirement, it may benecessary to relocate the bracket for lightingand air connections.

- During manoeuvring, the semi-trailer mustnot touch any parts of the tractor chassis,such as mudguards, brackets or lamps. Theminimum fifth wheel mounting height abovethe chassis is also determined by the heightof the tyres above the chassis with thesprings bottoming (metal on metal). In thecase of FTS, FTP and FTG tractors, thewheel clearance of the lifted rear steeredaxle or second axle should also be taken intoaccount. Also see section 2.14: "Wheelclearance".

- On high-volume semi-trailers used incombination with low-fifth wheel tractorchassis, there should always be a clearanceof at least 160 mm between the top of thechassis side members and the underside ofthe semi-trailer to allow manoeuvring atloading bays, etc. If 3-piece rear mudguardsare fitted, it may be necessary to remove thecentral sections when coupling up the semi-

trailer.

For further references concerning thefreedom of movement for the semi-trailer,also see ISO standard R 1726: 1989 E.

D value of fifth wheel

The D value is defined as the theoreticalreference value for the horizontalforce between,in this case, the tractor and the semi-trailer and istherefore taken as a basis for the maximum loadunder dynamic conditions. The formula below(from directive EC 94/20) can be used to

determine the minimum D value required for thefifth wheel.

Required freedom of movement

G000305

7

6

33


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where:

Fifth wheel and base plate

The following guidelines apply to the mounting ofthe fifth wheel and base plate:

- For the mounting of the fifth wheel, only usea fifth wheel base plate released by DAF,which has been tested as a part of the

vehicleand is mentioned as such in thevehicle certificate. Various separate baseplates are also available from DAF. Seesection 13.13: "Miscellaneous parts"for theavailble DAF part numbers'.

- The pre-drilled base plates should be fitted tothe angle sections on the chassis, using atleast 12*bolts. Only the use of M16x2 flangebolts(property class 10.9) fastenedaccording torque class A is permitted. Thebolt heads should point downwards toenable visual inspection. The holes in thepre-drilled angle sections have a pitch of 50

mm. Turning the DAF base plate through180 (see section 13.13: "Miscellaneousparts"for the availble DAF part numbers),gives fifth wheel position adjustment steps of25 mm. As a result, simple adjustment of thefifth wheel position (within the maximum andminimum KA dimension) is possible, withinthe limits of the maximum permitted axle andor chassis loads.- * To a maximum fifth wheel load of 20

tonnes. For the 12 mm base plate theuse of 8 bolts is sufficient up to amaximum fifth wheel load of 15 tonnes.

- The maximum permissible mounting heightof fifth wheel and base plate is H = 305 mm

- To prevent the bolts working loose, twoattachment boltsshould be used at each ofthe four corners of the base plate. If baseplates are used on which only oneattachment bolt can be fitted at each corner,40 mm spacer bushes (combined with longerflange bolts) must be fitted under the boltheads.

- The maximum distance between the outsideof the chassis frame and the attachmentbolts in the (non-pre-drilled) angle sections is45 mm

D = g 0, 6 GT G

G G - F+

xx

T A

A [kN]

SE0004

GA = Maximum permitted massof the semi-trailor.

(tonnes)

GT = Maximum permitted mass

of the tractor.

(tonnes)

F = Maximum permitted verti-cal mass on the fifth wheel.

(tonnes)

D = D value on the fifth wheel. (kN)

g = Gravitational acceleration. ( 10 m/s2)

Mounting of the base plate

G000292

MAX.45

MAX.305MIN. 1


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- The minimum clearance between undersideof the base plate and the top of chassis sidemember flanges is always 1 mm.

- Preferably use two-piece base plates for

applications involving frequent manoeuvringand off-the-road operation.

- The DAF base plates with a height of 80 and120 mm are therefore two-piece plates asstandard.

- The fifth wheel should be fitted inaccordance with the supplier's instructions.

For the tightening torques of DAF flangebolts, see the table in section2.6: "Attachment of components to thechassis".

Catwalk

If a catwalk is fitted, it must be attached to thechassis frame with rubber mounts. Make surethat sufficient clearance is left for the semi-trailerunder all circumstances.

WARNING! Operation of any pumpor superstructure system is theresponsibility of the bodybuilder andthe user. It is therefore importantthat clear instructions for use of thesuperstructure should be providedby the bodybuilder on or suppliedwith the vehicle.For more information see:

1.3: "Verificaton of superstructure"

Mounting of catwalk

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Documents

DAF Superstructures BodyBuilders.guide