Body builder instructions

Volvo Truck Corporation

Gteborg, Sweden

Supersedes VBI Release 09 from 6.09.

Changes are marked with a bar (|) in the
margin.

Date

Group

Release

Page

2.10

95

10

1(13)

Crane and tail lifts

Cranes, general and design
FM, FH VERSION2

Contents
General, page 2
Stability, page 5
Installation, page 6
Helper frame, cab mounted crane, page 9
Helper frame design, rear mounted crane, page 11
Rear mounted crane, page 12
Crane mounted behind cab, page 12
Front mounted crane stabilizers, page 13

88963462
ENG40870

English
Printed in Sweden

Volvo Truck Corporation

Body builder instructions

Date
2.10

Group

Release

95

10

Cranes
General
Crane mounting on Volvo trucks should be verified by
calculating strength to the chassis frame.
Crane calculation programs for Rear mounted
crane and Back of cab mounted crane are available
through the Volvo body builder instruction site at
http://vbi.trucks.volvo.com. Click Calculation Tools in
the main menu and select a function.
Note: An FO number, chassis number or OM number is
required.
Further instructions are available when one of the above
numbers has been submitted (click on the question mark
(?).

CE marking
In addition to the procedures recommended in
body builder instruction, the EU Machinery Directive
89/392/EEC is also applicable. The complete vehicle
(crane and chassis) is considered to be one machine
in accordance with the directive. It should therefore
comply with these regulations and display the CE mark if
the vehicle is to used in an EU-directive member state.
Please refer to Body builder instructions CE marking
for details.

Assembly
A crane is normally mounted behind the cab or at the
rear end of the vehicles chassis. This section contains
installation instructions for both cab and rear mounted
cranes on the Volvo FM, FH and NH chassis. The
installation instructions cover cranes with a maximum
lifting capacity of up to 40 tm for cranes mounted behind
cab and a maximum lifting capacity of up to 25 tm for rear
mounted cranes. To install cranes with lifting capacity not
covered by these instructions, please contact the Volvo
importer.
A crane puts a large load on the chassis frame. The
frame often needs to be reinforced by a helper frame.
See also Front mounted crane stabilizers, page 13

T9007987

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Volvo Truck Corporation

Body builder instructions

Crane stability test

The crane also affects the vehicles stability. The installer
of the crane is responsible for this, and must ensure that
the vehicle will not tip over when the crane is used for
lifting. The vehicle must be positioned on a flat surface.
Use the outrigger legs and make sure that they are placed
on firm ground. Block up the outrigger legs if necessary.
The Prohibit regulation function on the air suspension
should be activated, (only for airsuspended vehicles).
Tipping safety is achieved using the methods outlined in
Body builder instructions Tipper/Dumper installation.
Note: The installer of a crane or other lifting device is
responsible for the total stability of the vehicle under all
working conditions.

Date
2.10

Group

Release

95

10

Page
3(13)

Volvo Truck Corporation

Body builder instructions

Date
2.10

Group

Release

95

10

Restrictions
Installing a crane directly onto the chassis frame is not
permitted. Wear plates must be used, unless strength
calculations reveal need for additional reinforcement
by helper frame.

A rear mounted crane on an air suspension vehicle

must have spring brakes on the front axle.

With back mounted crane, the lower flange must not

be cut to make clearance/taper end for under mounted
towing member or for any other purposes.

When installing a crane on an air suspended vehicle,

the added function Prohibit regulation and the
associated switch should be installed. Please refer to
Body builder instructions Vehicle electronics.

The following crane installations are not covered in this

section and therefore must not be carried out without
authorization from the Volvo importer.

Cranes with a maximum lifting capacity exceeding 40

tm for cranes mounted behind cab or exceeding 25 tm
for rear mounted cranes.

An axle load calculation must be made for large, cab

mounted cranes. This should guarantee that the legal
and technical requirements regarding the maximum
permitted front axle loading are complied with under all
working conditions.

T9006102

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Volvo Truck Corporation

Body builder instructions

Date
2.10

Group

Release

95

10

Page
5(13)

Stability
Note: The body builder installing the crane or other lifting
device is responsible for the total stability of the vehicle
under all working conditions.

Operational directions for a vehicle with air suspension during crane

operation
The trucks air suspension system is equipped with
a switch to control the "Prohibit regulation" function
(used to lock the air suspension when the support
legs are taking the load. Please refer to Body builder
instructions Vehicle electronics, VECU and BBM).

The truck must be secured by support legs if the front

axle is to be lifted off the ground when the crane is
operated.

The positioning of air suspension vehicles for the

deployment of outrigger legs should be as follows:
1 Switch from automatic to manual control level on the
electrical control box.
Do not switch back to automatic level control until the
crane operation has been completed.
2 Select the correct working height by manually adjusting
the air suspension with the control box.
3 Lower the support legs to the ground until they provide
stable support.
Deactivate the air suspended control by using the Prohibit
control function (please refer to Body builder instructions
Vehicle electronics).

CAUTION
Never disconnect the power when the crane is in
operation.

Volvo Truck Corporation

Body builder instructions

Date
2.10

Group

Release

95

10

Installation
General
The following points should be considered for all crane
installations.

A crane should always be installed on wear plates or

a helper frame.

The correct calculations should be made for both

unladen and fully laden axle vehicle.

Utilize the calculation programs, available in the Order

information section at http://vbi.trucks.volvo.com,
to calculate the correct helper frame strength: crane
imposed load or crane displacement.

Stability calculation.
Specify the PTO and oil system.
Stability test.

Wear plates
Wear plates are used to mount a crane when the chassis
frame does not need to be reinforced. Please refer to
Body builder instructions Attachments.
The plates should be of the same material as the
helper frames. Please refer to Body builder instructions
Attachments.
The plates should be made of L-profiles with a cross
section of 90 x 90 x 6 mm, and should be 160 mm longer
than the crane base (with 80 mm in front and 80 mm
behind the crane base).
Note: 6 mm is the minimum permitted thickness although
8 mm is recommended as most chassis components are
adapted to an 8 mm plate in the upper hole row.
T9007060

Attach the wear plates to the chassis frame using bolted

joints. The distance from the bottom edge to the top
flange and to the centre of the bolt holes in the side wall
of the plate, should be at least 60 mm.

Restriction
The crane must never be mounted directly to the chassis
frame.

T9006123

Page
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Volvo Truck Corporation

Body builder instructions

Helper frame
Cranes with a high lifting capacity require a helperframe.
The crane helperframe is used to reinforce a part of the
truck chassis frame only, or the whole chassis frame from
back of cab rearwards.
The helperframe should be attached to the chassis frame
so that no "bumping effect" between the helperframe and
chassis frame occurs whilst the crane is being operated
or driven. The helperframe and the attachments should
be designed to provide a stable platform for the crane but
should not interfere with the vehicles performance. This
is achieved by stiffening in the correct way.
In the case of special transports, with a minimized chassis
height or extremely heavy crane installation, the truck can
be specified with an extra long inner liner which is made
to special order. Please refer to Body builder instructions
Attachments.
When a rectangular profile is used, the helperframe
cross members must be made of similar profiles and
materials, i.e. of the same material as the lengthways
members of the helper frame.
If two pairs of outrigger legs are used it is important that
the chassis is torsionally rigid between them. This is
achieved by using square profiles, cross members, and/or
diagonal reinforcement braces in the helper frame. No
changes need to be made to the design of the helper
frame section, regardless of whether one or two pairs of
outrigger legs are used.
Fix the helper frame to the chassis frame with attachment
plates and driven bolt unions. Please refer to Body builder
instructions Attachments.
Attachment plates, hole spacing, welding and driven bolt
joints should be designed and implemented according to
Body builder instructions Attachments.

Date
2.10

Group

Release

95

10

Page
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Volvo Truck Corporation

Body builder instructions

Date
2.10

Group

Release

95

10

It is important that the chassis frame is not damaged or

deformed during installation.

The attachment plates should be positioned at a

relative distance of maximum 1000 mm apart.
There should also be an attachment plate at the
beginning and end of the helper frame.

Weld the attachment plates to the helper frame.

Alternatively the plates can be attached to the helper
frame with driven bolts. Please refer to Body builder
instructions Attachments.

Mount the attachment plates to the end-frame with

four driven bolts. Use M14 bolts or M16 bolts if the
pre-punched holes are used.

Driven M14 bolts should be drilled together to 13.7 mm

diameter and M16 to 15.8 mm diameter.

Driven bolt joints should be implemented. Please refer

to Body builder instructions Attachments.

T9006149

Mounting cranes using clamps is not recommended and

should be avoided if possible. If clamps are used, the
spacer element (A) must be placed between the flanges
in the chassis and helper frame.

T9006126

Page
8(13)

Volvo Truck Corporation

Body builder instructions

Date
2.10

Group

Release

95

10

Helper frame, cab mounted crane

The helper frame should be positioned as far forward
as possible. For vehicles with short cabs a special
attachment plate is required at the front. Please refer to
Helper frame on vehicle with short cab L1EH1, page 10.
The helper frame should be attached with driven bolts.
Pleas refer to Body builder instructions Attachments.
If the helper frame is higher or lower than the sub-frame,
the top flange in the transition zone between them should
be at an inclination of 1:2. L is the reinforcement length
and can be found in both BOC crane calc (by activating
Required Wb) and the rear mounted crane calc.

T9008850

T9008849

Page
9(13)

Volvo Truck Corporation

Body builder instructions

Date
2.10

Group

Release

95

10

Helper frame on vehicle with short cab L1EH1

Standard attachment plates cannot be used at the front
for cab mounted cranes on vehicles with short cab
L1EH1. A special 8 mm thick plate must be manufactured
instead. Please refer to the adjacent diagram.

Attach the plate via holes (A) and (B) on the chassis
frame.

Drill the holes if they are not already pre-punched.

Note: Under no circumstances must holes be drilled in

positions other than (A) and (B).

CAUTION
Do not damage the engine attachment.
In position (A), the engine attachment has pre-prepared
holes for M14 bolts.

Existing bolt joints on the engine attachment must not

be released or dismantled.

Co-drill holes in the attachment plate and chassis

frame for driven bolt joints.

Drill clearance holes (C) in the attachment plate for the

bolts to the engine attachment.

T9006314

Page
10(13)

Volvo Truck Corporation

Body builder instructions

Date
2.10

Group

Release

95

10

Helper frame design, rear mounted crane

The helper frame should begin at least 3000 mm in front
of the first bogie axle.
On the rear section of the helper frame, the cross
members and end member should be of a similar design
to the chassis frame.
The helper frame should be reinforced by diagonal
bracing above the vehicle overhang, i.e. where the
crane is to be mounted. For a detailed description of
diagonal bracing, please refer to Body builder instruction
Customised overhang.

T9030156

To verify that the chassis frame will withstand forces and

moments caused by the crane mounted at the vehicles
rear overhang, utilise the rear mounted crane calculation
program, available in the Order information section at
http://vbi.trucks.volvo.com.
If, for the rear mounted crane installation, reinforcement
is required, an inner liner can be installed if the vehicle is
in order stage. Otherwise, the user can either select one
or more of the predefined reinforcement cross sections
the crane calculation program recommends, or define
another reinforcement in the Create section of the
calculation program.

T9030157

Basic technical data required to use the crane calculation

program is:

Total crane weight

Maximum dynamic crane moment
Required maximum crane lifting capacity
Distance between the crane support points
Chassis number or FO number

T9030249

For detailed requirements for running the Rear mounted

crane calculation program, please refer to the calculation
program help section.

T9008740

Page
11(13)

Volvo Truck Corporation

Body builder instructions

Date
2.10

Group

Release

95

10

Rear mounted crane

A rear mounted crane is normally mounted on a bracket.
Weld the bracket to the helper frame, or use attachment
plates. The attachment plates are fitted to the chassis
frame with driven bolts. Driven bolt joints should be
implemented according to Body builder instructions
Attachments.
For this type of mounting, the Rear frame length
parameter in the Rear mounted crane calculation should
be prolonged by the distance the crane bracket extends
beyond the chassis frame.
T9006172

T9006308

Crane mounted behind cab

A crane behind the cab should be mounted so that the
maximum distance from the front reference hole to the
centre of the crane is 930 mm.
To verify that the chassis frame will withstand forces and
moments caused by the crane mounted at the vehicles
rear overhang, utilise the back of cab crane calculation
program, available in the Order information section at
http://vbi.trucks.volvo.com.
The calculation program can handle crane capacities up
to 40 tm. For larger back of cab crane mountings, please
contact the Volvo importer.

T9007988

Page
12(13)

Volvo Truck Corporation

Body builder instructions

Date
2.10

Group

Release

95

10

Front mounted crane stabilizers

If the intention is to mount crane front stabilizer(s) for
behind cab crane mounting, then the single crane front
stabilizer or the dual stabilizers together can be loaded
up to 13,5 ton as axial force. Although, a number of
demands should be taken into consideration to be able to
utilize this force capacity:

The applied crane moment used in the analysis must

be the maximum Mdyn1 (Crane Dynamic Moment).

The chassis frame must be at least FRAMEHIG,

FRAME88 with full inner liner underneath the crane
installation and to the chassis frame start end.

It is recommend that the vehicle is ordered with an

extended frame and inner liner as well as a front
mounted draw beam.
The front mounted draw beam must be used by the
body builder. If this is not possible, the new (locally
designed) front cross member, and its connection to
the chassis side frames, must be able to handle the
load from the crane stabilizer (single or double).

The cranes main supporting legs must be in contact

with the ground before using the front support legs.

The front support legs shall be mounted as close as

possible to the bumper and chassis side rails.

The input force must be pure axial force.

The helper frame should be mounted to the frame

rigidly.

It is not permitted to use the cranes main and front

support legs to lift the front axle completely off the
ground.

The helper frame start part should be tapered

according to the VBI.

The front stabilizer axial force must be static.

The crane installation must start directly behind the
cab, the helper frame starts a maximum of 50 mm
behind the cab.

Note: If Mdyn is not available, use the following

approximation:
The crane size in kN multiplied by 1,45 for a high
speed lifting system. For instance, Mdyn for crane
35 tm x 1,45 = 507 kNm. For a crane without a high
speed lifting system the factor is 1,3 instead of 1,45. For
instance Mdyn for crane 35 tm x 1,3 = 450 kNm.

1Mdyn

= (lifting moment + crane arm moment) x Fdyn (>1.40)

T9009336

Single and dual front crane stabilizers.

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