Superstructure Instructions Crane and Tail Lift

Superstructure instructions
Volvo Truck Corporation

Göteborg, Sweden Crane and tail lift
Vehicle type Date Chapter Page
Contents FM, FH, NH 10.00 7.0 1(2)
Date Revised
Contents 7.0
Cranes, general 7.10 10.00 x
Introduction
Restrictions
Stability
Installation
Helper-frame, cab mounted crane
Helper-frame, rear mounted crane
Crane
Cranes, design basis 7.20 10.00 x
General, design basis
Cab mounted crane, RIGID and TRACTOR
Rear mounted crane, RIGID
Cranes, stability 7.30
General, stability
Stability, cab mounted crane, one pair of outrigger legs
Stability, two pairs of outrigger legs
Stability, rear mounted crane
Tail lift and rear mounted fork lift 7.40
General
Power consumption
Mounting of fork lift
TSP147280
ENG08971 English
Printed in Sweden
Page 2
Crane mounting 7.50

4x2 FRAME66 FRAMEHIG, Cab mounted crane
6x2 RIGID FRAME77 + LINER-P FRAMEMED, Cab mounted crane
6x2, 6x4, Cab mounted crane (1)
4x2 FRAME66 FRAMEHIG, Rear mounted crane
4x2, 6x2 FRAME77 + LINER-P FRAMEHIG, Rear mounted crane
6x2 FRAME77 + LINER-P FRAMEMED, Rear mounted crane
Vehicle type Date Section Page
Cranes, general FM, FH, NH 10.00 7.10 1(9)
Cranes, general
Introduction
CE marking
In addition to the procedures recommended in these su-
perstructure instructions the EU Machinery Directive
89/392/EEC is also applicable. The reason for this is that
the finished vehicle (crane and chassis) is considered to
be one machine in accordance with the directive. As
such it should comply with these regulations and be CE
marked to be used in an EU member state. See Section
8.10 ”CE marking” for details.
Assembly
A crane is normally mounted behind the cab or at the
rear end of the vehicle’s chassis. Section 7 ”Crane and
tail lift” contains installation instructions for cab and rear
mounted cranes on the Volvo FM, FH and NH chassis.
The installation instructions cover cranes with a maxi-
mum crane load of 350 kN (approx. 35 tm) and a total
crane weight of up to 4000 kg.
A crane puts a large load on the chassis frame. The
frame often requires to be reinforced with a helper-frame,
please refer to Section 7.20 “Cranes, design basis”.
The crane also affects the stability of the vehicle. You
have to make sure that the vehicle will not tip over when
the crane is used for lifting. The vehicle must be posi-
tioned on a flat surface. Use the outrigger legs and make
sure that they are on firm ground. Block up the outrigger
legs if necessary. Tipping safety is calculated with the
methods below Section 7.30 “Cranes, stability”.
T9006289
Page 2
Restrictions
• Crane installation direct on chassis frame.
• A rear mounted crane on an air suspension vehicle

must have spring brakes on the front axle.
The following crane installations are not considered in T9006102
this section. These installations must not be conducted

without authorization from the Volvo importer.
• Cranes with maximum crane load exceeding 350 kN

and with a total crane weight exceeding 4000 kg.
• Crane on chassis with FRAMELOW, 266 mm high

frame profile. This applies to both RIGID and TRAC-
TOR.
• An axle load calculation must be done for big, cab

mounted cranes. This should guarantee that the
maximum permitted front axle loading, both legally
and technically, is not exceeded under any working
conditions.
Superstructure instructions Crane and tail lift
Stability
Caution: The party installing a crane or other lifting de-
vice is responsible for the total stability of the vehicle
during all working conditions.
Work order for an air suspension vehicle for crane operation

Positioning of air suspension for deployment of outrigger
legs.
1 Switch to manual position on the control unit for the

air suspension. Do not return to drive position until
the crane operation has been completed.
T9007197
2 Select the correct working height by manually ad-
justing the air suspension with the control unit.
3 Lower the outrigger legs to the ground so that they

provide stable support. Do not lift the vehicle to
reduce the wheel and tyre loading on the ground. T9007198
4 If a reduction of the wheel and tyre loading on the

ground is required, part of the chassis weight can be
transferred to the outrigger legs by releasing air from
the air suspension bellows. This is done by pressing
the ”lower” button on the control unit. Do not evacu-
ate all the air from the air bellows. This can be
checked by pressing the sides of the air bellows.
Caution: The control unit must be set to manual T9007199

position all the time the crane is in operation. Never dis-
connect the power to the control unit when the crane is
in operation, or release the ”wander lead”, by turning the
starter key to stop position or switching off the battery
with the main switch.
Page 4
Installation
Never mount a crane directly on the chassis frame. A
crane should always be installed on wear plates or a
helper-frame.
Wear plates
Wear plates are used to mount a crane when the chas-
sis frame does not need to be reinforced, please refer to
Section 7.20 “Cranes, design basis”.
The plates should be of the same material as helper-
frames, please refer to Section 1.40 ”Attachment”.
They should be manufactured 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).
T9007060
Attach the wear plates with bolt unions to the chassis

frame. The distance from the bottom edge of the top
flange to the centre of the bolt holes in the web on the
plate should be at least 60 mm.
T9006123
Helper-frame
Cranes with a high lifting capacity require helper-frames
with heavy-duty profiles. To reduce the size of the
helper-frame it is recommended that the chassis is
ordered with factory-fitted full inner liner. This is particu-
larly important for Tractor vehicles, since the height of
the fifth wheel is affected.
When rectangular profile is used, the helper-frame 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 made torsionally rigid between them. This
is achieved by using square profiles, crossmembers, T9006149
and/or diagonal reinforcement braces in the helper-

frame. No changes need to be made to the design of the
helper-frame section, depending on whether one or two
pairs of outrigger legs are used.
Fix the helper-frame to the chassis frame with attach-

ment plates and driven bolt unions, please refer to
section1.40 ”Bolt unions”.
Attachment plates, hole spacing, welding and driven bolt

unions are designed and implemented as per Section
1.40 ”Attachment”.
• The attachment plates should be positioned at a rel-

ative distance of max. 1000 mm.
There should also be an attachment plate at the be-
ginning and end of the helper-frame.
• Weld the attachment plates to the helper-frame. Al-

ternatively the plates can be attached to the
helper-frame with driven bolts, please refer to Sec-
tion 1.40 ”Bolt unions”.
• Bolt the attachment plates to the helper-frame with

four driven bolts each. Use M14 bolts, or if the pre-
punched holes are used, M16 bolts.
Page 6
Helper-frame, cab mounted crane

The helper-frame should be drawn as far forward as pos-
sible. For vehicles with short cabs a special attachment
plate is required at the front, please refer to Section
7.10 “Helper-frame on vehicle with short cab L1H1”. The
helper-frame should be attached with driven bolts,
please refer to Section 1.40 ”Attachment”.
If the subframe is higher or lower than the helper-frame

the top flange in the transition zone between them should
be at an inclination of 1:2. The helper-frame should have
a minimum length of Lmin as per the frame diagram,
please refer to Section 7.20 “Cranes, design basis”.
If the subframe is lower than the helper-frame the transi-

tion from the helper-frame to the subframe must start
after Lmin.
T9006243
T9006244
Helper-frame on vehicle with short cab L1H1

Standard attachment plates cannot be used at the front
for cab mounted cranes on vehicles with short cab
L1H1. A special 8 mm thick plate must be manufactured,
please refer to diagram.
• Attach the plate in holes A and B on the chassis

frame.
• Drill 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 prepared
holes for M14 bolts.
• Existing bolt unions to the engine attachment must

not be released or dismantled.
• Co-drill holes in the attachment plate and chassis

frame for driven bolt unions.
T9006314
• Drill clearance holes C in the attachment plate for

existing bolts to the engine attachment.
Page 8
Helper-frame, rear mounted crane

The helper-frame should begin at least 1400 mm in front
of the rear axle (dimension C). The values for B and C
are indicated in the diagrams for crane displacement,
please refer to Section 7.20 “Diagram for crane dis-
placement, rear mounted crane”.
In the rear section of the helper-frame, the crossmem-

bers and end member should have a similar design to
the chassis frame. The distance between the crossmem-
bers can not be more than 1000 mm in the rear end.
The overhang on the helper-frame should be reinforced

with diagonal struts of 75 x 10 mm flat iron. The struts
should not be welded in the diagonal braces. How this
reinforcement of the frame overhang should be imple-
mented is described in detail in Section 2.10 ”Frame
reinforcement”.
T9007200
T9007201
T9006120
Crane
Cab mounted crane
A cab mounted crane should be mounted so that the
distance from the front reference hole to the centre of
the crane is max. 930 mm.
It is important that the chassis frame is not damaged or

deformed during the installation.
• Weld the attachment plates for the crane onto the

helper-frame. Alternatively, the attachment plates
can be fixed to the helper-frame with driven bolts,
please refer to section 1.40 ”Bolt unions”.
• Fit the attachment plates on the chassis frame by

means of driven bolt unions, with at least six M14 T9006124
bolts. If pre-punched holes are used, then M16 bolts

should be used.
• Driven M14 bolts shall be drilled together to Ø 13.7

mm and M16 to Ø 15.8 mm.
• Driven bolt unions should be implemented as per

Section 1.40 ”Bolt unions”.
The method of mounting cranes with clamps is not rec-

ommended and should be avoided. If clamps are use,
the spacer element (A) must be placed between the
flanges in the chassis and helper-frame.
T9006126
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 with driven bolts
on the chassis frame. Driven bolt unions should be im-
plemented as per Section 1.40 ”Bolt unions”.
T9006172
T9006308
Cranes, design basis FM, FH, NH 10.00 7.20 1(34)
Cranes, design basis

General, design basis
The requisite helper-frame should be selected by using
the crane installation instructions and crane diagrams on
the following pages. The material quality of the helper-
frame is indicated in Section 1.40 ”Attachment”. The
diagrams cover crane capacities of up to crane loadings
of 350 kN (ca 35 tm) and with a total crane weight of up
to 4000 kg.
The stability or inclination of the outrigger legs have not

been taken into consideration. All calculations are based
on the use of only one pair of outrigger legs.
T9006307
Cab mounted crane, RIGID and TRACTOR

The crane diagram for cab mounted crane consists of
two diagrams. These diagrams have a common horizon-
tal axis consisting of the total crane load Cm in kilo
Newton (kN). Curves for the selection of flexural resis-
tance and length of helper-frame are included for the
chassis frames for respective vehicles.
The upper section of the diagram is used to determine
the requisite bending moment, Wbx (cm3), or requisite
height H (mm) for the profile (channel section or rectan-
gular section) which is indicated on the vertical axis on
the right.
At the bottom of the top section of the diagram for crane

load, along the horizontal axis, there is a shaded area
designated ”Wear plates”. If the crane has a load less
than the initial valve for the line marked ”1” in the dia-
gram, then it is sufficient to mount the crane on wear
plates. If the crane has a load greater than the initial
value on the line marked ”1” in the diagram, then the
chassis requires reinforcing with a helper-frame.
In the bottom section of the diagram the requisite frame
length Lmin for the helper-frame is given in m.
T9007377
The diagram is an example, there are additional di-

agrams in section 7.50.
Page 2
Design basis of helper-frame

Calculate the total crane load acting on the chassis with
the following formula.
Calculation of crane load

The total crane load is calculated as follows:
((Mr x Mc ) + (Am x Ad )) x 9:81 (Newton conversion)

Cm = kN
Cf x 1000 (kilo conversion)
Cm = Total crane load (kN)

Mr = Max. crane reach (m)
Mc = Max. crane capacity at max. extended crane
jib (kg)
Am = Total crane weight (kg), standard net crane
weight without outrigger legs
Ad = Extension of crane jib’s centre of gravity at
max. extended jib (m)
Cf = Length between crane base’s attachment
points to chassis (m)
T9007202
Example of calculation
Typical 25 tm crane, mounted on a 6x2 RIGID FRAME77
FRAMEMED.
Mr = 10.0 m
Mc = 2.200 kg
Am = 3.200 kg
Ad = 2.50 m
Cf = 0.80 m
((10:0 x 2200) + (3200 x 2:50)) x 9:81 (Newton conversion)

Cm = kN
0:80 x 1000 (kilo conversion)
Cm = 368kN (rounded)
Page 4
Selection of helper-frame profile, top section

• Draw a vertical line up from the calculated total
value for Cm on the crane load scale, at the bottom
of the diagram, to the helper-frame curves in the di-
agrams for crane load, please refer to section 7.50.
• Alternative with bending resistance
1 Draw a horizontal line from the intersection with

the chosen numbered helper-frame profile to the
corresponding vertical axis on the left, and read
off the value for bending resistance, Wbx (cm3).
2 If the intersection is between two values,

choose the higher value of bending resistance.
The selected profile must be of a similar type to
the profile shown at the top of the selected
scale. In this example, we use a rectangular
profile of 155 cm3.
3 If the intersection is in the lower, shaded sec-
tion closest to the horizontal axis, all that is
needed is a wear plate of 90x90x6 mm.
• Alternative with profile height

1 Draw a horizontal line from the intersection to
the right-hand vertical axis and read off the
value for profile height, H in mm. T9007372
The diagram is an example, there are additional di-

2 If the intersection is between two values,
agrams in section 7.50.
choose the lower value of profile height. Read
off the other values for the chosen profile at the
top of the bending resistance scale, Wbx (cm3).
In this example, a rectangular profile of
200x100x6.3 mm was chosen. It may be possi-
ble to select more than one frame profile.
Selection of helper-frame length, lower section

Draw a line downwards from the rounded off value for
Cm until it intersects the curve for helper-frame length.
Draw a horizontal line from the point of intersection to

the vertical axis, and read off the length Lmin in metres.
In this example, 4.5 m.
Rear mounted crane, RIGID

Both diagrams (crane load and crane displacement) for
rear mounted cranes must be used for the selection of
an appropriate helper-frame. There are separate series
of diagrams for each ROH (Rear Over Hang). It is
assumed in each case that the outrigger legs are posi-
tioned behind the crane.
The distance marked B is calculated from the centre of

the rearmost axle to the crane’s centre of gravity when
stationary. If the distance B falls between two of the B
factors in the diagram for crane displacement, please re-
fer to Section 7.20 “Diagram for crane displacement,
rear mounted crane”, then the longer distance should be
selected.
The distance C is calculated from the centre of the lead-

ing drive axle to the beginning of the helper-frame. The
horizontal axis Cd in the diagram for crane displacement,
T9007200
please refer to Section 7.20 “Diagram for crane dis-
placement, rear mounted crane”, shows the total crane
weight in kg, including accessories, outrigger legs and
hydraulic oil, etc.
The horizontal axis Cm in the diagram for crane load

shows the total crane load.
The requisite bending resistance, Wbx, in cm3 can be
read off on the vertical axis on the left of the selected
helper-frame profile.
As an alternative, the helper-frame profile can be se-
lected on the basis of the intersection with the vertical
axis for the helper-frame chosen and the profile height,
H in mm, on the vertical axis on the right.
At the bottom of both diagrams, along the horizontal

axis, there is a shaded area. ”Wear plates”. If the crane
has a load less than the initial value for the line marked
T9007201
”1” in the diagram, then it is sufficient to mount the crane
on wear plates. If the crane has a load greater than the
initial value on the line marked ”1” in the diagram, then
the chassis needs to be reinforced with a helper-frame.
Important: Both diagrams should be consulted for selec-

tion of helper-frame. The results which require the
highest helper-frame and the highest bending resistance
shall be selected.
Page 6
Design basis of helper-frame

1 Calculate the total crane load acting on the chassis
with the following formula.
2 Calculate the total crane weight to be used with dis-

placement diagram.
3 Select the helper-frame profile with the diagrams for

crane load and crane displacement.
Calculation of crane load

The total crane load is calculated as follows:
((Mr x Mc ) + (Am x Ad )) x 9:81 (Newton conversion)

Cm = kN
Cf x 1000 (kilo conversion)
Cm = Total crane load (kN)

Mr = Max. crane reach (m)
Mc = Max. crane capacity at max. extended crane
jib (kg)
Am = Total crane weight (kg), standard net crane
weight without outrigger legs
Ad = Extension of crane jib’s centre of gravity at
max. extended jib (m)
Cf = Length between crane base’s attachment
points to chassis (m)
T9007203
Example of calculation
Typical 25 tm crane, mounted on a 4x2 RIGID FRAME66
FRAMEHIGH.
Cd = 3.600 kg
Mr = 10.0 m
Mc = 2.200 kg
Am = 3.200 kg
Ad = 2.50 m
Cf = 0.80 m
((10:0 x 2200) + (3200 x 2:50)) x 9:81 (Newton conversion)

Cm = kN
0:80 x 1000 (kilo conversion)
Cm = 368kN (rounded)
Selection of helper-frame profile

When selecting the helper-frame profile for a rear
mounted crane the design basis should take into consid-
eration both the crane load (Cm) and the frame stress
deriving from the crane’s dead weight (Cd) during trans-
port. The respective diagrams for crane load and crane
displacement should therefore be used for selection of
the helper-frame.
The diagram which requires the highest helper-frame

and the highest bending resistance is the diagram which
shall be selected.
The calculation is conducted in three steps:
1 Section 7.20 “Crane load”.
2 Section 7.20 “Crane displacement”.
3 Section 7.20 “Conclusions”.

Page 8
Crane load
The horizontal axis Cm in the diagram for crane load
(see foldout A7-J7) indicates the total crane load in kilo
Newton (kN).
• The calculated crane load Cm = 368 kN is marked

with a vertical line in the diagram for crane load.
1 Draw a horizontal line from the point of inter-

section between the selected, numbered
helper-frame profile and the vertical line for the
crane load Cm = 368 kN to the corresponding
vertical axis on the left and read off the value
for bending resistance. Wbx.
2 If the intersection is between two values, the

higher value of bending resistance shall be cho-
sen. The selected profile must be of a similar
T9007373
type to the profile shown at the top of the se-
lected scale. In this example, a rectangular The diagram is an example, there are additional di-
profile of bending resistance 90 cm3 was se- agrams in section 7.50.
lected;.

• Alternative with profile height
1 Draw a horizontal line from the intersection to

the right-hand vertical scale and read off the
value for profile height, H in mm.
2 If the intersection is between two values, the
higher value of profile height shall be chosen.
The other dimensions for the profile selected
are specified at the top of the bending resis-
tance scale, Wbx (cm3). In this example, a
rectangular profile of 150x80x6.3 mm was se-
lected. It may be possible to select more than
one frame profile.
• Diagrams for crane loads for different chassis are to

be found in the foldouts A7-J7 at the end of this
section.
• Now check the results with the crane displace-

ment diagrams, please refer to Section 7.20
“Diagram for crane displacement, rear mounted
crane”.
Crane displacement
The horizontal axis Cd in the diagrams for crane dis-
placement, please refer to Section 7.20 “Diagram for
crane displacement, rear mounted crane”, indicates the
crane’s total dead weight in kg, including hydraulic oil,
outrigger legs, and accessories, etc.
• The calculated total dead weight of the crane Cd =

3600 kg is marked with a vertical line in the diagram.

1 Draw a horizontal line from the point of inter-
section between the selected, numbered
helper-frame profile and the vertical line for the
crane’s dead weight Cd = 3600 kg to the corre-
sponding vertical axis on the left and read off
the value of bending resistance, Wbx (cm3).
2 If the intersection is between two values, select

the higher value of bending resistance s. The
selected profile must be of a similar type to the T9007374
profile shown at the top of the selected scale. In The diagram is an example, there are additional di-
this example, a rectangular profile is used, with agrams in section 7.50.
bending resistance 550 cm3.

• Alternative profile height
1 Draw a horizontal line from the intersection t the

right-hand vertical axis and read off the value of
profile height, H in mm.
2 If the intersection is between two values, select

the higher value of profile height. The other di-
mensions for the selected profile are given at
the top of the bending resistance scale, Wbx
(cm3). In this example, a rectangular profile is
used 250x200x12.5 mm. It may be possible to
select more than one frame profile.
• Now check the result with the diagrams for

crane load, please refer to section 7.50.
Page 10
Conclusions
In the calculation example, the highest helper-frame and
highest bending resistance were selected from the crane
displacement diagram. The crane displacement diagram
is therefore the diagram that provides the design basis.
The helper-frame was selected from this diagram, and is
a rectangular profile of 250x200x12.5 mm.
Note: When you calculate the helper-frame for a rear

mounted crane, we recommend that you choose the cor-
responding diagram for crane displacement and unfold
the corresponding diagram for crane loading on the side.
Both diagrams can then be studied together.
Diagram for crane displacement, rear mounted crane

4x2 RIGID RAD-A4 FRAME66 FRAMEHIG
C = -2500 B = 3200
T9007356
Page 12
4x2 RIGID RAD-A4 FRAME77 FRAMEHIG

C = -2500 B = 3200
T9007357
6x2 RIGID RADT-A6 FRAME77 FRAMEMED

C = -2000 B = 2700
T9007358
Page 14
6x2 RIGID RADT-A6 FRAME77 FRAMEMED

C = -2000 B = 2800
T9007359
6x2 RIGID RADT-A6 FRAME77 FRAMEHIG

C = -2000 B = 2700
T9007360
Page 16
6x2 RIGID RADT-A6 FRAME77 FRAMEHIG

C = -2000 B = 2800
T9007361
6x2 RIGID RADT-A6 FRAME77P FRAMEHIG

C = -2000 B = 2700
T9007362
Page 18
6x2 RIGID RADT-A6 FRAME77P FRAMEHIG

C = -2000 B = 2800
T9007363
6x2 RIGID RADT-AR FRAME77P FRAMEHIG

C = -2000 B = 2400
T9007364
Page 20

C = -2000 B = 2500
T9007365

C = -2000 B = 2600
T9007366
Page 22
6x2 RIGID RADT-AR FRAME77 + LINER-P FRAMEHIG

C = -2000 B = 2700
T9007367
6x4 RIGID RADD-A8 FRAME77 + LINER-P FRAMEHIG

C = -1400 B = 2400
T9007196
Page 24

C = -1400 B = 2500
T9007194

C = -1400 B = 2600
T9007191
Page 26

C = -1400 B = 2700
T9007190
6x4 RIGID RADD-BR FRAME77 + LINER-P FRAMEHIG

C = -1400 B = 2400
T9007368
Page 28

C = -1400 B = 2500
T9007369

C = -1400 B = 2600
T9007370
Page 30

C = -1400 B = 2700
T9007371
6x4 RIGID RADD-TR FRAME88 + LINER-P FRAMEHIG

C = -1400 B = 2400
T9007185
Page 32

C = -1400 B = 2500
T9007184

C = -1400 B = 2600
T9007183
Page 34

C = -1400 B = 2700
T9007193
Cranes, stability FM, FH, NH 10.00 7.30 1(4)
Cranes, stability
General, stability
It is the responsibility of the bodybuilder to ensure com-
pliance between the minimum safety factor for tipping
and the local regulations if they set higher requirements.
One method to calculate the stabilising and tipping
moments is proposed on the following pages. The calcu-
lations should be seen to provide guidance, but not as a
guarantee.
The use of a crane influences the stability of the vehicle

with a moment Mt and a vertical load. The moment Mt is
referred to as the tipping moment since it strives to tip
the vehicle. Mt also increases, in addition to the weight L
of the goods being lifted, with an increase in the effective
length of the jib a. In addition to the lifting moment from
the crane, the dead weight of the crane also contributes
to the tipping moment. T9006121
The opposing or stabilising moment Ms counteracts the

tipping moment. A vehicle remains stable if the stabilising
moment is greater than the tipping moment. The weight
of the chassis sections and superstructure also con-
tribute to the stabilising moment, and it also increases
with the distance between and pitch of the outrigger legs.
Tipping and tip-over line

Tipping happens quickly and cannot be prevented once
it has begun. The consequences are therefore often
serious. Tipping occurs around an imaginary line T-T, re-
ferred to as the tip-over line. The position of this line
varies, depending on the position of the crane, the out-
rigger legs, and the direction of lift.
T9006122
Page 2
Safety factor
The safety factor that counteracts tipping is the quotient
between the stabilising and tipping moment. It should be
at least 1.4, in so far as local regulations do not set
higher requirements. A safety factor of 1.4 is motivated
by the serious consequences of tipping, and the dy-
namic increment that results from the sudden stop of the
lifting movement.
Prerequisites for calculation

The following parameters are included in the calculations. is taken from the Volvo data sheets. The bodybuilder is
responsible for the weight of the superstructure.
GC = Weight of crane excl. jib.
GB = Weight of jib.
tB = Distance between centre of gravity of jib and
tip-over line.
MC = Maximum lifting moment of crane.
LMC = Minimum load that gives MC.
CWF = Weight of chassis, front.
CWR = Weight of chassis, rear.
CL = Centre line of vehicle.
GSU = Weight of superstructure unloaded, excl.
weight of crane.
MT = Tipping moment.
MS = Stabilising moment.
S = Safety factor.
LMC = Maximum lifting moment MC of crane divided
by maximum reach of crane. LMC is assumed to act
in the centre of gravity of the crane column.
MT = Max. lifting moment MC + GB x tB (if the centre of
gravity of the crane lies outside the tip-over line)
MS = The stabilising moment increases with the weight T9007288
of the crane, excluding the jib, LMC the weight of the

empty superstructure, and the part of the weight of the
chassis that lies outside the tipping line.
The weight of the jib GB is not included, even if its centre
of gravity lies inside the tip-over line.
The lever for each load in the opposing torque shall be
measured from the point of incidence of the load, at right
angles to the tip-over line.
S = MMTS
Information about crane capacity, crane weight etc. is
provided by the crane manufacturer. The chassis weight
T9006140
Cranes, stability FM, FH, NH 10.00 7.30 3(4)
Stability, cab mounted crane, one pair of outrigger legs

Three different lifts should be checked for cab mounted
cranes with one (front) pair of outrigger legs. These are
lifting backwards at an angle, lifting forwards at an angle
(not in directions between the front wheels), and lifting
forwards between the front wheels. The safety factor S
should fulfil the set requirements in all cases.
Lifting backwards at an angle

When lifting backwards at an angle the tip-over line T-T
is assumed to go through one of the outrigger legs and
the centre of the rear axle or bogie. The weight of the
chassis on the front axle CWF, increases the stabilising
moment.
S= M S CWF x a + (GC + LMC ) x b + GSU x c

MT = MC + (GB x tb )
”(GB 2tb)” is included only if the centre of gravity of the
jib lies outside the tip-over line.
T9006141
Lifting forwards at an angle

When lifting forwards at an angle the tip-over line T-T is
assumed to go through one of the outrigger legs and the
centre of the front axle(s). In this case, the weight of the
rear chassis CWR increases the stabilising moment Ms.
MS
S= M CWR x c + (GC + LMC) x b + GSU x d
T
=
MC + (GB x tB )
T9006598
Page 4
Lifting forwards
When lifting forwards the tip-over line T-T is assumed to
go through the front axle(s). Even here the weight of the
rear chassis increases the stabilising moment.
MS = CWR x c + (GC + LMC ) x b + GSU x d

S= MT MC + (GB x tB )
T9006595
Stability, two pairs of outrigger legs

If two pairs of outrigger legs are used and lifting is con-
ducted between the pair of outrigger legs, the tip-over
line T-T is assumed to go through the outrigger legs.
The stabilising moment MS increases with the weight of
the chassis at both the front and rear and also with the
weight of the superstructure and crane base.
MS
S= M ( CWF + CWR + GC + LMC + GSU ) x a
T
=
MC + (GB x tB )
T9006597
Stability, rear mounted crane

Lifting forwards at an angle should be checked for rear
mounted cranes with one (rear) pair of outrigger legs.
The tip-over line T-T is assumed to go through one of
the outrigger legs and the centre of the front axle(s). The
weight of the chassis on the rear axle/bogie increases
the stabilising moment MS.
MS = CWR x c + (GC + LMC ) x b + GSU x d

S= M T MC + (GB x tB )
T9006596
Tail lift and rear mounted fork lift FM, FH, NH 10.00 7.40 1(1)
Tail lift and rear mounted fork lift

General
A tail lift with up to 2000 kg lifting capacity may be in-
stalled on trucks with standard or short overhang without
chassis reinforcement.
T9006188
Power consumption
The power consumption must be checked. It may be
necessary to fit an extra battery or the largest generator.
The negative earth for the tail lift does not need to be
routed back to the battery’s negative terminal. The tail lift
can be earthed locally.
Care should be taken to ensure that the earth to the

chassis remains correct, and that the earth lead cannot
come loose, if the tail lift has a local earth.
Mounting of fork lift

Mounting a fork lift behind the superstructure puts con-
siderable strain on the rear chassis. Section 7.20
“Diagram for crane displacement, rear mounted crane”
can be used for the selection of an appropriate helper-
frame. The calculation requires access to the total weight
(kg) of the fork lift and the position of the centre of grav-
ity of the fork lift in relation to the trailing back axle when
installed on the vehicle. The position of the centre of
gravity in relation to the trailing rear axle then replaces
the B factor. If the calculated dimension falls between two
B factors, the longer dimension should always be used.
Volvo recommends contacting the importer if the calcu-

lated B factor exceeds the one given to ensure the
safety of the vehicle.
The helper-frame should be designed as per the informa-

tion in Section 7.10 “Helper-frame, rear mounted crane”.
Special attention should be given to torsional rigidity.
Crane mounting FM, FH, NH 10.00 7.50 1(10)
Crane mounting
T9007375
Page 2
T9007376
6x2 RIGID FRAME77 + LINER-P FRAMEMED, Cab mounted crane
T9007377
Page 4
T9007378
Note: FRAMME77P = LINER-P

1 Applicable for:
• RIGID and TRACTOR, FRAME77 FRAMEHIGH
• RADT-AR (only RIGID), FRAME77 + LINER-P FRAMEHIG
• RADD-A8/RADD-BR, FRAME77 + LINER-P FRAMEHIG

T9007379
Note: FRAMME77/88P = LINER-P

2 Applicable for:
• RIGID and TRACTOR, FRAME77/88 + LINER-P FRAMEHIGH
• RADT-A6/RADD-TR1/RADD-TR2
• RADT-AR (only TRACTOR)

Page 6
4x2 FRAME66 FRAMEHIG, Rear mounted crane
T9007380
T9007381
Page 8
6x2 FRAME77 + LINER-P FRAMEMED, Rear mounted crane
T9007382
T9007383

Page 10
T9007384

Superstructure Instructions Crane and Tail Lift

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Superstructure Instructions Crane and Tail Lift

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Superstructure instructions

Volvo Truck Corporation

Crane mounting 7.50

• A rear mounted crane on an air suspension vehicle

The following crane installations are not considered in T9006102

this section. These installations must not be conducted

• Cranes with maximum crane load exceeding 350 kN

• Crane on chassis with FRAMELOW, 266 mm high

• An axle load calculation must be done for big, cab

Work order for an air suspension vehicle for crane operation

1 Switch to manual position on the control unit for the

3 Lower the outrigger legs to the ground so that they

4 If a reduction of the wheel and tyre loading on the

Caution: The control unit must be set to manual T9007199

They should be manufactured of L-profiles with a cross

Attach the wear plates with bolt unions to the chassis

When rectangular profile is used, the helper-frame cross

If two pairs of outrigger legs are used it is important that

and/or diagonal reinforcement braces in the helper-

Fix the helper-frame to the chassis frame with attach-

Attachment plates, hole spacing, welding and driven bolt

• The attachment plates should be positioned at a rel-

• Weld the attachment plates to the helper-frame. Al-

• Bolt the attachment plates to the helper-frame with

Helper-frame, cab mounted crane

If the subframe is higher or lower than the helper-frame

If the subframe is lower than the helper-frame the transi-

Helper-frame on vehicle with short cab L1H1

• Attach the plate in holes A and B on the chassis

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

Caution: Do not damage the engine attachment.

• Existing bolt unions to the engine attachment must

• Co-drill holes in the attachment plate and chassis

• Drill clearance holes C in the attachment plate for

Helper-frame, rear mounted crane

In the rear section of the helper-frame, the crossmem-

The overhang on the helper-frame should be reinforced

It is important that the chassis frame is not damaged or

• Weld the attachment plates for the crane onto the

• Fit the attachment plates on the chassis frame by

bolts. If pre-punched holes are used, then M16 bolts

• Driven M14 bolts shall be drilled together to Ø 13.7

• Driven bolt unions should be implemented as per

The method of mounting cranes with clamps is not rec-

Rear mounted crane

Cranes, design basis

The stability or inclination of the outrigger legs have not

Cab mounted crane, RIGID and TRACTOR

At the bottom of the top section of the diagram for crane

The diagram is an example, there are additional di-

Design basis of helper-frame

Calculation of crane load

((Mr x Mc ) + (Am x Ad )) x 9:81 (Newton conversion)

Cm = Total crane load (kN)

((10:0 x 2200) + (3200 x 2:50)) x 9:81 (Newton conversion)

Selection of helper-frame profile, top section

• Alternative with bending resistance

1 Draw a horizontal line from the intersection with

2 If the intersection is between two values,

• Alternative with profile height

The diagram is an example, there are additional di-

Selection of helper-frame length, lower section

Draw a horizontal line from the point of intersection to

Rear mounted crane, RIGID