Body builder instructions

Volvo Truck Corporation

Supersedes VBI Release 14 from 10.18

Changes are marked with a bar (|) in the margin. Installation rigid
Tipper/Dumper
FM (4), FH (4)

Contents
“General”, page 2
“General restrictions”, page 2
“Installation”, page 3

“Tipper pivots”, page 3

“Design”, page 4

“Frame”, page 5

“Torsional stiffness of rear overhang”, page 6

“Tip ram”, page 8

“Support”, page 9
“Superstructure attachments”, page 10
“Attachments — Minimum requirements”, page 11
“Tipping stability”, page 12
“Testing the complete bodywork”, page 13
“Customer Adaptation guidelines for 16 tonne, tag axle”, page 13

Tipper/Dumper FM (4), FH (4)

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All Rights Reserved
Tipper/dumper
General
The instruction given in this chapter is applicable for tipper
as a complete vehicle but emphasises on the chassis and
its connections. The guidelines are based on tests and ex-
perience of the Volvo Truck design department and must
be followed to produce a complete tipper with high levels
of handling, comfort and quality.

General restrictions are shown below, and specific restric-

tions are shown in the appropriate section.

For information about mounting cranes, refer to body

builder instructions “Cranes”.

T9161089

General restrictions
WARNING
Air suspended tippers: Release air from the air bel-
lows before tipping. This is done by lowering the vehicle
to its lowest position using the manual control box.
When the air is released, the vehicle rests on the bump
stops thus increasing stability during tipping.
If the air is not released, a sudden release of load can
cause the chassis to jerk upwards due to the pressure
in the air bellows. This could damage the air suspen-
sion components, especially the shock absorbers and
reaction rods.

Tipper/Dumper FM (4), FH (4)

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 Installation
Tipper pivots
Front tipper pivot
The front tipper pivot must be located as far forward as
possible and a maximum distance of 600 mm from the
front frame reference hole.

A maximum distance of 900 mm applies to 8x2/8x4/8x6

and 10x4/10x6, double front axles.

Note: On trucks with a cab crane, the front tipping shaft

must be located immediately behind the crane base.

T9162461

3-way tipping

Rear tipper pivot

The rear tipper pivot must be located as close to the rear
axle as possible.

Maximum distances from the rear axle:

4x2 = 1200 mm
6x2/6x4 = 1000 mm
8x2/8x4 = 800 mm
8x4 (Tridem) = 1000 mm
10x4 (Tridem) = 600 mm
10x6 (Tridem) = 600 mm

T9162462

Backwards tipping

Restrictions

WARNING
GVW >34 tonne tippers, and tippers with and a long
rear tipping pivot should be controlled either by testing
or by calculating the high tipping forces in the rear
overhang.

WARNING
Maximum GVW for 5 axle trucks: 42t

Tipper/Dumper FM (4), FH (4)

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Design guideline
The shorter the rear tipping pivot the better tipping stabil-
ity. However, for any given rear pivot position, tipping
stability can be improved by reinforcing the rear overhang.
Refer to “Torsional stiffness of rear overhang”, page 6 .

Design
When specifying a tipper, it is important to achieve a com-
plete vehicle that is optimised to the operating conditions.
This is particularly important with tippers because they op-
erate under a wide variety of weights and conditions. Dif-
ferent countries also have varying legal demands or
guidelines.

It is the intension of this section to explain and give exam-

ples of how to combine the Volvo chassis with different
types of superstructure.

The diagram below shows many of the features that can

be used on tippers.

C9142082

A Pivoted attachment or elastic one-way

B Box profile
C Attachment in bogie section
E Stabilizer
F Leading front axle
G Trailing front axle
H Leading final drive
I Attachment stabilizer
J Closing cross member with box profile

Tipper/Dumper FM (4), FH (4)

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 Frame
Subframe/helper frame
The subframe/helper frame is the part of the bodywork
that distributes the load evenly on the chassis. It gives an
interface for attachments and provides clearance above
the chassis itself. It should also clear the mudguards
above the wheels and tyres during movement of the sus-
pension and twisting of the chassis.

For more information about the subframe/helper frame,

refer body builder instructions “Attachments” and “Frame
Reinforcements”.

Note: The subframe does not reinforcement the side

member, it reduces stresses in the rear section of the
side member during the tipping operation, if it is at-
tached with attachment plates.
When reinforcement of the side member is required, a
helper frame must be used. When installing the cranes,
refer to body builder instructions “Cranes”.

Cross member for subframe and helper frame

Tippers that are used to work in rough conditions are often
exposed to excessive frame torsion. Therefore the frames
must be reinforced with a cross member to become rigid
and strong. When fitting the cross member to a side mem-
ber the cross member should meet the web of the side
member and be connected by a tie plate. This results in a
better structure for dynamic loads.

T9007793

Design Guideline
If the characteristics of the chassis frame and subframe Sub-frame
differ too much (due to geometrical properties or steel
General U-120x80x6
properties), this may lead to fatigue cracks, especially in
welded areas that have been subjected to a high level of For heavy duty driving U-160x80x6
stress. (construction) and for 6x4,
8x2, 8x4
Note: The addition of a subframe is not to be considered
as a chassis frame reinforcement. When extra chassis 10x4/6 U-275x80x6
frame strength is needed, use helper frame.

For information about assembling cranes, refer to body

builder instructions “Cranes”.

Tipper/Dumper FM (4), FH (4)

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Torsional stiffness of rear overhang
Torsional stiffness of the rear overhang is first and fore-
most ensured by a short distance between rear axle and
rear pivot point. Never the less, torsional stiffness of rear
end of vehicle must be ensured, by a proper selection of
the following enhancements:

• Diagonal reinforcement

• Tip stabilizer

• Anti-roll bar in rear overhang

• Rear closing cross member with high torsional stiffness

• Boxed cross section of the sub-/helper frame at the

rear

Diagonal reinforcement
Diagonal reinforcement:

• increases the torsional stiffness at the rear of the vehicle

if fitted to the rear of the subframe

• increases tipping stability

• reduces stress

• transmits some of the forces from the tipper hinge di-

rectly to the bogie cross member.
It should be connected as close to the tipper hinge as pos-
sible and at its forward end should finish above the bogie
cross member.

Note: Box sections are generally recommended for the fit-

ting of a diagonal reinforcement. The dimensions will de-
pend on the amount of overhang, the payload and the
operating conditions. Some general guidelines are given
below:

Design guidelines
5 axle vehicles
• Box profile RHS 120x80x6 mm
3 & 4 axle vehicles
• Box profile RHS 80x80x6 mm
2 axle vehicles
• Box profile RHS 60x60x6 mm

• Flat bar or channel sections may be used if the over-

hang is short and the operating conditions are smooth.

T9007841

Tipper/Dumper FM (4), FH (4)

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 Tip stabiliser
The tip stabiliser:

• has a major stabilizing effect on the tipper

• reduces the sensitivity of the applied tip ram type, for

example steered or guided ram
The link in the tip stabiliser and its attachments to the
frame and tipper chassis are important to the stabilising
function. In order to have the maximum stabilising effect,
the link gap should be as small as possible.

Anti-roll bar in rear overhang

The anti-roll bar is important to the tipping stability for sev-
eral reasons:

• The loads are transmitted directly to the ground.

• The suspension roll stiffness is increased.

Anti-roll bar should be located in rear overhang for maxi-
mum tipping stability.

Note: The rear axles shall be equipped with anti-roll

bars.

Rear closing cross member

Adding a torsionally stiff closing cross member at the rear
end of the vehicle gives a significant contribution to the
tipping stability. The center piece of this cross member
should typically be of a box profile (closed cross section),
in order to give the cross member its high torsional stiff-
ness. Center pieces of open cross section type (e. g. U-
shaped beam) does not give a significant contribution to
the tipping stability.

C9142082

J Closing cross member with box profile

Cross section of the subframe and helper frame

Boxed cross section of the subframe and helper frame at
the rear of the vehicle increases the torsional stiffness.
Hence increasing the tipping stability.

Tipper/Dumper FM (4), FH (4)

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Tip ram
Under floor mounted RAM
The tip stabiliser have a major stabilising effect on the tip-
per body side-ways position relative to the frame during
unloading. Thereby resulting in less imposed side loading
and rod bending of the ram (hydraulic cylinder). Depend-
ing on the design of the ram, this can be very beneficial
for ram reliability and life.

Guidelines
The tip ram position and pivot assembly are outlined
below.

T9162464
T9162463

A – Reference point
B – Centre of rearmost axle
C – Front tipper pivot
D – Centre support
E – Rear tipper pivot
F – Tip ram

Tipper/Dumper FM (4), FH (4)

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 Support
In the lowered position, the platform must be supported by
two supports on each side. The supports should be evenly
distributed. For 4x2, one support per side is sufficient

For platforms with a central, front contact, support B is re-

quired in order to limit the rolling moment. These supports
must have a rubber cushion C with a minimum hardness of
70° Shore, a minimum thickness of 20 and a 10-15 mm
clearance. refer to the diagram.
A – Cross section
B – Support
C – Rubber cushion

T9113179

T9113178

Tipper/Dumper FM (4), FH (4)

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Superstructure attachments
Front section
The front section must be fitted with pivoted or elastic
one-way attachments. For heavy driving conditions, for
example construction site operations, an elastic one-way
attachment is preferable as well as a pivoted attachment
at the transition between the elastic one-way attachment
and the stiff attachment.

Rear section
The rear section must be fitted with stiff attachments. Ve-
hicles with a 3-way tipper should have an attachment near
the tipper ram.

T9094585

2 axle trucks
The rear attachment should be assembled with the cross
member at the rearmost rear spring anchorage.

Drill Ø14 mm holes in the frame side opposite the four

centre holes on the cross members upper tie plate, so that
the attachment plate can then be bolted in place with four
bolts.
3 and 4 axle trucks
The rearmost attachment should be assembled with the
end member.

• 6x2/8x2 at least 4 x M14 in hole Ø14 mm.

• 6x4/8x4 and at least 5 x M14 in hole Ø14 mm.

5 axle trucks
The rearmost attachment should be assembled with the
end member.

• 10x4/10x6, at least 7 x M14 in hole Ø14 mm.

Tipper/Dumper FM (4), FH (4)

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 Attachments — Minimum requirements

T9162465

Note: For road conditions RC-VROUG the use of elastic

one way attachments is recommended, but pivoted at-
tachments can be used if the bodywork is designed to be
very flexible.

Chassis Front section (A)1 Rear section (B)2

End plate (C)
variant All except rearmost Rearmost All

RC-SMOOT Or

Choice of end plate

depends on the axle
RC-ROUGH Or
combination and
bodywork.

RC-VROUG Or

1 The number of attachments depend on the wheelbase.

2 The number of attachments depend on the rear frame length.

Tipper/Dumper FM (4), FH (4)

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Tipping stability
This section concerns tipping stability, which is important
for the safety of the complete vehicle. Tippers have to be
adapted to become an optimised vehicle to suit the cus-
tomer operating conditions.

Note: The detailed design and construction of the ele-

ments that make up the complete vehicle can have a
significant effect on tipping stability. The vehicle should
be thoroughly tested by the body builder to ensure that
it is suitable to carry out all the operations for which it is
designed and meets all the necessary legislation
requirements.

Note: Volvo carries out tilt tests on a fully raised body

with a fixed load. The tilt test does not take into account
such dynamic effects as loose ground, wind, moving
loads etc. The tilt limits from these tests are NOT to
be applied as inclination limit of ground side-slope
whilst the vehicle is in real operation.

T9162466

This picture shows the example of an tipping stability test.

The COG lateral offset, causes a roll over moment (M) to

the vehicle. Counteracting M is the stability moment (K)
caused by the vehicle structure. Tip over will occur when
the roll-over moment is greater than the stability moment
or when the lateral displacement of the COG exceeds the
tyre roll-over point.

T9007840

Tipper/Dumper FM (4), FH (4)

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 Testing the complete bodywork
The body builder should test the finished vehicle to ensure
that it meets its operational and statutory requirements.
Volvo's tipper test is carried out with the platform fully
raised, with maximum axle pressure and a fixed load.

WARNING
Maximum GVW for 5 axle trucks: 42t

Customer Adaptation guidelines for 16 tonne, tag axle

For more information on this truck please
contact Volvo Trucks.

Design Guideline
If the characteristics of the chassis frame and subframe
differ too much (due to geometrical properties or steel
properties), this may lead to fatigue cracks, especially in
welded areas that have been subjected to a high level of
stress.

Note: A truck with a 10x4 axle configuration requires a

cross member over the third axle in the bogie.

Note: When extra frame strength is needed a helper

frame should be fitted.

Note: The addition of a subframe is not to be considered

as a chassis frame reinforcement.

Subframe
For heavy duty driving: 10x4 U-275x80x6

Tipper/Dumper FM (4), FH (4)

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 English 8.2020, 152464112
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Volvo Truck Corporation

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