Supplemental Information for EQUIPMENT MANUFACTURERS
TABLE OF CONTENT Table of Content ................................................................................................................................................................. 2 INTRODUCTION............................................................................................................................................................... 3 General Information ................................................................................................................................................... 3 Dimensions and weights ................................................................................................................................................. 4 Centre of gravity position ........................................................................................................................................... 7 Instructions ..................................................................................................................................................................... 8 Injury prevention ........................................................................................................................................................ 8 CHASSIS MODIFICATIONS ............................................................................................................................................... 9 Special precautions ..................................................................................................................................................... 9 Electrical system: ........................................................................................................................................................ 9 Rust and paint protection ......................................................................................................................................... 10 Frame welding .......................................................................................................................................................... 12 Subframe .................................................................................................................................................................. 12 Links .......................................................................................................................................................................... 13 Tipping platforms ...................................................................................................................................................... 14 Crane installation ...................................................................................................................................................... 15 Front snow equipment installation .......................................................................................................................... 17 Towing application .................................................................................................................................................... 19 Towing hook application ........................................................................................................................................... 20 POWER TAKE‐OFF (PTO) ............................................................................................................................................... 21 Engine (crankshaft) PTO ........................................................................................................................................... 23 Gearbox PTO ............................................................................................................................................................. 24 Transfer box PTO ...................................................................................................................................................... 25 FPT ENGINE CHARACTERISTICS CURVE: .................................................................................................................... 27 Chassis .......................................................................................................................................................................... 28
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INTRODUCTION GENERAL INFORMATION
This document gives directions and recommendations for vehicle modifications and for installation of custom bodies and structures made by independent builders onto the vehicle. The installation of any equipment onto the vehicle must be authorized by BREMACH through formal clearance which is released only after feasibility investigation. The clearances issued by the manufacturer shall be considered as valid only for the requested installation or modification; the compliance to requirements, suggestions and information contained in these rules, designed to ensure the functionality and vehicle safety, does not exempt the independent builder from the responsibility of the different achievements (project, execution, etc.) It is the Independent builder’s responsibility to do the installations or modifications in a professional manner. The manufacturer reserves the right to invalidate the warranty on the vehicle in case: ¾ The present rules have not been complied with ¾ The changes to the vehicle were not authorized ¾ The chassis is not suitable for the installed equipment
All modifications and special use applications accepted will have to guarantee the proper and safe functioning of all original vehicle parts. The modified vehicle must be capable of safe operation under all proposed on‐road and/or off‐road intended operating conditions. The modifications and/or installation of additional equipment must not make the final vehicle to be out of compliance with Federal, State and Local applicable safety and other laws and regulations. The Independent builder has to provide at the vehicle delivery, when necessary for the added equipment instructions for its service and maintenance and safe and proper operation.
DIMENSIONS AND WEIGHTS The dimension and maximum weights allowed on the axles are related on the technical descriptions and on the official documents released by the manufacturer. The tares included in the documents concern the vehicles with standard equipment; if any special equipment involves changes in weights and in the weight distribution on the axles, the modified information must be supplied to the end user of the vehicle. Note: Specification weights may have +/‐ 5% variance due to production variations. Before carrying out any modification it is necessary to weigh the chassis.
4
To define the position of the payload, the center of gravity, etc.
You can proceed according to the example shown below and on next page:
Wa
W
L
W = payload (complete with installed the superstructure)
Wb
Wa= payload loading on the front axle Wb= payload loading on the rear axle L = rear axle distance from the center of gravity
P = wheelbase
L=P
Wa W − Wb =P W W
5
The measured or calculated results have to be compared with the absolute weight limits for the vehicle as per the manufacturer’s documentation. Particularly important is the weight on the front axle, in order to assure the necessary steering attributes, in any load condition and on any road surface. The GAWR‐F (Gross Axle Weight Rating – FRONT) must not be exceeded under any circumstances. Pay special attention to vehicles with load concentrated on the rear overhang (crane, rear excavators) and with elevated center of gravity height. The rear superstructure overhang has to be built in compliance with the allowed loads on the axles, the restrictions for the length, and the position of the rear bar.
6
CENTRE OF GRAVITY POSITION Regarding the allocation of the payload on the axles, we consider that it is equally distributed, except in cases where the shape of load floor leads to a different load distribution. Obviously, for the equipment you have to consider the center of gravity in its actual location. For the superstructure installation you will need to provide loading and unloading systems, in order to avoid excessive variations of the distribution, and/or excessive loads on the axles. You have to distribute load uniformly between Right and Left sides of the vehicle, in order to not affect the behaviour, particularly the braking effect. The maximum equipment height allowed is specified on our approval documents.
7
INSTRUCTIONS
Follow provided instructions for the proper functioning of the vehicle with the added equipment. The modifications and special use applications must not alter the vehicle functionality during the normal operation, be it on‐road or off‐road. For Example: ¾ Easy access at the points that require maintenance and periodic inspections must be retained. In the case of closed type of superstructure, it must be provided special openings, covers or doors to allow easy access to any required service points; ¾ Design for the possibility to access, remove or disassemble any components that may need to be serviced, for example. ¾ Assure the same cooling conditions exist and any required air flow is not restricted by the additional equipment (radiator grille, radiator, air passages, cooling circuit, etc.). ¾ Any installed mudguards and/or wheel arches should assure the rear wheels have adequate room for free motion, even when chains or special tires are fitted. ¾ Any exterior projectors have to be checked after the vehicle modification is completed and for safety reasons if required additional markings such as reflex safety tape or illuminated markers have to be installed if necessary. ¾ It is the Independent builder’s responsibility to affix any parts supplied loose, with any incomplete vehicle, subject to any applicable safety or other rules or regulations.
Injury prevention Any structure and devices installed onto the vehicle have to comply with the any Federal, State or Local laws and requirements applicable to the prevention of injury. The
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compliance with these requirements will have to be addressed by the Independent builder that installs the additional equipment or modifies the vehicle in any manner.
CHASSIS MODIFICATIONS
SPECIAL PRECAUTIONS During welding, drilling, grinding and cutting operations close to the brake system, particularly if in proximity of plastic brake lines and/or electric cables, take precautions for their protection, and if necessary remove these parts during the customization work.
ELECTRICAL SYSTEM:
1) ALTERNATOR: a) In order to avoid diode rectifier damage, the battery must not be disconnected when the engine is running. b) In case you need to start the vehicle by towing, make sure the battery is connected. c) If you need to do a battery quick charge, Disconnect battery from the vehicle circuit. 2) GROUND CONNECTIONS: a) It is preferable that original vehicle connections are not altered b) If it is necessary to move these links, make sure that they provide proper grounding to the vehicle mass and ensure they are effective.
3)
ELECTRICAL CABLES:
The electrical cables have to be connected by junctions of the same type used originally. The added cable length has to be protected by a special sheath appropriately fixed with brackets.
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RUST AND PAINT PROTECTION All the vehicle parts (chassis, cab, etc.) that are modified have to be protected from oxidation and corrosion. The protection and painting operations have to be performed accurately on the added parts, in accordance with the vehicle manufacturer and adopting methods and devices provided by the paint manufacturer. Special precautions have to be taken to protect those parts where the paint could be harmful to their operation and/or protection (gaskets, rubber parts, flexible pipes, shafts and PTO flanges, hydraulic cylinders etc.). In case of dismantling wheels, you have to protect the area by hubs attack, in order to avoid thickness increase and mainly paint accumulation on the wheel disc flange
10
CHASSIS SECTION AND MATERIALS USED
3.5 t chassis
6.0 t chassis wheelbases 2600 – 3100 mm
6.0 t chassis wheelbase 3450 mm
COMPLETE CHASSIS BEAM MATERIAL Tube Material: S355 JL Break Resistance: Rm 510 / 680 N/mm2 Yield Limit: ReH 355 N/mm2 Elongation: > 20% C BEAM MATERIAL: S 420 MC Break Resistance: Rm 480 / 620 N/mm2 Yield Limit: ReH 420 N/mm2 Elongation: >19% LOCAL REINFORCEMENTS: S 235 JO Break Resistance: Rm 360 / 510 N/mm2 ReH 235 N/mm2 Yield Limit: Elongation: >24%
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FRAME WELDING The welding has to be carried out only by qualified and trained personnel and with appropriate equipment. During the welding operation connect the welder ground directly to the part, in order to protect the electric components (battery, alternator), and make sure that the negative (‐) clamp is disconnected from the battery. Any plastic pipes have to be protected or removed. The parts to be welded have to be without paint; the reinforced parts have to be deoxidized. After the work is completed, the modified parts have to be protected effectively against rust.
SUBFRAME The purpose of subframe is to ensure an uniform load distribution on the vehicle chassis and provide vehicle impact resistance and stiffness, depending on the vehicle use. For the subframe installation, note: ‐the material used for reinforced subframe and the supports for various equipment must have good weldability characteristics and mechanical properties not less than: Rm > 360 N/mm (37 kg/mm) i.e. Fe 360 C ReH > 235 N/mm (24 kg/mm) A > 25%. The additional structure spars shall be continuous, extended as far as possible toward the front of the vehicle. The profile section shape is defined by taking into account the subframe function and the type of superstructure. To connect the two beams of the chassis, a sufficient number of cross beams will have to be placed at the connections areas. For the cross members we recommend “open profiles” (i.e.: C shaped) or “box sections” where higher stiffness is needed. To
12
guarantee enough resistance to the connections, appropriate reinforcements must be added.
LINKS The choice of the link type used, it is very important for the contribution of the subframe in terms of strength and stiffness It may be elastic or rigid type, resistant to shear forces (longitudinal and transverse sealing plates); the choice must be made taking into consideration the kind of superstructure to be applied, and considering the stresses that the equipment shall forward to the vehicle frame during static or dynamic conditions. Number, size and fixing implementation, adequately distributed in the length of the subframe, must be such as to ensure a good connection between the vehicle chassis and subframe The screws must have material with strength class not less than 8.8, the nuts must be fitted with unscrewing system. The original connection elements present on the chassis have to be used in preference, if possible. Elastic type connections allow limited movement between the frame and subframe and lead to consider two resistant sections that work in parallel, for the chassis frame and added subframe; each structure will take part of the bending according to its inertia. The rigid connection of the two sections can be considered as a single resistant section, on the condition that the number and distribution connections are such as to withstand the resulting stresses.
13
TIPPING PLATFORMS The use of tipping platforms, both rear and trilateral generally subjects the frame to considerable stresses. The installation must also be complied with any requirements under the national law. Note: ¾ The pivot positioning for tipping should be as close as possible to the rear suspension support, in order not to affect the vehicle stability during the tipping and to not increase excessively the stresses on the chassis. ¾ Pay special attention with the lifting device position both to establish necessary support strength, and to realize an accurate and convenient connections; its position should be before the body with the payload center of gravity, in order to reduce the localized load weight. The effective body volume should be adjusted, in regard with the maximum weights allowed on the axles, to the material good weight to be carried (considered for the material excavated a specific weight of about 1600kg / m) ¾ The body‐builder will take care to preserve the functionality and vehicle parts safety, in compliance with the existing rules.(light position, hook)
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CRANE INSTALLATION The crane should be chosen taking into account its technical characteristics (crane weigh, maximum torque) and vehicle performances. The crane position and the payload will be carried out in compliance with load limits permitted for the vehicle. Applying the crane, observe the legal requirements specific to it, and check those required for the vehicle. During the crane work phase, the stabilizers (possibly hydraulic) will be placed and in contact with the ground. The numbers of stabilizer and subframe installation (in particular for its tensional rigidity: box sections, bars, etc) have to be done taking into consideration the crane maximum lifting moment and crane position. Vehicle stability verification during crane working should be carried out according to the regulations.
15
16
FRONT SNOW EQUIPMENT INSTALLATION The application of snow equipments in front of the vehicle (snowplough) should be realized through appropriate support structures. It should be met all the requirements and national regulations governing the application of this equipment During snow equipment use, with a maximum speed of 40 km/h (25 MPH), may be allowed (upon request) to increase the maximum permissible load on the front axle. The compliance with the load required have to be documented and guaranteed by the company that makes the installation The snow installation must entail the installation of two additional projectors to be mounted on the frame for extra headlights support applied to the snowplough itself. It is also strictly prohibited, and therefore not authorized, to perform any type of drilling on the space frame. 110
55
N° 4 through hole M12x1.75
40 80
110
55
75 150
Plate placed in the front of the two side members, to connect the snowplough support
Hole useful for lower snowplough connection, for longitudinal reaction.
17
Attachments control from the cab
18
TOWING APPLICATION The winch application is normally performed in the following points: ¾ On the front of the chassis ¾ On the rear of the chassis The application must be made in order to not affect the proper vehicle group parts functioning, in compliance with the heavyweights on the axes and following the instructions of the winch manufacturer. The fixing of the group and bodies on the vehicle frame, should be performed taking care to reinforce not only locally, the attack areas depending on the shot rope winch and particularly of its transverse component, where the traction is oblique. The power‐operated winches are used for low power and short duration, given the limited capacity of the battery and alternator. Comply with any safety requirements.
110 55
80
110
40
55
N° 4 through hole M12x1.75
Plate applied before in correspondence of the two side members, which will support the attachment of winch
75 150
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TOWING HOOK APPLICATION BREMACH vehicles are outfitted for towing hook and towing ball mounting. The towing hook application is possible using the appropriate drilling situated on the rear crossbar. The towing ball has be equipped with an appropriate support, connected on the upper side to the cross beam and below connected to the rear protection bar fixing brackets.
Rear crossbar with mounting hole for the towing hook and towing ball
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POWER TAKE‐OFF (PTO) For auxiliary equipment control such as tipper, crane and municipal vehicles, different types of power take‐offs can be fitted. Depending on required performances and use, the application can be fitted on: 1. GEARBOX 2. TRANSFER BOX 3. ENGINE 4. ON THE REAR OF THE VEHICLE Specifications and performances are indicated on power take‐off sheet attached. For defining the necessary power for instruments control, especially if high values are required, it is appropriate to consider also assimilated losses during the power transmission phase (5‐10% for mechanical transmissions, belts and gears and higher values for hydraulic controls). Selection of power take‐ off ratio has to be made in such a way the power absorption occurs in the engine constant torque reving range: low speeds (lower than 1000 RPM) have to be avoided. Transmission kinematic mechanism (angles, revs, torque) has to be carefully considered, from the power take‐off to the device, during the design step, and the dynamic behaviour in working situation, as prescribed by the transmission manufacturer. In calculating process, values of maximum power and maximum torque, have to be considered. To have good constant‐speed behaviour, angles with the same value at the joints are required. The design should avoid too high angular values. Example: “Z” solution is normally preferred to the “W” shown below.
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Engine PTO Gear box PTO
Transfer box PTO
For further explanation or for installation of groups with special characteristics, contact BREMACH Technical Dept. Presentation and approval for any transformation by the Competent Authority, are reserved to the supplier, as per national regulations.
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ENGINE (CRANKSHAFT) PTO
If PTO is attached to the crankshaft, can be used both with the vehicle standing or while it is being driven. This PTO drives a hydraulic pump through poly‐V rubber belt
Engine PTO with electromagnetic clutch: ENGINE : FPT F1A (85Kw) PTO Not available ENGINE : FPT F1C (107Kw – 130Kw) with poly‐V belt • POWER TAKE OFF: 13 Kw (18hp) @ 3000rpm (pump) • MAX. TORQUE: 41 Nm • PUMP: AP 200/22 • DISPLACEMENT: 22 cm³/rev • MAX FLOW: 40 l/min • MAX PRESSURE: 180 bar
‐Possibility to fit an integrated Hydraulic System on board:
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GEARBOX PTO
The gear box PTO has to be used only “in neutral position” and it has to be engaged / disengaged when the clutch is disengaged
GEARBOX:
ZF S6‐300 (F1A engine) • POWER TAKE OFF: • MAX. TORQUE: • GEAR PUMP:
ZF S6‐380 (F1C engine) POWER TAKE OFF: MAX. TORQUE: GEAR PUMP:
GEARBOX: • • •
ENGINE – GEARBOX F1A – S300 F1C – S380
RPM ENGINE 1 1
34 Kw @ 2000rpm (engine) 180 Nm ‐ 5 cm³/rev (l/m) ‐15 cm³/rev (l/m) ‐22 cm³/rev (l/m) ‐36 cm³/rev (l/m)
40 Kw @ 2000 rpm (engine) 180 Nm ‐ 5 cm³/rev (l/m) ‐15 cm³/rev (l/m) ‐22 cm³/rev (l/m) ‐36 cm³/rev (l/m)
PTO RPM OUTPUT 0,910 1,044
PTO LAT. ZF 6S‐300
TORQUE (Nm) INSIDE RATIO TEETH NUMBER
180
PTO LAT. ZF 6S‐ 380 VO 180
1,27
1,45
28
32
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TRANSFER BOX PTO
Transfer box PTO is normally used when the vehicle is stopped. If the application requires the vehicle to be driving, no change of gear has to be done. This PTO, thanks to the universal joint, can have the drive on the rear chassis crossbar. Depending on the usage, the suitable no. of revs can be chosen, selecting the suitable gearbox selection. • • •
POWER TAKE OFF: TORQUE UTILIZER:
55 KW (for higher/extreme use, contact the manufacturer) depending on engine curve and gear selection 1) Cardan Shaft 2) gear pump
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Example: ‐ Possibility to cool hydraulic oil with Stanley System on board
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IVECO / FPT ENGINE CHARACTERISTICS CURVE: • F1A 85 Kw – 270 Nm • F1C 107 Kw – 350 Nm • F1C 130 Kw – 400 Nm POWER Potenza 140
120
100
KW
80
60
F1C 130 KW F1C 107 KW F1A 85KW
40
20
0 500
1000
1500
2000
2500 Rpm
3000
3500
4000
TORQUE Coppia 450 400 350
Nm
300 250 200 150
F1C 130 KW F1C 107 KW F1A 85 KW
100 50 0 500
1000
1500
2000
2500 Rpm
3000
3500
4000
4500
4500
CHASSIS
Lc
1300 60
dr
df df '
dr '
T / T’
240
438
3000
860
1290
800
980
28 * with tyre 245/70 R 17.5
2050 (with larger mirrors- optional)
770
1700 – 1900 (with mirrors of send rate)
Dimensions refer to the weelhouses
1770 / 1785 *
‘ : vehicle load to “Maximum Total Admissible GVW” and to “Maximum Rear Admissible Mass”
29 380
N.B. The dimensions are referenced to ground with a tolerance of ± 20 mm
GWV. 3.5 t
GWV. 6.0t
S
L
A
without
X
X
980
4380
200mm
X
1180
4580
wheelbase extension
2600
3100
3450
B
C
Lc
L tot
545
1730
2620
4780
745
1930 2800
4960
400mm
X
1380
4780
945
2130
without
X
X
980
4880
1045
2230
4960
4960
200mm
X
X
1180
5080
1245
2430
5480
5480
400mm
X
1380
5280
1445
2630
5680
5680
without
X
980
5230
1395
2580
5630
5630
200mm
X
1180
5430
1595
2780
5830
5830
400mm
X
1380
5630
1795
2980
6030
6030
1185
wheelbase extension
2600
3100
GVW 3.5 t
GVW 6.0t
without
X
X
200mm
X
400mm
X
without
X
X
200mm
X
X
400
X
without 3450
T 3.5 t X4 ‐ 934 Xtreme ‐ 996 X4 ‐ 939 Xtreme ‐ 1002 X4 ‐ 944 Xtreme ‐ 1007
T 6.0t X4 ‐ 928 Xtreme ‐987 Not available
X4 ‐ 929 Xtreme ‐ 992 X4 ‐ 933 Xtreme ‐ 996 X4 ‐ 938 Xtreme ‐ 1000
X4 ‐ 924 Xtreme ‐ 983 X4 ‐ 928 Xtreme ‐ 987 Not available X4 ‐ 921 Xtreme ‐ 981 X4 ‐ 925 Xtreme ‐ 984 X4 ‐ 928 Xtreme ‐ 987
X
200mm
X
400mm
X
Not available
T' 3.5 t X4 ‐ 789 Xtreme ‐ 852 X4 ‐ 784 Xtreme ‐ 847 X4 ‐ 779 Xtreme ‐ 842 X4 ‐ 792 Xtreme ‐ 855 X4 ‐ 788 Xtreme ‐ 851 X4 ‐ 784 Xtreme ‐ 847
Not available
T' 6.0t X4 ‐ 764 Xtreme ‐ 839 Not available X4 ‐ 766 Xtreme ‐ 840 X4 ‐ 763 Xtreme ‐ 838 Not available X4 ‐ 768 Xtreme ‐ 841 X4 ‐ 765 Xtreme ‐ 839 X4 ‐ 762 Xtreme ‐ 838
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N.B. The dimensions are referenced to ground with a tolerance of ± 20 mm
Wheelbase Extension
2600
3100
GWV. 3.5 t
GWV. 6.0t
without
X
X
200
X
400
X
without
X
X
200
X
X
400
X
without 3450
df 3.5 t X4 ‐ 822 Xtreme ‐ 887 X4 ‐ 822 Xtreme ‐ 887 X4 ‐ 822 Xtreme ‐ 888 X4 ‐ 820 Xtreme ‐ 885 X4 ‐ 820 Xtreme ‐ 886 X4 ‐ 820 Xtreme ‐ 886
dr 3.5t X4 ‐ 906 Xtreme ‐968 X4 ‐ 905 Xtreme ‐ 968 X4 ‐ 905 Xtreme ‐ 968 X4 ‐ 905 Xtreme ‐ 969 X4 ‐ 905 Xtreme ‐ 968 X4 ‐ 904 Xtreme ‐ 967
X
200
X
400
X
Not available
Not available
df 6.0t X4 ‐ 821 Xtreme ‐ 887
dr 6.0t X4 ‐ 902 Xtreme ‐ 963
Not available
Not available
X4 ‐ 820 Xtreme ‐ 885 X4 ‐ 820 Xtreme ‐ 886
X4 ‐ 901 Xtreme ‐ 962 X4 ‐ 900 Xtreme ‐ 961
Not available
Not available
X4 ‐ 819 Xtreme ‐ 885 X4 ‐ 819 Xtreme ‐ 885 X4 ‐ 819 Xtreme ‐ 885
X4 ‐ 901 Xtreme ‐ 962 X4 ‐ 900 Xtreme ‐ 961 X4 ‐ 899 Xtreme ‐ 960
df' 6.0t X4 ‐ 826 Xtreme ‐ 873
dr' 6.0t X4 ‐ 779 Xtreme ‐ 847
Not available
Not available
X4 ‐ 826 Xtreme ‐ 873
X4 ‐ 779 Xtreme ‐ 847
Not available
Not available
X4 ‐ 826 Xtreme ‐ 873
X4 ‐ 779 Xtreme ‐ 847
GWV. 3.5 t
GWV 6.0t
without
X
X
200
X
400
X
without
X
X
200
X
X
400
X
without
X
200
X
400
X
wheelbase extension
2600
3100
3450
df' 3.5 t
X4 ‐ 870 Xtreme ‐ 937
Not available
dr' 3.5 t
X4 ‐ 809 Xtreme ‐ 873
Not available
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Document updated to March 15, 2010