BODYBUILDERS' GUIDELINES

Superstructures
SUPERSTRUCTURES
Superstructures

4.1
4.2
4.3
4.4
4.5
4.6
4.7
4.8
4.9

Page
Fixed body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Body with tail lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
Vehicle loading cranes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
Tipper bodies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
Tankers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
Concrete mixers and concrete pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
Public utility vehicles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
Front mounted equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
TRACTORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136

Date
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Superstructures

4. SUPERSTRUCTURES
4.1 FIXED BODY
For all the superstructures described in this
section, also see section 3: "General
information on superstructures".
Body attachment method BAM 1 is generally
sufficient for the mounting of a fixed body or
demountable body with sub-frame.
The tie rods must be attached to the chassis side
members, if possible near or against the cross
members. At least one attachment plate must
always be fitted between the front and rear spring
brackets of the rear axle(s).
A sub-frame is not necessary but can be
fitted, in order to obtain the required wheel
clearance. Also see the sections
2.10: "Chassis and cabine related
dimensions" and 2.14: "Wheel clearance".
Minimum requirement is the fitting on the chassis
of a strip or angle brace, to which the cross
members of the body can be welded. For the
mounting of box bodies without a sub-frame
DAF recommends the fitting of a number of extra
cross members in the floor of the body above or
as close as possible to the vehicle axles. As a
result of chassis flexing, additional pulling and
pushing forces are exerted on the floor of the
body. However, the bodybuilder remains at all
times responsible for the soundness of a
construction and the strength of the selfsupporting bodywork.

G000276

Fixed body with sub-frame, BAM 1

96120404-404

Tie rod mounting, body without sub-frame (with

mounting strip)

96120404-405

Attachment plate, body without sub-frame (with

mounting strip)
(High-)volume body
For (high-)volume applications DAF has various
'Low-Deck' rigid truck chassis in its range with a
low frame (260 mm with continuous inner
reinforcement flitches). If required, some of these
vehicles - for instance, FA/S/R Low-Deck - can be
specified with lower suspension, in combination
with speed-dependent height control and tyre
compression compensation. These chassis
require additional strength and/or stiffness of the
superstructure.

G000277

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

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Superstructures
A (semi-)self-supporting fixed or demountable
body, with or without a sub-frame, can be
mounted on these chassis. The superstructure
should be attached in accordance with body
attachment method BAM 1 or BAM 3a. The
choice is determined by the moment of inertia of
the sub-frame or the floor of the fixed body. The
same applies to the minimum required moment of
inertia of the floor of demountable bodies. For sub
frame dimensions see table.
Attachment according to BAM 1
Min. required body/sub-frame dimensions for chassis with 192 mm and 260 mm
high side members with continuous inner reinforcement flitches

Wheelbase
[m]

Chassis rear
overhang (AE)
[m]

Side member
section
(A)

WB > 5.40 -
6.00 (2)

AE 0.5 x WB

192x66.5x4.5
+ 180x47/62x4

WB 5.00

AE 0.6 x WB

260x75x6 +
245x65x5

WB 5.40 (1)

AE 0.5 x WB

WB 5.90
WB 7.30 (1)

Sub frame profile dimensions; st52 [mm]

FA (4x2)

FAR/S (6x2)

U 180x60x6

not applicable

U 200x70x7

260x75x6 +
246x60x5

U 100x60x6

not applicable

AE 0.6 x WB

260x75x7 +
245x65x5

U 80x50x6

U 220x80x8

AE 0.5 x WB

260x75x6 +
246x60x5

U 180x60x6

not applicable

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

Attachment according to BAM 3a

Min. required body/sub-frame dimensions for chassis with 192 mm and 260 mm
high side members with continuous inner reinforcement flitches
Wheelbase
[m]

Chassis rear
overhang (AE)
[m]

Side member
section
(A)

AE 0.6 x WB

192x66.5x4.5
+ 180x47/62x4

AE 0.6 x WB

260x75x7 +
245x65x5

(1)

AE 0.6 x WB

WB 5.90

WB > 5.40 -
6.00 (2)
WB 5.00
WB 5.40

WB 7.30
(1)

Sub frame profile dimensions; st52 [mm]

FA (4x2)

FAR/S (6x2)

U 80x50x6

not applicable

U 100x65x6

260x75x6 +
246x60x5

U 80x50x6

not applicable

AE 0.6 x WB

260x75x7 +
245x65x5

U 80x50x6

U 120x60x6

AE 0.6 x WB

260x75x6 +
246x60x5

U 140x60x6

not applicable

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

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Superstructures
Wheel clearance at the rear
On versions with speed-dependent height control
and tyre compression compensation, the
minimum clearance required above the tyres of
the driven axle has been reduced to 10 mm with
the springs bottoming (metal to metal). Also see
section 2.14: "Wheel clearance".
Body with twist-locks
When mounting (demountable) bodies without
sub-frame, with twist-locks, directly to the vehicle
chassis, fit the twist-locks to the side of the
chassis frame, using at least 6 M16 flange bolts
for each of them.
For (self-supporting) demountable bodies which
bear evenly on the chassis over its entire length,
there are no specific requirements with respect to
the position of the twist-locks, and the dimensions
given below may be departed from.

96120404-406

Attachment of twist locks

The twist-lock bracket should be fitted near a

chassis cross member. If this is impossible, you
are referred to section 2.6: "Attachment of
components to the chassis".
However, if a demountable body is supported at
only a few points, the twist-lock positions given
below must be adhered to. If the support points
are in other positions, e.g. as in the case of ISO
containers, DAF should be contacted.

max.
A

max.
1050
22032802-012

Position of the twist locks:

A:
1000 (LF)
1400 (CF - XF)
For the mounting of (demountable) bodies with
sub-frame in which the twist-locks are included,
BAM 1 is specified in most cases (without tail lift).

max.
A

max.
1300
22032802-023

Position of the twist locks

Make sure that demountable bodies rest on

the sub-frame or the chassis members, but in
no case directly on the twist-locks!

4.2 BODY WITH TAIL LIFT

Body with tail lift
The next table gives the minimum dimensions to
be adhered to for sub-frames of bodies with tail
lifts with capacities up to 2000 kg, depending
on the type of vehicle, the wheelbase, the chassis
dimensions and the rear overhang length. For
tail lifts with a higher capacity than specified
in the table, DAF should be contacted. Tail lifts
with a capacity higher than 2500 kg always
require the fitting of vehicle support legs to be
used during loading and unloading.

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Superstructures
For the mounting of the sub-frame for a
superstructure with tail lift, BAM 3b (CF75-85)
or BAM3 (LF / CF65) is specified in most
cases.
If according to DAF a sub-frame is not required
for structural strength or because of deflection
(see note 5)), a sub-frame in accordance with
BAM 1 may still be fitted, for example because of
the desired wheel clearance.
Take note of the effect of the tail lift on the vehicle
weight distribution in fully laden and partly laden
conditions. If necessary, refer to the TOPEC
calculations for axle load distribution of the partly
laden vehicle.

Attachment of the tail lift

With this type of superstructure, the tail lift
attachment can also be used to attach the subframe to the chassis. In that case, the tail lift is
bolted to the chassis frame and bolted or welded
to the sub-frame.

96120404-409

Attachment of the tail lift in accordance with BAM

3b
Superstructure with post type tail lift
A post type tail lift must always be fitted to the
body. Consult the supplier of the post type tail lift
for the correct mounting instructions.
Sub-frame dimensions
The following table gives an overview of the
minimum dimensions required for sub-frames.

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Superstructures
Minimum sub-frame dimensions for tail lifts with capacities up to 2000 kg (1)
Vehicle type
FA LF45 (3)
(4)

FA LF45
12 tonnes GVM

WB
[m]
4,30
5,40
4,30
5,40

Chassis sections
in rear overhang

5,35
6,30

U 140x60x6
U 120x60x6

192x66.5x4.5+180x62x4
0.50xWB

4,20
5,35
4,90

FA CF75-85
FA XF

FAG CF75-85

U 160x60x6

(1)
(2)
(3)
(4)
(5)

260x75x6

0.55xWB

U 200x60x6

260x75x7

U 160x60x6

310x75x7

U 80x60x6

310x75x7

0.50xWB

U 160x60x6
U 100x65x6
U 100x65x6

6,90

310x75x7

U 120x60x6

5,35

310x75x7 + 295x65x5

6,60

310x75x7 + 295x65x5

0.40xWB

U 80x60x6
U 140x60x6

260x75x7 + 245x65x5

U 100x60x6

310x75x7

U 160x60x6

5,50

310x75x7

U 200x60x6

4,20

310x75x7 + 295x65x5

4,80

260x75x7 + 245x65x5

5,30

310x75x7 + 295x65x5

U 160x60x6

5,90

260x75x7 + 245x65x5

U 200x60x6

6,10

310x75x7 + 295x65x5

U 200x60x6

0.55xWB

U 180x60x6

260x75x7 + 245x65x5

3,80
FAS/R CF75
FAS/R CF85
FAS/R XF
FAN CF75-85
FAN XF

U 80x60x6

U 180x60x6

260x75x7
5,70

U 140x60x6
U 120x60x6

260x75x6

7,30
FAN LF55

Sub-frame (2)
sections
U 120x60x6

192x66.5 x4.5

4,20
FA LF55
FA CF65

Maximum AE (5)
(value 3 %)

U 100x65x6
U 180x60x6

Consult DAF for tail lifts with a higher capacity, and for other combinations not mentioned in this overview.
The determination of the sub-frame dimensions is based on the use of Steel 37 (Fe 360 B according to EN10025).
Tail lift capacity 1000 kg.
Tail lift capacity 1500 kg.
Body length and AE to be determined on the basis of axle load calculation; consult TOPEC.

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Superstructures
WARNING! Vehicle stability during
operation of any superstructure
system is the responsibility of the
bodybuilder and the user. The user
should at all times make sure that
vehicle stability is guaranteed. It is
therefore important that clear
instructions for use of the
superstructure should be provided
by the bodybuilder on or supplied
with the vehicle.
For more information see:
1.3: "Verificaton of superstructure"

4.3 VEHICLE LOADING CRANES

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

crane immediately behind cab: BAM 2, or

crane at rear end of chassis: BAM 3a. or
BAM 3 (LF and CF65 series)
crane in combination with more than 2 crane
supports: BAM 4.

Consult DAF for any position other than the

two above-mentioned crane positions, for
instance for cranes mounted amidships.
Vehicle series

Side mem- Flitch dimensions

ber dimen[mm]
sions
[mm]

Max. crane capacity

Crane behind
cab. (1)[kNm]

Crane at rear
overhang
(1)[kNm]

100

75

150

100

FA LF45

192x66x4,5

(180x62x4,0)

FA CF65
FA / FAN LF55

260x75x6,0

(245x60x5,0)

FA CF75-85
FA XF

260x75x7,0

310x75x7,0

(295x65x5,0)

200

150

260x75x7,0

245x65x5,0

250

170

310x75x7,0

310x75x7,0

295x65x5,0

300

200

310x75x8,5

292x65x8,5

310x75x6,0

295x65x5,0

310x75x7,0

295x65x5,0

400

250

310x75x8,5

292x65x8,5

FAS/R FAG
FAN CF75-85
XF

FAC FAD
FAK FAQ FAX
CF85
XF

(2)
(2)

(2)

Number of
crane supports

2/4

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

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Superstructures
Attachment of the crane base
The number of attachment bolts under the crane
base depends on the attachment method and the
maximum capacity of the crane. It should always
be determined by and under the responsibility of
the supplier of the crane. In any case, the part of
the sub-frame on which the vehicle loading crane
is to be mounted, must be attached to the chassis
frame of the vehicle with large attachment plates
and flange bolts.

96120404-411

Attachment of the crane base

Sub-frame dimensions
Always use a sub-frame when mounting a crane
superstructure on a chassis frame. For the
dimensions of the required sub-frame, refer to
one of the two graphs shown below. The
following information will help you to choose the
applicable graph:
The 2 graphs (A and B) can be used to determine
the sub-frame dimensions as follows. Graph A:
from a crane capacity of, for instance, 140 kNm,
draw an imaginary horizontal line to the right until
it crosses the vertical line of the side member, for
instance 260x75x6 (LF55). The reading for the
sub-frame dimensions is box section 160x80x8.
The dimensions of the chassis members
(possibly with flitches) in the indicated critical
zones (*; see figure) of the chassis can now be
read from the bodybuilders' drawings.

max.

1700*

20061604-412

These drawings are available on the internet

(www.dafBBI.com).
Graph A: Crane immediately behind cab
Sub-frame material Fe 510 D, according to EN 10025 (St 52-3 according to
DIN 17100).

20061604-413

1700*

AE

Critical zones for mounting of cranes

Graph B: Crane at rear end of chassis

Sub-frame material Fe 510 D, according to EN 10025 (St 52-3 according to
DIN 17100).
Torsional stability
If a vehicle loading crane is fitted at the rear end
of the chassis, a torsional stiffener must be
provided in the rear overhang. The torsional
stiffening may be provided by the superstructure
itself or by a sub-frame stiffener; also see
'Torsional stability of the sub-frame' in section
3.1: "Superstructure with sub-frame". The
stability is determined by the vehicle, the load, the
position of the support legs and the structure of

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Superstructures
the surface under the support legs. Vehicles
with front leaf / rear air-suspension or full airsuspension. During crane operation; deflating
the suspension of the vehicle and than lifting the
chassis using the crane support legs can lead to
damage to the air bellows. Therefore the ECAS
air-suspension should be equipped with the
function to deflate the air-suspension to low
residual pressure to protect the air-bellows. For
installation of this function, please contact DAF
Sales Engineering.

Vehicle stability during operation of any

superstructure system is the responsibility of
the bodybuilder and the user. The user should
at all times make sure that vehicle stability is
guaranteed. It is therefore important that clear
instructions for use of the superstructure
should be provided on or supplied with the
vehicle.
Graph A
Minimum sub-frame dimensions for:
-

crane immediately behind the cab,

sub-frame material Fe 510 D.

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Superstructures
L (m)

G (kN)

,
66

19

,5

4,

0
18

47

2)

4,

62

6
x 7
75 x
x 75
0
26 0 x
26

6
x 7
75 x
x 75
0 x
31 10
3

66

19

26

75

24

65

5
5
x 5
8,
65 5 x
x
x 6
5
x
6
6
x
5
x
29 6
3
24
+ 9
+
29
6 +2
7
+
x
7
x
5
75 x
8,
75
x 5
x
x
0 x7
5
1
0
7
3 10
x
31
3
0
Box profile
31

65

260x140x8
400

250x100x8

380
360

220x120x8

340
320

200x80x8

300

180x80x8

280

160x80x8

260

140x70x6
120x60x6
100x60x6
80x60x5

240
220
200
180
160

140

G
GxL (kNm)
1)

120
100

3)

80
60
40
G000304

1.
2.
3.

Wx

Vehicle loading cranes, see section 4.3.

Chassis dimensions, see section
2.10: "Chassis and cabine related
dimensions".
Superstructure with sub-frame, see
section 3.1: "Superstructure with subframe".

Graph B
Minimum sub-frame dimensions for:
-

crane at rear end of chassis,

sub-frame material Fe 510 D.

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Superstructures
L (m)

G (kN)

x6

,5

2
19

4,

0
18

47

2)

,5

x4

5
6,

19

62

6
x 7
75 x
x 75
0
26 0 x
26

6
x 7
75 x
x 75
0 x
31 10
3

66

60

75

24

65

5
5
x 5
8,
x
65 x
5
x 65
6
6 x
5
x
3
29 6
24
+ 9
+
29
6 +2
7
+
x 7
x
5
8,
75 x
75
x
x 75
x
5
0
0
7
x
x
31 10
31
0
3
31
Box profile

65

250x100x8
220x120x8
200x80x8
250

180x80x8

225

160x80x8
140x70x6
120x60x6
100x60x6
80x60x5

200
175
150

125
100

G
75

GxL (kNm)
1)

3)

50

G000303

1.
2.
3.

118

Wx

Vehicle loading cranes, see section 4.3.

Chassis dimensions, see section
2.10: "Chassis and cabine related
dimensions".
Superstructure with sub-frame, see
section 3.1: "Superstructure with subframe".

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Superstructures
Recovery vehicles and hydraulic platforms
The superstructure should always be attached to
the chassis with a sub-frame or a self-supporting
("pontoon-type") sub-frame construction. If the
latter type is used, it is generally not possible to
provide a rigid attachment because of the
unequal distribution of strength and stiffness
between the chassis and sub-frame and
consequently the location of the neutral line of the
assembly. If the vehicle chassis frame has to
contribute to the strength of the superstructure,
DAF should be contacted.
20061604-418

Recovery vehicle, BAM 4

20061604-419

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

BAM 1
Vehicles with front leaf / rear air-suspension
or full air-suspension
During crane operation; deflating the suspension
of the vehicle and than lifting the chassis using
the crane support legs can lead to damage to the
air bellows. Therefore the ECAS air-suspension
should be equipped with the function to deflate
the air-suspension to low residual pressure to
protect the air-bellows. For installation of this
function, please contact DAF Sales Engineering.
WARNING! Vehicle stability during
operation of any superstructure
system is the responsibility of the
bodybuilder and the user. The user
should at all times make sure that
vehicle stability is guaranteed. It is
therefore important that clear
instructions for use of the
superstructure should be provided
by the bodybuilder on or supplied
with the vehicle.
For more information see:
1.3: "Verificaton of superstructure"

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Superstructures
4.4 TIPPER BODIES
Attachment methods for tipper bodies
Tipper with front-end ram

Version 1

BAM 3a

Tipper with central ram

Version 2

BAM 3a

Three-way tipper

Version 3

BAM 4 or BAM3a

Tipping demountable body

Version 4

BAM 4

For the mounting of tipper bodies, the following

general guidelines always apply:
-

4
-

Tipper bodies should preferably be fitted to

chassis with 310 mm high side members.
Depending on the application, tipper bodies
may, however, be fitted to chassis with 192
or 260 mm high side members; however, in
such cases the sub-frame will have to be of
a heavier design than when a chassis with
310 mm high side members is used.
Vehicles with front leaf / rear airsuspension or full air-suspension. During
tipping or body swop for demountables, the
air suspension should be lowered to bumpstop. This option can be activated
automatically or manual, please contact DAF
Sales Engineering.
It is not permitted to mount tipper bodies on
the FAN LF55, FAR chassis (6x2 vehicles
with single wheels on the trailing axle) and
FAX / FAQ chassis (8x2 vehicles with single
wheels on the trailing axle), because these
vehicle types were not developed for this
application. If, for a certain application, a
tipper body must be used on such chassis,
consultation with DAF is required, on the one
hand for verification and on the other to be
certain that the conditions set can be met.

In the table you will find the sub-frame data for

various tipper versions and also the maximum
distance (B) from pivot point to rear axle.

A
G000300

Tipper with front-end ram

B
G000299

Tipper with central ram

A
G000298

Three-way tipper
4

B
G000297

Tipping demountable body

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Superstructures
Sub-frame dimensions
Data for tipper bodies and sub-frames
Vehicle
type

GVM
max.
[tonne]

WB
[m]

Chassis section
near rear axle
[mm]

Tipper
type

A
Max.
[mm]

B
Max.
[mm]

Wx,min (1)
[cm3]

FA LF45

7.5-12

3.65

192x66,5x4.5

1,-,-,-

1000

1050

(2)

-,2,3,4

1000

1050

41.0

1,-,-,-

1000

1200

(2)

-,2,3,4

1000

1200

41.0

1,-,-,-

1200

1050

61.0

-,2-3-4

1200

1050

86.0

1,2,3,4

1200

1050

26.5

1,2,-,-

1200

1300

41.0

1,2,3,4

1200

1050

61.0

1,2,-,-

1200

1300

86.0

310x75x7+
295x65x5

1,2,3,4

1200

1050

85.0

1,2,-,-,

1200

1300

115.0

310x75x7

1,2,3,4

1200

650

116.0

1,2,-,-

1200

800 (4)

150.0

310x75x7 +
295x65x5

1,2,3,4

1200

650

26.5

1,2,-,-

1200

310x75x7 +
295x65x5

1,2,3,4

1200

1,2,-,-

1200

310x75x8.5 +
292x65x8.5

1,2,3,4

1200

650

85.0

1,2,-,-

1200

800 (3)

115.0

310x75x7 +
295x65x5

1,2,3,4

1200

650

85.0

1,2,-,-

1200

310x75x8.5 +
292x65x8.5

1,2,3,4

1200

1,2,-,-

1200

310x75x7 +
295x65x5

1,2,3,4

1200

1,2,-,-

1200

310x75x8.5 +
292x65x8.5

1,2,3,4

1200

1,2,-,-

1200

310x75x8.5 +
292x65x8.5

1,2,3,4

1200

650

250

1200

800 (3)

285

FA LF55
FA CF65

13-18

4.45

19

FA CF65
FA CF75-85
FA XF

20.5

FA CF65
FA CF75-85
FA XF

20.5

FAG CF75-85

28

FAS CF75-85
FAS XF
FAN CF75-85

28

FAT CF75-85
FAT XF

28

FAT CF85
FAT XF

33

FAC CF85
FAC CF85

34

4.80
5.55
5.55

(6)

(6)

FAD CF85
FAD XF

34

FAD CF85
FAD XF

37 (6)

FAD CF85
FAD XF

(6)

FAK CF85 XF
FAQ CF85

35.5

4.90

4.20

37 (6)

44

4.90

5.90

28

FAS CF75-85
FAS XF
FAN CF75-85

4.30

(6)

5.70
6.20
6.40
6.40
6.40
5.30

260x75x6
260x75x6
310x75x7

260x75x7

310x75x7 +
295x65x5

1,2,-,1,2,3,4

1200

800

(4)

650
800

800

(3)

(3)

650
800

(3)

650
800

(3)

650
800

(3)

1000

(5)

41.0
85.0
115.0

115.0
85.0
115.0
85.0
115.0
85.0
115.0

160

(1) Minimum required moment of resistance of one sub-frame side member.

(2) A sub-frame is not required for chassis strength or because of deflection, but can be mounted, for instance, to obtain sufficient
wheel clearance.
(3) Rear axles airsuspension B Max. is 1000 mm.
(4) FAS rear axles airsuspension B Max. is 1000 mm.
(5) Rear axles airsuspension.
(6) Independent chassis support in the rear overhang is recommended for increased stability during tipping operation.

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BODYBUILDERS' GUIDELINES
Superstructures
Attachment of ram and tipping pivot
Both the front-end ram and the central ram
should be attached in the sub-frame. Allowance
should be made for the space required for
driveline movements. The tipping pivot at the rear
of the tipper body should be attached to the subframe.

96120404-424

Attachment of the front-end ram

20061604-425

Tipper with front-end ram

Attachment of guide plate
The sub-frame should be provided with guide
plates at the front end of the tipper body to
prevent lateral movement of the body. To prevent
torsion in the sub-frame, it is recommended to fit
a cross member in the sub-frame here, too.

96120404-426

Guide plate

20061604-427

Tipper with central ram

122

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BODYBUILDERS' GUIDELINES
Superstructures
Attachment of ball pivot (three-way tipper)
The tipper body pivot should be attached to the
sub-frame. Braces can be bolted into position
and, if they are attached to the sub-frame, they
will also serve as retainer plates.

96120404-428

Attachment of ball pivot

4
20061604-429

Three-way tipper
Attachment of the demounting system
Irrespective of the type of system, the
demounting system should be attached to the
sub-frame. If the sub-frame of the demounting
system is wider than the vehicle chassis frame,
consoles can be used to mount the demounting
system. The top of the consoles must be flush
with the top of the chassis frame. If DAF consoles
are used for this purpose, the locating edge at the
top of their rear wall should be removed. The
consoles can be welded to the sub-frame and
attached to the chassis with flange bolts; also see
section 3.2: "BAM's - body attachment methods".

96120404-430

Attachment of sub-frame with console

20061604-431

Tipping demountable body

Stability by torsional stiffeners
In all cases, torsional stiffeners should be fitted in
the sub-frame rear overhang; see: 'Stability by
torsional stiffening of the sub-frame' in section
3.1: "Superstructure with sub-frame". Stability
during tipping depends on a number of factors
and is positively influenced by:
-

greater rigidity in the chassis (rear overhang)

and body,
ram(s) positioned as far as possible to the
front (front-end ram),

201222

123

BODYBUILDERS' GUIDELINES
Superstructures
-

shortest possible rear overhang and

favourable position of tipping pivot,
Independent chassis support in the rear
overhang. This chassis support can be fitted
at the rearmost axle, however the axle load
must not exceed twice the maximum
technical axle load. Alternative the chassis
support can be fitted at the end off the
chassis and supporting on ground level.
tipping stabiliser (scissors construction)
between body and chassis,
skilled operation and firm level surface for
the vehicle to stand on.

Vehicle stability during operation of any

superstructure system is the responsibility of
the bodybuilder and the user. The user should
at all times make sure that vehicle stability is
guaranteed. It is therefore important that clear
instructions for use of the superstructure
should be provided by the bodybuilder on or
supplied with the vehicle.
For more information see: 1.3: "Verificaton of
superstructure"

4.5 TANKERS
General
For torsionally rigid (self-supporting) body
constructions, including tanker superstructures,
console attachment can be opted for. However,
at certain vehicle speeds and under certain
conditions, such an attachment may lead to
annoying bending vibrations in the frame, which
may have a highly adverse effect on the driving
comfort. It is therefore important not to exceed
the indicated maximum positions of attachment
points on the frame.
In chapter 3 is shown how many consoles per
vehicle type and chassis segment are required. In
the event that less consoles per segment are
used, these consoles must be lengthened to have
a longer contact surface with the longitudinal. The
chassis load by the tanker support must be in
relation with the console dimension and
attachment.
The console attachment introduces a local
vertical point load which results in local
stresslevel in the chassis. Therefore the chassis
longitudinal must be reinforced with an innerliner,
in case there is no innerliner reinforcement a
subframe must be mounted.
The centre of gravity of the tanker body must be
as low as possible, in order to decrease the risc
for vehicle overturning.

124

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BODYBUILDERS' GUIDELINES
Superstructures
On trucks with tanker superstructures which are
to transport liquid goods, the need for lengthways
and crossways baffles must be considered.
The bodybuilder is free to make a choice from
the undermentioned body attachments,
depending on which construction (according
to his own insights and experience) is most
suitable for the superstructure in question. In
all cases, the bodybuilder remains
responsible for ensuring that the tank
construction is sufficiently strong for the
selected attachment and/or mounting method
of the tanker body.
Tanker body with sub-frame
Body attachment method BAM 1 should be
used for a tanker body with sub-frame. Take care
that the load is evenly distributed over the subframe, by using sufficient tank brackets. Also see
the figure opposite.
A:
1000 (LF)
1400 (CF - XF)

20061604-432

Body with sub-frame

max.
A

max.
600
22032802-015

Positions of superstructure attachment points

Tanker body on consoles (with or without
onboard weighing system)
The console attachment introduces a local
vertical point load which results in local stress in
the chassis. Therefore the chassis longitudinal
must be reinforced with an innerliner, in case
there is no innerliner reinforcement a subframe
must be mounted. The console attachment might
also introduce lateral torsion to the chassis
longitudinal. To eliminate this lateral torsion a
cross member must be present. Check section
consoles in 3.2: "BAM's - body attachment
methods".

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125

BODYBUILDERS' GUIDELINES
Superstructures
Console attachment, fixed
Body attachment method BAM 5 is used for
this. Fixed attachment of the tanker
superstructure is particularly suitable for two-axle
vehicles. Spacer bushes with a length of at least
30 mm should be used (see section 3.4: "Type of
superstructure/BAM matrix").
A:
1000 (LF)
1400 (CF - XF)
20061604-434

Console attachment

4
max.
A

max. max.
1050 1050
22032802-014

Positions of consoles on two-axle vehicles

Console attachment, semi-flexible
Bodyattachment method BAM 5 is used for this.
Consoles with pressure springs are used at the
front. Spring pre-tension should be 3 kN per
spring. In relation with a vertical static console
load of 20 kN two pressure springs should be
used,the pre-tension of each spring should be 3
kN.The minimum spring rate per spring is 225 N/
mm. Fixed superstructure-to- consoleattachment is used at the rear. For this, use
spacer bushes with a length of at least 30 mm
(see section 3.4: "Type of superstructure/BAM
matrix").
96120404-436

Console with pressure springs

96120404-437

Console with fixed attachment

126

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BODYBUILDERS' GUIDELINES
Superstructures
Console attachment, all-flexible
Body attachment method BAM 5 is used for
this. Consoles with pressure springs are used at
both front and rear. At the rear, rubbers are
added. These rubbers must always rest directly
on the console and may never be placed on, for
example, spacers. The rubbers used must not be
compressed more than 1 mm under a static load.
The tank brackets on consoles with pressure
springs and rubber must have a provision for
fixation of the superstructure in the longitudinal
and transverse directions.
A:
1000 (LF)
1400 (CF - XF)

96120404-438

Console with springs and rubber

max.
A

max. max.
1050 1050
22032802-013

Position of consoles on multi-axle vehicles

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BODYBUILDERS' GUIDELINES
Superstructures
Console attachment, three-point
(two-axle vehicles)

Body attachment method BAM 5is used for this.

The front mounting point of the tank is a springloaded swinging unit. In relation with a vertical
static console load of 20 kN per side aspecified
spring tension can be seen from the graph. With
a given dimension 'a', representing the distance
between the console springs, the spring tension
should be 'P'.
The consoles placed in front of the rear axle have
pressure springs. Those placed behind the rear
axle have fixed attachment.
A:
1000 (LF)
1400 (CF - XF)

20061604-440

Three-point attachment on two-axle vehicles

max.
A

max. max.
1050 1050
22032802-014

Position of consoles
a

96120404-441

Oscillating unit

P N/mm
800
600
400
200
0

640
360
240
a mm
400 800
200 600 1000
96120404-442

Graph

128

201222

BODYBUILDERS' GUIDELINES
Superstructures
Console attachment, three-point
(multi-axle vehicles)
Body attachment method BAM 5 is used for
this. The front mounting point is a tank bracket
attached with rubbers and springs to a cross
member resting on consoles.
The spring force of the machine rubbers used
should be:
-

vertical: 6 + 0.5 kN/mm,

horizontal: 7 + 0.5 kN/mm.

20061604-443

Three-point attachment on multi-axle vehicles

The consoles placed in front of the rear axle

centre have pressure springs. Those placed
behind the rear axle have fixed attachment.
A:
1000 (LF)
1400 (CF - XF)
WARNING! Operation of any
superstructure system is the
responsibility of the bodybuilder and
the user. It is therefore important
that clear instructions for use of the
superstructure should be provided
by the bodybuilder on or supplied
with the vehicle.
For more information see:
1.3: "Verificaton of superstructure"

4
max.
A

max. max.
1050 1050
22032802-013

Positions of consoles on multi-axle vehicles

400 - 650 mm

96120404-444

Front mounting

96120404-445

Mounting of machine rubber

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BODYBUILDERS' GUIDELINES
Superstructures
4.6 CONCRETE MIXERS AND
CONCRETE PUMPS
A sub-frame should always be used for concrete
mixers, concrete pumps and combined concrete
mixer/pump superstructures. BAM 4 (fully rigid
attachment) should be used for the mounting of
this sub-frame.
Consult DAF for the selection of the sub-frame
section.
20061604-446

Concrete mixer superstructure

20061604-448

Combined concrete mixer/ concrete pump

superstructure

20061604-447

Concrete pump superstructure

Torsional stability
In all cases torsional stiffeners should be fitted in
the rear overhang of the vehicle, in accordance
with 'Torsional stability of the sub-frame' in
section 3.1: "Superstructure with sub-frame".
WARNING! Vehicle stability during
operation of any superstructure
system is the responsibility of the
bodybuilder and the user. The user
should at all times make sure that
vehicle stability is guaranteed. It is
therefore important that clear
instructions for use of the
superstructure should be provided
by the bodybuilder on or supplied
with the vehicle.
For more information see:
1.3: "Verificaton of superstructure"

130

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BODYBUILDERS' GUIDELINES
Superstructures
4.7 PUBLIC UTILITY VEHICLES
There is a wide range of public utility vehicles of
advanced designs, often regarded as a machine
rather than a piece of transport equipment. The
customary attachment methods for the most
common superstructures are given below. In
case of doubt and/or if you have any technical
questions about necessary vehicle adaptations,
you should contact DAF.
Refuse collector bodies with a compactor at the
rear cause extreme high local load (more than
7500 kg) on the rear overhang of the chassis
frame. To support this high load in lateral
direction and for torsion, the rear end of the
chassis frame must be reinforced with a torsional
cruciform type stiffening. See an example of the
torsional cruciform stiffening in paragraph
'stability by torsional stiffening of the sub frame' in
chapter 3.1: "Superstructure with sub-frame".

20061604-449

Refuse collector with sub-frame

NOTE: On special request, an

alternative preparation for the FAG
refuse collector chassis can be ordered
at DAF. This FAG frame, with short rear
overhang of 740, 920 or 1000 mm, has
a 310x75x7 mm frame with full chassis
inner reinforcement profile (295x75x5
mm) and is equipped with a heavy duty
cross member at the location of the rear
axle. For this alternative chassis is no
extra subframe or torsional stiffening
required.

G000517

Heavy duty cross member

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BODYBUILDERS' GUIDELINES
Superstructures
Refuse collector with sub-frame
Body attachment method BAM 1 is used for a
refuse collector superstructure with sub-frame.
Contact DAF if extremely torsionally rigid
constructions are used.
A:
1000 (LF)
1400 (CF - XF)

20061604-450

Console attachment

4
max.
A

max. max.
1050 1050
22032802-024

Positions of consoles
Refuse collector on consoles (with or without
onboard weighing system)
The console attachment (BAM5) introduces a
local vertical point load which results in local
stress in the chassis. Therefore the chassis
longitudinal must be reinforced with an innerliner
and on multi-axle vehicles with rear compacter
also a heavy duty cross member is required, in
case that there are no inner reinforcements a
subframe must be mounted. The console
attachment might also introduce lateral torsion to
the chassis longitudinal. To eliminate this lateral
torsion a cross member must be fitted, on the
spot of the console, if not present. Check section
consoles in 3.2: "BAM's - body attachment
methods".

132

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BODYBUILDERS' GUIDELINES
Superstructures
Body attachment method BAM 5 is used for
this. In relation with a vertical static console load
of 20 kN two pressure springs should be used,
the pre-tension of each spring should be 3 kN.
The minimum spring rate per spring is 225 N/mm.
Consoles with pressure springs are used at the
front. Spring pre-tension should be 3 kN per
spring. Fixed superstructure-to-consoleattachment is used at the rear. For this, use
spacer bushes with a length of at least 30 mm
(see section 3.4: "Type of superstructure/BAM
matrix").

96120404-452

Console with pressure springs

4
96120404-453

Console with fixed attachment

Refuse collector with rotating drum
Always use a sub-frame and sufficient
attachment plates to mount the superstructure to
the chassis, in accordance with body
attachment method BAM 4.

20061604-455

Refuse collector with rotating drum

Road sweeper
The superstructure should always be fitted with a
sub-frame and in accordance with body
attachment method BAM 1. However, use BAM
3a for a tipping road sweeper superstructure. See
section 4.4: "Tipper bodies" for the required subframe dimensions.

20061604-454

Road sweeper with sub-frame

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133

BODYBUILDERS' GUIDELINES
Superstructures
(Tipping) gully emptier
The superstructure should always be fitted with a
sub-frame and in accordance with body
attachment method BAM 1. Use BAM 3afor
tipping superstructure. See section 4.4: "Tipper
bodies" for the required sub-frame dimensions.
Torsional stiffening must be provided in the
chassis rear overhang (in accordance with:
'Torsional stability of the sub-frame' in section
3.1: "Superstructure with sub-frame".
WARNING! Vehicle stability during
operation of any superstructure
system is the responsibility of the
bodybuilder and the user. The user
should at all times make sure that
vehicle stability is guaranteed. It is
therefore important that clear
instructions for use of the
superstructure should be provided
by the bodybuilder on or supplied
with the vehicle.
For more information see:
1.3: "Verificaton of superstructure"

20061604-456

(Tipping) gully emptier

B
G000296

Position of tipper pivot point

4.8 FRONT MOUNTED EQUIPMENT

The front mounting equipment is commonly fitted
to a mounting plate according DIN 76060. The
vehicle front mounting area has two attachment
points on each chassis side member. The
attachment points at the chassis are:
-

Upper part mounted to the towing lugs (one

on each side).
Lower part mounted to two areas on the
FUP (Front Underrun Protection) beam
frontal surface.

For the upper part; LF and CF65 series, it is

advice to make the fixation with the towing eyes,
there must be no play due to the attachment pins.
CF75-85 and XF, It is advice to take the diameter
dimensions of the fixation pen towing lug, as
supplied in the toolbox, to ensure a rigid and
close tolerance fit. For the lower part of the front
mounting construction, the reinforced sections on
the FUP beam must be used. These are the grey
marked areas (see illustration) directly in front of
the left and right hand leaf spring (or air
suspension) hanger bracket. Welding brackets or
studs onto the FUP is not allowed. Due to pulling
forces (i.e. towing) the fixation brackets should
preferably (partly) enclose the FUP beam at the
appointed fixation points.

134

G001192

Example of installation of front mounting

equipment.

201222

BODYBUILDERS' GUIDELINES
Superstructures
The maximum load and distance allowed for a
construction suspended as illustrated in the
image are:

G
G001266

Vehicle series

Maximum load [kN]

LF 45

Maximum distance [mm]

1200

LF 55 15 tonnes

7.5

1200

LF55 and CF65 18/19 tonnes

11.5

1200

15

1200

CF75 - 85 and XF
Snow plough equipment must be equipped with a
feature to reduce the transmission of shock
loadings in to the vehicle frame from striking
obstructions (sprung blades).
NOTE: The front mounting equipment
must comply with regulation ECE R61
and/or directive EC 92/114 external
protection of cabs. For equipment
supporting DIN brackets that have an
integrated towing lug construction the
maximum permitted weight of a towed
vehicle (including load) is 40 tons.
Towing may not take place at an angle
larger than 20 with the vehicle centre
line.
NOTE: All information applies to CF 75
- 85 and XF series produced from
respectively 2009 wk 49 and 2009 wk
21 onwards. Chassis produced before
these dates require a reinforced
support at the front (replacing the
standard) and an extra at the rear of the
FUP beam reaching towards the
chassis main longitudinal. Contact DAF
if in doubt.

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BODYBUILDERS' GUIDELINES
Superstructures
WARNING! Operation of any
superstructure system is the
responsibility of the bodybuilder and
the user. It is therefore important
that clear instructions for use of the
superstructure should be provided
by the bodybuilder on or supplied
with the vehicle.
For more information see:
1.3: "Verificaton of superstructure"

4.9 TRACTORS

DAF offers a wide range of tractor models, see

chapter 1.9: "DAF vehicle range" for more detail.
These tractor models are specifically designed to
cope with the characteristics, load conditions,
brake forces and road holding performance
related to pulling a semi-trailer. Therefore, only
the dedicated production released tractors are
allowed for this application. A truck chassis
modification into a tractor chassis is only
permitted with a Letter Of No Objection issued by
DAF Trucks.
WARNING! Tractor chassis used in a
tractor/truck application (e.g. car
transporter chassis) are not allowed
in combination with a Vehicle
Stability Control system.
Fifth wheel
DAF tractor chassis are provided with angle
sections for simple fifth wheel mounting. For
optimum utilisation of tractor/semi-trailer
combinations, it is highly important that the
technical specifications of tractor chassis and
semi-trailer should be carefully matched. Only
then will it be possible to determine the correct
position of the fifth wheel (KA dimension) and the
correct fifth wheel mounting height (HK
dimension).
To ensure quality and durability of the entire
construction, only fifth wheels and base
plates released by DAF must be mounted.
Mounting height and freedom of movement
Because of the required freedom of movement
for the semi-trailer, the fifth wheel mounting
height is determined by a number of factors:
-

A semi-trailer coupled to a tractor should, in

the straight-ahead position, have enough
freedom of movement to move 6 forwards,
7 backwards and 3 to each side (taken
from ISO standard R 1726).

136

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BODYBUILDERS' GUIDELINES
Superstructures
-

When turning, the front corners of the semitrailer must not touch the rear wall of the cab.
Swing clearance should be at least 200 mm.
This minimum clearance is highly dependent
on components on the rear wall of the cab,
such as the air intake system, the exhaust
and accessories that have been fitted. To
meet the minimum requirement, it may be
necessary to relocate the bracket for lighting
and air connections.
During manoeuvring, the semi-trailer must
not touch any parts of the tractor chassis,
such as mudguards, brackets or lamps. The
minimum fifth wheel mounting height above
the chassis is also determined by the height
of the tyres above the chassis with the
springs bottoming (metal on metal). In the
case of FTS, FTP and FTG tractors, the
wheel clearance of the lifted rear steered
axle or second axle should also be taken into
account. Also see section 2.14: "Wheel
clearance".
On high-volume semi-trailers used in
combination with low-fifth wheel tractor
chassis, there should always be a clearance
of at least 160 mm between the top of the
chassis side members and the underside of
the semi-trailer to allow manoeuvring at
loading bays, etc. If 3-piece rear mudguards
are fitted, it may be necessary to remove the
central sections when coupling up the semitrailer.

For further references concerning the

freedom of movement for the semi-trailer,
also see ISO standard R 1726: 1989 E.

7
3

6
G000305

Required freedom of movement

D value of fifth wheel
The D value is defined as the theoretical
reference value for the horizontal force between,
in this case, the tractor and the semi-trailer and is
therefore taken as a basis for the maximum load
under dynamic conditions. The formula below
(from directive EC 94/20) can be used to
determine the minimum D value required for the
fifth wheel.

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137

BODYBUILDERS' GUIDELINES
Superstructures
where:
GA = Maximum permitted mass
of the semi-trailor.
GT = Maximum permitted mass
of the tractor.
F
= Maximum permitted vertical mass on the fifth wheel.
D = D value on the fifth wheel.
g
= Gravitational acceleration.

(tonnes)

D= g x

0, 6 GT x G A [kN]
GT + G A - F
SE0004

(tonnes)
(tonnes)
(kN)
( 10 m/s2)

Fifth wheel and base plate

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

4
-

For the mounting of the fifth wheel, only use

a fifth wheel base plate released by DAF,
which has been tested as a part of the
vehicle and is mentioned as such in the
vehicle certificate. Various separate base
plates are also available from DAF. See
section 13.13: "Miscellaneous parts" for the
availble DAF part numbers'.
The pre-drilled base plates should be fitted to
the angle sections on the chassis, using at
least 12*bolts. Only the use of M16x2 flange
bolts(property class 10.9) fastened
according torque class A is permitted. The
bolt heads should point downwards to
enable visual inspection. The holes in the
pre-drilled angle sections have a pitch of 50
mm. Turning the DAF base plate through
180 (see section 13.13: "Miscellaneous
parts" for the availble DAF part numbers),
gives fifth wheel position adjustment steps of
25 mm. As a result, simple adjustment of the
fifth wheel position (within the maximum and
minimum KA dimension) is possible, within
the limits of the maximum permitted axle and
or chassis loads.
* To a maximum fifth wheel load of 20
tonnes. For the 12 mm base plate the
use of 8 bolts is sufficient up to a
maximum fifth wheel load of 15 tonnes.

MAX.305

MIN. 1

MAX.45
G000292

Mounting of the base plate

The maximum permissible mounting height

of fifth wheel and base plate is H = 305 mm
To prevent the bolts working loose, two
attachment bolts should be used at each of
the four corners of the base plate. If base
plates are used on which only one
attachment bolt can be fitted at each corner,
40 mm spacer bushes (combined with longer
flange bolts) must be fitted under the bolt
heads.
The maximum distance between the outside
of the chassis frame and the attachment
bolts in the (non-pre-drilled) angle sections is
45 mm

138

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BODYBUILDERS' GUIDELINES
Superstructures
-

The minimum clearance between underside

of the base plate and the top of chassis side
member flanges is always 1 mm.
Preferably use two-piece base plates for
applications involving frequent manoeuvring
and off-the-road operation.
The DAF base plates with a height of 80 and
120 mm are therefore two-piece plates as
standard.
The fifth wheel should be fitted in
accordance with the supplier's instructions.

For the tightening torques of DAF flange

bolts, see the table in section
2.6: "Attachment of components to the
chassis".

Catwalk
If a catwalk is fitted, it must be attached to the
chassis frame with rubber mounts. Make sure
that sufficient clearance is left for the semi-trailer
under all circumstances.
WARNING! Operation of any pump
or superstructure system is the
responsibility of the bodybuilder and
the user. It is therefore important
that clear instructions for use of the
superstructure should be provided
by the bodybuilder on or supplied
with the vehicle.
For more information see:
1.3: "Verificaton of superstructure"

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Mounting of catwalk

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BODYBUILDERS' GUIDELINES
Superstructures

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