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Sisu Truck Body Builder Manual.Pdf

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Sisu Truck Body Builder Manual.Pdf Cover Record 2 Contents Cover..........................................................1 Record ............................................................................2 Regulations relating to the bodyworks of vehicles .............15 Machinery Directive (EC countries) ................................................15 Regulations given by the authorities ...............................................15 1 Truck, bodywork, machine ...............................................17 2 Bodywork categorization.................................................17 2.1 Bodyworks, group 1:..........................................17 2.1.1 Group 1 includes ................................................17 2.2 Bodyworks, group 2 ..........................................18 2.2.1 According to the Machinery Directive 98/37/EC ...........................18 2.2.2 Group 2 bodyworks ..............................................18 2.3 Vehicle/machinery ...........................................19 3 Regulations, Group 1 ...................................................20 3.1 Masses and main dimensions of vehicles and vehicle combinations in international traffic (EC countries).................................21 3.1.1 Trailer axle weight table, EU countries .................................22 3.1.2 Maximum laden masses of vehicles in the EU ............................23 3.1.3 Maximum laden masses of trailers in the EU .............................23 3.1.4 Maximum laden masses of combination vehicles in the EU ...................24 3.1.5 Vehicle, trailer and combination vehicle lengths in the EU ....................25 3.1.6 Maximum width and height of vehicles and trailers in the EU ..................25 3.1.7 Maneuverability in the EU ..........................................25 3.2 Other regulations relating to the structures and operation of vehicles.........26 3.3 Brake adapting .............................................26 3.4 Licenced mounting and repair ...................................26 3.4.1 Licencing for modifications and repairs.................................27 3.5 Bodyworks ................................................27 4 Regulations, Group 2 ...................................................28 4.1 General ..................................................28 4.1.1 Responsibility ..................................................28 4.1.2 Conformity ....................................................28 4.2 Certifying the conformity .......................................29 4.2.1 Procedure based on the declaration by the manufacturer of the machinery ........30 4.2.2 EC type-examination procedure .....................................30 4.2.3 Declaration of conformity ..........................................30 4.2.3.1 Declaration A. ...............................................31 4.2.3.2 Declaration B. ...............................................32 4.2.3.3 Declaration C. ...............................................32 4.2.4 Other certificates................................................32 5 CE marking .............................................................33 5.1 General ..................................................33 5.2 CEmark..................................................33 5.3 Examples of the declaration of conformity and CE marking................34 6 Instructions, indications and technical documentation .....................38 7 Notified body ............................................................39 Contents 3 8 Acquiring the regulations .................................................39 9 General safety instructions ...............................................41 9.1 Dangers ..................................................41 9.1.1 Falling .......................................................42 9.1.2 Rolling over ..................................................42 9.1.3 Electric shock ..................................................42 9.1.4 Pneumatics ...................................................43 9.1.5 Hydraulics ....................................................43 9.1.6 Coolant ......................................................43 9.1.7 Refrigerant....................................................44 9.2 Unintentional starting/moving of the vehicle..........................44 General bodywork constructioning guidelines ................45 Notes on bodywork construction: ...............................................46 1 Forces acting on vehicles ................................................47 1.1 Examining the forces .........................................47 1.1.1 Static forces ...................................................47 1.1.2 Dynamic forces.................................................47 1.1.3 Lateral forces ..................................................48 1.1.4 Torsionalforces.................................................48 1.1.5 Stress acting on the frame beams ....................................48 2 Sisu frame beams .......................................................49 2.1 Sisu S-series frame material ....................................50 2.2 Sisu E-series frame material ....................................50 2.2.1 Heat treatment .................................................50 3 Strengthening the vehicle’s frame ........................................50 3.1 General ..................................................50 3.1.1 Diagonal support................................................50 3.1.2 Other strengthening..............................................50 4 Subframe ...............................................................51 4.1 General ..................................................51 4.1.1 Subframe function...............................................51 4.2 Material ..................................................51 4.3 Subframe construction and dimensioning ...........................52 4.3.1 General ......................................................52 4.3.2 Subframe general requirements .....................................52 4.3.3 Subframe material section .........................................53 4.3.4 Subframe bending resistance .......................................54 4.3.5 Subframe plate bracings ..........................................55 4.3.6 Subframe truss bracing ...........................................56 4.3.7 Notes for mounting ..............................................57 4.4 Subframe mounting brackets....................................58 4.4.1 Mounting bracket material .........................................58 4.4.2 Flexible mounting brackets .........................................58 4.4.3 Rigid mounting bracket ...........................................58 4.4.4 Dimensioning the mounting brackets ..................................59 4.4.5 Mounting bracket location..........................................60 4.5 Bolted joints................................................61 4.5.1 General ......................................................61 4.5.2 Bolted-joint dimensioning, tightening ..................................61 4.5.3 Frame holes ...................................................62 4 Contents 4.5.4 Drilling holes...................................................63 Record...........................................................................64 Flexible bodywork ............................................65 1 Tipping platforms ........................................................67 1.1 General .................................................67 1.1.1 Tipping stability .................................................67 1.2 General construction principles ..................................68 1.2.1 Tipping support .................................................69 1.2.2 Tipping-gear mounting ............................................69 1.2.3 Tipping stability test ..............................................70 1.3 Construction ...............................................70 1.3.1 Hydraulics ....................................................70 1.3.2 Tipping gear control device .........................................70 1.3.3 Tipping cylinder/tipping gear ........................................70 1.3.4 Mounting the tipping gear on a vehicle with a high frame .....................71 1.3.5 Warnings .....................................................71 1.3.6 Platform supports ...............................................72 1.3.7 Tipping-platform side guides........................................73 1.3.8 Tipping-platform service support .....................................73 1.4 Tipping-platform subframe ....................................74 1.4.1 Subframe bending resistance .......................................75 1.4.2 Truss bracing ..................................................76 1.4.3 Subframe mounting..............................................76 1.4.4 Rearmost plate bracket in vehicles with a lift bogie .........................77 1.4.5 Closing the rear of the frame ........................................77 1.5 Chassis frame rear overhang....................................78 1.6 Tipping platforms in trucks with high frames ..........................78 1.6.1 General ......................................................78 1.6.2 Tipping-axle mounting ............................................78 1.6.3 Frame truss bracing..............................................79 2 Fixed platform or van body ...............................................80 2.1 General ..................................................80 2.2
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