Homemade manipulator for a gazelle drawings. Installation instructions for crane manipulator installations (CMU). Before installation of CMU

A crane-manipulator is a power plant mounted on movable platforms. It lifts and carries heavy loads in a short amount of time. You can make such equipment yourself and install a homemade crane in the back of a truck.

Popular Models

Loader cranes are produced in:

  • Japan.
  • China.
  • Russia.
  • Germany.
  • Italy.
  • Korea.

You can choose the model of the power plant from the following trademarks leading world manufacturers:

  • Atlas;
  • Amco Veba;
  • Effer;
  • Hiab;
  • Ferrari;
  • Fassi;
  • Palfinger epsilon;
  • Unique;
  • isuzu;
  • Foton;
  • XCMG;
  • Atlant;
  • BAKM;
  • Velmash.


Foton installations have a load capacity of 6 tons, and their length is more than 6 m. Foton Olli transports goods and is useful in construction work.

Crane installation Isuzu QL 1100 TMA is one of the novelties Japanese company. Load capacity - 5.5 tons, length about 6 m.

The Hiab 600EP5HiPro loader crane lifts loads up to 16 tons. It can be used to move large and oversized cargo. Equipped with remote control remote control. This device able to lift loads that are located near its wheels.

Mini-crane moves cargo weighing up to 3 tons. Popular models:

  • SOROKIN 8.10.
  • AE&T 1t T62201.
  • AE&T 1t T62101.
  • SOROKIN 8.6.
  • SOROKIN8.2.
  • SOROKIN 8.22.
  • SOROKIN 8.3.


A suitable crane installation on a Gazelle should lift a weight of 800 kg. These are the models:

  • RM 3622 CE, manufacturer - Italy, mounted behind the cab;
  • Unik URA - 100, manufacturer - Japan, mounted inside the onboard platform.

Gazelle with CMU is suitable for transportation of bulky and light cargo, as well as for loading and unloading.

How to make and install yourself

You can carry out the installation of a truck crane yourself. It is installed on the vehicle. To do this, you need to remove the body from the chassis in order to change the subframe, because. factory construction is weak and may crack. The subframe must be made by hand because it is forbidden to attach the crane installation directly to the frame.


It can be welded from outer (18 mm) and inner channels. The planks are bent so that they follow the shape of the frame. The smaller rail is inserted into the larger channel to form a rectangle. Finished channels are attached to the welded frame. A fire hose is laid between them and the base to level the plane of the planks and frame.

A crane is mounted on a subframe, which includes:

  • beam;
  • arrow;
  • support posts;
  • special ladders.

With the help of special ladders, the installation is fixed. It is necessary to put spacers into the ladders, which can be made like this.

Sometimes do-it-yourself hydraulic manipulator installation viewed by customers as saving money. But this is not always justified.
should be carried out in accordance with technical regulations Customs Union"On the safety of wheeled vehicles"

Before installation of the CMU.

  1. Filling out and registration of an application to the traffic police for the conversion of a car.

IMPORTANT! INSTALLATION OF CMU IS ALLOWED TO BE PERFORMED ONLY BY ORGANIZATIONS HAVING A CERTIFICATE OF CONFORMITY CONFIRMING THE RIGHT TO CARRY OUT SUCH WORKS.

Otherwise, it is necessary to pass the certification of the tool, workplace, technologies in the body authorized to issue conclusions on changes to the design vehicle.

Attention. All actions to make changes to the design of the vehicle (installation of the CMU) are allowed to be carried out only by the owner of the car! Those. the car must be registered, and the owner must indicate the person who wants to make changes (in this case, the installation of the CMU). Accordingly, the crane installation must have a cargo customs declaration(original GTD with blue seals) i.e. cleared by customs, and it is necessary to have a contract of sale for the owner of the car.

Body dismantling.

As a rule, this stage does not cause difficulties, however, it is necessary to foresee the costs of new ladders in advance, because in most cases, due to the corrosion process, they are not unscrewed and they are simply cut off. It is also necessary to have technological supports under the body (4 racks under the body with a height of approximately 800 mm) for installing the body after installation in order to avoid deformation of the wings on the body or the latter must be dismantled in advance. As lifting mechanism usually a crane manipulator with a capacity of up to 3 tons is ordered or any other is used (crane, beam crane, hoist, etc.)

  1. Pump selection. Pump installation. Installation of PTO (power take-off box).

Pump selection stage. The pump can be of any production (domestic, imported), as well as any design (gear, axial piston, rotary piston, etc.). Attention! The pump is not tied to a specific brand or model of a crane-manipulator installation (for example: KMU TADANO, UNIK) and can be absolutely anything. The manufacturer cannot know in advance the purpose of the crane installation. For example: CMU CAN BE USED AS STATIONARY AND DRIVE FROM ELECTRIC PUMP STATION . The pump must comply with the requirements of the CMU hydraulic system and be mounted on the PTO of the corresponding vehicle. . For any hydraulic equipment (in our case, a crane installation), the pump is selected based on the required pressure (indicated in atm, bar or MPa), as well as the required equipment capacity. All data are indicated in the technical documentation for the equipment (KMU) or you can navigate according to the data on the nameplate of the main equipment distributor. As a rule, on all crane installations, the pressure range is from 180 to 220 atm, but there may be exceptions. Consequently, the installation of domestic pumps of the NSh series is fundamentally wrong, since these pumps (the NSh pump of the 3rd series with the type designation NSh 32-3L) are designed for operating pressure no more than 160 atm!!! It will work at the limit, and will not provide the necessary speed and load characteristics of the crane installation. The load capacity in the CMU hydraulic system directly depends on the pressure. Further. In terms of performance, the pump is selected based on the volume of the hydraulic components of the system (in the absence of data from the CMU manufacturer). The speed of the actuators depends on the performance of the pumps. Here, when calculating the final performance of the pump, it is necessary to take into account the volume of the pump (cm 3) and engine speed. Remember, the operating speed of diesel engines and gasoline engines is different.

Important! Observe the direction of rotation of the pump depending on the direction of rotation of the PTO output shaft!

Pump installation, KOM.

It is necessary to drain the oil from the gearbox (then do not forget to fill the oil back), dismantle the technological plug under the PTO at the gearbox, mount the power take-off (PTO), do not forget about the PTO and gearbox seal (the same between the pump and the PTO), install directly pump or cardan, depending on the version of the PTO. It is more convenient to screw the pressure fitting and the fitting under the suction hose onto the pump in advance, do not forget about the seals. When mounting the pump through a universal joint, when choosing a pump, pay attention to the design of the pump output shaft bearing. In case the pump is to be installed through the universal joint without additional support with bearing, the installation of a pump with bronze bushings should be discarded.

Note. When choosing a PTO, pay attention to the method of inclusion. PTOs are produced with pneumoelectric and mechanical actuation. In the first case, it is necessary to connect the PEM with the pneumatic system of the machine, as well as install the electromagnetic valve (PEM) and connect it through the PEM control button in the cab. In the second case, a hole is drilled in the floor of the cab of the car and a PTO control cable is inserted into the cab through it.

At this stage of installation, it is necessary to transfer air receivers, fuel tanks, tool boxes, batteries (if necessary). In the event that the CMU has folding legs (in the transport position, the legs are installed vertically upwards and retract), nothing needs to be transferred. This version of the execution is usually present on the CMU of European production.

  1. Fitting CMU on the frame.

At this stage, it is necessary to “throw” the CMU onto the frame, mark the places of reinforcement on the frame, calculate the design of the subframe, provide for technological distances between the CMU base and the cabin, the CMU and the body. Calculate the height of the subframe under the base of the CMU (take into account the height of the cabin to ensure free rotation of the CMU around its axis), take into account the extreme top point the height of the entire installation, in order to avoid traffic violations.

  1. Subframe manufacturing. Reinforcement of the frame at the attachment points of the CMU. Frame extension. Body shortening. Transfer of the rear fenders on the body.

Subframe manufacturing.

Today, there are 2 main options for manufacturing a subframe, namely: making a short subframe directly under the base of the CMU and making a single long subframe under the base of the CMU and the body. There is also the option of reinforcing the car frame itself with a bent profile. The purpose for all is the same - to evenly distribute the load of the weight of the CMU on the frame of the machine, as well as to exclude frame deformation (torsion) during the lifting operations of the CMU. None of these methods guarantee the absolute safety of the frame. All have their own merits and demerits. The main rule is not to overload the car during operation, observe the speed limit (the quieter the better), try to move along smooth roads and stretch the CMU fastening studs in a timely manner, monitor the condition of the frame.

Frame reinforcement. In the places where the CMU base is attached under the mounting studs, it is possible to reinforce the frame to prevent frame breakage.

Recently, quite often cargo onboard vehicles have been equipped with crane installations. This is due to the great competition in the service sector, in the provision of which cranes are used. For this reason, the owners of such cars want to get special equipment, which today is quite in demand due to its widespread use in construction. Moreover, thanks to a large number offers on the Russian market, you can purchase various booms for loader cranes manufactured by South Korean and Japanese manufacturers. Manipulator installations can have different carrying capacity (from 1 to 10 tons).

Today, services for the installation of such a device as a crane-manipulator (CMU) on the chassis of trucks are offered by many private companies. The cost of such a service can be from 60 to 100 thousand rubles. When determining it, the load capacity of the crane installation and the type of vehicle chassis are taken into account. This work may take 3 to 4 weeks to complete. However, in the case self installation crane-manipulator freight car can do without least cost due to the possibility of saving money and time.

Work order

1. First you need to move the body and put the subframe. Moving the body back frees up space behind the cab, on which the crane itself will then be installed. Prior to this, it is necessary to remove the body from the chassis, because. subframe needs to be replaced. The use of a standard subframe is not possible due to its insufficient strength and unsuitable length, since it must exceed the length of the structure. To prevent cracks from forming in the frame, it is strictly forbidden to attach the manipulator directly to it!

For welding the subframe, two separate channels are used, the size of which is inside is 0.16 cm, and from the outside - 0.18 cm. Before welding, the channels are bent as accurately as possible along the entire plane of the frame. A smaller channel is inserted into the large channel. This is done in such a way that a rectangle is formed, which is then boiled around the entire perimeter.

2. At the installation site of the boom, the welding seam must be made continuous, since the movement of the manipulator will be carried out together with the crane, which has a large dead weight

3. It is better to adjust the length of the subframe after attaching the body to it.

Installation of CMU

After welding, the channels are attached to the frame. To obtain a solid subframe for connecting channels, it is necessary to use a small cut and, using welding machine, perform a seam. Fastening the trim to the frame cross member must be carried out taking into account the possibility of attaching the channel with a bolt to the cross member.

At the end of welding, a CMU is installed on the finished subframe behind the vehicle cab. Usually, ladders are used with the boom to attach the crane to the frame. A self-made spacer must be inserted into the stepladder. After carrying out these works, a rectangle is formed from a conventional channel that is resistant to heavy loads. It is necessary to tighten the ladders with great effort. In the process of work, they need to be periodically tightened.

Types of arrows and features of their fastening

Depending on the type CMU can be:

  • a device equipped with a straight telescopic boom. Such a unit can have 7 separate sections. Its installation is carried out on a rotary column, which is additionally equipped with a suspension, which includes a cable with a hook. Separate sections of this type of boom are extended as a result of the hydraulic cylinders;
  • installation where the boom is hinged. The equipment of such a crane includes an articulated boom mounted on a base that rotates. Most often, the second link is of the telescopic type and can include no more than 10 sections.

What safety measures must be observed when performing work on the installation of CMU?

To prevent the crane from moving relative to the plane of the frame, corners of 40 or 50 mm in size must be welded to the subframe at the back and front, ensuring a firm fixation of the installation. At the time of attaching the body to the subframe, a gap of about 200 mm should be left between the body and the CMU. With the help of bolts to the subframe, the cross members of the body are fastened. After that, a hydraulic pump must be connected for the operation of the manipulator.

Installing a crane on a truck is enough hard work requiring great responsibility. Therefore, if it is impossible to do it yourself, it is better to use ready-made crane services offered by our company. In this case, it will be guaranteed professional performance work, which will avoid problems such as repairing the frame as a result of the formation of a crack in it.

With the advent of competition from the crane manipulators mounted on the chassis of a truck, popularly referred to as "I LOAD - I DRIVE ITSELF", many owners of flatbed trucks began to think about installing a crane installation (the so-called boom or CMU) on their car, so that as a result get the most demanded special equipment. Currently on Russian market many offers for the sale of such arrows with a lifting capacity of 1 to 10 tons made in Japan and South Korea. In our article, we will not touch on the issue of choosing a CMU, but consider its installation on the frame of a flatbed truck. Many firms offer to do this job. The price for such a service as of today 03/27/2012 in the city of Kazan is from 60 to 100 thousand rubles, depending on the load capacity of the boom and the selected chassis. Order execution time - 3 - 4 weeks. I suggest you save your time and money and tell you how you can install a crane manipulator on your truck chassis on your own.

As a car, we will choose the most common KAMAZ truck in the Russian Federation. We will install on it the KANGLIM KS1256G-II manipulator (with a maximum load capacity of 6.5 tons and an outreach of 19 meters) manufactured in South Korea. Installation weight 3.5 tons.

The basis for attaching the unit to the frame is the subframe, which we will produce! Mounting the manipulator directly to the frame is strictly prohibited, as the frame immediately cracks!

First stage. It is necessary to move the car body back to appear free space behind the cab, necessary for mounting the CMU. It is better to completely remove the body from the chassis, as you will have to change the subframe. This replacement is due to two needs:

  1. it is too weak - made of a thin metal square;
  2. we will mount a crane installation on it, so its length should be longer.

The need to install the boom on a common subframe (bodies and installations) is due to the fact that its work zone this is the body of the car and the space on the sides of the truck behind the cab. In other words, the center of gravity of the CMU with the load will be closer to the center of the frame, and if the subframe for the crane installation is separated from the subframe of the body, then the frame at the end of the boom subframe may bend. That is, the area of ​​pressure of the manipulator on the frame with the disconnected subframes will be several times less than with the combined ones.

We weld the subframe from two 18 mm channels. (outer) and 16 mm. (interior). It is visible in the figure

Before welding, it is necessary to bend the channel so that they repeat the plane of the frame, since the latter is not straight, it expands at the attachment point of the gearbox, above which the manipulator will be located. We insert the smaller channel into the larger one so that we get a rectangle, and boil in small segments along the entire length. The weld at the installation site of the boom must be continuous (not interrupted), since the automanipulator will always move with a CMU, which has a decent mass. The length of the subframe can be cut off immediately (70-90 cm under the boom + body length), but it is better to do this after attaching the body (this will allow you to adjust its location). I propose not to shorten the body, because the larger it is, the more different types goods can be transported. It's just that the body will move back 70-90 cm relative to the old position, and it will not break, since we are making a strong subframe. It is important that the total length of the road train does not exceed 12 meters!

Second phase. We fasten the welded channels to the frame with the help of ladders, while placing a fire hose between the channels and the frame. This can be seen in the following figure.

The figure already shows the attached body. But this will happen only at the last stage.

A fire hose is needed to level the planes of the frame and channel, as they are not perfectly even. The applied ladders are standard, which are used by the Kama plant for attaching the body to the frame. In order for the subframe to turn out to be solid, we connect the welded channels with a cut of the channel using a welded seam. We weld the cut of the channel over the frame cross member in such a way that this channel is then screwed to the cross member with a bolted connection. Since after the checkpoint there are at least two crossbars in the back of the truck, we also make at least two of the connections described above. The more such connections, the stronger the subframe will be attached to the frame.

Third stage. We install the manipulator on the subframe behind the cab. Included with the boom are special ladders, with which we attach the installation to the frame through the subframe. It is important to put a special spacer into the ladder. She is shown in the photo.

How to make it? We take a piece of pipe with an inner diameter slightly larger than the diameter of the ladder. We make the length of the pipe about half the height of the frame. We cut off a piece of a thick plate (thickness 7-10 mm.) In the form of a rectangle, the smaller side of which is about 8-9 cm, and the larger one so that it fits tightly inside the frame in height. The cut pipe is welded to the plate in the center. If the described spacer is not installed, then the manipulator step-ladder, when tightened, will bend the horizontal planes of the frame and the frame will weaken. As a result, we get a rectangle in cross section, and not a U-shaped channel, which is much stronger. Then we tighten the ladders with great effort, which, after some time after the operation of the truck, must be tightened.

Fourth stage. To exclude the movement of the CMU along the frame, we weld corners (“four” or “five”) to the subframe in front and behind the manipulator perpendicular to the frame. it additional measure fixation.

Fifth stage. We mount the body to the subframe, leaving a gap of 15-20 cm between crane installation and the beginning of the body. We fasten the cross members of the body bolted connections to the subframe, in the same way as it was previously attached by the manufacturer.

This completes our installation and it remains only to connect the hydraulic pump, due to which all the work of the crane of the manipulator takes place. We will consider this issue in the next article.

on a gazelle very often they work with overload. they carry 3 tons each, and the most courageous and 4 tons each. Of course, it’s better not to drive past traffic police posts like that. Below is an article with a couple of examples. installation of a manipulator on a gazelle with a rough calculation of the carrying capacity.

A gazelle with a manipulator is the most economical option crane-manipulator. The maneuverability of the Gazelle (GAZ-3302) is a significant advantage when working in tight urban environments. Another plus of the Gazelle is the availability of maintenance and inexpensive spare parts; any car service will be happy to take on the repair and maintenance of such a car. The crane-manipulator installation is able to simplify loading and unloading operations on an onboard vehicle. GAZ-3302 with a manipulator is suitable for transporting small loads.

Carrying capacity of the Gazelle with the manipulator.

Low load capacity is the main drawback of installing a manipulator on a Gazelle (GAZ-3302). When mounting the CMU on the Gazelle, it should be understood that after installing the manipulator, the carrying capacity of the car will significantly decrease.

To install the CMU on the chassis, a subframe must be installed, thereby reinforcing the design of the car. The subframe is, simply speaking, a steel floor, its weight for a GAZ-3302 car is about 250 kg. Manipulators of the smallest series of various manufacturers are installed on the Gazelle. Such manipulators, together with outriggers, have a mass of about 400-550 kg. To accurately calculate the load capacity of a Gazelle-based loader crane, you need to know the mass of the overframe and the CMU itself.

Let's calculate the carrying capacity of a Gazelle with a manipulator using an example:

  • The maximum permitted weight of the GAZ-3302 is 3500 kg.
  • The mass of the Gazelle with an onboard platform is about 2 tons. Subframe weight - 250 kg.
  • The mass of the CMU is 450 kg.

Let's carry out the calculation and subtract the mass of the vehicle with the equipment from the permitted mass:

3500 kg - 2000 kg - 250 kg - 450 kg = 800 kg.

The total load capacity of such a car will be 800 kg. Please note that the above calculation has a large error. You can get the exact carrying capacity of a Gazelle with a manipulator only by making a calculation taking into account the parameters of a specific CMU model, however, it is not possible to significantly increase the carrying capacity of such a vehicle.

Choosing CMU for GAZ-3302

As noted above, the lifting capacity of a loader crane based on the GAZ-3302 is highly dependent on the mass of the CMU. Manipulators of the smallest series of some manufacturers are suitable for installation on a Gazelle. For the Gazelle, a manipulator capable of lifting 800 kg and installing it on the entire length of the onboard platform (3 m) is quite sufficient.

Here are some examples of compatible manipulators:

PM 3622 CE (Italy) is an inexpensive middle class of hydraulic manipulators, mounted behind the cab.

  • number of boom sections: 3
  • maximum load moment (tm): 2.9
  • maximum load capacity at minimum reach, kg (m): 990 kg (2.90 m)
  • load capacity at maximum reach, kg (m): 465 kg (6.05 m)
  • mass of CMU (kg): 425 kg
  • outriggers in basic configuration: manual extension, width STD 3.55m

UNIC URA-100 (Japan) - cable manipulators are mounted inside the onboard platform, do not require a subframe. Cons: very high price, delivery only on order, unstable machines.

  • number of boom sections: 3
  • maximum load moment (tm): 1.8
  • maximum load capacity at minimum reach, kg (m): 1,015 (2.90)
  • load capacity at maximum reach, kg (m): 430 kg (3.9 m)
  • mass of CMU (kg): 480 kg

Tasks that are on the shoulder of a Gazelle with a manipulator.

A gazelle equipped with a loader crane has a lower carrying capacity compared to a base vehicle. Gazelle with CMU is perfect for the tasks of loading and unloading and transporting large-sized and light loads. For example, a Gazelle with CMU can be used in horticultural markets for transporting seedlings, for landscaping work on summer cottages, as a crane and truck for assembly teams.

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