3. Crane Installation

Chapter 6

CHAPTER 6

Crane Installation

In this Chapter 1 2 3 4 5 6 7 8 9

Guideline for Crane Installation.......................... .............................. ..... 3 Safe Crane Handling.......................... ............................. ...................... 5 Crane Model Features .......................... .............................. ................ 11 Mounting of Cranes with Combination Combination Crane Base ............................ 37 Crane Installation on removable Mounting Console ........................... 44 Crane Installation with Trailer Frame .................................................. 45 Crane Installation with Tube Base .................................................... .. 46 Stationary mounted loading crane ........................... ........................... 47 Installation of PC Cranes ............................. ............................. .......... 50

Edition: 08/2012

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Chapter Chapter 6 Crane Installat Installation ion

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Edition: Edition: 08/2012

Guideli Guideline ne for Crane Installat Installation ion

1


Guideline for Crane Installatio Installation n For planning and assembling of a crane on a vehicle it is important to proceed in the following order: 1.

g n i n n a l P

2.

3.A

y l b m e s s A

3.B

Installation Installation planning of the crane 

Define crane position on the vehicle



Calculate the height of the vehicle



Axle load calculation



Stability calculation



Selection of additional stabilizer (if necessary)



Dimensioning of PTO and hydraulic pump



Dimensioning of tank volume and oil cooler (if necessary)



Definition of dead point for cranes without continuous rotation

Selection and calculati on of a sub frame 

Flexible / torsion-resistant sub frame



Shear-yielding / shear-resistant frame connection



Strength calculation of sub frame

Crane Crane installation wit h tru ck standard crane base 

Manufacturing and assembling to the chassis of sub frame including wear plates and base shear plates



Positioning of the crane on the sub frame by means of proper lifting accessories



Positioning and tack welding welding of mounting bushes and mechanical crane stops



Remove crane from sub frame



Welding of mounting mounting bushes and mechanical crane stops



Painting of sub frame, base shear plates, mounting bushes and mechanical crane stops



Positioning of crane on sub frame and fixing with with mounting bolts

Crane Crane installation wit h combi nation crane base 

Fixing of base shear plates on the chassis frame



Positioning of crane and additional stabilizer on the chassis and tack welding to the base shear plates



Pre manufacturing of sub frame modules



Positioning of sub frame modules on the chassis



Welding of the the sub frame modules, the crane crane base and the base shear plates



Painting of sub frame modules

Chapter 3

Chapter 5

Chapter 6

Chapter 6

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Edition: Edition: 08/2012

4.

y l b m e s s A

5.

6.

Connecting of crane hydraulic 

Assembly of hydraulic pump



Connecting of oil pipes and hoses



Filling of hydraulic tank with hydraulic oil

Connectin g of crane electric 

Connecting of main line to the crane



Matching of of stabilizer positions of crane and additional stabilizer stabilizer (if existing) according current installation



Establishing of vehicle interfaces (motor start / stop, motor speed adjustment, transport position monitoring)

Start up of crane 

Functional check



Setting of pressures



Setting loading limits and safety systems

Chapter 8

Chapter 9

Chapter 12

p U t r a t S

7.

Handover to the end custo mer 

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Handover to the end customer according PALFINGER handover guidelines

Chapter 12

Safe Crane Handli Handling ng

2

Safe Safe Crane Hand Handli ling ng

2.1

Transport


During transportation from the company to the customer of the cranes take care that the fastening attachments are not damaging the parts of the cranes. All accessories are packed in boxes which are not allowed to be removed until the bodybuilding process. Do not damage the boxes!

2.2 2.2

Unloading and bodybuildi bodyb uildi ng process During the unloading process trough the bodybuilder or a third party consider of all safety rules and accident controls. Unload the crane and all its accessories safely and don’t throw boxes, etc. from the platform of the transporting vehicle. When the parts are unloaden check the parts for damages and completeness. If there are damages, note it on the shipping documents. Never pull or push the crane and it´s accessories on the floor. The using of chains and cables is just allowed if there is no direct contact between the crane parts and the lifting equipment. Consult the technical data sheets to find the dead weight of the crane. Be sure to take into account any accessories that have been installed

Attention! For a safe crane handling always use sufficient dimensioned devices (belts, chains). Best is to use original PALFINGER handling systems! During the crane handling danger of sq ueezing ueezing is given. Always be in a safety distance!

Introduction of our new system of crane lifting accessories which have been especially designed for the handling of PALFINGER cranes for shipment, installations and repair jobs. The following points have been checked very carefully to ensure a trouble free use of the equipment: 

Safety



Protection of the crane painting



Universal for different crane types



Fast and quick handling

Following crane lifting accessories are available at the moment:

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Chapter 6 Crane Installation

2.3

Edition: 08/2012

Lifting accessories for small and medium cranes models Lifting accessories for cranes from 4mt - 30mt --> HXE2262 / EKD105 / EKD107

2.3.1

Crane series 2000 HXE2262

PK 4501 - PK 29002

Illustration 06-6001; HXE2262

2.3.2

Crane series 2010 EKD 105 +HI 273 +EQ 042

PK 8502 HP PK 9002-EH PK11002 HP PK 12002-EH Illustration 06-6002; EKD105

EKD 107 +HI 042 +EQ 042

PK 13001 PK 13001-K PK 13002 HP PK 14001-EH PK 14002-EH PK 14502-SH PK 16001 HP PK 16001-K PK 16002 HP PK 18001-EH PK 18002-EH PK 18502-SH

Illustration 06-6003; EKD107

(See Service Information C07/2008) All cranes of the High-Performance-Series (> PK 18502 SH – PK 34002 SH) are delivered with a shackle at the main boom. This shackle could be used for transport. In this case you have to be careful because the position of the shackle is not in line with the centre of gravity of the crane. The result is that the crane will be sloped. This could be avoided by using PALFINGER lifting equipment mentioned above.

Illustration 06-1001; Shackle High-Performance-Series

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Safe Crane Handling

2.4


Lifting accessories for medium and heavy cranes models Lifting accessories for 30mt - 100mt --> EKD-108 EKD 108

PK 36002 - PK 100002 Truck with standard base


Lifting accessories for 60mt - 150mt --> EKD-106 EKD 106

PK 60002 - PK 150002 For combined crane base (EGG base)


The following documents are included with each EKD-106 and EKD-108 accessory: 

Conformity declaration



General operating manual for lifting accessories from the supplier



PALFINGER specific operator manual about the proper using of the accessories

Advice! Check the operating m anual for l ifti ng a PALFINGER crane in Extranet Patis-onli ne.

For using the lifting accessories EKD-106 and EKD-108, the lifting height of the overhead crane shall be at least 4.7 to 5 m (including a truck frame height of approx.1.5 m). (See Service Information C07/2008)

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2.5

Edition: 08/2012

Handling of PC cranes: For the handling of a PC crane put in a shackle into the occupancy drill hole and lift it with an indoor crane or an other lifting device.

Illustration 06-1004; Shackle PC crane

2.6

Lif ting accessories for EPSILON cranes Depending on the crane model, EPSILON cranes have 2 shackles respectively 2 eyes where you can connect the hook of the lifting accessory. The position is near by the centre of gravity of the crane. With these lifting points it is possible to lift the crane from the palette in a straight position.

Illustration 06-7001; Transport shackle respectively -eyes of EPSILON cranes

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Safe Crane Handling


At EPSILON Z-cranes with telescopable main boom there are no shackles respectively eyes to hook on the lifting device. In this case you have to use a hoisting sling for lifting the crane.

Illustration 06-7002; Hook on with hoisting sling at EPSILON Z-crane

At EPSILON L-cranes out of the S-class there are no shackles respectively eyes to hook on the lifting device. In this case you have to use a hoisting sling for lifting the crane. You have to take care in following points: 

Due to the sharp edge you have to use an edge protection below the main boom to avoid damaging of the hoisting sling.



The hoisting sling has to be put like a loop around the main boom.

Illustration 06-7003; Hook on with hoisting sling at EPSILON L-crane out of the S-class

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2.7

Edition: 08/2012

Common security advice for using crane lifting accessories The crane must to be secured during the working process until the fixation on the truck or on a residential place is done by mounting bolts or welding angles.

2.8

Demounting of the crane Before loosening the screws of the crane you have to secure the crane. If an EGG base is used it can be necessary to grind the welding connections. Afterwards the hydraulic- and electric lines can be demounted. The stability of the crane has to be guaranteed in each step of the working process.

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Crane Model Features

3


3.1

Component designation

3.1.1

Crane with continuou s rotation system


The crane in the drawing below is an example and shows crane components which may be found on the crane as options, depending on the exact design and crane model.

Illustration 06-1005; Main components of a crane with continous rotation system

1

Ground control – control valve side, opposite side

2

Rigid stabilizer cylinder

3

Crane mounting bolts

4

Tiltable stabilizer cylinder

5

Telescopic outrigger beams

6

Base

7

Continuous rotation system with gear rim

8

Lift cylinder

9

Emergency control stand on the crane column

12

Linkage system

13

Main boom

14

Rope winch

15

Outer boom lift cylinder

16

Outer boom

17

Extension cylinder for hydraulic extension booms

18

Hydraulic oil tank with oil level indicator

19

Extension booms

20

Mechanical extension booms

10

Balance

21

Load hook

11

Crane column

22

Remote control handset

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3.1.2

Edition: 08/2012

Crane with out contin uous rotation system The crane in the drawing below is an example and shows crane components which may be found on the crane as options, depending on the exact design and crane model. 1

23

1

1

12

1

14

13

1

9

1

1

7

15

1 8 11 1 12

6 1 7 1

17 1 18 9 1

2

5 1

16

2 1

19

3 1

1 5

4 1

20

1

10

3

22

1

21

Illustration 06-1006; Main components of a crane without continuous rotation system

1

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Ground control – control valve side, opposite side

2

Rigid stabilizer cylinder

3

Crane mounting bolts

4

Tiltable stabilizer cylinder

5

Telescopic outrigger beams

6

Base

7

Slewing system

8

Lift cylinder

9

Manual outrigger interlock system

10

Balance

11

Crane column

12

Linkage system

13

Main boom

14

Rope winch

15

Outer boom lift cylinder

16

Outer boom

17

Extension cylinder for hydraulic extension booms

18

Hydraulic oil tank with oil level indicator

19

Extension booms

20

Mechanical extension booms

21

Load hook

22

Remote control handset

23

Top seat


3.2


General mounting instructions In general, the loading crane is placed on the sub frame of the truck and bolted to it with mounting bolts.

Advice! The number of mou nting bol ts and the fastening points can be found i n the pertinent technical data sheets.

It is permitted to combine mounting points BRI-4 and BRI-8 (mounting points I to IV, see illustration 06-1051) which are show in the technical data sheets. This means that it could be possible to have different constructions of mounting points (connection between crane and sub frame) for one crane installation.

Illustration 06-1051; Mounting bolts –mounting points at the crane

I-IV

Mounting points for connection between crane and sub frame

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Edition: 08/2012

Beware! Cranes with con ventional crane base (mounting with mounting bolts) may never be placed directly on the chassis frame.

Illustration 06-1032; General view of crane installation with mounting bolts

1 2 3 4 5 6 7 8 9 10

Crane base Balance Chassis frame Sub frame Base shear plate Mounting bolts Mounting washer plate Mounting bush Crane stops Wear plates for sub frames

Rectangular mounting washer plates (7) must be placed between the fastening bracket and the nut. The mounting bolts (6) must be sec ured with a self-locking nut or a conternut at both ends and tightened by using a torque spanner.

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The below specified fastening torque is defined for the delivery condition of the mounting bolts. This delivery conditions are for: - Uncoated mounting bolt:

lightly oiled

- Coated mounting bolt:

not oiled

The tolerance range for the fastening torque is +/- 10% of requirement.

8.8 Thread Diameter M16 x 1,5 M20 x 1,5 M24 x 1,5 M30 x 1,5 M33 x 1,5 (only EPSILON) M36 x 1,5 M42 x 1,5 M48 x 1,5

Strength Class resp. Material C40 42CrMo4V Fastening Torque [Nm]

120 140

210 450 900 1220 1550 2500 3700

Beware! The projection length of the bolt above the self-locking nut / conter-nut must be at least three full turns of the thread (3 x thread pitch).

Make sure that the cross beam of the crane base is solidly placed on the sub frame (part 4, illustration 06-1032). If there is a gap, fill it with steel plates which must be welded to the sub frame. In the crane area the sub frame has to be designed in a rigid version and must be connected to the vehicle frame in a shear resistant way (see chapter 5 “Sub frame”).

3.2.1

Tightening sequence of mounti ng bolts Following sequence has to be observed during installation of crane: 1. 2. 3.

To install the base free of stress, all mounting bolts must be pre-installed. Tighten bolts with 50% of fastening torque but not more as 200Nm (diagonal, see illustration 06-1027). Tighten bolts with torque spanner to predetermined tightening moment.

If its impossible to pre-install all mounting bolts caused by the crane arm following steps must be accomplished: 1. 2. 3. 4.

Install mounting bolts on at least 3 mounting points. Tighten bolts with 50% of fastening torque but not more as 200Nm (diagonal, see illustration 06-1027). Lift outer boom and install bolts on the 4th mounting point. Tighten with torque spanner to predetermined tightening moment.

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Edition: 08/2012

Illustration 06-1027; Tighten sequence of mounting bolts:

Advice! The number of moun ting bol ts and the fastening points can be found i n the pertinent technical data sheets.

Attention! Alway s t ig ht en mou nt in g b ol ts in th e di ago nal way and th e pr op er t or qu e!

Attention! Only original PALFINGER bolt connections may be used. These can be bought from the PALFINGER Equip ment Centre.

Attention! The mounting bolts (part 6, see illustration 06-1032) delivered with the crane were made of high-strength material and may not be reshaped by either hot o r cold methods. Re-cutting of t he thread of the mounti ng bolts is not p ermitted.

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3.2.2


Wear plates on the sub frame Wear plates may be situated at the contact points of the crane so that the cross-section of the sub frame is not weakened by wear and subsidence.

Illustration 06-1028; Wear plates

1 2 3 4 5

Sub frame Crane base Wear plate Balance Base shear plate

If it is not defined in the installation manual of the truck manufacturer, the screws for the connecting between chassis and sub frame must be mounted from the internal side of the chassis frame. The nuts were screwed on from the outside of the chassis frame. The tightening of the connection is done by the nut. The screw head is used only for hold up.

Attention! Loose, damaged or excessively tightened bolt s are susceptible to b reak under load. This creates an acute risk of fatality to the operator and oth ers.

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3.2.3

Edition: 08/2012

Mechanical stop between crane and sub frame The mounting bolts are not capable to bear the crane moments. Therefor it is necessary to install mechanical stops to the crane and the sub frame. The mechanical stop prevents the longitudinal- and transverse displacement of the crane on the sub frame.

PALFINGER delivers appropriate mechanical stops with each mounting kit. This stops are adapted to the several crane models.

Advice! Areas g ri nd ed d ow n t o b are metal fo r w eld in g w or k mu st be p ro tected agai nst c or ro sion again once the welding work is d one.

In the following list are the mechanical stop kits and the necessary welding seams in accordance to the torsional crane moment specified: Crane to rsional moment (dynamic) Mt [kNm] Techn. Info Sheet: DTDAMDYNA/05

 5,0

 16,0

 27,0

 42,0

 55,0

 85,0

 105,0

EPSILON

Design

A

B

B

B

C

C

C

B

Part Nr.

HT10348 HT10349

HT7940 HT7941

HT7940 HT7941

HT7940 HT7941

HT11012 HT11013

HT11012 HT11013

HT11012 HT11013

E14011 E14012

 6

 8

 8

 10

 10

 12

 12

 8

Thickness connection plate [mm] Material quality connection plate

 S355

Filler material

Z1; see Chapter 4 „Welding at Bodywork and Crane“

Quality class

C DIN EN ISO 5817

Preheating

see Chapter 4 „Welding at Bodywork and Crane“

Min. thickness welding seam a [mm]

3

4

5

6

6

7

8

8

Beware! Welding may be done only by p eople in possession of a valid welder’s certificate in accordanc e with EN 287-1 or with an equ ivalent natio nal welder’s cert ifi cate. The area to which the welding certificate applies must cover the full sco pe of the work to be done (see chapter 4 ‘Welding o n Crane and Att achment’).

For the definition of the welding seam type and the welding seam length you will find the appertaining drawings on the next pages.

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Mechanical stop design A:

Illustration 06-1019; Mechanical stop, design A

Mechanical stop design B:

Illustration 06-1020; Mechanical stop, design B for PALFINGER loader crane respectively EPSILON crane

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Edition: 08/2012

Mechanical stop design C:

Illustration 06-1021; Mechanical stop, design C

Advice! The use of the old “ stop plates“ for PALFINGER loadercranes is not permitted any more due to the missing locking against transverse movement of the crane (see illustration 06-1022)!

1 ..... 2 ..... 3 ..... 4 ..... 5 .....

Illustration 06-1022; “Stop plates”

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Crane base Balance Sub frame Chassis frame Stop plates



The old stop plates are only used for EPSILON L-cranes (long logs) without crossbeam at the crane base.

Illustration 06-7004; EPSILON L-crane base with stop plates

1 2 3 4 3.2.4

EPSILON crane base for L-crane Stop plates Sub frame Chassis frame

Washer plate with lock against rotation PALFINGER provides mounting bolts with diameter M24, M30, M36 and M42 washer plates with integrated lock against rotation. EPSILON only uses this washer plate for diameter M30. Following illustration shows a washer plate with lock against rotation:

Illustration 06-6003; Washer plate with lock against rotation

A B D

Lock against rotation for wide bolt slots Lock against rotation for narrow bolt slots Hole for mounting bolt

1 2

2 notches per side for the inspection of the proper assembly of the washer 4 piece lock against rotation for wide and narrow bolt slots

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Edition: 08/2012

For the function of the washer plate with lock against rotation it is a requirement that the washer plate is positioned on the crane base properly. Each washer plate with lock against rotation can be used for two widths of bolt slots (e.g. the washer for mounting bolt M24 can be used for a bolt slot with a width of 25 and 31 mm) The lock against rotation of the washer has to be set with the proper width onto the bolt slot. The clearance between the washer and the bolt slot has a tolerance of maximal 1,5 mm. Each washer has for the visual inspection on the bottom side notches (see illustration 066003, position 1). By proper mounting of the washer this notches are in line with the inner edge of the bolt slot (see illustration 06-1017 and 06-1018)

Attention! During assembly of t he washer plate with lock against rotation always take care that the washer plate is positi oned properly. For inco rrect assembly the danger of damaging may occur. This creates an acute risk of fatality to the operator and others.

T C E R R O C

Illustration 06-1017; Correct assembly of the wascher plate with lock against rotation

E S L A F

Illustration 06-1018; False assembly of the wascher plate with lock against rotation

D T

Diameter of mounting bolt Width of bolt slot

1 2

Notch at the washer Inner edge of the bolt slot

By the use of washer with lock against rotation it is not necessary to weld the washer towards the crane base after the assembly. Due to the serial coating of the washer, a painting of the washer after the mounting is also not necessary.

22 / 52



Advice! The use of old washers (HTR1140, HX 077, HTR1051 and HTR3382) is still permitted (see point 3.2.5), but the mixing old w ashers and n ew washers wi th lo ck against rotation on one crane is not permitted.

3.2.5

Washer plate witho ut lock against rotation Washer plates with lock against rotation for mounting bolts with diameter of M20 and M48 are not available. For this diameter steel plates with an appropriate hole have to be used as washer plates. To avoid the rotating respectively slipping of the washer plate it is necessary that the plate is welded to the crane base after installation. The length of this welding seam has to be at least 20mm to avoid increased hardness in the area of the welding (see chapter 4 ‘Welding on Crane and Attachment’). This type of washer plates are also used for EPSILON cranes with mounting bolts diameter of M24 and M33.

Illustration 06-1033; Assembly of the wascher plate without lock against rotation

1 2 3 L

Mounting bolt Washer plate without lock against rotation Welding seam for securing the washer plate Length of the welding seam (min. 20 mm)

The washer plates without lock against rotation also have to be used for PALFINGER st cranes with an ordering date before 1 of July 2011 (e.g. rebuilding or spare parts). The reason for these is the modified tolerances for the mounting bolt slots at the crane base. Areas grinded down to bare metal for welding work must be protected against corrosion again once the welding work is done.

3.2.6

Bolt protectio n cap After finishing the assembly the bolt protection cap has to be putted on the mounting bolt respectively nut. All components are included in the mounting kit.

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Edition: 08/2012

1 ..... 2 ..... 3 ..... 4 .....

Balance Sub frame Chassis frame bolt protection cap

Illustration 06-1023; Bolt protection cap

3.3

Single mounting bolt installation (BRI-4) The mounting bushing is welded to the base shear plate. PALFINGER provides for the mounting bushes pre manufactured welded kits.

Illustration 06-1026; Crane installation BRI-4

1 2 3

Mounting bush Washer hardened (HV300) Mounting bolt

At the BRI-4 installation a hardened washer HV300 (part 2) is used between the nut and the bush. All components are included in the mounting kit. This type of installation can be used for all types of loadercranes. For EPSILON cranes this application is not permitted. For EPSILON cranes you must always use 2 mounting bolts for each mounting slot, this means mounting bushes are permitted for using of 2 mounting bolts for each mounting point.

24 / 52



When positioning the mounting bushes it is necessary to keep a gap of at least 5 mm between the upper edge of the bush and the lower edge of the crane base. This is to ensure that the crane base is solidly placed on the sub frame.

Illustration 06-1031; Gap between crane base and mounting bush

3.3.1

Connection of mounti ng bush to sub frame (design standard mounting bush) The following list shows the PALFINGER mounting bushes as a function of the mounting bolt diameter including the required welding seam thickness for the bushes. The diameter of the mounting bolts can be found in the pertinent technical data sheets.

Mount ing bol t Max. mounting bolt force FBr [kN] Suitable mounting bush ET Nr. Bush length [mm] Thickness connection plate [mm] Material quality connection plate

M20x1,5

M24x1,5

M30x1,5

M36x1,5

M42x1,5

M48x1,5

85

125

200

290

400

530

HXE-4534

HXE-3144

HXE-3145

HXE-9084

HXE-2527

HXE-4514

 120

 160

 160

 214

 214

 310

 6

 8

 8

 10

 12

 12

 S355

Z1; see Chapter 4 „Welding at Bodywork and Crane“ C DIN EN ISO 5817

Filler material Quality class Preheating


Min. welding seam thickness aW [mm ]

4,5

6

7

8

10

10

Beware! Welding may be done only by p eople in possession of a valid welder’s certificate in accordance with EN 287-1 or with an equivalent national welder’s certificate (see chapter 4 ‘Welding on Crane and Attachment’).

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Edition: 08/2012

Following illustrations 06-1034 and 06-1035 should attend as extension to the list mentioned above:

Illustration 06-1034; Connection of mounting bush to sub frame, design standard mounting bush M20, M24, M30 and M36

Illustration 06-1035; Connection of mounting bush to sub frame, design standard mounting bush M42 and M48

26 / 52


3.3.2


Connection of mounti ng bush to sub frame (design standard mounti ng bush shortened) If necessary it is possible to shorten the standard bush according the following list. The required gusset plates and welding seams are defined also in the following list.

Mounting bolt Max. mounting bolt force FBr [kN] Mounting bush length [mm]

M20x1,5

M24x1,5

M30x1,5

M36x1,5

M42x1,5

M48x1,5

85

125

200

290

400

530

 58

 78

 78

 120

HXE-3144

HXE-3145

HXE-9084

 8

 8

 10

Suitable mounting bolt bush HXE-4534 P. No. Thickness connection plate  6 [mm] Thickness gusset plate 1 6 s [mm] Material quality of connection and gusset plate

1

1

8

8

1

8

S355

Z1 see Chapter 4 „Welding at Bodywork and Crane“ C DIN EN ISO 5817

Filler material Quality class Preheating

Approval Approval from from PALFINGER PALFINGER required required


Min. welding seam thickness aW1 [mm] Min. welding seam thickness aW2 [mm]

5

6

8

8

4

5

7

7


Following illustrations 06-1036 should attend as extension to the list mentioned above:

Illustration 06-1036; Connection of mounting bush to sub frame, design standard mounting bush shortened M20, M24, M30 und M36

27 / 52


3.3.3

Edition: 08/2012

Connection of mounting bush to sub frame (design mounting bush directly on the base shear plate, unshortened length) If required the mounting bush can be welded directly to the base shear plate without mounting plate. In the following list are the required bushes and welding seams defined.

Mount ing bol t Max. mounting bolt force FBr [kN] Suitable mounting bolt bush P. No. Recommended mounting bush length [mm] Thickness connection plate [mm] Material quality of connection plate

M20x1,5

M24x1,5

M30x1,5

M36x1,5

M42x1,5

M48x1,5

85

125

200

290

400

530

HBS-7804

HBS-761

HBS-110

HBS-3366

HBS-3076

HBS-7801

120

160

160

214

214

310

 6

 8

 8

 10

 12

 12

 S355

Z1 see Chapter 4 „Welding at Bodywork and Crane“ C

Filler material Quality class

DIN EN ISO 5817

Preheating


Minimum welding depth x (**)[mm] Control dimension b [mm] Min. welding seam thickness aW [mm]

15

19

22

27

33

38

5

6

7

24 46 10

26

30

52 12

56 12

(**) Minimum welding depth has to be checked by a welding test!!!


Following illustrations 06-1037 should attend as extension to the list mentioned above:

Illustration 06-1037; Connection of mounting bush to sub frame, design mounting bush directly on the base shear plate, unshortened length M20, M24, M30, M36, M42 and M48

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3.3.4


Connection of mounting bush to sub frame (design mounting bush directly on the base shear plate, shortened length) If required the shortened mounting bush can be welded directly to the base shear plate without mounting plate. In the following list are the required bushes, gusset plates and welding seams defined.

Mounti ng bolt Max. mounting bolt force FBr [kN] Mounting bush length [mm] External diameter bush D [mm] Internal diameter bush d [mm] Thickness connection plate [mm] Thickness gusset plate s [mm] Material quality of connection and gusset plate Filler material Quality class

M20x1,5

M24x1,5

M30x1,5

M36x1,5

M42x1,5

M48x1,5

85

125

200

290

400

530

 58

 78

 78

 100

 38

 42

 51

 60

 1

22

 6  1

6

26

 1

33

 8

 1

 8

 1

 1

8

8

38

 1

 10  1

8

S355

Approval Approval from from Z1 PALFINGER PALFINGER see Chapter 4 „Welding at Bodywork and Crane“ required required C DIN EN ISO 5817

Preheating


Minimum welding depth x (**)[mm] Control dimension b [mm] Min. welding seam thickness aW1 [mm] Min. welding seam thickness aW2 [mm]

15

19

22

24

27

33

40

46

5

6

8

10

4

5

7

7

(**) Minimum welding depth has to be checked by a welding test!!!

Beware! Welding may be done only by p eople in possession of a valid welder’s certificate in accordance with EN 287-1 or with an equivalent national welder’s certificate (see chapter 4 ‘Welding on Crane and Attachment’). Following illustrations 06-1038 should attend as extension to the list mentioned above:

Illustration 06-1038; Connection of mounting bush to sub frame, design mounting bush directly on the base shear plate, shortened length M20, M24, M30, M36, M42 and M48

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Edition: 08/2012

3.4

Double mounting bolt installation (BRI-8)

3.4.1

Option with mounti ng plate For the double mounting bolt installation with mounting plates, steel plates are laid under the chassis frame and two mounting bolts are inserted. When this option is chosen, the chassis frame must be secured from compression (see part 3, illustration 06-1029). The support profile must be secured from slipping by using of a screw which is connected to the chassis frame (see part 4, illustration 06-1029).

Illustration 06-1029; Double mounting bolt installation BRI-8

1 2 3 4 5

Build-up level of crane Mounting bolt Support profile Securing of support profile Mounting plate

This type of installation can be used for loading cranes of up to 35 mt lift moment. During installation of the mounting plates a hardened washer HV300 (see part 1, illustration 06-1024) is used at the hole. At the long hole a washer with lock against rotation (see part 3, illustration 06-1024) is used. The regulations described in point 3.2.4 are also valid for the assembly of the washer with lock against rotation. All components are included in the mounting kit.

Illustration 06-1024; Crane installation BRI-8

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1 2 3


Washer hardened (HV300) Mounting plate Washer with lock against rotation

When assembling the mounting plate you should take care, that the graven article number in the mounting plate is at the averted side of the washer (graven article number is on the top).

Illustration 06-1025; Postioning of mounting plate for BRI-8

1 2

3.4.2

Position of graven article number on the mounting plate Position of washer with lock against rotation by assembly

Option with mounti ng bush In this mounting option, the first bushing is welded to the base shear plate on the outside and the second bushing is welded into the sub frame. The mounting bushings should be placed so that the mounting bolts can be easily tightened. This type of installation can be used for all types of cranes.

Illustration 06-1030; Installation with mounting bush for BRI-8

1 2

Build-up level of crane Mounting bush

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3.5

Edition: 08/2012

Fitting the stabilizer cylind ers to the crane extension arms When fitting the stabilizer cylinders to the extension arms the following points need to be taken into account:



Clean flange surfaces on both sides of any dirt and foreign bodies. The surface protection must not be removed



The fixing screws must be tightened with the required tightening torque and secured with screw-locking adhesive. Before applying the adhesive the thread must be cleaned and degreased. To avoid cold shock effects it has to be guarantied that the environment and the glued parts will have the requested minimum temperature required by the screw-locking adhesive. Following adhesives are approved by PALFINGER (the specification of the adhesive supplier must be cons idered during processing): o o o

LOCTITE 243 (alternative LOCTITE 245) VARY BOND 12-43 (alternative VARY BOND 12-45) WIKO 02K43 (alternative WIKO 02K45)



Tighten fixing bolts with the prescribed amount of torque.



The stabilizer cylinder must always be secured to the stabilizer outrigger using the fastening bolts provided (A).

Illustration 06-1052; Bolting the stabilizer cylinder to the extension arm

Stabilizer plate extensions may only be used in accordance with technical information sheets. No other stabilizer plate extensions are permitted without separate approval from PALFINGER! No modification of the flange plates on the stabilizer outrigger or stabilizer cylinder (e.g. extension by one row of holes) is permitted without separate approval from PALFINGER!

Caution! No bolts oth er than those specified may be used to fix the stabilizer cylinders to the extension arms!

Caution! Loose, damaged or excessively tightened bolt s are susceptible to b reak under load. This creates an acute risk of fatality to the operator and oth ers.

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Tightening torque ISO-screws in Nm: (not oiled and not lubricated) Screw: ISO 4762, ISO 4014 Nut: ISO 4032 Washer: ISO 7090

3.6

Screw thread:

Screw strength: 10.9

M 12

100

M 14

165

M 16

245

Crane installation of EPSILON crane base without crossbeam The EPSILON crane base for long log vehicles are delivered without integrated crossbeam. Therefore an additional stabilizer is assembled together with the crane base Following additional stabilizer options are distincted:

3.6.1

EPSILON crane base wit h flapd own-stabil izer Crossbeam, flapdown stabilizer and balancing rod are delivered separately. After installation of the crossbeam on the sub frame the flapdown stabilizer are welded to the crossbeam. Afterwards the balancing rod is mounted to the flapdown stabilizer.

Illustration 06-7005; EPSILON L-crane base with flapdown stabilizers

1 2 3 4 5 6 7 8 9

Crossbeam Base shear plates Sub frame Chassis frame Mounting bolts Mounting bushes Flapdown stabilizer Balancing rod Connection plate

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Edition: 08/2012

If crane base and crossbeam of the additional stabilizer do not have the same level it is necessary to put a steel plate between crossbeam and connection plate to get the same level. This additional steel plate has to be welded to the connection plate.

Advice! The crossbeam has to b e secured against slippi ng with mechanical stop according poi nt 3.2.3

3.6.2

EPSILON crane base wit h additional stabilizer In this case an EPSILON additional stabilizer is mounted together with the c rane base

Illustration 06-7006; EPSILON L-Crane base with EPSILON additional stabilizer

1 2 3 4 5 6 7

Crossbeam of additional stabilizer Base shear plates Sub frame Chassis frame Mounting bolts Mounting bushes Connection plate

If crane base and crossbeam of the additional stabilizer do not have the same level it is necessary to put a steel plate between crossbeam and connection plate to get the same level. This additional steel plate has to be welded to the connection plate.

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Advice! The crossbeam has to b e secured against slippi ng with mechanical stop accordin g poi nt 3.2.3

3.6.3 EPSILON Off-Road-Crane and Communal-crane ins tallation The crane is installed directly on the mounting frame and has to be fixed with screws (see table below). The mounting frame can realised with through hole (see option A, illustration 06-7007) or with threaded hole (see option B, illustration 06-7007). For option A a self-locking nut has to be used.

Communal

Detail X

Off-Road

3

A 1

Y

2

Y

1 2 X

3 B 1

X

Y

2

Y

1

2

Illustration 06-7007; EPSILON Off-Road-Crane and Communal-Crane installation

1 Mounting frame / Chassis frame 2 Crane base 3 Distance bush Y Clamping length

Communal

OFF-ROAD

C

C

M

S

X

Screw (ISO4014)

M16

M24

M24

M24

M24

Self-locking n ut (DIN 931)

M16

M24

M24

M24

M24

Strength class

10.9

12.9

12.9

12.9

12.9

Quantity

16

8

8

10

14

Clamping l ength Y [mm]

60

70

70

70

70

Crane class

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Edition: 08/2012

The required clamping length „Y“ of the screws (see table above) has to be observed. In order to fulfill this requirement, it is allowed to use distance bushes (see illustration 06-7007, part 3).

As corrosion protection the lower side of the crane base is only primed by EPSILON. Before mounting of the crane the primer has to be grinded down. Also the mounting area at the frame has to be free of any coating (steel to steel connection between crane and mounting frame)

Advice! Take care in steel to steel conn ection b etween crane and mou ntin g frame. If there is no steel to steel connection a loosening of the mounti ng screws is possible.

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Mounting of Cranes with Combination Crane Base


4

Mountin g of Cranes with Combination Crane Base

4.1

Component designation The crane in the drawing below is an example and shows crane components which may be found on the crane as options, depending on the exact design and crane model.

11

10

9

8

7 1

2

3

4

5

6

Illustration 06-1007; Component designation of a crane with combination crane base

1 2 3 4 5 6 7 8 9 10 11

4.2

Combination crane base Bearing ring mount Support cylinder Crane support (cross-beam) Welding connection point Welding connection point Load booms Oil tank Oil cooler Main boom Crane column with control valve

Combination crane base The combination crane base (EGG) serves as both as a crane base and as a fully equivalent replacement for a sub frame. Depending on the mounting variant, the sub frame modules are welded directly to the welding connection points, Components 1 and 6). There is no crane base balance on this combination crane base. The crane is designed to be secured to the base shear plates on the truck chassis by welded connections. The mounting bolt connection otherwise used is therefore unnecessary. The crane support must be positioned in front of the bearing ring mount to achieve better stability and to realize the maximum length of the boom system with a low crane height. This type of construction design makes it possible to keep the construction heights very low even with maximum equipment on the crane and the chassis.

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Edition: 08/2012

There is a free space (7) for truck components which are above the chassis frame (e.g., transmission parts, etc.) in the front lower area of the combination crane base. This will prevent virtually all collisions with these components.

8

1

2

3

4

5

6

7

Illustration 06-1008; Combination crane base

1 2 3 4 5 6 7 8

4.3

Welding connection point Control panel support Bearing ring mount Support cylinder Crane support (cross-beam) Welding connection point Free space for protruding components of the truck chassis (transmission, ...) Oil tank and oil cooler

System description for the mounting As already mentioned in Chapter 5 Sub frame, the crane is positioned directly on the chassis frame and connected to the base shear plates (see Chapter Sub frame) shear resistant and torsion resistant by welding. The combination crane base has been dimensioned so that a sub frame is not necessary in this area. The other sub frame modules are welded to the connection points of the combination crane base at the front and back. In this chapter, the mounting on a tractor is described as an example. The mounting of the sub frames with adjacent loading bridge, pallet or container platform is carried out similarly. The only difference will be in the varying hei ghts and lengths of the sub frames. Contact PALFINGER for all other special mounting variants (mounting in the middle, ...).

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5

1

2

3

Illustration 06-1009; System description for installation with combination crane base

1 2 3 4 5

Truck chassis Front sub frame module (frame end) Auxiliary support Crane Rear sub frame module

The following chronological work steps described below are recommended for carrying out the complete mounting:

4.4



Preparation of the truck chassis (see chapter 3 “Equipment Recommendations for the Vehicle”).



Position and tack the crane and auxiliary support to the chassis (the position of the crane and the auxiliary support is determined on the basis of the axle load calculation).



Prefabricate the sub frame modules (see Chapter 6 “Prefabrication of the Rear Sub frame Module”).



Placement of the sub frame modules on the chassis.



Welding the sub frame modules to the crane or the base shear plates.

Prefabrication of the rear sub frame module The following descriptions of the sub frame module are intended for informational purposes only. The design of the sub frame modules is ess entially dependent on the following factors 

Available raw material (sheet metal, moulded tubes, ...)



Required sheet thickness and grade of steel



Production process (available canting press, welding procedure, ...)

and can deviate accordingly from the following description. An opening must be provided in the front part of the sub frame module so that the middle cross-piece and the base plate of the combination crane base can be welded to the sub frame module; this opening is then welded closed with a closing plate (1) to complete the mounting of the sub frame.

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Edition: 08/2012

1

Illustration 06-1010; Design rear sub frame module

Section A-A

Illustration 06-1011; Design rear sub frame module section A-A

Section B-B Flat steel as welding puddle protection

Slot for I-seam Illustration 06-1012; Design rear sub frame module section B-B

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Illustration 06-1013; Design rear sub frame module

4.5

Mounting of the rear sub frame modul e Park the vehicle on a level surface and check the parallelism of the frame. Before mounting the rear sub frame module, the surface of the welding area must be thoroughly stripped and cleaned of any residual paint and dirt. The sub frame module must be placed so that it rests solidly on the chassis frame or on the base shear plates. Once the sub frame module has been aligned and tacked, the welding work must progress in such a manner that any distortion can be kept to a minimum or virtually eliminated (e.g., by having two welders opposite one another, ...).

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Edition: 08/2012

5

4

1

2

3

Illustration 06-1014; Mounting of rear sub frame module

1 2 3 4 5

Crane Chassis frame or base shear plate Additional stabilizer Rear sub frame module Closing plate

The rear sub frame module must be welded to the crane or the base shear plate in the following areas: 1. 2. 3.

Connection – combination crane base and the bending area of the sub frame module with the base shear plate. Connection – rear area of the sub frame module with the base shear plate. Connection – combination crane base with the sub frame module.

After the middle cross-piece and the base plate of the combination crane base have been welded to the sub frame module, the opening i n this area must be welded closed with a closing plate.

4.6

Production and mounting of the front sub frame modul e (frame end) A suitable frame end must be prepared in the front area so that the bending forces can be smoothly transferred to the chassis frame. This is welded at the front to the combination crane base and the base shear plates. The frame end must be adapted to the available space in this area. Allowance must be made for any open space for maintenance work on the transmission or other components. If there is enough space, the recess (3) in the frame end can be left out.

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1

3

2

Illustration 06-1015; Design front sub frame module

1 2 3

Combination crane base Front sub frame module (frame end) Free space for protruding components of the truck chassis (transmission, ...)

Illustration 06-1016; Illustration of front sub frame module (only for information

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5

Edition: 08/2012

Crane Installation on removable Mountin g Console If you want the dismounting of the crane to be simple, a removable mounting console is usually the best solution.

Illustration 06-1039; Installation on removable mounting console

1 2 3 4

Mounting console Mounting parts of removable mounting console at the chassis frame Chassis frame Sub frame

The mounting console is mounted on the rear of the vehicle by using holding plates. The holding plates are mounted according to their own separate mounting instruction. The mounting instruction for the crane installation on removable mounting console can be downloaded in PATIS online on the PALFINGER Extranet.

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Crane Installation with Trailer Frame

6


Crane Installation with Trailer Frame When mounting cranes with a trailer frame, the frame is mounted laterally on the sub frame. The connection to the sub frame is done with the bearing plates designed for this purpose. The exact welding guidelines for the individual trailer frames can be seen in the technical data sheets or obtained from PALFINGER.

1

2

3

1 2 3

Crane Sub frame Trailer frame

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7

Edition: 08/2012

Crane Installation with Tube Base The crane base on cranes which have a rotary joint on the slewing gear can be integrated completely into the sub frame. The standard crane base is then replaced by a so-called tube base which is welded into the sub frame. Instead of the crane support, one or more auxiliary supports are installed.

Beware! After wel di ng th e tu be b ase, the f lan ge p lat e must be ex amined fo r d isto rt io n f ro m th e welding with out f ail; if the tolerances have been exceeded, suitable procedures must be used to correct the distortio n.

2

1

1 2 3

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Tube base Auxiliary supports Sub frame

3

Stationary mounted loading crane

8


Station ary mounted loading crane Stationary mounted cranes are cranes installed on a rigid substructure (e.g. concrete foundation). As stationary mounting of cranes does not correspond with any series, it must be planned in detail in advance. In order to reduce the impact load on the crane - which is higher on a rigid substructure suitable measures need to be taken by the body builder to protect the crane components and the substructure, such as:



Classification of stationary mounted loading cranes in lift class HC2 corresponding EN12999:2011 (truck mounted cranes are assigned to HC1). As a result the crane's load capacity gets reduced. The reduction depends on the maximum vertical hook speed or grab speed and can be determined as follows (dynamic coefficients in formula according to EN12999:2011) and is valid for all not SH cranes.

1,05  0,17  p max



1,10  0,34 

vh 2  100 vh

[%]

2

Alternatively it is possible to read the graph in illustration 06-9001 to determine the working pressure.

100% 99% 98% 97% 96% 95%

] 94% % [ 93% x a 92% m p 91%

90% 89% 88% 87% 86% 85% 0

0,2

0,4

0,6

0,8

1

1,2

1,4

1,6

vh [m/s] Illustration 06-9001; Reduction of the working pressure in dependence of the maximum vertical hook speed or grab speed for not SH cranes

Vh pmax

maximum vertical hook speed or grab speed [m/s] crane reduction (in HC2) referred to maximum working pressure in case of truck mounting crane (HC1)

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Edition: 08/2012

After working pressure reduction the body builder must attach ne w load capacity charts on the crane and in the operator manual!

Note! For SH cranes the working pressure for stationary in stallation must be reduced to 95% of the maximum working p ressure!

Note! For EPSILON cranes the working pressure for stationary application must always be reduced to 80 % of the maximum working pressure! Not all of the EPSILON crane models are suitable for stationary application, therefore contact EPSILON and clarify thi s question when planning the use of your crane.



Alternatively to the reduction of the load capacity you can also install an amply dimensioned pressure accumulator at the lifting cylinder. Warning: The declaration of conformity for the crane must be re-issued by the body builder.



It needs to be checked if the standard crane base can be used for stationary mounting (see technical datasheets). If stationary crane mounting is not permissible with the standard crane base, you can contact PALFINGER. In combination with suitable arrangements (e.g. pipe bracket) it could be possible to realize stationary installation.

Note! Stationary crane mounting with combination cr ane base (integral base frame) is not permitted!



Additionally to the capacity reduction also the slewing movement of the crane should be diminished in EPSILON cranes. This can be done via pressure accumulator, electronic damping, brake valve, etc.

The correct classification of lifting class, hoist types and capacity load groups according to EN12999:2011 or the implementation of suitable measures for impact reduction lie in the responsibility of the body builder. Furthermore the body builder is responsible for the correct design of the substructure and the crane mounting. In case of any uncertainties, contact the acceptance authority or PALFINGER.

Warning! Improper use for o ther than the i ntended purposes can cause the crane components to break.

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Stationary mounted loading crane


Examples of stationary mounted cranes

Illustration 06-1053; Loading crane with Marine base frame stationary mounted on steel pipe bracket

Illustration 06-1055; Loading crane with standard base frame stationary mounted on reinforced concrete foundation

Illustration 06-1054; Loading crane with Marine base frame stationary mounted on a reinforced concrete foundation

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9

Edition: 08/2012

Installation of PC Cranes

First, the pivotal point or the mounting position of the crane on the vehicle must be determined and marked.

Attention! When selecting the mounting position, make sure that the control station is no t in the vicinity of th e vehicle exhaust p ipe (emissions).

Remove the mounting, if possible with the sub frame, from the vehicle. Then prepare a mounting plate with the same size as the crane base. The mounting plate should be made of steel plate which is at least 20 mm thick.

An appropriate substructure must e xist in the chassis area to ensure trouble-free installation and function. If a suitable substructure is not already in place, a suitable sub frame construction must be prepared (unless the vehicle manufacturer prescribes or recommends other actions).

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Installation of PC Cranes


The sub frame can be secured to the vehicle using mounting bolts or other mounting elements.

Beware! If the sub frame is secured using d ouble mounting brackets, the chassis frame must be protected f rom com pressio n (see Chapter6.3.4, Crane Install ation / Double Mounting Bol t Installation).

During the assembly of the crane on the mounting plate it is necessary to put 4 distance washer at the fixing points with a thickness of 3mm and an outer diameter of 50 mm between the crane base and the mounting plate (PALFINGER order number HT9430). (See technical data sheet, PATIS-Online)

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3. Crane Installation

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