3. Crane Installation

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Chapter 6

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In this Chapter

1 Guideline for Crane Installation ............................................................. 3 2 Safe Crane Handling ............................................................................. 5 3 Crane Model Features ........................................................................ 11 4 Mounting of Cranes with Combination Crane Base ............................ 37 5 Crane Installation on removable Mounting Console ........................... 44 6 Crane Installation with Trailer Frame .................................................. 45 7

Crane Installation with Tube Base ...................................................... 46

8 Stationary mounted loading crane ...................................................... 47 9 Installation of PC Cranes .................................................................... 50

C H A P T E R 6

Crane Installation

Edition: 08/2012


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Chapter 6 Crane Installation Edition: 08/2012

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Guideline for Crane Installation Chapter 6 Crane Installation

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1 Guideline for Crane InstallationFor planning and assembling of a crane on a vehicle it is important to proceed in the follow-ing order:

P l a n n i n g

1. 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

Chapter 3

2. Selection and calculation of a sub frame

Flexible / torsion-resistant sub frame

Shear-yielding / shear-resistant frame connection

Strength calculation of sub frame

Chapter 5

A s s e m b l y

3.A

3.B

Crane installation with truck standard crane base

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

Positioning of the crane on the sub frame by means of properlifting accessories

Positioning and tack welding of mounting bushes and mechani-cal crane stops

Remove crane from sub frame

Welding of mounting bushes and mechanical crane stops

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

Positioning of crane on sub frame and fixing with mounting bolts

Crane installation with combination crane base

Fixing of base shear plates on the chassis frame

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

Pre manufacturing of sub frame modules

Positioning of sub frame modules on the chassis

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

Painting of sub frame modules

Chapter 6

Chapter 6


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A s s e m b l y

4. Connecting of crane hydraulic

Assembly of hydraulic pump

Connecting of oil pipes and hoses

Filling of hydraulic tank with hydraulic oil

Chapter 8

5. Connecting of crane electric

Connecting of main line to the crane

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

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

Chapter 9

S t a r t U p

6. Start up of crane

Functional check

Setting of pressures

Setting loading limits and safety systems

Chapter 12

7. Handover to the end customer

Handover to the end customer according PALFINGER hando-ver guidelines

Chapter 12


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Safe Crane Handling Chapter 6 Crane Installation

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2 Safe Crane Handling

2.1 Transport

During transportation from the company to the customer of the cranes take care that the fas-

tening attachments are not damaging the parts of the cranes. All accessories are packed inboxes which are not allowed to be removed until the bodybuilding process. Do not damagethe boxes!

2.2 Unloading and bodybuilding process

During the unloading process trough the bodybuilder or a third party consider of all safetyrules and accident controls. Unload the crane and all its accessories safely and don’t throwboxes, etc. from the platform of the transporting vehicle.

When the parts are unloaden check the parts for damages and completeness. If there aredamages, note it on the shipping documents. Never pull or push the crane and it´s accesso-ries on the floor. The using of chains and cables is just allowed if there is no direct contactbetween the crane parts and the lifting equipment.

Consult the technical data sheets to find the dead weight of the crane. Be sure to take intoaccount 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 squeezing is given. Always be in a safety dis-tance!

Introduction of our new system of crane lifting accessories which have been especially de-signed 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 theequipment:

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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2.3 Lift ing 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-KPK 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 deliveredwith a shackle at the main boom. This shackle could be used for transport. In this case youhave to be careful because the position of the shackle is not in line with the centre of gravityof the crane. The result is that the crane will be sloped. This could be avoided by usingPALFINGER lifting equipment mentioned above.

Illustration 06-1001; Shackle High-Performance-Series


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2.4 Lift ing 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 (EGGbase)


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 manual for l ifti ng a PALFINGER crane in Extranet Patis-online.

For using the lifting accessories EKD-106 and EKD-108, the lifting height of the overheadcrane 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 Handling of PC cranes:

For the handling of a PC crane put in a shackle into the occupancy drill hole and lift it with anindoor 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 eyeswhere you can connect the hook of the lifting accessory. The position is near by the centreof gravity of the crane. With these lifting points it is possible to lift the crane from the palettein a straight position.

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


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At EPSILON Z-cranes with telescopable main boom there are no shackles respectively eyesto 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 onthe 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 toavoid 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 Common security advice for using crane lif ting accessories

The crane must to be secured during the working process until the fixation on the truck oron a residential place is done by mounting bolts or welding angles.

2.8 Demounting of the craneBefore loosening the screws of the crane you have to secure the crane. If an EGG base isused 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 Chapter 6 Crane Installation

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3 Crane Model Features

3.1 Component designation

3.1.1 Crane with continuous rotation system

The crane in the drawing below is an example and shows crane components which may befound 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 cranecolumn

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 hydraulicextension booms

18 Hydraulic oil tank with oil levelindicator

19 Extension booms

20 Mechanical extension booms

21 Load hook

22 Remote control handset


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3.1.2 Crane without continuous rotation system

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

12

15

19

118

17

16

1

131

14 1

9 1

15

12

17

2

19

16

20

211

13

3 22

1

121

23

10

111

18

1

7

14

15

1

Illustration 06-1006; Main components of a crane without continuous 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 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 hydraulicextension booms

18 Hydraulic oil tank with oil levelindicator

19 Extension booms

20 Mechanical extension booms

21 Load hook

22 Remote control handset

23 Top seat


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3.2 General mounting instructions

In general, the loading crane is placed on the sub frame of the truck and bolted to it withmounting bolts.

Advice!

The number of mounting bol ts and the fastening points can be found in the pertinenttechnical data sheets.

It is permitted to combine mounting points BRI-4 and BRI-8 (mounting points I to IV, see il-lustration 06-1051) which are show in the technical data sheets. This means that it could bepossible to have different constructions of mounting points (connection between crane andsub 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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Beware!

Cranes with conventional crane base (mounting with mounting bolts) may never beplaced directly on the chassis frame.

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

1 Crane base2 Balance3 Chassis frame4 Sub frame5 Base shear plate6 Mounting bolts7 Mounting washer plate8 Mounting bush9 Crane stops10 Wear plates for sub frames

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


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The below specified fastening torque is defined for the delivery condition of the mountingbolts. 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.

Strength Class resp. Material

8.8 C40 42CrMo4V

Thread Diameter Fastening Torque [Nm]

M16 x 1,5 120

M20 x 1,5 140 210

M24 x 1,5 450

M30 x 1,5 900

M33 x 1,5 (only EPSILON) 1220

M36 x 1,5 1550

M42 x 1,5 2500M48 x 1,5 3700

Beware!

The projection length of the bolt above the self-locking nut / conter-nut must be atleast 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 subframe.

In the crane area the sub frame has to be designed in a rigid version and must be connectedto the vehicle frame in a shear resistant way (see chapter 5 “Sub frame”).

3.2.1 Tightening sequence of mounting bolts

Following sequence has to be observed during installation of crane:

1. To install the base free of stress, all mounting bolts must be pre-installed.

2. Tighten bolts with 50% of fastening torque but not more as 200Nm (diagonal, see illus-tration 06-1027).

3. Tighten bolts with torque spanner to predetermined tightening moment.

If its impossible to pre-install all mounting bolts caused by the crane arm following stepsmust be accomplished:

1. Install mounting bolts on at least 3 mounting points.

2. Tighten bolts with 50% of fastening torque but not more as 200Nm (diagonal, see illus-tration 06-1027).

3. Lift outer boom and install bolts on the 4th mounting point.

4. Tighten with torque spanner to predetermined tightening moment.


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Illustration 06-1027; Tighten sequence of mounting bolts:

Advice!

The number of mounting bol ts and the fastening points can be found in the pertinenttechnical data sheets.

Attention!

Always t ighten mount ing bol ts in the diagonal way and the proper torque!

Attention! Only original PALFINGER bolt connections may be used. These can be bought fromthe PALFINGER Equipment Centre.

Attention!

The mounting bolts (part 6, see illustration 06-1032) delivered with the crane weremade of high-strength material and may not be reshaped by either hot o r cold meth-ods. Re-cutting of the thread of the mounting bolts is not permitted.


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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 ofthe sub frame is not weakened by wear and subsidence.

Illustration 06-1028; Wear plates

1 Sub frame2 Crane base3 Wear plate4 Balance5 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 thechassis frame. The nuts were screwed on from the outside of the chassis frame. The tight-ening 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 others.


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3.2.3 Mechanical stop between crane and sub frame

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

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

Advice!

Areas grinded down to bare metal for welding work must be protected against corro-sion again once the welding work is done.

In the following list are the mechanical stop kits and the necessary welding seams in ac-cordance to the torsional crane moment specified:

Crane to rsionalmoment (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.HT10348HT10349

HT7940HT7941

HT7940HT7941

HT7940HT7941

HT11012HT11013

HT11012HT11013

HT11012HT11013

E14011E14012

Thickness connectionplate [mm]

6 8 8 10 10 12 12 8

Material qualityconnection plate

S355

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

Quality classC

DIN EN ISO 5817

Preheating see Chapter 4 „Welding at Bodywork and Crane“

Min. thicknesswelding seama [mm]

3 4 5 6 6 7 8 8

Beware!

Welding may be done only by people in possession of a valid welder’s certificate inaccordance with EN 287-1 or with an equivalent national welder’s cert ificate. The areato which the welding certificate applies must cover the full scope of the work to bedone (see chapter 4 ‘Welding on Crane and Attachment’).

For the definition of the welding seam type and the welding seam length you will find the ap-pertaining 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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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 anymore due to the missing locking against transverse movement of the crane (seeillustration 06-1022)!

Illustration 06-1022; “Stop plates”

1 ..... Crane base

2 ..... Balance

3 ..... Sub frame

4 ..... Chassis frame

5 ..... Stop plates


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

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

1 EPSILON crane base for L-crane2 Stop plates3 Sub frame4 Chassis frame

3.2.4 Washer plate with lock against rotation

PALFINGER provides mounting bolts with diameter M24, M30, M36 and M42 washer plateswith 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 Lock against rotation for wide bolt slotsB Lock against rotation for narrow bolt slotsD Hole for mounting bolt

1 2 notches per side for the inspection of the proper assembly of the washer2 4 piece lock against rotation for wide and narrow bolt slots


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For the function of the washer plate with lock against rotation it is a requirement that thewasher plate is positioned on the crane base properly. Each washer plate with lock againstrotation can be used for two widths of bolt slots (e.g. the washer for mounting bolt M24 canbe 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 06-6003, position 1). By proper mounting of the washer this notches are in line with the inneredge of the bolt slot (see illustration 06-1017 and 06-1018)

Attention!

During assembly of the washer plate with lock against rotation always take care thatthe washer plate is positi oned properly. For incorrect assembly the danger of damag-ing may occur. This creates an acute risk of fatality to the operator and others.

C O R R E C T

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

F A L S E

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

D Diameter of mounting boltT Width of bolt slot

1 Notch at the washer2 Inner edge of the bolt slot

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


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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 new washers wi th lock against rota-tion on one crane is not permitted.

3.2.5 Washer plate without lock against rotation

Washer plates with lock against rotation for mounting bolts with diameter of M20 and M48are not available. For this diameter steel plates with an appropriate hole have to be used aswasher plates. To avoid the rotating respectively slipping of the washer plate it is necessarythat the plate is welded to the crane base after installation. The length of this welding seamhas to be at least 20mm to avoid increased hardness in the area of the welding (see chapter4 ‘Welding on Crane and Attachment’).

This type of washer plates are also used for EPSILON cranes with mounting bolts diameterof M24 and M33.

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

1 Mounting bolt2 Washer plate without lock against rotation3 Welding seam for securing the washer plateL Length of the welding seam (min. 20 mm)

The washer plates without lock against rotation also have to be used for PALFINGERcranes with an ordering date before 1st of July 2011 (e.g. rebuilding or spare parts). The rea-son 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 corrosionagain once the welding work is done.

3.2.6 Bolt protection cap

After finishing the assembly the bolt protection cap has to be putted on the mounting bolt re-spectively nut. All components are included in the mounting kit.


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Illustration 06-1023; Bolt protection cap

1 ..... Balance

2 ..... Sub frame

3 ..... Chassis frame

4 ..... bolt protection cap

3.3 Single mounting bolt installation (BRI-4)

The mounting bushing is welded to the base shear plate. PALFINGER provides for themounting bushes pre manufactured welded kits.

Illustration 06-1026; Crane installation BRI-4

1 Mounting bush2 Washer hardened (HV300)3 Mounting bolt

At the BRI-4 installation a hardened washer HV300 (part 2) is used between the nut and thebush. 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 al-ways use 2 mounting bolts for each mounting slot, this means mounting bushes are permit-ted for using of 2 mounting bolts for each mounting point.


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When positioning the mounting bushes it is necessary to keep a gap of at least 5 mm be-tween the upper edge of the bush and the lower edge of the crane base. This is to ensurethat 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 mounting bush to sub frame (design standard mounting bush)

The following list shows the PALFINGER mounting bushes as a function of the mountingbolt diameter including the required welding seam thickness for the bushes. The diameter ofthe mounting bolts can be found in the pertinent technical data sheets.

Mount ing bol t M20x1,5 M24x1,5 M30x1,5 M36x1,5 M42x1,5 M48x1,5

Max. mounting bolt forceFBr [kN]

85 125 200 290 400 530

Suitable mounting bushET Nr.

HXE-4534 HXE-3144 HXE-3145 HXE-9084 HXE-2527 HXE-4514

Bush length [mm] 120 160 160 214 214 310

Thickness connection plate[mm]

6 8 8 10 12 12

Material quality connectionplate

S355

Filler materialZ1;

see Chapter 4 „Welding at Bodywork and Crane“

Quality class CDIN EN ISO 5817


Min. welding seam thick-ness aW [mm]

4,5 6 7 8 10 10

Beware!

Welding may be done only by people in possession of a valid welder’s certificate inaccordance with EN 287-1 or with an equivalent national welder’s certificate (seechapter 4 ‘Welding on Crane and Attachment’).


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

Illustration 06-1034; Connection of mounting bush to sub frame, design standard mounting bush M20, M24, M30 andM36

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


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3.3.2 Connection of mounting bush to sub frame (design standard mounting bush shortened)

If necessary it is possible to shorten the standard bush according the following list. The re-quired gusset plates and welding seams are defined also in the following list.

Mounting bolt M20x1,5 M24x1,5 M30x1,5 M36x1,5 M42x1,5 M48x1,5

Max. mounting bolt forceFBr [kN]

85 125 200 290 400 530

Mounting bush length [mm] 58 78 78 120

Approvalfrom

PALFINGER

required

Approvalfrom

PALFINGER

required

Suitable mounting bolt bushP. No.

HXE-4534 HXE-3144 HXE-3145 HXE-9084


6 8 8 10

Thickness gusset plates [mm]

6 1 8

1 8

1 8

1

Material quality of connec-tion and gusset plate

S355

Filler materialZ1

see Chapter 4 „Welding at Bodywork and Crane“Quality class

CDIN EN ISO 5817


Min. welding seam thick-ness aW1 [mm]

5 6 8 8

Min. welding seam thick-ness aW2 [mm]

4 5 7 7

Beware!


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


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3.3.3 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 mount-ing plate. In the following list are the required bushes and welding seams defined.

Mount ing bol t M20x1,5 M24x1,5 M30x1,5 M36x1,5 M42x1,5 M48x1,5Max. mounting bolt forceFBr [kN]

85 125 200 290 400 530

Suitable mounting bolt bushP. No.

HBS-7804 HBS-761 HBS-110 HBS-3366 HBS-3076 HBS-7801

Recommended mountingbush length [mm]

120 160 160 214 214 310


6 8 8 10 12 12

Material quality of connec-tion plate

S355

Filler materialZ1

see Chapter 4 „Welding at Bodywork and Crane“

Quality classC

DIN EN ISO 5817


Minimum welding depthx (**)[mm]

15 19 22 24 26 30

Control dimensionb [mm]

27 33 38 46 52 56

Min. welding seam thick-ness aW [mm]

5 6 7 10 12 12

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

Beware!


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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3.4 Double mounting bolt installation (BRI-8)

3.4.1 Option with mounting plate

For the double mounting bolt installation with mounting plates, steel plates are laid under thechassis frame and two mounting bolts are inserted. When this option is chosen, the chassisframe must be secured from compression (see part 3, illustration 06-1029). The support pro-

file must be secured from slipping by using of a screw which is connected to the chassisframe (see part 4, illustration 06-1029).

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

1 Build-up level of crane2 Mounting bolt3 Support profile4 Securing of support profile5 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, illustration06-1024) 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 theassembly of the washer with lock against rotation. All components are included in themounting kit.

Illustration 06-1024; Crane installation BRI-8


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1 Washer hardened (HV300)2 Mounting plate3 Washer with lock against rotation

When assembling the mounting plate you should take care, that the graven article number inthe 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 Position of graven article number on the mounting plate2 Position of washer with lock against rotation by assembly

3.4.2 Option with mounting bush

In this mounting option, the first bushing is welded to the base shear plate on the outsideand the second bushing is welded into the sub frame. The mounting bushings should beplaced 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 Build-up level of crane2 Mounting bush


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3.5 Fitting the stabilizer cylinders to the crane extension arms

When fitting the stabilizer cylinders to the extension arms the following points need to betaken into account:

Clean flange surfaces on both sides of any dirt and foreign bodies. The surface protec-

tion 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 cleanedand degreased. To avoid cold shock effects it has to be guarantied that the environmentand the glued parts will have the requested minimum temperature required by thescrew-locking adhesive. Following adhesives are approved by PALFINGER (the specifi-cation of the adhesive supplier must be considered during processing):

o LOCTITE 243 (alternative LOCTITE 245)

o VARY BOND 12-43 (alternative VARY BOND 12-45)

o 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 fas-tening 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 informationsheets. No other stabilizer plate extensions are permitted without separate approval fromPALFINGER!

No modification of the flange plates on the stabilizer outrigger or stabilizer cylinder (e.g. ex-tension by one row of holes) is permitted without separate approval from PALFINGER!

Caution!No bolts other than those specified may be used to fix the stabilizer cylinders to theextension 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 others.


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Tightening torque ISO-screws in Nm:

(not oiled and not lubricated)

Screw: ISO 4762, ISO 4014Nut: ISO 4032Washer: ISO 7090

Screw thread: Screw strength: 10.9

M 12 100

M 14 165

M 16 245

3.6 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 with flapdown-stabil izer

Crossbeam, flapdown stabilizer and balancing rod are delivered separately. After installationof the crossbeam on the sub frame the flapdown stabilizer are welded to the crossbeam. Af-terwards the balancing rod is mounted to the flapdown stabilizer.

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

1 Crossbeam2 Base shear plates3 Sub frame4 Chassis frame5 Mounting bolts6 Mounting bushes7 Flapdown stabilizer8 Balancing rod9 Connection plate


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If crane base and crossbeam of the additional stabilizer do not have the same level it is nec-essary 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 be secured against slipping with mechanical stop accordingpoint 3.2.3

3.6.2 EPSILON crane base with additional stabilizer

In this case an EPSILON additional stabilizer is mounted together with the crane base

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

1 Crossbeam of additional stabilizer2 Base shear plates3 Sub frame

4 Chassis frame5 Mounting bolts6 Mounting bushes7 Connection plate

If crane base and crossbeam of the additional stabilizer do not have the same level it is nec-essary 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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The required clamping length „Y“ of the screws (see table above) has to be observed. In or-der 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. Beforemounting 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 mountingframe)

Advice!

Take care in steel to steel connection between crane and mounting frame. If there isno steel to steel connection a loosening of the mounti ng screws is possible.


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Mounting of Cranes with Combination Crane Base Chapter 6 Crane Installation

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4 Mounting 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.

1

2 3 4 5 6

7

891011

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

1 Combination crane base2 Bearing ring mount3 Support cylinder4 Crane support (cross-beam)5 Welding connection point6 Welding connection point7 Load booms8 Oil tank9 Oil cooler10 Main boom11 Crane column with control valve

4.2 Combination crane base

The combination crane base (EGG) serves as both as a crane base and as a fully equiva-lent replacement for a sub frame. Depending on the mounting variant, the sub frame mod-ules 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 tobe secured to the base shear plates on the truck chassis by welded connections. Themounting bolt connection otherwise used is therefore unnecessary.

The crane support must be positioned in front of the bearing ring mount to achieve betterstability and to realize the maximum length of the boom system with a low crane height. Thistype of construction design makes it possible to keep the construction heights very low evenwith maximum equipment on the crane and the chassis.


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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 pre-vent virtually all collisions with these components.

1 2 3 4 5 6 7

8

Illustration 06-1008; Combination crane base

1 Welding connection point2 Control panel support

3 Bearing ring mount4 Support cylinder5 Crane support (cross-beam)6 Welding connection point7 Free space for protruding components of the truck chassis (transmission, ...)8 Oil tank and oil cooler

4.3 System description for the mounting

As already mentioned in Chapter 5 Sub frame, the crane is positioned directly on the chas-sis frame and connected to the base shear plates (see Chapter Sub frame) shear resistantand torsion resistant by welding. The combination crane base has been dimensioned so thata 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 thesub frames with adjacent loading bridge, pallet or container platform is carried out similarly.The only difference will be in the varying heights and lengths of the sub frames.

Contact PALFINGER for all other special mounting variants (mounting in the middle, ...).


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1 2

5

3

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

1 Truck chassis2 Front sub frame module (frame end)3 Auxiliary support4 Crane5 Rear sub frame module

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

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

Position and tack the crane and auxiliary support to the chassis (the position of thecrane 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 Subframe Module”).

Placement of the sub frame modules on the chassis.

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

4.4 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 essentially 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 middlecross-piece and the base plate of the combination crane base can be welded to the subframe module; this opening is then welded closed with a closing plate (1) to complete themounting of the sub frame.


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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 modulePark 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 thor-oughly 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 thebase shear plates.

Once the sub frame module has been aligned and tacked, the welding work must progressin 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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1

2 3

45

Illustration 06-1014; Mounting of rear sub frame module

1 Crane2 Chassis frame or base shear plate3 Additional stabilizer4 Rear sub frame module5 Closing plate

The rear sub frame module must be welded to the crane or the base shear plate in the fol-lowing areas:

1. Connection – combination crane base and the bending area of the sub frame modulewith the base shear plate.

2. Connection – rear area of the sub frame module with the base shear plate.

3. Connection – combination crane base with the sub frame module.

After the middle cross-piece and the base plate of the combination crane base have beenwelded to the sub frame module, the opening in this area must be welded closed with a clos-ing plate.

4.6 Production and mounting of the front sub frame module (frame end)

A suitable frame end must be prepared in the front area so that the bending forces can besmoothly transferred to the chassis frame. This is welded at the front to the combinationcrane base and the base shear plates.

The frame end must be adapted to the available space in this area. Allowance must bemade for any open space for maintenance work on the transmission or other components. Ifthere is enough space, the recess (3) in the frame end can be left out.


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1

23

Illustration 06-1015; Design front sub frame module

1 Combination crane base2 Front sub frame module (frame end)3 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 Crane Installation on removable Mounting ConsoleIf you want the dismounting of the crane to be simple, a removable mounting console isusually the best solution.

Illustration 06-1039; Installation on removable mounting console

1 Mounting console

2 Mounting parts of removable mounting console at the chassis frame3 Chassis frame4 Sub frame

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


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Crane Installation with Trailer Frame Chapter 6 Crane Installation

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6 Crane Installation with Trailer FrameWhen 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 da-ta sheets or obtained from PALFINGER.

1 2

3

1 Crane2 Sub frame3 Trailer frame


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7 Crane Installation with Tube BaseThe crane base on cranes which have a rotary joint on the slewing gear can be integratedcompletely into the sub frame. The standard crane base is then replaced by a so-called tubebase which is welded into the sub frame.

Instead of the crane support, one or more auxiliary supports are installed.

Beware!

After welding the tube base, the f lange plate must be examined for distort ion from thewelding without fail; if the tolerances have been exceeded, suitable procedures mustbe used to correct the distortion.

1

2 3

1 Tube base2 Auxiliary supports3 Sub frame


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Stationary mounted loading crane Chapter 6 Crane Installation

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8 Stationary mounted loading craneStationary mounted cranes are cranes installed on a rigid substructure (e.g. concrete foun-dation). As stationary mounting of cranes does not correspond with any series, it must beplanned 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 componentsand the substructure, such as:

Classification of stationary mounted loading cranes in lift class HC2 correspondingEN12999:2011 (truck mounted cranes are assigned to HC1). As a result the crane'sload capacity gets reduced. The reduction depends on the maximum vertical hookspeed or grab speed and can be determined as follows (dynamic coefficients in formulaaccording to EN12999:2011) and is valid for all not SH cranes.

[%] 100

2

v0,341,10

2

v0,171,05

ph

h

max

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

85%

86%

87%

88%

89%

90%

91%

92%

93%

94%

95%

96%

97%

98%

99%

100%

0 0,2 0,4 0,6 0,8 1 1,2 1,4 1,6

vh [m/s]

p m a x

[ % ]

Illustration 06-9001; Reduction of the working pressure in dependence of the maximum vertical hook speed or grabspeed for not SH cranes

Vh maximum vertical hook speed or grab speed [m/s]

pmax crane reduction (in HC2) referred to maximum working pressure in case of truckmounting crane (HC1)


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After working pressure reduction the body builder must attach new load capacity chartson the crane and in the operator manual!

Note!

For SH cranes the working pressure for stationary installation must be reduced to 95%

of the maximum working p ressure!

Note!

For EPSILON cranes the working pressure for stationary application must always bereduced to 80 % of the maximum working pressure!

Not all of the EPSILON crane models are suitable for stationary application, thereforecontact 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 dimen-sioned pressure accumulator at the lifting cylinder.

Warning: The declaration of conformity for the crane must be re-issued by the bodybuilder.

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 thestandard crane base, you can contact PALFINGER. In combination with suitable ar-rangements (e.g. pipe bracket) it could be possible to realize stationary installation.

Note!

Stationary crane mounting with combination crane base (integral base frame) is notpermitted!

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

The correct classification of lifting class, hoist types and capacity load groups according toEN12999:2011 or the implementation of suitable measures for impact reduction lie in the re-sponsibility of the body builder. Furthermore the body builder is responsible for the correctdesign of the substructure and the crane mounting. In case of any uncertainties, contact theacceptance authority or PALFINGER.

Warning!

Improper use for o ther than the intended purposes can cause the crane componentsto break.


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Stationary mounted loading crane Chapter 6 Crane Installation

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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 Installation of PC Cranes

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

Attention!

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

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

An appropriate substructure must exist in the chassis area to ensure trouble-free installationand function. If a suitable substructure is not already in place, a suitable sub frame construc-tion must be prepared (unless the vehicle manufacturer prescribes or recommends other ac-tions).


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Installation of PC Cranes Chapter 6 Crane Installation

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The sub frame can be secured to the vehicle using mounting bolts or other mounting ele-ments.

Beware!

If the sub frame is secured using double mounting brackets, the chassis frame mustbe protected f rom compression (see Chapter6.3.4, Crane Installation / Double Mount-ing Bol t Installation).

During the assembly of the crane on the mounting plate it is necessary to put 4 distancewasher at the fixing points with a thickness of 3mm and an outer diameter of 50 mm be-tween 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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