General Remarks and Information. Mounting Preparations. Auxiliary Frame. Securing the Crane. Mounting Auxiliary Supports

Transcription

1 Contents General Remarks and Information This chapter contains remarks about laws and regulations which must be observed when mounting this crane. You will also find references to the standards and regulations which are mentioned. Mounting Preparations This chapter contains information about preparing the crane for mounting, such as the calculation of the axle load and stability, calculation of the auxiliary frame, calculation of the hydraulic drive and much more. Auxiliary Frame This chapter contains remarks on working on the chassis frame and information on preparing and mounting the auxiliary frame. Securing the Crane The various ways the different crane models can be secured are described in this chapter. Mounting Auxiliary Supports The chapter describes the method for mounting auxiliary supports and what you must pay attention to during the mounting. Mounting Remarks for the Crane Hydraulics This chapter describes the hydraulic system of the crane and how the crane must be connected to the hydraulics supply. The Crane s Electrical System This chapter describes the electrical system of the crane and how the crane must be connected to the power supply. Mounting Auxiliary Devices Here we describe what you must pay attention to when mounting auxiliary devices from Palfinger. Delivery of the Crane You will find information regarding everything that must be noted before and during the delivery of the crane in this chapter.

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3 General Remarks and Information Chapter 1 CONTENTS 1.1. GENERAL WORKING WITH THE MOUNTING INSTRUCTIONS APPLICABILITY SYMBOLS USEDINTHEMOUNTING INSTRUCTIONS REGULATIONS, LAWS AND GENERAL REMARKS RESPONSIBILITY WARRANTY LIABILITY QUALITY ASSURANCE CE CERTIFICATION MODIFICATIONS TO THE CRANE PROPER USE PRE-INSPECTION BY PALFINGER REFERENCES TO STANDARDS AND REGULATIONS EXCERPT FROM STANDARDS EXPLANATION OF TERMS MODEL CODES /CODES FOR PALFINGER CRANES AND ACCESSORIES WHEEL FORMULA MAJOR DIMENSIONS OF THE WELDING SEAM... 10

4 1.1-1 General

5 General General Working with the Mounting Instructions The PALFINGER mounting instructions are your guide to mounting a crane. The precise mounting of the crane, e.g., selection of the correct chassis, secondary drive, pump, calculation verifications, and so forth, should be considered at the time the crane is sold. These instructions contain technical instructions, remarks and standards which must be observed during the mounting of the crane. In addition, they have useful remarks regarding the proper mounting of the crane. You can obtain the latest issue of these mounting instructions as well as additional technical documentation from your PALFINGER general representative or on the Internet. The general representative is obligated to provide these mounting instructions to the company which manufactures the superstructure. PALFINGER reserves the right to change these mounting instructions at any time or to issue instructions for the mounting of individual cranes which deviate from these mounting instructions Applicability These mounting instructions are applicable to PALFINGER knuckle boom cranes, telescoping cranes, PW cranes and PC cranes, but not to marine and railway cranes. Contact the PALFINGER general representative or the PALFINGER Customer Service for special models or special superstructures Symbols Used in the Mounting Instructions The following symbols are used in these mounting instructions: This symbols indicates important information which must be observed without fail when mounting a crane. This symbol refers to additional information and tips which may be helpful during the mounting of a crane.

6 1.2-1 Regulations, Laws and General Remarks 1.2. Regulations, Laws and General Remarks Responsibility The responsibility for the proper design, manufacture and mounting of superstructures and the modification of chassis is always and exclusively and in full that of the company which manufactures or mounts the superstructure or carries out the modification (product liability). Superstructures and/or modifications approved in writing by PALFINGER do not release the superstructure manufacturer from his product responsibility. If the company carrying out the work notices an error in the planning stage or in the intentions of the customer, the user, his own personnel or the vehicle manufacturer, it must point out the error to the person in question. The company is responsible for ensuring that the operational and traffic safety, the servicing opportunities and the driving properties do not have any adverse characteristics. With respect to operational and traffic safety, the company must work according to state-of-the-art technology, the legal statutes of the particular country, the standards and the acknowledged rules of the specialist field with respect to design, static calculations, the manufacture of superstructures, the instructions and the operating instructions. More difficult conditions of operation must be considered separately. The companies mounting the cranes are liable for damage which is a consequence of inadequate functional and operational safety or incorrect operating instructions. PALFINGER therefore demands from the superstructure manufacturer: Greatest possible safety in accordance with the latest technology Understandable and adequate operating instructions Easily visible and permanently mounted signs warning of danger areas for operators and/or third persons Observance of the necessary protective measures in order to prevent risks in accordance with EN 1050 (e.g., crushing, shearing, squirting of liquids...) Warranty Warranty claims may be asserted solely on the basis of the purchase contract between the buyer and the seller. Consequently, the warranty obligation is solely the responsibility of the seller of the delivered object in each case. The seller may assert neither guarantee nor warranty claims against PALFINGER if the mounting instructions have not been observed or if the machine has been used improperly. In addition, the dealer may assert neither guarantee nor warranty claims against PALFINGER if an unsuitable chassis or an unsuitable superstructure with respect to the intended use of the crane is chosen, or if the damage to the crane is caused by the superstructure or the type and execution of the mounting of the superstructure, or by improper operation Liability If the mounting company determines that there are defects in the PALFINGER product, the latter must be notified. Any liability on the part of PALFINGER, especially for consequential damage, is hereby excluded to the extent that said exclusion is legally permissible. PALFINGER s liability for damage as a consequence of slight negligence (culpa levis) is also excluded. The company which carries out the mounting must indemnify PALFINGER from any and every liability with respect to the former s customers or other third parties, to the extent that any damage which has occurred is a consequence of the company s failure to observe these mounting instructions, or if damage to the crane superstructure is caused by improper design, manufacture, mounting or instructions.

7 Regulations, Laws and General Remarks Quality Assurance In view of international product liability legislation, continuous quality monitoring during the performance of conversions and the manufacture or mounting of superstructures is required. We recommend that the manufacturer of the superstructures set up a quality management system in conformity with general requirements and generally accepted principles (e.g., in accordance with DIN EN ISO 9000) CE Certification In the EU and in certain other countries, the Machine Directive 98/37EG as currently applicable and supplemented by harmonized standards must be considered during the mounting of the crane. As a motor vehicle with a mounted crane is deemed to be a single machine according to the EU Machine Directive, this combination (truck + crane + any additional devices) must be equipped with a CE certification and a conformity declaration by the mounting company. Since the truck loading crane is an interchangeable piece of equipment in the sense of the Machine Directive, the crane is delivered ex works PALFINGER with the CE certification and conformity declaration. The conformity declaration of the crane must be supplemented by the conformity declaration of the mounting company. If a crane is delivered without the components required for CE (e.g., supports), PALFINGER will issue a manufacturer s declaration and the crane will be delivered without a conformity declaration and CE certification. In this case, the mounting company is responsible for the conformity procedure in accordance with the aforementioned Machine Directive. PALFINGER original accessories correspond to CE requirements, i.e., the conformity procedure for the delivered component has already been carried out by Palfinger. So the mounting company must provide verification only for the complete superstructure. During the mounting, the company must work in accordance with the aforementioned Machine Directive and issue the required verifications such as hazard analysis, risk assessment and description of the remaining risk in its appendix to the operating instructions. The Machine Directive prescribes a type test by an authorized agency for any machines intended to lift people. If any modifications are made to the equipment, or if there is a deviation from the proper use of the equipment as a loading crane, a new conformity declaration must be issued by the mounting company Modifications to the Crane Modifications to the crane without consultation and written approval by PALFINGER are not permitted for reasons of safety, product liability and PALFINGER s guarantee. If modifications are made to the crane, PALFINGER Customer Service must be consulted in advance and written approval from the manufacturer must have been obtained. This is especially important if the loadbearing crane components are welded, drilled or worked on in any other way which could adversely affect the statics. Modifications of this nature may be made only in authorized workshops approved by PALFINGER Proper Use The crane may be used only in the scope of its classification see technical sheet (e.g., H1B3). PALFINGER Customer Service must be consulted before using the crane in any other way. Improper use, such as grab operation (with the exception of bulk materials), stationary mounting, use with wood and junk... leads to premature wearing and overloading of components.

8 1.2-8 Regulations, Laws and General Remarks Pre-inspection by PALFINGER A pre-inspection by Palfinger is not required if the crane mounting or modifications are carried out in accordance with these mounting instructions. If PALFINGER performs a pre-inspection for a crane mounting, it will cover only the basic compatibility with the chassis used in this case and the interfaces to the superstructure (e.g., dimensions and securing of the auxiliary frame). The pre-inspection is a service offered by PALFINGER and does not release the mounting company from its obligation to verify the compatibility itself once again. The mounting company bears sole and exclusive responsibility for the compatibility; PALFINGER does not assume any liability for the compatibility. PALFINGER reserves the right to refuse to issue approval of the crane mounting or modifications even if a comparable approval had been granted earlier. Technical progress does not allow similar situations to be treated the same without question.

9 References to Standards and Regulations References to Standards and Regulations Excerpt from Standards STANDARD No. DESIGNATION ISO 9000 Quality Management Systems EN 280 Transportable Lifting Workman Baskets EN Testing of Welders EN EN EN 439 Machine Safety Basic Terms Machine Safety Technical Guidelines Welding Additives Shield Gases for Arc Welding and Cutting EN 440 EN 499 EN 719 Welding Additives Wire Electrodes and Weld Metal for Metal-Gas-shielded Welding of Unalloyed Steels and Fine-grained Steels Classification Welding Additives Encased Rod Electrodes for Arc Manual Welding of Unalloyed Steels and Fine-grained Steels Classification Welding Supervision Tasks and Responsibilities EN Welding Quality Requirements Arc Welding of Metallic Materials, Part 1 EN 1050 Machine Safety Guidelines for Risk Assessment EN EN EN EN Hot-rolled Products Made of Unalloyed Structural Steels, Technical Terms and Conditions of Delivery Hot-rolled Products Made of Fine-grain Structural Steels Suitable for Welding Metal Products Types of Inspection Certificates EN Cranes Loading Cranes DIN DIN DIN DIN DIN Cranes Basic Principles for Steel Girders Calculation Principles for Construction Design and Execution Calculation of Motor Vehicle Cranes Cranes, Stability DIN Steel Constructions Measurement and Design DIN /A1 Steel Constructions Measurement and Design Amendment A1 EN EN Arc Welded Connections on Steel Guidelines for the Evaluation Groups of Irregularities Arc Manual Welding, Gas-shielded Welding and Gas Welding, Welding Seam Preparation for Steel

10 1.4-1 Explanation of Terms 1.4. Explanation of Terms Model Codes / Codes for PALFINGER Cranes and Accessories Crane Model Code PK L E XXX I I I I I I I I I I I Code for additional crane equipment I I I I Code for the number of hydraulic telescoping extensions I I I Main boom model I I Number of linkage systems I Lift moment code Crane designation Model Codes for Second Knuckle System (Fly-jib) PJ 101 A XXX I I I I I I I Code for additional crane equipment I I Code for the number of hydraulic telescoping extensions I Lift moment code Code for second knuckle system Crane designation PC PALFINGER compact crane PK PALFINGER crane PKK PALFINGER crane with short knuckle boom PW PALFINGER wallboard PJ Second knuckle system Main boom model () Standard model L Long main boom EL Extra-long main boom T Telescoping main boom Code for the number of hydraulic telescoping extensions () 1 extension A 2 extensions B 3 extensions C 4 extensions D 5 extensions E 6 extensions F 7 extensions G 8 extensions H 9 extensions

11 Explanation of Terms Codes for additional crane equipment -12V 12-Volt model -24V 24-Volt model 2 Hose equipment for one accessory / pan 4 Hose equipment for two accessories / pan 6 Hose equipment for three accessories / pan F (FL) Controls ground H Controls high seat HKONS High seat console with storage space for remote control panel I Controls raised stand J Controls cab RC Remote control OC Continuous pump NK Emergency controls crane column KK1 Joystick control high seat KL0 Linear control high seat LS Load sensing CE EEA-approved model R0 Outriggers extendable on one side R1 Outriggers extendable on both sides R2 Lengthened outriggers extendable on both sides R3 Telescoping outriggers X Hydraulically extendable outriggers STZS Supporting cylinders rigid STZY Supporting cylinders slewable SR.. Support of high seat, controllable EGG Combination crane base TKKR Oil tank mounted on crane base OT No tank on crane base SHB Lifting power limitation dependent on slewing angle S Winch without end position switch and extension stop SH Winch mounted on main boom SHS Winch with overload cut-off SHES Winch mounted on main boom with electrohydraulic extension stop and end position switch SK Winch mounted on knuckle boom SKS Winch mounted on knuckle boom SKES Winch mounted on knuckle boom with electrohydraulic extension stop and end position switch SES Winch with end position switch and extension stop SBM Slewing restriction with manometer TOQU Dead centre above crossbeam TOWI Dead centre above rocker OE Overload protection acoustical or optical OFB Overload protection electrohydraulic with pendulum OFS Overload protection electrohydraulic with pendulum OSE Overload protection electrohydraulic without pendulum OS Overload protection - hydraulic OSK Overload protection hydraulic OSK(M) Overload protection hydraulic with manometer OM Overload protection with manometer 2K Double ring system V.. Mechanical extension (number) W Counterweight 1GETR 1 slewing gearbox 2GETR 2 slewing gearboxes

12 1.4-2 Explanation of Terms Wheel Formula Besides the motor vehicle type, the wheel formula can be used for a more precise designation of the chassis. It is a common expression, but has not been standardized. Dual tires are regarded and counted as one wheel position. Example: 6x4 6 = Total number of wheel positions x = No information 4 = Number of driven wheels A chassis with the wheel formula 6x4 is thus a three-axle vehicle with two driven axles. More exact information about the precise designation of the chassis can be found in the mounting instructions of the truck manufacturer Major Dimensions of the Welding Seam Welding seam symbols and measurements of welding seams are shown in these mounting instructions in accordance with EN Seam thickness a Is the height of the largest isosceles triangle which can be drawn in the cross-section drawing. Leg length z Is the leg length of the largest isosceles triangle which can be drawn in the cross-section drawing. Flat seam Convex seam Concave seam z z z a a a Illustration 1-14 Illustration 1-15 Illustration 1-16 In these mounting instructions, the fillet weld is always measured with the seam thickness a.

13 Mounting Preparations Chapter 2 CONTENTS 2.1. GENERAL REMARKS ON PROJECT PREPARATION TECHNICAL DATA SHEETS OF THE CRANE VEHICLE CRANE POSITIONS ON THE CHASSIS EQUIPMENT RECOMMENDATIONS FOR THE VEHICLE TOTAL HEIGHTOFTHEVEHICLE AXLE LOAD AND STABILITY CALCULATION SELECTION AND CALCULATION OF AN AUXILIARY SUPPORT AUXILIARY FRAME CALCULATION HYDRAULICS HYDRAULIC DRIVE DETERMINING THE REQUIRED TANK VOLUME /OILCOOLER... 25

14 2.1-3 Allgemein

15 General General Remarks on Project Preparation It is a sensible idea to consider in detail the arrangement and function of the mounting as a whole during the planning phase. The standard EN12999 (5.10) as well as provisions applicable in the particular country (maximum dimensions, axle load, permissible total weight,...) must be observed under all circumstances. An area must be left clear in accordance with the standard (e.g., around the crane column, raised stand, high seat...) so that crushing, shearing or damage is avoided. The mounting must not interfere with a clear view of the working area. If necessary, a different / additional operating stand must be provided (e.g., remote control, raised stand...). Space must be allowed around the motors and pumps, switch cabinets, cabs, auxiliary drives,... so that maintenance may be performed without interference. The operating space must not be exposed to emissions (relocation of the emission pipe according to vehicle manufacturer s instructions, or an exhaust line from the engines into the open air). Cranes which cannot be collapsed to the width of the vehicle require a protection device above the mounting or the driver s cab to prevent the crane boom from swivelling out, and there must be a monitoring device of the main boom position with a warning device in the driver s cab. The following information is essential for project planning: o Determine space requirements (e.g., calculating height for vehicle mounting) o Axle load and stability calculation or foundation calculation o Tension sign on chassis and auxiliary frame or foundation o Engine output: engine / secondary drive power output, pumps and leads dimensioning o If available verification of permissible support force on the supplementary support Technical Data Sheets of the Crane We have prepared comprehensive technical data sheets for all of the crane models and the various options; these sheets provide information regarding all of the important dimensions, dead weights, lift moments, loads, hydraulic and electric circuit diagrams, mounting sheets, and similar information.

16 2.2-1 Vehicle 2.2. Vehicle Crane Positions on the Chassis There are three different types of mounting, depending on the way the crane will be used: o o o Front mounting: crane is mounted behind the driver cab. Rear mounting: crane is mounted at the end of the chassis frame. Special mounting: crane is mounted in the middle of the chassis frame, for example. The comments below will describe the advantages and disadvantages of each of the mountings mentioned above. The best possible mounting for the customer s intended use should be selected during the project planning. The mounting examples below do not give specific indications of the possible mountings of the various crane models. It is always necessary to perform axle load and stability calculations. Front mounting: Illustration 2-01 Front mounting of a loading crane from the light and medium crane series on a double-axle chassis (4x2) with a loading bridge and without auxiliary supports Front mounting of a loading crane from the medium crane series with a loading bridge and an auxiliary support at the rear on a triple-axle chassis (6x4). Illustration 2-02

17 Vehicle Front mounting of a loading crane with combination crane base from the crane series for heavy loads on a four-axle tractor (8x4) and with auxiliary support at the rear. Illustration 2-03 o o o o o Advantages Good stability towards the back (good working area towards the back 180 ). This type of mounting is suitable for tractors, models with loading bridges or container platforms. Relatively light load on the rear axle Relatively inexpensive auxiliary frame design Long load can be transported well (load can protrude over the rear) o o o Disadvantages Poor stability towards the front. Heavy load on front axle. Depending on the crane s dead weight, an increase in the permissible front axle load or a double-axle at the front may be required. Loss of reach towards the rear. Rear mounting: Rear mounting of a loading crane from the light and medium crane series on a double-axle chassis (4x2) with a loading bridge and without auxiliary supports Illustration 2-04 Rear mounting of a long-boom crane on a triple-axle chassis (6x4) with loading bridge and an auxiliary support in the front area. Illustration 2-05

18 2.2-1 Vehicle Rear mounting of a loading crane with second knuckle system from the crane series for heavy loads on a triple-axle chassis (6x4) with loading bridge and an auxiliary support in the front area. Illustration 2-06 Advantages o Good stability towards the front. o This mounting type is suitable only for loading bridges and similar equipment. o Relief for front axle (but can have adverse effects on steering properties). o No loss of reach towards the rear. o Simple loading and unloading of a trailer is possible when the crane is mounted at the rear. o Good working area 360. o o o o Disadvantages Difficult to transport long loads. Heavy load on the rear axle A second auxiliary support is often required for lift performance >48mt. Since higher torsion moments may occur when using rear mounting, a torsionresistant auxiliary frame or greater stability factors are required. A straightforward rear mounting is as a rule not possible, or possible only under special conditions, for a crane lift moment of 800 knm or greater. Special mounting: Mounting of a loading crane from the series for heavy loads on a four-axle truck chassis (short wheelbase). Two auxiliary supports have been mounted to achieve adequate stability, whereby the auxiliary support at the rear can be slewed towards the back. Illustration 2-07 Crane mounted on a double-axle semitrailer with an auxiliary support at the rear. Illustration 2-08

19 Vehicle Mounting of a loading crane on a wheel loader Illustration 2-09 o Advantages Customer-specific mounting special requirements of the customer can be taken into account during the planning. The optimization of the mounting allows a maximum of performance requirements to be achieved. o Disadvantages The specific requirements of the customer generally lead to increased design and mounting expenditures mounting usually expensive.

20 2.2-2 Vehicle Equipment Recommendations for the Vehicle Space requirements for crane and mounting It must be determined in the preliminary stage whether transmission components which protrude beyond the chassis frame or other components of the truck (shock absorbers, springs, hydraulic pump, auxiliary drive, air reservoir...) may lead to collision problems with the auxiliary frame or the crane. It must also be determined if there is adequate space for the spring travel of the axles. Parking brake It is a sensible idea to equip the front axle(s) with a parking brake to achieve better stability during crane operation. Selection of the length for the rear overhang (L) The rear overhang (L) must be adjusted to the loading bridge length, or, based on the standard length of the rear overhang, the achievable loading bridge length must be determined (see Illustration 2-10a) for a front mounting of the crane. If an auxiliary support is required for a crane mounting on a tractor, the length of the rear overhang must be long enough so that the auxiliary support can be attached properly (see Illustration 2-10b). It is therefore a sensible idea to select the required length of the rear overhang (L) when ordering the vehicle so that the vehicle customizer is not required to make any modifications to the frame The rear overhang must be selected in accordance with the space requirements of the crane when the crane is mounted at the rear (see Illustration 2-10c). L Illustration 2-10a Illustration -10b Illustration 2-10c. Legal and national provisions must be observed in allowing for the overhang at the rear!

21 Vehicle Preparation of the truck chassis frame with lateral base shear plates The plates or moulded parts which are bolted to the side of the vehicle frame and then welded at the top to the auxiliary frame or the combination base of the crane are known as lateral base shear plates. The base shear plates are necessary for static or rigidity reasons in the area underneath the loading crane and in the area of the auxiliary support. They are used to create a bending-resistant and a shearresistant connection between the vehicle frame and the crane or auxiliary frame. They are also included in the cross-section calculation. 1 Loading crane 2 Base shear plate 3 Chassis frame 4 Auxiliary frame Illustration 2-11 Some truck suppliers already offer fitted base shear plates which, if desired, can be pre-mounted. It is a quality assurance measure, and usually economically advantageous, if the base shear plates are taken into account when the truck is ordered. The vehicle customizer can then avoid the complicated work of mounting the base shear plates. Ask your truck supplier about this!! More detailed information about design, dimensioning and material quality of the base shear plates can be found in Chapter 3.3. Connecting Elements on the Auxiliary Frame.

22 2.2-3 Vehicle Front frame reinforcement for the mounting of support cylinders in front of the driver s cab 1 If it is supposed to be possible to make full use of the crane moment even above the driver s cab, this can be achieved by mounting one or two support cylinders (1) in front of the driver s cab. This requires a suitable bending-resistant chassis frame from under the driver s cab all the way to the bumper at the front. The vehicle customizer must clarify, in binding agreement with the truck manufacturer, the permissible bending moment on the chassis frame or what support forces may be applied to the front support cylinders. Some truck manufacturers offer so-called snowplough attachments or towing attachments as special equipment. As a rule, this special equipment is well-suited for the mounting of support cylinders. Illustration Total Height of the Vehicle A height calculation verifies that the total height of the vehicle remains within the defined limits (legal provisions or restrictions due to intended use). Influencing factors: o Vehicle mounting height, incl. auxiliary frame o Crane height: --> folded --> over loading surface --> second knuckle system Before beginning the mounting, measure the frame height of the chassis and the height of the crane and compare the measurements with the height calculation.

23 Vehicle Crane with conventional crane basic frame The chassis frame must be reinforced with an auxiliary frame. The following formula can be used to calculate the overall height of the vehicle: H + GES = HFG + HHR HK H GES... Total height H FG... Chassis height H HR... Auxiliary frame height H K... Total crane height (see technical data sheets) HFG HHR HK HGES Illustration 2-12a Crane with combination basic frame The crane is placed directly on the chassis frame, so the total height can be calculated according to the following formula: H H + H GES = H GES... Total height FG K H FG... Chassis height H K... Total crane height (see technical data sheets) HFG HK HGES Illustration 2-13

24 2.2-4 Vehicle Axle Load and Stability Calculation The determination of the axle load and the calculation of the stability factor against tipping over are absolutely essential for vehicle optimization and correct mounting design. The mounting must be designed so that a lateral weight difference does not cause any tilting of the vehicle. Permissible limits may be obtained from the truck manufacturer. The calculation program PACWIN can be used as an aid to calculate the axle load and stability factors easily. Palfinger Customer Service and all general representatives will be glad to give you more information about this program. You will also find further information about calculating the axle load in most mounting guidelines of the truck manufacturers. Axle load calculation All of the weights of the mounted components (crane, auxiliary frame, tank...) must be distributed between the front and rear axles in accordance with the moment rate, whereby the reaction forces should always be related to the theoretical middle of the front or rear axle. The front axle(s) of the vehicle must always be loaded with a minimum share of the total weight of the vehicle in order to avoid negative steering characteristics. Precise information is obtainable from the truck manufacturer. Theoretical wheelbase The theoretical wheelbase is a theoretical value used in calculating the axle loads. The definition is shown in the following illustrations. The wheelbase effective for turning used in calculating the turning tracks is not always identical with the theoretical wheelbase required for calculating the axle load. Determining the theoretical wheelbase l th for a double-axle chassis RA th... theor. rear axle middle G zul1... perm. axle load of the 1st axle G zul1... perm. axle load of the 2nd axle l Wheelbase from 1 st to 2 nd axle l th... theoretical wheelbase zul1 = zul2 l th = l 12 Illustration 1-11

25 Vehicle Determining the theoretical wheelbase l th for a triple-axle chassis RA th... theor. rear axle middle G zul1... perm. axle load of the 1st axle G zul1... perm. axle load of the 2nd axle G zul1... perm. axle load of the 3rd axle l Wheelbase from 1 st to 2 nd axle l Wheelbase from 2 nd to 3 rd axle l th... theoretical wheelbase zul1 Illustration 1-12 zul2 zul3 l th = l 12 G + G zul3 zul2 * l + G 23 zul3 Determining the theoretical wheelbase l th for a four-axle chassis with two front and two rear axles for any axle loads zul1 zul2 zul3 zul4 RA th... theor. rear axle middle FA th... theor. front axle middle G zul1... perm. axle load of the 1st axle G zul1... perm. axle load of the 2nd axle G zul1... perm. axle load of the 3rd axle G zul1... perm. axle load of the 4th axle l Wheelbase from 1 st to 2 nd axle l Wheelbase from 2 nd to 3 rd axle l Wheelbase from 3 rd to 4 th axle l th... theoretical wheelbase Illustration 1-13 l th = l 23 G + G zul1 zul1 * l + G 12 zul2 G + G zul4 zul3 * l + G 34 zul4 Stability calculation The vehicle must be stable throughout the entire working area. This can be achieved by using the following systems: o o o o Adequate support width Auxiliary supports Slewing limitation Lift moment restriction in certain slewing areas (SHB) The safety factor against tipping over is the ratio of the total of all stabilizing moments to the total of all tip moments. ΣM S = Σ M S K S... M S... M M... Safety factor against tipping over Total of all stabilizing moments Total of all tipping moments The safety factor against tipping over, also called the stability factor (S), must be observed in accordance with EN12999 or the regulations specific to the country.

26 2.2-5 Vehicle Selection and Calculation of an Auxiliary Support Preselection of an auxiliary support Which auxiliary support is required or suitable for a crane mounting is basically dependent on the size of the crane, the truck chassis weight, the mounting position and type of mounting and similar factors. An axle load and stability calculation is also required for the correct selection of an auxiliary support (see Chapter 2.2-4). The following diagram may be used to preselect quickly an auxiliary support. The diagrams 2-01a and 2-01b below can be used to determine the minimum support width of an auxiliary support. To do so, draw a horizontal line on the crane lift moment scale (see technical crane data sheets) and a vertical line at the permissible total weight of the truck chassis. The point where these two lines cross shows the minimum support width (w) of the auxiliary support. This value can now be used to select the appropriate auxiliary support. When an auxiliary support has been selected, the next step is to determine the expected support force F ST using the diagram 2-02 and to compare it with the permissible values of the auxiliary support according to the technical sheet. If the calculated support force is greater than the permissible support force of the selected auxiliary support, a stronger auxiliary support must be selected. Begin with the upper part of Diagram 2-02 and determine where the support width of the selected auxiliary support (w) and the distance from the middle of the crane column to the middle of the auxiliary support (L) intersect. Note that the actual support width of the selected auxiliary support must be used to calculate the support force F ST and not the value determined using the Diagrams 2-01a or 2-01b. From this intersection, draw a line running parallel to the circular arc down to the end of the diagram. From this point, draw a vertical line to the lower diagram. The final step is to draw a horizontal line to the right to the maximum crane lift moment scale. The intersection of these lines is the support force F ST to be expected. The support force thus determined must be multiplied by a factor of 1.08 for crane models which are not equipped with HPLS. The diagrams below may be used only for the preselection of an auxiliary support. They do not replace the stability calculation or the static and rigidity verification. The permissible load values of the ground can be seen in the operating instructions for each particular crane. The support plates obtainable from Palfinger may be used for soft surfaces. Appropriate fittings should be provided on the vehicle for this purpose in the proximity of the support.

27 Vehicle Diagram for determining the minimum support width (w) of the auxiliary support for front mounting of the crane ,5 m 8,0 m 7,5 m 7,0 m 6,5 m 6,0 m Max. crane lift moment [knm] ,5 m 5,0 3,5 2,1 m 0,0 m Permissible total weight in t Diagram 2-01a. Diagram for determining the minimum support width (w) of the auxiliary support for rear mounting of the crane Max. crane lift moment [knm] Permissible total weight in t Diagram 2-01b Combination not possible Two front axles required No auxiliary support required Undefined area

28 kN 3 140kN15kN 170kN 90kN 15kN kN1 67,5kN10kN85kN 50kN 25kN 12,5kN Vehicle Diagram for determining the support force F ST on the auxiliary support L L L [m] w 7 2 w [m] kn 190 kn 170 kn 155 kn kn kn 112,5 kn kn 100 kn 85 kn 500 Max. crane lift moment [knm] ,5 kn 50 kn Diagram Cranes with HPLS...F ST = F Cranes without HPLS...F ST = F * 1.08

29 Vehicle Calculating the max. support force on the auxiliary support The following calculation procedure may be used for a more precise determination of the max. support force (F ST ) on the auxiliary support. It is based on the European standard pren12999:2000 (lift load coefficient H1). The calculation is described for a front-mounted loading crane. It can also be used analogously for a rear-mounted crane. Determining the max. dynamic crane lift moment M K (H1): M K is to be determined for a maximum overhang (see stability calculation) M = 1.1* M K E me * 9.81* x ME = 1000 ml * 9.81* R ML = 1000 Φ = 1.1* * ν 2 + Φ E h 2 * M L M K... M E... m E... x E... M L... m L... R... Φ 2... ν h... max. dyn. crane lift moment in knm Moment from dead weight of boom system in knm Mass of boom system in kg Distance from crane column middle to centre of gravity boom system in m Moment from lift load in knm Mass of lift load in kg Distance from crane column middle to lift load in m Lift load coefficient (H1) Lift speed Crane with HPLS ν h 0.75m/s Crane without HPLS ν h 1.5m/s Determining the max. support force on the support cylinder of the auxiliary support: M F ST = L K ST F ST... M K... L ST... max. support force in kn max. dyn. crane lift moment in knm Shortest distance crane column middle to support cylinder of the auxiliary support in m 6 L S T Illustration Truck front axle 2... Loading crane 3... Truck rear axle 4... Auxiliary support 5... Support cylinder auxiliary support 6... Crane column middle

30 2.2-6 Vehicle Auxiliary Frame Calculation The auxiliary frame must be dimensioned in accordance with currently applicable technical regulations or standards. The max. dynamic crane lift moment M K must be calculated according to EN12999 (see Chapter 2.2-5). The calculation program PAF (PAlfinger Frame) can be used to calculate the tension in the chassis and auxiliary frames as well as the support forces on the auxiliary support. PALFINGER Customer Service and all country representatives will be glad to give you more information about this program. Flexible, torsion-resistant crane mounting A) Flexible crane mounting: A flexible crane mounting is a mounting which has low resistance to twisting. In this type of mounting, the mounting follows the movements of the chassis frame when the vehicle is driving over uneven surfaces, subjecting the mounting and the chassis to strong twisting motions. Advantages and disadvantages of a flexible crane mounting: Advantages Disadvantages o Usually low-cost mounting. o Only low torsion moments can be o Good driving properties on uneven transferred to the mounting. terrain. o Wide spring fluctuations during crane o Low tensions from torsion in the operation mounting. o Suitable only for cranes up to about 25mt. Illustration 1-06 Since flexible crane mountings can transfer only low torsion moments, they are only suitable for crane mountings without auxiliary support. You will find more information on flexible auxiliary frame designs in Chapter

31 Vehicle B) Torsion-resistant crane mounting A torsion-resistance crane mounting is a mounting which has high resistance to twisting. Since this mounting s own rigidity permits little torsion in the chassis, the driving properties are worse on uneven terrain. Advantages and disadvantages of a torsion-resistance crane mounting: o o o Advantages High torsion moments in the mounting can be transferred. Little spring fluctuation during crane operation. Suitable for cranes with high lift moment (>25mt) and for rear-mounted cranes o o o Disadvantages Usually expensive mounting. Poorer driving properties on uneven terrain (all-wheel drive often required). High tensions from torsion in the mounting. Illustration 1-07 Since torsion-resistance mountings can transfer high torsion moments, they are well-suited for crane mountings with auxiliary support and for rear-mounted cranes. You will find more information on torsion-resistant auxiliary frame designs in Chapter

32 2.2-6 Vehicle Shear-yielding / shear-resistant frame connections A) Shear-yielding frame connections There is a shear-yielding frame connection if the frame systems allow a longitudinal shift as a consequence of a bending stress on the contact surfaces (see bar model Illustration 1-08). The vertical force F causes both bars to bend, leading to a maximum tension on the outer fibres of the individual frame systems. The tension is 0 is the neutral fibres n. n F σ σ +σ +σ Illustration 1-08 F... vertical force n... neutral fibres -σ... Compressive stress +σ... Tensile stress All of the mountings or auxiliary frames which are bolted to the chassis with fastening angles or similar devices are to be regarded as shear-yielding connections. Relative motion between the vehicle chassis and the auxiliary frame is possible to a limited extent. Shear-yielding fastenings should always be selected as long as they are adequate for the task. You will find more information on shear-yielding connecting elements in Chapter B) Shear-resistant frame connections There is a shear-resistant frame connection when a longitudinal shift of the two frame systems is no longer possible (see bar model Illustration 1-09). This can be assured, for example, by mounting shearresistant connecting elements such as base shear plates on the ends of the frame systems. The max. tensions now occur only in the outer fibres of the complete frame system. n F σ +σ Illustration 1-09 F... vertical force n... neutral fibres -σ... Compressive stress +σ... Tensile stress Relative motion between the frame and the auxiliary frame are no longer possible when shear-resistant connections are used. They should be used when shear-yielding fastenings are no longer adequate, or if the auxiliary frame would have unreasonably large cross-section dimensions if a shear-yielding connection were used. Shear-resistant connecting elements are connected positive-fit with the frame systems (rivets, driven bolt connection). The shear-resistant connection must be designed according to the mounting instructions of the truck manufacturer. You will find more information on shear-resistant connecting elements in Chapter

33 Vehicle C) Combined frame connection The connection types shear-yielding and shear-resistant can also be combined. This means that the shear-resistant connection is used only in the area requiring this type of connection. Otherwise, the shear-yielding connection is used. a F b F... vertical force a... Area of shear-resistant connection b... Area of shear-yielding connection Illustration 1-10 For example, a shear-resistant connection can be selected in the crane area, then there can be a changeover to the shear-yielding connections for the rest of the frame, if permitted by rigidity and stability values. Before beginning the mounting, the chassis and the crane must be weighed and compared with the results of the axle load and stability calculation. In cases of greater deviation, the calculation or the crane arrangement must be corrected. A practical stability test according to EN12999 or another standard specific to the country must be carried out after completion of the mounting.

34 2.3-1 Hydraulics 2.3. Hydraulics Hydraulic Drive The purpose of this calculation is to determine the correct dimensioning of the hydraulic drive for the loading crane. Determining the required data such as conveyance quantity and max. operating pressure according to the technical data sheets of the crane. The following points must be considered to determine the correct design: o Permissible output and torque o Consideration of the total efficiency factor o Selection of the correct gear transmission ratio with ideal motor rotational speed o Correct selection of the rotational direction o Critical rotational speed o Useful life o Maximum length and bend angles of the drive shaft (if required) o Cooling (no heat build-up) o Mounting and accessibility Calculating the efficiency factor The efficiency factor is the ratio of the output performance to the input performance. The output performance is always less than the input performance, which is why the efficiency factor η is always <1 or <100%. When several units are connected to one another in a series, the individual efficiency factors are multiplied. Sample calculations of several efficiency factors An auxiliary drive drives a pump, which in turn drives a hydraulic pump by a drive shaft system with two articulations. Individual efficiency factors: Auxiliary drive η pto =0.9 Drive shaft articulation a η 1 =0.95 Drive shaft articulation b η 2 =0.95 Hydraulic pump η p =0.9 Total efficiency factor: η tot = η pto * η 1 * η 2 * η p η tot = 0.9 * 0.95 * 0.95 * 0.9 = 0.75

35 Hydraulics Calculating the required drive output If a variable displacement pump is used, the calculation must be based on its maximum discharge flow. Formula for drive output, taking into account the discharge flow (Q) and the operating pressure (p): P = qv * p 60 * η tot The drive train (engine, gear box, secondary drive, drive shaft...) must be designed for the calculated output as a minimum. P q v p η tot Drive performance [kw] Discharge flow (volume flow) [l/min] Operating pressure [Mpa] (1MPa = 10 bar) Total efficiency factor Determining the ratings of the hydraulic pumps Depending on their use, either pumps with constant discharge flow or pumps with variable displacement may be used. There are the following construction types of constant flow pumps: o Geared pumps (as a rule up to a max. 230 bar) o Piston pumps (suitable for higher pressures) V i tot n p g qv *1000 = n * i * η = i = n ge en en * i * i pto tot tot n = n p en vol V g Displacement volume of the pump (rating) per revolution [cm³] q v Discharge flow (volume flow) [l/min] n en Motor rotational speed [min -1 ] n p Pump rotational speed [min -1 ] η vol Volumetric efficiency factor i tot Gear transmission ratio total i ge Gear transmission ratio in gearbox Gear transmission ratio in auxiliary drive i pto The total gear transmission ratio (i tot ) is the ratio of the pump rotational speed to the motor rotational speed. The gear transmission ratios can be found in the pertinent technical data sheets of the product manufacturers. The rotational speed of combustion engines must be observed as recommended by the engine manufacturer. Generally this is between 800 and 100 min -1 for vehicle engines. The volumetric efficiency factor (η vol ) of a hydraulic pump (axial piston pumps or geared pumps) can generally be taken at about Precise data is available from the pump manufacturer. The hydraulic pump must not be operated above the permitted rotational speed under any circumstances. The pump should always operate in the optimal rotational speed range (see data sheet of the hydraulic pump) to achieve a high efficiency factor and operational quietness.

36 2.3-1 Hydraulics Calculating the torque Every auxiliary drive and drive shaft has a maximum permissible torque and a maximum permissible drive output under certain operational conditions. These must be checked during project planning. The efficiency factor (η) changes, depending on the unit the torque is supposed to be calculated for Æ see calculation of the efficiency factor qv * p*159 Vg * p T = = n * η 2* π * η p x x T Torque [Nm] q v Discharge flow (volume flow) [l/min] p Operating pressure [Mpa] (1MPa = 10 bar) n p Pump rotational speed [min -1 ] η x Product of the individual efficiency factors V g Displacement volume of the pump (rating) per revolution [cm³] Calculating the max. weight moment of hydraulic pumps for direct mounting When a hydraulic pump is mounted directly on a gear box (e.g., auxiliary drive), the weight moment of the pump must be checked. The purpose of this calculation is to verify that the weight moment of the pump does not put excessive strain on the gear box housing. The permissible value can be found in the technical data sheets from the gear box manufacturer. If the weight moment of the hydraulic pump is not shown in the technical data sheets, this value can be calculated according to the formula below. 1 2 = 1... Gear box / Auxiliary drive 2... Hydraulic pump Mmp mp * 9,81* s M mp Weight moment of the pump [Nm] 1000 m P Dead weight of the pump [kg] Illustration 2-15 s Distance from mounting flange to centre of gravity of the pump [mm] Always observe the guidelines issued by the manufacturers of the pump, motor and gear box.

37 Hydraulics Determining the required tank volume / Oil cooler The following rule applies for the calculation of the required tank volume on a loading crane: Q Tank =2to3* Q Pump(s) Q Tank Tank volume [ l] Q Pump(s) Pump discharge flow [ l/min] If operating with two circulatory systems, the volume flow of both pumps must be added together for the calculation of the tank volume! Following principles apply: Generally speaking, a large tank is always the better solution because of the greater cooling effect. The standard tank is adequate for cranes with a medium number of extensions, and for applications of average operating duration and no large accessories. A larger (external) tank must be provided for cranes with a large number of hydraulic extensions, auxiliary supports, fly jibs or other additional devices which require a large quantity of oil when all cylinders are extended. A large (external) tank must be provided for cranes in continuous operation as well as for all applications with remote control. We recommend the installation of an oil cooler for continuous operation or the use of remote control. The tank must be placed as close as possible to the pump and the suction lines led to the pump as straight as possible to reduce the risk of cavitation. The mounting of the tank above the level of the pump also reduces the risk of cavitation. A separately mounted tank must always be used for rear-mounted cranes as the suction line is too long for the integrated tank on the crane. A shut-off valve must be installed in the suction line immediately after the intake sockets so that the leads or the pump can be changed without emptying the tank.