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Contents

1General Remarks and InformationThis chapter contains remarks about laws and regulations which must beobserved when mounting this crane. You will also find references to thestandards and regulations which are mentioned.

2Mounting PreparationsThis chapter contains information about preparing the crane for mounting,such as the calculation of the axle load and stability, calculation of theauxiliary frame, calculation of the hydraulic drive and much more.

3Auxiliary FrameThis chapter contains remarks on working on the chassis frame andinformation on preparing and mounting the auxiliary frame.

4Securing the CraneThe various ways the different crane models can be secured are describedin this chapter.

5Mounting Auxiliary SupportsThe chapter describes the method for mounting auxiliary supports and whatyou must pay attention to during the mounting.

6Mounting Remarks for the Crane HydraulicsThis chapter describes the hydraulic system of the crane and how the cranemust be connected to the hydraulics supply.

7The Crane’s Electrical SystemThis chapter describes the electrical system of the crane and how the cranemust be connected to the power supply.

8Mounting Auxiliary DevicesHere we describe what you must pay attention to when mounting auxiliarydevices from Palfinger.

9Delivery of the CraneYou will find information regarding everything that must be noted before andduring the delivery of the crane in this chapter.

CONTENTS

1.1. GENERAL ...................................................................................... 3

1.1-1 WORKING WITH THE MOUNTING INSTRUCTIONS................................. 31.1-2 APPLICABILITY ............................................................................... 31.1-3 SYMBOLS USED IN THE MOUNTING INSTRUCTIONS ............................ 3

1.2. REGULATIONS, LAWS AND GENERAL REMARKS............................... 4

1.2-1 RESPONSIBILITY............................................................................. 41.2-2 WARRANTY.................................................................................... 41.2-3 LIABILITY ....................................................................................... 41.2-4 QUALITY ASSURANCE..................................................................... 51.2-5 CE CERTIFICATION ........................................................................ 51.2-6 MODIFICATIONS TO THE CRANE ....................................................... 51.2-7 PROPER USE................................................................................. 51.2-8 PRE-INSPECTION BY PALFINGER .................................................. 6

1.3. REFERENCES TO STANDARDS AND REGULATIONS ............................ 7

1.3-1 EXCERPT FROM STANDARDS........................................................... 7

1.4. EXPLANATION OF TERMS................................................................ 8

1.4-1 MODEL CODES / CODES FOR PALFINGER CRANES ANDACCESSORIES................................................................................ 8

1.4-2 WHEEL FORMULA......................................................................... 101.4-3 MAJOR DIMENSIONS OF THE WELDING SEAM.................................. 10

General Remarks and Information Chapter 1

1.1-1 General

General 1.1-11.1. General

1.1-1 Working with the Mounting InstructionsThe PALFINGER mounting instructions are your guide to mounting a crane. The precise mountingof 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 containtechnical instructions, remarks and standards which must be observed during the mounting of thecrane. 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 technicaldocumentation from your PALFINGER general representative or on the Internet. The generalrepresentative is obligated to provide these mounting instructions to the company whichmanufactures the superstructure.

PALFINGER reserves the right to change these mounting instructions at any time or to issueinstructions for the mounting of individual cranes which deviate from these mounting instructions.

1.1-2 ApplicabilityThese mounting instructions are applicable to PALFINGER knuckle boom cranes, telescopingcranes, PW cranes and PC cranes, but not to marine and railway cranes. Contact the PALFINGERgeneral representative or the PALFINGER Customer Service for special models or specialsuperstructures.

1.1-3 Symbols Used in the Mounting InstructionsThe following symbols are used in these mounting instructions:

This symbols indicates important information which must be observed without fail whenmounting a crane.

This symbol refers to additional information and tips which may be helpful during themounting of a crane.

1.2-1 Regulations, Laws and General Remarks1.2. Regulations, Laws and General Remarks

1.2-1 ResponsibilityThe responsibility for the proper design, manufacture and mounting of superstructures and themodification of chassis is always and exclusively and in full that of the company whichmanufactures or mounts the superstructure or carries out the modification (product liability).Superstructures and/or modifications approved in writing by PALFINGER do not release thesuperstructure manufacturer from his product responsibility.

If the company carrying out the work notices an error in the planning stage or in the intentions ofthe customer, the user, his own personnel or the vehicle manufacturer, it must point out the error tothe person in question.

The company is responsible for ensuring that the operational and traffic safety, the servicingopportunities 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-arttechnology, the legal statutes of the particular country, the standards and the acknowledged rulesof 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 beconsidered separately.

The companies mounting the cranes are liable for damage which is a consequence of inadequatefunctional and operational safety or incorrect operating instructions. PALFINGER thereforedemands 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/orthird persons

• Observance of the necessary protective measures in order to prevent risks in accordance withEN 1050 (e.g., crushing, shearing, squirting of liquids ...)

1.2-2 WarrantyWarranty claims may be asserted solely on the basis of the purchase contract between the buyerand the seller. Consequently, the warranty obligation is solely the responsibility of the seller of thedelivered object in each case.

The seller may assert neither guarantee nor warranty claims against PALFINGER if the mountinginstructions have not been observed or if the machine has been used improperly. In addition, thedealer may assert neither guarantee nor warranty claims against PALFINGER if an unsuitablechassis or an unsuitable superstructure with respect to the intended use of the crane is chosen, orif the damage to the crane is caused by the superstructure or the type and execution of themounting of the superstructure, or by improper operation.

1.2-3 LiabilityIf the mounting company determines that there are defects in the PALFINGER product, the lattermust be notified. Any liability on the part of PALFINGER, especially for consequential damage, ishereby excluded to the extent that said exclusion is legally permissible. PALFINGER’s liability fordamage as a consequence of slight negligence (culpa levis) is also excluded.

The company which carries out the mounting must indemnify PALFINGER from any and everyliability with respect to the former’s customers or other third parties, to the extent that any damagewhich has occurred is a consequence of the company’s failure to observe these mountinginstructions, or if damage to the crane superstructure is caused by improper design, manufacture,mounting or instructions.

Regulations, Laws and General Remarks 1.2-4

1.2-4 Quality AssuranceIn view of international product liability legislation, continuous quality monitoring during theperformance of conversions and the manufacture or mounting of superstructures is required.

We recommend that the manufacturer of the superstructures set up a quality management systemin conformity with general requirements and generally accepted principles (e.g., in accordance withDIN EN ISO 9000).

1.2-5 CE CertificationIn the EU and in certain other countries, the Machine Directive 98/37EG as currently applicable andsupplemented by harmonized standards must be considered during the mounting of the crane. Asa motor vehicle with a mounted crane is deemed to be a single machine according to the EUMachine Directive, this combination (truck + crane + any additional devices) must be equipped witha 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 MachineDirective, the crane is delivered ex works PALFINGER with the CE certification and conformitydeclaration. The conformity declaration of the crane must be supplemented by the conformitydeclaration of the mounting company.

If a crane is delivered without the components required for CE (e.g., supports), PALFINGER willissue a manufacturer’s declaration and the crane will be delivered without a conformity declarationand CE certification. In this case, the mounting company is responsible for the conformityprocedure in accordance with the aforementioned Machine Directive. PALFINGER originalaccessories correspond to CE requirements, i.e., the conformity procedure for the deliveredcomponent has already been carried out by Palfinger. So the mounting company must provideverification only for the complete superstructure.

During the mounting, the company must work in accordance with the aforementioned MachineDirective and issue the required verifications such as hazard analysis, risk assessment anddescription 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 intendedto lift people.

If any modifications are made to the equipment, or if there is a deviation from the proper use of theequipment as a loading crane, a new conformity declaration must be issued by the mountingcompany.

1.2-6 Modifications to the CraneModifications to the crane without consultation and written approval by PALFINGER are notpermitted for reasons of safety, product liability and PALFINGER’s guarantee. If modifications aremade to the crane, PALFINGER Customer Service must be consulted in advance and writtenapproval from the manufacturer must have been obtained. This is especially important if the load-bearing crane components are welded, drilled or worked on in any other way which could adverselyaffect the statics.

Modifications of this nature may be made only in authorized workshops approved by PALFINGER.

1.2-7 Proper UseThe 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.

1.2-8 Regulations, Laws and General Remarks

1.2-8 Pre-inspection by PALFINGERA pre-inspection by Palfinger is not required if the crane mounting or modifications are carried outin accordance with these mounting instructions.

If PALFINGER performs a pre-inspection for a crane mounting, it will cover only the basiccompatibility 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 byPALFINGER and does not release the mounting company from its obligation to verify thecompatibility itself once again. The mounting company bears sole and exclusive responsibility forthe compatibility; PALFINGER does not assume any liability for the compatibility.

PALFINGER reserves the right to refuse to issue approval of the crane mounting or modificationseven if a comparable approval had been granted earlier. Technical progress does not allow similarsituations to be treated the same without question.

References to Standards and Regulations 1.3-1

1.3. References to Standards and Regulations

1.3-1 Excerpt from StandardsSTANDARD No. DESIGNATION

ISO 9000 Quality Management Systems

EN 280 Transportable Lifting Workman Baskets

EN 287-1 Testing of Welders

EN 292-1EN 292-2

Machine Safety – Basic TermsMachine Safety – Technical Guidelines

EN 439 Welding Additives – Shield Gases for Arc Welding and Cutting

EN 440 Welding Additives – Wire Electrodes and Weld Metal for Metal-Gas-shieldedWelding of Unalloyed Steels and Fine-grained Steels – Classification

EN 499 Welding Additives – Encased Rod Electrodes for Arc Manual Welding ofUnalloyed Steels and Fine-grained Steels – Classification

EN 719 Welding Supervision – Tasks and Responsibilities

EN 729-1 Welding Quality Requirements – Arc Welding of Metallic Materials, Part 1

EN 1050 Machine Safety – Guidelines for Risk Assessment

EN 10025 Hot-rolled Products Made of Unalloyed Structural Steels, Technical Terms andConditions of Delivery

EN 10113-1EN 10113-2

Hot-rolled Products Made of Fine-grain Structural Steels Suitable for Welding

EN 10204 Metal Products – Types of Inspection Certificates

EN 12999 Cranes – Loading Cranes

DIN 15018DIN 15018-1DIN 15018-2DIN 15018-3

Cranes – Basic Principles for Steel Girders– Calculation– Principles for Construction Design and Execution– Calculation of Motor Vehicle Cranes

DIN 15019 Cranes, Stability

DIN 18800-1 Steel Constructions – Measurement and Design

DIN 18800-1/A1 Steel Constructions – Measurement and Design – Amendment A1

EN 25817 Arc Welded Connections on Steel – Guidelines for the Evaluation Groups ofIrregularities

EN 29692 Arc Manual Welding, Gas-shielded Welding and Gas Welding, Welding SeamPreparation for Steel

1.4-1 Explanation of Terms1.4. Explanation of Terms

1.4-1 Model Codes / Codes for PALFINGER Cranes and Accessories

Crane Model Code

P K 36001 L E XXXI I I I I II I I I I Code for additional crane equipmentI I I I Code for the number of hydraulic telescoping

extensionsI I I Main boom modelI I Number of linkage systemsI Lift moment code

Crane designation

Model Codes for Second Knuckle System (Fly-jib)

P J 101 A XXXI I I II I I Code for additional crane equipmentI I Code for the number of hydraulic telescoping extensionsI Lift moment code

Code for second knuckle system

Crane designation

PC PALFINGER compact cranePK PALFINGER cranePKK PALFINGER crane with short knuckle boomPW PALFINGER wallboard

PJ Second knuckle system

Main boom model

() Standard modelL Long main boomEL Extra-long main boomT Telescoping main boom

Code for the number of hydraulic telescoping extensions

() 1 extensionA 2 extensionsB 3 extensionsC 4 extensionsD 5 extensionsE 6 extensionsF 7 extensionsG 8 extensionsH 9 extensions

Explanation of Terms 1.4-1

Codes for additional crane equipment

-12V 12-Volt model-24V 24-Volt model2 Hose equipment for one accessory / pan4 Hose equipment for two accessories / pan6 Hose equipment for three accessories / panF (FL) Controls – groundH Controls – high seatHKONS High seat console with storage space for remote control panelI Controls – raised standJ Controls – cabRC Remote controlOC Continuous pumpNK Emergency controls – crane columnKK1 Joystick control – high seatKL0 Linear control – high seatLS Load sensingCE EEA-approved modelR0 Outriggers extendable on one sideR1 Outriggers extendable on both sidesR2 Lengthened outriggers extendable on both sidesR3 Telescoping outriggersX Hydraulically extendable outriggersSTZS Supporting cylinders – rigidSTZY Supporting cylinders – slewableSR.. Support of high seat, controllableEGG Combination crane baseTKKR Oil tank mounted on crane baseOT No tank on crane baseSHB Lifting power limitation dependent on slewing angleS Winch without end position switch and extension stopSH Winch mounted on main boomSHS Winch with overload cut-offSHES Winch mounted on main boom with electrohydraulic extension stop and end position switchSK Winch mounted on knuckle boomSKS Winch mounted on knuckle boomSKES Winch mounted on knuckle boom with electrohydraulic extension stop and end position

switchSES Winch with end position switch and extension stopSBM Slewing restriction with manometerTOQU Dead centre above crossbeamTOWI Dead centre above rockerOE Overload protection – acoustical or opticalOFB Overload protection – electrohydraulic with pendulumOFS Overload protection – electrohydraulic with pendulumOSE Overload protection – electrohydraulic without pendulumOS Overload protection - hydraulicOSK Overload protection – hydraulicOSK(M) Overload protection – hydraulic with manometerOM Overload protection with manometer2K Double ring systemV.. Mechanical extension (number)W Counterweight1GETR 1 slewing gearbox2GETR 2 slewing gearboxes

1.4-2 Explanation of Terms

1.4-2 Wheel FormulaBesides the motor vehicle type, the wheel formula can be used for a more precise designation ofthe chassis. It is a common expression, but has not been standardized. Dual tires are regarded andcounted 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 mountinginstructions of the truck manufacturer.

1.4-3 Major Dimensions of the Welding Seam

Welding seam symbols and measurements of welding seams are shown in these mountinginstructions in accordance with EN22553.

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

z

a

Illustration 1-14

Convex seam

a

z

Illustration 1-15

Concave seam

z

a

Illustration 1-16

In these mounting instructions, the fillet weld is always measured with the seam thickness “a”.

CONTENTS

2.1. GENERAL ...................................................................................... 3

2.1-1 REMARKS ON PROJECT PREPARATION ............................................. 32.1-2 TECHNICAL DATA SHEETS OF THE CRANE ........................................ 3

2.2. VEHICLE........................................................................................ 4

2.2-1 CRANE POSITIONS ON THE CHASSIS ................................................ 42.2-2 EQUIPMENT RECOMMENDATIONS FOR THE VEHICLE.......................... 82.2-3 TOTAL HEIGHT OF THE VEHICLE .................................................... 102.2-4 AXLE LOAD AND STABILITY CALCULATION....................................... 122.2-5 SELECTION AND CALCULATION OF AN AUXILIARY SUPPORT.............. 142.2-6 AUXILIARY FRAME CALCULATION ................................................... 18

2.3. HYDRAULICS ............................................................................... 22

2.3-1 HYDRAULIC DRIVE........................................................................ 222.3-2 DETERMINING THE REQUIRED TANK VOLUME / OIL COOLER .............. 25

Mounting Preparations Chapter 2

2.1-3 Allgemein


2.1-1 Remarks on Project PreparationIt is a sensible idea to consider in detail the arrangement and function of the mounting as a wholeduring the planning phase.

The standard EN12999 (5.10) as well as provisions applicable in the particular country (maximumdimensions, 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, raisedstand, high seat ...) so that crushing, shearing or damage is avoided. The mounting must not interferewith a clear view of the working area. If necessary, a different / additional operating stand must beprovided (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 tovehicle 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 themounting or the driver’s cab to prevent the crane boom from swivelling out, and there must be amonitoring 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 calculationo Tension sign on chassis and auxiliary frame or foundationo Engine output: engine / secondary drive power output, pumps and leads

dimensioningo If available – verification of permissible support force on the

supplementary support

2.1-2 Technical Data Sheets of the CraneWe have prepared comprehensive technical data sheets for all of the crane models and the variousoptions; these sheets provide information regarding all of the important dimensions, dead weights, liftmoments, loads, hydraulic and electric circuit diagrams, mounting sheets, and similar information.

2.2-1 Vehicle2.2. Vehicle

2.2-1 Crane Positions on the ChassisThere are three different types of mounting, depending on the way the crane will be used:

o Front mounting: crane is mounted behind the driver cab.

o Rear mounting: crane is mounted at the end of the chassis frame.

o 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 mountingsmentioned above. The best possible mounting for the customer’s intended use should be selectedduring the project planning.

The mounting examples below do not give specific indications of the possiblemountings of the various crane models. It is always necessary to perform axleload and stability calculations.

Front mounting:

Illustration 2-01

Front mounting of a loading cranefrom the light and medium craneseries on a double-axle chassis(4x2) with a loading bridge andwithout auxiliary supports

Illustration 2-02

Front mounting of a loading cranefrom the medium crane series witha loading bridge and an auxiliarysupport at the rear on a triple-axlechassis (6x4).

Vehicle 2.2-1

Illustration 2-03

Front mounting of a loading cranewith combination crane base fromthe crane series for heavy loadson a four-axle tractor (8x4) andwith auxiliary support at the rear.

Advantages Disadvantageso Good stability towards the back (good

working area towards the back – 180°).o This type of mounting is suitable for

tractors, models with loading bridges orcontainer platforms.

o Relatively light load on the rear axleo Relatively inexpensive auxiliary frame

designo Long load can be transported well (load

can protrude over the rear)

o Poor stability towards the front.o Heavy load on front axle. Depending on

the crane’s dead weight, an increase inthe permissible front axle load or adouble-axle at the front may be required.

o Loss of reach towards the rear.

Rear mounting:

Illustration 2-04

Rear mounting of a loading cranefrom the light and medium craneseries on a double-axle chassis(4x2) with a loading bridge andwithout auxiliary supports

Illustration 2-05

Rear mounting of a long-boomcrane on a triple-axle chassis(6x4) with loading bridge and anauxiliary support in the front area.

2.2-1 Vehicle

Illustration 2-06

Rear mounting of a loading cranewith second knuckle system fromthe crane series for heavy loadson a triple-axle chassis (6x4) withloading bridge and an auxiliarysupport in the front area.

Advantages Disadvantageso 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 atthe rear.

o Good working area – 360°.

o Difficult to transport long loads.o Heavy load on the rear axleo A second auxiliary support is often

required for lift performance >48mt.o Since higher torsion moments may occur

when using rear mounting, a torsion-resistant auxiliary frame or greaterstability factors are required.

A straightforward rear mounting is as a rule not possible, or possible onlyunder special conditions, for a crane lift moment of 800 kNm or greater.

Special mounting:

Illustration 2-07

Mounting of a loading crane fromthe series for heavy loads on afour-axle truck chassis (shortwheelbase). Two auxiliarysupports have been mounted toachieve adequate stability,whereby the auxiliary support atthe rear can be slewed towardsthe back.

Illustration 2-08

Crane mounted on a double-axlesemitrailer with an auxiliarysupport at the rear.

Vehicle 2.2-1

Illustration 2-09

Mounting of a loading crane on awheel loader

Advantages Disadvantageso Customer-specific mounting – special

requirements of the customer can be takeninto account during the planning. Theoptimization of the mounting allows amaximum of performance requirements tobe achieved.

o The specific requirements of thecustomer generally lead to increaseddesign and mounting expenditures –mounting usually expensive.

2.2-2 Vehicle

2.2-2 Equipment Recommendations for the Vehicle

Space requirements for crane and mounting

It must be determined in the preliminary stage whether transmission components which protrudebeyond 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. Itmust 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 duringcrane 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 lengthof 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 overhangmust 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 tomake any modifications to the frame

The rear overhang must be selected in accordance with the space requirements of the crane when thecrane 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 atthe rear!

Vehicle 2.2-2

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 thetop 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 loadingcrane and in the area of the auxiliary support. They are used to create a bending-resistant and a shear-resistant connection between the vehicle frame and the crane or auxiliary frame. They are alsoincluded in the cross-section calculation.

4 3 2 12Illustration 2-11

1 Loading crane2 Base shear plate3 Chassis frame4 Auxiliary frame

Some truck suppliers already offer fitted base shear plates which, if desired,can be pre-mounted. It is a quality assurance measure, and usuallyeconomically advantageous, if the base shear plates are taken into accountwhen the truck is ordered. The vehicle customizer can then avoid thecomplicated work of mounting the base shear plates. Ask your truck supplierabout this!!

More detailed information about design, dimensioning and material quality of the base shear plates canbe found in Chapter 3.3. Connecting Elements on the Auxiliary Frame.

2.2-3 Vehicle

Front frame reinforcement for the mounting of support cylinders in front of the driver’scab

1

Illustration 2-12

If it is supposed to be possible to make full use ofthe crane moment even above the driver’s cab,this can be achieved by mounting one or twosupport cylinders (1) in front of the driver’s cab.This requires a suitable bending-resistantchassis frame from under the driver’s cab all theway to the bumper at the front.The vehicle customizer must clarify, in bindingagreement with the truck manufacturer, thepermissible bending moment on the chassisframe or what support forces may be applied tothe front support cylinders.Some truck manufacturers offer so-calledsnowplough attachments or towing attachmentsas special equipment. As a rule, this specialequipment is well-suited for the mounting ofsupport cylinders.

2.2-3 Total Height of the VehicleA height calculation verifies that the total height of the vehicle remains within the defined limits (legalprovisions 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 andthe height of the crane and compare the measurements with the heightcalculation.

Vehicle 2.2-3

Crane with conventional crane basic frame

The chassis frame must be reinforced with an auxiliary frame. The following formula can be used tocalculate the overall height of the vehicle:

KHRFGGES HHHH ++= HGES ............... Total heightHFG ................. Chassis heightHHR ................. Auxiliary frame heightHK ................ Total crane height (see technical data sheets)

HF

G

HG

ES

HH

R

HK

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 thefollowing formula:

KFGGES HHH += HGES ............... Total heightHFG ................. Chassis heightHK ................ Total crane height (see technical data sheets)

HK

HF

G

HG

ES

Illustration 2-13

2.2-4 Vehicle

2.2-4 Axle Load and Stability Calculation

The determination of the axle load and the calculation of the stability factor against tipping over areabsolutely 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 thevehicle. Permissible limits may be obtained from the truck manufacturer.

The calculation program “PACWIN” can be used as an aid to calculate the axleload and stability factors easily. Palfinger Customer Service and all generalrepresentatives will be glad to give you more information about this program.You will also find further information about calculating the axle load in mostmounting guidelines of the truck manufacturers.

Axle load calculation

All of the weights of the mounted components (crane, auxiliary frame, tank ...) must be distributedbetween the front and rear axles in accordance with the moment rate, whereby the reaction forcesshould 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 thevehicle in order to avoid negative steering characteristics. Precise information is obtainable from thetruck manufacturer.

Theoretical wheelbase

The theoretical wheelbase is a theoretical value used in calculating the axle loads. The definition isshown in the following illustrations.

The wheelbase effective for turning used in calculating the turning tracks is notalways identical with the theoretical wheelbase required for calculating the axleload.

Determining the theoretical wheelbase lth for a double-axle chassis

zul2zul1

=Illustration 1-11

RAth ..... theor. rear axle middleGzul1 ..... perm. axle load of the 1st axleGzul1 ..... perm. axle load of the 2nd axlel12 ......... Wheelbase from 1st to 2nd axlelth .......... theoretical wheelbase

12th ll =

Vehicle 2.2-4

Determining the theoretical wheelbase lth for a triple-axle chassis

zul3zul1 zul2

Illustration 1-12

RAth ..... theor. rear axle middleGzul1 ..... perm. axle load of the 1st axleGzul1 ..... perm. axle load of the 2nd axleGzul1 ..... perm. axle load of the 3rd axlel12 ......... Wheelbase from 1st to 2nd axlel23 ......... Wheelbase from 2nd to 3rd axlelth .......... theoretical wheelbase

3zul2zul

233zul12th GG

l*Gll

++=

Determining the theoretical wheelbase lth for a four-axle chassis with two front and two rear axles forany axle loads

zul1 zul3 zul4zul2

Illustration 1-13

RAth ..... theor. rear axle middleFAth ..... theor. front axle middleGzul1 ..... perm. axle load of the 1st axleGzul1 ..... perm. axle load of the 2nd axleGzul1 ..... perm. axle load of the 3rd axleGzul1 ..... perm. axle load of the 4th axlel12 ......... Wheelbase from 1st to 2nd axlel23 ......... Wheelbase from 2nd to 3rd axlel34 ......... Wheelbase from 3rd to 4th axlelth .......... theoretical wheelbase

4zul3zul

344zul

2zul1zul

121zul23th GG

l*GGGl*G

ll+

++

+=

Stability calculation

The vehicle must be stable throughout the entire working area. This can be achieved by using thefollowing systems:

o Adequate support widtho Auxiliary supportso Slewing limitationo 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 alltip moments.

K

S

MM

SΣΣ=

S .............�MS ........�MM .......

Safety factor against tipping overTotal of all stabilizing momentsTotal of all tipping moments

The safety factor against tipping over, also called the stability factor (S), must be observed inaccordance with EN12999 or the regulations specific to the country.

2.2-5 Vehicle

2.2-5 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 sizeof 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 anauxiliary support.

To do so, draw a horizontal line on the crane lift moment scale (see technical crane data sheets) and avertical line at the permissible total weight of the truck chassis. The point where these two lines crossshows the minimum support width (w) of the auxiliary support. This value can now be used to selectthe appropriate auxiliary support.

When an auxiliary support has been selected, the next step is to determine the expected support forceFST using the diagram 2-02 and to compare it with the permissible values of the auxiliary supportaccording to the technical sheet. If the calculated support force is greater than the permissible supportforce 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 selectedauxiliary support (w) and the distance from the middle of the crane column to the middle of the auxiliarysupport (L) intersect. Note that the actual support width of the selected auxiliary support must be usedto calculate the support force FST 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 tothe right to the maximum crane lift moment scale. The intersection of these lines is the support forceFST to be expected. The support force thus determined must be multiplied by a factor of 1.08 for cranemodels which are not equipped with HPLS.

The diagrams below may be used only for the preselection of an auxiliarysupport. They do not replace the stability calculation or the static and rigidityverification.

The permissible load values of the ground can be seen in the operating instructions for each particularcrane. The support plates obtainable from Palfinger may be used for soft surfaces. Appropriate fittingsshould be provided on the vehicle for this purpose in the proximity of the support.

Vehicle 2.2-5

Diagram for determining the minimum support width (w) of the auxiliary support for front mounting ofthe crane

Max

.cra

nelif

tmom

ent[

kNm

]

50

250

450

650

850

1050

6 10 14 18 22 26 30 34 38

2,1 m

5,0 m

5,5 m

6,0 m

6,5 m

7,0 m

3,5 m

8,5 m

2,1 m

0,0 m

32

7,5 m

8,0 m

41

150

350

550

750

950

Permissible total weight in tDiagram 2-01a .

Diagram for determining the minimum support width (w) of the auxiliary support for rear mounting of thecrane

Max

.cra

nelif

tmom

ent[

kNm

]

6 10 14 18 22 26 30 34 3832 4150

250

450

650

850

1050

150

350

550

750

950

Permissible total weight in tDiagram 2-01b

Combination not possible

Two front axles required

No auxiliary support required

Undefined area

2.2-5 Vehicle

Diagram for determining the support force F ST on the auxiliary support

LL L [m]

w w [m]

Max

. cra

ne li

ft m

omen

t [kN

m]

0123

100200300

400500600700800 67,5 kN100 kN85 kN900

1000

0

1100

50 kN1 17 kN125 kN

140 kN155 kN

112,5 kN

170 kN1 90 kN210 kN 155 kN3

45

0

1

2

3

4

5

6

7

8

90 1 2 3 4 5 6 7 8 9

100

200

300

400

500

600

700

800

67,5 kN

100 kN

85 kN

900

1000

0

1100

50 kN

117 kN

125 kN

140 kN

155 kN

112,5 kN

170 kN190 kN210 kN 155 kN

2

3

4

5

1

Diagram 2-02 .

Cranes with HPLS ..........FST = F

Cranes without HPLS .....FST = F * 1.08

Vehicle 2.2-5

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 (FST) 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 MK (H1): MK is to be determined for a maximum overhang (see stability calculation)

L2EK M*M*1.1M Φ+=

h2

LL

EEE

*132.0*1.11000

R*81.9*mM

1000x*81.9*mM

ν=Φ

=

=

MK ..... ME .... mE .... xE ..... ML .... mL .... R ...... Φ2 .... νh .....

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 νh ≈ 0.75m/s Crane without HPLS νh ≈ 1.5m/s

Determining the max. support force on the support cylinder of the auxiliary support:

ST

KST L

MF =

FST .... MK ..... LST ....

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

1

2 3

4

56 LS T

Illustration 2-14

1 ..... Truck front axle 2 ..... Loading crane 3 ..... Truck rear axle 4 ..... Auxiliary support 5 ..... Support cylinder auxiliary support 6 ..... Crane column middle

2.2-6 Vehicle

2.2-6 Auxiliary Frame Calculation

The auxiliary frame must be dimensioned in accordance with currently applicable technical regulationsor standards.

The max. dynamic crane lift moment MK must be calculated according to EN12999 (seeChapter 2.2-5).

The calculation program “PAF” (PAlfinger Frame) can be used to calculate thetension in the chassis and auxiliary frames as well as the support forces on theauxiliary support. PALFINGER Customer Service and all countryrepresentatives 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 unevensurfaces, subjecting the mounting and the chassis to strong twisting motions.

Advantages and disadvantages of a flexible crane mounting:

Advantages Disadvantageso Usually low-cost mounting.o Good driving properties on uneven

terrain.o Low tensions from torsion in the

mounting.

o Only low torsion moments can betransferred to the mounting.

o Wide spring fluctuations during craneoperation

o Suitable only for cranes up to about 25mt.

Illustration 1-06

Since flexible crane mountings can transfer only low torsion moments, they areonly suitable for crane mountings without auxiliary support.

You will find more information on flexible auxiliary frame designs in Chapter 3.2-1.

Vehicle 2.2-6

B) Torsion-resistant crane mounting

A torsion-resistance crane mounting is a mounting which has high resistance to twisting. Since thismounting’s own rigidity permits little torsion in the chassis, the driving properties are worse on uneventerrain.

Advantages and disadvantages of a torsion-resistance crane mounting:

Advantages Disadvantageso High torsion moments in the mounting

can be transferred.o Little spring fluctuation during crane

operation.o Suitable for cranes with high lift

moment (>25mt) and for rear-mountedcranes

o Usually expensive mounting.o Poorer driving properties on uneven terrain

(all-wheel drive often required).o High tensions from torsion in the mounting.

Illustration 1-07

Since torsion-resistance mountings can transfer high torsion moments, they arewell-suited for crane mountings with auxiliary support and for rear-mountedcranes.

You will find more information on torsion-resistant auxiliary frame designs in Chapter 3.1-2.

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 aconsequence of a bending stress on the contact surfaces (see bar model Illustration 1-08). The verticalforce F causes both bars to bend, leading to a maximum tension on the outer fibres of the individualframe systems. The tension is 0 is the neutral fibres “n”.

Fn

−σ+σ

+σ−σ

Illustration 1-08

F......... vertical forcen ........ 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 similardevices are to be regarded as shear-yielding connections. Relative motion between the vehicle chassisand the auxiliary frame is possible to a limited extent. Shear-yielding fastenings should always beselected as long as they are adequate for the task. You will find more information on shear-yieldingconnecting elements in Chapter 3.4-1.

B) Shear-resistant frame connections

There is a shear-resistant frame connection when a longitudinal shift of the two frame systems is nolonger possible (see bar model Illustration 1-09). This can be assured, for example, by mounting shear-resistant 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.

Fn

+σ

−σ

Illustration 1-09

F......... vertical forcen ........ neutral fibres-σ ....... Compressive stress+σ ...... Tensile stress

Relative motion between the frame and the auxiliary frame are no longer possible when shear-resistantconnections are used. They should be used when shear-yielding fastenings are no longer adequate, orif the auxiliary frame would have unreasonably large cross-section dimensions if a shear-yieldingconnection were used.

Shear-resistant connecting elements are connected positive-fit with the frame systems (rivets, drivenbolt connection).

The shear-resistant connection must be designed according to the mounting instructions of the truckmanufacturer. You will find more information on shear-resistant connecting elements in Chapter 3.3-2.

Vehicle 2.2-6

C) Combined frame connection

The connection types shear-yielding and shear-resistant can also be combined. This means that theshear-resistant connection is used only in the area requiring this type of connection. Otherwise, theshear-yielding connection is used.

Fa b

Illustration 1-10

F........ vertical forcea ........ Area of shear-resistantconnectionb ........ Area of shear-yielding connection

For example, a shear-resistant connection can be selected in the crane area, then there can be achangeover to the shear-yielding connections for the rest of the frame, if permitted by rigidity andstability values.

Before beginning the mounting, the chassis and the crane must be weighedand compared with the results of the axle load and stability calculation. Incases of greater deviation, the calculation or the crane arrangement must becorrected.A practical stability test according to EN12999 or another standard specific tothe country must be carried out after completion of the mounting.

2.3-1 Hydraulics2.3. Hydraulics

2.3-1 Hydraulic DriveThe purpose of this calculation is to determine the correct dimensioning of the hydraulic drive for theloading crane.

Determining the required data such as conveyance quantity and max. operating pressure according tothe 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 outputperformance 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 efficiencyfactors 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 twoarticulations.

Individual efficiency factors:

Auxiliary drive ηpto = 0.9

Drive shaft articulation a η1 = 0.95

Drive shaft articulation b η2 = 0.95

Hydraulic pump ηp = 0.9

Total efficiency factor:

ηtot = ηpto * η1 * η2 * ηp

ηtot = 0.9 * 0.95 * 0.95 * 0.9 = 0.75

Hydraulics 2.3-1

Calculating the required drive output

If a variable displacement pump is used, the calculation must be based on its maximum discharge flow.

P Drive performance [kW]qv Discharge flow (volume flow) [l/min]p Operating pressure [Mpa] (1MPa = 10 bar)ηtot Total efficiency factor

Formula for drive output, taking into account thedischarge flow (Q) and the operating pressure (p):

tot

v

*60p*q

Pη

=

The drive train (engine, gear box, secondary drive,drive shaft ...) must be designed for the calculatedoutput as a minimum.

Determining the ratings of the hydraulic pumps

Depending on their use, either pumps with constant discharge flow or pumps with variabledisplacement 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)

Vg Displacement volume of the pump (rating)per revolution [cm³]

qv Discharge flow (volume flow) [l/min]nen Motor rotational speed [min-1]np Pump rotational speed [min-1]ηvol Volumetric efficiency factoritot Gear transmission ratio totalige Gear transmission ratio in gearbox

voltoten

vg *i*n

1000*qV

η=

totenp

en

pptogetot

i*nn

n

ni*ii

=

==

ipto Gear transmission ratio in auxiliary drive

The total gear transmission ratio (itot) is the ratio of the pump rotational speed to the motor rotationalspeed. The gear transmission ratios can be found in the pertinent technical data sheets of the productmanufacturers.

The rotational speed of combustion engines must be observed as recommended by the enginemanufacturer. Generally this is between 800 and 100 min-1 for vehicle engines.

The volumetric efficiency factor (ηvol) of a hydraulic pump (axial piston pumps or geared pumps) cangenerally be taken at about 0.95. Precise data is available from the pump manufacturer.

The hydraulic pump must not be operated above the permitted rotational speedunder any circumstances. The pump should always operate in the optimalrotational speed range (see data sheet of the hydraulic pump) to achieve a highefficiency factor and operational quietness.

2.3-1 Hydraulics

Calculating the torque

Every auxiliary drive and drive shaft has a maximum permissible torque and a maximum permissibledrive 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� see calculation of the efficiency factor

T Torque [Nm]qv Discharge flow (volume flow) [l/min]p Operating pressure [Mpa] (1MPa = 10 bar)np Pump rotational speed [min-1]

x

g

xp

vpV

n

pqT

ηπη **2

*

*

159** ==

ηx Product of the individual efficiency factorsVg 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 ofthe pump must be checked. The purpose of this calculation is to verify that the weight moment of thepump does not put excessive strain on the gear box housing. The permissible value can be found inthe 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 becalculated according to the formula below.

1 ..... Gear box / Auxiliary drive2 ..... Hydraulic pump

Mmp Weight moment of the pump [Nm]mP Dead weight of the pump [kg]

1 2

1000s*81,9*m

M Pmp =

Illustration 2-15 s Distance from mounting flange to centre ofgravity of the pump [mm]

Always observe the guidelines issued by the manufacturers of the pump, motorand gear box.

Hydraulics 2.3-2

2.3-2 Determining the required tank volume / Oil cooler

The following rule applies for the calculation of the required tank volume on a loading crane:

QTank = 2 to 3 * QPump(s) QTank Tank volume [ l]QPump(s) Pump discharge flow [ l/min]

If operating with two circulatory systems, the volume flow of both pumps must be added together forthe 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 ofaverage 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 allcylinders are extended.

A large (external) tank must be provided for cranes in continuous operation as well as for allapplications 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 asstraight 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 toolong 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 theleads or the pump can be changed without emptying the tank.

2.3-2 Hydraulics

CONTENTS

3.1. REMARKS ON WORKING ON THE CHASSIS FRAME

3.1-1 ALIGNING THE CHASSIS BEFORE BEGINNING THE MOUNTING

3.1-2 DRILLING ON THE CHASSIS FRAME3.1-3 WELDING ON THE CHASSIS FRAME

3.1-4 MOUNTING HEAVY COMPONENTS

3.2. AUXILIARY FRAME DESIGN

3.2-1 FLEXIBLE AUXILIARY FRAME3.2-2 TORSION-RESISTANT AUXILIARY FRAMES

3.3. SELECTION OF MATERIAL AND WELDING PROCEDURE

3.3-1 SELECTION OF AUXILIARY FRAME MATERIAL

3.3-2 SELECTION OF THE WELDING PROCEDURE3.3-3 GENERAL REMARKS ON WELDING

3.4. CONNECTING ELEMENTS ON THE AUXILIARY FRAME.

3.4-1 SHEAR-YIELDING CONNECTING ELEMENTS

3.4-2 SHEAR-RESISTANT CONNECTING ELEMENTS3.4-3 COMBINING SHEAR-YIELDING – SHEAR-RESISTANT CONNECTING

ELEMENTS

3.5. GENERAL PRODUCTION AND MOUNTING REMARKS

3.5-1 TYPES OF JOINTS OF SHEETS AND MOULDED TUBES

3.5-2 BOLT CONNECTIONS FOR THE MOUNTING

Auxiliary Frames Chapter 3

3.1-1 Remarks on Working on the Chassis Frame

2. Ü13. Ü1

Remarks on Working on the Chassis Frame 3.1-13.1. Remarks on Working on the Chassis Frame

3.1-1 Aligning the Chassis Before Beginning the MountingBefore beginning work on the mounting, the chassis frame must be aligned completely level in order toensure irreproachable overall quality and a long useful life of the mounted vehicle. The main chassisbeams must be lying parallel, and the frame must not be entangled.A minimum of 3 adjustable supports must be used to align a chassis with pneumatic suspension.These supports must not be removed during the mounting.

The chassis must be aligned again any time the vehicle has been driven.

Illustration 1-01

3.1-2 Drilling on the Chassis FrameAll of the fastenings must be fixed with bolts to the web of the main chassis beams.

It is absolutely forbidden to drill or otherwise make holes in the flanges of the chassis frame as theycause a high concentration of tension. The only exception is the drilling of holes in the frame overhangwhich are required to mount the finishing cross-beam.

Illustration 1-02

The pre-drilled master gage for holes should primarily be used for mounting the auxiliary frame andother components to the chassis. If more holes are required, they should be drilled according to theguidelines of the truck manufacturer.

3.1-3 Remarks on Working on the Chassis Frame

In general, however, the minimum distances must be observed in accordance with the followingillustration. The maximum hole diameter in the frame area between the front and rear axle(s) is about20 mm.

Illustration 1-03

A: Distance from hole to chassis flange min. 3 x D or min. 40 mmB: min. 4 x DC: min. 3 x D

3.1-3 Welding on the Chassis FrameGeneral

Welding on the chassis frame should be avoided whenever possible. If it is necessary to do weldingwork – for example, because the chassis must be extended – it must be done with the greatest care bycompetent personnel. The truck manufacturer’s guidelines must be strictly followed.

It is strictly forbidden to weld the mounting unit to the chassis frame.

Modifications of the chassis (modification of the wheelbase, the rear overhang,...) must be done in conformity with the vehicle manufacturer’s provisions.

Electric welding on the mounting

Trucks today are equipped with a large number of electronic controls and sensitive components suchas ABS, automatic transmission, torque amplifiers, etc. To prevent damage to these components, thefollowing remarks on welding work must be followed in addition to the instructions from the truckmanufacturer.

• Disconnect the minus and plus cable on the battery.ATTENTION – disconnect the minus pole of the truck battery first!

• Attach the earth connection of the welding current source as close as possible to the point beingwelded.

• The current must not flow through supports or connection points.

• Protect plastic pipes and electrical lines.

• Protect plate springs and bellows.

Remarks on Working on the Chassis Frame 3.1-4

Welding holes closed

If new holes must be drilled at a distance closer than three times the hole diameter to an existing hole,the existing holes must be welded closed. Proceed as follows:

• Chamfer the hole to 2/3 of the material thickness.

• Place a copper disk on the inner side of the hole.

• Weld the hole closed. If the diameter of the hole is greater than ∅20 mm, us a chamfered disk asfilling.

• Weld the hole closed on the inner side as well.

Illustration 1-04

3.1-4 Mounting Heavy ComponentsHeavy components such as battery casings, fuel tanks, spare tyres, oil tanks, etc., put significant stresson the chassis frame. Whenever heavy components are moved or mounted, observe the followingpoints:

• Mount the component as close as possible to a cross-beam. Attaching an inner and/or outerreinforcement plate can distribute the torque stress so that the stress on the frame is reduced.

Illustration 1-05

• Washers must be placed on the inner side of the chassis frame for the mounting bolts (min. 200HB).

• We recommend using “driven bolt connections” for large components (see Chapter 3.4-2).

• A sufficient number of bolts and a large clamping surface should be used so that there is littlestress on the frame. Whenever possible, use the existing holes. If additional holes must be drilled,observe the notes in the chapter “1.4-2 Drilling in the Chassis Frame”.

3.2-1 Auxiliary Frame Design3.2. Auxiliary Frame Design

The auxiliary frame is the connecting link between the loading crane and the motor vehicle. When thecrane is in operation, the auxiliary frame, together with the chassis frame, must withstand all of theexternal stresses (bending stress, torsion stress, ...). In addition to the constructive design, it isextremely important to select the correct material and the appropriate welding procedure for theauxiliary frame to prevent failure of the component.

The auxiliary frame must be produced according to state-of-the-art technologyand acknowledged rules of production.

3.2-1 Flexible Auxiliary FrameThe following auxiliary frame models can be used for a flexible crane mounting. Since all of theseauxiliary frames are made of standard steel profiles, production is relatively low in cost.

The auxiliary frame must be made torsion-resistant in the area of the crane through the use ofadditional cross-beams, longitudinal supports or belt sheets. Open profiles must be closed to form abox profile.

Since flexible auxiliary frames can transfer only low torsion moments, they are only suitable for cranemountings without auxiliary support.

Models of flexible auxiliary frames

Illustration 3-01

Auxiliary frames made of C profiles:Auxiliary frames of this design are especiallyflexible and are therefore only used formounting cranes with a low lift moment.

Illustration 3-02

Auxiliary frames made of nested C profile:Due to the doubling of the upper and lowerbelt, a substantially higher bending momentcan be applied to a nested C profile. Thetorsion resistance is comparable to that of arectangular hollow profile.

Auxiliary frame made of rectangular hollowprofile:Rectangular profiles can absorb relativelyhigh bending moments with good torsionresistance.

Illustration 3-031 ....... Longitudinal supports2 ....... Cross-beams

Auxiliary Frame Design 3.2-2

3.2-2 Torsion-resistant Auxiliary FramesThe following auxiliary frame models can be used for a torsion-resistant crane mounting. Theseexamples can be individually modified according to production possibilities.

These auxiliary frames are resistant to bending and torsion due to their closed construction. Becausethey are more complex to produce, these auxiliary frames are generally more expensive than theflexible auxiliary frames and should be used only in situations where they are necessary.

Since torsion-resistant crane mountings can transmit high bending and torsion moments, they are well-suited to crane mountings with auxiliary support.

Tension certifications are absolutely essential for the chassis frame and theauxiliary frame!

Models of torsion-resistant auxiliary frames

Illustration 3-04

Auxiliary frame made of canted sheet mouldedparts:For this auxiliary frame, a steel sheet is bent into aC profile and welded to other bent sheet mouldedparts into a box profile.Advantage: few welding seams, little distortion, nocomplicated welding seam preparation required.Disadvantage: production problems for thick steelsheets

1 2

Illustration 3-05

Auxiliary frame with upper and lower shell:For this auxiliary frame, steel sheets are bent intoshells and welded bluntly into a box profile. As areinforcement for rigidity, either two or three webplates or another C profile are welded in.Advantage: few welding seams, little distortion.Disadvantage: production problems with thick steelsheet, complicated welding seam preparation

1 ....... Welding puddle protection2 ....... Plug welding seam

3.2-2 Auxiliary Frame Design

21Illustration 3-06

Auxiliary frame made of rectangular hollow profile:For this auxiliary frame, rectangular hollow profilesand steel sheets are welded together into a closedbox profile. One or two web plates can be weldedin as reinforcements for rigidity.Advantage: simple to manufacture.Disadvantage: there are currently no rectangularhollow profiles made of high-strength fine-grainedconstruction steel; only hot-rolled hollow profilesmay be used.

21Illustration 3-07

Auxiliary frame made of straight steel sheets:The auxiliary frame is welded with straight steelsheets into a closed box profile. The thickness ofthe sheet and number of belt sheets is selectedaccording to the required rigidity and constructionheight.

Advantages: it is also possible to use thick sheets,high bending and torsion resistance.

Disadvantages: many welding seams, danger ofwelding distortion, complicated production.

1 ....... Welding puddle protection2 ....... Plug welding seam

Selection of Material and Welding Procedure 3.3-13.3. Selection of Material and Welding Procedure

3.3-1 Selection of Auxiliary Frame Material

The material for the auxiliary frame module should be selected on the basis of the followingconsiderations:

o The material quality (strength) should be as low as possible or only as high as necessary(reason: weldability decreases as strength increases).

o The material should have a fine-grained structure (fine-grained construction steel).

o The material must well-suited for welding using the selected welding procedure.

o The material should have adequate notch impact work and tenacity.

o The material should be unsusceptible to cold cracking.

o Further mechanical and technological properties must be suitable for the production process(e.g.: good cold formability, ...).

Examples of materials:

Material designation Nominalthickness

Yield stress (ReH)in N/mm2

STANDARD No.:

S355J0 unalloyedconstruction steel

≤ 16 mm 355 EN 10025 (March 1994)

S460MC Fine-grainedconstruction steel

≤ 50 mm 460 EN 10149-2 (Nov. 1995)

S500QL Fine-grainedconstruction steel

≤ 50 mm 500 EN 10137-2 (Nov. 1995)

S700MC Fine-grainedconstruction steel

≤ 50 mm 700 EN 10149-2 (Nov. 1995)

As the sheet thickness and strength increase, so does the risk of a coldcrack during welding.

3.3-2 Selection of the Welding ProcedureThe selection of the welding procedure is primarily dependent on the material and the productionprocess. As a rule, the metal-gas-shielded welding MAG-M (metal-active gas welding with mixed gas)is used.

The selection of the protective gas and the welding additive as well as theform of the welding seam and its thickness is the responsibility of thewelding supervisor.

The welding may be done only by people in possession of a valid welder’scertificate in accordance with EN 287-1 or with an equivalent nationalwelder’s certificate.

3.3-3 Selection of Material and Welding Procedure

3.3-3 General Remarks on WeldingLimits on thickness of seam.

Minimum thickness of seam amin :

The minimum seam thickness amin may not be less than 2 mm (see also DIN 18800). In addition,

5.0maxmin −≥ ta is prescribed for the minimum seam thickness for technical reasons. This

formula applies to sheet thicknesses up to 30 mm.

Maximum seam thickness amax :

In general, the maximum seam thickness should not exceed 0.7 times the minimum wall thickness.

minmax *7.0 ta = t = sheet thickness

• Vertical-down welds are not permitted anywhere on the mounting.

Connecting Elements on the Auxiliary Frame. 3.4-13.4. Connecting Elements on the Auxiliary Frame.

The connections between the auxiliary frame and the chassis frame or either shear-yielding or shear-resistant. The number and type of mounting elements are selected in accordance with the mountingguidelines from the truck manufacturer.

3.4-1 Shear-yielding Connecting Elements(See Chapter 2.2-6)

Examples of shear-yielding connecting elements

A) Fastening angles B) Fastening angles in combination with diskspring

C) Fastening angles with spacers D) Bride mounting

3.4-2 Connecting Elements on the Auxiliary Frame.

3.4-2 Shear-resistant Connecting Elements(See Chapter 2.2-6)

A) Mounting sheets

The mounting sheets must be welded on to the auxiliary frame as shown below:

The welding seam 1 must be drawn across the entirewidth of the mounting sheet. The welding must goaround the corners of the sheet.Weld completely around the opening in the mountingsheet (welding seam 2).

B) Fastening angle with mounting claw

The auxiliary frame is bolted to the chassis frame witha fastening angle and the web is clamped withmounting claws.

Connecting Elements on the Auxiliary Frame. 3.4-2

C) Base shear plate

The plates or moulded parts which are bolted to the side of the vehicle frame and then welded at thetop to the auxiliary frame or the combination base of the crane are known as lateral base shear plates.

A generous number of base shear plates is necessary for static or rigidity reasons in the areaunderneath the loading crane and in the area of the auxiliary support.

These base shear plates are used to create a bending-resistant and a shear-resistant connectionbetween the vehicle frame and the crane or auxiliary frame. They are also included in the cross-sectioncalculation.

4 3 2 12Illustration 2-11

1 Loading crane2 Base shear plate3 Chassis frame4 Auxiliary frame

Please see the information about the base shear plates in Chapter 2.2-2 Equipment Recommendationsfor the Vehicle.

When mounting on a vehicle with a short wheelbase, it makes good sense to prepare the base shearplates to be as continuous as possible.

2Illustration 3-16


Dimension and material of the base shear plates

The base shear plates should always be of the same grade of steel as the chassis frame (but with aminimum yield stress ReH � 420 N/mm2). Moreover, the material for the base shear plate should havethe following quality features:

o Fine-grained structure (fine-grained construction steel)

o Good weldability

o Adequate notch impact work and tenacity

B

A

1

2

3

4

C

s

A

1

3

4 s

Illustration 3-12A Width of chassis framesB Width of chassis frames / combination crane baseC Width of base shear plates Thickness of base shear plate1 Combination crane base / auxiliary frame2 Reinforcement angle3 Base shear plate4 Chassis frame

The base shear plate is bolted to the chassis frame and welded to the auxiliary frame. If the auxiliaryframe is the same width as the chassis frame, the base shear plate is attached flush (see left-handillustration). If the auxiliary frame or the combination crane base is wider than the chassis frame, thewidth is equalized using the base shear plate (see right-hand illustration).

Select the width of the base shear plate (C) so that a fillet weld of the thickness a=0.7*s can be placedwithout obstruction. Weld on reinforcement angles at intervals of about 800 mm to 1000 mm on thesides of the base shear plates (see Illustration 3-12, Component 2).

Recommended sheet thickness “s” of the base shear plates, dependent on the crane lift moment

Max. crane lift moment in kNm Sheet thickness “s” inmm

≤ 200 6201 to 350 8351 to 750 10> 750 12


The mounting possibilities for base shear plates shown below are available for the various mountingvariations and differing frame cross-sections so that a technically correct solution can be found forevery mounting.

Mounting forms for base shear plates when the auxiliary frame is the same width asthe chassis frame

Example 1

Illustration 3-18

A straight steel sheet is bolted to the side ofthe chassis frame and welded to the auxiliaryframe. This variant is suitable only forrelatively strong chassis frames (doubleframes).

Advantages: Fast, relatively simple andeconomical production.

Disadvantages: Often not suitable for thin-walled chassis frames (single frames).

Example 2

Illustration 3-19a

For this variant, the base shear plate isdivided into three parts. The chassis frame isreinforced by the two angles.

Advantages:Fast, relatively simple and economicalproduction. Also suitable for single chassisframes.


Example 3

Illustration 3-20

One-piece angled base shear plate. Thismounting form also results in a reinforcementof the chassis frame.

Advantages:Also suitable for single chassis frames.

Disadvantage:Mounting is somewhat more complicated.

Example 4

Illustration 3-21

Two-piece base shear plate which is weldedtogether with a fillet weld. The greater thethickness of the lower steel plate, the morethe chassis frame can be reinforced.

Advantages:Also suitable for single chassis frames.

Disadvantage:Mounting is more complicated.


Mounting forms for base shear plates when the auxiliary fame or the combinationcrane base is wider than the chassis frame

Example 1

Illustration 3-18a

In this variant, the base shear plate is cantedonce and bolted laterally to the chassis frame(torsion-resistant connection).This variant is suitable only for relativelystrong chassis frames (double frames).

Advantages:Fast, relatively simple and economicalproduction.

Disadvantages:Often not suitable for thin-walled chassisframes (single frames).

Example 2

Illustration 3-19a

Construction type “Mercedes Benz” – thebase shear plate is divided into two pieces (2angles) with an interior frame reinforcement.

Advantages:Fast, relatively simple and economicalproduction. Also suitable for single chassisframes.


Example 3

Illustration 3-20a

For relatively thin-walled or single chassisframes, it may be advantageous or evennecessary to design the base shear platein a Z shape.

Advantage:Single chassis frames can be reinforcedwith the plates into bending-resistantframes.

Disadvantage:Difficult mounting of the base shear plate

Example 4

Illustration 3-21a

Using the two-piece base shear plate canequalize any distortion in the auxiliaryframe module by later mounting the upperpart of the base shear plate.

Advantage:Possible to equalize heights. Internaltensions can be prevented for the mostpart.

Disadvantage:High production expenditures.

3.4-3 Combining Shear-yielding – Shear-resistant Connecting ElementsIt is also possible to combine the shear-yielding and shear-resistant connection types (see alsoChapter 2.2-6). This means that the shear-resistant connection is used only in the area requiring thistype of connection. Otherwise, the shear-yielding connection is used. For example, a shear-resistantconnection can be selected in the crane area, then there can be a changeover to the shear-yieldingconnections for the rest of the frame, if permitted by rigidity and stability values.

General Production and Mounting Remarks 3.5-13.5. General Production and Mounting Remarks

3.5-1 Types of Joints of Sheets and Moulded TubesIt is recommended that the auxiliary frame be prefabricated to such an extent that it need only beconnected to the chassis frame on the vehicle; this will prevent stress on the chassis frame.

If metal sheets or moulded tubes must be extended, they should be joined either offset (x ≈ auxiliaryframe height) or at an angle (α ≈ 30° to 45°) to one another.

X

Illustration 3-25

Choose a welding order which will prevent distortion almost entirely.

3.5-2 Bolt Connections for the MountingMaterials and dimensions

Bolts and locknuts for fastening the mountings must be strength category 10.9 as a minimum. Washersmust have a hardness of at least 200 HB.

Mountings are normally fastened to the chassis frame with M14 bolts. Under certain circumstances,M16 bolts are also used.

Bolt connection with friction connection

A force transmission with a friction connection can function only if the bolt is very tight. If the bolts usedare too short, the bolt connection will become loose due to so-called “subsidence”. The bolts must beretightened if the connection is to function properly.

Using spacers allows you to achieve the correct bolt length, thus creating a permanent bolt connection.

Area of application: bolt connections which need not withstand high shear forces (e.g., for the mountingof supplementary tanks or for shear-yielding mountings).

3.5-2 General Production and Mounting Remarks

Shear-resistant bolt connection

Only positive-fit connecting elements are shear-resistant. Shear-resistant bolt connections are “drivenbolt connections” (fitted bolts) or bolt connection if the hole play is ≤ 0.2 mm, full-shaft bolts with aminimum quality of 10.9 are used and the minimum bolt length is assured.

Area of application: fastening of base shear plates, as substitute for rivets, fastening of cross-beams, ...

A shear-resistant bolt connection may be tightened only at the nut. Torquemoments can be found in Section “4.9”.

CONTENTS

4.1. SAFE CRANE HANDLING

4.1-1 SEPARATE LIFTING EQUIPMENT FOR LOADING CRANES OF THE SMALLAND MEDIUM MODEL SERIES

4.1-2 SEPARATE LIFTING EQUIPMENT FOR LOADING CRANES OF THE MEDIUMAND LARGE MODEL SERIES

4.1-3 SEPARATE LIFTING EQUIPMENT FOR LOADING CRANES WITHCOMBINATION CRANE BASE

4.2. MOUNTING CRANE USING BRIDE BOLTS

4.2-1 CRANE MODEL FEATURES

4.2-2 GENERAL MOUNTING INSTRUCTIONS4.2-3 POSSIBILITIES OF SECURING THE CRANE

4.3. MOUNTING OF CRANES WITH COMBINATION CRANE BASE

4.3-1 CRANE MODEL FEATURES

4.3-2 SYSTEM DESCRIPTION FOR THE MOUNTING4.3-3 PREFABRICATION OF THE REAR AUXILIARY FRAME MODULE

4.3-4 MOUNTING OF THE REAR AUXILIARY FRAME MODULE4.3-5 PRODUCTION AND MOUNTING OF THE FRONT AUXILIARY FRAME

MODULE (FRAME END)

4.4. CRANE MOUNTING ON REMOVABLE MOUNTING CONSOLE

4.4-1 REMARKS ON CONSOLE MOUNTING

4.5. CRANE MOUNTING WITH SADDLE FRAME OR TUBE BASE

4.5-1 CRANE MOUNTING WITH SADDLE FRAME4.5-2 CRANE MOUNTING WITH TUBE BASE

4.6. STATIONARY MOUNTED LOADING CRANES

4.6-1 REMARKS ON A STATIONARY MOUNTING

4.7. MOUNTING OF A PC CRANE

4.7-1 REMARKS ON THE MOUNTING

4.8. ADDITIONAL WORK BEFORE AND DURING THE CRANE MOUNTING

4.8-1 ADJUST DEAD POINT

4.8-2 CRANE SUPPORT4.8-3 RAISED CONTROL POSITIONS

4.8-4 PROTECTIVE DEVICES ON THE VEHICLE4.8-5 WARNING DEVICES

Securing the Crane Chapter 4

4.1-1 Safe Crane Handling

Ü1

1. Ü12. Ü13. Ü14. Ü1

Safe Crane Handling 4.1-1

4.1. Safe Crane Handling

Consult the technical data sheets to find the dead weight of the crane. Be sure to take into account anyaccessories that have been installed.

Safe handling of the crane can be guaranteed only by the use of suitable andproperly dimensioned separate lifting equipment, belts, and similar objects.When handling the crane, there is an extreme risk of being crushed. Stay at a safedistance from the equipment at all times.

4.1-1 Separate Lifting Equipment for Loading Cranes of the Small and Medium ModelSeriesLifting equipment for cranes from 4 mt – 30 mt --> HXE2262

(see Service Information 010/2002)

4.1-2 Separate Lifting Equipment for Loading Cranes of the Medium and Large ModelSeriesLifting equipment for 30 mt – 40 mt --> EKD-044

Lifting equipment for 40 mt – 70 mt --> EKD-045

(see Service Information 010/2002)

4.1-3 Safe Crane Handling

4.1-3 Separate Lifting Equipment for Loading Cranes with Combination Crane BaseThe lifting points on the crane are found at the main boom anchor and at the end of the telescopingsystem.

Illustration 4-10

1

Illustration 4-11

Illustration 4-12

The separate lifting equipment must be attached tothe main boom anchor with two bolts (1).This lifting device is not included in the scope ofdelivery of the crane.

The telescoping arm package must besecured with a belt or similar object.

Mounting Crane Using Bride Bolts 4.2-1

4.2. Mounting Crane Using Bride Bolts

4.2-1 Crane Model Features

Component designation

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

1

2A

10

687

3

4

5

12

2313 14

15

16

18

19

2021

1 10 6

22

2B

17

22

91 Operating elements 12 Lift cylinder

2A Control panel – control valve side (Side A) 13 Main boom

2B Control panel – Opposition side (Side B) 14 Knuckle cylinder

3 Support cylinders 15 Knuckle boom

4 Support outriggers 16 Knuckle boom position sensor

5 Oil tank 17 Telescoping cylinder

6 Bride bolts 18 Hydraulic telescoping booms

7 Rocker 19 Mechanically extendable prolongations

8 Crane base 20 Remote control panel (transmitter)

9 Control valve block 21 Load hook

10 Slewing gear (restricted) 22 Linkage system

11 Crane column 23 Winch

4.2-2 Mounting Crane Using Bride Bolts

4.2-2 General Mounting Instructions

In general, the loading crane is placed on the auxiliary frame of the truck and bolted to it with bridebolts. The number of bride bolts and the fastening points can be seen in the pertinent technical datasheets.

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

1

23456

7

8

Illustration 4-20

1 ..... Crane base2 ..... Rocker3 ..... Auxiliary frame4 ..... Chassis frame5 ..... Base shear plate6 ..... Spacer plate7 ..... Bride bolts8 ..... Stops

Rectangular spacer plates (6) must be placed between the bride fastening bracket and the nut, thenwelded to the bride fastening bracket after the mounting.

The bride bolts (7) must be secured with a self-locking nut or a counternut at both ends and tightenedusing a torque spanner. The tightening torque for the bride bolts can be found in the operatinginstructions for the crane.

Make sure that the beam of the crane base is solidly placed on the auxiliary frame (3). If there is a gap,fill it with steel plates which must be welded to the auxiliary frame.

Slipping of the crane must be prevented by the use of four stops (8) so that the slewing forces aretransmitted to the substructure. The stops must be put into place before the crane is set down.

Make sure that the stops affect the cross-beam directly and not the bridebrackets of the rocker.The bride bolts (7) delivered with the crane are made of high-strength materialand may not be reshaped by either hot or cold methods. Under no circumstancesmay the threading of the bride bolts be recut.

Mounting Crane Using Bride Bolts 4.2-3

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

The auxiliary frame must be torsion-resistant and shear-resistant in the area of the crane (see Chapter2.2-6).

4.2-3 Possibilities of Securing the CraneIf the vehicle manufacturer has not prescribed special securing regulations (e.g., his own mountingplates, etc.), one of the following possibilities may be chosen.

Double bride fastening

A) Variant with bride plate

For the double bride fastening with bride plates, a steel plate is laid under the chassis frame and two bride boltsare inserted. When this variant is chosen, the chassis frame must be secured from compression (seeComponent 4). The support profile must be secured from slipping by using a bushing which meshes with thebride bolt.

1 2

3 4Illustration 4-51

1 ..... Bride bolts2 ..... Mounting level of crane3 ..... Bride plate4 ..... Support profile

This type of securing can be used for loading cranes of up to 35 mt lift moment.

4.2-3 Mounting Crane Using Bride Bolts

B) Variant with mounting bushing

In this mounting type, the first bushing is welded to the base shear plate on the outside and the secondbushing is welded into the auxiliary frame. The mounting bushings should be placed so that the bridebolts can be easily tightened. Two lateral reinforcement plates A must also be welded to the outerbushing.

This type of securing can be used for all types of cranes.

Single bride securing

The mounting bushing is welded to the base shear plate and supported with two lateral reinforcementplates A.

This type of securing may also be used for all types of cranes.

Mounting of Cranes with Combination Crane Base 4.3-1

4.3. Mounting of Cranes with Combination Crane Base

4.3-1 Crane Model Features

Component designation

1

2 3 4 5 6

7

891011

Illustration 4-301 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

Combination crane base

The combination crane base serves as both a crane basis and as a fully equivalent replacement for anauxiliary frame. Depending on the mounting variant, the auxiliary frame modules are welded directly tothe welding connection points (see Illustration 4-31, Components 1 and 6).

There is no crane base rocker on this combination crane base. The crane is designed to be secured tothe base shear plates on the truck chassis by welded connections. The bride bolt connection otherwiseused is therefore unnecessary.

The crane support must be positioned in front of the bearing ring mount to achieve better stability andto realize the maximum length of the boom system with a low crane height. This type of constructiondesign makes it possible to keep the construction heights very low even with maximum equipment onthe crane and the chassis.

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

4.3-2 Mounting of Cranes with Combination Crane Base

1 2 3 4 5 6 7

8

Illustration 4-31

1 Welding connection point2 Control panel support3 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

4.3-2 System Description for the MountingAs has already been described in Chapter 4.3-1, the crane is positioned directly on the chassis frameand connected to the base shear plates (see Chapter 3.4-2) shear resistant and torsion resistant bywelding. The combination crane base has been dimensioned so that an auxiliary frame is notnecessary in this area. The other auxiliary frame modules are welded to the connection points of thecombination crane base at the front and back.

In this chapter, the mounting on a tractor is described as an example. The mounting of the auxiliaryframes with adjacent loading bridge, pallet or container platform is carried out similarly. The onlydifference will be in the varying heights and lengths of the auxiliary frames.Consult Palfinger for all other special mounting variants (mounting in the middle, ...).


12

1 2

4 5

3Illustration 4-32

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

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

o Preparation of the truck chassis (see chapter 2.2-2, Equipment Recommendations for theVehicle).

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

o Prefabricate the auxiliary frame modules (see Chapter 4.3-3 Prefabrication of the RearAuxiliary Frame Module).

o Placement of the auxiliary frame modules on the chassis.

o Welding the auxiliary frame modules to the crane or the base shear plates.

4.3-3 Prefabrication of the Rear Auxiliary Frame ModuleThe following descriptions of the auxiliary frame module are intended for informational purposes only.

The design of the auxiliary frame modules is essentially dependent on the following factors

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

o Required sheet thickness and grade of steel

o 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 auxiliary frame module so that the middle cross-piece and the base plate of the combination crane base can be welded to the auxiliary frame module;this opening is then welded closed with a closing plate (1) to complete the mounting of the auxiliaryframe.

1

CUT A-A

CUT B-BFlat steel as welding puddle protection

Slot for I seamIllustration 4-33


Illustration 4-34

4.3-4 Mounting of the Rear Auxiliary Frame ModulePark the vehicle on a level surface and check the parallelism of the frame.

Before mounting the rear auxiliary frame module, the surface of the welding area must be thoroughlystripped and cleaned of any residual paint and dirt.

The auxiliary frame module must be placed so that it rests solidly on the chassis frame or on the baseshear plates.

Once the auxiliary frame module has been aligned and tacked, the welding work must progress in sucha manner that any distortion can be kept to a minimum or virtually eliminated (e.g., by having twowelders opposite one another, ...).


1

2 3

45

Illustration 4-35

1 ..... Crane2 ..... Chassis frame or base shear plate3 ..... Auxiliary support4 ..... Rear auxiliary frame module5 ..... Closing plate

The rear auxiliary frame module must be welded to the crane or the base shear plate in the followingareas:

1. Connection – combination crane base and the bending area of the auxiliary frame module withthe base shear plate.

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

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

After the middle cross-piece and the base plate of the combination crane base have been welded tothe auxiliary frame module, the opening in this area must be welded closed with a closing plate (seeIllustration 4-35, Component 5).


4.3-5 Production and Mounting of the Front Auxiliary Frame Module (Frame End)A suitable frame end must be prepared in the front area so that the bending forces can be smoothlytransferred to the chassis frame. This is welded at the front to the combination crane base and thebase shear plates.

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

1

23Illustration 4-36

1 ..... Combination crane base2 ..... Front auxiliary frame module (frame end)3 ..... Free space for protruding components of the truck chassis (transmission, ...)

Illustration 4-37

These illustrations are for informational purposes only!!

4.4-1 Crane Mounting on Removable Mounting Console

4.4. Crane Mounting on Removable Mounting Console

4.4-1 Remarks on Console MountingIf you want the dismounting of the crane to be simple, a removable mounting console is usually thebest solution.

3 4

1

2

Illustration 4-501 ..... Mounting console2 ..... Base shear plates3 ..... Chassis frame4 ..... Auxiliary frame

The mounting console is mounted on the rear of the vehicle using holding plates. The holding platesare mounted according to their own separate mounting guidelines.

If an oil cooler is planned for the crane hydraulics, it must be mounted onthe vehicle. The oil cooler may not under any circumstances be mountedon the removable mounting console or on the crane.

A pressure control valve must be mounted in the pressure line betweenthe hydraulic pump and the quick-release fastener on the mountingconsole for the protection of the hydraulic pump and the auxiliary drive.

Crane Mounting with Saddle Frame or Tube Base 4.5-1

4.5. Crane Mounting with Saddle Frame or Tube Base

4.5-1 Crane Mounting with Saddle FrameWhen mounting cranes with a saddle frame, the frame is mounted laterally on the auxiliary frame. Theconnection to the auxiliary frame is done with the bearing plates designed for this purpose. The exactwelding guidelines for the individual saddle frames can be seen in the technical data sheets orobtained from PALFINGER.

1 2

3

Illustration 4-52

1 ..... Crane2 ..... Auxiliary frame3 ..... Saddle frame

4.5-2 Crane Mounting with Tube BaseThe crane base on cranes which have a rotary joint on the slewing gear can be integrated completelyinto the auxiliary frame. The standard crane base is then replaced by a so-called tube base which iswelded into the auxiliary frame.

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

After welding the tube base, the flange plate must be examined for distortionfrom the welding without fail; if the tolerances have been exceeded, suitableprocedures must be used to correct the distortion.

4.5-2 Crane Mounting with Saddle Frame or Tube Base

1

2 3

Illustration 4-53

1 ..... Tube base2 ..... Auxiliary supports3 ..... Auxiliary frame

Stationary Mounted Loading Cranes 4.6-1

4.6. Stationary Mounted Loading Cranes

4.6-1 Remarks on a Stationary MountingStationary mounting means that the crane has been mounted on a rigid substructure.

To reduce the increased shock stress on the crane which results from the rigid substructure, suitableprecautions to protect the crane components or the substructure must be taken, e.g.:

• Setting the lift category to H2 (EN12999)

• Installation of an adequately dimensioned pressure accumulator on the lift cylinder

• It must be determined if the standard crane base can be used for the stationary mounting.

The correct setting of the lift category or the implementation of the appropriate measures to reduceshock is the responsibility of the mounting company. Moreover, the mounting company is responsiblefor the correct design of the substructure and the mounting of the crane. If any points are not clear, thecompany should consult the inspection authorities or PALFINGER.

Improper use can lead to breakage of the crane components.

4.6-1 Stationary Mounted Loading Cranes

Example of stationary crane mountings

Illustration 4-54

Stationary mounting of aloading crane with marineframe on a tube base made ofsteel.

Illustration 4-55

Stationary mounting of aloading crane on a foundationmade of steel concrete.

Mounting of a PC Crane 4.7-1

4.7. Mounting of a PC Crane

4.7-1 Remarks on the Mounting

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

When selecting the mounting position, make sure that the control panel is not inthe vicinity of the vehicle tailpipe (emissions).

Remove the mounting, if possible with the auxiliary frame, from the vehicle. Then prepare a mountingplate with the same size as the crane base. The mounting plate should be made of steel plate which isat least 15 mm thick.

4.7-1 Mounting of a PC Crane

An appropriate substructure must exist in the chassis area to ensure trouble-free securing andfunction. If a suitable substructure is not already in place, a suitable auxiliary frame construction mustbe prepared (unless the vehicle manufacturer prescribes or recommends other actions).

Illustration 4-56

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

If the auxiliary frame is secured using double bride brackets, the chassis framemust be protected from compression (see Chapter 4.2-3).

Additional Work Before and During the Crane Mounting 4.8-1

4.8. Additional Work Before and During the Crane Mounting

4.8-1 Adjust Dead PointWhen mounting cranes which do not have an infinite slewing gear, it is important to note the position ofthe dead point before placing the crane. This point is marked by the factory on the crane base with thefollowing symbol.

Illustration 4-57

If it is necessary to change the dead point, this must be done in accordance with Service InformationNo. 021/94.

4.8-2 Crane SupportWhen mounting cranes on which the factory did not mount the support cylinders for transport reasons,the following points must be observed during mounting:

• Clean flange areas.

• Mount the handle for mechanically extendable support.

• Tighten the fastening screws of the support cylinders with a torque spanner (see OperatingInstructions 6.1-1 for the values).

The support cylinder must always be secured with all of the fastening screws (A)to the support outrigger.

• The lock function of the mechanical support outriggers when retracted must be guaranteed. Werecommend a warning light in the driver’s cab as a check of the support lock for safety reasons.

• Support outriggers and support cylinders must be visible during extension and retraction. If this isnot possible for both sides, operation must be restricted to the visible side. This can be done byremoving the hand lever or disconnecting the opposite control.

• Contact surfaces of mechanical support outriggers should not be lubricated (cleanliness in theoperating area).

• If support plates were supplied with the crane, a transport base should be provided in the vicinity ofthe supports.

4.8-3

4.8-3 Raised Control PositionsThe mounting company must install climbing aids (non-slip steps, handles) and guard rails inconformity with standards and regulations of the pertinent country on cranes with a raised stand or highseat. It must be possible for the crane operator to reach the operating position without danger. It mustbe guaranteed that control levers are not unintentionally activated or used as handles when theoperator is climbing to the position.

Note the additional space requirement for a high seat (risk of being crushed!).

4.8-4 Protective Devices on the Vehicleo Protection from emissions

o Protection from rotary movements (drive shaft)

o Lateral restriction for the crane outrigger stored on the loading area: Measures must be takento ensure that the crane (and/or accessories fastened to it) do not protrude over the width ofthe vehicle during transport.

4.8-5 Warning Deviceso Acoustical warning for people about to enter a hazardous area. Requirement for reach of 12 m

or more according to EN12999 5.6.7 --> connect to vehicle horn or the horn which can beobtained from Palfinger (EMV certified).

o Transport position monitoring of main boom: required when stored above loading area –according to EN12999 5.6.1.3.

o Optional: Support outriggers retracted or locked, support cylinders retracted.

CONTENTS

5.1. GENERAL MOUNTING REMARKS

5.1-1 MOUNTING REMARKS

5.2. INSTALLATION POSSIBILITIES

5.2-1 ADDITIONAL SUPPORT ABOVE THE CHASSIS FRAME:5.2-2 ADDITIONAL SUPPORT BELOW THE CHASSIS FRAME:

5.3. SECURING POSSIBILITIES

5.3-1 SECURING THE ADDITIONAL SUPPORT ABOVE THE CHASSIS FRAME

5.3-2 SECURING THE ADDITIONAL SUPPORT BELOW THE CHASSIS FRAME

5.4. SPECIAL MODELS OF SUPPORTING SYSTEMS

5.4-1 ADDITIONAL SUPPORT EXTENDABLE TO THE BACK (DRAWER)5.4-2 ADDITIONAL SUPPORT CYLINDER(S) IN FRONT OF THE DRIVER’S CAB

Mounting of Additional Supports Chapter 5

5.1-1 General Mounting Remarks

2. Ü13. Ü14. Ü15. Ü1

General Mounting Remarks 5.1-15.1. General Mounting Remarks

5.1-1 Mounting RemarksThe position of the additional support must not impair the functioning of the vehicle components or themaintenance work on the truck. If necessary, spacers must be placed between the additional supportand the chassis frame.

• The clearance of the drive shaft and the spring travel of the axles must be guaranteed withoutrestriction.

• Sufficient ground clearance must be assured (observe angle of driving slope α). Moreover, theremust be adequate extension length H of the support cylinder (take into consideration during projectplanning).

The auxiliary frame must be produced torsion-resistant (see Chapters 2.2-6 and3.2-2) so that torsion moments can be transferred to the additional support.

H

5.2-1 Installation Possibilities

5.2. Installation Possibilities

5.2-1 Additional Support Above the Chassis Frame:As a rule, additional support is installed over the chassis frame (superstructure mounting) if the crane ismounted at the rear. The additional support is then integrated into the front area of the auxiliary frame.

5.2-2 Additional Support Below the Chassis Frame:Additional support below the chassis frame (substructure mounting) is usually used for front-mountedloading cranes. The additional support is installed in the rear area under the chassis frame.

Superstructure additional support

Substructure additional

Securing Possibilities 5.3-15.3. Securing Possibilities

5.3-1 Securing the Additional Support Above the Chassis FrameAs a rule, the additional support is welded into the auxiliary frame for superstructure mounting. Thesub-belt of the auxiliary frame then runs under the additional support and should not be discontinuous.

5.3-2 Securing the Additional Support Below the Chassis Frame

A) Weld additional support under the chassis frame

The additional support is placed under the chassis frame and welded to the base shear plate.Customized reinforcement plates should be mounted on both sides to achieve adequate stability.

Upper belt of auxiliary frame

Base plate

Lower belt ofauxiliary frameBase shear plate

5.3-2 Securing Possibilities

B) Mount additional support using bride bolts under the chassis frame:

If bride bolts are used to mount the additional support under the chassis, four bushings must be weldedonto the base shear plate, just as for the crane mounting, and supported with lateral reinforcementplates.

Four stops which effectively prevent slipping of the cross-beam (see Chapter 4.2-2) must be mountedon the outside of the additional support, just as for the crane.

Bride bolts must be tightened using a torque spanner.

Special Models of Supporting Systems 5.4-15.4. Special Models of Supporting Systems

5.4-1 Additional Support Extendable to the Back (Drawer)If the stability of rear-mounted cranes is not adequate in the back area, this can be compensated bytwo additional support cylinders which can be extended hydraulically towards the back.

The so-called “drawer” is individually designed for the vehicle, while the required support cylinders aretaken from Palfinger’s existing hydraulics systems.

The drawer must be placed so that the function of a trailer hitch is not impaired.

5.4-2 Additional Support Cylinder(s) in Front of the Driver’s CabThe stability above the driver’s cab is generally not complete when loading cranes have been mountedat the front. The stability in this area can be substantially improved by installing one or two supportcylinders (1) in front of the driver’s cab. The size and design of the additional support cylinders arecustomized for the vehicle.

The vehicle must be equipped with a reinforced chassis frame in the front area before supportcylinders can be mounted in front of the driver’s cab. Some truck manufacturers offer so-calledsnowplough attachments or towing attachments as special equipment. As a rule, they are well suitedfor the mounting of these support cylinders (1).

The max. permissible support forces of the support cylinders depend primarily on the design of thefront chassis frame and must therefore be discussed in every case with the pertinent truckmanufacturer.

1

Illustration 5-09

Drawer

5.4-2 Special Models of Supporting Systems

CONTENTS

6.1. GENERAL ...................................................................................... 3

6.1-1 HYDRAULICS ON THE CRANE ........................................................... 3

6.2. OIL LINES ON THE LOADING CRANE AND MOUNTING......................... 4

6.2-1 PIPES............................................................................................ 46.2-2 HOSES .......................................................................................... 46.2-3 PRESSURE LINES ........................................................................... 46.2-4 RETURN LINE................................................................................. 56.2-5 SUCTION LINE................................................................................ 56.2-6 LEAK OIL LINE OF THE CRANE ......................................................... 66.2-7 LEAK OIL LINE OF THE HYDRAULIC PUMP ......................................... 66.2-8 LOAD-SENSING LINE OF THE VARIABLE DISPLACEMENT PUMP ............ 66.2-9 SELECTION OF THE HYDRAULIC LINE CROSS-SECTION....................... 7

6.3. FILTER .......................................................................................... 9

6.3-1 DESCRIPTION................................................................................. 96.3-2 FILTER INSTALLATION AND MAINTENANCE......................................... 9

6.4. OIL TANK .................................................................................... 10

6.4-1 DESCRIPTION............................................................................... 106.4-2 MOUNTING OF EXTERNAL OIL TANKS ............................................. 106.4-3 TANK FILLING............................................................................... 11

6.5. INSTALLATION AND COMMISSIONING OF THE HYDRAULIC PUMP ....... 12

6.5-1 INSTALLATION OF THE HYDRAULIC PUMP........................................ 126.5-2 SETTINGS ON THE HYDRAULIC PUMP ............................................. 12

6.6. OIL COOLER................................................................................ 13

6.6-1 MODEL TYPES ............................................................................. 136.6-2 CONNECTION OF OIL COOLERS ..................................................... 13

6.7. HYDRAULIC OIL ........................................................................... 14

6.7-1 SELECTION OF THE BASE OIL ........................................................ 146.7-2 GENERAL REQUIREMENTS: ........................................................... 146.7-3 SELECTION OF THE VISCOSITY CLASSIFICATION: ............................. 156.7-4 MULTIGRADE OILS........................................................................ 166.7-5 COMPRESSIBILITY AND EXPANSION:............................................... 166.7-6 OIL MAINTENANCE ....................................................................... 16

Mounting Remarks for the Crane Hydraulics Chapter 6

6.1-1 General

2. Ü13. Ü14. Ü15. Ü16. Ü1


6.1-1 Hydraulics on the CraneThe right hydraulic connections are an important factor for the trouble-free operation of a hydraulicloading crane.

When mounting a loading crane, the mounting company will normally have to install all of the lines andcomponents described below, with the exception of the high-pressure filter.

Many crane models have the option of ordering the oil tank and oil cooler pre-mounted. Then only thehydraulic pump, the suction line and pressure lines as well as any necessary leak oil and LS lines mustbe mounted.

When the crane is mounted on the rear of the vehicle, an integrated cranetank must not be used as the suction line would be too long. There wouldthen be the risk of a cavitation of the hydraulic pump.

1 ........ Hydraulic pump2 ........ High-pressure filter3 ........ Loading crane4 ........ Oil cooler5 ........ Oil tank with return and

ventilation filter

A ........ Suction lineB ........ Return lineC ........ High-pressure line

6.2-1 Oil Lines on the Loading Crane and Mounting

6.2. Oil Lines on the Loading Crane and Mounting

Make sure that the pipes, hoses and connecting elements are adequately burst-proof.

Pipe: safety factor 2.5 against bursting; test certificate 2.2 required.

Hoses: safety factor 4 against bursting; test certificate 2.2 required.

Covers must be mounted above the hoses in the area of the control panel.

If the connection pump-crane can be uncoupled, the line must be secured with a pressure controlvalve.

6.2-1 PipesCold-bent hydraulic pipes should always be bent using a pipe bending machine. The radius ofcurvature should be at least three times the pipe diameter (observe any additional manufacturer’sinstructions). Avoid cross-section strictures at the point of the bending at all costs.

After bending, cut the pipes to the correct length and remove burrs from the pipe ends. Carefully rinseout the pipes before installing them.

Cotton waste and other fibrous material must not be used to clean hydrauliccomponents.Dirty or otherwise corroded pipes must not be installed.

The pipes must always be laid free of tension in order to avoid any additional stress on the pipes,flanges and screw connections (leak tightness).

Long pipes must be fastened additionally with elastic clamps.

Follow manufacturer’s instructions when mounting screw connections.

6.2-2 HosesHose lines are used in hydraulics to join connections which move relative to one another. In addition,hose lines have a damping effect on transmission of structure-borne sound.

Hoses may not be mounted so that they are taut or twisted under any circumstances.

Observe installation regulations and manufacturer’s technical information regarding laying and useprecisely .

6.2-3 Pressure LinesThe input line to the crane and the working lines on the crane fall under “pressure lines”.

Characteristics:

Oil speed relatively great: v = (3), 5 - 7 m/s

Pressure very high: pmax = 350 (430) bar

Discharge is max. pump flow Qmax = QPump

Relatively small line diameter

By nature, the greatest line friction is caused in the pressure lines due to the installation of valves andthe relatively small diameter. Always strive to lay the lines so that there is as little hydraulic resistanceas possible (no unnecessary angles, etc.).

Oil Lines on the Loading Crane and Mounting 6.2-4

6.2-4 Return LineThe return line is the connection between the control block and tank for the oil flowing back.

If it is required, the oil cooler is built into the return line.

Characteristics:

Large diameter so that dynamic pressure stays low

No pressure (except dyn. pressure) p = 0 - about 15 bar

Oil speed low v = 1 - 3 m/s

Discharge high Qmax = about 2 x QPump

6.2-5 Suction LineThe suction line is the connection between the tank and the pump; it should be as large andas short as possible.

Characteristics:

Very large diameter

Oil speed minimal v = 0.5 -1 m/s

To prevent cavitation, no hydraulic components may be built into this line.

The line cross-section should be selected so that the pressure at the suction connection does not fallbelow 0.8 bar (abs.) and does not exceed 2 bar (abs.).

Make sure that the connections are airtight.

Only hoses which are pressure-proof against the external air pressure (e.g., plastic hoses withsupportive spiral) may be used.


6.2-6 Leak Oil Line of the CraneLeak oil from the hydraulic motors must be returned without pressure to the tank, above all for craneswith infinite slewing gear and/or with a winch.

The leak oil line must therefore lead to a separate leak oil connection on the tank, standard onPalfinger tanks.

The leak oil line is always led through the rotary distributor, even if it is not used, on cranes with infiniteslewing gear. This simplifies the later addition of a winch if this should be required.

Under no circumstances may the leak oil line be combined with the return line of the crane as thedynamic pressure of the system would otherwise build up in the leak oil line.

The leak oil line must end under the oil level of the hydraulic tank. But you must be sure to lead theconnection into the tank from above.

6.2-7 Leak Oil Line of the Hydraulic PumpIf hydraulic pumps with their own leak oil line are used, the line must also lead back to the tank withoutpressure.

It is important that this line is led under the oil level in the tank to prevent air from being “sucked in” bythis line. In addition, the line must be laid in such a way that the housing of the hydraulic pump isalways filled with oil and that air is prevented from entering at the radial seal, even during longer idletimes.

Whether this line is necessary or not depends on the pump model (see pump manufacturer’sdocumentation). Observe strictly any mounting instructions from the manufacturer.

6.2-8 Load-sensing Line of the Variable Displacement PumpIf a variable displacement pump is used, the load-sensing line must be connected between the LSconnection on the proportional distributor valve and the signal input on the variable discharge pump.

The LS line is always drawn through the rotary distributor, even if this is not used, on cranes withinfinite slewing gear. This simplifies a later conversion to variable discharge pump which may bedesired.

Oil Lines on the Loading Crane and Mounting 6.2-9

6.2-9 Selection of the Hydraulic Line Cross-sectionThe selection of the line cross-section is extremely important so that frictional loss in the pressure areais kept as small as possible and the oil flow in the suction area is not disrupted.

The table below shows the recommended flow speeds:

Suction line 0.5 – 1 m/s

Return line 1 – 3 m/s

Input line 3 – 3 m/s

Work lines 5 – 7 m/s

The longer the line, the larger the cross-section that should be selected!

0,4

0,5

1

1,5

2

2,5

3

45678

4

5

10

15

20

30

40

50

60

70

8090

100

150

4

5

6

7

8910

15

20

25

30

40

50

1"

1¼"

1½"

¾"

½"

¼"

2½"

2"

3"

60

70

Sau

gR

eto

ur

Dru

ck

Strömungs-geschwindigkeit

v [m/s]Leitungs-

InnendurchmesserZoll - mm

VolumenstromQ [l/min]

Monogramm zur Berechnungvon Leitungsquerschnitten

Monogram for calculating line cross-sections

Volume flow

Line inner diameter

Flow speed

Return

Pressure

By combining the two factors volume flow [l/min] and flow speed [m/s], the above table will give you theoptimum line cross-section.


Attention: Use here the actual volume flow in the line, not the pump flow (especially return line).

Pay careful attention to the correct dimensioning of the lines and hoses.If the lines are dimensioned too small, there will be excessive dynamic pressurein the lines, leading to excessive heating of the oil.

Filter 6.3-16.3. Filter

6.3-1 DescriptionIn normal situations, a high-pressure filter and a return filter are installed on the crane. Moreover, aventilation filter is used on the tank. Suction filters are not recommended due to the risk of cavitation.

Filters must be designed for the system (oil flow); damage results if the flow rate is too great.

Every hydraulic filter has an integrated bypass which responds when the opening pressure has beenreached and allows the oil flow to pass through unfiltered.

The following are used:

High-pressure filter with a fineness of 6µ and a beta6 value of at least 75 for about 110 l/min flowrate, bypass opening pressure 0.35 MPa.

Return filter with a fineness of 10µ in the sizes 100 and 180 l/min, bypass opening pressure0.15 MPa

Ventilation filter with a fineness of 40µ in the size 200 l/min.

1 2 3 4

1. Ventilation filter

2. Return filter

3. High-pressure filter

4. Hydraulic symbol filter + bypass

6.3-2 Filter Installation and MaintenanceOptimal access is especially important so that maintenance work can be performed quicklyand carefully.

The purity of the hydraulic fluid and the useful life of the hydraulic system are directly related to oneanother. Rinsing during commissioning or after installation work on the system is especially important.

Changing all of the filter elements (including the tank ventilation filter) after commissioning has provenvaluable. All of the filter elements must be changed after 50 operating hours at the latest.

All of the other maintenance intervals can be found in the operating instructions.

Only original PALFINGER filter elements may be used.If parts from other companies are used, the warranty and guaranteeclaims are void.

6.4-1 Oil Tank

6.4. Oil Tank

6.4-1 Description

In the hydraulic system, the tank serves as an equalizing tank for the volume difference of thedifferential cylinders; in addition, its large exterior surface has a considerable cooling effect.

Besides the return and ventilation filters and the required connections, an oil tank must also beequipped with steadying plates (baffles) to prevent flow turbulence in the tank.

Every tank consists of the following components.

Tankkörper

Ansaugstutzen

Ölstandsanzeige

Rücklauffilter

Rücklaufstutzen

Einfüllstutzen

Ablaßschraube

Schwallblech

Return filter

Tank body

Return connection

Oil fill indicator

Drain plug

Suction connection

Fill connection

Baffle

On most of the tanks, a thermometer which shows the oil temperature has been integrated into the filllevel gauge.

You will find information and remarks on determination of the tank size in Chapter 2.7.

6.4-2 Mounting of External Oil TanksThe tank must be positioned as close as possible to the pump and the suction line must be laid asstraight as possible to the pump to reduce the risk of cavitation.

Oil Tank 6.4-3

♦ The mounting of the tank above the level of the pump also reduces the risk of cavitation (observeinstructions from pump manufacturer!).

♦ A separately mounted tank must always be used for rear-mounted cranes as the suction line is toolong for the integrated tank on the crane.

♦ When mounting the tank (selecting the mounting position), make sure that

– The tank can be filled without any trouble– Servicing work (changing filters) is not obstructed– All of the connections are easily accessible– The fill level indicator is easily visible

♦ A shut-off valve must be installed in the suction line immediately after the intake sockets so that theleads or the pump can be changed without emptying the tank.

♦ Emissions from the engine may not be led to the outside in the vicinity of the oil tank.

♦ Before mounting the oil tank, check to see that the inside is clean and clean carefully if needed.When modifications have been made to the tank by drilling, etc., the tank must be cleanedthoroughly.

6.4-3 Tank FillingTanks may only be filled when they are cold and with the crane in transport position.Fill the tank only to the mean value shown on the fill indicator.

A suitable filter must be used when filling the tanks as the oil as delivered does not meet therequirements of the necessary purity classification as a rule.

Never fill the tank completely as the oil expands as the temperature rises (about 0.1% for each degreeCelsius).

When the oil is changed, the tank must be cleaned and any contamination residues which have beendeposited removed.

6.5-1 Installation and Commissioning of the Hydraulic Pump

6.5. Installation and Commissioning of the Hydraulic Pump

6.5-1 Installation of the Hydraulic PumpAs a rule, any installation position of the pump may be selected. However, the pump housing mustalways be filled with hydraulic oil and may not drain, even when idle for a longer time.

Make absolutely sure that the rotation direction of the hydraulic pump is correct.

Installation of a speed governor to maintain a constant motor rotational speed is recommended.

When using drive shafts, observe the manufacturer’s guidelines (cover guards for rotating shafts andmeasures to reduce the noise).

You can find information about the required line connections in Chapter 6.2.

You will find the selection and dimensioning of the hydraulic pump in Chapter 2.7.

Observe manufacturer’s installation instructions.

Pre-installed, easily accessible measurement connections simplify pressuremeasurements during commissioning and when looking for the possible cause ofmalfunctions!

6.5-2 Settings on the Hydraulic PumpContinuous pump

The following setting is required on the continuous pump:

Maximum pressure (p) in (MPa)

The maximum pressure of the crane (main overpressure) is set on the pressure control valve of thedistributor valve for continuous pump systems. The maximum pressure of the hydraulic pump in thiscase must be set at a value about 10% higher than the maximum pressure of the crane.

Variable discharge pump:

The following settings are required on the variable discharge pump:

Standby pressure (p) in (MPa)

The standby pressure is usually set by the factory and ranges between 2.5 and 4.5 MPa.

Increasing the standby pressures makes the load-sensing signal “harder”, causing the crane torespond more quickly to required movements, but also increasing the energy loss in the hydraulicsystem.

Maximum pressure (p) in (MPa)

The maximum pressure of the crane (main overpressure) is set on the pressurecontrol valve of the variable discharge pump for load-sensing systems.The setting on the distributor valve has been set by the factory at a value about10% higher and must not be changed.

The exact setting values of the hydraulic system can be found in the pertinent technical data sheets.

After completing the settings on the hydraulic pump, the setting screws must be sealed with lead seals.

Oil Cooler 6.6-16.6. Oil Cooler

6.6-1 Model TypesAs a rule, only air coolers can be used on loading cranes.

They are installed in the return line of the crane and are turned on and off by a thermostat.

Palfinger offers models with varying cooling performance; selection of the cooler depends on the cranesize.

As a rule, the oil cooler suggested in the crane’s price list is selected; in cases of extreme use (e.g.,continuous grab operation), the next-largest cooler (also shown in the crane’s price list) is to be used.

Oil cooler and hydraulic symbol for oil cooler!

6.6-2 Connection of Oil CoolersThe oil cooler must be connected hydraulically to the return line of the crane.

The oil cooler must be mounted on the vehicle when removable consoles are used. (see also Chapter4.4)

If the thermostat on the oil cooler can be regulated manually, it must be set between 30° and 45° C. Asetting above 45° C is useless as the cooler then has too little effective cooling time.

Oil coolers always have separate electric connections; as a rule, connect them with the auxiliary drive.

See the description “Electric Crane Connection”.

6.7-1 Hydraulic Oil

6.7. Hydraulic Oil

6.7-1 Selection of the Base OilHydraulic oil is primarily used to transfer energy within the hydraulic system.

In addition, it should lubricate the moving parts of the hydraulic components, protect the parts fromcorrosion and carry away dirt particles and heat.

Generally the following base oils are available for use:

♦ Mineral oil

Is well suited for use with loading cranes and can be procured anywhere with uniform criteria. As arule, Palfinger cranes are tested with mineral oil.

♦ Native-based oils

These biologically degradable oils can also be used, but careful attention must be paid to the criteria(especially in the temperature range).

♦ Synthetic-based oils

Synthetic ester oils in particular are often used in lieu of mineral oil. They are biologically degradableand have outstanding values for a wide range of requirements. Be sure in this case as well that theselected oil meets the specific requirements.

♦ Oils with special properties

If special properties are required (e.g., non-flammable, etc.), special oils may be used (e.g., glycol basefor offshore use). The manufacturer must always be consulted in these cases.

6.7-2 General Requirements:

The hydraulic oil must meet the following general requirements:

♦ Temperature range (depending on viscosity) –30° to 80° C (see 7.3 as well)

♦ Purity classification at least 15/12 (according to ISO 4406)

♦ Good protection from corrosion and oxidation (type HLP)

♦ Gut lubrication

♦ Good air separation capability

♦ Low foam production

♦ Neutrality with regard to seals and hydraulic hoses

♦ The viscosity must be selected for the intended use (ambient temperature), see the viscosity-temperature diagram (7.3)

Hydraulic Oil 6.7-3

6.7-3 Selection of the Viscosity Classification:The viscosity is a key indicator of the tenacity of a (hydraulic) oil and is also known as the tensilestrength.

It is dependent on the temperature of the medium and is shown in [mm²/s] or [cSt].

As the temperature rises, the viscosity falls and the oil becomes more viscous [sic] or vice-versa.

The viscosity must be selected according to the ambient temperature, while making sure that the limitsare not exceeded during operation.

The limits are:

High temperature range (continuous operation) 9 cSt normal 12 cSt

Low temperature range (cold start) 2000 cSt normal 200 cSt

The viscosity-temperature diagram enables you to select the viscosity classification in general:

the designation of the hydraulic oil (e.g., HLP 68) is based on a temperature of 40° C. This means thatan oil with the designation HLP 46 has a viscosity of 46 cSt at 40° C.

Recommended range

6.7-4 Hydraulic Oil

6.7-4 Multigrade OilsMultigrade oils are more expensive than hydraulic oils with a fixed viscosity index, but theycover a greater temperature range. So they can save you the work, for example, of changingbetween “summer oil” and “winter oil” in cold countries.

niedrig hochTemperatur

nied

righo

chV

isko

sitä

t

hyd HLP 68

hyd HLP 32

hyd HLP-M 46

Viscosity Low High

Temperature

6.7-5 Compressibility and Expansion:Although hydraulic oil is regarded as “incompressible,” the compressibility of oil is actually 0.7 Vol% fora pressure difference of 100 bar.

100 bar � - 0.7%Vol.

Oil expands greatly when heated, which is why tanks must never be filled completely.

10 bar � + 0.7%Vol.

6.7-6 Oil MaintenanceAs a rule, hydraulic oil is changed after about 1000 operating hours. This is about once a year,together with the filter change.

This interval can be extended if the oil is properly maintained and cared for, especially if it is wellfiltered (see the oil manufacturer’s documentation as well).

High temperatures have a particularly negative effect on the useful life. Normally a crane should beoperated between 30° and 60° C.

The installation of an oil cooler or the reduction of the volume flow is absolutely essential if thetemperatures in a system are higher.

CONTENTS

7.1. POWER REQUIREMENTS ................................................................. 3

7.1-1 GENERAL ...................................................................................... 37.1-2 POWER REQUIREMENTS ................................................................. 37.1-3 CURRENT CONSUMPTION................................................................ 3

7.2. CRANE CONNECTION...................................................................... 4

7.2-1 CONNECTING THE MAIN LINE........................................................... 47.2-2 CONNECTING ELECTRICAL ACCESSORIES......................................... 5

The Crane’s Electrical System Chapter 7

7.1-1 Power Requirements

Power Requirements 7.1-1

7.1. Power Requirements

7.1-1 GeneralAlmost all crane models today require an electrical connection because of the diverse safety features.

All of the cranes are delivered pre-wired and must only be properly connected to the power source.

Depending on the equipment on the crane, several power lines may be required.

Care should always be taken that the right equipment is provided when the crane is ordered.

A distinction is made between:

• 12 V system

• 24 V system

7.1-2 Power RequirementsThe voltage supplied to the crane must be within certain tolerances, depending on the system, iftrouble-free electrical operation is to be assured.

The target values shown below apply:

• 12 V system 11 – 14 V at the terminals of the crane switch box

• 24 V system 22 – 28 V at the terminals of the crane switch box

If the voltage is too high, the magnetic valves will not close and the crane will not function.

Excess voltage overburdens the magnets and causes them to “burn out”!

7.1-3 Current ConsumptionIn addition, each line must be protected from excess current consumption.

The crane does NOT have a safety fuse in the line when it comes from thefactory.

However, some of the systems mounted on the crane have fuses installed at the factory.

Radio remote control Palfinger 10 A plus, 30 A minus in the housing

Radio remote control Hetronic 7.5 A in the receiver housing

Paltronic 50 7.5 A in the main device

7.2-1 Crane Connection

7.2. Crane Connection

7.2-1 Connecting the Main LineThe crane must be protected by a fuse in the vehicle fuse box so that the fuse can be changedimmediately and without difficulty in the event of damage. The required fuse strength is shown on asticker on the crane power line (8A as a rule).

The crane must be turned on using an external switch or together with theauxiliary drive switch (relay switch). Never use the ignition or steady plus!! Thiswould inevitably cause damage from overheating to the magnetic valves.

7,5A

1

2

3

1. Auxiliary drive switch (relay switch) or external switch

2. Fuse 8A/24V; 16A/12V

3. Line with increased cross-section for greater lengths

Nominal cross-section:

Depending on the equipment, Palfinger cranes are produced with 1.5² or 2.5² lines.

As a rule, this is adequate.

If the lines are very long (e.g., rear mounting or mounting on a semitrailer), it is necessary to increasethe nominal cross-section to the next size so that the voltage losses which occur are kept to aminimum.

If devices are used which consume a lot of current (e.g., spotlights) and are not connected separately,an increase in the cross-section will also be necessary. Generally, however, such devices are alwaysconnected to an external power source.

Crane Connection 7.2-2

7.2-2 Connecting Electrical AccessoriesOil Cooler:

Oil coolers are connected separately on all models (even when they are mounted as standard).

So every oil cooler has its own line which must be protected by an 8 A fuse.

It must also be connected via an external switch or the auxiliary drive switch.

Never use the ignition or battery.

The oil cooler must also always have current whenever the crane has current.

However, it may operate only when the integrated thermostat has been turned on.

8A Kran

Ein/AusCrane On/Off

Charger for the radio remote control:

The charger for the radio remote control must always be mounted in the driver’s cab so that a chargedbattery is available whenever needed.

It must be connected to steady plus to ensure that a charged battery is always available.

This is true for all types of remote controls.

Unintentional discharging of the vehicle battery is not possible because all of the chargers turn off afterthe charging process has been completed.

7.2-2 Crane Connection

CONTENTS

8.1. GENERAL ...................................................................................... 3

8.1-1 PREREQUISITES FOR THE MOUNTING OF AUXILIARY DEVICES............. 3

8.2. PREPARATORY WORK AND MOUNTING ............................................ 4

8.2-1 PALFINGER FLY JIB (ADDITIONAL KNUCKLE BOOM) ........................... 48.2-2 ROTATOR, GRAB, STONE-STACKING GRIPPER, PALLET FORK............ 58.2-3 MECHANICAL EXTENSIONS.............................................................. 68.2-4 WINCH .......................................................................................... 78.2-5 ELEVATOR WORKMAN BASKET........................................................ 8

Mounting Auxiliary Devices Chapter 8

8.1-1 General

General 8.1-1

8.1. General

8.1-1 Prerequisites for the Mounting of Auxiliary DevicesA Palfinger crane can be operated with a number of different auxiliary devices. In the EEA and somecountries, auxiliary devices must bear their own CE certification (see as well the relevant operatinginstructions for the specific crane).

Observe the following points when you are mounting any auxiliary devices:

• The auxiliary device must be suitable for the crane in terms of size and lifting capacity.

• When mounting the device on the crane, the manufacturer’s mounting instructions for the deviceand, to the extent applicable, any regulations specific to the country must be observed.

• Check for the existence of laws specific to the country which regulate the use or operation of anauxiliary device.

• Make sure there is a type plate on the auxiliary device with the following information:

ManufacturerType designationSerial numberDeadweightOperating pressureCapacityMax. permissible lifting weightYear built

• Some of these auxiliary devices must be attached to the crane using the Palfinger specialsuspension gear. Mount the Palfinger special suspension gear according to the sketch below.

If the Palfinger special suspension gear is not used for these devices, the load-bearing boom may be damaged. (Loss of guarantee)

If a hydraulically driven auxiliary device is used, the crane must also be equipped with the appropriatecontrol valve and additional piping on the load-bearing boom. Exact data can be found in the hydrauliccircuit diagrams of the specific crane or auxiliary device.

The scope of application, the preparatory work and the mounting of Palfinger auxiliary devices isexplained in the following.

8.2-1 Preparatory Work and Mounting

8.2. Preparatory Work and Mounting

8.2-1 Palfinger Fly Jib (Additional Knuckle Boom)

The Palfinger Fly Jib is a second knuckle boom systemand serves to extend reach and broaden the range ofpossible uses.

See the technical sheets of the crane to find out which fly jib is the right one for your crane.

Adapt the insert:

Weld the appropriate spacer plates to the insert. Then grind down the spacer plates, if necessary, farenough so that the fly jib fits firmly in the crane’s telescoping boom, but can nevertheless be easilyattached and removed. If the insert has too much play in the telescoping boom, oscillation duringoperation may lead to damage to the fly jib or the telescoping boom.

Then a stop must be welded to the insert. Position it so that the connecting pin can be easily pushedthrough the connecting hole without applying pressure.

The selection of the protective gas and the welding additive as well as the formof the welding seam and its thickness is the responsibility of the weldingsupervisor.

The welding may be done only by people in possession of a valid welder’scertificate in accordance with EN 287-1 or with an equivalent national welder’scertificate.

Stop

If the fly jib is mounted on the crane, the connecting pin must be secured properly with the appropriatesafety materials.

Preparatory Work and Mounting 8.2-2

8.2-2 Rotator, Grab, Stone-stacking Gripper, Pallet ForkRotators are used in combination with auxiliary devices which must be slewable (gripper, pallet fork,etc.). Depending on the use, you can choose between two attachment variants (rotator on the auxiliarydevice).

Mounting on the auxiliary device (grab, stone-stacking gripper, pallet fork, etc.)

♦ The auxiliary device may be mounted and dismounted only by trained personnel.

♦ The permissible total weight of the vehicle (vehicle registration certificate) must be observed.

♦ The auxiliary device may be attached only to suitable device carriers.

Paint must be removed from all of the contact surfaces before the auxiliarydevice is mounted on the rotator.

Rotator Type G Rotator Type GF

The selection of the type of rotator depends on the frequency with which the auxiliary device will bechanged. If you are using a number of auxiliary devices, use Rotator Type G. If one auxiliary device isbeing used, use Rotator Type GF.

Palfinger rotators must be mounted with the appropriate upper suspension on the load suspensiongear of the crane’s telescoping boom. The bolt which is used to pin the rotator must be properlysecured with the appropriate safety materials.


8.2-3 Mechanical ExtensionsMechanical extensions are used to increase the reach. You can find the appropriate mechanicalextensions for your crane in the mounting sheet DA069.

Adapt extensions:

Place the sliders and lateral guides in the last telescopingboom/extension.

Position the guides and the sliders for the mechanicalextension at the designated places.

Slide the mechanical extension into the last telescoping boom.

Screw the stops on the upper side of the last telescopingboom so tightly that the connecting pins of the extensionand the telescoping boom are flush.

Adjust the distances with the sliders and guides so that the extension fits firmly, but is neverthelesseasy to slide in and out.

After mounting, the type plates must be mounted and the maximum lifting weight must be painted onthe side of the extension as described in DA069.

Preparatory Work and Mounting 8.2-4

8.2-4 WinchWhen mounting the winch, a distinction is made between a winch on the main boom and a winch onthe knuckle boom.

Mounting on the main boom:

The winch is mounted on the main boom by positioning it and then bolting it tightly into place at thedesignated drill holes using mounting rails. See the technical information sheet “Winch Mounting” forthe specific crane.

Mounting on the knuckle boom:

A console which is used to fasten the winch must be welded to the knuckle boom. See the technicalinformation sheet “Winch Mounting” for the specific crane.

The selection of the protective gas and the welding additive as well as theform of the welding seam and its thickness is the responsibility of thewelding supervisor.

The welding may be done only by people in possession of a valid welder’scertificate in accordance with EN 287-1 or with an equivalent nationalwelder’s certificate.

Deflection pulleys, trolley heads and intermediate pulleys must be mounted in accordance with theinstructions in the technical information sheets.

Hydraulics:

There must be an additional section on the control valve. Make sure that this section is equipped with aslide bar with an open zero setting. Otherwise, it must be replaced. You must be sure that the oil leakhose from the winch motor (hydraulic motor) is led back to the tank without any pressure whenconnecting pipes or hoses.


8.2-5 Elevator Workman BasketThe elevator workman basket was developed so that a Palfinger loading crane could also be used totransport people for work in high places. Equipped with a remote control, the workman basket is a fullyfunctional elevator work platform.

After the workman basket has been mounted, the vehicle must be in a stable position in the entireworking area of the crane. The crane used must be able to lift a minimum lifting weight of (deadweightof the basket + lifting weight of the basket x 1.5) in the entire working area.

The crane must be equipped with a Palfinger remote control system (RC operation).

The crane may be operated only by using the remote control system while the workman basket is inuse. All of the other control panels must be locked during this period.

It must be possible to slew and lower the crane using a manual pump and emergency lowering systemif the hydraulic system fails.

Adaptation of the insert:

Fasten the appropriate spacer plates to the insert. Then grind down the spacer plates, if necessary, farenough so that the insert of the workman basket fits firmly in the crane’s telescoping boom, but cannevertheless be easily attached and removed. If the insert has too much play in the telescoping boom,oscillation during operation may lead to the person in the workman basket falling.

Preparatory Work and Mounting 8.2-5Emergency slewing equipment:

A manual pump must be installed in the hydraulics system so that the load-bearing boom with the workmanbasket can be slewed out of a possible danger zone before the emergency lowering.

Distributor valve

Rotary distributor

Support

Direction control valve

Collecting block

High-pressure filter

Oil cooler

Emergency motor

Pump

Crane speed:

The crane may not perform any movement faster than 0.4 metres per second as long as the workman basket isattached to the crane. This is ensured by programming the remote control system for workman basket operation.Please contact the Palfinger Customer Service about this.

Power requirements:

An electric cable (7-pin/2.5mm²) must be laid to the end of the load-bearing boom for workman baskets (BB014)with electric level regulation. It can be laid in the hose channels, or a cable drum on the knuckle boom can beused.

8.2-5 Preparatory Work and MountingHydraulics:

Single additional piping (2) must be mounted on the crane for workman baskets (BB015) with hydraulic levelregulation. A special control valve with a section for the level regulation is also required.

But please note that the operation of elevator work platforms may be subject to varying safety regulations indifferent countries. Always enquire about applicable laws in your country.

CONTENTS

9.1. DELIVERY...................................................................................... 3

9.1-1 PRE-DELIVERY INSPECTION............................................................. 39.1-2 SURRENDER OF THE CRANE TO THE CUSTOMER ............................... 4

Delivery of the Crane Chapter 9

9.1-1 Delivery

Delivery 9.1-1

9.1. Delivery

9.1-1 Pre-delivery InspectionThe pre-delivery inspection is carried out to ensure that the customer receives a fully functional cranewithout any defects or problems. This inspection is carried out according to the points listed in theservice manual, including a load test.

Load test

During this load test, the stability, lifting load values, overload protection, etc., are checked. The loadtest may be carried out only by trained personnel.

The following steps are to be conducted:

• The oil tank must be filled to the maximum level of the oil level indicator. The crane is in transportposition.

• The hydraulic system and the electric power of the crane must be turned on.

• All of the hydraulic cylinders must be fully extended and retracted once.

• Make sure that all of the crane movements are possible without restriction and do not collide withthe truck superstructure or the driver’s cab. All of the hose lengths and the laying of the hoses mustbe checked at the same time. This is especially important whenever modifications have been madeto the crane (dead point moved, special support, etc.). The stability (safety factor according tocountry regulations) of the vehicle in the entire working area of the crane must be checkedaccording to the lifting weight values shown on the lifting weight sign.

• All of the pipe and hose connections must be checked again for leakage and, if necessary,tightened.

• The pressure settings on the individual valves must be checked again and adjusted if necessary.They must then be sealed with lead seals to prevent any changes in the pressure settings of thevalves being made later (customer) (changes of the pressure settings on the valves may be madeonly by professional workshops which have been authorized by Palfinger).

• If the machine is equipped with an overload protection (slewing limitation), it must also be tested. Ifnecessary, the setting must be corrected.

• Check of points of risk of crushing and shearing.

If any defects are discovered, they must be corrected by the mounting company and entered in theservice manual (pre-delivery inspection list).

+ 8%0,8 m10 m

1000 kg 1000 kg

0.8 m

9.1-2 Delivery

9.1-2 Surrender of the Crane to the CustomerThe mounting company must instruct the crane operator in the operation of the crane when the craneis surrendered to the customer (Palfinger operating instructions). Any hazards during crane operationand possible effects of the mounting company’s work on the driving properties must also be pointedout to the customer. (See the remarks on hazards in the operating instructions as well!)

At this time, all of the documents such as service manual, operating instructions, includingsupplements referring to the mounting, and, in the EU and certain countries, the conformity declarationare handed over.

The delivery coupon in the service manual (warranty) must be filled out and signed by the mountingcompany. It must also be signed by the customer. Otherwise there are no warranty claims for thecustomer.

The pre-delivery coupon and the delivery coupon are to be filled out and sent to the appropriategeneral representative by the mounting company, who will then forward these two documents toPalfinger, Customer Service Department.

contents · contents 1 general remarks and ... made to the crane, palfinger customer service must...

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