Crane Installation

Chapter 6
CHAPTER 6
Crane Installation
In this Chapter
1
2
3
4
5
6
7
8
9
Guideline for Crane Installation............................................................. 3

Safe Crane Handling............................................................................. 5
Crane Model Features ........................................................................ 11
Mounting of Cranes with Combination Crane Base ............................ 37
Crane Installation on removable Mounting Console ........................... 44
Crane Installation with Trailer Frame .................................................. 45
Crane Installation with Tube Base ...................................................... 46
Stationary mounted loading crane ...................................................... 47
Installation of PC Cranes .................................................................... 50
Edition: 08/2012
1 / 52
Chapter 6 Crane Installation
2 / 52
Edition: 08/2012
Guideline for Crane Installation
Guideline for Crane Installation

For planning and assembling of a crane on a vehicle it is important to proceed in the following order:
1.
Installation planning of the crane
Chapter 3
Define crane position on the vehicle

Calculate the height of the vehicle
Axle load calculation
Stability calculation
Selection of additional stabilizer (if necessary)
Dimensioning of PTO and hydraulic pump
Dimensioning of tank volume and oil cooler (if necessary)
Planning
Definition of dead point for cranes without continuous rotation
2.
Selection and calculation of a sub frame
Chapter 5
Flexible / torsion-resistant sub frame

Shear-yielding / shear-resistant frame connection
Strength calculation of sub frame
3.A
Crane installation with truck standard crane base
Chapter 6
Manufacturing and assembling to the chassis of sub frame

including wear plates and base shear plates
Positioning of the crane on the sub frame by means of proper
lifting accessories
Positioning and tack welding of mounting bushes and mechanical crane stops
Remove crane from sub frame
Welding of mounting bushes and mechanical crane stops
Painting of sub frame, base shear plates, mounting bushes and
mechanical crane stops
Assembly
Positioning of crane on sub frame and fixing with mounting bolts

3.B
Crane installation with combination crane base
Chapter 6
Fixing of base shear plates on the chassis frame

Positioning of crane and additional stabilizer on the chassis and
tack welding to the base shear plates
Pre manufacturing of sub frame modules
Positioning of sub frame modules on the chassis
Welding of the sub frame modules, the crane base and the
base shear plates
Painting of sub frame modules
3 / 52
Edition: 08/2012
4.
Connecting of crane hydraulic
Chapter 8
Assembly of hydraulic pump

Connecting of oil pipes and hoses
Assembly
Filling of hydraulic tank with hydraulic oil
5.
Connecting of crane electric
Chapter 9
Connecting of main line to the crane

Matching of stabilizer positions of crane and additional stabilizer
(if existing) according current installation
Establishing of vehicle interfaces (motor start / stop, motor
speed adjustment, transport position monitoring)
6.
Start up of crane
Chapter 12
Functional check
Setting of pressures
Start Up
Setting loading limits and safety systems
7.
Handover to the end customer

Handover to the end customer according PALFINGER handover guidelines
4 / 52
Chapter 12
Safe Crane Handling
Safe Crane Handling
2.1
Transport
During transportation from the company to the customer of the cranes take care that the fastening attachments are not damaging the parts of the cranes. All accessories are packed in
boxes which are not allowed to be removed until the bodybuilding process. Do not damage
the boxes!
2.2
Unloading and bodybuilding process

During the unloading process trough the bodybuilder or a third party consider of all safety
rules and accident controls. Unload the crane and all its accessories safely and dont throw
boxes, etc. from the platform of the transporting vehicle.
When the parts are unloaden check the parts for damages and completeness. If there are
damages, note it on the shipping documents. Never pull or push the crane and its accessories on the floor. The using of chains and cables is just allowed if there is no direct contact
between the crane parts and the lifting equipment.
Consult the technical data sheets to find the dead weight of the crane. Be sure to take into
account any accessories that have been installed
Attention!
For a safe crane handling always use sufficient dimensioned devices (belts, chains).
Best is to use original PALFINGER handling systems!
During the crane handling danger of squeezing is given. Always be in a safety distance!
Introduction of our new system of crane lifting accessories which have been especially designed for the handling of PALFINGER cranes for shipment, installations and repair jobs.
The following points have been checked very carefully to ensure a trouble free use of the
equipment:
Safety
Protection of the crane painting
Universal for different crane types
Fast and quick handling
Following crane lifting accessories are available at the moment:
5 / 52
2.3
Edition: 08/2012
Lifting accessories for small and medium cranes models

Lifting accessories for cranes from 4mt - 30mt --> HXE2262 / EKD105 / EKD107
2.3.1
Crane series 2000

HXE2262
PK 4501 - PK 29002
Illustration 06-6001; HXE2262
2.3.2
Crane series 2010

EKD 105
+HI 273
+EQ 042
PK 8502 HP
PK 9002-EH
PK11002 HP
PK 12002-EH
Illustration 06-6002; EKD105
EKD 107
+HI 042
+EQ 042
PK 13001
PK 13001-K
PK 13002 HP
PK 14001-EH
PK 14002-EH
PK 14502-SH
PK 16001 HP
PK 16001-K
PK 16002 HP
PK 18001-EH
PK 18002-EH
PK 18502-SH
(See Service Information C07/2008)

All cranes of the High-Performance-Series (> PK 18502 SH PK 34002 SH) are delivered
with a shackle at the main boom. This shackle could be used for transport. In this case you
have to be careful because the position of the shackle is not in line with the centre of gravity
of the crane. The result is that the crane will be sloped. This could be avoided by using
PALFINGER lifting equipment mentioned above.
Illustration 06-1001; Shackle High-Performance-Series
6 / 52
Safe Crane Handling
2.4
Lifting accessories for medium and heavy cranes models

Lifting accessories for 30mt - 100mt --> EKD-108
EKD 108
PK 36002 - PK 100002
Truck with standard base
Lifting accessories for 60mt - 150mt --> EKD-106

EKD 106
PK 60002 - PK 150002
For combined crane base (EGG
base)
The following documents are included with each EKD-106 and EKD-108 accessory:
Conformity declaration
General operating manual for lifting accessories from the supplier
PALFINGER specific operator manual about the proper using of the accessories
Advice!
Check the operating manual for lifting a PALFINGER crane in Extranet Patis-online.
For using the lifting accessories EKD-106 and EKD-108, the lifting height of the overhead
crane shall be at least 4.7 to 5 m (including a truck frame height of approx.1.5 m).
(See Service Information C07/2008)
7 / 52
2.5
Edition: 08/2012
Handling of PC cranes:
For the handling of a PC crane put in a shackle into the occupancy drill hole and lift it with an
indoor crane or an other lifting device.
Illustration 06-1004; Shackle PC crane
2.6
Lifting accessories for EPSILON cranes

Depending on the crane model, EPSILON cranes have 2 shackles respectively 2 eyes
where you can connect the hook of the lifting accessory. The position is near by the centre
of gravity of the crane. With these lifting points it is possible to lift the crane from the palette
in a straight position.
Illustration 06-7001; Transport shackle respectively -eyes of EPSILON cranes
8 / 52
Safe Crane Handling
At EPSILON Z-cranes with telescopable main boom there are no shackles respectively eyes
to hook on the lifting device. In this case you have to use a hoisting sling for lifting the crane.
Illustration 06-7002; Hook on with hoisting sling at EPSILON Z-crane
At EPSILON L-cranes out of the S-class there are no shackles respectively eyes to hook on
the lifting device. In this case you have to use a hoisting sling for lifting the crane.
You have to take care in following points:
Due to the sharp edge you have to use an edge protection below the main boom to
avoid damaging of the hoisting sling.
The hoisting sling has to be put like a loop around the main boom.
Illustration 06-7003; Hook on with hoisting sling at EPSILON L-crane out of the S-class
9 / 52
2.7
Edition: 08/2012
Common security advice for using crane lifting accessories

The crane must to be secured during the working process until the fixation on the truck or
on a residential place is done by mounting bolts or welding angles.
2.8
Demounting of the crane

Before loosening the screws of the crane you have to secure the crane. If an EGG base is
used it can be necessary to grind the welding connections.
Afterwards the hydraulic- and electric lines can be demounted.
The stability of the crane has to be guaranteed in each step of the working process.
10 / 52
Crane Model Features
3.1
Component designation
3.1.1
Crane with continuous rotation system
The crane in the drawing below is an example and shows crane components which may be
found on the crane as options, depending on the exact design and crane model.
Illustration 06-1005; Main components of a crane with continous rotation system
Ground control control valve side,

opposite side
Rigid stabilizer cylinder
Crane mounting bolts
Tiltable stabilizer cylinder
Telescopic outrigger beams
Base
Continuous rotation system with gear rim
Lift cylinder
Emergency control stand on the crane

column
12
Linkage system
13
Main boom
14
Rope winch
15
Outer boom lift cylinder
16
Outer boom
17
Extension cylinder for hydraulic

extension booms
18
Hydraulic oil tank with oil level

indicator
19
Extension booms
20
Mechanical extension booms
10
Balance
21
Load hook
11
Crane column
22
Remote control handset
11 / 52
3.1.2
Edition: 08/2012
Crane without continuous rotation system

1
15
17
19
13
1
14
1
12
1
23
1
8
11
1
12
6
1
7
1
17
1
18
9
1
5
1
16
2
1
19
3
1
1
5
4
1
20
10
22
21
Illustration 06-1006; Main components of a crane without continuous rotation system
12 / 52
Ground control control valve side,

opposite side
Rigid stabilizer cylinder
Crane mounting bolts
Tiltable stabilizer cylinder
Telescopic outrigger beams
Base
Slewing system
Lift cylinder
Manual outrigger interlock system
10
Balance
11
Crane column
12
Linkage system
13
Main boom
14
Rope winch
15
Outer boom lift cylinder
16
Outer boom
17
Extension cylinder for hydraulic

extension booms
18
Hydraulic oil tank with oil level

indicator
19
Extension booms
20
Mechanical extension booms
21
Load hook
22
Remote control handset
23
Top seat
3.2
General mounting instructions

In general, the loading crane is placed on the sub frame of the truck and bolted to it with
mounting bolts.
Advice!
The number of mounting bolts and the fastening points can be found in the pertinent
technical data sheets.
It is permitted to combine mounting points BRI-4 and BRI-8 (mounting points I to IV, see illustration 06-1051) which are show in the technical data sheets. This means that it could be
possible to have different constructions of mounting points (connection between crane and
sub frame) for one crane installation.
Illustration 06-1051; Mounting bolts mounting points at the crane
I-IV
Mounting points for connection between crane and sub frame
13 / 52
Edition: 08/2012
Beware!
Cranes with conventional crane base (mounting with mounting bolts) may never be
placed directly on the chassis frame.
Illustration 06-1032; General view of crane installation with mounting bolts
1
2
3
4
5
6
7
8
9
10
Crane base
Balance
Chassis frame
Sub frame
Base shear plate
Mounting bolts
Mounting washer plate
Mounting bush
Crane stops
Wear plates for sub frames
Rectangular mounting washer plates (7) must be placed between the fastening bracket and
the nut. The mounting bolts (6) must be secured with a self-locking nut or a conternut at both
ends and tightened by using a torque spanner.
14 / 52
The below specified fastening torque is defined for the delivery condition of the mounting
bolts. This delivery conditions are for:
- Uncoated mounting bolt:
lightly oiled
- Coated mounting bolt:
not oiled
The tolerance range for the fastening torque is +/- 10% of requirement.
8.8
Thread Diameter
M16 x 1,5
M20 x 1,5
M24 x 1,5
M30 x 1,5
M33 x 1,5 (only EPSILON)
M36 x 1,5
M42 x 1,5
M48 x 1,5
Strength Class resp. Material

C40
42CrMo4V
Fastening Torque [Nm]
120
140
210
450
900
1220
1550
2500
3700
Beware!
The projection length of the bolt above the self-locking nut / conter-nut must be at
least three full turns of the thread (3 x thread pitch).
Make sure that the cross beam of the crane base is solidly placed on the sub frame (part 4,
illustration 06-1032). If there is a gap, fill it with steel plates which must be welded to the sub
frame.
In the crane area the sub frame has to be designed in a rigid version and must be connected
to the vehicle frame in a shear resistant way (see chapter 5 Sub frame).
3.2.1
Tightening sequence of mounting bolts

Following sequence has to be observed during installation of crane:
1. To install the base free of stress, all mounting bolts must be pre-installed.
2. Tighten bolts with 50% of fastening torque but not more as 200Nm (diagonal, see illustration 06-1027).
3. Tighten bolts with torque spanner to predetermined tightening moment.
If its impossible to pre-install all mounting bolts caused by the crane arm following steps
must be accomplished:
1. Install mounting bolts on at least 3 mounting points.
2. Tighten bolts with 50% of fastening torque but not more as 200Nm (diagonal, see illustration 06-1027).
3. Lift outer boom and install bolts on the 4th mounting point.
4. Tighten with torque spanner to predetermined tightening moment.
15 / 52
Edition: 08/2012
Illustration 06-1027; Tighten sequence of mounting bolts:
Advice!
The number of mounting bolts and the fastening points can be found in the pertinent
technical data sheets.
Attention!
Always tighten mounting bolts in the diagonal way and the proper torque!
Attention!
Only original PALFINGER bolt connections may be used. These can be bought from
the PALFINGER Equipment Centre.
Attention!
The mounting bolts (part 6, see illustration 06-1032) delivered with the crane were
made of high-strength material and may not be reshaped by either hot or cold methods. Re-cutting of the thread of the mounting bolts is not permitted.
16 / 52
3.2.2
Wear plates on the sub frame

Wear plates may be situated at the contact points of the crane so that the cross-section of
the sub frame is not weakened by wear and subsidence.
Illustration 06-1028; Wear plates
1
2
3
4
5
Sub frame
Crane base
Wear plate
Balance
Base shear plate
If it is not defined in the installation manual of the truck manufacturer, the screws for the
connecting between chassis and sub frame must be mounted from the internal side of the
chassis frame. The nuts were screwed on from the outside of the chassis frame. The tightening of the connection is done by the nut. The screw head is used only for hold up.
Attention!
Loose, damaged or excessively tightened bolts are susceptible to break under load.
This creates an acute risk of fatality to the operator and others.
17 / 52
3.2.3
Edition: 08/2012
Mechanical stop between crane and sub frame

The mounting bolts are not capable to bear the crane moments. Therefor it is necessary to
install mechanical stops to the crane and the sub frame. The mechanical stop prevents the
longitudinal- and transverse displacement of the crane on the sub frame.
PALFINGER delivers appropriate mechanical stops with each mounting kit. This
stops are adapted to the several crane models.
Advice!
Areas grinded down to bare metal for welding work must be protected against corrosion again once the welding work is done.
In the following list are the mechanical stop kits and the necessary welding seams in accordance to the torsional crane moment specified:
Crane torsional
moment (dynamic)
Mt [kNm]
Techn. Info Sheet:
DTDAMDYNA/05
5,0
16,0
27,0
42,0
55,0
85,0
Design
Part Nr.
HT10348
HT10349
HT7940
HT7941
HT7940
HT7941
HT7940
HT7941
HT11012
HT11013
HT11012
HT11013
HT11012
HT11013
E14011
E14012
10
10
12
12
Thickness connection
plate [mm]
Material quality
connection plate
105,0 EPSILON
S355
Filler material
Z1;
see Chapter 4 Welding at Bodywork and Crane
Quality class
C
DIN EN ISO 5817
Preheating
Min. thickness
welding seam
a [mm]
Beware!
Welding may be done only by people in possession of a valid welders certificate in
accordance with EN 287-1 or with an equivalent national welders certificate. The area
to which the welding certificate applies must cover the full scope of the work to be
done (see chapter 4 Welding on Crane and Attachment).
For the definition of the welding seam type and the welding seam length you will find the appertaining drawings on the next pages.
18 / 52
Mechanical stop design A:
Illustration 06-1019; Mechanical stop, design A
Mechanical stop design B:
Illustration 06-1020; Mechanical stop, design B for PALFINGER loader crane respectively EPSILON crane
19 / 52
Edition: 08/2012
Mechanical stop design C:
Illustration 06-1021; Mechanical stop, design C
Advice!
The use of the old stop plates for PALFINGER loadercranes is not permitted any
more due to the missing locking against transverse movement of the crane (see
illustration 06-1022)!
1 .....
2 .....
3 .....
4 .....
5 .....
Illustration 06-1022; Stop plates
20 / 52
Crane base
Balance
Sub frame
Chassis frame
Stop plates
The old stop plates are only used for EPSILON L-cranes (long logs) without crossbeam at
the crane base.
Illustration 06-7004; EPSILON L-crane base with stop plates
1
2
3
4
3.2.4
EPSILON crane base for L-crane

Stop plates
Sub frame
Chassis frame
Washer plate with lock against rotation

PALFINGER provides mounting bolts with diameter M24, M30, M36 and M42 washer plates
with integrated lock against rotation.
EPSILON only uses this washer plate for diameter M30.
Following illustration shows a washer plate with lock against rotation:
Illustration 06-6003; Washer plate with lock against rotation
A Lock against rotation for wide bolt slots

B Lock against rotation for narrow bolt slots
D Hole for mounting bolt
1
2
2 notches per side for the inspection of the proper assembly of the washer
4 piece lock against rotation for wide and narrow bolt slots
21 / 52
Edition: 08/2012
For the function of the washer plate with lock against rotation it is a requirement that the
washer plate is positioned on the crane base properly. Each washer plate with lock against
rotation can be used for two widths of bolt slots (e.g. the washer for mounting bolt M24 can
be used for a bolt slot with a width of 25 and 31 mm)
The lock against rotation of the washer has to be set with the proper width onto the bolt slot.
The clearance between the washer and the bolt slot has a tolerance of maximal 1,5 mm.
Each washer has for the visual inspection on the bottom side notches (see illustration 066003, position 1). By proper mounting of the washer this notches are in line with the inner
edge of the bolt slot (see illustration 06-1017 and 06-1018)
Attention!
CORRECT
During assembly of the washer plate with lock against rotation always take care that
the washer plate is positioned properly. For incorrect assembly the danger of damaging may occur. This creates an acute risk of fatality to the operator and others.
FALSE
Illustration 06-1017; Correct assembly of the wascher plate with lock against rotation
Illustration 06-1018; False assembly of the wascher plate with lock against rotation
D Diameter of mounting bolt

T Width of bolt slot
1
2
Notch at the washer

Inner edge of the bolt slot
By the use of washer with lock against rotation it is not necessary to weld the
washer towards the crane base after the assembly. Due to the serial coating of the
washer, a painting of the washer after the mounting is also not necessary.
22 / 52
Advice!
The use of old washers (HTR1140, HX 077, HTR1051 and HTR3382) is still permitted
(see point 3.2.5), but the mixing old washers and new washers with lock against rotation on one crane is not permitted.
3.2.5
Washer plate without lock against rotation

Washer plates with lock against rotation for mounting bolts with diameter of M20 and M48
are not available. For this diameter steel plates with an appropriate hole have to be used as
washer plates. To avoid the rotating respectively slipping of the washer plate it is necessary
that the plate is welded to the crane base after installation. The length of this welding seam
has to be at least 20mm to avoid increased hardness in the area of the welding (see chapter
4 Welding on Crane and Attachment).
This type of washer plates are also used for EPSILON cranes with mounting bolts diameter
of M24 and M33.
Illustration 06-1033; Assembly of the wascher plate without lock against rotation
1
2
3
L
Mounting bolt
Washer plate without lock against rotation
Welding seam for securing the washer plate
Length of the welding seam (min. 20 mm)
The washer plates without lock against rotation also have to be used for PALFINGER
st
cranes with an ordering date before 1 of July 2011 (e.g. rebuilding or spare parts). The reason for these is the modified tolerances for the mounting bolt slots at the crane base.
Areas grinded down to bare metal for welding work must be protected against corrosion
again once the welding work is done.
3.2.6
Bolt protection cap

After finishing the assembly the bolt protection cap has to be putted on the mounting bolt respectively nut. All components are included in the mounting kit.
23 / 52
Edition: 08/2012
1 .....
2 .....
3 .....
4 .....
Balance
Sub frame
Chassis frame
bolt protection cap
Illustration 06-1023; Bolt protection cap
3.3
Single mounting bolt installation (BRI-4)

The mounting bushing is welded to the base shear plate. PALFINGER provides for the
mounting bushes pre manufactured welded kits.
Illustration 06-1026; Crane installation BRI-4
1
2
3
Mounting bush
Washer hardened (HV300)
Mounting bolt
At the BRI-4 installation a hardened washer HV300 (part 2) is used between the nut and the
bush. All components are included in the mounting kit.
This type of installation can be used for all types of loadercranes.
For EPSILON cranes this application is not permitted. For EPSILON cranes you must always use 2 mounting bolts for each mounting slot, this means mounting bushes are permitted for using of 2 mounting bolts for each mounting point.
24 / 52
When positioning the mounting bushes it is necessary to keep a gap of at least 5 mm between the upper edge of the bush and the lower edge of the crane base. This is to ensure
that the crane base is solidly placed on the sub frame.
Illustration 06-1031; Gap between crane base and mounting bush
3.3.1
Connection of mounting bush to sub frame (design standard mounting bush)

The following list shows the PALFINGER mounting bushes as a function of the mounting
bolt diameter including the required welding seam thickness for the bushes. The diameter of
the mounting bolts can be found in the pertinent technical data sheets.
Mounting bolt
Max. mounting bolt force
FBr [kN]
Suitable mounting bush
ET Nr.
Bush length [mm]
Thickness connection plate
[mm]
Material quality connection
plate
M20x1,5
M24x1,5
M30x1,5
M36x1,5
M42x1,5
M48x1,5
85
125
200
290
400
530
HXE-4534
HXE-3144
HXE-3145
HXE-9084
HXE-2527
HXE-4514
120
160
160
214
214
310
10
12
12
S355
Z1;
C
DIN EN ISO 5817
Filler material
Quality class
Preheating
Min. welding seam thickness aW [mm]
4,5
10
10
Beware!
accordance with EN 287-1 or with an equivalent national welders certificate (see
chapter 4 Welding on Crane and Attachment).
25 / 52
Edition: 08/2012
Following illustrations 06-1034 and 06-1035 should attend as extension to the list mentioned
above:
Illustration 06-1034; Connection of mounting bush to sub frame, design standard mounting bush M20, M24, M30 and
M36
Illustration 06-1035; Connection of mounting bush to sub frame, design standard mounting bush M42 and M48
26 / 52
3.3.2
Connection of mounting bush to sub frame (design standard mounting bush shortened)
If necessary it is possible to shorten the standard bush according the following list. The required gusset plates and welding seams are defined also in the following list.
Mounting bolt
FBr [kN]
Mounting bush length [mm]
M20x1,5
M24x1,5
M30x1,5
M36x1,5
M42x1,5
M48x1,5
85
125
200
290
400
530
58
78
78
120
HXE-3144
HXE-3145
HXE-9084
10
8 1
8 1
8 1
Suitable mounting bolt bush

HXE-4534
P. No.
6
[mm]
Thickness gusset plate
6 1
s [mm]
Material quality of connection and gusset plate
S355
Z1
C
DIN EN ISO 5817
Filler material
Quality class
Preheating
Approval
Approval
from
from
PALFINGER PALFINGER
required
required
Min. welding seam thickness aW1 [mm]

Beware!
Following illustrations 06-1036 should attend as extension to the list mentioned above:
Illustration 06-1036; Connection of mounting bush to sub frame, design standard mounting bush shortened M20, M24,
M30 und M36
27 / 52
3.3.3
Edition: 08/2012
Connection of mounting bush to sub frame (design mounting bush directly on the base shear
plate, unshortened length)
If required the mounting bush can be welded directly to the base shear plate without mounting plate. In the following list are the required bushes and welding seams defined.
Mounting bolt
FBr [kN]
Suitable mounting bolt bush
P. No.
Recommended mounting
bush length [mm]
[mm]
Material quality of connection plate
M20x1,5
M24x1,5
M30x1,5
M36x1,5
M42x1,5
M48x1,5
85
125
200
290
400
530
HBS-7804
HBS-761
HBS-110
HBS-3366
HBS-3076
HBS-7801
120
160
160
214
214
310
10
12
12
S355
Z1
C
Filler material
Quality class
DIN EN ISO 5817
Preheating
Minimum welding depth

x (**)[mm]
Control dimension
b [mm]
Min. welding seam thickness aW [mm]
15
19
22
24
26
30
27
33
38
46
52
56
10
12
12
(**) Minimum welding depth has to be checked by a welding test!!!
Beware!
Illustration 06-1037; Connection of mounting bush to sub frame, design mounting bush directly on the base shear plate,
unshortened length M20, M24, M30, M36, M42 and M48
28 / 52
3.3.4
Connection of mounting bush to sub frame (design mounting bush directly on the base shear
plate, shortened length)
If required the shortened mounting bush can be welded directly to the base shear plate
without mounting plate. In the following list are the required bushes, gusset plates and welding seams defined.
Mounting bolt
M20x1,5
M24x1,5
M30x1,5
M36x1,5
M42x1,5
M48x1,5
85
125
200
290
400
530
Mounting bush length [mm]
58
78
78
100
External diameter bush

D [mm]
Internal diameter bush
d [mm]
[mm]
Thickness gusset plate
s [mm]
Material quality of connection and gusset plate
38
42
51
60

FBr [kN]
Filler material
Quality class
22
6
1
26
33
38
10
1
S355
Approval
Approval
from
from
Z1
see Chapter 4 Welding at Bodywork and Crane PALFINGER PALFINGER
required
required
C
DIN EN ISO 5817
Preheating
Minimum welding depth

x (**)[mm]
Control dimension
b [mm]
15
19
22
24
27
33
40
46
10
(**) Minimum welding depth has to be checked by a welding test!!!
Beware!
Illustration 06-1038; Connection of mounting bush to sub frame, design mounting bush directly on the base shear plate,
shortened length M20, M24, M30, M36, M42 and M48
29 / 52
Edition: 08/2012
3.4
Double mounting bolt installation (BRI-8)
3.4.1
Option with mounting plate

For the double mounting bolt installation with mounting plates, steel plates are laid under the
chassis frame and two mounting bolts are inserted. When this option is chosen, the chassis
frame must be secured from compression (see part 3, illustration 06-1029). The support profile must be secured from slipping by using of a screw which is connected to the chassis
frame (see part 4, illustration 06-1029).
Illustration 06-1029; Double mounting bolt installation BRI-8
1
2
3
4
5
Build-up level of crane

Mounting bolt
Support profile
Securing of support profile
Mounting plate
This type of installation can be used for loading cranes of up to 35 mt lift moment.
During installation of the mounting plates a hardened washer HV300 (see part 1, illustration
06-1024) is used at the hole. At the long hole a washer with lock against rotation (see part 3,
illustration 06-1024) is used. The regulations described in point 3.2.4 are also valid for the
assembly of the washer with lock against rotation. All components are included in the
mounting kit.
Illustration 06-1024; Crane installation BRI-8
30 / 52
1
2
3
Washer hardened (HV300)

Mounting plate
Washer with lock against rotation
When assembling the mounting plate you should take care, that the graven article number in
the mounting plate is at the averted side of the washer (graven article number is on the top).
Illustration 06-1025; Postioning of mounting plate for BRI-8
1
2
3.4.2
Position of graven article number on the mounting plate

Position of washer with lock against rotation by assembly
Option with mounting bush

In this mounting option, the first bushing is welded to the base shear plate on the outside
and the second bushing is welded into the sub frame. The mounting bushings should be
placed so that the mounting bolts can be easily tightened.
This type of installation can be used for all types of cranes.
Illustration 06-1030; Installation with mounting bush for BRI-8
1
2
Build-up level of crane

Mounting bush
31 / 52
3.5
Edition: 08/2012
Fitting the stabilizer cylinders to the crane extension arms

When fitting the stabilizer cylinders to the extension arms the following points need to be
taken into account:
Clean flange surfaces on both sides of any dirt and foreign bodies. The surface protection must not be removed
The fixing screws must be tightened with the required tightening torque and secured
with screw-locking adhesive. Before applying the adhesive the thread must be cleaned
and degreased. To avoid cold shock effects it has to be guarantied that the environment
and the glued parts will have the requested minimum temperature required by the
screw-locking adhesive. Following adhesives are approved by PALFINGER (the specification of the adhesive supplier must be considered during processing):
o
o
o
LOCTITE 243 (alternative LOCTITE 245)

VARY BOND 12-43 (alternative VARY BOND 12-45)
WIKO 02K43 (alternative WIKO 02K45)
Tighten fixing bolts with the prescribed amount of torque.

The stabilizer cylinder must always be secured to the stabilizer outrigger using the fastening bolts provided (A).
Illustration 06-1052; Bolting the stabilizer cylinder to the extension arm
Stabilizer plate extensions may only be used in accordance with technical information
sheets. No other stabilizer plate extensions are permitted without separate approval from
PALFINGER!
No modification of the flange plates on the stabilizer outrigger or stabilizer cylinder (e.g. extension by one row of holes) is permitted without separate approval from PALFINGER!
Caution!
No bolts other than those specified may be used to fix the stabilizer cylinders to the
extension arms!
Caution!
Loose, damaged or excessively tightened bolts are susceptible to break under load.
This creates an acute risk of fatality to the operator and others.
32 / 52
Tightening torque ISO-screws in Nm:

(not oiled and not lubricated)
Screw:
ISO 4762, ISO 4014
Nut:
ISO 4032
Washer: ISO 7090
3.6
Screw thread:
Screw strength: 10.9
M 12
100
M 14
165
M 16
245
Crane installation of EPSILON crane base without crossbeam

The EPSILON crane base for long log vehicles are delivered without integrated crossbeam.
Therefore an additional stabilizer is assembled together with the crane base
Following additional stabilizer options are distincted:
3.6.1
EPSILON crane base with flapdown-stabilizer

Crossbeam, flapdown stabilizer and balancing rod are delivered separately. After installation
of the crossbeam on the sub frame the flapdown stabilizer are welded to the crossbeam. Afterwards the balancing rod is mounted to the flapdown stabilizer.
Illustration 06-7005; EPSILON L-crane base with flapdown stabilizers
1
2
3
4
5
6
7
8
9
Crossbeam
Base shear plates
Sub frame
Chassis frame
Mounting bolts
Mounting bushes
Flapdown stabilizer
Balancing rod
Connection plate
33 / 52
Edition: 08/2012
If crane base and crossbeam of the additional stabilizer do not have the same level it is necessary to put a steel plate between crossbeam and connection plate to get the same level.
This additional steel plate has to be welded to the connection plate.
Advice!
The crossbeam has to be secured against slipping with mechanical stop according
point 3.2.3
3.6.2
EPSILON crane base with additional stabilizer

In this case an EPSILON additional stabilizer is mounted together with the crane base
Illustration 06-7006; EPSILON L-Crane base with EPSILON additional stabilizer
1
2
3
4
5
6
7
Crossbeam of additional stabilizer

Base shear plates
Sub frame
Chassis frame
Mounting bolts
Mounting bushes
Connection plate
If crane base and crossbeam of the additional stabilizer do not have the same level it is necessary to put a steel plate between crossbeam and connection plate to get the same level.
This additional steel plate has to be welded to the connection plate.
34 / 52
Advice!
The crossbeam has to be secured against slipping with mechanical stop according
point 3.2.3
EPSILON Off-Road-Crane and Communal-crane installation

The crane is installed directly on the mounting frame and has to be fixed with screws (see
table below).
The mounting frame can realised with through hole (see option A, illustration 06-7007) or
with threaded hole (see option B, illustration 06-7007). For option A a self-locking nut has to
be used.
3
2
Detail X
Off-Road
Communal
1
2
X
1
X
B
Y
3.6.3
Illustration 06-7007; EPSILON Off-Road-Crane and Communal-Crane installation
1
2
3
Y
Mounting frame / Chassis frame

Crane base
Distance bush
Clamping length
Communal
Crane class
OFF-ROAD
Screw (ISO4014)
M16
M24
M24
M24
M24
Self-locking nut
(DIN 931)
M16
M24
M24
M24
M24
Strength class
10.9
12.9
12.9
12.9
12.9
Quantity
16
10
14
Clamping length Y [mm]
60
70
70
70
70
35 / 52
Edition: 08/2012
The required clamping length Y of the screws (see table above) has to be observed. In order to fulfill this requirement, it is allowed to use distance bushes (see illustration 06-7007,
part 3).
As corrosion protection the lower side of the crane base is only primed by EPSILON. Before
mounting of the crane the primer has to be grinded down. Also the mounting area at the
frame has to be free of any coating (steel to steel connection between crane and mounting
frame)
Advice!
Take care in steel to steel connection between crane and mounting frame. If there is
no steel to steel connection a loosening of the mounting screws is possible.
36 / 52
Mounting of Cranes with Combination Crane Base
4.1
Component designation
11
10
7
1
Illustration 06-1007; Component designation of a crane with combination crane base
1
2
3
4
5
6
7
8
9
10
11
4.2
Combination crane base

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

The combination crane base (EGG) serves as both as a crane base and as a fully equivalent replacement for a sub frame. Depending on the mounting variant, the sub frame modules are welded directly to the welding connection points, Components 1 and 6).
There is no crane base balance on this combination crane base. The crane is designed to
be secured to the base shear plates on the truck chassis by welded connections. The
mounting bolt connection otherwise used is therefore unnecessary.
The crane support must be positioned in front of the bearing ring mount to achieve better
stability and to realize the maximum length of the boom system with a low crane height. This
type of construction design makes it possible to keep the construction heights very low even
with maximum equipment on the crane and the chassis.
37 / 52
Edition: 08/2012
There is a free space (7) for truck components which are above the chassis frame (e.g.,
transmission parts, etc.) in the front lower area of the combination crane base. This will prevent virtually all collisions with these components.
Illustration 06-1008; Combination crane base
1
2
3
4
5
6
7
8
4.3

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

As already mentioned in Chapter 5 Sub frame, the crane is positioned directly on the chassis frame and connected to the base shear plates (see Chapter Sub frame) shear resistant
and torsion resistant by welding. The combination crane base has been dimensioned so that
a sub frame is not necessary in this area. The other sub frame modules are welded to the
connection points of the combination crane base at the front and back.
In this chapter, the mounting on a tractor is described as an example. The mounting of the
sub frames with adjacent loading bridge, pallet or container platform is carried out similarly.
The only difference will be in the varying heights and lengths of the sub frames.
Contact PALFINGER for all other special mounting variants (mounting in the middle, ...).
38 / 52
Illustration 06-1009; System description for installation with combination crane base
1
2
3
4
5
Truck chassis
Front sub frame module (frame end)
Auxiliary support
Crane
Rear sub frame module
The following chronological work steps described below are recommended for carrying out
the complete mounting:
4.4
Preparation of the truck chassis (see chapter 3 Equipment Recommendations for the
Vehicle).
Position and tack the crane and auxiliary support to the chassis (the position of the
crane and the auxiliary support is determined on the basis of the axle load calculation).
Prefabricate the sub frame modules (see Chapter 6 Prefabrication of the Rear Sub
frame Module).
Placement of the sub frame modules on the chassis.
Welding the sub frame modules to the crane or the base shear plates.
Prefabrication of the rear sub frame module

The following descriptions of the sub frame module are intended for informational purposes
only.
The design of the sub frame modules is essentially dependent on the following factors
Available raw material (sheet metal, moulded tubes, ...)

Required sheet thickness and grade of steel
Production process (available canting press, welding procedure, ...)
and can deviate accordingly from the following description.

An opening must be provided in the front part of the sub frame module so that the middle
cross-piece and the base plate of the combination crane base can be welded to the sub
frame module; this opening is then welded closed with a closing plate (1) to complete the
mounting of the sub frame.
39 / 52
Edition: 08/2012
Illustration 06-1010; Design rear sub frame module
Section A-A
Illustration 06-1011; Design rear sub frame module section A-A
Section B-B
Flat steel as welding puddle protection
Slot for I-seam

Illustration 06-1012; Design rear sub frame module section B-B
40 / 52
Illustration 06-1013; Design rear sub frame module
4.5
Mounting of the rear sub frame module

Park the vehicle on a level surface and check the parallelism of the frame.
Before mounting the rear sub frame module, the surface of the welding area must be thoroughly stripped and cleaned of any residual paint and dirt.
The sub frame module must be placed so that it rests solidly on the chassis frame or on the
base shear plates.
Once the sub frame module has been aligned and tacked, the welding work must progress
in such a manner that any distortion can be kept to a minimum or virtually eliminated (e.g.,
by having two welders opposite one another, ...).
41 / 52
Edition: 08/2012
Illustration 06-1014; Mounting of rear sub frame module
1
2
3
4
5
Crane
Chassis frame or base shear plate
Additional stabilizer
Rear sub frame module
Closing plate
The rear sub frame module must be welded to the crane or the base shear plate in the following areas:
1. Connection combination crane base and the bending area of the sub frame module
with the base shear plate.
2. Connection rear area of the sub frame module with the base shear plate.
3. Connection combination crane base with the sub frame module.
After the middle cross-piece and the base plate of the combination crane base have been
welded to the sub frame module, the opening in this area must be welded closed with a closing plate.
4.6
Production and mounting of the front sub frame module (frame end)
A suitable frame end must be prepared in the front area so that the bending forces can be
smoothly transferred to the chassis frame. This is welded at the front to the combination
crane base and the base shear plates.
The frame end must be adapted to the available space in this area. Allowance must be
made for any open space for maintenance work on the transmission or other components. If
there is enough space, the recess (3) in the frame end can be left out.
42 / 52
Illustration 06-1015; Design front sub frame module
1
2
3

Front sub frame module (frame end)
Free space for protruding components of the truck chassis (transmission, ...)
Illustration 06-1016; Illustration of front sub frame module (only for information
43 / 52
Edition: 08/2012
Crane Installation on removable Mounting Console

If you want the dismounting of the crane to be simple, a removable mounting console is
usually the best solution.
Illustration 06-1039; Installation on removable mounting console
1
2
3
4
Mounting console
Mounting parts of removable mounting console at the chassis frame
Chassis frame
Sub frame
The mounting console is mounted on the rear of the vehicle by using holding plates. The
holding plates are mounted according to their own separate mounting instruction. The
mounting instruction for the crane installation on removable mounting console can be downloaded in PATIS online on the PALFINGER Extranet.
44 / 52
Crane Installation with Trailer Frame
Crane Installation with Trailer Frame

When mounting cranes with a trailer frame, the frame is mounted laterally on the sub frame.
The connection to the sub frame is done with the bearing plates designed for this purpose.
The exact welding guidelines for the individual trailer frames can be seen in the technical data sheets or obtained from PALFINGER.
1
2
3
Crane
Sub frame
Trailer frame
45 / 52
Edition: 08/2012
Crane Installation with Tube Base

The crane base on cranes which have a rotary joint on the slewing gear can be integrated
completely into the sub frame. The standard crane base is then replaced by a so-called tube
base which is welded into the sub frame.
Instead of the crane support, one or more auxiliary supports are installed.
Beware!
After welding the tube base, the flange plate must be examined for distortion from the
welding without fail; if the tolerances have been exceeded, suitable procedures must
be used to correct the distortion.
1
2
3
46 / 52
Tube base
Auxiliary supports
Sub frame
Stationary mounted loading crane

Stationary mounted cranes are cranes installed on a rigid substructure (e.g. concrete foundation). As stationary mounting of cranes does not correspond with any series, it must be
planned in detail in advance.
In order to reduce the impact load on the crane - which is higher on a rigid substructure suitable measures need to be taken by the body builder to protect the crane components
and the substructure, such as:
Classification of stationary mounted loading cranes in lift class HC2 corresponding

EN12999:2011 (truck mounted cranes are assigned to HC1). As a result the crane's
load capacity gets reduced. The reduction depends on the maximum vertical hook
speed or grab speed and can be determined as follows (dynamic coefficients in formula
according to EN12999:2011) and is valid for all not SH cranes.
vh
2 100
vh
1,10 0,34
2
1,05 0,17
p max
[%]
Alternatively it is possible to read the graph in illustration 06-9001 to determine the

working pressure.
100%
99%
98%
97%
96%
95%
pmax [%]
94%
93%
92%
91%
90%
89%
88%
87%
86%
85%
0
0,2
0,4
0,6
0,8
1,2
1,4
1,6
vh [m/s]
Illustration 06-9001; Reduction of the working pressure in dependence of the maximum vertical hook speed or grab
speed for not SH cranes
maximum vertical hook speed or grab speed [m/s]

Vh
pmax crane reduction (in HC2) referred to maximum working pressure in case of truck
mounting crane (HC1)
47 / 52
Edition: 08/2012
After working pressure reduction the body builder must attach new load capacity charts
on the crane and in the operator manual!
Note!
For SH cranes the working pressure for stationary installation must be reduced to 95%
of the maximum working pressure!
Note!
For EPSILON cranes the working pressure for stationary application must always be
reduced to 80 % of the maximum working pressure!
Not all of the EPSILON crane models are suitable for stationary application, therefore
contact EPSILON and clarify this question when planning the use of your crane.
Alternatively to the reduction of the load capacity you can also install an amply dimensioned pressure accumulator at the lifting cylinder.
Warning: The declaration of conformity for the crane must be re-issued by the body
builder.
It needs to be checked if the standard crane base can be used for stationary mounting
(see technical datasheets). If stationary crane mounting is not permissible with the
standard crane base, you can contact PALFINGER. In combination with suitable arrangements (e.g. pipe bracket) it could be possible to realize stationary installation.
Note!
Stationary crane mounting with combination crane base (integral base frame) is not
permitted!
Additionally to the capacity reduction also the slewing movement of the crane should be
diminished in EPSILON cranes. This can be done via pressure accumulator, electronic
damping, brake valve, etc.
The correct classification of lifting class, hoist types and capacity load groups according to
EN12999:2011 or the implementation of suitable measures for impact reduction lie in the responsibility of the body builder. Furthermore the body builder is responsible for the correct
design of the substructure and the crane mounting. In case of any uncertainties, contact the
acceptance authority or PALFINGER.
Warning!
Improper use for other than the intended purposes can cause the crane components
to break.
48 / 52
Examples of stationary mounted cranes
Illustration 06-1053; Loading crane with Marine base frame stationary mounted on steel pipe bracket
Illustration 06-1055; Loading crane with standard base frame stationary mounted on reinforced concrete foundation
Illustration 06-1054; Loading crane with Marine base frame stationary mounted on a reinforced concrete foundation
49 / 52
Edition: 08/2012
Installation of PC Cranes
First, the pivotal point or the mounting position of the crane on the vehicle must be determined and marked.
Attention!
When selecting the mounting position, make sure that the control station is not in the
vicinity of the vehicle exhaust pipe (emissions).
Remove the mounting, if possible with the sub frame, from the vehicle. Then prepare a
mounting plate with the same size as the crane base. The mounting plate should be made of
steel plate which is at least 20 mm thick.
An appropriate substructure must exist in the chassis area to ensure trouble-free installation
and function. If a suitable substructure is not already in place, a suitable sub frame construction must be prepared (unless the vehicle manufacturer prescribes or recommends other actions).
50 / 52
Installation of PC Cranes
The sub frame can be secured to the vehicle using mounting bolts or other mounting elements.
Beware!
If the sub frame is secured using double mounting brackets, the chassis frame must
be protected from compression (see Chapter6.3.4, Crane Installation / Double Mounting Bolt Installation).
During the assembly of the crane on the mounting plate it is necessary to put 4 distance
washer at the fixing points with a thickness of 3mm and an outer diameter of 50 mm between the crane base and the mounting plate (PALFINGER order number HT9430).
(See technical data sheet, PATIS-Online)
51 / 52
52 / 52
Edition: 08/2012

Crane Installation

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Crane Installation

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Chapter 6

Guideline for Crane Installation............................................................. 3

Chapter 6 Crane Installation

Guideline for Crane Installation

Guideline for Crane Installation

Installation planning of the crane

Define crane position on the vehicle

Definition of dead point for cranes without continuous rotation

Selection and calculation of a sub frame

Flexible / torsion-resistant sub frame