2. Crane Models and Geometry

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TRAININGLoader crane

Crane models andgeometry

Original training documentation

2014/01

PALFINGER AGFranz-Wolfram-Scherer-Straße 245020 Salzburg / Austriawww.palfinger.com

http://www.palfinger.com/http://www.palfinger.com/


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Index Crane models and geometry

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Index

1 General........................................................................................... 4 1.1

Introduction and handling of this document ..................................... 4

1.2 Validity ............................................................................................ 4

1.3

Symbols in this document ............................................................... 4

2 Crane and fly-jib components ...................................................... 5 2.1 Crane components ......................................................................... 5 2.2

Fly-jib components .......................................................................... 6

2.3 Slewing system ............................................................................... 7 2.4

Variants of controlling the crane ...................................................... 8

2.5 Support variants ........................................................................... 10 2.6 Extension system (Hydraulic extensions) ...................................... 11

3 Types of cranes ........................................................................... 13 3.1 LKW-Modelle ................................................................................ 13

3.2

Wood-, Recycling-, Clamshell bucket grab cranes ........................ 13 3.3 Marine cranes ............................................................................... 13

3.4

Railway ......................................................................................... 14

3.5 Special applications ...................................................................... 14

4 Arm system ................................................................................. 15 4.1

Standard ....................................................................................... 15

4.2 K-models (PKxxxK-models) .......................................................... 15 4.3

Long arm models .......................................................................... 16

5 Load capacity diagram ............................................................... 17

6

Crane moments ........................................................................... 18 6.1 Lifting moment .............................................................................. 18

6.2 Load moment ................................................................................ 18 6.3

Own moment ................................................................................ 20

6.4 Force on the lifting cylinder: .......................................................... 21 6.5 Classification moment ................................................................... 22 6.6 Load capacity diagrams ................................................................ 23

7 Link systems ............................................................................... 24 7.1

Principle ........................................................................................ 24

7.2 Advantages of link systems .......................................................... 27 7.3 Single Link System ....................................................................... 27

7.4

Power Link System ....................................................................... 27

7.5 Power Link Plus ............................................................................ 28


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Crane and fly-jib components Crane models and geometry

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2 Crane and fly-jib components

2.1 Crane components

1. Ground control – control valve side,opposite side

2. Rigid stabilizer cylinder3. Crane mounting bolts

4. Tiltable stabilizer cylinder

5. Telescopic outrigger beams

6. Base

7. Endless slewing system with gear rim

8. Lift cylinder

9. Emergency operator station on thecrane column

10. Balance

11. Column

12. Linkage system

13. Main boom

14. Rope winch

15. Outer boom lift cylinder

16. Outer boom

17. Extension cylinder for hydraulicextension booms

18. Hydraulic oil tank with oil temperatureindicator and oil level indicator

19. Extension booms

20. Mechanical extension booms

21. Hook

22. Remote control handset

5

6

14

16

19

3

1

11

1

4

7

9

15

1

8

1

12 13 12

2110 3

18

17

2

20

23 22


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Crane models and geometry Crane and fly-jib components

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2.2 Fly-jib components

1. Insert

2. Linkage system3. Outer boom lift cylinder

4. Outer boom

5. Extension cylinder

6. Hoop guard

7. Hydraulic extension booms

8. Mechanical extension booms

9. Support plate

11

12

3 4

1

51

9

7

8

1

6


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2.3 Slewing system

The slewing system of a loader crane is the connection between the fixed crane base andthe slewable crane column.

Independent on the model, PALFINGER differentiates between two designs.

2.3.1 Piston rack slewing system

2.3.2 Endless slewing system

The PALFINGER endless slewing system enables unlimited movement of the crane. Incontrast to a conventional piston rack slewing system, slewing is done by a hydraulic motor,

as opposed to pistons with a sprocket.

Advantages:

Faster unloading, because the cane can be slewed wherever needed from anyposition

Safe and smooth crane slewing

Higher slewing moment

Smooth movements without bearing clearance, even after many years of service


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2.4 Variants of controlling the crane

Depending on the model, there are multiple available variants of controlling the crane.PALFINGER distinguishes between the following variants.

Modern cranes are controlled via RRC. The “FFST” option can be selected additionally towith any of the variants below.

2.4.1 Floor control

All cranes with piston rack slewing system and without high stand are equipped with floorcontrol. The control valve is mounted on the crane base.

2.4.2 Emergency control on crane column (NK)

Cranes equipped with an endless slewing system are usually operated by RRC. Because ofthis, the control valve can be mounted on the crane column. To create a hydraulicconnection between the pump and the control valve, a hydraulic rotary distributer is built intothe column.


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2.4.3 High stand

Optional to the floor control a high stand can be ordered. The control valve is mounted onthe crane base.

2.4.4 High seat

Special crane models (e.g. PK27001EK) can be ordered with a high seat if needed. Thecontrol valve on these cranes is mounted behind or below the high seat. Actuation is doneeither via control rods or a hydraulic pilot control.

Optionally a bracket to hold the RRC is available


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2.5 Support variants

PALFINGER offers different support variants. They are distinguished by different ordercodes:

R – Support of normal crane bases

EGG Support of integral bases

Numbers 1-4 – Shows the different outrigger lengths (stays empty if no stabilizersare equipped)

X – Hydraulically extendable outriggers

Y – Hydraulically tiltable stabilizers

Possible variants:

R

R1

R2

R2X (Y)

R3X (Y)

R4X (Y)


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2.6 Extension system (Hydraulic extensions)

PALFINGER loader cranes and fly-jibs can be ordered with varying amounts of hydraulicextensions

PK92002 SH + PJ170 with the maximum of possible extensions in this configuration

2.6.1 Crane extensions

Every PALFINGER crane has hat least one hydraulic extension. All hydraulic extensionsexcept this first one are denoted with a letter. The first additional extension is called “A”, thesecond “B” and so on. A maximum of 9 (“H”) additional extensions are possible.

STD

B

D

F

H


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2.6.2 Fly-jib extensions

PALFINGER cranes can be equipped with an additional knuckle boom system called fly-jib.Fly- jibs also can be ordered with different hydraulic extensions. A maximum of 7 (“F”)extensions is possible.

2.6.3 Mechanical extensions

If the hydraulic outreach is not enough, the crane or the fly-jib can be equipped withmechanical extensions.

V1

To include mechanical extensions into the overload protection system, a pressure switchhas to be mounted.

The set load for the switch is the maximum load of the mechanical extensions according tothe data sheet..


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Types of cranes Crane models and geometry

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3 Types of cranes

PALFINGER offers different cranes for different areas of deployment. They are differentiatedlike this:

3.1 LKW-Modelle

PC PALFINGER Compact craneNo knuckle boom. Below 4 mt

PK PALFINGER Knucke boom craneDenotes truck mounted cranesDifferent versions for each type are possibleBest-selling modelsSizes from 4 up to 200 mt

PW Wallboard cranes for North America. Internal extension system

3.2 Wood-, Recycling-, Clamshell bucket grab cranes

CMQSX

PALFINGER EPSILON cranes are classified according to their powerCompactMiddleMiddle-HeavyHeavyHeavy Duty

3.3 Marine cranes

PKxxM PALFINGER PK crane for marine use

PSxxM Stiff-Boom marine crane based on PK cranes

PSM Stiff-Boom marine crane with its own power pack, endless slewing system andcable winch

PKM Marine crane based on PK cranes with independent power pack

PTM Telescope marine crane

PFM Heavy Duty marine crane


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Crane models and geometry Types of cranes

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3.4 Railway

PKR Railway crane

PB4 Bridge inspection unit

PA.. Manlift for various areas of deployment – mainly railway use

PFD Positioner for contact wires and carrying cables

PR Foldable crane column

3.5 Special applications

Cranes for special applications can vary and differ in naming.


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Arm system Crane models and geometry

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4 Arm system

4.1 Standard

Normally cranes are equipped with an arm system, that enables the crane to fold to 2.5mvehicle with. This limits the length of the main boom, the knuckle boom and the extensions.

4.2 K-models (PKxxxK-models)

K model cranes have the extension systemof a smaller model. This leads to a higherhook height and saves weight. K cranescannot however have the maximum ofextensions


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Crane models and geometry Arm system

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4.3 Long arm models

If the crane needs as much outreach as possible and if it does not have to be folded duringtransport, a long arm model can be used.

Theses cranes are mainly used in building material transport and at carpentry shops.

Long arm models are designated with L (long) or EL (extra long) after the crane designation.

(eg. PK24001 L, PK 27001 EL)


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Load capacity diagram Crane models and geometry

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5 Load capacity diagram

The load capacity of a PALFINGER crane is represented with load capacity diagrams. Theyshow the maximal lifting force in certain working positions. Load capacity diagrams can befound in the operator manual and in the control area of the crane.

Example: Load capacity diagram of the PK12002 EH (with Power Link system):


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Crane models and geometry Crane moments

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6 Crane moments

6.1 Lifting moment

The lifting moment is the moment that the lifting cylinder has to generate. It is included in thecrane designation (Example: PK 12002 SH = 12 mt lifting moment).

FZyl = 326 kN = 33,25 tX = 0,406 m (max.)Z = 90°

6.2 Load momentThe load moment is the moment that the load exerts on the lifting cylinder. The load iscalculated at the bolt. The standard hook is calculated as a part of the crane and thusignored for the laod moment. (Moment = force x distance)


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Crane moments Crane models and geometry

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The load moment is dependent on the outreach, because of the change of the centre ofgravity has to be taken into account. If the extensions are retracted, the possible loadmoment increases dramatically.

The amount and weight of the extensions has a negative effect on the laod moment. Themore extensions, the less the crane can lift because of its own weight.


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6.3 Own moment

The own moment describes the moment that is exerted by the cranes own weight. Most ofthis moment is exerted by the arm system.

What counts toward the cranes own moment:

Hose equipment up to the coupling

Rope winch including guide pulleys

Standard hook

What counts toward the load moment:

Roll head

Load attachment

Rotator, Rotator hook, grappler, manual extensions …

Weighing hook,…


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6.4 Force on the lifting cylinder:

To be able to calculate the lifting moment (load moment and weight moment) of a crane theforce at the lifting cylinder has to be known.

Formula: p=F/A

Example:PK 12002-EHPiston diameter = 110 mmMOV 350 bar = 350 kg/cm² = 35 MPa

p = F / A => F= p x A

F = p x A =F = 350 kg/cm² x 95 cm² =F = 33250 kg = 33,25 t = 326 kN

The lifting force of the lifting cylinder of the PK 12002-EH is equal to a load of 326 kNmeaning 33,25t on the piston.

This force is exerted on the main boom either directly or via a power link system.


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6.5 Classification moment

The shown arm position shows the position in wich the classification moment of a crane isdefined.

Main boom in strongest position

Knucke boom horizontal

Extension system with one extension - retracted

Example: PK12002-EH Arm position as shownClassification moment = Load momentDistance x Load = 3,7m x 3000 kg = 11,1 mt


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6.6 Load capacity diagrams

Load capacity diagrams show the lifting power dependent on the arm position

Cranes with multiple extensions cannot lift as much as cranes with less extensions becauseof their own weight. Every extension variant has its own load capacity diagram

Example: PK12002-EH and PK12002-EH D


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Crane models and geometry Link systems

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7 Link systems

7.1 Principle

The simplest variant of connecting the main boom and the knuckle boom is connecting themwithout a power link system.

In this case the main cylinder is and the knuckle boom cylinders are connected directly totheir end points. The disadvantage of this type is a varying speed and force throughout thearea of movement.

This results in slanting lines on the load capacity diagram.

The last number of a crane designation shows the amount of integrated link systems

PK 12000 no link systems

PK 12001 link system between main boom and knuckle boom

PK 12002 two link systems


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Link systems Crane models and geometry

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Connection of the arm systems with link systems is technically more challenging, it howeverprovides some advantages. The speed and force is equal over the whole area of movement.


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Because of the construction – the distance “a” stays the same over the whole working areaof the boom system. Because of that also the load moment stays constant.

M = F Zyl * a = constant


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Link systems Crane models and geometry

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7.2 Advantages of link systems

The maximal load can be lifted vertically. This leads to a higher outreach withmaximal load. Load curves on the laod diagram are vertical aswell.

Even with maximum angle on the knuckle boom the crane can still lift the maximumload.

Simpler operation of the crane because of the constant speedHigher operating radius of the knucke boom (up to 180°)

Higher loads can be lifted near the crane column

7.3 Single Link System

Cranes with single link system have one link system between the main boom and theknuckle boom.

7.4 Power Link System

Power link cranes have the single link system and additionally a link system between thecrane column and the main boom.


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7.5 Power Link Plus

Power Link Plus enables the operator the overstretch the knuckle boom by 15°

Documents

2. Crane Models and Geometry