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TRAINING Loader crane

Crane models and geometry

Original training documentation

2014/01 PALFINGER AG Franz-Wolfram-Scherer-Straße 24 5020 Salzburg / Austria www.palfinger.com

Index

Crane models and geometry

Index 1 1.1 1.2 1.3

General........................................................................................... 4 Introduction and handling of this document ..................................... 4 Validity ............................................................................................ 4 Symbols in this document ............................................................... 4

2.1 2.2 2.3 2.4 2.5 2.6

Crane and fly-jib components ...................................................... 5 Crane components ......................................................................... 5 Fly-jib components.......................................................................... 6 Slewing system ............................................................................... 7 Variants of controlling the crane...................................................... 8 Support variants ........................................................................... 10 Extension system (Hydraulic extensions) ...................................... 11

3.1 3.2 3.3 3.4 3.5

Types of cranes ........................................................................... 13 LKW-Modelle ................................................................................ 13 Wood-, Recycling-, Clamshell bucket grab cranes ........................ 13 Marine cranes ............................................................................... 13 Railway ......................................................................................... 14 Special applications ...................................................................... 14

4.1 4.2 4.3

Arm system ................................................................................. 15 Standard ....................................................................................... 15 K-models (PKxxxK-models) .......................................................... 15 Long arm models .......................................................................... 16

2

3

4

5

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

6 6.1 6.2 6.3 6.4 6.5 6.6

Crane moments ........................................................................... 18 Lifting moment .............................................................................. 18 Load moment................................................................................ 18 Own moment ................................................................................ 20 Force on the lifting cylinder: .......................................................... 21 Classification moment ................................................................... 22 Load capacity diagrams ................................................................ 23

7.1 7.2 7.3 7.4 7.5

Link systems ............................................................................... 24 Principle ........................................................................................ 24 Advantages of link systems .......................................................... 27 Single Link System ....................................................................... 27 Power Link System ....................................................................... 27 Power Link Plus ............................................................................ 28

7

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Crane models and geometry

General

1 General 1.1

Introduction and handling of this document This PALFINGER training document is a technical description about systems on a loader crane. It will be expensed for PALFINGER trainings on loader cranes and should be a reference book for service and repair work. These training documents have been produced for PALFINGER service workshops. An appropriate knowledge about the product and a basic education will be assumed.

1.2

Validity This training document applies without any time limitation for the described system. It is possible due to further developments that newer versions of this document are already available. The respectively newest edition of this training document and further technical documents are available on the PALFINGER Extranet in the range PATIS-Online / service documents. Registration can be done at https://www.palfinger.com PALFINGER keeps the right to change the documents at any times without notice. © Copyright by PALFINGER Copying (also in Extracts) only after written permission from: PALFINGER AG Franz-Wolfram-Scherer-Straße 24 A-5020 Salzburg/Austria

1.3

Symbols in this document To make the document clearly structured and easily readable, important references, instructions and risks are highlighted by symbols and special words.

Caution! Symbol and special word will be used for imminent danger. If the safety instructions are ignored, acute danger for life exists for the operator and others.

Attention! Symbol and special word will be used for imminent danger. If the safety instructions are ignored, acute danger for life exists for the operator and others.

Note! Symbol and special word will be used for a very important note which makes operation of the machine easier.

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Crane and fly-jib components

Crane models and geometry

2 Crane and fly-jib components 2.1

Crane components 12 1

1

11

13

14

15

12

1 16 9 8 7 6

17

5

18

19

4 20 2

1

3

Ground control – control valve side, opposite side 2. Rigid stabilizer cylinder 3. Crane mounting bolts 4. Tiltable stabilizer cylinder 5. Telescopic outrigger beams 6. Base 7. Endless slewing system with gear rim 8. Lift cylinder 9. Emergency operator station on the crane column 10. Balance 11. Column 12. Linkage system 1.

10

13. 14. 15. 16. 17. 18. 19. 20. 21. 22.

3

23

22

21

Main boom Rope winch Outer boom lift cylinder Outer boom Extension cylinder for hydraulic extension booms Hydraulic oil tank with oil temperature indicator and oil level indicator Extension booms Mechanical extension booms Hook Remote control handset

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Crane models and geometry

2.2

Crane and fly-jib components

Fly-jib components 5

1

6

1

1

9

8

7

2 1

1

3

1. 2. 3. 4. 5. 6. 7. 8. 9.

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Insert Linkage system Outer boom lift cylinder Outer boom Extension cylinder Hoop guard Hydraulic extension booms Mechanical extension booms Support plate

4

Crane and fly-jib components

2.3

Crane models and geometry

Slewing system The slewing system of a loader crane is the connection between the fixed crane base and the 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. In contrast 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 any position Safe and smooth crane slewing Higher slewing moment Smooth movements without bearing clearance, even after many years of service

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Crane models and geometry

2.4

Crane and fly-jib components

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 to with any of the variants below.

2.4.1

Floor control All cranes with piston rack slewing system and without high stand are equipped with floor control. 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 of this, the control valve can be mounted on the crane column. To create a hydraulic connection between the pump and the control valve, a hydraulic rotary distributer is built into the column.

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Crane and fly-jib components

2.4.3

Crane models and geometry

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

2.4.4

High seat Special crane models (e.g. PK27001EK) can be ordered with a high seat if needed. The control valve on these cranes is mounted behind or below the high seat. Actuation is done either via control rods or a hydraulic pilot control. Optionally a bracket to hold the RRC is available

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Crane models and geometry

2.5

Crane and fly-jib components

Support variants PALFINGER offers different support variants. They are distinguished by different order codes: R – Support of normal crane bases EGG Support of integral bases Numbers 1-4 – Shows the different outrigger lengths (stays empty if no stabilizers are equipped) X – Hydraulically extendable outriggers Y – Hydraulically tiltable stabilizers

Possible variants:

R

R1

R2 R2X (Y)

R3X (Y)

R4X (Y)

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Crane and fly-jib components

2.6

Crane models and geometry

Extension system (Hydraulic extensions) PALFINGER loader cranes and fly-jibs can be ordered with varying amounts of hydraulic extensions

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 extensions except this first one are denoted with a letter. The first additional extension is called “A”, the second “B” and so on. A maximum of 9 (“H”) additional extensions are possible.

STD

B

D

F

H

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Crane models and geometry

2.6.2

Crane and fly-jib components

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 with mechanical extensions.

V1

To include mechanical extensions into the overload protection system, a pressure switch has to be mounted. The set load for the switch is the maximum load of the mechanical extensions according to the data sheet..

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Types of cranes

Crane models and geometry

3 Types of cranes PALFINGER offers different cranes for different areas of deployment. They are differentiated like this:

3.1

3.2

LKW-Modelle

PC

PALFINGER Compact crane No knuckle boom. Below 4 mt

PK

PALFINGER Knucke boom crane Denotes truck mounted cranes Different versions for each type are possible Best-selling models Sizes from 4 up to 200 mt

PW

Wallboard cranes for North America. Internal extension system

Wood-, Recycling-, Clamshell bucket grab cranes

C M Q S X

3.3

PALFINGER EPSILON cranes are classified according to their power Compact Middle Middle-Heavy Heavy Heavy Duty

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 and cable 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

3.4

3.5

Types of cranes

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

Special applications Cranes for special applications can vary and differ in naming.

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Arm system

Crane models and geometry

4 Arm system 4.1

Standard Normally cranes are equipped with an arm system, that enables the crane to fold to 2.5m vehicle 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 system of a smaller model. This leads to a higher hook height and saves weight. K cranes cannot however have the maximum of extensions

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Crane models and geometry

4.3

Arm system

Long arm models If the crane needs as much outreach as possible and if it does not have to be folded during transport, 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

5 Load capacity diagram The load capacity of a PALFINGER crane is represented with load capacity diagrams. They show the maximal lifting force in certain working positions. Load capacity diagrams can be found 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

6 Crane moments 6.1

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

FZyl X Z

6.2

= 326 kN = 33,25 t = 0,406 m (max.) = 90°

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

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Crane moments

Crane models and geometry

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

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

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Crane models and geometry

6.3

Crane moments

Own moment The own moment describes the moment that is exerted by the cranes own weight. Most of this 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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Crane moments

6.4

Crane models and geometry

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

Formula: p=F/A Example: PK 12002-EH Piston diameter = 110 mm MOV 350 bar = 350 kg/cm² = 35 MPa p = F / A => F= p x A F=pxA= 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 kN meaning 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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Crane models and geometry

6.5

Crane moments

Classification moment The shown arm position shows the position in wich the classification moment of a crane is defined.

Main boom in strongest position Knucke boom horizontal Extension system with one extension - retracted Example: PK12002-EH Arm position as shown Classification moment = Load moment Distance x Load = 3,7m x 3000 kg = 11,1 mt

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Crane moments

6.6

Crane models and geometry

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 because of 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

7 Link systems 7.1

Principle The simplest variant of connecting the main boom and the knuckle boom is connecting them without a power link system. In this case the main cylinder is and the knuckle boom cylinders are connected directly to their end points. The disadvantage of this type is a varying speed and force throughout the area 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

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PK 12000

no link systems

PK 12001

link system between main boom and knuckle boom

PK 12002

two link systems

Link systems

Crane models and geometry

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

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Crane models and geometry

Link systems

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

M = F Zyl * a = constant

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Link systems

7.2

Crane models and geometry

Advantages of link systems The maximal load can be lifted vertically. This leads to a higher outreach with maximal load. Load curves on the laod diagram are vertical aswell. Even with maximum angle on the knuckle boom the crane can still lift the maximum load. Simpler operation of the crane because of the constant speed Higher 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 the knuckle boom.

7.4

Power Link System Power link cranes have the single link system and additionally a link system between the crane column and the main boom.

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Crane models and geometry

7.5

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

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Link systems