TRAINING

Loader crane

Crane models and

geometry

Original training documentation

2014/01
PALFINGER AG
Franz-Wolfram-Scherer-Strae 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

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

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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-Strae 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

11

13

14

15

12

1
16
9
8
7
6

17

18

19

4
20
2

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.

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

2
1

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

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:

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

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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/cm = 35 MPa
p = F / A => F= p x A
F=pxA=
F = 350 kg/cm x 95 cm =
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