Download - Palfinger

Issue #1
The magazine with a passion for crane technology
Design
follows function
Powerful
Personalities
The new heavy-duty range of
cranes by PALFINGER

palfinger – passion – performance – power – perfection
We proudly present "crane passion"
Dear Partners and
best loading crane" – that has been our
Friends of PALFINGER,
driving force for 50 years!
With the creation of our new magazine
crane passion, we have launched a on up to High Performance. With our
In the meantime, PALFINGER has moved
publication whose sole aim is to explore new High Performance line, successfully
PALFINGER’s crane technology. It represents,
in other words, a clear commit-
plainly illustrated our leading role in
launched in September, 2007, we have
ment to our core competency. Cranes the loading crane sector. And now, as
in all of their complexity – from the we follow up with the first model of
development to the production phase – our new heavy-duty range, we clearly
will be the focus of the magazine. confirm PALFINGER’s technological
dominance in the market.
With this publication we hope to give
our customers an idea of the PALFINGER Get ready for some dynamic personalities,
both hip and replete with inner
world of crane technology and also
convey a sense of PALFINGER’s unique qualities. Get ready for the new crane
spirit – since there’s a lot more than generation by PALFINGER!
just technology behind a PALFINGER
crane. A "true PALFINGER" is the sum of
passion, emotion, vision and individuals,
plus a sound, global corporation with a Wolfgang Pilz
sense of responsibility.
CMO and managing director of the
crane and hookloader divisions
Passion has many facets. Passion for
innovation, technology, aesthetics and
perfection – with the understanding
of being the leader in technology. For
PALFINGER it is not enough to merely
rank among the best: "To build the Enjoy reading!

A Passion for
Crane Technology
crane passion | 3

Table of Contents
Editorial 2–3
Design follows function 6–7
Powerful Personalities 8–9
The Art of Finding the
Right Material 10–11
What Else You’ll Find in a
PALFINGER High Performance
Heavy-Duty Crane 12–13
Protecting the Environment
is Second Nature 14–15
Cranes with a Profile 16–19
crane passion | 5

follows function
What you’ll find in a PALFINGER product
is more than just the sum of its steel,
hydraulic and electronic components.
As compared to the competition, the
added benefits of our products lie in the
experience, stability, responsibility, and
clearly defined areas of expertise that
went into making them. The factors
underlying our success include our
readiness to meet the ever-changing
demands of the market, our exceptional
commitment to research and development,
our state-of-the-art production
facilities, as well as our permanent focus
on design.
Our passion for continual improvement
in functionality, efficiency and safety is
the mainspring for the innovative and
on-going development of our products.
Our cooperation with universities forms
the basis for a wealth of patents and
technical innovations.
"Innovation results from our passion
for the continual improvement of our
products, processes and organization."
Good design is not just a question of
good taste. As a global player in the
market, we simply owe our customers
good design!
These days, even hydraulic machinery
and lifting systems are expected to
meet ever-increasing demands regarding
automation, comfort, ergonomics,
and intelligent control technologies.
PALFINGER meets these demands headon
with its routine design studies and
by intelligently implementing new ideas
into its products.
Functional design elements increase
on-the-job comfort and facilitate service
and maintenance. In addition to its
functional advantages, a visually attractive
product will also serve as a priceless
advertising tool for its operators.
The knowledge gained from over four
years of development, the constructive
feedback from numerous clients, as
well as the know-how acquired from 50
years in the crane business all went into
the new High Performance crane generation.
"The highest quality at competitive
prices" has always been our goal. In
order to meet these high standards, we
have focused our attention on "quality"
design.
crane passion | 6

Quality design must first of all serve its
purpose – that is, it has to be functional.
But more than that, it also has to
be simple, attractive and economically
viable.
The new design elements of the High
Performance crane include attractive
covers and casings out of premium
synthetics that protect the crane from
damage and weather, a newly designed
control stand, along with many other
clever details. Numerous tests and field
studies contributed to the design of
the new control stand, which is unique
in terms of shape, appearance and
comfort!
A Dialogue on Design
Development
For PALFINGER design is evolutionary:
innovation and development are truly an
ongoing, fluid process. Acting on new
ideas while improving old ones is a team
effort, a dialogue among clients, dealers,
product management, engineers, and
sales and service staff.
Realizing that "the customer is the best
developer", we always have an open
ear for customer demands and ideas.
In the development phase, we attempt
to incorporate features into our new
machinery which will ultimately benefit
the customer in terms of on-the-job
comfort, technical advancements, safety,
and assembly and service friendliness.
Naturally, our service partners are also in
close contact with our customers. Their
demands, too, are incorporated into
our products. In periodic quality circles
comprised of service, development, and
quality control departments, market
needs and ideas are analyzed, forwarded
and integrated into the future development
of our products.
"Direct contact with dealers and crane
operators is very important to me. Starting
with these initial contacts, our design
process takes place 'from the inside
out' with a team of engineers, product
management and marketing staff,"
states the industrial designer Heinrich
Krug. He has been designing PALFINGER
cranes for 15 years.
crane passion | 7

Powerful
Personalities:
The new heavy-duty
range of cranes by
PALFINGER
Innovative technology, functional
and attractive design,
comfortable equipment, and
exceptional capacity have all
joined together for the new
PALFINGER High Performance
heavy-duty crane.
Finally! This is the crane the industry has
been waiting for: "one class stronger"
than its predecessor, unmatched in
style, and outfitted, so to speak, in a
tailor-made suit complete with clever
design elements – the new PK 50002
EH High Performance!
Under the banner "Reduce to the max",
our new stylistic vocabulary is with
it. – In terms of design and selection
of materials. Synthetic cover elements
dominate the appearance. The synthetic
covers over the control valve, slewing
system and hydraulic hoses are all real
eye-catchers.
Synthetic covers protect sensitive crane
components against dirt and impact.
That reduces service and maintenance
time and greatly extends the life of your
loading crane.
A crane that immediately stands out
from the crowd with its new stylistic
vocabulary. A crane in both concept and
performance – just like a PALFINGER
should be.
PALFINGER. The most intelligent
interpretation since the introduction
of loading cranes.
crane passion | 9

The Art of
finding
the rightMAterial
At PALFINGER, nothing is left to chance. The synthetics, along with their manufacturing process,
for all cover and functional design elements were specially developed in collaboration with
universities and synthetics experts from the auto industry.
The synthetics used in the crane column
casings are manufactured by means of
the R-RIM process (Reinforced Reaction
Injection Molding).
Wherever ergonomics, durability and
shock-absorbent elements are called for,
parts molded out of polyurethane foam
are the ideal solution. Density, shore
hardness, tensile strength, color and the
fitting of fasteners and reinforcement
elements can all be perfectly adjusted to
each other. Surfaces can be designed in
a wide array of options through the use
of various structures and colors. The R-
RIM production process makes optimal
design and the robust, yet light-weight
construction of crane casings possible.
Another advantage of the R-RIM process
is that small components can first
be inserted into the tool form before
the reaction takes place. This so-called
"insertion technique" enables the small
components to be integrated directly
and stably into the design parts before
being secured by foam.
crane passion | 10

All crane column casings are applied
with a pearl structure coating for longlasting
UV protection.
Qualities of synthetic casings
at a glance:
- Optimal light-weight construction
- Ergonomic shapes
- High resistance to temperature
and UV rays
- Premium appearance and surface feel
- Impact-resistant, sturdy and robust
Job-oriented stress tests confirm
the durability of synthetic
casings.
The process: In R-RIM (Reinforced reaction
injection molding) two components
(polyol and isocyanate) and a flexibilizer
are mixed in a so-called mix head to
increase impact resistance and injected
under high pressure into a molding
tool. The exothermic reaction of the
components produces the thermoset
plastic polyurethane, which can then be
removed from the tool.
Treads designed to be both functional
and highly resistant are produced with
the aid of a polyamide plastic reinforced
with fiber glass. These components
are formed using the well-established
injection molding process.
ca. 80-90 kg
ca. 30 kg
crane passion | 11

Double slewing mechanism
with two rotary drives
Maintenance-free boom
extension system
Internally routed hose guide
on the main boom
The source of power. The double slewing
mechanism with two rotary drives is
absolutely unique in this performance
class. Since the two gears are hydraulically
oppositely prestressed, the crane’s
slewing play is reduced to a minimum – a
priceless advantage for jobs requiring a
high outreach.
PALFINGER’s maintenance-free boom
extension system is a clear commitment
to service-friendliness and environmental
protection. The use of sliding elements
made from special synthetic material
and the well-established KTL cathotic
dip painting means that the operator no
longer needs to service the boom system.
That not only saves time and money, but
also protects the environment.
The hydraulic hoses between the main
and outer booms are internally routed.
This invention, which is to be patented,
provides protection against dirt and
damage.

crane passion | 13
Integrated oil tank
Cable winch
PALFINGER "inside"
Integrating the oil tank on the base
helps to save space. Additional room for
installation on the chassis is no longer
necessary.
The lateral cable guide of the cable
winch on crane/fly jib combinations is
the smart answer to questions of how
to increase comfort, facilitate work and
save time. The cable can be sheaved and
remain in transport position, thus making
unthreading of the cable, disassembly of
the trolley head, and intermediate and
reversing pulleys all things of the past.
In addition to the perfect hardware, the
new cranes are also distinguished by
their numerous "soft skills" which make
life easier for their operators:
KTL, PAL 50, RRC, AOS, DPS, ISC
Also available is a laterally tiltable cable
winch, which minimizes the total height
of the crane.

Protecting the Environment
is Second Nature
Innovation – Comfort – Safety –
Environmental protection
In addition to its passion for ongoing improvements in
functionality, efficiency and safety, PALFINGER is also aware
of its responsibility towards people (employees, dealers and
customers) and the environment. Sustainability, careful management
of resources, and product ecology are thus firmly
anchored in its corporate philosophy. The use of environmentally
compatible, recyclable and biodegradable substances
and materials is second nature to PALFINGER.
With the introduction of its new High Performance line,
PALFINGER is not only paving the way towards intelligent
consolidation – by "simply making the best even better" –
but is also aiming for product ecology and recyclability. Steel
components, hydraulic valves, brackets and pipes can all be
completely recycled.

Maintenance-free boom extension system
The sliding elements are molded from special synthetic material and have self-lubricating
properties. No further servicing is required after the primary lubrication, in which the
same grease is used as in the food industry. All other elements (slide rails, slide blocks,
etc.) run without grease. They have only a secondary function as sliding elements; they
are primarily adjustment and guiding elements. Special synthetic materials are also used
for these elements in order to protect the boom against corrosion.
Environmentally compatible coating technology
PALFINGER High Performance cranes are coated by cathotic dip painting. In addition
to the benefits of KTL coating, the environmental compatibility of both the paints and
the painting process is also striking: the two-pack paints used in the process are watersoluble.
Chromium VI-free surfaces of pipes, small parts and fittings
All hydraulic pipes, fittings, small parts and brackets found on PALFINGER
High Performance cranes are also coated using chromium VI-free methods.
Biodegradable hydraulic oil
On request, PALFINGER offers its customers a fully synthetic, environmentally sound hydraulic
oil with rapid biodegradability for environmental crane operation. This oil guarantees
smooth, year-round operation even under extreme conditions and when subjected to
large changes in temperature.
Lightweight construction saves resources
A PALFINGER crane is a "lightweight" – that means, a higher payload and lower operating
costs. The lightweight construction reduces the crane’s fuel consumption and thus
makes a significant contribution towards reducing CO2 emissions.
Load sensing – reduced fuel consumption
By fitting the control unit with a proportional valve capable of load sensing, PALFINGER
cranes are ready for efficient and economical variable displacement pump operation.
The advantages are clear: less fuel consumption (fuel savings of up to 20%!), enhanced
capacity for precision and multi-function control, and less stress on the entire hydraulic
system since the oil remains cooler!
Choosing a PALFINGER crane is a corporate decision that aims for value,
reliability and sustainability.
crane passion | 15

Cranes
with a
Profile

"Deluxe" Hexagonal
Tube Production
Hexagonal tubes are an essential component
of a crane’s boom extension
system. Naturally, the more precisely
these parts can be produced, the more
precisely the entire crane will be able to
function.
In recent years PALFINGER has been
working at full tilt to increase the
production capacity for all product areas
and to heighten the efficiency of the
production flow. The investments made
focus on optimizing processes – which
means, reducing lead time and inventory
as well as maximizing quality and
productivity. One component of the
€ 80 million capital investment program
is the new hexagonal tube production
line at the Lengau plant in Austria.
The basis of PALFINGER’s success is
its technological superiority, driven by
innovation, and its high level of product
quality. A cornerstone of this success is
its commitment to research & development
and its implementation of the
latest production technologies
With its expansive quality campaign,
based on ambitious and comprehensive
investments in new production technologies
at PALFINGER production sites,
the PALFINGER Group has created the
framework which will allow it to uphold
its high quality standards of its products
in the future.
The modernization and expansion of
the existing hexagonal tube production
plant in Lengau firmly aims to achieve
the following goals: to increase production
capacity by approximately 40%,
to increase efficiency by introducing a
high level of automation, to improve
product quality and process safety, to
expand PALFINGER’s role as the leader in
technology, and to secure the Austrian
production site at Lengau for the longterm.
Continued on page 18/19
crane passion | 17

crane passion | 18
Continues from page 16/17
Hexagonal tubes
Hexagonal tubes are an essential component
of a crane’s boom extension system.
The so-called extension and outer booms
are based on hexagonal section tubes,
which are manufactured out of highstrength
steel with utmost precision. Workers
attach additional steel components to
these sections which are then welded by robots
in perfect, reproducible quality. Thanks
to the new technology, high-strength steel
can be processed with utmost precision.
Even the slightest production deviations can
thereby be avoided, resulting in even more
precise crane movements.
The new plant
The new plant is highly automated. It is
comprised of the latest 4 and 5 KW laser
cutting machines, new 800to and 1000to
edging machines, new longitudinal welding
and alignment machinery, as well as several
new robotic welding systems. An edge-angle
correction system and automatic alignment
of the sections increase the sectional
accuracy of the parts. The new longitudinal
welding system, with its optimal clamping
concept and optical locking of the welding
gap, guarantees penetration welding and,
thus, the best possible welding quality.
The new small-parts edging machine, with
edge-angle correction system for better use
with robots, increases the precision of small
parts.

KP-Cranep01+E
PALFINGER AG · 5101 Bergheim/Salzburg, Austria · E-Mail info@palfinger.com · www.palfinger.com