Page 1 Operating Manual Hydraulic Crane PC 3800 Serial number: DB1140+NAEN Edition: 11/2016 Palfinger North America 7942 Dorchester Rd. Niagara Falls, ON L2G 7W7 www.palfinger.com...
Page 3 Dear customer, thank you for purchasing and putting your faith in a quality product from PALFINGER. During the development and manufacture of your unit, everything was done to ensure that the equipment operates reliably and safely. Please note the information that follows so that you can work with your PALFINGER product reliably and cost-effectively over the long term.
Page 5: Table Of Contents
Contents Contents Notes regarding the operating instructions ............1 Operating instructions ....................... 3 Validity of operating instructions ..................3 Terms ..........................4 Symbols ..........................5 Graphics and pictures ....................... 5 Safety and Health Standards .................. 7 Safety for individuals ......................9 Use for intended purpose / limits of the device ...............
Page 6 Contents Vehicle inclination ......................71 Supporting the vehicle ....................72 Pulling outrigger beams out manually ................75 Stabilizer cylinders ......................76 Bringing the load arm to working position ............... 76 Daily function check of safety equipment................ 78 Crane operation ....................79 Load limits ........................
Page 7: Notes Regarding The Operating Instructions
Chapter 1 H A P T E R Notes regarding the operating instructions In this chapter Operating instructions ................. 3 Validity of operating instructions ..............3 Terms ......................4 Symbols ..................... 5 Graphics and pictures ................. 5...
Page 9: Operating Instructions
Changes since going to press PALFINGER is anxious to apply the latest and most advanced technology in their devices by further development. This may result in deviations between operating instructions and the actual unit. Please contact your PALFINGER partner immediately if any function in this operating instruction is described insufficiently or incorrectly.
Page 10: Terms
Provides assistance but does not operate the unit. Installer Fits the unit to the vehicle. Service partner Authorized by PALFINGER. Expert Someone with sufficient knowledge of loading cranes due to their technical training and experience who is familiar with the relevant government laws and regulations to the extent that they can assess whether the equipment is safe for operation.
Page 11: Symbols
Chapter 1 Notes regarding the operating instructions Symbols The layout of the operating instructions is designed to make important notes, instructions or warnings particularly clear by using symbols and signaling words. Danger! These symbols and the Danger! signal word are used for immediately threatening dangers of fatal injury.
Page 13: Safety And Health Standards
Chapter 2 H A P T E R Safety and Health Standards In this chapter Safety for individuals .................. 9 Use for intended purpose / limits of the device ......... 10 Residual risks ................... 11 Government regulations and standards for operating the unit ....12 Adverse working conditions ..............
Page 15: Safety For Individuals
Chapter 2 Safety and Health Standards Safety for individuals This unit is an item of working machinery. It has been constructed and built in accordance with prevailing EU standards, guidelines and safety provisions. During use, maintenance or servicing unforeseen risks to individuals, the device or other things may nevertheless arise. The safety of the operators and other persons must be top priority.
Page 16: Use For Intended Purpose / Limits Of The Device
Safety and Health Standards Use for intended purpose / limits of the device Use the crane only within the load limits shown on the load capacity chart to lift, move, carry and set down loads. For load capacity chart refer to chapter 13, 'Technical description'. Caution! Improper use endangers people and causes damages to the crane and loss of warranty and liability.
Page 17: Residual Risks
The device is started up after it is known to be defective. • Maintenance hast not been carried out or only insufficiently. • Servicing has been carried out by a service workshop other than PALFINGER partner. • Parts other than original PALFINGER spare parts have been installed. Residual risks The present operating instructions are meant as a guideline.
Page 18: Government Regulations And Standards For Operating The Unit
Safety and Health Standards Government regulations and standards for operating the unit The operator must know about and follow the national regulations, standards and safety provisions for operating the unit. If the operating instructions contain regulations and safety provisions that contradict the national laws and regulations, the national laws and regulations have priority.
Page 19: Risk Of Falling
Chapter 2 Safety and Health Standards Risk of falling Warning! Climbing up on the unit can lead to the individual falling or the unit being damaged. There is an acute danger of accident. Climbing on the unit is prohibited. Exception: Climbing up to operating stands using climbing aids (see ‘High stand, top seat’, Chapter 6) or climbing to the emergency operator station at the crane column (see ‘Emergency control operation after remote control failure’, Chapter 5).
Page 20 Safety and Health Standards Required minimum distances The crushing point for the parts of the body specified above are not considered to be dangerous locations provided that the specified safety distances are not undershot. It must also be ensured that the next biggest part of the body cannot get into the crushing point.
Page 21: Risk Of Burns
Chapter 2 Safety and Health Standards Risk of burns Some components can become extremely hot during operation (lines, hoses, valves, valve operating levers, hose connections, hydraulic cylinders, oil motors, pumps etc.). Contact with these parts can cause burns! Risk of scalding if oil escapes! In order to avoid burns, the exhaust system of the vehicle must be covered in the operating area, or a safe distance must be maintained.
Page 22: Dangers Caused By Exhaust
Safety and Health Standards Dangers caused by exhaust Exhaust components such as carbon monoxide, nitrous oxides or diesel soot can put the operator on the operator station at risk. It must therefore be ensured that: • the vehicle exhaust does not flow into the vicinity of operating stands. •...
Page 23 Chapter 2 Safety and Health Standards Minimum distances from live lines Voltage Minimum distance up to 1,000 Volts 1.0 meter (3.3 feet) unknown or over 1,000 Volts 5.0 meters (16.5 feet) Actions to take in the event of flashover Note! An accident with severe consequences can only be prevented by the correct response.
Page 24: After Maintenance, Service And Repairs
Safety and Health Standards After maintenance, service and repairs Note! Every time after maintenance, repair or service it is absolutely necessary to check the function of all safety equipment on the device (stand ard and optional)!
Page 25: General
Chapter 3 H A P T E R General In this chapter CE symbol ....................21 Structure of system ................... 21 Modifications to unit .................. 22 Operators ....................22...
Page 27: Ce Symbol
Carry out any legally required acceptance. If the design differs from that of a truck loading crane (example: stationary installation) the load values may change. If you need any further information please contact your PALFINGER partner. Crane delivery to operating company / operator •...
Page 28: Modifications To Unit
If operating company or operator modify the unit or remove protective devices this may create severe risk of fatal injury! Modifications to the unit may only be made by PALFINGER service partners. Operators This system is a working machine that can be extremely dangerous to the operator and other persons if it is operated incorrectly or improperly.
Page 29: Device And Function
Chapter 4 H A P T E R Device and function In this chapter Main components ..................25 Function labels ..................27 Overview of labels ..................30...
Page 31: Main Components
Chapter 4 Device and function Main components The illustrated crane is an example and shows components which may be optional on your unit, depending on model and version. Find the names of the main components on the next page.
Page 32 Device and function Crane base Assembly frame High-tensile, high-alloy bolts Swivel motor Crane column Lifting cylinder Main boom Extension cylinder Hydraulic extension booms Mechanical extension boom Stabilizer outriggers Cam lock Stabilizer cylinders Crank-down stabilizer Hydraulic oil tank Operator station Rope winch Pulley head Hook Radio remote control...
Page 33: Function Labels
Chapter 4 Device and function Function labels The function labels are explained below. The order of functions (symbols) may be different on your operator station from the example shown below. Therefore it is absolutely essential to familiarize yourself with the symbols and how they are arranged on your device. Stabilizer cylinder Retract Extend...
Page 34 Device and function Symbols of remote control console Depending on the labelling of the panel buttons (levels 1 and 2) the following functions are enabled by pushing the buttons: Slew clockwise (right) Slew counter-clockwise (left) Lower main boom Lift main boom Extend extension boom Retract extension boom Lower rope winch...
Page 35 Chapter 4 Device and function Rotator clockwise (right) Warning horn Working light on / off Motor start Motor stop Increase engine RPM Reduce / increase speed...
Page 36: Overview Of Labels
Device and function Overview of labels The labels are part of the unit, they serve to protect the operator and others and facilitate correct crane operation. Danger! Missing, damaged or illegible labels increase the risk of accidents! Missing, damaged or illegible labels lead to operating errors and mistakes during crane operation; they must be replaced immediately.
Page 37 Chapter 4 Device and function Company name label Position: Both sides on main boom and fly-jib Crane model label Position: Both sides of main boom. Meaning: Product title. Indication for completely extended outrigger beam Position: On the outrigger beam. Meaning: Outrigger beam completely extended.
Page 38 Device and function Identification plate for manual boom extensions Position: On manual extensions. Meaning: Information about year built, device type, maximum capacity. Risk if ignored: Damages to the crane and risk of fatal injury. Operating lever instruction label Position: On operating stand. Meaning: Indicates the functions of the operating levers.
Page 39 Chapter 4 Device and function 10. Functional label / covering film Position: Covers drilled holes and cut-outs on the device (in or near the operating area) where there is increased risk of getting crushed, cut or injured by shearing. Position on the overview of labels meant as example.
Page 40 Device and function Labels for North America Following labels are only used in USA and Canada. Operators have to read and understand all additional labels. Electrocution hazard (manual or manual / RRC control) Position: Near the operator station. Meaning: Shows minimum required distances to live electrical power lines;...
Page 41 Chapter 4 Device and function Stay clear of the boom Position: Near the operator station. Meaning: Stand on the side opposite the boom when folding or stowing the crane. Stay clear of the boom when operating or servicing the crane. Risk if ignored: Death or serious injury.
Page 42 Device and function Danger of moving stabilizer Position: On every stabilizer cylinder. Meaning: Do not operate any stabilizer unless you or a signal person can see that all personnel are clear of the stabilizer and its ground contact point. Risk if ignored: Serious crushing injury.
Page 43 Chapter 4 Device and function Winch / falling load hazard (if equipped) Position: Near the operator station. Meaning: Avoid two-block situation. Risk if ignored: Death or serious injury. Electrocution hazard remote control (if equipped) Position: On the RRC handset. Meaning: Shows minimum required distances to live electrical power lines;...
Page 45: Safety Equipment
Chapter 5 H A P T E R Safety equipment In this chapter General ....................41 Emergency cut-off button / push-button ............ 41 Capacity indicator ..................42 Hydraulic overload protection ..............43 Overload protection in radio remote control operation ......43 Transport position monitoring system ............
Page 47: General
Chapter 5 Safety equipment General PALFINGER has developed safety systems that protect the operator and the unit in order to guarantee safe operation. Safety systems are adjusted before delivery of the unit to the operating company/operator. Danger! Any unauthorized manipulation to the safety devices leads to danger of fatal injury.
Page 48: Capacity Indicator
Safety equipment Release the emergency cut-off button only in safe working conditions. Capacity indicator If the crane is equipped with a capacity indicator, it shows the current load status on a three-color scale. The capacity indicator does not protect the crane from overloading. Color Crane utilization 1 = green:...
Page 49: Hydraulic Overload Protection
Chapter 5 Safety equipment Hydraulic overload protection When the crane reaches the overload range the locking cylinders push the hand levers that increase the load moment back into neutral positions. The following movements will then be blocked: Lower main boom Extend extension boom The hand levers will only be released when the load moment has been reduced.
Page 50: Transport Position Monitoring System
Caution! Emergency operation may only be used to move the crane to the transport position. After this contact a PALFINGER partner immediately to get the crane repaired. If you continue working you put yourself and others at risk of fatality.
Page 51 After having put down the load move the crane in transport position (refer to 'Moving the crane in transport position' in chapter 9). Continuing to work is not permitted! • Contact a PALFINGER partner immediately to get the crane repaired.
Page 52 Safety equipment Caution! If the operator cannot observe all support/crane movements or the lifted load from the crane's emergency operator station, there is risk of fatal injury. If it is not possible to fully observe all • stabilization components; • crane movements and the resulting load path;...
Page 53: Ancillary Equipment
Chapter 6 H A P T E R Ancillary equipment In this chapter General ....................49 Slingers, other attachments to lift the load ..........50 Ancillary equipment .................. 51 Remote control ..................58...
Page 55: General
• Are always considered as part of the load (except rope winch and fly-jib). • Always attach and secure them using original PALFINGER bolts and securing devices. Danger! Depending on the type of ancillary equipment, the crane has to be turned off before attaching the device. Follow the relevant...
Page 56: Slingers, Other Attachments To Lift The Load
• Different hooks and shackles are provided for some crane models. Depending on the load, the relevant PALFINGER hook and shackle with bolt must be used on the associated lifting gear • Observe the load capacity given on the load lifting gear.
Page 57: Ancillary Equipment
Ancillary equipment Rope winch Use the rope winch only to lift loads vertically. Any other use is prohibited. Use only PALFINGER rope winches, ropes and winch components (pulley heads, attaching and safety material, etc.) for rope winch operation. Note! For assembly, weight and use of winch components such as pulley head, rope, rope diameter, etc.
Page 58 Ancillary equipment Assembling the pulley head: • Extend the extension booms until approx. 50 cm (2 ft) before the pulley head. Insert connecting block into extension boom and secure with pin. Secure pin with spring cotter. Lower extension boom until lifting gear fits onto pulley head, and secure with pin. Secure pin with a linch pin.
Page 59 Chapter 6 Ancillary equipment Observe the safe distances given in chapter 2 during all works you carry out on the pulley head. Winch components with composite pulleys Danger! When using composite pulleys exclusively, the inner braid strands may break before the outer braid strands after longer periods of use.
Page 60 Ancillary equipment Warning! If the rope rubs against crane components it gets damaged. The rope may tear, and this creates risk of fatality for the operator and others. The rope should run smoothly over the pulleys and not rub anywhere. Rope winch operation examples For one-strand rope winch operation For two-strand rope winch operation:...
Page 61 Chapter 6 Ancillary equipment Ensure there is enough distance (A) between pulley head and lower load block during all winch operations. Winding up the rope: Warning! Injuries can result, if rope is tightened by hand. • Never tighten the rope by hand. •...
Page 62 Ancillary equipment Crane without overload protection device • • Do not overload the crane Do not overload the rope winch with the lifting power of the crane. components/accessory equipment such as hydraulic extendible booms, manual extensions, etc. using the lifting power of the rope winch. Danger! Rope might be pulled off the drum if there are too few rope wraps left on the drum.
Page 63 XXXX KG XXXX KG The maximum load capacity of the manual extensions must be written on both sides of the extension by the installer. If this specification is missing, contact your PALFINGER partner. Pulling out/pushing in mechanical manual extensions Danger! Always secure mechanical manual extensions properly.
Page 64: Remote Control
Guarantee and warranty immediately expire when any manipulations to the radio remote control system (remote control console and receiver) become obvious. Components of the remote control Only original PALFINGER components must be used to operate the remote control system. Guidelines to prevent dangers •...
Page 65 Chapter 6 Ancillary equipment Components Remote control console Receiver Charging cable • Carrying strap Accessories • Magnet antenna • Charger (optional)
Page 66 PALFINGER service partners. Prior to the remote control console being used for the first time, every operator must be trained by an authorized PALFINGER service partner. Operators must familiarize themselves with the functions assigned to their console's buttons. STOP-button...
Page 67 Chapter 6 Ancillary equipment 1. STOP-button The emergency-stop button switches the remote control console off and hence stops all crane functions. For how to operate it refer to Emergency cut-off button/ push-button (see "Emergency cut-off button / push-button" Page 41). 2.
Page 68 LED is illuminated: During start-up as soon as the STOP-button is pressed Remaining For PALFINGER partner. functions: 8. Crane function on level 1 All functions that are displayed on the buttons are on level 1. The functions are only displayed if the crane is equipped with them.
Page 69 Chapter 6 Ancillary equipment Service All service work must be carried out by PALFINGER service partners in compliance with the PALFINGER training documents and service records. Non-compliance results in loss of any warranty and liability. Every service and repair must be recorded in the service manual and signed or stamped by a PALFINGER service partner.
Page 71: Preparing For Crane Operation
Chapter 7 H A P T E R Preparing for crane operation In this chapter Watch out for faults before and during operation ........67 Working range ..................68 Starting the crane ..................69 Preparing for remote operation ..............69 Vehicle inclination ..................
Page 73: Watch Out For Faults Before And During Operation
If the following damage or faults are found on the unit, auxiliary equipment, load-bearing equipment or vehicle, do not start operation or stop operation immediately and contact your PALFINGER partner: • Lack of lubrication.
Page 74: Working Range
Preparing for crane operation Working range Danger! There is acute danger to life for operators and others in the entire working range of the crane (slewing range and under suspended loads). Allowing bystanders in the working range is grossly negligent. •...
Page 75: Starting The Crane
Chapter 7 Preparing for crane operation Starting the crane • Park the vehicle as close as possible to the loading place. Note! Working at shorter outreach generally increases the crane lifetime. • Engage the parking brake. • Air suspension axles must be inactive during crane operation. •...
Page 76 If malfunctions occur, let all buttons go immediately and push the STOP-button. The remote control console may only be used once the malfunction has been corrected by a PALFINGER service partner. The remote control operation stops automatically if: •...
Page 77: Vehicle Inclination
Chapter 7 Preparing for crane operation Vehicle inclination Only after having supported and levelled the vehicle properly it is allowed to operate the crane. Declination indicator When the air bubble is in the middle, the vehicle is levelled. When the air bubble is between the two circles, the vehicle inclination is between 0°...
Page 78: Supporting The Vehicle
Preparing for crane operation Supporting the vehicle Danger! If the vehicle is not properly supported it may tip over. Working without proper support is prohibited. This creates an acute risk of fatal injury. The crane must not be moved in working position until the vehicle has been properly supported. Note! The parking brake must be pulled all the time when supporting the vehicle and during loading.
Page 79 The supporting force values are specified in chapter 13, ‘Technical Sheets’. Note! High-quality supporting pads are available from all PALFINGER partners. Caution! If the movement ranges of the supports are not completely in view of the operator there is an acute risk of accident and danger to...
Page 80 Preparing for crane operation When supporting the crane choose an operating station from where you may view the complete support movement range. Always keep moving crane components in view. No persons and objects are allowed to be in the movement area of the stabilizer outriggers / stabilizer cylinders. The outrigger beams and stabilizer cylinders need to be operated separately on both sides.
Page 81: Pulling Outrigger Beams Out Manually
Chapter 7 Preparing for crane operation In order to ensure safe operation follow the below sequence of stabilizing your vehicle: Note! Depending on the equipment available on your vehicle like front stabilizer, rear stabilizers or additional stabilizers one or several points may not apply to your model.
Page 82: Stabilizer Cylinders
Preparing for crane operation Stabilizer cylinders Hydraulic stabilizers • Operator station: Radio-controlled Then pull out the stabilizer cylinders one after the operation: other so that you may view the danger zone. Crank-down stabilizers If the crane is equipped with crank-down stabilizers, crank down the stabilizer extensions until the support jacks have firm ground contact.
Page 83 Chapter 7 Preparing for crane operation Caution! Not maintaining the minimum distances creates an acute risk of fatality for the operator and others. • The operator must have full view of all crane movements. All safety notes of chapter 2 shall be observed. Caution! Extending the extension booms before the main boom is in nearly vertical position causes acute risk of fatality for the operator.
Page 84: Daily Function Check Of Safety Equipment
Working with a defective emergency cut-off button is grossly negligent. Do not operate the crane and contact a PALFINGER service partner. • Operate any crane function. The crane must move perfectly in all directions.
Page 85: Crane Operation
Chapter 8 H A P T E R Crane operation In this chapter Load limits ....................81 Working position of the crane ..............81 Loads ....................... 84 Working with loads ................... 85...
Page 87: Load Limits
Chapter 8 Crane operation Load limits Caution! Exceeding the permissible ranges, load capacities and/or maximum load may affect the vehicle stability and/or cause the crane components to break; it is therefore prohibited. There is severe danger to life for the operator and others. Load capacity label: Maximum load capacity of the crane.
Page 88 Crane operation Working range Optimum working range: XX° XX° = optimum angle of main boom (between 15° and 30°, dependent on crane type). When the main boom is below the horizontal the maximum lifting moment cannot be reached, therefore you should avoid this position. Refer to load capacity chart attached to the crane.
Page 89 Chapter 8 Crane operation Load handling close to the crane using long lifting gear • Lift the load with the extension booms as far as possible retracted (1, 2). • Lower the load arm to 60°. • If necessary extend the hydraulic extension booms. Upper limit range: Boom system between 60°...
Page 90: Loads
Crane operation Working with loads in an operating range over 80° is prohibited. 70° 60° Loads Before loading/unloading • Before lifting any loads check if the load lifting gear is used correctly. • Observe special instructions about load handling and/or lifting gear (e.g. lifting points, center of gravity, orientation, etc.) •...
Page 91: Working With Loads
Chapter 8 Crane operation Working with loads Caution! There is acute danger to life for operators and others in the entire working range of the crane. • Notes in chapter 7 'Working range' shall be observed. • Every time before moving the crane, make sure that there are no persons in the working range of the crane (danger zone).
Page 92 Crane operation Attaching / detaching loads • Position the load arm as required. Stop the crane movements. Caution! When the load is attached or detached by the operator while the crane is still in operation this creates • through unauthorized crane operation, •...
Page 93 Chapter 8 Crane operation Caution! If controls are unintentionally operated with the load and/or crane components, there is an acute risk of fatal injury to the operator and others. During all crane operations, maintain an adequate distance between the load, crane components and controls.
Page 94 Crane operation Lowering the load Caution! In cranes without overload protection system, the load lowers uncontrollably when the permissible load moment is exceeded. Refer to chapter 5, 'Capacity indicator'. Don't increase the outreach when lowering the load. If you increase the outreach when lowering the load, the load may lower uncontrollably. Monitor the capacity indicator.
Page 95 Chapter 8 Crane operation Loading of the rope Moving the load at the acute angle (A) places less load on the rope than moving it at the obtuse angle (B). This protects the rope. Higher load on the rope (B) puts strain on the rope and causes quicker wear.
Page 97: Ending Operation
Chapter 9 H A P T E R Ending operation In this chapter Bringing the crane into transport position ..........93 Retracting the stabilizers ................94 Ending radio remote control operation ............97 Before driving ................... 97...
Page 99: Bringing The Crane Into Transport Position
Chapter 9 Ending operation Bringing the crane into transport position All safety notes of chapter 2 shall be observed. Caution! If the manual extension booms are not properly pinned and secured, they will slide out of the extension booms when folding the crane.
Page 100: Retracting The Stabilizers
Ending operation Resting the boom on the vehicle platform or boom support Danger! If the boom system is not secured against any side movements this creates an acute danger to life of all road users. Not knowing the vehicle's total height and not observing the clearance heights creates an acute risk of fatal injury.
Page 101 Chapter 9 Ending operation When retracting the supports choose an operating station from where you may view the complete support movement range. Always keep moving supports in view. No persons and objects are allowed to be in the movement area of the outrigger beam / stabilizer cylinders. The outrigger beams and stabilizer cylinders need to be operated separately on both sides.
Page 102 Ending operation Retract stabilizer cylinder • Operator station: Radio-controlled Retract the stabilizer cylinders separately to operation: always have full view of the danger zone. Warning! When retracting the opposite stabilizer cylinders the operator must always have full view of these cylinders. If the crane is equipped with crank-down stabilizers, wind in the stabilizer extensions completely.
Page 103: Ending Radio Remote Control Operation
Chapter 9 Ending operation Ending radio remote control operation • Push the stop button. • Charge the battery. • Secure the remote control console against unauthorized use. After finishing all crane movements • Turn off the crane. • Secure the crane against unauthorized use. •...
Page 104 Ending operation The driver must know the total height, total width, axle loads and gross vehicle weight (including crane, ancillary equipment and load) and act accordingly (refer to chapter 5 "Monitoring the transport position"). Note! If the crane is equipped with a transport position indicator, monitor the signal.
Page 105: Maintenance
Chapter 10 H A P T E R Maintenance In this chapter General ....................101 Operating hours counter ................. 102 Maintenance ................... 103 Cleaning ....................104 Visual inspection ..................105 Machine lubrication ................. 107 Hydraulic oil change ................112 Paint repair ..................... 115...
Page 107: General
No costs will be accepted by PALFINGER for damage to the equipment or accidents caused by failure to carry out maintenance work or service work properly, or by non-compliance with national law.
Page 108: Operating Hours Counter
After this period, the display shows the number of operating hours until the next service. The service must be carried out by a PALFINGER service workshop at around 0 hours and logged accordingly in the service manual. If the crane is used for less than 500 hours a year, a service must be arranged at least once annually.
Page 109: Maintenance
Have only qualified personnel carry out maintenance. Maintenance and servicing recommendations in these operating instructions are of general nature and apply to several PALFINGER products. Maintenance has to be carried out after every 50 operating hours. However, the maintenance intervals depend also on application, duty cycle and environmental conditions.
Page 110: Cleaning
Maintenance Cleaning Note! Thorough cleaning increases the reliability and the service life of the unit. Use only environmentally friendly, pH neutral and skin-friendly cleaning agents. This protects the environment and avoids oxidations on the unit. Warning! Oil and grease must not be released into the environment. Clean the device only in suitable places (oil separator).
Page 111: Visual Inspection
Check completeness and function of bolts, screws, pins and locking devices; check pins for any deformation and sufficient security (e. g. lynch pins). • Tighten any loose bolts/nuts to appropriate torque specification. Contact a PALFINGER partner for additional information as needed. Immediately replace any missing or inoperative hardware.
Page 112 Maintenance Rope winch components Refer also to chapter 13, 'Technical description'. • Intermediate rollers for completeness and correct attachment. • Pulley head, lower load block for functionality and correct attachment. • All rope pulleys for damage, ease of movement and wear. Visual inspection of rope Refer also to chapter 6, 'Rope winch'.
Page 113: Machine Lubrication
If lubricant comes into contact with the skin, clean surface of skin with fresh water. Lubricant specification Note! PALFINGER recommends using biodegradable grease. Do not mix incompatible lubricants. Even biodegradable grease must not be released into the environment.
Page 114 Maintenance Grease: Available from most PALFINGER partners according to national guidelines under Order no. EZ982 – 5 kg (11 lb) can Order no. EZ1432 – 50 kg (110 lb) barrel Tested according Technical data Structure smooth Consistency (NLGI) DIN 51818...
Page 115 Hydraulic extension booms, mechanical extension booms Lubricate column bearing Crank of stabilizer Rope winch (limit switch, rope) Hook *) Lubrication points indicated by this symbol must never be lubricated with grease. If lubricating is necessary (chattering, creaking), only use PALFINGER Teflon® spray.
Page 116 Maintenance The illustrated crane is an example and shows components which may be optional on your unit, depending on model and version.
Page 117 Therefore turn off the crane every time before lubricating. Grease nipples must take grease easily. Replace any damaged or seized grease nipples. If it is impossible to press in grease even after replacing the nipple, contact your PALFINGER partner. Lubricating:...
Page 118: Hydraulic Oil Change
For the operating company this means cost saving and also a reduced quantity of discarded oil and therefore a less pollution. Have oil maintenance carried out by a PALFINGER partner on a yearly basis. Hydraulic oil maintenance Oil maintenance includes the following actions: •...
Page 119 The ideal operating temperature of the hydraulic fluid is between + 30 and + 60ºC (+86°F and +140°F). Always read off hydraulic fluid temperature after using the crane. If this temperature range is exceeded frequently, please contact a PALFINGER service partner. Recommended characteristics •...
Page 120 Maintenance Limits for oil selection Please pay attention to the temperature dependence of the viscosity when choosing an oil. Note! Please contact the PALFINGER partner when selecting the recommended hydraulic oils and oil filters. 0 °C Viscosity mm²/s or cSt ISO reference temperature in °Celsius...
Page 121: Paint Repair
Reduces service life. • Mixtures of synthetic esters and mineral oils are no longer biodegradable. • etc. Paint repair Note! Repair paint damage caused by bird dropping, salt water or similar immediately. Protects the unit against corrosion. Refer to PALFINGER repair instructions.
Page 123: Service
Chapter 11 H A P T E R Service In this chapter General ....................119 Check of threaded fasteners ..............119 Initial servicing after 50 operating hours ..........121 Initial servicing after one year ..............121 After every 500 operating hours or once every year ....... 121 After every 3000 working hours or once every three years .....
Page 125: General
Chapter 11 Service General Note! All service work must be carried out by PALFINGER service partners in compliance with the PALFINGER training documents and service records. Non-compliance results in loss of any warranty and liability. Time left until next service - refer to Operating hours counter.
Page 126 Service Thread: Stability: 5.6 Stability: 6.8 Stability: 8.8 Stability: 10.9 Stability: 12.9 0.7 (0.6) 0.9 (0.7) 1.2 (0.9) 1.5 (1.2) 1.7 (1.3) 2.1 (1.6) 2.6 (2) 3.9 (2.9) 4.5 (3.4) 3.4 (2.6) 4.3 (3.2) 5.2 (3.9) 7.6 (5.7) 8.9 (6.6) 5.9 (4.4) 7.3 (5.4) 9 (6.7)
Page 127: Initial Servicing After 50 Operating Hours
Chapter 11 Service Initial servicing after 50 operating hours Description Activity Oil filter package Worm slewing drive (check level - lower worm must run in grease) Hydraulic fluid level (unsupported and in transport position) Tighten hydraulic lines / hoses, screw joints Crane base fixing Initial servicing after one year Description...
Page 128: After Every 3000 Working Hours Or Once Every Three Years
The gear oil must be replaced during the first annual service. And after that after every 3000 working hours or once every three years, whichever comes first. Only the PALFINGER approved gear oil PALFINGER GEAR GUARD must be used. Property Unit Density at 15°C...
Page 129: Check Of Control Equipment
Repairs have to be recorded in the service manual. • If a repair is not carried out by a PALFINGER partner warranty will become void. Lowering rate The lowering rate must not exceed 0.2 % of the outreach per minute.
Page 131: Decommissioning And Disposal
Chapter 12 H A P T E R Decommissioning and disposal In this chapter Decommissioning and disposal guidelines..........127...
Page 133: Decommissioning And Disposal Guidelines
• Contact your PALFINGER partner for proper disassembly of the unit. • Disassemble the unit into single parts according to the instructions of your PALFINGER partner. Disposal Warning! Clean all oily and greasy parts before disposal. Oil and grease must not be released into the environment.
Page 135: Index
Index Index Decommissioning and disposal • 125 Decommissioning and disposal Additionally in remote control mode • 69 guidelines • 127 Adverse working conditions • 12 Device and function • 23 After every 3000 working hours or once every three years • 122 After every 500 operating hours or once Emergency cut-off button / push-button •...
Page 136 Index Safety equipment • 39 Safety for individuals • 9 Initial servicing after 50 operating hours • Service • 117 Slingers, other attachments to lift the Initial servicing after one year • 121 load • 50 Stabilizer cylinders • 76 Labels for North America •...
Page 137: Technical Description
Chapter 13 H A P T E R Technical description...
Page 139 Technical Specification PC 3800 JI (S026-ST-A) Edition 03/2015 PALFINGER AG Lamprechtshausener Bundesstraße 8 5101 Bergheim / Austria www.palfinger.com...
Page 140 PC 3800 JI 0.01000 Signs and symbols - abbreviation -->123456789 Valid to crane number 123456789--> Valid from crane number Page-A Control valve side Page-B Counter control side Installation width without hose-equipment 2, 4, 2/4 Installation width with hose-equipment ABST Support...
Page 141 0.02000 PC 3800 JI Signs and symbols - abbreviation Integrated Stability Control ISC01 Support control+SHB ISC-S ISC standard ISC-L ISC light+SHB HPSC-L High Performance Stability Control light HPSC continuous High Performance Stability Control OELKU Oil cooler ÖLK01 Oil cooler 8.5kW, mounted ÖLK02...
Page 142 PC 3800 JI 0.03000 Signs and symbols - abbreviation STRAN Rope winch, strand 1 strand 2 strand 4 strand STEIL Monitoring the steep position STEIL1 Monitoring the steep position STEIL2 Monitoring the steep position - Fly-Jib Stabilizer plates Standard Extension 100mm...
Page 143 010.03100 Working positions 010.04100 Rope winch SH,SHE 0.8t 010.05100 Control stand 010.05110 Counter control 010.05120 Radio remote control 010.06100 Stationary mounting LIFTING CAPACITY DIAGRAM 020.01100JI Lifting capacity diagram PC 3800 A 020.02100JI Lifting capacity diagram PC 3800 B www.palfinger.com 03/2015...
Page 144 PC 3800 JI 010.01100 Specifications Subject to change, production tolerances have to be taken into account. Basic data Classification: H1/B2 EN12999 3,7 mt (36,5 kNm) Max. lifting moment: [26,920 ft.lb] 2000 kg Max. lifting capacity: [4,400 lb] 5,0 m Max. hydraulic outreach: [16' 50"]...
Page 145 010.01110 PC 3800 JI Crane weight Subject to change, production tolerances have to be taken into account. Crane weight 258 kg [570 lb] HYA A 283 kg [624 lb] HYA B Additional weight Control system Control stand Counter control FFST...
Page 146 PC 3800 JI 010.01120 Extension Subject to change, production tolerances have to be taken into account. Max. outreach 5,0 m 6,0 m HYA A [16 ft] [20 ft] 6,0 m 7,1 m HYA B [20 ft] [23 ft] Weight 18 kg...
Page 147 010.02100 PC 3800 JI Transport position Subject to change, production tolerances have to be taken into account. 1018 [40.08] PC 3800 V2B 779 [30.65] PC 3800 A,V1A,B 153 [6.04] 220 [8.66] [7.09] 360 [14.17] 360 [14.17] 445 [17.52] www.palfinger.com 03/2015...
Page 148 PC 3800 JI 010.02110 Transport position SH,SHE Subject to change, production tolerances have to be taken into account. A 931 [36.67] 129 [5.10] V1A,B 981 [38.63] 224 [8.82] V2A,V1B 1024 [40.33] EP 984 SH EP 979 SHE 206 [8.11] 220 [8.66] [7.09]...
Page 149 010.03100 PC 3800 JI Working positions Subject to change, production tolerances have to be taken into account. 372 [14.63] 70 [2.76] 140 [5.51] 210 [8.27] 153 [6.04] 1447 [56.97] 1690 [66.54] www.palfinger.com 03/2015...
Page 150 PC 3800 JI 010.04100 Rope winch SH,SHE 0.8t Subject to change, production tolerances have to be taken into account. HI 042 PC 3800 A, V1A,V2A,B,V1B EQ 042 HHK 400 UR316 HIS 329 EQ 042 123 [4.84] 569 [22.40] 4xES 032 720 [28.35]...
Page 151 010.05100 PC 3800 JI Control stand Subject to change, production tolerances have to be taken into account. 295 [11.60] 478 [18.83] 161 [6.34] 250 [9.85] 106 [4.17] 212 [8.35] 9 [.35] www.palfinger.com 03/2015...
Page 152 PC 3800 JI 010.05110 Counter control Subject to change, production tolerances have to be taken into account. 385 [15.16] 110 [4.31] 174 [6.85] 330 [12.99] 03/2015 www.palfinger.com...
Page 153 010.05120 PC 3800 JI Radio remote control Subject to change, production tolerances have to be taken into account. 607 [23.90] 571 [22.48] www.palfinger.com 03/2015...
Page 154 PC 3800 JI 010.06100 Stationary mounting Subject to change, production tolerances have to be taken into account. 4xES 1398 4xEK 176 4xHT9430 4xEK 176 4xEM 029 300 [11.81] 190 [7.48] Fixation Tightening torque 80 mm 462 Nm ES 1398 (KMG02436A) [3.15"]...
Page 155 020.01100JI PC 3800 JI Lifting capacity diagram PC 3800 A Subject to change, production tolerances have to be taken into account. 12ft 16ft max 2000kg max 4400lbs 1240kg 20ft 2750lbs 1060kg 71° 2350lbs 60° 980kg 2150lbs 1820kg 45° 4000lbs 16ft...
Page 156 PC 3800 JI 020.02100JI Lifting capacity diagram PC 3800 B Subject to change, production tolerances have to be taken into account. 12ft 16ft max 2000kg 920kg max 4400lbs 24ft 2050lbs 790kg 71° 1740lbs 60° 1220kg 720kg 20ft 2700lbs 1600lbs 45°...

Palfinger PC 3800 Operating Manual

Notes Regarding the Operating Instructions

Chapter 1

Safety and Health Standards

Chapter 2

General

Chapter 3

Device and Function

Safety Equipment

Chapter 5

Ancillary Equipment

Chapter 6

Preparing for Crane Operation

Chapter 7

Crane Operation

Chapter 8

Ending Operation

Chapter 9

Maintenance

Chapter 10

Service

Chapter 11

Decommissioning and Disposal

Index

Technical Description

Quick Links

Need help?

Questions and answers

Related Manuals for Palfinger PC 3800

Summary of Contents for Palfinger PC 3800

Table of Contents