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 ............... 10 Residual risks .........................
Page 6 Contents Preparing for crane operation ................151 Watch out for faults before and during operation............153 Preparing for remote operation..................154 Cable operation ......................157 Working range ......................158 Starting the crane ......................159 Supporting the vehicle ....................160 Stabilizer outriggers...................... 166 Stabilizer cylinder ......................
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
PALFINGER DVD 'On the crane'. 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....11 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'. Danger! 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.
Page 18: Adverse Working Conditions
Safety and Health Standards Adverse working conditions Do not operate the crane at wind speeds of 50 km/h (30 mph) and above; at wind speeds from 34 km/h (20 mph) when lifting bulky loads or working in near vertical position; Wind speed in Description km/h...
Page 19: Danger Of Getting Crushed
Chapter 2 Safety and Health Standards Warning! If you need to climb up the machine for instance for visual checks, maintenance and servicing absolutely use a climbing aid (e.g. ladder). Danger of getting crushed Danger! If the minimum distances specified below are undershot, there is an acute risk of crushing.
Page 20: Risk Of Burns
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 21: Dangers Caused By Exhaust
Chapter 2 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. when working in closed rooms, the vehicle exhaust must be led outside using suitable auxiliary materials.
Page 22 Safety and Health Standards Minimum distances from live lines Voltage Minimum distance up to 1000 Volts 1.0 meter (3.3 feet) unknown or over 1000 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 23: After Maintenance, Service And Repairs
Chapter 2 Safety and Health Standards Before rescuing any persons out of the electric circuit turn off the life electric line. 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 Comprehensive training in how to operate the equipment and accessories.
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 Remote control ..................27 Explanation of the operating labels ............44 PALcom P7 menu..................57 Meaning of the symbols................57 Hazard warning symbols ................58 Overview of labels ..................
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 Hauptbauteile Ground control (display unit at the crane) control valve side, opposite side Rigid stabilizer cylinder Crane mounting bolts Tiltable stabilizer cylinder Telescopic outrigger beams Base Endless slewing system with gear rim Lifting cylinder Emergency operator station on the crane column Balance Crane column Linkage system...
Page 33: Remote Control
(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 Before starting the remote control console make sure that any operating lever is not actuated.
Page 34 The type plates on the remote control console, receiver, charging unit and battery indicate the serial number of the part and other information, serve to identify the system, are necessary for communication with PALFINGER service partners. Remote control console type plate Battery type plate...
Page 35 Chapter 4 Device and function Receiver Receiver mounted to crane. Status indicator Connector for cable connection from receiver to remote control console Charging unit and battery Battery: 2 pieces Charger: With indication of the various operating statuses Accessories Diverse accessories Waist strap (optionally diagonal strap) Magnet antenna Cable for cable operation...
Page 36 Device and function Variants The PALcom remote control console can be fitted out in a number of different variants. Depending on the configuration of the crane to be controlled and the number of proportional functions required to do this, the remote control console's design may vary from the base version. Remote control console size Large remote control console for a maximum of 9 Small remote control console for a maximum of 6...
Page 37 Chapter 4 Device and function Large remote control console: Linear lever - 4 functions Joystick - 4 functions (2 - 0 - 2) Linear lever - 5 functions Joystick - 6 functions (2 - 2 - 2) Linear lever - 6 functions Joystick - 6 functions (3 - 0 - 3) Linear lever - 7 functions Joystick - 7 functions (2 - 3 - 2)
Page 38 Device and function Small remote control console: Linear lever - 4 functions Joystick - 4 functions (2 - 0 - 2) Linear lever - 5 functions Joystick - 6 functions (2 - 2 - 2) Linear lever - 6 functions Joystick - 6 functions (3 - 0 - 3)
Page 39 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, switches and indicators.
Page 40 Device and function 1. Rotary switch for speed pre-selection The rotary switch for selecting the speeds of all crane movements has 4 settings and can be set to 25 / 50 / 75 or 100% of the maximum speed. The speed level can be modified during operation in any way you wish. 2.
Page 41 Chapter 4 Device and function 5. Emergency cut-off button The emergency cut-off button switches the remote control console off and hence stops all crane functions. All monitoring and displaying elements on the crane remain active. For its operation refer to ‘Emergency cut-off button’, chapter 5. 6.
Page 42 Device and function 7. Proportional operating lever Linear lever Joystick with 2 functions Joystick with 3 functions 8. Key switch on remote control console ON/OFF Refer to ‘Preparing for remote operation’, chapter 7 and ‘Ending remote operation’, chapter 9. 9. Panels for digital functions Right panel - default: The following functions are provided for this panel and always assigned in the same way (where included).
Page 43 Chapter 4 Device and function 10. Deadman button for two-hand operation Is needed for releasing, etc. for various functions. For example: Open grab / brick fork. Only assigned with ADD software option. 11. OK button Only for this menu. Confirm when asked for confirmation. Switch on the display's background lighting.
Page 44 Device and function Display unit on the crane (terminal) Each crane is fitted with at least one display unit, which permits the menu to be used on the crane itself. Equates to rotating the PALdrive to the left on the remote control console. (Select) equates to pressing the PALdrive on the remote control console.
Page 45 (see graphic). Note! The plug connector for connecting the wireless system cable (remote control console to receiver) is also the plug connection for direct programming of the system by your PALFINGER service partner.
Page 46 Device and function Charger and battery The PALFINGER charger has an indicator showing the different operating states. Note! The charger is generally fitted inside the vehicle. For doing this correctly the following rules apply: The charger should ideally be fitted vertically.
Page 47 The 'Refresh' function is not available when charging from mains power. Mains power LED (1) green - Charger OK. Mains power LED (1) flashing red - Charger faulty, contact PALFINGER service partner. Charging process Normal charging: LED flashes green.
Page 48 5° and 40°C is recommended. The battery should not be stored at temperatures outside of the specified range. The PALFINGER battery is made of nickel metal hydride cells (capacity 2000 mAh, nominal voltage 7.2V). Remote control console and charger can only be operated with original PALFINGER batteries.
Page 49 Every time servicing is carried out the RC console is checked as well to make sure it is working properly. 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.
Page 50: Explanation Of The Operating Labels
Device and function Explanation of the operating labels The order of the functions (symbols) may be different on your operating station (crane or remote control handset) from the examples shown below. It is therefore absolutely essential to familiarize yourself with the functions (symbols) and how they are arranged on your device / remote control handset.
Page 51 Chapter 4 Device and function Main boom Lower Lift (hoist) Outer boom Lower Lift (hoist) Boom extension Extend Retract Rotator Clockwise (right) Counter-clockwise (left)
Page 52 Device and function Grab Open Close Rope winch Lift (hoist) Lower Fly-jib - main boom Lower Lift (hoist) Fly-jib - extension boom Extend Retract...
Page 53 Chapter 4 Device and function Symbols of remote control console Depending on the operating lever labels on the console, the following hydraulic crane movements can be made by moving the levers, joysticks and rotary levers in the direction of the arrow: Slewing Clockwise Anticlockwise...
Page 54 Device and function Boom extension Extend Retract Retract Extend Extend Retract Retract Extend Fly-jib - main boom Lower Lift (hoist) Lift (hoist) Lower...
Page 55 Chapter 4 Device and function Fly-jib - extension boom Extend Retract Retract Extend Extend Retract Retract Extend Extend Retract Retract Extend...
Page 56 Device and function Rotator Clockwise Anticlockwise Anticlockwise Clockwise Clockwise Anticlockwise Anticlockwise Clockwise Clockwise Anticlockwise Anticlockwise Clockwise...
Page 57 Chapter 4 Device and function Grab Open Close Close Open Open Close Close Open Open Close Close Open...
Page 58 Device and function Rope winch Lift (hoist) Lower Lower Lift (hoist) Lift (hoist) Lower Lower Lift (hoist) Alternating operation of fly-jib or grab Lower / open Lift (hoist) / close Lift (hoist) / open Lower / close...
Page 59 Chapter 4 Device and function Alternating operation of fly-jib extension boom or rotator Extend / clockwise Retract / anticlockwise Retract / clockwise Extend / anticlockwise Extend / clockwise Retract / anticlockwise Retract / clockwise Extend / anticlockwise Alternating operation of rope winch or rotator Lift (hoist) / clockwise Lower / anticlockwise Lower / clockwise...
Page 60 Device and function Stabilizer front left Extend stabilizer outrigger Extend stabilizer cylinder beam Retract stabilizer outrigger Retract stabilizer cylinder beam Stabilizer rear left Extend stabilizer outrigger Extend stabilizer cylinder beam Retract stabilizer outrigger Retract stabilizer cylinder beam Stabilizer front right Extend stabilizer outrigger Extend stabilizer cylinder beam...
Page 61 Chapter 4 Device and function Stabilizer rear right Extend stabilizer outrigger Extend stabilizer cylinder beam Retract stabilizer outrigger Retract stabilizer cylinder beam Stabilizer left Extend stabilizer outrigger Extend stabilizer cylinder beam Retract stabilizer outrigger Retract stabilizer cylinder beam Stabilizer right Extend stabilizer outrigger Extend stabilizer cylinder beam...
Page 62 Device and function Extra support stabilization (with joystick control and 8+ functions only) Extend stabilizer outrigger Extend stabilizer cylinder beam Retract stabilizer outrigger Retract stabilizer cylinder beam Crane support stabilization (with joystick control and 8+ functions only) Extend stabilizer outrigger Extend stabilizer cylinder beam Retract stabilizer outrigger...
Page 63: Palcom P7 Menu
Chapter 4 Device and function PALcom P7 menu Refer to chapter ‘Safety equipment, Paltronic 150 control system, PALcom P7’. Meaning of the symbols On the crane: Working light on/off Warning horn OLP button Switch between rotator and fly jib main boom Switch between grab and fly jib extension Power Link rope winch Manual operating mode...
Page 64: Hazard Warning Symbols
Device and function On the remote control console: Motor start / stop Speed adjustment on vehicle engine Return oil utilization off / on Manual AOS Warning horn Hazard warning symbols Check operating instructions Crane crushing hazard Stabilizer supports crushing hazard No high pressure water jet cleaning...
Page 65: Overview Of Labels
Chapter 4 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 66 Device and function Overview of labels:...
Page 67 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. Warning sign 'Keep out from under suspended loads' Position: On both sides of outer boom or main boom. Meaning: It is prohibited to step under the suspended load.
Page 68 Device and function Radio controlled stabilizer warning sign Position: In the case of equipment with radio controlled support on all operating stands. Meaning: Note that the support can be extended or retracted using the remote control. Risk if ignored: Danger of injury by supports moving out or in. Indication for completely extended stabilizer outriggers Position: On the outrigger beam.
Page 69 Chapter 4 Device and function 10. Load capacity label Position: Operating stand, main boom Meaning: Specification of loads, load ranges and ranges. Risk if ignored: Overloading the crane, danger of the vehicle tipping over. 11. Instruction label: Folding/unfolding crane Position: Back of crane column and main boom Meaning: Controls order, unfold/fold crane.
Page 70 30 Mpa B min m ax 65 I/min 60 m/min 5 Rope's minimum breaking load 6 18kN Palfinger Europe GmbH Franz-W.-Scherer-Str. 24 3 22kN 5101 Bergheim / Austria 6 Load capacity for number of rope layers 1 25kN www.palfinger.com 7 Company address The identification plate may not be changed or removed.
Page 71 Chapter 4 Device and function 18. 'Do not step in this area' prohibition sign Position: In places that must not be entered. Meaning: It is prohibited to step in these areas. Risk if ignored: Damage to crane and risk of injury. 19.
Page 72 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 73 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 74 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 75 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 77: Safety Equipment
Chapter 5 H A P T E R Safety equipment In this chapter General ....................73 Emergency cut-off button................73 Paltronic 150 control system..............74 Paltronic 150 safety equipment standard..........100 HPSC stability control................108 Transport position monitoring system ............. 114 Securing a person to a crane..............
Page 79: 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 80: Paltronic 150 Control System
Safety equipment Paltronic 150 control system Paltronic 150 is an electronic crane control system. It contains all of the safety systems that are contained within the standard crane configuration and that can be used during crane operation. Cranes that are equipped with Paltronic 150 are operated by remote control. Note! Use manual operation only in emergencies! Activating Paltronic 150...
Page 81 Chapter 5 Safety equipment PALcom P7 Display menu navigation General The purpose of the display is to inform and communicate with the operator. The graphics and information shown vary based on the working / operating situation. However, the display is always split into 4 sections, which are illustrated below using two examples (crane and stabilizer operation).
Page 82 Safety equipment Scroll bar The scroll bar is used to navigate and select the different sub-menus. They are selected using the PALdrive. The active menu item appears yellow, with all other items gray. Note! The system only ever shows functions that are available on the crane. Depending on the crane configuration different selection options are therefore available.
Page 83 For how to quit a message refer to 'Pop-up graphics' (Paltronic 5 control system, chapter 5). Note! The status code helps your PALFINGER service partner to analyze the problem accurately. Display example:...
Page 84 Safety equipment Joystick display The joystick display always appears whenever what you have selected on the menu means that the operating levers have a function different to the main functionality. The levers get represented according to the assignment set in the Paltronic system. Note! The different colors on the joystick display are color coded with the respective function on the main display area.
Page 85 Chapter 5 Safety equipment Main display area In the main display area there is a depiction of the crane fitted with the chosen equipment.The capacity utilization of the crane and of the fly-jib (if any) are shown as percentages. Maximum version example: Depiction of the crane.
Page 86 Safety equipment Rope winch lever deactivated. If the crane or an additional appliance becomes overloaded, the triggering component gets shown in red and the movement arrows for all movements still possible in the situation are shown in green. Crane overload example: Overloaded crane shown in red.
Page 87 Chapter 5 Safety equipment F2 function menu The F2 function menu is used for switching general functions on and off. Available functions, if present: Working light: Switch working light on or off. Press SELECT button. Console lighting: Switch console's background lighting on or off. Press SELECT button.
Page 88 Safety equipment F1 function menu The F1 function menu is used for switching crane-specific functions on and off. Available functions, if present: Active Oscillation System AOS: Switch AOS off/on - Press SELECT button. For how to operate AOS see 'AOS system’ in chapter 5. OLP function: Deactivate OLP (overload protection) function - Press SELECT button.
Page 89 Chapter 5 Safety equipment ‘Stabilization’ menu item The menu shows a graphic depiction of the current stabilization status and for the radio-controlled support option of the operating functions' lever assignment. The depiction corresponds to the type of control (lever types and function assignment) programmed in the Paltronic system. 'Stabilization' mode selection: Stabilization mode can be selected by selecting 'Stabilization' on the menu or via the stabilization mode quick access button.
Page 90 Safety equipment Switch from right to left side of the crane (with joystick control and 8+ functions only) For crane and additional support control via joysticks you switch between right and left side of the crane as follows: Scroll with the PALdrive in stabilization mode. Confirm selection with OK.
Page 91 Chapter 5 Safety equipment On the support menu select front stabilization (if included and controllable via RC console). Example depiction: 5) Front supports display Depiction of the control levers for each front stabilizer's function color-coded.
Page 92 Safety equipment Rope winch menu item On the rope winch menu you are able to switch all functions relating to the winch on or off. Available functions, if present: Rope winch system - Synchronised rope control SRC: Switch SRC off/on - Press SELECT button. The system does not function if the rope winch is switched off.
Page 93 Chapter 5 Safety equipment Switch from rope winch to rotator mode: This function is available only if the rope winch lever has been assigned a second function. In this example rotator. Press SELECT button and reply to confirmation prompt by pressing OK. If rotator mode is activated, the corresponding symbol is shown in the main display area in place of the rope winch.
Page 94 Safety equipment Set-up menu item The set-up menu is used to select various operating modes for a crane with special equipment. The following modes are available under 'Set-up' if the crane is equipped accordingly: SRC AOS Switching over of a crane with fly-jib to grab / rotator operation instead of the fly-jib.
Page 95 Chapter 5 Safety equipment Switching over of the fly-jib to grab / rotator: on cranes with fly-jib it is possible by taking this off to operate other add-on devices (e.g. grab / rotator). Note! When the fly-jib has been taken off, grab / rotator operation must be activated separately, otherwise the functions are blocked.
Page 96 Safety equipment Switching over rope winch to counter weight: On cranes with wireless remote control and movable counter weight the latter is controlled using the rope winch lever. To move the counter weight, select this function: Switch over from rope winch to counter weight: Crane in radio-controlled mode.
Page 97 Chapter 5 Safety equipment Service: Display of crane's servicing data: Last service carried out on the crane (day/month/year). Crane's total operating hours. Crane's operating hours until next service (example: already 53 hours past scheduled time for service, thus displayed in red with a minus sign).
Page 98 Safety equipment Status codes: Display of saved Paltronic status codes: List of five errors that occurred last in chronological order - the most recently registered code listed first. Status reports (example: overload) do not get displayed. Date the last error occurred. Status code.
Page 99 Chapter 5 Safety equipment Contact details display: Display of the PALFINGER service partner's contact details saved in the crane control system. It is from this that contact details are entered when shipping the appliance. Oil status display: Display of current data relating to the oil status (if the tank has the necessary sensors).
Page 100 Safety equipment Custom menu item (optional) Provides special functions on truck bodies. Up to 6 customized functions possible (2, 4 or 6 functions). The displayed variants are only examples. Depending on the custom configuration the presentation may vary on your model. Example: Large remote control console, linear lever - 7 functions.
Page 101 Note! A status code shown at the bottom of the pop-up graphic informs the PALFINGER service partner about precise details of the fault. A red bar above the status code represents a dangerous situation (example: instability).
Page 102 Safety equipment Possible pop-up graphics Prohibited range: Gets shown if the crane is blocked as a result of reaching a programmed boundary area (example: cabin protection). All movements that would go further into the prohibited area get blocked. Remedy: Move out of the blocked area. Instability: Gets shown if the crane stability is within a critical range (overload stability, stabilization force, etc.).
Page 103 All movements that in this situation can no longer be monitored or are dangerous get blocked. Remedy: Quit pop-up - if the error persists, contact PALFINGER service partner. Hardware / software fault: Gets shown whenever there is a hardware or software fault. Remedy: Quit pop-up - if the error persists, contact PALFINGER service partner.
Page 104 Remedy: Move lever into neutral position. Quit pop-up - if the error persists, contact PALFINGER service partner. Sensor signal comparison: Gets shown if the sensors’ signal values are not the same. Remedy: Quit pop-up - if the error persists, contact PALFINGER service partner.
Page 105 (example: an operator tries to execute a function from the manual terminal that is possible only via the RC console). Missing symbols: Gets shown if the graphics in the wireless remote control system or one of the terminals do not match the crane configuration. Remedy: Contact PALFINGER service partner.
Page 106: Paltronic 150 Safety Equipment Standard
All movements that reduce stability (with reduced load limits); All movements that can cause static overloading of a component. The current overload situation is displayed on the Paltronic 150 display unit on the crane and/or the remote control handset. The setting is made by PALFINGER...
Page 107 Chapter 5 Safety equipment Geometry monitoring Danger! At a boom position higher than 60° abrupt crane movements may lead to an excessive side or rear loading of the boom system. Consequently the load may fall down. This creates an acute risk of fatality for the operator and others.
Page 108 Safety equipment Function - without fly-jib: No acoustic warning signal. Capacity indicator is not flashing. All movements that increase the outer boom angle are blocked. Display of status code Paltronic 033.000 Example crane with fly-jib: As the knuckle boom angle increases, the possible overstretching angle of the fly-jib reduces. The possible overstretching angle depends on the fly-jib model.
Page 109 Chapter 5 Safety equipment Load-dependent geometry monitoring Example crane: The load-dependent geometry monitoring system provides a boom system control that takes the boom angle and the lifted load into account. Function - without fly-jib: Acoustic warning signal. Capacity indicator flashes. All movements that increase the outer boom angle are blocked.
Page 110 Safety equipment Note: Load-dependent geometry monitoring Crane overload Various blocking functions between load-dependent geometry monitoring and normal crane overload. Soft stop The automatic "soft stop function" stops certain crane movements before the mechanical end stop is reached. The movement of the crane function is gently braked when this takes place. Jerky crane movements and load impacts from the suspended load are prevented.
Page 111 Chapter 5 Safety equipment Negative load limits Because of the design of the boom system of the crane - particularly because of the arrangement of the sliding elements - negative loads (e.g. pushing with the boom system) are extremely unfavorable for the crane.
Page 112 Safety equipment OLP function Purpose: If it is impossible in an overload situation to make load moment decreasing movements, the crane can be moved out of the overload situation by using the OLP (overload protection) function. Function: With the OLP function (that can be disabled) it is possible to release all blocked crane movements in case of an overload for 1.5 seconds.
Page 113 Chapter 5 Safety equipment Return oil utilization EXP /EXS PALFINGER loading cranes are equipped with a hydraulic return oil utilization system that is activated during normal operation. This increases the extending speed of the actuator system to the retraction speed, meaning that the booms move at the same speed in both directions.
Page 114: Hpsc Stability Control
The vibration alarm (a signal the operator can feel) gets activated: whenever an error or information message is issued. HPSC stability control Purpose of HPSC PALFINGER's High Performance Stability Control system (HPSC) is an electronic system that monitors the stability of vehicles with loading cranes. Benefits for the operator Note!
Page 115 Chapter 5 Safety equipment Operation You may only utilize the maximum allowable lifting power of the loading crane when the carrier vehicle is sufficiently stable. Therefore it is required to extend all stabilizer outriggers completely (even with available additional stabilizers); that all stabilizer cylinders are completely on the ground (even with available additional stabilizers).
Page 116 Safety equipment How to park and support the vehicle correctly It is better to extend the outriggers further on the crane's working side than on the opposite side. This way the crane has more or even maximum lifting power on the working side. optimally supported crane inappropriately supported crane The loading crane's lifting power on the working side is higher if the opposite side is also supported.
Page 117 Chapter 5 Safety equipment Vehicles with additional stabilizers should better be supported using both stabilizers on the working side. If only the crane stabilizer is used it is necessary to reduce more lifting power because of the higher chassis torsion. optimally supported crane inappropriately supported crane HPSC in combination with Paltronic 150...
Page 118 Safety equipment HPSC options LCA (load capacity area) LCA01, LCA02 and LCA03 or a combination of these safety systems are optionally available. They are needed to calculate the crane's stability when additional supports or a ballast weight are applied. The installer has to adjust these optional features.
Page 119 Chapter 5 Safety equipment LCA03 starts automatically when the ballast weight is being attached and stops when it is being removed. Danger! If you use other ballast weight for LCA03 than the one defined by the installer, this implies danger of the vehicle tipping over and thus, risk of fatal injury! For LCA03 use only the ballast weight defined and calculated by the installer.
Page 120: Transport Position Monitoring System
Safety equipment Transport position monitoring system The following systems are optionally available; in Europe they are mandatory: Main boom put down on vehicle platform - height warning. Alarm for positions of hydraulic stabilizer enlargement, alarm for lock of manually operated stabilizer enlargement.
Page 121: Emergency Operation After Remote Control Failure
Crane with control valve on crane base Operate the crane via manual control station. Any loading and unloading can be finished. Contact your PALFINGER partner.
Page 122 Use the control station on the base only to move the crane to the transport position (emergency operation). and contact a PALFINGER partner immediately to get the crane repaired. If you continue working you put yourself and others at risk of fatality.
Page 123 If no suitable platform is available, the operator must climb down from the vehicle and climb onto the vehicle again at the opposite side. Move the crane to transport position as described in chapter 9, and contact your PALFINGER partner immediately.
Page 124: Emergency Control During Basket Operation
As it is lowered, people in the workman basket must remain crouched. Carefully lower the basket and slowly put it down on even ground, so that the people may exit it safely. The crane may still be folded in transport position. After this contact your PALFINGER partner immediately.
Page 125: Failure Of Electric System
(see 'Load limits, loads', chapter Move the crane in transport position as described in chapter 9. Screw in the by-pass screw as far as it will go. Retract the stabilizers. Contact a PALFINGER partner immediately to get the crane repaired.
Page 126 (2). Retracting the stabilizers. Move to the neutral position again. Turn bypass screw 90° to the right (clockwise) (3). 1. Crane position Contact a PALFINGER partner immediately to 2. HPCO position (support) get the crane repaired. 3. Neutral position...
Page 127: Ancillary Equipment
Chapter 6 H A P T E R Ancillary equipment In this chapter General ....................123 Slingers, other attachments to lift the load ..........124 Ancillary equipment ................125 Additional crane equipment ..............150...
Page 129: General
The maximum load capacity is defined by the weakest load lifting gear used. Load lifting gear and ancillary equipment: 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.
Page 130: 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 131: Ancillary Equipment
Chapter 6 Ancillary equipment Ancillary equipment Quick connect coupling for auxiliary hydraulic equipment A number of ancillary equipment such as grab, rotator, fly-jib, etc. are powered hydraulically. Therefore the hydraulic system of the auxiliary equipment has to be connected to the crane’s hydraulic system. Warning! Incorrectly connected or dirty couplings may lead to oil leakage (environmental pollution) or failure of the auxiliary equipment.
Page 132 Ancillary equipment Multiple coupling Connecting: Switch to manual operation (in case of Paltronic). Switch off the pump. Operate all levers for accessory equipment such as basket, grab, rotator etc. to release residual pressure. Make sure all operating levers are in neutral position. Open the protective lid (1) until it locks.
Page 133 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 (guide pulleys, pulley heads, attaching and safety material, etc.) for the rope winch operation. Note! For the position of rope winch components refer to chapter ‘Technical Description’.
Page 134 Ancillary equipment Power Link rope winch (foldable winch) A crane being operated with rope winch on the main boom and fly-jib may be equipped with a Power Link rope winch. This is required with certain fly-jib variants as otherwise the crane cannot be folded into transport position.
Page 135 Chapter 6 Ancillary equipment Preparing rope winch operation Note! Depending on your model observe the sections ‘RTC (rope tension control)’ and ‘SRC Synchronous rope winch control’ in chapter ‘Safety equipment’ regarding the assembly procedure! Danger! When you don’t turn off the crane between the assembly steps, crane functions may be actuated unintendedly.
Page 136 Ancillary equipment 1 Move the load arm into working position (see ‘Move the load arm to a working position’ in chapter ‘Preparing for crane operation’): Move the outer boom in vertical position. Push the extension booms out to distance A (until approx. 50 cm (2 ft) before the pulley head).
Page 137 Chapter 6 Ancillary equipment 3 Reeving the rope and mounting intermediate pulleys: Bring the boom into a position where all components of the rope winch like winch, pulley head and the like are easily accessible. Briefly actuate ‘Lower rope winch’ to slacken the rope.
Page 138 Ancillary equipment Note! For the position of the intermediate pulleys refer to the ‘Technical data’ and mount them as described below. Warning! Incorrectly mounted intermediate pulleys may get damaged or damage other crane components. When mounting the intermediate pulleys observe the correct fitting direction.
Page 139 Chapter 6 Ancillary equipment 5 Assemble the lower load block. Note! For the lower load block’s capacity refer to ‘Technical data’. Rope winch operation examples: 1 - single-strand 2 - double-strand 4 - four-strand Fasten and lock the rope (thimbles) to the lower load block using pins. Winch components with composite pulleys Danger! When using composite pulleys exclusively, the inner braid strands...
Page 140 Ancillary equipment Rope winch on main boom If the outer boom with retracted boom system is overstretched, the rope may rub on the first extension boom. This may damage the rope and the extension boom. In order to prevent this, extend the boom system before starting rope winch operation until it no longer protrudes out of the back side of the outer boom.
Page 141 Chapter 6 Ancillary equipment Extend/retract extension booms in winch operation Danger! When extending the extension booms and / or unfolding the outer boom, the rope is tightened. If the unwound rope is too short the lower load block will be pulled to the pulley head at full force (two-blocking). In case of rope winches without overload protection system: Rope may break if not unspooled enough.
Page 142 Ancillary equipment Rope winch with end position protection The built-in end layer limiting switch stops the winch when only three wraps of rope remain on the drum. Pulley head in working position / transport position In order to avoid having to remove the pulley head every time at the end of rope winch operation, it can be moved to the transport position (method depends on model).
Page 143 Chapter 6 Ancillary equipment Pulley head that folds up to the side: Working position: Remove locking facility from connection pin A. Pull out connection pin A. Swivel pulley head around bolt B to the working position Fix pulley head in working position with connection pin B.
Page 144 Ancillary equipment RTC (rope tension control) General Purpose: RTC (rope tension control) makes it possible to fold / unfold cranes with the rope reeved, and also to work with hook for a short time with the rope reeved and fly-jib. Regardless of the working steps or crane position the rope always remains under tension.
Page 145 Chapter 6 Ancillary equipment Operation Moving the crane into transport position: Remove the lower load block and store it properly. Caution! If the rope is not reeved in all of the provided deflection pulleys and intermediate pulleys, it may rub against parts and hence get damaged or even break.
Page 146 Ancillary equipment For how to move the pulley head that folds up in the lateral direction in working position / transport position refer to ‘Ancillary equipment’, chapter 6. Apply only light tension to the rope using the 'Raise rope winch' function. Caution! With active RTC the rope winch tensions the rope automatically when a lever is being deflected (exception - ‘Slewing’).
Page 147 Chapter 6 Ancillary equipment Unfolding the crane into working position: Caution! If the rope is not reeved in all of the provided deflection pulleys and intermediate pulleys, it may rub against parts and hence get damaged or even break. This may lead to severe injury. Make sure the rope is properly reeved over all provided deflection pulleys and intermediate pulleys.
Page 148 Ancillary equipment Operating with crane hook with RTC for a short time With RTC it is possible to lift a load with the fly jib without having to unreeve the rope. Precondition: The crane is completely unfolded. Power Link rope winch in working position. The rope is properly reeved over all provided deflection pulleys and intermediate pulleys.
Page 149 This creates an acute risk of fatality for the operator and others. Some of the load lifting gear and ancillary equipment require the use of special PALFINGER hardware. More detailed information about the PALFINGER special load lug is available at all PALFINGER partners.
Page 150 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.
Page 151 This creates an acute risk of fatal injury. Manual extension booms that are extended/retracted must be properly secured using original PALFINGER connection pins and lynch pins. Danger! People standing in front of the crane boom while the manual extension booms are extended are in acute danger to life.
Page 152 Ancillary equipment Overload protection system for manual boom extensions In the EU and certain other countries, manual extension booms must only be operated with an overload protection system, which includes a sensor unit between the load lug and the hook. Danger! The sensor unit must not be overloaded.
Page 153 Chapter 6 Ancillary equipment Attaching the sensor unit: Turn off the crane. Remove the crane hook. Attach the sensor unit to the correct extension. Plug in the connecting cable. Set the operation mode selector switch to the number of extensions pulled out. Turn on the crane.
Page 154 Ancillary equipment Attaching the cable properly: Note! When you reeve two cables in the intermediate pulleys they will rub against each other and may get damaged. Never reeve two cables in one intermediate pulley. Example: SRC-operation Example: Workman basket operation Before you may reeve the cable from the cable drum detach and secure properly the accessory to be connected (pulley head, fly-jib, workman basket, etc.).
Page 155 Chapter 6 Ancillary equipment AOS system Purpose The active oscillation suppression system (AOS) serves for damping and suppressing vertical oscillations of boom and load. These oscillations may be caused by: putting down or lifting up loads in a jerky movement; changing the boom speed in a jerky movement;...
Page 156: Additional Crane Equipment
Ancillary equipment Additional crane equipment Fly jib Refer to operating instructions of the fly jib. Workman basket Refer to operating instructions of the workman basket. Note! In order to prevent the pto from stopping, it is absolutely necessary that the automatic engine speed increase function is active or the engine is run at increased speed.
Page 157: 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 ........153 Preparing for remote operation ............... 154 Cable operation ..................157 Working range ..................158 Starting the crane ................... 159 Supporting the vehicle ................
Page 159: Watch Out For Faults Before And During Operation
If the following damage or faults are found on the remote control handset, unit, ancillary equipment, load-bearing equipment or carrier vehicle, do not start operation or stop operation immediately and contact your PALFINGER partner: Lack of lubrication. Damage to or cracks in components/weld seams.
Page 160: Preparing For Remote Operation
Preparing for crane operation Preparing for remote operation The PALcom remote control console is used when the crane is being operated in radio-controlled mode. Cabled operation is possible as an emergency back-up mode. Danger! The radio remote control needs to be checked for any malfunctions every time before starting to work, failure to do so may result in severe risk of fatality for the operator and others.
Page 161 Chapter 7 Preparing for crane operation Start remote control console: Levers are in the neutral position. Emergency cut-off button on the console is unlocked. Note! If the battery voltage is extremely low, the remote control transmitter cannot be started. Start remote control console: Insert battery into remote control console (1), ensure contacts are aligned correctly, push in and gently press down until it snaps into place.
Page 162 There is no wireless connection (see below). The battery is empty. Any crane function was not operated for more than 5 minutes. A PALFINGER service partner can individually set the period. To be able to continue working, the remote control handset must be restarted.
Page 163: Cable Operation
Chapter 7 Preparing for crane operation Cable operation Note! Cable operation is used as an emergency back-up mode if the wireless link fails. Cable mode is also provided for use in areas where emitting wireless signals is not allowed (e.g. hospitals, nuclear power plants, etc.) Setting up cable operation Cable operation is established by attaching the connection cable supplied between the remote control console and the receiver.
Page 164: 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. The operator must have full view of the crane movements and the loading/unloading point.
Page 165: 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. Engage the PTO at idle and then select correct engine speed.
Page 166: Supporting The Vehicle
Preparing for crane operation Supporting the vehicle Caution! 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 167 Chapter 7 Preparing for crane operation Ground condition Check the floor for the following: Stability. Cavities (manhole covers, pipelines, etc.). Sufficient distance to any drop offs, holes, ditches, etc. Ground inclination 5° maximum in all directions. Increase the support area according to the supporting surface conditions (refer to table) or find a suitable supporting surface.
Page 168 Preparing for crane operation Note! High-quality supporting pads are available from all PALFINGER partners. Operating station support Danger! 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 life.
Page 169 Chapter 7 Preparing for crane operation Stabilizing in general The stabilizer outriggers and stabilizer cylinders must be extended or retracted separately on both sides. To do so, alternately use both operating stations. Fully extend / retract the stabilizer outriggers (mark must be visible). If your crane is equipped with a stability control system refer ‘HPSC stability control’, chapter 5.
Page 170 Preparing for crane operation Stabilizing sequence The crane stabilizers are designed for absorbing only the crane load! If the vehicle is lifted completely during crane operation, the crane support can fail. Danger! If the vehicle is lifted partly or completely when on the stabilizers the stabilizing system will be under significantly higher load.
Page 171 Chapter 7 Preparing for crane operation Manual support operating stand (on crane) If the crane is equipped with manually operated stabilizers: Set the key switch to support operation; Extend outrigger beam and support cylinder properly at crane operating station. Support operation via remote control If the crane is equipped with radio controlled stabilizers: Set the key switch to remote operation.
Page 172: Stabilizer Outriggers
Preparing for crane operation Note! The key switch must not be moved to support operation. If the key switch is set to support operation, the support can only be operated manually. Attention - Manual operation only for emergency operation, refer to chapter 'Crane control systems', section 'Emergency operation after remote control failure'! Stabilizer outriggers Note!
Page 173: Stabilizer Cylinder
Chapter 7 Preparing for crane operation Stabilizer cylinder Extending rigid stabilizer cylinders via operator station Extend the stabilizer cylinder until it has firm ground contact. Extending manually tiltable stabilizer cylinders via operator station Moving the tiltable stabilizer cylinders in supporting position: Firmly hold the stabilizer cylinder.
Page 174 Preparing for crane operation Extending hydraulically tiltable stabilizer cylinders via operator station Briefly press the function "Retract stabilizer cylinders" until the stabilizer cylinder is unlocked. Extend the hydraulic outrigger beams completely. Open latch lever of stabilizer cylinder. Activate the function ‘Extend stabilizer cylinder’ and tilt it down carefully and slowly.
Page 175 Chapter 7 Preparing for crane operation Extending rigid stabilizer cylinders via radio remote control Extend the stabilizer cylinder until it has firm ground contact. Extending manually tiltable stabilizer cylinders via radio remote control Moving the tiltable stabilizer cylinders in supporting position: Firmly hold the stabilizer cylinder.
Page 176 Preparing for crane operation Extending hydraulically tiltable stabilizer cylinders via radio remote control Briefly press the function "Retract stabilizer cylinders" until the stabilizer cylinder is unlocked. Without HPSC: Extend stabilizer outriggers completely. With HPSC: Extend stabilizer outriggers. Extend the hydraulic outrigger beams completely.
Page 177 Chapter 7 Preparing for crane operation Moving the tiltable stabilizer with pivot rods in supporting position: Danger! If the pin for the pivot rods is removed while the stabilizer cylinder points upwards, the stabilizer will fall down uncontrollably. There is risk of fatal injury! Situation: After having moved out the stabilizer the distance between the support jack and the ground is too small to push in the supporting plate.
Page 178: Vehicle Inclination
Preparing for crane operation Vehicle inclination Only after having supported and levelled the vehicle properly it is allowed to operate the crane. Declination indicator Every crane support control station has a 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 179: Unfolding The Crane
Chapter 7 Preparing for crane operation Unfolding the crane Set the key switch to remote operation. Prerequisites for unfolding the crane Danger! If the manual extension booms are not properly pinned and secured, they will slide out of the extension booms when unfolding the crane. This creates an acute risk of fatality for the operator and others.
Page 180 Preparing for crane operation Unfolding the crane Danger! There is acute danger to life for operators and others, and device and auxiliary components may get damaged if the steps are not carried out in the given order. Always carry out the steps in the correct order. Move the main boom to a near-vertical position.
Page 181: 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. Press the emergency cut-off button while the crane is moving. The crane must come to a stop.
Page 183: Crane Operation
Chapter 8 H A P T E R Crane operation In this chapter Load limits ....................179 Working position of the crane ..............180 Loads ..................... 182 Working with loads ................. 183 SRC Synchronised rope control.............. 189 Securing a person to a crane..............192 Operation of AOS system ...............
Page 185: Load Limits
Chapter 8 Crane operation Load limits Danger! 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. This represents an acute danger to life for the operator and others. Load capacity label: Maximum load capacity of the crane.
Page 186: Working Position Of The Crane
Crane operation Working position of the crane Load capacity, component wear, and working life of the crane are among others dependent on the working position. In adverse working positions: the bearings, joints and crane components are under higher stress and therefore wear out quicker; the specified load may not be reached;...
Page 187 Chapter 8 Crane operation Load handling close to the crane using rope winch or 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. 60°...
Page 188: Loads
Crane operation Boom system above 80°: Caution! At a boom position higher than 80°side loading and/or backwards loading may occur because of outer boom being overstretched. Consequently the load may fall down. This creates an acute risk of fatality for the operator and others. Working with loads in an operating range over 80°...
Page 189: 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.
Page 190 Crane operation Attaching / detaching loads Position the boom 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, by unintended actuation of control equipment on the operator station or handset of the remote control acute danger to life for the operator and others.
Page 191 Chapter 8 Crane operation Caution! Abrupt crane movements can make the load swing. Consequently the load may fall down. This creates an acute risk of fatality for the operator and others. Carry out all crane movements smoothly. Grasp the operating lever of the crane function firmly. Press the lever slowly until the crane responds.
Page 192 Crane operation Caution! Operating crane functions at full working speed to the cylinder stop: increases the wear of components and reduces the life of the crane; the load may fall down. This creates an acute risk of fatality for the operator and others. It is prohibited to operate crane functions (with / without load) at full speed to the cylinder stop.
Page 193 Chapter 8 Crane operation Landing the load The landing area must be free of obstacles. Don’t land the load on ice or snow. Don't land the load on drop offs, bumps, slopes, holes, ditches, etc. Land the load only on solid level ground; if necessary use suitable blocks or boards. When the load is put down, the load on the main boom must not be relieved suddenly.
Page 194 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 195: Src Synchronised Rope Control
Chapter 8 Crane operation SRC Synchronised rope control General Purpose: SRC (synchronised rope control) makes working with the rope winch considerably easier. It helps the crane driver to fully concentrate on the actual crane movements and the load. Function: The sensor unit in the pulley head monitors the rope being wound /unwound and synchronises the rope winch.
Page 196 Crane operation Operation Assembling/disassembling the pulley head: See 'Ancillary equipment', chapter 5. Danger! Before working on either the pulley head or rope deactivate SRC and disconnect the sensor on the pulley head from mains! Otherwise there is an acute risk of crushing and therefore a risk of injury! Pulley head assembly - first step: Disconnect the SRC cable from the pulley head! Pulley head assembly - last step: Connect the SRC cable to the pulley head! Activating SRC:...
Page 197 Chapter 8 Crane operation Danger! The remote control's emergency cut-off button stops the SRC, but does not deactivate it! There is an acute risk of crushing and therefore a risk of injury! Please note The following is required for perfect control: The sensor controlled rope pulley must rotate smoothly.
Page 198: Securing A Person To A Crane
Crane operation Securing a person to a crane General From a standing height of 2 meters a fall arrester is mandatory. Generally cranes must never be used for protecting people against falls. Only in justified special cases it is allowed to secure people using the crane while complying with specific parameters and fulfilling exactly defined preconditions.
Page 199 Chapter 8 Crane operation Requirements and actions for personal fall protection on loading crane: Organizational requirements: There is no alternative way of securing a person at the place of work (for example, a fall-arrest system on a building). All national regulations are being met. The permission to secure someone to the crane (according to D-A-CH-S industry group) applies only in Austria, Germany, Switzerland and Italy subject to special conditions, see relevant working paper: http://www.bauforumplus.eu/absturz/dachs-dokumente0/d-a-ch-s-dokumente-deutsch/...
Page 200 Crane operation All maintenance and servicing jobs prescribed by Palfinger have been carried out and can be verified. All device components and safety features on the device are working perfectly and are free of any defects. Further risks to be taken into account Effects of wind and other environmental factors.
Page 201 Chapter 8 Crane operation Note! Activating this function will only be possible if the below conditions have been met. Otherwise the effect described will occur. Condition Effect if condition is not met Activation impossible (only possible via handset). When activation is attempted on the crane’s operator terminal, the following message appears: Remote control handset must be on.
Page 202 Crane operation Fall protection mode is on and active. Controls are in radio operation mode. Remote control handset is in cable operation mode. Fall protection mode is on, but not active. Controls are in radio operation mode. Remote control handset is not in cable operation mode. Note! On switching the system on and off, this function gets automatically deactivated.
Page 203 Chapter 8 Crane operation Attach the fall arrester to the crane's lifting gear (shackle - A). Secure the fastener to a second independent securing point (B) (for example: peg hole in the extension boom). Attach the fall arrester to the crane's lifting gear (shackle - A). Secure the fastener to a second independent securing point (B - for example: hook).
Page 204 Crane operation Put crane in a position suitable for securing the person and shut it down Place the crane in a position where the fall arrester is at a distance of 5m minimum from the person to be protected and if possible vertically above. Secure the crane against unintended motions: Set the key switch on the remote control console to OFF.
Page 205: Operation Of Aos System
Chapter 8 Crane operation Secure the crane against unintended motions: Set the key switch on the remote control console to OFF. Note! Do not actuate the emergency cut-off button on the crane. Ending protection operation The person to be protected exits the danger zone. Detach the safety harness of the person to be secured from the fall arrester.
Page 206 Crane operation The slide button is in status ON (4). AOS is shown in the status bar (5). AOS is activated. Crane operation with activated AOS-P3 Warning! During damping the main boom may move considerably, even if the operator has not actuated any main boom movement. Always observe the main boom while operating the crane with activated AOS.
Page 207 Chapter 8 Crane operation Deactivating AOS system P3 Deactivating AOS Using the multi-function wheel select F1 from the scroll bar (1). Press Select. AOS is highlighted yellow, the slide button is in status ON (2). AOS is shown in the status bar (3). Press Select.
Page 209: Ending Operation
Chapter 9 H A P T E R Ending operation In this chapter Folding the crane into transport position ..........205 Retracting the stabilizers ................ 207 Before driving ..................214...
Page 211: Folding The Crane Into Transport Position
Chapter 9 Ending operation Folding the crane into transport position All safety notes of chapter 2 shall be observed. Prerequisites for folding the crane Extension booms are retracted, pinned and secured. No bystanders or obstacles are in the movement range of the crane. Ancillary equipment is secured or removed and securely stored, refer to chapter 6.
Page 212 Ending operation Folding the crane Extend the extension booms about 50 cm (20"). Fold the outer boom completely. Retract the hydraulic extension booms The suspension eye on the first extension boom must be above the catch. Unfold the outer boom. Slew the crane until the folding arrow on the base and the mark on the crane column and are aligned (set-down position) .
Page 213: Retracting The Stabilizers
Chapter 9 Ending operation Secure the boom system sufficiently against side movements. When the boom rests on the vehicle platform the vehicle's total height may change. Note! If the crane is equipped with a transport position indicator, monitor the signal. Retracting the stabilizers Danger! If the load arm is not in transport position while retracting the...
Page 214 Ending operation Danger! Incompletely retracted and/or unsecured stabilizer cylinders and stabilizer outriggers create an acute risk of fatality for the operator and others. Inadequate or lack of securing of stabilizer cylinders and/or outrigger beams is prohibited. There is then an acute risk of fatality for the operator and others.
Page 215 Chapter 9 Ending operation Stabilizer cylinder Retracting the tiltable stabilizer with pivot rods Situation: The pin has been removed from the pivot rods while the stabilizers are active. Note! Absolutely, reinsert the pin for the pivot rods before retracting the stabilizers.
Page 216 Ending operation Retracting rigid stabilizer cylinders via operator station Retract the stabilizer cylinders completely. Retracting manually tiltable stabilizer cylinders via operator station Retract the tiltable stabilizer cylinders in transport position: Retract the stabilizer cylinders completely. Open latch lever of stabilizer cylinder. Pivot stabilizer cylinder into transport position.
Page 217 Chapter 9 Ending operation Operate the function ‘Retract stabilizer cylinder’ and tilt the cylinder up carefully and slowly. Close latch lever and make sure it is in the locked position. Retract the outrigger beams completely. Stow supporting pads away in the correct way. Retracting rigid stabilizer cylinders via radio remote control Retract the stabilizer cylinders completely.
Page 218 Ending operation When the stabilizer cylinder is in transport position: Close latch lever and make sure it is in the locked position. Retracting hydraulically tiltable stabilizer cylinders via radio remote control Retract the stabilizer cylinders until the outrigger beams are unloaded. Open latch lever of stabilizer cylinder.
Page 219 Chapter 9 Ending operation Stabilizer outriggers Pushing in manually Stabilizer cylinders must be completely retracted and in transport position. Turn the primary lock handle to the stop. Push the outrigger beam completely in; until the primary lock engages. Check whether the safety catch has engaged by attempting to move the outrigger beam in and out.
Page 220: Before Driving
Ending operation Before driving Danger! Incompletely retracted stabilizer outriggers create a severe risk of fatality for the operator and others. Starting to drive without securing the crane and supports properly is prohibited. Therefore every time before starting to drive check that: the crane has not been tampered with by unauthorized persons;...
Page 221 Chapter 9 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 systems for transport position'). Note! If the crane is equipped with a transport position indicator, monitor the signal.
Page 223: Maintenance
Chapter 10 H A P T E R Maintenance In this chapter General ....................219 Operating hours counter ................. 220 Maintenance................... 221 Cleaning ....................222 Visual inspection ..................223 Machine lubrication................. 226 Hydraulic oil change, filter change ............231 Paint repair ..................... 234...
Page 225: 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 226: Operating Hours Counter
If the service intervals are not adhered to or not carried out by an authorised PALFINGER service partner, the warranty is invalidated. After servicing the PALFINGER service center resets the service interval to 1000 hours.
Page 227: 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 228: 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 229: 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.
Page 230 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 231 Chapter 10 Maintenance Labels Check for legibility and completeness. Check the load lifting gear Hooks for cracks, deformations and wear. Sensor unit of manual extension booms for cracks, deformation, leaks and wear. Mark (A) must not be visible. Safety latch for proper function. Check of safety devices Refer to 'Daily function check of the safety equipment' chapter 7.
Page 232: 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 233 Chapter 10 Maintenance Rope grease: Available from most PALFINGER partners according to national guidelines under Order no. W100084145 Note! The extension booms are low-maintenance. If unexpected problems occur during operation such as chatter or creaking, use only PALFINGER Teflon® spray on the slide surfaces.
Page 234 Maintenance The illustrated crane is an example and shows components which may be optional on your unit, depending on model and version.
Page 235 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 236 It can sometimes be necessary to spray in some Palfinger Teflon® Spray to assist the build-up of this layer. It is also possible that in process blank spots may arise on the gliding surface.
Page 237: Hydraulic Oil Change, Filter 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: Oil filtration.
Page 238 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 Favorable viscosity/temperature behavior.
Page 239 Chapter 10 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 240: 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 241: Service
Chapter 11 H A P T E R Service In this chapter General ....................237 Check of threaded fasteners..............237 Service symbols ..................239 Initial servicing after 50 operating hours ..........239 Initial servicing after one year ..............239 After every 1000 operating hours or once every year ......240 After every 3000 working hours or once every three years .....
Page 243: 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 244 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 245: Initial Servicing After 50 Operating Hours
Chapter 11 Service Service symbols Functional check Change Visual check Check bolts for tightness Teflon® spray Grease Rope grease Initial servicing after 50 operating hours Description Activity Oil filter package Slewing system / slewing gear Hydraulic fluid level (unsupported and in transport position) Inner and outer slewing ring bolts (refer to slewing ring bolt service) Tighten hydraulic lines / hoses, screw joints Crane base fixing...
Page 246: After Every 1000 Operating Hours Or Once Every Year
Service After every 1000 operating hours or once every year Description Activity Oil filter package - hydraulic oil Slewing system Slewing gear - oil Crane base fixing Inner and outer slewing ring bolts (refer to slewing ring bolt service) Hydraulic lines / hoses, screw joints Rope winch limit switch Rope winch transmission oil Remote control...
Page 247: Every 6 Years
Activity Hydraulic hoses Hook and shackle Hook and shackle inspections done by a PALFINGER partner have to comply with national regulations and be carried out in intervals of 12 months maximum. Danger! If hooks are used that have not been sufficiently maintained or are damaged or worn, there is an acute risk of accidents and therefore risk of fatal injury to the operators and others.
Page 248: Slewing Ring Bolts - Initial Servicing, Annual Service, 1000 Hours Service
900 Nm If the check reveals one or several loose slewing ring bolts (>30°), contact the PALFINGER service. PALFINGER slewing ring bolts may be turned in only when not oiled. All connecting parts must be clean and free of grease.
Page 249 Release the emergency cut-off button. Repeat the inspection until you have checked all outside slewing ring bolts. Replacement of parts: Note! If servicing or repair works require slewing ring bolts to be replaced, refer to the PALFINGER service records and PALFINGER training documents.
Page 250: Gear Oil
Damages to the unit must be repaired immediately by a PALFINGER partner. 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 251: Decommissioning And Disposal
Chapter 12 H A P T E R Decommissioning and disposal In this chapter Decommissioning and disposal guidelines..........247...
Page 253: Decommissioning And Disposal Guidelines
Improper disassembly can cause an increased danger of accident. 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 255: Index
Index Index Danger from power lines • 15 Danger of getting crushed • 13 Activating Paltronic 150 • 74 Dangers caused by exhaust • 15 Additional crane equipment • 150 Deactivating AOS system P3 • 201 Adverse working conditions • 12 Decommissioning and disposal •...
Page 256 Index Government regulations and standards On the remote control console: • 58 for operating the unit • 11 Operating hours counter • 220 Grab • 143 Operating instructions • 3 Graphics and pictures • 5 Operation • 109 Guidelines to prevent dangers • 27 Operation of AOS system •...
Page 257 Index Slingers, other attachments to lift the load • 124 SRC Synchronised rope control • 150, Stabilizer cylinder • 167, 209 Stabilizer outriggers • 166, 213 Stabilizing sequence • 164 Starting the crane • 159 Storage, maintenance and care of the wireless system •...
Page 259: Technical Description
Chapter 13 H A P T E R Technical description...

Palfinger PK 34002-SH P7 Original Operating Manual

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