Summary of Contents for Palfinger Clocktower PK2400 TK
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Translation of the original Operation Instruction Operating and maintenance manual Clocktower PK2400 TK Edition 08-2015...
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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.
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 ...............
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Contents Remote control safety shutdown ..................74 Cable operation ......................74 Working range ........................ 75 Starting the crane ......................76 Unfolding the crane ......................78 Daily function check of safety equipment................ 80 Crane operation ....................81 Load limits ........................83 Working position of the crane ..................
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...
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.
Provides assistance but does not operate the unit. Installer Fits the unit to the building. 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.
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.
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 ..............
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 objects may nevertheless arise. The safety of the operators and other persons must be top priority.
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.
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.
Safety and Health Standards Adverse working conditions Do not operate the crane at wind speeds from 10 m/s (22.4 mph). Wind speed in Description km/h Beaufort Larger branches and trees begin to sway, whitecaps 8.0 to <10.8 29 - 38 18.4 to <25.3 on lakes.
Chapter 2 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.
Chapter 3 H A P T E R General In this chapter CE symbol ....................17 Structure of system ................... 17 Modifications to unit .................. 18 Operators ....................18...
Chapter 3 General CE symbol In the EU and in certain countries, the unit may only be operated with A valid CE symbol for the unit and the superstructure. A valid conformity declaration for the unit and the superstructure. EU requirements are thus fulfilled.
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.
Chapter 4 H A P T E R Device and function In this chapter Main components ..................21 Remote control ..................24 Overview of operator station ..............29 Hazard warning symbols ................30 Remote control console - main functions ..........31 Overview of labels ..................
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. Main components...
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Device and function Item 1 Work lights Item 10 Extension booms of outer boom Item 2 Two lifting cylinders Item 11 Base Item 3 Main boom Item 12 Hydraulic unit (illustration 9.1) Item 4 Extension booms of main Item 13 Crane column boom Item 5...
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Chapter 4 Device and function Item 19 Oil cooler 1 Item 24 Operator station Item 20 High pressure filter Item 25 Switch cabinet of power unit Item 21 Oil cooler 2 Item 26 Rope protection cylinder Item 22 Filter for cooling circuit Item 27 Paltronic 150 control Item 23...
Device and function Remote control Note! The wireless remote control system (remote control console, receiver) complies with the applicable EMV directive. So the unit will as far as possible not interfere with other systems or get interfered by them at the place of application. Button/switch assignments Danger! If the remote control handset is operated without training...
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Chapter 4 Device and function Overview of remote control Note! The charging time of the radio remote control battery is 3 hours! Description Function towards the body Function away from body Slewing drive to the left Slewing drive to the right Lift main boom Lower main boom Retract extension booms...
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Device and function Deadman button of rope protection cylinder Warning horn Change crane speed Left Speed one level down Right Speed one level up Emergency cut-off button Push the emergency cut-off button only in an emergency situation. To resume work, unlock the button by pulling and turning it. RC handset start button Running release / deadman button of crane interlock Restart of radio remote control...
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Chapter 4 Device and function Remote control handset - symbols Slewing Clockwise Anticlockwise Main boom Lower Lift (hoist) Boom extension Extend Retract Rope winch Lower Lift (hoist) Outer boom Lower Lift (hoist)
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Device and function Boom extension Extend Retract Rope protection cylinder Retract Extend Crane interlock Unlock Lock...
Chapter 4 Device and function Overview of operator station Description Key switch - Workman basket and crane operation Connection for remote control cable Emergency cut-off Key switch - Stabilizer (free), RC and manual control Function towards the body Function away from body Slewing drive to the left Slewing drive to the right Lift main boom...
Device and function Emergency control (1) Loosen the screws of the console. (2) Mount the lever and actuate emergency control. Hazard warning symbols Check operating instructions Crane crushing hazard No high pressure water jet cleaning...
Chapter 4 Device and function Remote control console - main functions Start switch On LED lights up (red). Speed button Speed LED (green) Radio connection status LED (red) Emergency off / switch off Motor start / stop button 1 - Start switch (start the remote control) Prerequisites for starting: ...
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3 x reduced speed (25%) LED flashes green three times The speed is saved and again active at restart. The 3 reduced speeds can be set up (modified) by the PALFINGER service partner. The proportionality of the control levers is retained.
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Replace damaged gaskets immediately (risk of humidity). Replace damaged operating elements such as keys, buttons, levers immediately and contact a PALFINGER partner. Have the remote control handset checked for proper operation every time servicing is carried out.
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Device and function Battery for remote control. Use the handset only with the original batteries. Information! A new battery is not yet fully charged when delivered! First read the safety guidelines, then the charging instructions. The battery will reach its full capacity only after having completed the first three to five charging / discharging cycles.
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Red and green LED's illuminate. Battery that has been inserted is defective and must be Red LED illuminates, green LED off. replaced. Contact your PALFINGER partner. Information! Batteries must always be fully charged and discharged, otherwise the service life of the batteries will be considerably shorter.
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. The operator must know where the signs are placed on the crane and what they mean. Danger! Missing, damaged or illegible labels increase the risk of accidents!
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Chapter 4 Device and function Load capacity label Position: Operating stand, main boom Meaning: Specification of loads, load ranges and ranges. Risk if ignored: Crane overload, forces in foundations exceeded -> danger of breakage Type plate Position: On the crane column. Meaning: Information about 1 Machine type 2 Internal code...
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Device and function Workman basket Position: Inside workman basket Meaning: Instructions for basket operation Maximum weight; personal safety equipment, wind speed, compulsory use of helmet Risk if ignored: In case of non-compliance there is acute risk of injury or even fatal injury to you and others. 10.
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Chapter 4 Device and function 12. Emergency pump Position: Operator station Meaning: Switch position for emergency pump Risk if ignored: 13. Safety strips Position: lower area of power unit Meaning: Danger of getting crushed Risk if ignored: In case of non-compliance there is severe danger of injury.
Chapter 5 H A P T E R Safety equipment In this chapter General ....................43 Emergency cut-off button ................43 Paltronic 150 control system ..............44 Menu and function overview ..............49 Paltronic 150 safety equipment standard ..........58 Emergency operation after remote control failure ........
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 control equipment leads to danger of fatal injury.
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...
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Chapter 5 Safety equipment Operating and display unit Function key (up) Function key (down) Function keys for selecting the softkey functions Function key (Enter) Function key (Escape) General The display on the screen of the Paltronic 150 consists of the following areas: Status indicator Graphical display of operating status Softkey...
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Safety equipment Fault indicator If a limit condition or error occurs during operation (Paltronic displays a code that is not 000), the status indicator switches to the error indicator. The following error types are possible: ERROR Errors that require a crane service are displayed with an error code.
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Chapter 5 Safety equipment 2 - Crane picture The crane is displayed depending on its equipment. The following symbols are possible: Representation of extension boom for crane without fly jib. Symbol for crane with fly jib Crane with rope winch The arrows in the main display indicate which crane movements are currently possible If all movements are possible, no arrows are displayed.
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Safety equipment Function keys Change to previous menu. The "Up" and "Down" (Up) function keys make it possible to switch between Switch to next menu. softkey menu functions. (Down) Makes it possible to leave the current The "Escape" and "Enter" (Escape) display and go to the previously function keys are used to...
Chapter 5 Safety equipment Menu and function overview Functionality of all menus in the Paltronic 150 graphical display. The functionality can change depending on the version. Main menu level 1 F1: LAMP function F2: RTC function F3: AOS function F4: OLP function Main menu level 2 F1: INFO sub-menu F1: Service sub-sub-menu...
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Safety equipment Softkey menus The softkey menus are operated using function keys F1 to F4. 3 levels are allocated for softkey functions, between which you can switch using the 'Up' and 'Down' function keys. Main menu level 1 Crane functions that can be enabled/disabled are arranged in level 1. The functions are only displayed if the crane is equipped with them.
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Chapter 5 Safety equipment Main menu level 2 The menu functions arranged in level 2 call up an additional sub-menu in the graphical display. INFO opens the information display with additional sub-menus. STICK opens the different support menus, depending on the crane configuration.
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Safety equipment INFO sub-menu The INFO menu is selected from level 2 using the F1 INFO function. Service sub-sub-menu (SERV) The 'Service' sub-menu can be selected in the INFO menu using the F1 SERV function. 18293h The value displayed at the top left shows the total operating hours of the crane.
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Chapter 5 Safety equipment OIL sub-sub-menu The INFO menu can be selected using the F2 OIL function of the 'Oil status' sub- menu. The current oil temperature and the current filling level of the tank can be displayed using the 'Oil status' menu.
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Safety equipment Error (ERR) sub-sub-menu The 'Error' sub-menu can be selected in the INFO menu using the F3 SERV function. The error memory of the Paltronic can be read out using the 'Error' menu. Four error lines are shown on the display. You can scroll through the list using the 'Up' and 'Down' keys.
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Chapter 5 Safety equipment RTC (rope tension control) General Purpose: RTC (rope tension control) makes it possible to fold / unfold cranes with the rope reeved, and also for a short time to use the hook with the rope reeved and the fly-jib. Regardless of the steps or crane position the rope always remains under tension.
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Safety equipment Operation Moving the crane in transport position (folding the crane, refer to 'Moving the crane in transport position' in chapter 9): Remove the lower load block and store it properly. Thread the rope in the safety pin. Danger! When the rope runs over the pulley head, moving the extension booms of the fly-jib may break the rope.
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Chapter 5 Safety equipment Operation with crane hook and RTC With RTC switched on it is possible to use a crane hook on the fly-jib. The rope needs not be unreeved for this. Precondition: The crane is completely unfolded. ...
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...
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Chapter 5 Safety equipment Geometry monitoring Load-dependent geometry monitoring The load-dependent geometry monitoring system provides a boom system control that takes the boom angle and the lifted load into account. Function - with fly-jib: Acoustic warning signal. Capacity indicator flashes. ...
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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. The Paltronic 150 contains two load limits that restrict the negative load of the boom system to a set limit.
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Pressing the OLP button resets all error codes. However, if an error code is displayed again after pressing the OLP button, the cause of the code has not been remedied. A PALFINGER service workshop may need to be visited to remedy the problem. Warning horn Cranes that are operated by remote control and/or have a range of more than 12 meters must be equipped with a warning horn in the EU and certain other countries.
If the remote control still does not work: Set the key switch to manual operation. Operate the crane from the emergency operator station. Any loading and unloading can be finished. Contact your PALFINGER partner. Danger! If the operator cannot observe the crane movements or the lifted load from the crane's emergency operator station, there is severe risk of fatal injury.
Chapter 5 Safety equipment Emergency control from operator station On the operator station set system to manual operation. Loosen the cover and screw on the levers. Failure of electric system If the crane stops because of a fault in the electric or electronic systems ...
Are always considered as part of the load (except rope winch and fly-jib plus provided lower load block). Always attach and secure them using original PALFINGER bolts and securing devices. Slingers, other attachments to lift the load Hook Danger! Undersized, incorrectly attached, defective or unsecured crane hooks or lower load block may cause the load to drop.
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Lock the bolts for the lower load block with pin retention (lynch pin). Use only original bolts for the lower load block! Have any damaged safety latch or lynch pin immediately replaced by a PALFINGER partner. Warning! When attaching and detaching loads, be aware of increased risk of crushing.
Chapter 7 H A P T E R Preparing for crane operation In this chapter Use for intended purpose / limits of the device ......... 71 Watch out for faults before and during operation ........73 Preparing for remote operation ..............74 Remote control safety shutdown ...............
Chapter 7 Preparing for crane operation Use for intended purpose / limits of the device Danger! Improper use endangers people and causes damages to the unit and loss of warranty and liability. Use the crane only within the load limits shown on the load capacity chart to lift, move, carry and set down loads.
If the following damage or faults are found on the remote control handset, device, ancillary equipment, load-bearing equipment or foundation points, do not start operation or stop operation immediately and contact your PALFINGER partner: Lack of lubrication.
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. Danger! Working with a defective remote control handset creates an acute risk of fatality for the operator and others.
Chapter 7 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. ...
Preparing for crane operation Starting the crane Note! Only one person shall operate the crane at a time. Operator station Switch on the main switch (ON). Switch main operation to (1). Push the lever to Normal (1). How to work with radio remote control ...
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Chapter 7 Preparing for crane operation Attach lower load block At the remote control handset deactivate RTC. Slacken the rope until the slack rope device responds. 1. Disassemble the rope thimbles 2 From the top pull the rope into the lower load block (1) and pin it (2), attach the securing pin (3)! At least 1 meter of rope must be free.
Preparing for crane operation Danger! If loads are not lifted from directly below the pulley head in rope winch operation: The load may swing uncontrollably; The rope, the pulley head and the pulley can be damaged; The rope may run out off the roller of the pulley head; ...
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Chapter 7 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. The crane is in transport position.
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.
Chapter 8 H A P T E R Crane operation In this chapter Load limits ....................83 Working position of the crane ..............83 Loads ....................... 85 Working with loads ................... 86 Workman basket..................91...
Chapter 8 Crane operation Load limits 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; ...
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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). Put the boom at an angle between 70° and 80°. ...
Chapter 8 Crane operation Loads Material basket Before loading/unloading Before lifting any loads check if the load lifting gear (1) is used correctly. Observe special instructions about load handling and/or lifting gear (e.g. lifting points, center of gravity, orientation, etc.) ...
Crane operation Working with loads Danger! 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. The operator is responsible for indicating (cordon off) the danger zone. ...
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Chapter 8 Crane operation Attaching / detaching loads Position the boom as required. Stop the crane movements. Danger! When the load is attached or detached by the operator while the crane is still in operation this creates through unauthorized crane operation, ...
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Crane operation Danger! 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. ...
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Chapter 8 Crane operation In case of emergency In case of emergency stop all crane movements immediately (refer to chapter 5, 'Emergency cut-off button'). Lowering the load Danger! In cranes without overload protection system, the load lowers uncontrollably when the permissible load moment is exceeded. Refer to chapter 5, 'Capacity indicator'.
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Crane operation Work interruptions If it is necessary to leave the crane unattended: Land the load. Secure the boom system. Turn off the crane. Secure the crane against unauthorized use. Resuming work If crane has been left unattended, check whether the crane has been tampered with before resuming crane operation.
Assembly, acceptance and periodic inspection The assembly of the working platform on the crane is to be carried out in accordance with the valid assembly guidelines of the PALFINGER company and must be done by an authorised PALFINGER service centre.
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Crane operation In the case of modifications to, as well as attachments on the device which affect stability, mechanical strength and operational safety, the manufacturer's consent must be obtained. Modifications and attachments which increase the effect of the wind on the device are forbidden. Furthermore, country-specific regulations concerning body-building and guidelines are to be observed, and the statutory acceptance tests are to be complied with.
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Crane operation Putting basket in operation For basket operation it is required that the lower load block is put down on the intended place before. Put down the lower load block on the provided panel and disassemble it. Mount the provided chain with scale to the shackle and connect it with the basket.
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Chapter 8 Crane operation Moving the basket in working position The maximum wind speed for working in and with the basket is 10 m/s. The warning horn activates automatically: at a wind speed of 8 m/s = intermittent alarm ...
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Crane operation Danger! Do not use any objects such as ladders or boxes in the basket to take a higher stand. Climbing the guard rails is prohibited - there is acute danger of falling. Load capacity Regardless of their weight, a maximum of 2 persons may be in the elevated work platform. The maximum working load of the working platform may not be exceeded.
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Chapter 8 Crane operation Options to fasten the belt (as depicted) It is not allowed to use equipment and objects to step on for raising up the operator's position in the basket. It is forbidden to stand under the suspended platform. ...
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Crane operation Ending workman basket operation Lower the workman basket smoothly and put it down carefully on the ground. Only when put down on even terrain, it is permitted to exit the basket. Warning! Avoid a hard touch down of the basket, because this may damage various equipment.
Chapter 9 Ending operation H A P T E R Ending operation In this chapter Folding the crane into transport position ..........100 Before driving ..................102...
Ending operation Folding the crane into transport position All safety notes of chapter 2 shall be observed. Prerequisites for folding the crane 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. ...
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Chapter 9 Ending operation Folding the crane Put the main boom in nearly vertical position of 60°/70° using 60° the function 'Lift main boom'. With the ‘Retract extension booms’ function completely move in the extension booms. With the ‘Retract telescopic extension booms’...
Ending operation Before driving Therefore every time before starting to drive check that: the crane has not been tampered with by unauthorized persons; the crane (hydraulic pump) is off; the crane is secured for transport and side movement is not possible. Danger! Any winch components, load fixing gear, etc.
Rope winch at winding device Precondition: Winding device mounted Unreeve the rope, loosen the bolt. Disassemble the pulleys (rope guide). Lift them main boom to c. 80°. Extend the extension boom by one length. Move the outer boom into transport position. Reeve the rope in the winding device.
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Start to wind up the rope: The rope must fit tight on the inside of the winding device. A break is required every time one winding is finished. After the last winding the cCrane stops automatically (three windings remain). Loosen the grid on the crane (rope winch).
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Bridging the rope pulley Loosen the screws of the rope winch (loosen rope) Bridging the pulley Rope is slack / loose Get the rope from the front. Pull it onto the blue rope.
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Under tension wind up the rope, make sure the rope doesn’t jump out of the pulley. Closing the device: 1 Re-plug the coupling 2 Bar through pulley head 3 Mount the hanging system 4 Hang in the system...
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.
Index Index Ending operation • 99 Ending workman basket operation • 98 Activating Paltronic 150 • 44 Adverse working conditions • 12 After maintenance, service and repairs • Failure of electric system • 63 Folding the crane • 101 Ancillary equipment • 65 Folding the crane into transport position •...
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Index Notes regarding the operating Use for intended purpose / limits of the instructions • 1 device • 10, 71 Operating and display unit • 45 Validity of operating instructions • 3 Operating instructions • 3 Operators • 18 Watch out for faults before and during Overview of labels •...
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