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 Foreseeable misuse of the device .................. 10 Residual risks .........................
Page 6 Contents Ancillary equipment ..................... 73 General........................... 75 Slingers, other attachments to lift the load..............77 Ancillary equipment ......................78 Additional crane equipment .................... 90 Preparing for crane operation ................97 Use for intended purpose / limits of the device ............... 99 Watch out for faults before and during operation............
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 Foreseeable misuse of the device ..........10 Residual risks ................10 Government regulations and standards for operating the unit..11 Adverse working conditions ............11 Risk of falling ................12 Danger of getting crushed ............13 Risk of burns ................14...
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: Foreseeable Misuse Of The Device
The present operating instructions are meant as a guideline. With their help qualified operators will be able to operate the device safely. During operation, however, dangerous situations may develop which are unforeseeable for PALFINGER. Therefore, PALFINGER cannot include such hazardous situations in these operating instructions.
Page 17: Government Regulations And Standards For Operating The Unit
Chapter 2 Safety and Health Standards Government regulations and standards for operating the unit The operator must know about and follow the national regulations, standards and safety provisions for operating the unit. If the operating instructions contain regulations and safety provisions that contradict the national laws and regulations, the national laws and regulations have priority.
Page 18: Risk Of Falling
Safety and Health Standards Risk of falling Warning! Climbing up on the unit can lead to the individual falling or the unit being damaged. There is an acute danger of accident. Climbing on the unit is prohibited. Exceptions: Climbing up to operating stands using climbing aids (see "High stand, high seat", Chapter 6) or climbing to the emergency operator station at the crane column (see "Emergency control operation after remote control failure", Chapter 5).
Page 19: Danger Of Getting Crushed
Chapter 2 Safety and Health Standards Danger of getting crushed Danger! If the minimum distances specified below are undershot, there is an acute risk of crushing. Operating situations in which the operators or other persons are at risk of crushing are prohibited! 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.
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 meters (100.58 cm) 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 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 (standard 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 Function labels ................27 Switches / buttons ...............30 Hazard warning symbols .............31 Overview of labels ...............31...
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 Main components Ground control – control valve side, opposite side Crane mounting bolts Tiltable stabilizer cylinder Rigid stabilizer cylinder Stabilizer outrigger Telescopic outrigger beams Manual outrigger interlock system Hydraulic oil tank with oil temperature indicator and oil level indicator Slewing system Base Crane column...
Page 33: Function Labels
Chapter 4 Device and function Function labels The function labels are explained below. The order of functions (symbols) may be different on your operator station from the example shown below. Therefore it is absolutely essential to familiarize yourself with the symbols and how they are arranged on your device. For the symbols on the remote control refer to the remote control operating instructions.
Page 34 Device and function Main boom Lower Lift (hoist) Outer boom Lower Lift (hoist) Extension boom Extend Retract Rotator Clockwise (right) Counter-clockwise (left) Grab Open Close...
Page 35 Chapter 4 Device and function Rope winch Lift (hoist) Lower Fly jib - main boom Lower Lift (hoist) Fly-jib - extension boom Extend Retract...
Page 36: Switches / Buttons
Device and function Switches / buttons Switch between rotator and fly jib main boom Switch between grab and fly jib extension OLP Button Warning horn Working light on/off Remote control operating mode ‘Extend support outrigger beam’ push button, remote control Manual operating mode Support operation Motor start...
Page 37: Hazard Warning Symbols
Chapter 4 Device and function Engine rpm up/down Seat heat off/on Hazard warning symbols Check operating instructions Crane crushing hazard Stabilizer supports crushing hazard No high pressure water jet cleaning Overview of labels The labels are part of the unit, they serve to protect the operator and others and facilitate correct crane operation.
Page 38 Device and function Overview of labels:...
Page 39 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. Hazardous area Position: On the outrigger box and extension cylinders. Closes drilled assembly holes on stabilizer outriggers where there is increased danger of getting crushed, cut and injured by shearing.
Page 40 Device and function Instruction label: Folding/unfolding crane Position: Back of crane column and main boom. Meaning: Controls order, unfold/fold crane. Risk if ignored: Damages to the crane and risk of fatal injury. Folding arrow Position: Back of crane column and crane base. Meaning: Indicates the transport position.
Page 41 2 Rope standard designation 76 kN 30 Mpa B min m ax 65 I/min 60 m/min 3 Serial number Palfinger Europe GmbH 6 18kN Franz-W.-Scherer-Str. 24 3 22kN 4 Year built 5101 Bergheim / Austria 1 25kN www.palfinger.com 5 Rope's minimum breaking load...
Page 42 Device and function 14. Radio controlled support 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.
Page 43 Chapter 4 Device and function 18. Warning sign Position: On the stabilizer cylinders. Meaning: Warning of hazardous areas. Risk if ignored: Risk of injury by the tilting up stabilizer. 19. Functional label / covering film Position: Covers drilled holes and cut-outs on the device (in or near the operating area) where there is increased risk of getting crushed, cut or injured by shearing.
Page 44 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 45 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 46 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 47 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 49: Crane Control Systems
Chapter 5 H A P T E R Crane control systems In this chapter General ..................45 Emergency cut-off button.............45 Capacity indicator ................46 Paltronic 50 Control System ............47 Stability control (ISC - S) .............53 HPSC stability control..............55 HPSC-L stability control...............61 High stand slewing limiter IS............62 Geometry monitoring ..............63 Steep position monitoring ............66 Steep position monitoring system up to 5+ extension + fly jib ..67...
Page 51: General
Chapter 5 Crane control systems 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.
Page 52: Capacity Indicator
Crane control systems Capacity indicator If the crane is equipped with a capacity indicator, it shows the current load status on a three-color scale. The capacity indicator does not protect the crane from overloading. Color Crane utilization 1 = green: Working range 2 = yellow: Limit range...
Page 53: Paltronic 50 Control System
Chapter 5 Crane control systems Paltronic 50 Control System Paltronic 50 is an electronic crane control system. Display Emergency cut-off button Capacity indicator Paltronic 50 stand-by mode HPLS button OLP button Warning horn Reset button Overload situation indicator Refer also to steep position monitoring.
Page 54 Crane control systems 3 Paltronic 50 stand-by mode The PAL 50 stand-by key deactivates/activates the Paltronic's stand- by mode while operating the crane. Stand-by mode: Press PAL 50 stand-by key. LED goes out. All crane functions and operating features are inactive. Switching on: Press PAL 50 stand-by key.
Page 55 4 HPLS (only in remote control mode on HPLS models) HPLS: System to increase the crane’s load capacity. If required PALFINGER HPLS can be used to increase the crane’s lifting force by reducing the speed of the crane functions. Switching HPLS on/off: Press the HPLS button on the display unit.
Page 56 Crane control systems Simulated overload situation If you move the main boom of the crane or fly jib up to the stop the load moment restricting system activates. This is caused by the pressure peak in the lifting cylinder. After this any crane movements that increase the load moment are blocked.
Page 57 The crane is ready for operation if there are no more errors. If the crane is not ready for operation after a reset: Contact a PALFINGER partner (refer also to „Failure of the crane’s electric system”, chapter 5) 6 Overload situation / movement restriction indication It shows the crane system that triggered the overload protection device.
Page 58 Crane control systems Overload situation with capacity indicator (capacity indicator flashes) Stability control Reduce the outreach / slew back. Crane Reduce the outreach. 2. Fly-jib Reduce the fly-jib outreach. Rope winch Retract extension boom or lower the load. Geometry monitoring system - Reduce outer boom angle, retract crane extension booms.
Page 59: Stability Control (Isc - S)
If the crane is delivered with CE conformity, it is standard equipped with stability control (ISC - S). The incorporation of the support situation in the load moment limiter is realized using this system at PALFINGER. This means that the crane may even be operated when the support outrigger beams are not fully extended.
Page 60 Crane control systems ISC - S (Integrated Stability Control - standard) The following work areas / support situations exist with this variant: All outrigger beams fully extended and all support cylinders on the ground (working ranges 1 and Outrigger beams not fully extended and all support cylinders on the ground (working range 3). Vehicle not supported, not all support cylinders on the ground (working range 4).
Page 61: Hpsc Stability Control
Chapter 5 Crane control systems 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! When equipped with HPSC, loading cranes are stable even if the vehicle's stabilizer cylinders and outrigger beams are only partly or not extended / used.
Page 62 Crane control systems 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). If this is impossible for instance because of limited space, and the vehicle is therefore only partly or not supported at all, you may still work with those cranes equipped with the HPSC system.
Page 63 Chapter 5 Crane control systems The loading crane's lifting power on the working side is higher if the opposite side is also supported. If this is not the case the lifting moment will be reduced in all ranges because of the insufficient stability of the vehicle.
Page 64 Crane control systems HPSC in combination with Paltronic 50 Switch-off in limit situations Upon reaching the safety limit allowable in the respective position (due to high load moment), the system switches off all crane movements that impair the vehicle stability. In such a case the capacity indicator starts flashing at 100% and the LED shows the text "Overload within reduced load limit".
Page 65 Chapter 5 Crane control systems 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 66 Crane control systems 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. Combination of LCAs It is possible to combine various load capacity areas.
Page 67: Hpsc-L Stability Control
Chapter 5 Crane control systems HPSC-L stability control Purpose of HPSC-L PALFINGER's High Performance Stability Control Light (HPSC-L) is an electronic system that monitors the stability of vehicles with loading cranes. Benefits for the operator Information! With HPSC-L loading cranes are stable even if the vehicle's stabilizer cylinders and outrigger beams are only partly or not extended / used.
Page 68: High Stand Slewing Limiter Is
Crane control systems High stand slewing limiter IS IS001 Locks the slewing range above the high stand to protect the operator. Range is setup by the installer. IS002 Locks the slewing range above the high stand to protect the operator. Range is setup by the installer.
Page 69: Geometry Monitoring
Chapter 5 Crane control systems 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 70 Crane control systems 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. As the outer boom angle increases (load-independent, 30° to 70°) the overstretching angle of the fly-jib gradually reduces.
Page 71 Chapter 5 Crane control systems 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 72: Steep Position Monitoring
Crane control systems Steep position monitoring Danger! At a boom position higher than 60° abrupt crane movements overstretching of outer boom or fly-jib 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 73: Steep Position Monitoring System Up To 5+ Extension + Fly Jib
Chapter 5 Crane control systems Steep position monitoring system up to 5+ extension + fly jib Refer to operating instructions of the fly jib. OSK overload protection system Hydraulic overload protection device with outer boom blocked on both sides: When the crane reaches the overload range the locking cylinders push all hand levers that increase the load moment back into neutral position.
Page 74: Transport Position Monitoring System
Crane control systems When the main boom is completely extended to the stop and any crane movements that reduce the load moment cannot be executed, take the following steps to unlock the crane functions: Press the lever "Retract extension booms" and ..
Page 75: Emergency Operation After Remote Control Failure
2) Emergency operation of radio-controlled support 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 all support/crane movements or the lifted load from the crane's emergency operator station, there is risk of fatal injury.
Page 76: Failure Of Electric System
9. Screw in the by-pass screw as far as it will go. Retract the stabilizer cylinders and outrigger beams. Contact a PALFINGER partner immediately to get the crane repaired. All other cranes (without ISC) Remove the seal.
Page 77 Press the pin and lock it by turning it. Put down the load without increasing range and load moment (see "Load limits, loads", chapter 8) Move the crane in transport position as described in chapter Contact a PALFINGER partner immediately to get the crane repaired.
Page 79: Ancillary Equipment
Chapter 6 H A P T E R Ancillary equipment In this chapter General ..................75 Slingers, other attachments to lift the load ........77 Ancillary equipment ..............78 Additional crane equipment ............90...
Page 81: General
PALFINGER partners. Any damages or accidents caused by the use of unsuited ancillary equipment and/or load lifting gear are not covered by the PALFINGER warranty. The crane can be operated with a number of different ancillary equipment and load lifting gear.
Page 82 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. Danger! Depending on the type of ancillary equipment, the crane has to be turned off before attaching the device.
Page 83: 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 84: Ancillary Equipment
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 85 Chapter 6 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 86 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!
Page 87 Chapter 6 Ancillary equipment Assembling the pulley head: Put the main boom in horizontal position, outer boom in vertical position (refer 'Moving crane in working position' in chapter 7) Extend the extension booms until approx. 50 cm (2 ft) before the pulley head. Put the connecting block into the extension boom.
Page 88 Ancillary equipment Observe the safe distances given in chapter 2 during all works you carry out on the pulley head. Winch components with composite pulleys Danger! When using composite pulleys exclusively, the inner braid strands may break before the outer braid strands after longer periods of use.
Page 89 Chapter 6 Ancillary equipment Rope deflecting angle Note! In order to keep the rope deflecting angle ( as small as possible, extend at least one extension boom completely before winch operation. Purpose: This will lead to better rope winding behavior. Small entry angle into rope pulleys.
Page 90 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).
Page 91 Chapter 6 Ancillary equipment Winding up the rope: Warning! Injuries can result, if rope is tightened by hand. Never tighten the rope by hand. Use a weight when winding up the rope (1). Prevent rope kinks (2) and slack rope (3). If the lower rope layers are rarely or never used, unwind the rope after every 100 working hours and wind it up again while tightening it.
Page 92 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. Refer to "Paltronic 50" in chapter 5. Ending rope winch operation (load-arm still in working position) Warning! The crane must be switched off between the individual disassembly steps.
Page 93 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 94 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 linch pins. Danger! People standing in front of the crane boom while the manual extension booms are extended are in acute danger to life.
Page 95 Chapter 6 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 96: Additional Crane Equipment
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 97 Chapter 6 Ancillary equipment Use the equipment provided (ladder, telescopic rail, handles) when entering or leaving the high stand / top seat. Note! Keep the required minimum distances to all crushing points (refer to chapter 2 'Safety and Health Standards', 'Danger of getting crushed').
Page 98 Ancillary equipment High stand components 1. High stand operator console Can swivel to the side 2. Remote holder Holder for remote control, can swivel to the side...
Page 99 Chapter 6 Ancillary equipment 3. Guard rails Installing the guard rails: Pull them out until they lock. Danger! If the guard rails are not completely pulled and locked they may fall back down. There is then risk of falling and hence risk of fatality for the operator and others.
Page 100 Check whether the green control lamp is on. If not, exit the high stand immediately! Contact your PALFINGER partner! Danger! If you continue to operate the crane from the high stand although the red control lamp is on, this presents risk of crushing and even fatal injury for the operator and others.
Page 101 Chapter 6 Ancillary equipment 9. Clamping screw for tilting the remote holder Tilting the remote holder: Loosen the clamping screw (a) slightly. Lift the remote holder (b) above the safety pin. Turn the remote holder to the desired position and snap it in the safety pin. Fix the remote holder using the clamping screw (a).
Page 103: Preparing For Crane Operation
Chapter 7 H A P T E R Preparing for crane operation In this chapter Use for intended purpose / limits of the device ......99 Watch out for faults before and during operation .......100 Working range ................101 Starting the crane ..............102 Supporting the vehicle ...............102 Stabilizer outriggers..............107 Stabilizer cylinder ..............108...
Page 105: Use For Intended Purpose / Limits Of The Device
To attach loads to other positions on the crane than the intended ones; Any excavating work with the grab (refer to 'Grab', chapter 6 'Ancillary equipment'). To transport persons. Exception: Transporting persons in the PALFINGER workman basket, only on specially equipped cranes. National laws, regulations and standards must be complied with. Note! Matching workman baskets are available from all PALFINGER partners.
Page 106: Watch Out For Faults Before And During Operation
If the following damage or faults are found on the unit, auxiliary equipment, load-bearing equipment or vehicle, do not start operation or stop operation immediately and contact your PALFINGER partner: Lack of lubrication. Damage to or cracks in components/weld seams.
Page 107: Working Range
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. The operator must have full view of the crane movements and the loading/unloading point.
Page 108: Starting The Crane
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 109 Chapter 7 Preparing for crane operation If the vehicle is equipped with additional supports, they must be extended as described below. The vehicle is only stable with the supports fully extended (crane support and additional support if present). All safety notes of chapter 2 shall be observed. Ground condition Check the floor for the following: Stability.
Page 110 Load capacity of the soil [N/cm² or psi] The supporting force values are specified in chapter 13, ‘Technical Sheets’. 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 111 Chapter 7 Preparing for crane operation Supports, general The outrigger beams and stabilizer cylinders need to be operated separately on both sides. Change the operating station. Fully extend the outrigger beams (mark must be visible). If your crane is equipped with a stability control system refer to chapter 5, 'Safety equipment'. Move tiltable stabilizer cylinders into their position only after extending the outrigger beam.
Page 112 Preparing for crane operation Do not lift the vehicle, this overloads the support and reduces the braking effect. If your crane is equipped with stability control or remote control, set the key switch to support operation (exception with remote controlled stabilizer outrigger beams).
Page 113: Stabilizer Outriggers
Chapter 7 Preparing for crane operation Stabilizer outriggers Manually extendible Open the secondary lock. Turn the primary lock handle to the stop. Pull the outrigger beam completely out by the handgrip until the safety catch engages. Danger! An unlocked outrigger beam creates a high risk of accident and danger to life.
Page 114: Stabilizer Cylinder
Preparing for crane operation Stabilizer cylinder Rigid Extend the stabilizer cylinder until it has firm ground contact. Manually tiltable Moving the tiltable stabilizer cylinders in supporting position: Firmly hold the stabilizer cylinder. Open latch lever. Slew stabilizer cylinder carefully into support position.
Page 115 Chapter 7 Preparing for crane operation Hydraulically tiltable 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. Close latch lever and make sure it is in the locked position.
Page 116: 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 117: Unfolding The Crane
Chapter 7 Preparing for crane operation Unfolding the crane If your crane is equipped with a key switch, it must be set to either manual operation or remote control. 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.
Page 118 Preparing for crane operation Only extend the extension booms when the main boom has been raised to a near-vertical position. Refer to "Unfolding the crane". Remote control Danger! When the operator is in the folding/unfolding area of the crane there is an acute risk of fatal injury.
Page 119 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. Move the main boom to a near-vertical position.
Page 120: Daily Function Check Of Control Systems
Operating a crane with defective overload protection system is grossly negligent. Do not operate the crane and contact a PALFINGER service partner. For checking the Paltronic 50 function it is necessary to simulate an overload situation (see also OLP function).
Page 121 To check the seat occupancy monitoring system lift off the seat a little until it is free and carefully actuate a crane lever. The crane must not move. If crane movements are enabled: Do not operate the crane and contact a PALFINGER service partner.
Page 123: Crane Operation
Chapter 8 H A P T E R Crane operation In this chapter Load limits .................119 Working position of the crane ............120 Loads ..................122 Working with loads ..............123...
Page 125: 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 126: 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 127 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 128: Loads
Crane operation Boom position higher than 80°: Danger! 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 129: Working With Loads
Chapter 8 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. Every time before moving the crane, make sure that there are no persons in the working range of the crane.
Page 130 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, 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 131 Chapter 8 Crane operation Danger! If controls are unintentionally operated with the load and/or crane components, there is an acute risk of fatal injury to the operator and others. During all crane operations, maintain an adequate distance between the load, crane components and controls.
Page 132 Crane operation Danger! 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 133 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 134 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 135: Ending Operation
Chapter 9 H A P T E R Ending operation In this chapter Folding the crane into transport position ........131 Retracting the stabilizers ............135 Before driving ................140...
Page 137: 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 138 Ending operation Remote control Danger! When the operator is in the folding/unfolding area of the crane there is an acute risk of fatal injury. Choose a position outside the danger zone of the crane. Note! Starting position to fold the crane: Main boom in near-vertical position, extension booms fully retracted.
Page 139 Chapter 9 Ending operation Folding the crane Extend the extension booms about 50 cm (20"). Fold in 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 140 Ending operation Resting the boom on the vehicle platform or boom support Danger! If the boom system is not secured against any side movements this creates an acute danger to life of all road users. Not knowing the vehicle's total height and not observing the clearance heights creates an acute risk of fatal injury.
Page 141: Retracting The Stabilizers
Chapter 9 Ending operation Retracting the stabilizers Danger! If the load arm is not in transport position while retracting the supports the vehicle may tip over. This creates an acute risk of fatal injury. Retract the supports only when the boom system is in transport position. If the vehicle is equipped with additional supports, they also must be retracted.
Page 142 Ending operation Neither the operator nor bystanders are allowed to step in the slew range of the stabilizer cylinder. Push in all manual outrigger beams completely, lock and secure them. Retract the hydraulic outrigger beams completely. If your crane is equipped with stability control or remote control, set the key switch to support operation (exception with remote controlled stabilizer outrigger beams).
Page 143 Chapter 9 Ending operation Stabilizer cylinder Rigid Retract the stabilizer cylinders completely. Manually tiltable 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. When the stabilizer cylinder is in transport position: Close latch lever and make sure it is in the locked position.
Page 144 Ending operation Hydraulically tiltable Retract the stabilizer cylinders until the outrigger beams are unloaded. Open latch lever of stabilizer cylinder. 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.
Page 145 Chapter 9 Ending operation Danger! An unlocked outrigger beam creates a high risk of accident and danger to life. 4 Check whether the beam locks have engaged properly by attempting to move the outrigger beams in and out. Retracting hydraulically Retract the outrigger beams completely.
Page 146: Before Driving
Ending operation Before driving Danger! Incompletely retracted stabilizer cylinders create an acute 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 147 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 149: Maintenance
Chapter 10 H A P T E R Maintenance In this chapter General ..................145 Operating hours counter ............146 Maintenance................147 Cleaning ..................148 Visual inspection ...............149 Machine lubrication..............152 Hydraulic oil change, filter change ..........157 Paint repair ................160...
Page 151: 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 152: Operating Hours Counter
Maintenance Operating hours counter The operating hours counter has three display modes with one mode selection button. Total operating hours. Operating hours until next service. Serial number of unit. "Mode" selection button. When turning the crane on the counter starts. The last used mode is displayed. Pressing the MODE button changes between "Total operating hours"...
Page 153: Maintenance
The counter counts up from 0 with a minus (-) sign, showing the exceeded service time. After servicing the PALFINGER service center resets the service interval to 1000 hours. Maintenance Maintenance and servicing recommendations in these operating instructions are of general nature and apply to several PALFINGER products.
Page 154: 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. Clean the device only in suitable places (oil separator). Do not use abrasive rags, brushes, etc.
Page 155: Visual Inspection
Check completeness and function of bolts, screws, pins and locking devices; check pins for any deformation and sufficient security (e. g. linch pins). Tighten any loose bolts/nuts to appropriate torque specification. Contact a PALFINGER partner for additional information as needed.
Page 156 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 157 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 control equipment Refer to 'Daily function check of the control systems' chapter 7.
Page 158: Machine Lubrication
Maintenance Machine lubrication Lubricant specification Note! PALFINGER recommends using biodegradable grease. Do not mix incompatible lubricants. Even biodegradable grease must not be released into the environment. Lubricants must be free of solids. Do not use graphite lubricant. Warning! Use of incorrect lubricants, failure to follow maintenance intervals or lack of lubrication may cause damage to the unit and increase repair cost and downtime.
Page 159 Chapter 10 Maintenance Note! The extension booms are maintenance free. If unexpected problems occur during operation such as chatter or creaking, use only PALFINGER Teflon® spray on the slide surfaces. Rope grease: Available from most PALFINGER partners according to national guidelines under Order no.
Page 160 Maintenance...
Page 161 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 162 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 163: Hydraulic Oil Change, Filter Change
Chapter 10 Maintenance Rope grease Warning! Sticking out strands can cause severe hand injuries when you lubricate the rope. Therefore always wear appropriate gloves when lubricating the rope. Wind off the rope while tightening it. Apply rope grease over the entire rope length using a cloth or brush. Rewind the rope under tension.
Page 164 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 165 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 166: Paint Repair
Maintenance Mixing capability Note! Hydraulic oils are intermixable. Hydraulic oils must not be mixed with other fluids. Reasons for not mixing different oils: Reduces service life. Mixtures of synthetic esters and mineral oils are no longer biodegradable. etc. Paint repair Note! Repair paint damage immediately.
Page 167: Service
Chapter 11 H A P T E R Service In this chapter General ..................163 Threaded fasteners ..............164 Initial servicing after 50 operating hours ........166 After every 1000 operating hours or once every year ....167 Every 6 years ................167 Hook and shackle..............168 Check of control equipment ............169 Protective hoses................169 Repairs..................169...
Page 169: 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 170: Threaded Fasteners
Service Threaded fasteners Danger! Loose, damaged or excessively tightened screws are susceptible to break under load. There is risk of fatal injury. Note! Tighten the screws only using the torque wrench and applying the prescribed torque. ISO bolt torques in Nm (ft.lbs): Tolerance range +/- 10% Bolts: DIN EN ISO 4762, 4014 Nuts:...
Page 171 Chapter 11 Service Tightening torques for Bride screws in Nm (ft.lbs): Tolerance range +/- Bolt thread: Stability: 8.8 M 16 x 1.5 120 (89) Bolt thread: Material: C40 M 20 x 1.5 140 (103) Bolt thread: Material: 42 Cr Mo 4v M 20 x 1.5 210 (155) M 24 x 1.5...
Page 172: Initial Servicing After 50 Operating Hours
Service Service symbols Functional check Change Visual inspection Check bolts for tightness Teflon® spray Grease Rope grease Initial servicing after 50 operating hours Description Activity Oil filter package Slewing cylinder Slewing gear Hydraulic fluid level (unsupported and in transport position) Tighten hydraulic lines / hoses, screw joints Crane base fixing...
Page 173: After Every 1000 Operating Hours Or Once Every Year
Chapter 11 Service After every 1000 operating hours or once every year Description Activity Oil filter package - hydraulic oil Slewing cylinder Slewing gear - oil Crane base fixing Hydraulic lines / hoses, screw joints Rope winch limit switch Rope winch transmission oil Remote control All control equipment Central lubrication...
Page 174: Hook And Shackle
Service 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 175: Check Of Control Equipment
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 177: Decommissioning And Disposal
Chapter 12 H A P T E R Decommissioning and disposal In this chapter Decommissioning and disposal guidelines ........173...
Page 179: 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 181: Index
Index Index Folding the crane into transport position - Additional crane equipment - 90 Foreseeable misuse of the device - 10 Adverse working conditions - 11 Function - 55, 61 After every 1000 operating hours or once Function labels - 27 every year - 167 Functional check of seat occupancy After maintenance, service and repairs -...
Page 182 Index Main components - 25, 26 Starting the crane - 102 Maintenance - 143, 147 Steep position monitoring - 66, 122 Mechanical extension booms - 87 Steep position monitoring system up to Modifications to unit - 22 5+ extension + fly jib - 67 Structure of system - 21 Supporting the vehicle - 102 Noise emission - 14...
Page 183: Technical Description
Chapter 13 H A P T E R Technical description...

Palfinger PK9001-EH Operator's Manual

Quick Links

Need help?

Questions and answers

Subscribe to Our Youtube Channel

Related Manuals for Palfinger PK9001-EH

Summary of Contents for Palfinger PK9001-EH

Table of Contents