Palfinger PSM Series Operator's Manual
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Palfinger PSM Series Operator's Manual

Palfinger PSM Series Operator's Manual

Hydraulic crane
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Operators Manual
PSM
Hydraulic Crane
Translation of the original Operator Manual
Equipment number :
CPDB0009
Version : 2011/10
PALFINGER AG
Franz-Wolfram-Scherer-Straße 24
5020 Salzburg / Austria
www.palfinger.com

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  • Page 1 Operators Manual Hydraulic Crane Translation of the original Operator Manual Equipment number : CPDB0009 Version : 2011/10 PALFINGER AG Franz-Wolfram-Scherer-Straße 24 5020 Salzburg / Austria www.palfinger.com...
  • Page 2 DANGER – ATTENTION: Indicates situations of severe danger which may cause great risks for health and safety of the operating personnel if handled without care. ATTENTION – TIP: Indicates that a proper conduct is required so that health and safety of the operating personnel are not put at risk and no economic damages are caused.
  • Page 3 Dear Customer Many thanks for choosing to a PALFINGER MARINE product. We have done everything to ensure optimal and safe operation in the design and production of your crane. To ensure that your crane works reliably and economically for many years, please observe the following: Observe the safety instruction (possible dangers).
  • Page 5 Safety instructions It is also in your own interest to observe these instructions very carefully. Before operation of the crane This chapter provides you with important safety instructions which must be followed each time before starting operation. Start operation of the crane This chapter gives you all the necessary information to properly start operation of your crane.

  • Page 7: Table Of Contents

    Safety instructions Chapter 1 Safety instructions CONTENTS N OVERVIEW OF THE DANGERS 1.1-1 ULES FOR THE AVOIDANCE OF DANGERS REREQUISITES 1.2-1 CE-S YMBOL 1.2-2 SSEMBLY ACCEPTANCE AND REGULAR INSPECTION OF THE CRANE UNIT 1.2-3 EQUIREMENTS FOR THE OPERATING PERSONNEL 1.2-4 AFETY DEVICES NOT TO BE TAMPERED WITH 1.2-5 RANE OPERATION IN ADVERSE OPERATING CONDITIONS...

  • Page 9: An Overview Of The Dangers

    Select the right control stand. Pick up and secure loads in the due and proper manner. Use of load lifting gear and ancillary equipment supplied by PALFINGER MARINE Secure attachment of ancillary equipment. Adherence to the max. lifting capacity of the crane, ancillary equipment and load lifting gear.

  • Page 10: Prerequisites

    The firm operating the crane is responsible for ensuring that the regular inspections required by law are carried out. Any use other than the one intended by the company PALFINGER MARINE as well as constructional changes that affect the stability of load-bearing components need to be approved by the manufacturer.

  • Page 11: Requirements For The Operating Personnel

    Prerequisites 1.2-3 1.2-3 Requirements for the operating personnel Operation of the crane requires skill, ability and experience. Therefore only entrust persons with the operation of the crane: who are physically and mentally suitable for this (not tired, and not under the influence of alcohol, drugs or medication).

  • Page 12: During Crane Operation

    1.3-1 During crane operation During crane operation 1.3-1 Avoid danger of crushing Avoid operating situations in which there is a risk of you or bystanders being crushed by the crane, or load. The crush point is not regarded as a danger point for the body parts stated if the safety distances highlighted below are complied with and it is ensured that the next-biggest body part cannot penetrate.

  • Page 13: Action In The Event Of Flashover

    During crane operation 1.3-4 For overhead power lines and contact lines of electric railways the following minimum distances apply: up to ..à 1.500 V ..1,0 m over ..à 1.500 V ..1,5 m up to ..à 1.000 V ..1,0 m over ..

  • Page 14: Action In The Event Of Defects

    1.3-5 During crane operation 1.3-5 Action in the event of defects Observe the crane during operation for any sudden signs of any defects. If you discover the following damage or defects to the crane, ancillary equipment, load lifting gear or fixing from the crane you must stop crane operation immediately: Damages or cracks on load-bearing parts.
  • Page 15 Before operation of the crane Chapter 2 Before operation of the crane Contents HECKS 2.1-1 AILY VISUAL INSPECTION...
  • Page 17 Checks 2.1-1 Checks 2.1-1 Daily visual inspection Check the crane and its mounting once daily for visible defects, damages or alterations. The “man-riding” basket has to be maintained and protected against corrosion on a regular basis. This action is absolutely necessary as corrosion may lead to a wall thickness reduction (3 mm). Carry out this inspection very carefully every time: alterations or damages not detected because of carelessness or old habits are a major source of accidents.
  • Page 19 Start operation of the crane Chapter 3 Start operation of the crane ONTENTS N OVERVIEW OF THE CRANE 3.1-1 (PSM ESIGN 3.1-2 PERATING ELEMENTS REPARING FOR CRANE OPERATION 3.2-1 OLD START IN LOW OUTSIDE TEMPERATURES 3.2-2 UTTING CRANE INTO OPERATING POSITION...
  • Page 21 An overview of the crane 3.1-1 An overview of the crane 3.1-1 Design (PSM xxx)
  • Page 22 3.1-2 An overview of the crane Sockel Cab (rotating) Turntable Oil cooler Crane column Oil heating Slewing gear Filler filter, ventilation filter Lifting cylinder Engine Main boom Pump Winch with cut-off Slip ring body Rope Bore hole for oil drain (2x) Pulley head Glass gauges (min., Max.) Load attachment...
  • Page 23 Preparing for crane operation 3.2-1 Preparing for crane operation 3.2-1 Cold start in low outside temperatures In outside temperatures below freezing: Check the oil level. Switch on the pump assembly at lowest engine speed. Let the oil pump around without pressure for a few minutes so that it warms up a little.
  • Page 24 3.2-2 Preparing for crane operation Extending the crane: PSM xxx: Observe every safety instruction mentioned in chapter 1. Move the main boom in a near-vertical position using the function “Lift main boom”. Anyway, avoid moving the main boom up to the top end. The crane is now ready for operation.
  • Page 25 Crane operation Chapter 4 Crane operation ONTENTS URING CRANE OPERATION 4.1-1 EEP THE WORKING RANGE IN VIEW 4.1-2 OADING ACTIVITY 4.1-3 BSERVE LOAD LIMITS AFETY DEVICES 4.2-1 MERGENCY OFF BUTTON HPLS – S 4.2-2 YSTEM 4.2-3 VERLOAD PROTECTION SYSTEM 4.2-4 ANUAL PUMP EMERGENCY OPERATION OPTION DDITIONAL EQUIPMENT...
  • Page 27 During crane operation 4.1-1 During crane operation 4.1-1 Keep the working range in view Always keep a close eye on the suspended load, especially during slewing motions. Ensure there is sufficient light on the working site. The crane must be operated by no more than one operator at a time. During loading activities, the crane operator must always have the hand levers at his fingertips.

  • Page 28: During Crane Operation

    4.1-2 During crane operation 4.1-2 Loading activity Only use the crane for lifting loads and never for freeing, hitting, pulling (dragging) loads, pressing or driving against solid obstacles or for towing. Any angled hoisting is prohibited. The transportation of persons is only permissible in workman baskets specially constructed for the purpose.
  • Page 29 During crane operation 4.1-2 Loads must only be attached and removed when the crane is completely at a standstill. Before moving the load arm ensures that the person who has attached or removed the load is no longer in the danger area of the crane.

  • Page 30: Observe Load Limits

    4.1-3 During crane operation At load (100%): At load (80%): max. 5° Heel max. 15° Heel max. 2° Trim max. 2° Trim A = Inclination B = Lifting moment C = Slew load D = Hold load When working with a load, do not lower the main boom to full retraction since the overload protection system does not function in that boom configuration.
  • Page 31 During crane operation 4.1-3 Lowering a heavy load from an extended boom configuration must be performed without increasing the outreach, otherwise the admissible load limit may be exceeded. For cranes with no overload protection or fitted with an overload indicator only, this causes the booms to lower uncontrollably.

  • Page 32: Safety Devices

    4.2-1 Safety devices Safety devices Using safety devices can avoid accidents. They are for your protection therefore you should make sure which of the below safety devices are available on your crane. 4.2-1 Emergency off button The emergency CUT-OFF button is a safety device which, when pressed, brings the crane to an immediate stop.

  • Page 33: Hpls - System

    Safety devices 4.2-2 Test the function of the CUT-OFF button every time before working: Actuate a crane function and simultaneously press the CUT-OFF button: the crane should im- mediately come to stop. Crane movements should no longer be possible. If the crane motions do not stop IMMEDIATELY, then cease operation of the crane! HPLS –...
  • Page 34 4.2-3 Safety devices Pressure peak button: Lifting the lift cylinders up to the stop activates the overload protection. Reason for this is a pressure peak in the lifting cylinder which develops when running to the stop end (with our without load). It is impossible to release this pressure peak as the function „Lower main boom“...

  • Page 35: Manual Pump Emergency Operation (Option)

    After this see a PALFINGER MARINE authorized repair centre immediately. The device (by-pass screw) that allows you to bring your crane in emergency operation is always on the emergency off magnet valve.

  • Page 36: Additional Equipment

    For some accessories, a special suspension from PALFINGER MARINE must be employed and mounted according to the following sketch. Otherwise, damages to the attachment are possible and such a case is not covered by the warranty.

  • Page 37: Rope Winch

    4.3-2 Rope winch For rope winch operation only use PALFINGER MARINE rope winches, pulleys, pulley heads, etc. Mount the winch components (intermediate pulleys, pulley heads) as shown in the technical sheet. Use the correct bolts and bolt locks for each of the pulleys.
  • Page 38 4.3-2 Additional equipment If during working with the rope winch the rope is wound off to less than three full turns the rope may be pulled out of its fastening in the rope drum. This will cause the load to drop, which means an acute accident danger for you and other persons.

  • Page 39: Standing Platform, Top Seat, Cabin, Protection Cover

    Additional equipment 4.3-3 4.3-3 Standing platform, Top seat, Cabin, Protection cover Use the railings, ladder or handles to climb onto the standing platform or the top seat. Be extremely careful not to touch any operating elements. Handles, step treads and standing spaces must at all times be clear from dirt, oil or ice. Clean if necessary.
  • Page 40 4.3-3 Additional equipment Description of the operating elements 1. Manometer 2. Emergency-off button 3. Switch for remote control radio operation – manual operation 4. Pressure peak button 5. Capacity shield (Crane) 6. Operation symbol 7. Capacity shield (Rope winch) 8. Lever...

  • Page 41: Remote Control

    Additional equipment 4.3-4 4.3-4 Remote control In order to be able to make smooth precise crane movements during remote-controlled operation the carry belt for the transmitter panel must be used. The remote control unit is ready for operation as soon as the start button is pressed. All operating levers must be in neutral position.

  • Page 42: Mergency Operation Following Failure Of The Remote Control Console

    Remove the operating lever (1) and screw it onto the control valve on the crane function “Slew”. Pay attention to the arrangement of the crane functions on the emergency control unit! Then put the crane into transport position and contact a PALFINGER MARINE authorized service centre to repair the operational disruption.
  • Page 43 After crane operation Chapter 5 After crane operation ONTENTS NDING CRANE OPERATION 5.1-1 UTTING CRANE IN TRANSPORT POSITION FTER CRANE OPERATION 5.2-1 ECURING AND TRANSPORTING THE LOAD...
  • Page 45 Ending crane operation 5.1-1 Ending crane operation 5.1-1 Putting crane in transport position In your activity observe all the safety instructions in Chapter 1. Cranes with remote control operation: On cranes with radio remote control make sure that you are not in the area of the slewing or descending boom.
  • Page 46 5.2-1 After crane operation After crane operation 5.2-1 Securing and transporting the load Secure the load in accordance with the regulations before starting the trip. Before starting the trip check that the hydraulic pump is switched off. It is necessary to operate the main switch for remote control radio to interrupt power supply (24 V) to the remote control.
  • Page 47 Maintenance and service Chapter 6 Maintenance and service ONTENTS AINTENANCE 6.1-1 ARRANTY PROVISIONS 6.1-2 CHEDULE OF AINTENANCE 6.1-3 (PSM LANE OF MAINTENANCE 6.1-4 LANE OF MAINTENANCE 6.1-5 UBRICATION 6.1-6 YDRAULIC OILS 6.1-7 IL CHANGE OIL MAINTENANCE LEANING THE PLANT 6.2-1 LEANING AGENTS AND EQUIPMENT 6.2-2 EPAIRING PAINT DAMAGE...
  • Page 49 Maintenance 6.1-1 Maintenance 6.1-1 Warranty provisions Regrettably, during servicing, we have noticed repeatedly that our recommendations for maintenance and lubrication of the crane have been ignored. We are not liable for any costs for damage resulting from insufficient maintenance and lubrication. It is in your own interest to carry out the maintenance and lubrication of your work platform regularly and in accordance with the instructions.

  • Page 50: Maintenance

    6.1-2 Maintenance every 50 hours / smallest once a month Turntable (slew 360°) Continuous rotation Thrust bearing Gear oil (inspection glass, fuel lever plunger) Main boom cylinder pivot Main boom pivot Rope winch Rope Pulley head Load hook, function control of safety flap Thrust turntable Fixation of crane base Cab rotating...

  • Page 51: Plane Of Maintenance

    Maintenance 6.1-3 6.1-3 Plane of maintenance (PSM xxx)

  • Page 52: Plane Of Maintenance (Ps Xxx M)

    6.1-4 Maintenance 6.1-4 Plane of maintenance (PS xxx M)

  • Page 53: Lubrication

    6.1-5 6.1-5 Lubrication The following maintenance and care instructions apply to all PALFINGER MARINE cranes. Therefore this chapter includes also hints which do not refer to your crane. Deficient or incorrect lubrication causes increased wear out and consequently unnecessary repairs (downtimes) of the crane.
  • Page 54 6.1-6 Maintenance How to grease the bearings on the crane correctly: Before greasing clean the spot thoroughly, yet dirt that gets into the bearing hole together with the grease causes quick wear-out of the bearing. Then press fresh grease into the bearing on the intended grease spots (oil holes etc.) until it comes out off the bearing.
  • Page 55 Maintenance 6.1-6 As the viscosity of hydraulic oils is strongly influenced by temperature changes, compromises during their selection cannot be avoided. The following limiting values are valid for your PALFINGER MARINE work platform: ISO Reference Temperature °C temperature High temperature range: ................10 cSt Cold start limit: ......

  • Page 56: Hydraulic Oils

    6.1-6 Maintenance Biodegradable oils are better for the environment than conventional hydraulic oils. Anyway, even these oils must not be disposed into nature. Releasing oils (including biodegradable oils) into the natural environment is not permitted! The hydraulic oils listed in our recommendation may be mixed with one another, but only mineral oils with mineral oils and bio-oils with bio-oils.

  • Page 57: Oil Change / Oil Maintenance

    Maintenance 6.1-7 6.1-7 Oil change / oil maintenance The annual maintenance of oil can significantly increase its working life. Apart from the saving in costs, this means a drastically reduced amount of waste oil and less contamination of the environment. All rams must be fully retracted when changing the oil or topping up the hydraulic oil.
  • Page 58 6.1-7 Maintenance The following nomogram gives the service life of the fully synthetic ester oils: Max. oil Service life in temperature years Working hours per year The hydraulic oil service should be performed before each cold weather period, or at least once a year.
  • Page 59 Maintenance 6.1-7 Tank volume (PSM xxx): PSM 190 140 litres PSM 330 280 litres PSM 580 420 litres PSM 850 600 litres PSM 1130 800 litres PSM 1700 1000 litres Power supply (PSM xxx): The oil supply for the hydraulic system is completely integrated in the crane column. The pump enclosure is located in the lower part of the crane column and is totally separated from the tank.
  • Page 60 6.1-7 Maintenance Water trap (PSM xxx): Major fluctuations of oil temperature -25 deg to +60 deg may occur during operation of the crane, all depending on location and weather conditions. Condensation in the oil tank is therefore unavoidable. In order to protect against damages due to frost, a drain fitted beside the control stand which allows to be drained accumulated condensation water.
  • Page 61 Cleaning the plant 6.2-1 Cleaning the plant 6.2-1 Cleaning agents and equipment Regular expert care will serve to preserve the value of your crane. How often the crane needs to be washed depends on how frequently it is used, the season, weather influences and so on. Road salt, oils, dust, etc.

  • Page 62: Cleaning The Plant

    6.2-2 Cleaning the plant 6.2-2 Repairing paint damage If you discover paint damage on your crane, you must take care of it immediately. Damaged places must be sanded off and coated with a primer before painting. Repair damaged paint to avoid corrosion! Degrease damaged paint.
  • Page 63 Appendix Chapter 7 Appendix ONTENTS – C RANE ODELS 7.1-1 ENERAL NFORMATION 7.1-2 ECHNICAL NFORMATION 7.1-3 NFORMATION ON AFETY 7.1-4 NFORMATION ON AFETY PECIFIC TO THE RANE...
  • Page 65 EEx – Crane Models 7.1-1 EEx – Crane Models 7.1-1 General Information Objective of the Manual This manual has been prepared by the machine manufacturer with the aim of providing information about safe operation of the equipment to the people who are authorized to carry out work procedures for transport, handling, installation, servicing, repair, disassembly and disposal of the crane.
  • Page 66 EEx – Crane Models 7.1-1 Labelling of the Product Additional Plate for Cranes and Accessories with ATEX Option (Example) Legibility of the Type Plate All of the information shown on the type plate must be clearly legible at all times, so the plate should be cleaned regularly.
  • Page 67 EEx – Crane Models 7.1-1 Overhaul An overhaul comprises replacement of bearings and/or other mechanical components which display so much wear and tear that the operation of the crane is adversely affected. In addition, an overhaul includes a check of all of the crane components (gaskets, washers, deaeration valves, etc.). These materials must be disposed of in conformity with applicable environmental protection laws.
  • Page 68 Safety Data for Cranes Conforming to Directive 94/9/CE As a precaution, make selection with service factor Use only synthetic lubricants (oil and grease). Use washers made of VITON, for example, original PALFINGER MARINE spare parts. Mount deaeration screws with spring return valve (e.g., for gear box).
  • Page 69 EEx – Crane Models 7.1-3 Ambient Conditions The use of the crane in potentially explosive atmospheres or in areas where the use of components protected from explosion is mandatory is prohibited, unless expressly stated otherwise. The data shown on the type plate regarding the maximum surface temperature refers to measurements taken under normal ambient conditions and at a standard installation.
  • Page 70 EEx – Crane Models 7.1-4 Maintenance, service and repair work may be carried out solely by experienced service personnel who are aware of any hazards which may exist. Precautionary measures which will intervene in the event of a dangerous situation and eliminate the risk must be taken for the equipment as a whole.
  • Page 71 EEx – Crane Models 7.1-4 Sliding Points Gliding points must be thoroughly lubricated at specific intervals to avoid electrostatic build-up. This is especially the case for bearing points of plastic bearings (e.g., sleeve pack on the boom extension). Before Starting Up the Crane Every time the crane is started up, a thorough visual inspection must first be conducted to ensure safe operation (e.g., damage to paint, damage to coated load attachments, hooks, etc.).
  • Page 72 EEx – Crane Models 7.1-4 Hydraulic Components Care must be taken that hydraulic components such as pumps do not run hot during operation as defined by the temperature classes (T1 ... T6), or that these parts (including control valves, valves) remain about 20°...
  • Page 73 7.1-4 Crane Settings None of the crane settings may be modified. With the company PALFINGER MARINE the changes must be co-ordinated. Danger from sparking! Speeds which are set too high (e.g., for the winch) are likely to cause a collision! General Normally the cranes are classified as EEx II 3G T3 (T4).

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