Page 3 Dear customer. Many thanks for choosing a PALFINGER product. We have done everything to ensure optimal and safe opera- tion in the design and production of your crane. To ensure that your crane works reliably and economi- cally for many years, please observe the following: •...
Page 4 Inhalt...
Page 5 Contents Inhalt Safety Instructions It is also in your own interest to observe these instructions very carefully. Before Crane Operation This chapter provides you with important safety instructions which must be followed each time before starting an operation. Running a Crane / Starting Crane Operation This chapter gives you all the necessary information to properly start operation of your crane.
Page 6 Inhalt...
Page 7: Table Of Contents
Safety Instructions Chapter 1 ONTENTS 1.1. VERVIEW OF DANGERS 1.1-1 ULES FOR THE AVOIDANCE OF DANGERS 1.2. REREQUISITES 1.2-1 SYMBOL 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 1.2-6...
Page 8: Overview Of Dangers
Overview of dangers 1.1-1...
Page 9: Rules For The Avoidance Of Dangers
Select the adequate control stand. Pick up and secure loads in the due and proper manner. Use of load lifting gear and ancillary equipment supplied by PALFINGER. Secure attachment of ancillary equipment. Adherence to the max. lifting capacity of the crane, ancillary equipment and load lifting gear.
Page 10: Prerequisites
1.2-2 Assembly, acceptance and regular inspection of the crane unit The crane must be assembled according to the valid assembly rules of PALFINGER. The valid Installation Instructions may be obtained from the responsible general representative. After successful crane mounting the vehicle still has to be stable throughout the entire working area of the crane.
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 (not tired, and not under the influence of alcohol, drugs or medication).
Page 12: Intended Use
Lifting persons is only allowed in specifically produced workman baskets. In addition, national regulations and laws regarding the transport of persons have to be observed. In order to ensure optimum operation you should operate the crane using a PALFINGER workman basket. 1.3.
Page 13: Keep Distance From Power Lines
During crane operation 1.3-4 1.3-4 Keep distance from power lines Keep the required minimum distances away from power lines. If this is not possible because of the particular work being carried out the lines must be disconnected (switched off). Neither the appearance nor the height of electric power lines indicates their voltage. In case of lines where the voltage is not known a distance of at least 5 metres between the crane and the line must be maintained.
Page 14: Action In The Event Of Flashover
During crane operation 1.3-5 1.3-5 Action in the event of flashover If the crane touches a power line only your correct reaction can prevent a serious accident. If you touch the crane, vehicle or load or if you try to leave your location you will put youself in acute danger of fatal injury.
Page 15: Action In The Event Of Defects
During crane operation 1.3-6 1.3-6 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 the carrier vehicle you must stop crane operation immediately: •...
Page 16 During crane operation 1.3-6...
Page 17 Before crane operation Chapter 2 CONTENTS 2.1. HECKS 2.1-1 AILY VISUAL INSPECTION AND FUNCTIONAL CHECK...
Page 18 2.1-1 Checks...
Page 19 Checks 2.1-1 2.1. Checks 2.1-1 Daily visual inspection and functional check Check the crane and its assembly daily for externally visible defects, damage and changes. Conduct this inspection carefully each time; routine and habit represent a major source of danger because changes are difficult to recognise.
Page 20 2.1-1 Checks...
Page 21 Starting up the crane Chapter 3 CONTENTS 3.1. N OVERVIEW OF THE CRANE 3.1-1 3.1-2 ONTROLS 3.2. REPARING FOR CRANE OPERATION 3.2-1 OLD START IN LOW OUTSIDE TEMPERATURES 3.2-2 UPPORTING VEHICLE PROPERLY 3.2-3 YDRAULICALLY EXTENDABLE OUTRIGGERS 3.2-4 XTENDING THE STABILIZER CYLINDERS 3.2-5 ANUAL SLEW SUPPORT 3.2-6...
Page 22: An Overview Of The Crane
3.1-1 An overview of the crane...
Page 23: Set-Up
An overview of the crane 3.1-1 3.1. An overview of the crane 3.1-1 Set-up The crane displayed below is an example and shows crane components that can optionally be on your crane depending on model and crane type. Control unit (crane support) Main boom 2A Operating stand - control valve side (Side Outer boom cylinder...
Page 24: Controls
3.1-2 An overview of the crane 3.1-2 Controls The symbols for the control unit are explained below. The sequence of crane functions (symbols) on the emergency control stand or the remote control console may differ from the example shown below. Please therefore always note the symbol arrangement (crane functions) on the control stand of your crane or the arrangement of the symbols on the remote control console.
Page 25 An overview of the crane 3.1-2 Crane function: Stabilizer cylinder Crane function: Stabilizer cylinder retracting retracting extending extending Crane function: Ancillary fly-jib arm Crane function: Ancillary fly-jib extension boom raising extending lowering retracting Crane function: Ancillary rope winch down Switch mechanically between support operation and crane operation: Control stand Control stand (Side B)
Page 26 3.1-2 An overview of the crane Use pushbutton to switch between support operation and crane operation: Crane operation Support operation (lamp in pushbutton not on) (lamp in pushbutton on) Choose the preferred position with the key switch (support/crane operation) Support operation: Crane automatic mode: Crane manual mode: Display field with key switch for cranes with Paltronic 50 (Paltronic display on remote control panel)
Page 27: Preparing For Crane Operation
Preparing for crane operation 3.2-1 3.2. Preparing for crane operation 3.2-1 Cold start in low outside temperatures In case of outside temperatures below freezing point: Appearances, operating stations (spaces occupied) and all mobil crane construction units are to be cleaned if necessary before beginning of the work from ice and snow to. •...
Page 28 3.2-2 Preparing for crane operation Working in arm positions up to 60° Level the vehicle so that the inclination is maximum 3° in every direction. If the vehicle is secured in a maximum inclination of 3°, the load lifting gear must not exceed 60°. Due to the reduced guiding function of the hexagon profile of the extension boom may cause the load lifting gear to swing to the side and the load to drop.
Page 29 This will prevent the crane from sinking into the ground during loading or unloading work. Suitable supports can be obtained from PALFINGER. Other supports used by you must not break or sink because of the loadings when working with the crane. Supporting the vehicle...
Page 30 3.2-2 Preparing for crane operation The necessary support area can be roughly calculated as follows. The values for the supporting force can be found in the Technical Sheets of the respective crane. Supporting force F (N) Support area A (cm²) = ---------------------------------------------------------- Load bearing capacity of the ground (N/cm²) Permissible pressure on the ground (load-bearing capacity of the ground) to DIN 1054 Filled not artificially compacted ground...
Page 31: Hydraulically Extendable Outriggers
Preparing for crane operation 3.2-3 When being supported, the vehicle must not be lifted out of the springs in order not to overload the support and not to reduce the braking effect. On vehicles with air suspension ensure that the air-sprung axles are not automatically adjusted during crane operation.
Page 32: Manual Slew Support
3.2-5 Preparing for crane operation 3.2-5 Manual slew support In order to extend the stabilizer cylinder, they need to be in support position. Follow the sybsequent procedure: Follow all the safety instructions in Chapter 1. Open the pin on the stabilizer cylinder. While opening the pin, hold the stabilizer cylinder constant..
Page 33: 3.2-6 Extending The Hydraulic Support Outriggers
Preparing for crane operation 3.2-6 3.2-6 Extending the hydraulic support outriggers Before extending the support outriggers shortly press the function ‚Retract support outrigger’ until it swings up to the stop. Now the support outrigger is released from the safety hook. It can be moved out. This way you avoid that the support moves down unintended while extending to the required support width.
Page 34: 3.2-7 Extending The Hydraulic Pivotable Support Outriggers
3.2-7 Preparing for crane operation 3.2-7 Extending the hydraulic pivotable support outriggers • Press the function ‚Extend stabilizer cylinder’ until the stabilizer is in vertical position. When extending the stabilizer cylinder ensure that it swivels downward in a wide radius diagonally to the outrigger. •...
Page 35: Putting Crane Into Operating Position
Preparing for crane operation 3.2-8 3.2-8 Putting crane into operating position The preconditions for extending the crane are: the vehicle is properly supported and the mechanical extensions are retracted and secured as described in Chapter 4.3 If extensions or a fly jib are not properly retracted and secured, they can slide out of the hydraulic extension booms when the crane is being extended and then represent a high accident risk for you and others.
Page 36 3.2-8 Preparing for crane operation Extending the crane: The thrusting arms may only be extracted with the main boom being in nearly vertical position. Extracting the thrusting arms before the main boom is nearly in vertical position causes acute risk of fatality for you. Move the boom from its support on the crane base into a steep position.
Page 37 Crane operations Chapter 4 CONTENS 4.1. URING CRANE OPERATION 4.1-1 ORKING AREA 4.1-2 OADING ACTIVITY 4.1-3 AINTAIN LOAD LIMITS 4.2. AVETY DEVICES 4.2-1 MERGENCY FF BUTTON 4.2-2 OAD MOMENT LIMIT SYSTEMS 4.2-3 OAD MOMENT LIMIT SYSTEMS 4.2-4 SHB 01 4.2-5 50 - ALTRONIC CRANE OPERATION STAND...
Page 38 4.1-1 During crane operation...
Page 39 During crane operation 4.1-1 4.1. During crane operation 4.1-1 Working area Select your working area so that: • you can make the crane movements without being hindered by trees, masts, lines or other objects. • That not other works are carried out in the movement area which you need for your work or that you endanger other people with the crane.
Page 40 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 vehicles. Any angled hoisting is prohibited. Further, the country-specific regulations for truck loading crane operation are to be observed. In a deviation from the set-up as a truck loading crane (e.g.
Page 41 During crane operation 4.1-3 When the main boom is below the horizontal line (area A) the maximum lifting power is not reached. Therefore this arm position should be avoided. If you anyway work in this position, please note that the maximum lifting power of the crane cannot be applied.
Page 42 4.1-3 During crane operation Never exceed the lifting capacities stated on ancillary equipment and load lifting gear. When using sling ropes, sling chains and lifting straps observe the loading table of the respective manufacturer. In working with mechanical extensions the permissible lifting capacity of the extension used determines the maximum permissible lifting capacity.
Page 43 Savety devices 4.2-1 4.2. Savety 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 Off switch is a safety device which when operated immediately brings the crane to a standstill.
Page 44 4.2-2 Savety devices 4.2-2 Load moment limit systems OSK floor control / raised seat control (overload protection hydraulically with hinged arm locked on both sides): If you should enter the overload range with your crane, the hand levers for all functions which increase the load moment will be pushed into neutral position by blocking cylinders.
Page 45 Savety devices 4.2-2 OSK-overload safety device with push-botton valve • Press the push button valve • While you press the push button valve, lower the main boom. Note that when lowering the hinged arm above horizontal the load moment is increased (see page 4.2-3). The hand levers are only released again after the load moment has been reduced.
Page 46 4.2-3 Savety devices 4.2-3 Load moment limit systems Overload protection OFB (Electro-hydraulic overload protection with sensing of outer boom position) This system possesses an LED indicator which shows the current operating state. For normal crane operation, the diodes are green. When in overload, a red flashing indicator shows what part caused the overload system to come into action: either the crane, the fly-jib or the limit stop of the rope winch.
Page 47 Savety devices 4.2-4 • Actuate the function “lower main boom” and hold it in this position. • Press the button If case of mistake, you can repeat this procedure again after 30 seconds. If the magnet valve of the overload safety device switches off during crane operation due to power failure you can put the crane in transport position following the instructions in chapter 4.2-5.
Page 48 4.2-5 Savety devices 4.2-5 Paltronic 50 - crane operation stand Display on the crane operation stand: EMERGENCY OFF switch Capacity utilisation indicator (60-100%) On/Off switch HPLS system On/Off switch OLP pushbutton / warning horn Load moment limitation: slewing-angle-dependent lifting capacity control Load moment limitation: 2 hinged system Load moment limitation: crane...
Page 49 Savety devices 4.2-5 During operation During operation of the crane the capacity utilisation of the crane (from 60%) can be read off in 10% steps on the capacity utilisation indicator on the control panel of the Paltronic 50 60, 70, 80% LED green. 90% LED yellow (with acoustic warning). 100% LED red.
Page 50 4.2-5 Savety devices Warning horn On cranes with an outreach of more than 12 metres the OLP button also serves as a warning horn. To sound the horn you have to keep the OLP button pressed down for more than half a second. Slewing dependend-lifting capacity adjust The slewing angle-dependent lifting capacity control responds if stability is endangered by the crane position in connection with further slewing.
Page 51 Savety devices 4.2-5 Crane overload protection, crane with switched HPLS operation or Fly jib The crane overload protection responds if you enter the overload range with the crane (boom, hinged arm, extendable arms) or, if fitted, with the 2nd hinged system. The particular overload situation with which the crane is in the overload range is indicated by means of the LED (lights up red).
Page 52 4.2-5 Savety devices Winch overload protection (push stop) The overload protection for the winch responds when the rope winch (push stop) is in the overload range. This is indicated on the control panel by the LED for the winch symbol (lights up red). The following functions are no longer possible: - boom: .................raising...
Page 53 Savety devices 4.2-5 Transport Position Monitor If your Paltronic 50 is equipped with a transport position monitor (light display in the driver’s cab), current is provided from the truck’s ignition. The transport position monitor is only an additional check. Follow the procedure described in Chapter 5 before moving the truck.
Page 54 4.2-6 Savety devices 4.2-6 Paltronic 50 – Remote controle stand Display on the remote control stand (transmitter): Display – load moment limitation slewing-angle-dependent lifting capacity control Capacity utilisation indicator (60-100%) Display - load moment limitation: 2 hinged system Display - Paltronic 50 ON / OFF Display - load moment limitation: crane Display –...
Page 55 Savety devices 4.2-6 During operation During operation of the crane the capacity utilisation of the crane (from 60%) can be read off in 10% steps on the capacity utilisation indicator on the control panel of the Paltronic 50 60, 70, 80% LED green. 90% LED yellow (with acoustic warning).
Page 56 4.2-6 Savety devices Warning horn On cranes with an outreach of more than 12 metres the OLP button also serves as a warning horn. To sound the horn you have to keep the OLP button pressed down for more than half a second. Slewing dependend-lifting capacity adjust The slewing angle-dependent lifting capacity control responds if stability is endangered by the crane position in connection with further slewing.
Page 57 Savety devices 4.2-6 Crane overload protection, crane with switched HPLS operation or Fly jib The crane overload protection responds if you enter the overload range with the crane (boom, hinged arm, extendable arms) or, if fitted, with the 2nd hinged system. The particular overload situation with which the crane is in the overload range is indicated by means of the LED (lights up red).
Page 58 4.2-6 Savety devices Function check Before starting work a function check without load must always be carried out: Move the boom with maximum speed to the stop. The overload protection must respond when the stop is reached. (Avoid this test position during operation of the crane). •...
Page 59 Savety devices 4.2-7 4.2-7 Emergency control operation and emergency operation Emergency control operation of the crane after failure of the remote control unit. If there is a failure of the remote control unit on your crane, check whether the accumulator is empty or defective by inserting a charged accumulator in the transmitter of the remote control unit.
Page 60 Once crane movements are possible again the load moment must be immediately reduced. • Visit a Palfinger service workshop immediately to have the fault repaired. It is not permissible to continue to operate the crane! Putting the crane into emergency operation status as described above deactivates all safety devices such as Emergency-Off, load limiting systems and SHB.
Page 61 2 seconds. 4.3-2 Manual Activation of the AOS Function Palfinger has developed the manual AOS to prevent the load-bearing arm from moving upwards during a constant load reduction (e.g., emptying of a cement bucket). The upward movement is compensated electrohydraulically.
Page 62 4.3-3 Additional equipment When you are working with load carrying equipment or accessories such as load hooks, mechanical extensions, winch components, etc., always make sure that the equipment has been properly secured. Always use the proper bolts and securing elements (cotter pins, lock nuts, etc.) for the load carrying equipment or accessories.
Page 63 Additional equipment 4.3-3 Separating screw couplings: • Switch off pump • Remove pressure from the lines by operating the control levers in both switching positions. • Separate dust caps • Separate screw couplings. • Screw on dust caps and stow the hoses properly in the hose boxes. Multifaster Plug, guiding bolt and coupling have to be cleaned every time before starting the Multifaster.
Page 64 4.3-3 Additional equipment Separating the Multifaster: • Switch off pump • Remove pressure from the lines by operating the control levers in both switching positions Press the safety button (1) Open the tightening lever (2) Remove the plug and store it in a safe place (3) Withdraw the tightening lever (4) until the safety button locks.
Page 65 Inadequately secured mechanical extensions represent a danger of fatal injury for you and other people. Always use the bolts and spring cotters provided by Palfinger. The maximum load capacity of the crane is always determined by the weakest load taking element.
Page 66 4.3-4 Additional equipment Overload protection device for extensions: The overload protection device for extensions allows you to operate the mechanical extensions (two maximum) with the overload protection. Working with overload protection device for extensions: Disassemble the load hook Assemble the overload hook (secure with bolt) Plug in the cable Set the operation mode selection switch in the required position For extension 1 set the switch on 1...
Page 67 Whenever you use the crane in rope winch operation, the vehicle must be secured horizontally. For rope winch operation only use Palfinger 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 68 4.3-5 Additional equipment When working with the rope winch it has to be ensured that: • the rope winch is not overloaded with the lifting capacity of the crane. • crane components such as hydraulic extendable arms, mechanical extensions and pulleys etc. are not overloaded with the lifting capacity of the rope winch.
Page 69 Additional equipment 4.3-5 Loading and unloading work in rope pulley operation or with long load suspension (observe load limits): Always work with the lowest possible load moment in rope pulley operation (long load suspension) as well. You will increase the safety of the loading or unloading procedure and the useful lifetime of your crane.
Page 70 4.3-6 Additional equipment 4.3-6 Raised stand, raised seat To climb up to the raised seat or raised stand the aids provided must be used (ladder, handles). Make sure that you do not activate any controls when climbing up. When working from the raised seat always ensure that there is enough clearance between the raised seat and the load (see 1.3-1).
Page 71 The remote control is not operational until the start button is pressed. For this the operating levers must be in neutral position. If the EMERGENCY-Off switch is pressed in the unit will not start. Operation of the Palfinger radio remote control is explained in the operating instructions supplied with the unit.
Page 72 4.3-7 Additional equipment Additional functions: Optional according to crane equipment. HPLS On / Off Truck engine On / Off Change speed of truck engine Lever to left increase speed Lever in the middle = standard speed Lever to right increase speed as required (automatically) Return oil processing On / Off No function (is available for special functions) Switch between support operation and crane operation*...
Page 73 Starting up the crane Chapter 3 CONTENTS 3.1. N OVERVIEW OF THE CRANE 3.1-1 3.1-2 ONTROLS 3.2. REPARING FOR CRANE OPERATION 3.2-1 OLD START IN LOW OUTSIDE TEMPERATURES 3.2-2 UPPORTING VEHICLE PROPERLY 3.2-3 YDRAULICALLY EXTENDABLE OUTRIGGERS 3.2-4 XTENDING THE SUPPORT CYLINDERS 3.2-5 XTENDING THE HYDRAULIC SUPPORT OUTRIGGERS 3.2-6...
Page 74: An Overview Of The Crane
3.1-1 An overview of the crane...
Page 75: Set-Up
An overview of the crane 3.1-1 3.1. An overview of the crane 3.1-1 Set-up The crane displayed in the following is an example and shows crane components that can optionally be on your crane depending on model and crane type. Control unit crane support Main boom 2A Control unit - control valve side (Side A)
Page 76 3.1-2 An overview of the crane 3.1-2 Controls The symbols for the control elements are explained in the following. The sequence of crane functions (symbols) on the emergency control stand or the remote control console may differ from the example shown below. Please therefore always note the symbol arrangement (crane functions) on the control stand of your crane or the arrangement of the symbols on the remote control console.
Page 77 An overview of the crane 3.1-2 Crane function: Support cylinder left side Crane function: Support cylinder right side retracting retracting extending extending Crane function: Ancillary fly-jib arm Crane function: Ancillary fly-jib extendable arm raising extending lowering retracting Crane function: Ancillary rope winch down...
Page 78 3.1-2 An overview of the crane Display field with key switch for cranes with Paltronic 50 (Paltronic display on remote control panel) Emergency-Off Key-operated switch for switching OLP–button and for cranes with an between remote control console and outreach of more than 12 metres also manual operation (emergency control the warning horn.
Page 79: Preparing For Crane Operation
Preparing for crane operation 3.2-1 3.2. Preparing for crane operation 3.2-1 Cold start in low outside temperatures In outside temperatures below freezing: Appearances, operating stations (spaces occupied) and all mobil crane construction units are to be cleaned if necessary before beginning of the work from ice and snow to. •...
Page 80 3.2-2 Preparing for crane operation Working in arm positions up 60° Level the vehicle so that the inclination is maximum 3° in every direction. When the vehicle stands in a maximum inclination of 3° then the angle of 60° must not be exceeded with the load-bearing arm.Due to the reduced guiding function of the hexagon profile of the extendable arm this may cause the load-bearing arm swinging to the side and the load being dropped.
Page 81 This will prevent the crane from sinking into the ground during loading or unloading work. Suitable supports can be obtained from PALFINGER. Other supports used by you must not break or sink under the loadings that occur when working with the crane. Supporting the...
Page 82 3.2-2 Preparing for crane operation The necessary support area can be roughly calculated as follows. The values for the supporting force can be found in the Technical Sheets of the respective crane. Supporting force F (N) Support area A (cm²) = ---------------------------------------------------------- Load-bearing capacity of the ground (N/cm²) Permissible pressure on the ground (load-bearing capacity of the ground) to DIN 1054 Filled ground, not artificially compacted...
Page 83: Hydraulically Extendable Outriggers
Preparing for crane operation 3.2-3 When being supported the vehicle must not be lifted out of the springs in order not to overload the support and not to reduce the braking effect. On vehicles with air suspension ensure that the air-sprung axles are not automatically adjusted during crane operation.
Page 84: 3.2-5 Extending The Hydraulic Support Outriggers
3.2-5 Preparing for crane operation 3.2-5 Extending the hydraulic support outriggers Before extending the support outriggers shortly press the function ‚Retract support outrigger’ until it swings up to the stop. Now the support outrigger is released from the safety hook. It can be moved out. This way you avoid that the support moves down unintended while extending to the required support width.
Page 85: 3.2-6 Extending The Hydraulic Pivotable Support Outriggers
Preparing for crane operation 3.2-6 3.2-6 Extending the hydraulic pivotable support outriggers • Press the function ‚Extend support cylinder’ until the support is in vertical position. When extending the support cylinder ensure that it swivels downward in a wide radius diagonally to the outrigger. •...
Page 86: Putting Crane Into Operating Position
3.2-7 Preparing for crane operation 3.2-7 Putting crane into operating position The preconditions for extending the crane are: the vehicle is properly supported and the mechanical extensions are retracted and secured as described in Chapter 4.3 If extensions or a fly jib are not properly retracted and secured they can slide out of the hydraulic extendable arms when the crane is being extended and then represent a high accident risk for you and others.
Page 87 Preparing for crane operation 3.2-7 Extending the crane: The thrusting arms may only be extracted with the main boom being in nearly vertical position. Extracting the thrusting arms before the main boom is nearly in vertical position causes acute risk of fatality for you. Move the boom from its support on the crane base into a steep position.
Page 88 3.2-7 Preparing for crane operation...
Page 89 Crane operations Chapter 4 CONTENS 4.1. URING CRANE OPERATION 4.1-1 ORKING AREA 4.1-2 OADING ACTIVITY 4.1-3 AINTAIN LOAD LIMITS 4.2. AVETY DEVICES 4.2-1 MERGENCY FF BUTTON 4.2-2 OAD MOMENT INDICATOR 4.2-3 OAD MOMENT LIMIT SYSTEMS 4.2-4 OAD MOMENT LIMIT SYSTEMS 4.2-5 SHB 01 4.2-6...
Page 90 4.1-1 During crane operation...
Page 91 During crane operation 4.1-1 4.1. During crane operation 4.1-1 Working area Select your working area so that: • you can make the crane movements without being hindered by trees, masts, lines or other objects. • That not other works are carried out in the movement area which you need for your work or that you endanger other people with the crane.
Page 92 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 vehicles. Any angled hoisting is prohibited. Further, the country-specific regulations for truck loading crane operation are to be observed. In a deviation from the set-up as a truck loading crane (e.g.
Page 93 During crane operation 4.1-3 When the main boom is below the horizontal line (area A) the maximum lifting power is not reached. Therefore this arm position should be avoided. If you anyway work in this position, please note that the maximum lifting power of the crane cannot be applied.
Page 94 4.1-3 During crane operation Never exceed the lifting capacities stated on ancillary equipment and load lifting gear. When using sling ropes, sling chains and lifting straps observe the loading table of the respective manufacturer. In working with mechanical extensions the permissible lifting capacity of the extension used determines the maximum permissible lifting capacity.
Page 95 Savety devices 4.2-1 4.2. Savety 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 Off switch is a safety device which when operated immediately brings the crane to a standstill.
Page 96 4.2-3 Savety devices 4.2-3 Load moment limit systems OSK floor control / raised seat control (overload protection hydraulically with hinged arm locked on both sides): If you should enter the overload range with your crane, the hand levers for all functions which increase the load moment will be pushed into neutral position by blocking cylinders.
Page 97 Savety devices 4.2-3 OSK-overload safety device with push-botton valve • Press the push button valve • While you press the push button valve, lower the main boom. Note that when lowering the hinged arm above horizontal the load moment is increased (see page 4.2-3). The hand levers are only released again after the load moment has been reduced.
Page 98 4.2-4 Savety devices 4.2-4 Load moment limit systems Overload protection OFB (Electro-hydraulic overload protection with sensing of outer boom position) This system possesses an LED indicator which shows the current operating state. For normal crane operation, the diodes are green. When in overload, a red flashing indicator shows what part caused the overload system to come into action: either the crane, the fly-jib or the limit stop of the rope winch.
Page 99 Savety devices 4.2-5 • Actuate the function “lower main boom” and hold it in this position. • Press the button If case of mistake, you can repeat this procedure again after 30 seconds. If the magnet valve of the overload safety device switches off during crane operation due to power failure you can put the crane in transport position following the instructions in chapter 4.2-5.
Page 100 4.2-6 Savety devices 4.2-6 Paltronic 50 - crane operation stand Display on the crane operation stand: EMERGENCY OFF switch Capacity utilisation indicator (60-100%) On/Off switch HPLS system On/Off switch OLP pushbutton / warning horn Load moment limitation: slewing-angle-dependent lifting capacity control Load moment limitation: 2 hinged system Load moment limitation: crane...
Page 101 Savety devices 4.2-6 During operation During operation of the crane the capacity utilisation of the crane (from 60%) can be read off in 10% steps on the capacity utilisation indicator on the control panel of the Paltronic 50 60, 70, 80% LED green. 90% LED yellow (with acoustic warning). 100% LED red.
Page 102 4.2-6 Savety devices Warning horn On cranes with an outreach of more than 12 metres the OLP button also serves as a warning horn. To sound the horn you have to keep the OLP button pressed down for more than half a second. Slewing dependend-lifting capacity adjust The slewing angle-dependent lifting capacity control responds if stability is endangered by the crane position in connection with further slewing.
Page 103 Savety devices 4.2-6 Crane overload protection, crane with switched HPLS operation or Fly jib The crane overload protection responds if you enter the overload range with the crane (boom, hinged arm, extendable arms) or, if fitted, with the 2nd hinged system. The particular overload situation with which the crane is in the overload range is indicated by means of the LED (lights up red).
Page 104 4.2-6 Savety devices Winch overload protection (push stop) The overload protection for the winch responds when the rope winch (push stop) is in the overload range. This is indicated on the control panel by the LED for the winch symbol (lights up red). The following functions are no longer possible: - boom: ................
Page 105 Savety devices 4.2-6 Transport Position Monitor If your Paltronic 50 is equipped with a transport position monitor (light display in the driver’s cab), current is provided from the truck’s ignition. The transport position monitor is only an additional check. Follow the procedure described in Chapter 5 before moving the truck.
Page 106 4.2-7 Savety devices 4.2-7 Emergency control operation and emergency operation Emergency control operation of the crane after failure of the remote control unit. If there is a failure of the remote control unit on your crane, check whether the accumulator is empty or defective by inserting a charged accumulator in the transmitter of the remote control unit.
Page 107 Once crane movements are possible again the load moment must be immediately reduced. • Visit a Palfinger service workshop immediately to have the fault repaired. It is not permissible to continue to operate the crane! Putting the crane into emergency operation status as described above deactivates all safety devices such as Emergency-Off, load limiting systems and SHB.
Page 108 2 seconds. 4.3-2 Manual Activation of the AOS Function Palfinger has developed the manual AOS to prevent the load-bearing arm from moving upwards during a constant load reduction (e.g., emptying of a cement bucket). The upward movement is compensated electrohydraulically.
Page 109 Additional equipment 4.3-3 When you are working with load carrying equipment or accessories such as load hooks, mechanical extensions, winch components, etc., always make sure that the equipment has been properly secured. Always use the proper bolts and securing elements (cotter pins, lock nuts, etc.) for the load carrying equipment or accessories.
Page 110 4.3-3 Additional equipment Separating screw couplings: • Switch off pump • Remove pressure from the lines by operating the control levers in both switching positions. • Separate dust caps • Separate screw couplings. • Screw on dust caps and stow the hoses properly in the hose boxes. Multifaster Plug, guiding bolt and coupling have to be cleaned every time before starting the Multifaster.
Page 111 Additional equipment 4.3-3 Separating the Multifaster: • Switch off pump • Remove pressure from the lines by operating the control levers in both switching positions Press the safety button (1) Open the tightening lever (2) Remove the plug and store it in a safe place (3) Withdraw the tightening lever (4) until the safety button locks.
Page 112 Inadequately secured mechanical extensions represent a danger of fatal injury for you and other people. Always use the bolts and spring cotters provided by Palfinger. The maximum load capacity of the crane is always determined by the weakest load taking element.
Page 113 Additional equipment 4.3-4 Overload protection device for extensions: The overload protection device for extensions allows you to operate the mechanical extensions (two maximum) with the overload protection. Working with overload protection device for extensions: Disassemble the load hook Assemble the overload hook (secure with bolt) Plug in the cable Set the operation mode selection switch in the required position For extension 1 set the switch on 1...
Page 114 Whenever you use the crane in rope winch operation, the vehicle must be secured horizontally. For rope winch operation only use Palfinger 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 115 Additional equipment 4.3-5 When working with the rope winch it has to be ensured that: • the rope winch is not overloaded with the lifting capacity of the crane. • crane components such as hydraulic extendable arms, mechanical extensions and pulleys etc. are not overloaded with the lifting capacity of the rope winch.
Page 116 4.3-5 Additional equipment Loading and unloading work in rope pulley operation or with long load suspension (observe load limits): Always work with the lowest possible load moment in rope pulley operation (long load suspension) as well. You will increase the safety of the loading or unloading procedure and the useful lifetime of your crane.
Page 117 Additional equipment 4.3-6 4.3-6 Raised stand, raised seat To climb up to the raised seat or raised stand the aids provided must be used (ladder, handles). Make sure that you do not activate any controls when climbing up. When working from the raised seat always ensure that there is enough clearance between the raised seat and the load (see 1.3-1).
Page 118 4.3-6 Additional equipment...
Page 119 Ending crane operation Chapter 5 CONTENTS 5.1. NDING CRANE OPERATION 5.1-1 UTTING CRANE IN TRANSPORT POSITION 5.1-2 ETRACTING THE SUPPORT 5.1-3 ETRACTING THE SUPPORT CYLINDERS 5.1-4 YDRAULICALLY RETRACTABLE OUTRIGGERS 5.1-5 ETRACTING OUTRIGGERS WITH HYDRAULIC HINGED SUPPORT CYLINDERS 5.1-6 ETRACTING HYDRAULIC SUPPORT OUTRIGGERS 5.2.
Page 120: Ending Crane Operation Chapter
5.1-1 Ending crane operation...
Page 121: Putting Crane In Transport Position
Ending crane operation 5.1-1 5.1. Ending crane operation 5.1-1 Putting crane in transport position In your activity observe all the safety instructions in Chapter 1 Cranes with RC operation: On cranes with radio remote control make sure that you are not in the area of the slewing or descending boom.
Page 122 5.1-1 Ending crane operation • Fold in the hinged arm completely. • Slew the crane across the direction of travel, observe the marking (retraction arrows) on the crane pillar and crane base. • Fold in the extendable arm until the load arm rests in the support for it on the crane base.
Page 123: Retracting The Support
Ending crane operation 5.1-2 5.1-2 Retracting the support Retract each support cylinder individually so that you always have its area of movement in your field of vision. As it is being retracted the entire support swivels upwards, therefore ensure before retracting the supports that there is enough area of movement for this.
Page 124: Hydraulically Retractable Outriggers
5.1-4 Ending crane operation 5.1-4 Hydraulically retractable outriggers Before the outriggers can be retracted the support cylinders must have been completely retracted. Before retracting the outriggers make sure that there are no persons and objects in the movement area of the outriggers and support cylinders (for minimum distances see Chapter 1.3). Always retract the outriggers completely.
Page 125: Retracting Outriggers With Hydraulic Hinged Support
Ending crane operation 5.1-5 5.1-5 Retracting outriggers with hydraulic hinged support cylinders Before you are allowed to retract the support cylinders the crane must be in transport position. Then proceed as follows: Before retracting the outriggers make sure that there are no persons and objects in the movement area of the outriggers and support cylinders (for minimum distances see Chapter 1.3).
Page 126 5.1-6 Ending crane operation To avoid unnecessary oil heating, move the “Crane operation / Support operation” switch lever to crane operation immediately after the support has been retracted. If your vehicle is fitted with an additional support, retract this as described previously, observing all safety instructions relating to the support.
Page 127: After Crane Operation
After crane operation 5.2-1 5.2. 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 to drive check: • if the hydraulic pump is off. • that the load is securely fixed and doesn’t protrude over the vehicle. •...
Page 128 5.2-1 After crane operation...
Page 129 Maintenance and service Chapter 6 Contents 6.1. AINTENANCE 6.1-1 ARRANTY PROVISIONS 6.1-2 HECKING BOLTED CONNECTIONS 6.1-3 1000 IM BEARING SCREWS INITIAL SERVICING SERVICING AFTER HOURS 6.1-4 UBRICATION 6.1-5 PERATING OURS OUNTER 6.1-6 YDRAULIC FLUIDS 6.1-7 IL CHANGE IL MAINTENANCE 6.2. ARE OF THE CRANE 6.2-1 LEANING AGENTS AND EQUIPMENT...
Page 130: Maintenance
6.1-1 Maintenance...
Page 131: Warranty Provisions
Maintenance 6.1-1 6.1. Maintenance 6.1-1 Warranty provisions During servicing work we have repeatedly found that our recommendations for maintenance and lubrication of the crane are neglected. We bear no costs for consequential damage attributable to deficient maintenance and lubrication. It is therefore in your interest for the maintenance of your crane to be carried out regularly and in compliance with the regulations.
Page 132 6.1-2 Maintenance 6.1-2 Checking bolted connections Loose bolts may fracture under load. Tightening torques in Nm for the following ISO standards: Bolts 4762,4014 Nuts 4032 Washers 7090 Lightly oiled condition Thread - Strenght class diameter 10.9 M 10 M 12 M 14 M 16 M 18...
Page 133 Maintenance 6.1-2 Maintenance schedule After the first 50 hours Initial service Oil filter package Fastening bolts - support cylinders Fastening bolts – Slewing mechanism Securing screws for rim bearing internal / external 6.1-4 Crane base fastening Hydraulic lines/hoses, retighten screw connections every 50 hours or after more than 3 months standing time Hook, function control of hook safety flap Main boom bearing, hinge pin...
Page 134 6.1-2 Maintenance...
Page 135: Im Bearing Screws
If you find one or several loose rim bearing screws (>30%) immediately contact the Palfinger customer service. Screw in only unoiled Palfinger rim bearing screws. Make sure that all connecting parts are clean and grease-free. Use only Palfinger rim bearing screws (special coating).
Page 136 Repeat the check until all external rim bearing screws have been checked. Component replacement: If it is necessary to release rim bearing screws due to servicing or repair works please refer to the Palfinger servicing document and the Palfinger training document.
Page 137: Lubrication
6.1-4 Lubrication The following maintenance and care instructions apply to all Palfinger cranes. In this Chapter you will therefore find instructions which do not relate to your crane Inadequate or incorrect lubrication leads to increased wear and therefore to unnecessary repairs (idle time) to the crane.
Page 138 Before lubricating the pillar bearing raise the boom to its full height so that the lubricaton grease can spread evenly in the bearings. The pillar bearing should be lubricated via the lubrication points provided by Palfinger. If you lubricate by means of central lubrication ensure that adequate lubrication takes place.
Page 139: Operating Hours Counter
Maintenance 6.1-5 • Next remove any excess grease. Surplus grease is a source of accidents caused by slipping and also contaminates the environment. As most of the lubrication points on the crane involve lubrication loss (grease is consumed or enters the environment), we recommend the use of biodegradable greases.
Page 140: Hydraulic Fluids
As the viscosity of hydraulic fluids changes considerably through fluctuations in temperature, compromises cannot be avoided in their selection. For your PALFINGER crane the following limit values apply: • High temperatur range: 10 cSt •...
Page 141: Oil Change / Oil Maintenance
Maintenance 6.1-7 Owing to different basic products different service temperatures apply: • Fluids based on mineral oil: approx. -30 bis +80°C • Biodegradable fluids: Fully synthetic ester: approx. -30 bis +80°C Native ester: approx. -20 bis +80°C Fluids based on rape oil: approx.
Page 142: Care Of The Crane
6.2-1 Care of the crane 6.2. Care of the crane 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. etc.. Road salt, oils, dust, etc.
Page 143: Repairing Paint Damage
Care of the crane 6.2-2 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. 6.2-3 Removal from service and disposal If the crane is taken out of service and dismantled from the vehicle its parts must be disposed of properly.
Page 144 6.2-3 Care of the crane...
Page 145 Technical description Chapter 7 Contents Specifications Lifting capacity diagrams Weights and centers of gravity Hydraulic diagrams Rope winch...

Palfinger PK85002 Operating Manual

Safety Instructions Chapter 1 Contents

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Section 3

Ending Crane Operation Chapter 5

Maintenance and Service Chapter 6

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