Operating Manual Hydraulic Crane

1

Operating Manual

Hydraulic Crane

PC 3800

Serial number:

DB1140+NAEN

Edition: 11/2016

Palfinger North America

7942 Dorchester Rd.

Niagara Falls, ON L2G 7W7

www.palfinger.com

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. • Please follow all safety instructions. • Please maintain your PALFINGER unit in accordance with regulations. • Please adhere to the prescribed maintenance intervals. • The unit must be cleaned at regular intervals, since dirt increases the

amount of wear. • Contamination by grease and oil increases the risk of accidents. • All prohibitions and notes in these operating instructions must be

complied with, since they protect your life and the lives of other persons.

We wish you great success with your PALFINGER product!

Contents

Notes regarding the operating instructions ......................................................... 1 Operating instructions ....................................................................................................... 3 Validity of operating instructions ....................................................................................... 3 Terms ............................................................................................................................... 4 Symbols ............................................................................................................................ 5 Graphics and pictures ....................................................................................................... 5

Safety and Health Standards .................................................................................. 7 Safety for individuals ........................................................................................................ 9 Use for intended purpose / limits of the device ............................................................... 10 Residual risks ................................................................................................................. 11 Government regulations and standards for operating the unit ........................................ 12 Adverse working conditions ............................................................................................ 12 Risk of falling .................................................................................................................. 13 Danger of getting crushed .............................................................................................. 13 Risk of burns................................................................................................................... 15 Noise emission ............................................................................................................... 15 Dangers caused by exhaust ........................................................................................... 16 Danger from power lines ................................................................................................ 16 After maintenance, service and repairs .......................................................................... 18

General ...................................................................................................................19 CE symbol ...................................................................................................................... 21 Structure of system ......................................................................................................... 21 Modifications to unit ........................................................................................................ 22 Operators........................................................................................................................ 22

Device and function ..............................................................................................23 Main components ........................................................................................................... 25 Function labels ............................................................................................................... 27 Overview of labels .......................................................................................................... 30

Safety equipment ...................................................................................................39 General ........................................................................................................................... 41 Emergency cut-off button / push-button .......................................................................... 41 Capacity indicator ........................................................................................................... 42 Hydraulic overload protection ......................................................................................... 43 Overload protection in radio remote control operation .................................................... 43 Transport position monitoring system ............................................................................. 44 Emergency operation after remote control failure ........................................................... 44

Ancillary equipment ..............................................................................................47 General ........................................................................................................................... 49 Slingers, other attachments to lift the load ...................................................................... 50 Ancillary equipment ........................................................................................................ 51 Remote control ............................................................................................................... 58

Preparing for crane operation ..............................................................................65 Watch out for faults before and during operation ............................................................ 67 Working range ................................................................................................................ 68 Starting the crane ........................................................................................................... 69 Preparing for remote operation ....................................................................................... 69

Contents

Contents

Vehicle inclination ........................................................................................................... 71 Supporting the vehicle .................................................................................................... 72 Pulling outrigger beams out manually ............................................................................. 75 Stabilizer cylinders .......................................................................................................... 76 Bringing the load arm to working position ....................................................................... 76 Daily function check of safety equipment........................................................................ 78

Crane operation .................................................................................................... 79 Load limits ...................................................................................................................... 81 Working position of the crane ......................................................................................... 81 Loads .............................................................................................................................. 84 Working with loads ......................................................................................................... 85

Ending operation .................................................................................................. 91 Bringing the crane into transport position ....................................................................... 93 Retracting the stabilizers ................................................................................................ 94 Ending radio remote control operation ............................................................................ 97 Before driving ................................................................................................................. 97

Maintenance .......................................................................................................... 99 General ......................................................................................................................... 101 Operating hours counter ............................................................................................... 102 Maintenance ................................................................................................................. 103 Cleaning ....................................................................................................................... 104 Visual inspection ........................................................................................................... 105 Machine lubrication ....................................................................................................... 107 Hydraulic oil change ..................................................................................................... 112 Paint repair ................................................................................................................... 115

Service ................................................................................................................. 117 General ......................................................................................................................... 119 Check of threaded fasteners ......................................................................................... 119 Initial servicing after 50 operating hours ....................................................................... 121 Initial servicing after one year ....................................................................................... 121 After every 500 operating hours or once every year ..................................................... 121 After every 3000 working hours or once every three years .......................................... 122 Every 6 years ................................................................................................................ 122 Gear oil ......................................................................................................................... 122 Check of control equipment .......................................................................................... 123 Protective hoses ........................................................................................................... 123 Repairs ......................................................................................................................... 123 Lowering rate ................................................................................................................ 123

Decommissioning and disposal ........................................................................ 125 Decommissioning and disposal guidelines ................................................................... 127

Index..................................................................................................................... 129

Technical description ......................................................................................... 131

Chapter 1

In this chapter

Operating instructions ................................................................................. 3 Validity of operating instructions ................................................................. 3 Terms ......................................................................................................... 4 Symbols ..................................................................................................... 5 Graphics and pictures ................................................................................. 5

C H A P T E R 1

Notes regarding the operating instructions

1

Chapter 1 Notes regarding the operating instructions

Operating instructions The operating instructions have been prepared to explain operation of the unit.

The operating instructions are part of the unit.

Always keep the operating instructions with the unit (driver’s cab).

Note! In case of damage or loss of these operating instructions please contact your PALFINGER partner and request a new copy.

Neither the operating instructions nor the annexed Technical Sheets replace proper operator training.

Please contact your PALFINGER partner immediately if there is anything in this operating instruction which requires explanation. We appreciate any suggestions received from our customers; they help us to make the operating instructions ever more user friendly. PALFINGER assume no responsibility for the translation. In case of faulty or inaccurate translations the German version of the present operating instructions shall prevail.

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.

The specifications, pictures and descriptions shown in these operating instructions do not qualify for any legal claims.

© Copyright by PALFINGER Copying (even in extracts) only permitted with written

approval from: PALFINGER AG Lamprechtshausener Bundesstraße 8 A-5101 Bergheim near Salzburg

Validity of operating instructions These operating instructions are only valid for the equipment shown on the front page. They are only applicable in conjunction with the operating instructions from all other auxiliary equipment that is used on the equipment/vehicle.

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Notes regarding the operating instructions

Terms Operating company The owner, lessee, renter of the unit, uses the unit, operates the unit either himself or

entrusts a third party with the operation. Operator Anyone who starts up the unit. Start Switch unit on, irrespective of purpose (operation, maintenance, service etc.) Assistant 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.

Properly A person who observes and complies with all duties of care that his work involves acts properly.

Negligent A person who disregards the duties that his work involves acts (grossly) negligently. (Grossly) negligent Who fails to observe what should be obvious to anybody under the respective

circumstances. Load moment The moment that is exerted by the load, ancillary equipment, lifting devices, etc. that

are hanging on a hook. Inherent moment The moment that is exerted by the dead weight of the boom system. Lifting capacity Consists of the load moment and the inherent moment Lifting power The force needed to lift an object. Overload situation Reaching of the maximum permissible load for the current working position. Working position Crane position. Working range The area that is required to carry out the work. Movement range The area within which the crane can be moved. Load range The range within which the respective crane can handle loads. Load path The course of the path that is taken my the moved load. Hold load Holding the lifted load under the supervision of the operator whilst the crane safety

systems are activated. Setup status Crane that has been prepared for the respective work. EU European Union. CE marking Shows that the unit has been manufactured in accordance with the EU directives. Operating instruction Produced in addition to these operating instructions by the operating company for

special operating conditions. Emergency operation Operating mode that is not for normal crane operation. Used to put the crane into

transport position after a failure of the electrical system and/or the safety equipment.

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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. Ignoring this instruction will result in death or serious injury for operator and others.

Warning! These symbols and the Warning! signal word are used for immediately threatening dangers. Ignoring this instruction could result in death or serious injury for operator and others. Damage to the unit or property can also result.

Note! The symbol and signal word are used for particularly important notes which make working with the unit easier.

Symbol for operating lever:

In neutral position Operated

Graphics and pictures

Note! Some of the pictures (for instance of the crane) in these instructions are symbolic representations and for illustration only.

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Chapter 2

In this chapter

Safety for individuals .................................................................................. 9 Use for intended purpose / limits of the device ......................................... 10 Residual risks ........................................................................................... 11 Government regulations and standards for operating the unit ................... 12 Adverse working conditions ...................................................................... 12 Risk of falling ............................................................................................ 13 Danger of getting crushed ........................................................................ 13 Risk of burns ............................................................................................ 15 Noise emission ......................................................................................... 15 Dangers caused by exhaust ..................................................................... 16 Danger from power lines ........................................................................... 16 After maintenance, service and repairs ..................................................... 18

C H A P T E R 2

Safety and Health Standards

7

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.

Operating situations in which the operators or other persons are in danger are prohibited.

If used incorrectly or negligently and/or operated wrongly the unit can potentially be extremely dangerous.

In the event of manipulation or commissioning of the unit, the operator must ensure that neither he nor any other person is in the danger area!

The operator must recognize and understand all safety instructions in the operating instructions and the meaning of all signs.

Safety clothing During any work on the unit such as: • Cleaning and maintenance • Setting up • All sorts of checks • Operation • Service and repairs

safety clothing that is suitable for the respective danger must be worn.

Before putting on the safety clothing, remove jewelry (example: rings, chains, bracelets etc.).

Personal safety equipment:

Operation: safety clothing, work gloves, hard-capped boots, helmet.

Other activities: depending on the type of danger (example: hearing protection in case of increased noise exposure, safety goggles, work gloves, safety belt).

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Use for intended purpose / limits of the device Use the crane only within the load limits shown on the load capacity chart to lift, move, carry and set down loads. For load capacity chart refer to chapter 13, 'Technical description'.

Caution! Improper use endangers people and causes damages to the crane and loss of warranty and liability.

If the operating instructions of any ancillary equipment or instructions prepared by the operating company allow other use (for instance excavating or diagonal pull), which contradict these operating instructions, then the crane's operating instructions shall have priority.

It is allowed to: • Load/unload your own vehicle or another vehicle; • Lift and move loads at or down from large heights; • Lift and move loads below ground level; • Lift loads up to a specific height and hold them in this height for assembly works (e.g. rafters, steel

girders, etc.) • Occasional grab application for lifting and moving bulk materials such as loose sand, gravel etc.

Caution! If the device is used against orders there is severe risk of fatal injury to the operator and others.

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It is not allowed: • To use the device for other purposes than the ones specified above; • To use the device for logging and scrap application; • To push against obstacles or loads; • To pull, to pull things loose, any diagonal pull; • Abrupt release of boom system load; • To attach loads to other positions on the crane than the intended ones; • To move dangerous loads (e.g. molten material). • 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.

Accidents caused by incorrect use are grossly negligent if: • The device is not used as intended. • The device is started and used by untrained, unqualified individuals. • The present operating instructions are neglected. • The device is started up after it is known to be defective. • Maintenance hast not been carried out or only insufficiently. • Servicing has been carried out by a service workshop other than PALFINGER partner. • Parts other than original PALFINGER spare parts have been installed.

Residual risks The present operating instructions are meant as a guideline. 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.

When such hazardous situations occur the operator has to act responsibly, with foresight and safety-awareness, yet he is responsible for the safety of all people and others involved.

The safety of people always must be of top priority.

11


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.

Adverse working conditions Do not operate the crane • at wind speeds of 50 km/h (30 mph) and above; • at wind speeds from 34 km/h (20 mph) when lifting bulky loads or working in near vertical position;

Wind speed in Beaufort Description m/s km/h mph

0 -2 Wind can be felt on the face or exposed skin. Tree leaves rustle.

max. 3.4 max. 11 max. 8.1

3 Leaves and twigs are in constant motion while the wind will extend light flags.

3.4 to <5.5 12 - 19 8.1 to <12.7

4 Branches are in motion, the wind will raise dust, leaves, and loose paper.

5.5 to < 8.0 20 - 28 12.7 to <18.4

5 Larger branches and trees begin to sway, whitecaps on lakes.

8.0 to <10.8 29 - 38 18.4 to <25.3

6 Large tree branches are in motion, the wind whistles in overhead wires.

10.8 to <13.9 39 - 49 25.3 to <32.2

7

Whole trees are moving in the wind while walking becomes affected by the wind.

13.9 to <17.2 50 - 61 32.2 to <39.1

• When thunderstorms are approaching and during thunderstorms. • At ambient temperatures below -30ºC (-22°F) or above +50ºC (122°F). Average ambient

temperature must not exceed +40°C (104°F) during operation.

Danger! Ignoring these instructions on working conditions may lead to risk of fatal injury for the operator and others and/or to damages to the crane.

12


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.

Exception: Climbing up to operating stands using climbing aids (see ‘High stand, top seat’, Chapter 6) or climbing to the emergency operator station at the crane column (see ‘Emergency control operation after remote control failure’, Chapter 5).

Cables, sensors, sensor attachment lugs, drivers for sensors etc. may not be used as steps and / or handles.

Warning! If you need to climb up the machine for instance for visual checks, maintenance and servicing absolutely use a climbing aid (e.g. ladder).

Danger of getting crushed

Caution! If the minimum distances specified below are undershot, there is acute risk of crushing.

Operating situations in which the operators or other persons are at risk of crushing are prohibited!

13


Required minimum distances

The crushing point for the parts of the body specified above are not considered to be dangerous locations provided that the specified safety distances are not undershot. It must also be ensured that the next biggest part of the body cannot get into the crushing point.

Crushing points

Possible crushing points.

More crushing points may result from your installation and use.

14


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.

No smoking! No naked flame!

Noise emission Warning!

Permanent low or short high noise emission levels endanger the health of operators and bystanders.

Main source of noise: Vehicle motor.

Protective measures: Ear protection.

Operators have to comply with the relevant national noise control standards and laws.

Measuring values Near operating stands of loading cranes which are mounted to Diesel motor vehicles (also in case of remote control operation within 1 m (3,3 feet) from the vehicle) the sound pressure level depends on vehicle model, status of operation (idling speed, full load) and crane installation, so the following values can be reached: • At low or high idling speed of the vehicle engine 72 to 84 dB(A) • In crane operation 79 to 86 dB(A) • The sound power level is between 92 and 100 dB(A).

Note! In order to reduce noise exposure it is recommended to maintain a low idling speed and use the remote control at a distance from the vehicle motor greater than 1 m (3,3 feet).

15


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.

Danger from power lines Caution! Even approaching a power line may lead to an electric

shock. The operator will receive a fatal electric shock.

Condition and height of power lines do not say anything about their voltage.

If the voltage is unknown, the minimum distance from lines is 5 meters (16.5 feet). This applies to the crane, ancillary equipment, rope winch, rope, load handling attachment and load.

Note! The national minimum distances from live power lines may differ from the minimum distances specified in this document. The operator is therefore obliged to comply with the respective national regulations.

• The minimum distance from power lines must be observed at all times. • Working above power lines is prohibited. • Before starting work, obtain information about the voltage of the lines from the line operator. • If you need to be closer than the minimum distance for work reasons, the lines must be switched

off. Being closer than the minimum distance without switching off the lines is grossly negligent and potentially fatal!

Also to be considered: Power lines move in the wind. Power lines can also be out of the operator's view.

The main boom of the crane or the load can swing because of a jerky movement (including up and down). This unwanted movement may mean that you get closer to power line. The crane, ancillary devices, the load handling attachment or the load may be electrified.

16


Minimum distances from live lines

Voltage Minimum distance

up to 1,000 Volts 1.0 meter (3.3 feet)

unknown or over 1,000 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.

• Stay calm, do not move. • Warn persons standing in the vicinity and direct them to observe the safety distance.

Danger! Upon contact with a live electric line with the ground, a potential gradient occurs. Within the potential gradient there is acute danger to life.

• The minimum distance to the vehicle, device, load or broken power lines is 20 meters / 66 feet (potential gradient).

• Leave the danger zone of potential gradient only by jumping with both feet. Keep your legs closed because of the step voltage.

• Under no circumstances you should leave the high stand, top seat, driver's cab, truck bed or workman basket; stay where you are and don't touch anything.

• Do not touch the device, the load or the broken lines. • Immediately arrange the switch-off of the live electric line.

Danger! Approaching any persons, devices or loads situated inside the electric circuit creates acute danger to life.

• Before rescuing any persons out of the electric circuit turn off the life electric line.

17


After maintenance, service and repairs

Note! Every time after maintenance, repair or service it is absolutely necessary to check the function of all safety equipment on the device (stand ard and optional)!

18

Chapter 3

In this chapter

CE symbol ................................................................................................ 21 Structure of system ................................................................................... 21 Modifications to unit .................................................................................. 22 Operators ................................................................................................. 22

C H A P T E R 3

General

19

Chapter 3 General

CE symbol In the EU and in certain countries, the unit may only be operated with

• A valid CE symbol for the unit and the superstructure. • A valid conformity declaration for the unit and the superstructure.

EU requirements are thus fulfilled.

CE marking: Shows that the unit has been manufactured in accordance with the EU directives.

Auxiliary devices require their own CE markings and their own conformity declaration.

I

Structure of system Through a PALFINGER partner in compliance with the Palfinger installation guidelines.

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. • Note concerning any dangers and residual risks. • Explanation of all control equipment. • Delivery of maintenance manual, operating instructions (including any additions required by

installation) and declarations of conformity for vehicle, crane and ancillary equipment, etc. • Confirmation of any legally required acceptance. • Registration: Warranty.

The company operating the equipment has to initiate any legally required periodic inspections.

21

General

Modifications to unit

Note! The operating company or operator are not allowed to modify the unit and to remove any protective devices! Exception: Corrosion protection and maintenance works according to chapter 'Maintenance'.

Danger! 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. For this reason, the unit may only be started up by persons who meet all of the conditions specified below.

Caution! If the unit is operated without training and/or knowledge of these operating instructions, there is an acute risk of fatal injury for operators and other persons.

Note! The operating company must provide operators with comprehensive training or have such training carried out. These operators must meet all of the requirements mentioned in this document.

The following is required of the operator when operating this unit: • Comprehensive training on this unit. • Be familiar with the contents of these operating instructions. • Have understood the training and the operating instructions. • Be familiar with the contents of the operating instructions of all additional equipment used. • Be familiar with the respective national regulations, standards and laws concerning the operation

of this unit and all auxiliary devices that are used. • Physical and mental fitness for the job. • Be responsible, reliable and able to concentrate. • The legally required training (pay attention to national laws). • Be in no way incapacitated by alcohol, drugs or medication. • Fulfill the minimum age requirement (pay attention to national laws).

22

Chapter 4

In this chapter

Main components ..................................................................................... 25 Function labels ......................................................................................... 27 Overview of labels .................................................................................... 30

C H A P T E R 4

Device and function

23

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.

12

2

4

10

9

87 19

15

11

13

16

14

1

65

3

17 18

20

Find the names of the main components on the next page.

25

Device and function

1 Crane base 2 Assembly frame 3 High-tensile, high-alloy bolts 4 Swivel motor 5 Crane column 6 Lifting cylinder 7 Main boom

8 Extension cylinder

9 Hydraulic extension booms

10 Mechanical extension boom

11 Stabilizer outriggers

12 Cam lock

13 Stabilizer cylinders

14 Crank-down stabilizer

15 Hydraulic oil tank

16 Operator station

17 Rope winch

18 Pulley head

19 Hook

20 Radio remote control

26


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.

Stabilizer cylinder

Retract Extend

Slewing

Clockwise (right) Counter-clockwise (left)

Main boom

Lower Lift (hoist)

Extension boom

Extend Retract

27

Device and function

Symbols of remote control console Depending on the labelling of the panel buttons (levels 1 and 2) the following functions are enabled by pushing the buttons:

Slew clockwise (right)

Slew counter-clockwise (left)

Lower main boom

Lift main boom

Extend extension boom

Retract extension boom

Lower rope winch

Raise rope winch

Extend outrigger beam

Retract outrigger beam

Extend stabilizer cylinder

Retract stabilizer cylinder

Open grab

Close grab

Rotator counter-clockwise (left)

28


Rotator clockwise (right)

Warning horn

Working light on / off

Motor start

Motor stop

Increase engine RPM

Reduce / increase speed

29

Device and function

Overview of labels The labels are part of the unit, they serve to protect the operator and others and facilitate correct crane operation.

Danger! Missing, damaged or illegible labels increase the risk of accidents!

Missing, damaged or illegible labels lead to operating errors and mistakes during crane operation; they must be replaced immediately.

Overview of labels:

30


1. 1. Company name label

Position: Both sides on main boom and fly-jib

2. Crane model label

Position: Both sides of main boom. Meaning: Product title.

3. Indication for completely extended outrigger beam

Position: On the outrigger beam. Meaning: Outrigger beam completely extended. Risk if ignored: If outrigger beam is not completely extended the vehicle stability may be reduced.

4. Type plate

Position: On the crane column. Meaning: Information about 1 Machine type 2 Internal code 3 Serial number 4 Year built 5 Company address The identification plate may not be changed or removed.

5. Load capacity label

Position: Operating stand. Meaning: Specification of loads, load ranges and ranges. Risk if ignored: Overloading the crane, danger of the vehicle tipping over.

31

Device and function

6. Identification plate for manual boom extensions

Position: On manual extensions. Meaning: Information about year built, device type, maximum capacity. Risk if ignored: Damages to the crane and risk of fatal injury.

7. Operating lever instruction label

Position: On operating stand. Meaning: Indicates the functions of the operating levers. Risk if ignored: Risk of unintended crane operations and danger to life.

8. Warning sign 'Keep out from under suspended loads'.

Position: On both sides of outer boom or main boom. Meaning: It is prohibited to step under the suspended load. Risk if ignored: Risk of fatal injury by falling loads.

9. Pulley head identification plate

Position: On the pulley head. Meaning: Information about year built, device type, technical data. The identification plate may not be changed or removed. Risk if ignored: Damages to the crane and risk of fatal injury.

32


10. 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. Position on the overview of labels meant as example. Depending on crane design the position may vary. Meaning: Serves to exclude the danger of getting crushed, cut and injured by shearing. Risk if ignored: If this label is missing or damaged there is danger of getting crushed, cut or injured by shearing.

33

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; remote control not insulated. Risk if ignored: Death or serious injury.

Electrocution hazard

Position: On 4 sides of the vehicle. Meaning: Bystanders keep distance from the crane/vehicle in case

of flash over. Risk if ignored: Death or serious injury.

Never ride the boom or hoist people

Position: Near the operator station. Meaning: Under no circumstances shall any personnel be

transported on a boom, hook, load, or any device attached to the crane, boom or load line.

Risk if ignored: Death or serious injury.

34


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.


Well trained operator

Position: Near the operator station. Meaning: Only well trained operators must operate the crane. Risk if ignored: Death or serious injury.

Operating conditions and requirements

Position: Near the operator station. Meaning: Observe all operating conditions and requirements. Risk if ignored: Death or serious injury.

Overload hazard

Position: Near the operator station. Meaning: Don't exceed loads, work areas, ratings. Risk if ignored: Death or serious injury.

35

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.

Crane mounting and prescribed inspections

Position: Near the operator station. Meaning: Do all prescribed inspections and maintenance practices. Risk if ignored: Death or serious injury.

Keep clear or rotating drive shaft, power take off

Position: On both sides of the vehicle. Meaning: Keep clear of rotating drive shaft. Never work on or near

an installed power take off or drive line with the engine running.


Manual extension booms (if equipped)

Position: Near the operator station. Meaning: How to operate manual boom extensions. Risk if ignored: Death or serious injury.

36


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; remote control not insulated. Risk if ignored: Death or serious injury.

37

Chapter 5

In this chapter

General .................................................................................................... 41 Emergency cut-off button / push-button .................................................... 41 Capacity indicator ..................................................................................... 42 Hydraulic overload protection ................................................................... 43 Overload protection in radio remote control operation .............................. 43 Transport position monitoring system ....................................................... 44 Emergency operation after remote control failure ..................................... 44

C H A P T E R 5

Safety equipment

39

Chapter 5 Safety equipment

General

PALFINGER has developed safety systems that protect the operator and the unit in order to guarantee safe operation.

Safety systems are adjusted before delivery of the unit to the operating company/operator.

Danger! Any unauthorized manipulation to the safety devices leads to danger of fatal injury.

Only PALFINGER service partners are allowed to set up and adjust the safety equipment.

Manipulating or inactivating these safety features is not allowed.

Danger! In case of failure of any protective device, stop operating the unit immediately and contact your PALFINGER partner. There is severe risk of fatal injury!

Note! Any warranty and liability of the manufacturer will expire if unauthorized persons manipulate the safety features or seals are broken.

On the operating company's/operator’s request the PALFINGER service partner has to replace any missing or damaged seals immediately.

Emergency cut-off button / push-button The emergency cut-off button / push-button stops all crane functions within 0.5 seconds (500 ms) after activation in an emergency situation.

An emergency cut-off button can be found at every operating station and on the radio remote control handset.

1. In a dangerous situation let go all operating elements immediately. 2. Actuate the emergency cut-off.

All crane functions stop.

Caution! Releasing the emergency cut-off button before ensuring safe crane operation leads to acute risk of fatal injury.

41

Safety equipment

Release the emergency cut-off button only in safe working conditions.

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.

1

2

3

Color Crane utilization 1 = green: Working range 2 = yellow: Limit range Lower operating speed. 3 = Red: Overload range Reduce load moment immediately.

Watch de capacity indicator while operating the crane.

Danger! If the load moment is not reduced immediately upon reaching the overload range (example: retract extension booms) the crane will be overloaded or become unstable. The load may sink uncontrollably. This creates an acute risk of fatal injury.

It is prohibited to work in the red range.

While working in the limit range, do not increase the horizontal reach any further when lowering the load.

42


Hydraulic overload protection When the crane reaches the overload range the locking cylinders push the hand levers that increase the load moment back into neutral positions.

The following movements will then be blocked:

Lower main boom Extend extension boom

The hand levers will only be released when the load moment has been reduced.

If possible, reduce the load moment by operating the ‘Retract extension boom’ function. After this all crane functions will be operable.

No movements possible: If crane movements that reduce the load moment are not possible because of the crane position (all extension booms retracted), take the following steps to unlock the crane functions:

If the main boom is locked in the upper stop, actuate the touch valve and

lower the main boom until the hand levers (operating levers) are released.

Warning! The load moment briefly increases while the main boom is being lowered above the horizontal.

All crane functions are operable again.

Overload protection in radio remote control operation When the crane reaches the overload range all functions that increase the load moment get blocked, only those functions are still enabled that reduce the load moment.

Movements that increase the load moment will then be blocked: • Raise / lower main boom. • Extend the extension boom. • Raise rope winch.

The crane functions will only be released when the load moment has been reduced. Example: Retract extension boom.

If crane movements that increase the load moment are not possible because of the rope winch (cut-off), actuate ‘Lower the rope winch’ and land the load.

43

Safety equipment

Transport position monitoring system The following systems are optionally available:

Main boom in horizontal position - maximum 0° (height warning) - legally required in Europe (EN12999).

Monitoring of the manual outrigger beams (interlock) – legally required in Europe (EN 12999).

Usually the installer connects all above mentioned systems to a warning light and buzzer, as well as immobilizer, etc. in the driver's cab.

Emergency operation after remote control failure Small handset (P4):

Remove the battery and insert the charged spare battery. Charge the battery you removed immediately.

If the crane movements are still not possible even via radio remote control:

Caution! In emergency operation mode all safety devices such as emergency cut-off button, transport position monitoring and all load moment restricting systems, etc. are ineffective. Immediately reduce the load moment in emergency operation. If you continue working you put yourself and others at risk of fatality. Immediately end loading operations.

Caution! Emergency operation may only be used to move the crane to the transport position. After this contact a PALFINGER partner immediately to get the crane repaired. If you continue working you put yourself and others at risk of fatality. Immediately end loading operations.

44


Set the crane to emergency mode. Remove the cover of the control box.

Crane with PTO (power-take-off)

Equipped with power pack (electric motor): For sending the external signal to the power pack it is necessary to press also button B in addition to the procedure described below.

1. Remove the seal from the override button A. 2. Press the override button to its stop. 3. Turn it counter-clockwise by 180°. 4. Then let the override button go.

The crane is now in emergency mode.

Moving the crane into transport position in emergency mode: Operate the crane from the emergency operator station. • If a load has been raised, put it down without increasing the load moment. • To put down the load you may perform only those crane movements that reduce the load moment.

Before starting to operate the crane, familiarize with the arrangement of the control symbols on the emergency operator station.

Keep a safe distance away from all moving parts of the crane and the load (see 'Minimum distances' Chapter 2). • After having put down the load move the crane in transport position (refer to 'Moving the crane in

transport position' in chapter 9).

Continuing to work is not permitted! • Contact a PALFINGER partner immediately to get the crane repaired.

45

Safety equipment

Caution! 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.

If it is not possible to fully observe all • stabilization components; • crane movements and the resulting load path; • loads;

from the emergency operator station during support and/or crane operation, the operator must be given signals by a qualified signaller.

46

Chapter 6

In this chapter

General .................................................................................................... 49 Slingers, other attachments to lift the load ................................................ 50 Ancillary equipment .................................................................................. 51 Remote control ......................................................................................... 58

C H A P T E R 6

Ancillary equipment

47

Chapter 6 Ancillary equipment

General

Note! Use only accessories that are suitable for use on the relevant loader crane.

Note! Matching ancillary equipment and load lifting gear are available from all 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.

Example of ancillary equipment: Rope winch, grab, rotator, manual extension, hydraulic palette forks, auger, etc.

Example of load lifting gear and lifting equipment: Hooks, ropes, chains, belts, shackles, palette forks, etc.

Depending on the type of equipment, a plate might be attached informing about: • Name of the model • Year of manufacture • Manufacturer • Serial number • Dead weight • Maximum permissible load capacity • Operating pressure • etc.

.

The operator must be trained on all the ancillary equipment, load lifting gear and lifting equipment used and has to understand the relevant operating instructions.

Danger! There is acute danger of fatal injury if 1. the crane is overloaded by ancillary equipment and/or

load lifting gear; 2. ancillary equipment, load lifting gear and/or lifting devices

are overloaded using the crane.

Observe the load capacities of ancillary equipment, load lifting gear and lifting equipment.

Observe the maximum permissible angle of inclination for lifting devices.

The maximum load capacity is defined by the weakest load lifting gear used.

Load lifting gear and ancillary equipment: • Are always considered as part of the load (except rope winch and fly-jib). • Always attach and secure them using original PALFINGER bolts and securing devices.

Danger! Depending on the type of ancillary equipment, the crane has to be turned off before attaching the device. Follow the relevant instructions. Keep the minimum distances (see chapter 2).

49

Ancillary equipment

Carry out any necessary steps for attachment • before starting to operate the crane, • when the device is turned off. • Let only professional operators or trained personnel

carry out and complete assembly works.

Slingers, other attachments to lift the load Hook

Danger! Undersized, incorrectly attached, defective or unsecured crane hooks or shackles may cause the load to drop. This creates an acute risk of fatality for the operator and others.

• Use hook and shackle suitable for the weight of the load that is being lifted. • 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. • The safety latch of the hook must close by means of spring pressure after the load has been

attached. • Secure the shackle pin with the linchpin. Use only the original pin for the shackle!

• Have any damaged safety latch or linch pin immediately replaced by a PALFINGER partner.

Warning! When attaching and detaching loads, be aware of increased risk of crushing.

Keep the required minimum distances to all crushing points (refer 'Danger of getting crushed' in chapter 2).

50


Ancillary equipment 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 (pulley heads, attaching and safety material, etc.) for rope winch operation.

Note! For assembly, weight and use of winch components such as pulley head, rope, rope diameter, etc. refer to chapter 13 "Technical Description".

Ropes must be in good condition (see 'Rope discarding', in the maintenance chapter 10).

Assemble the rope winch components before starting work (boom in working position):

Danger! Failure to maintain the minimum distances represents an acute risk of fatality for the operator and others.

Keep the required minimum distances to all crushing points (refer 'Danger of getting crushed' in chapter 2).

For the position of the pulley head and rope refer to the "Technical Description" in chapter 13.

Carry out and complete any necessary assembly works before starting to operate the crane.

Warning! Turn off the crane power during assembly steps, where crane movement is not required. Failure to do this will result in an acute risk of injury (potentially fatal).

Structure:

1. Rope winch 2. Pulley head 3. Lower load block

51

Ancillary equipment

Assembling the pulley head: • Extend the extension booms until approx. 50 cm (2 ft) before the pulley head.

1. Insert connecting block into extension boom and secure with pin. 2. Secure pin with spring cotter. 3. Lower extension boom until lifting gear fits onto pulley head, and secure with pin. 4. Secure pin with a linch pin. 5. Rotate the pulley head upwards, until it can be secured with the connecting block. 6. Secure pin with a linch pin.

• Reel off sufficient rope. • Switch off crane. • Reeve the rope. • Assemble the lower load block. • Check rope guidance and rope. • While operating the winch the rope must run over all of the pulleys (additional rollers etc.).

Danger! If the rope is not properly reeved, this may lead to damages. There is risk of injury or even fatal injury.

Example:

• Move the load arm to a working position.

Warning! When mounting or dismounting the crane and while moving it in transport or working position there is serious risk of getting crushed!

52


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. This may lead to unexpected rope failure and falling down loads.

At least one steel pulley must be used. When using composite pulleys exclusively, the inner braid strands may break before the outer braid strands after longer periods of use. Therefore rope breakage may not be detected during normal inspection.

Single-strand winch operation with composite pulley head (1) is prohibited. The lower load block must be equipped with a steel pulley (2). Single-strand winch operation is not permitted.

12

Rope deflecting angle

Note! In order to keep the rope deflecting angle (α) 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.

53

Ancillary equipment

Warning! If the rope rubs against crane components it gets damaged. The rope may tear, and this creates risk of fatality for the operator and others.

The rope should run smoothly over the pulleys and not rub anywhere.

Rope winch operation examples

For one-strand rope winch operation

For two-strand rope winch operation: 1. Fit additional pulley head for extending to two-

strand operation in pulley head. 2. Secure with pin. 3. Secure pin with a linch pin. 4. Insert clamping sleeve.

Extend/retract extension booms in winch operation

Danger! Rope is shortened when extension booms are extended. If the unwound rope is too short the lower load block will be pulled to the pulley head at full force (two-blocking). In case of rope winches without overload protection system: Rope may break if not unspooled enough. This may lead to unexpected rope failure and falling down loads. In case of rope winches with overload protection system: The rope winch components are protected, but this working position must generally be avoided.

54


Ensure there is enough distance (A) between pulley head and lower load block during all winch operations.

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.

55

Ancillary equipment

Crane without overload protection device

• Do not overload the crane components/accessory equipment such as hydraulic extendible booms, manual extensions, etc. using the lifting power of the rope winch.

• Do not overload the rope winch with the lifting power of the crane.

Danger! Rope might be pulled off the drum if there are too few rope wraps left on the drum. This may lead to unexpected rope failure and falling down loads.

• At least three wraps of rope must be left on the drum.

Ending rope winch operation (load-arm still in working position)

Warning! The crane must be switched off between the individual disassembly steps. Failure to do this will result in an acute risk of injury (potentially fatal).

If disassembly of winch components is necessary: • Lower the load arm boom (to carry out the following work) • Reel off sufficient rope. • Switch off crane. • Disassemble the lower load block and store it properly. • Unreeve the rope, pin it to the storage point and secure it properly. • Turn on the crane. • Slowly and carefully operate the winch to tighten the rope.

• Switch off crane. • Disassemble and store the winch components properly (pulley head etc.).

56


Mechanical extension booms

Danger! If extensions are overloaded with the lifting power of the crane, the load may fall down. This creates an acute risk of fatality for the operator and others.

After pulling out the manual extension you can read the maximum load capacity on both sides. The maximum load capacity is also printed on the identification plate of the manual extension. This may not be exceeded, even if the manual extension has been fully pushed in and secured.

Information! Loads that are heavier than the maximum load capacity of the manual extension boom must be attached to the last hydraulic extension boom.

XXXX KG XXXX KG

The maximum load capacity of the manual extensions must be written on both sides of the extension by the installer. If this specification is missing, contact your PALFINGER partner.

Pulling out/pushing in mechanical manual extensions

Danger! Always secure mechanical manual extensions properly. Inadequately securing manual extensions, or failing to secure them, is grossly negligent. 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.

The operator must stand to the side of the boom system when extending or retracting the manual extension boom.

• Make sure that all manual extension booms are secured properly. • Move the load arm to the set-up position. • Turn off the crane. • Remove the linch pin from the connecting pin, pull out connecting pin. • Pull out the manual extension boom to the securing position.

• Put in the connection pin and secure it with the linch pin. • Turn on the crane.

57

Ancillary equipment

Remote control

Note! The wireless remote control system (remote control console, receiver) complies with the applicable EMV directive. So the unit will as far as possible not interfere with other systems or get interfered by them at the place of application.

General All safety regulations included in the operating instructions of the crane must be observed.

Crane control systems Safety features serve to protect the operator, so it is not allowed to manipulate or inactivate them. Guarantee and warranty immediately expire when any manipulations to the radio remote control system (remote control console and receiver) become obvious.

Components of the remote control Only original PALFINGER components must be used to operate the remote control system.

Guidelines to prevent dangers • Make sure not to actuate any operating elements before starting the remote control console. • If dangers occur push the STOP button. • Have defective components (remote control console, receiver, accessories) immediately repaired

or replaced at a PALFINGER service partner. • Immediately stop crane operation in the event of any malfunctions. • Always fully charge the battery. • Do not operate any crane functions while attaching and detaching loads. • The position of the operator must always be outside the danger zone of the crane. • The operator must have full view of the crane movements and the working range.

58


Components

Remote control console

Receiver

Charging cable

Accessories • Carrying strap • Magnet antenna • Charger (optional)

59

Ancillary equipment

Operating levers The remote control console shown is an example of a standard version and is shown with the functions preset by PALFINGER.

Note! The assignment of functions to the buttons can, if desired by the customer, partly be changed by authorized PALFINGER service partners.

Prior to the remote control console being used for the first time, every operator must be trained by an authorized PALFINGER service partner. Operators must familiarize themselves with the functions assigned to their console's buttons.

12

3

4

65

7

8

9

1 STOP-button 2 Function key FN 3 Key for functions 4 Status LED 5 Indicator LED 6 Battery status indicator 7 Additional indicator LED 8 Crane function on level 1 (example: counter-clockwise slewing) 9 Crane function on level 2 (example: lifting the stabilizer cylinder)

60


1. STOP-button The emergency-stop button switches the remote control console off and hence stops all crane functions.

For how to operate it refer to Emergency cut-off button/ push-button (see "Emergency cut-off button / push-button" Page 41).

2. Function key FN The FN function key switches the remote control console on and is used to select the crane functions (levels 1 and 2).

Start remote control console See also Preparing for remote operation (Page 69).

1. Press the STOP-button and hold it down. 2. Press the function key FN and let both

buttons go. The remote control console is switched on.

Note! The level that is active gets shown on the display.

Changing levels (1/2)

1

2

• Function key FN is not pressed. Level 1 is active. Example: counter-clockwise slewing. • Function key FN is pressed. Level 2 is active. Example: Lift up the stabilizer cylinder.

3. Buttons for crane functions The crane functions’ buttons are proportional push-buttons for which double assignment is possible (levels 1 and 2, see above). The depth of button operation corresponds to the movement speed of the function that is activated.

4. Status LED

The red LED indicates whether the remote control console is on or off. LED off: Remote control console is off. LED on: Remote control console is on.

5. Indicator LED Indicates the currently active level of the buttons for crane functions. 1. - Level 1 2. - Level 2

61

Ancillary equipment

6. Battery status indicator The status indicator has two LEDs that show the remaining battery capacity (high / low).

While charging via cable (cigarette lighter) it furthermore indicates when charging is completed.

LED is flashing: Remote control console is being charged.

LED is illuminated: Remote control console is fully charged.

7. Additional indicator LED

LED is illuminated: During start-up as soon as the STOP-button is pressed

Remaining functions:

For PALFINGER partner.

8. Crane function on level 1 All functions that are displayed on the buttons are on level 1.

The functions are only displayed if the crane is equipped with them.

9. Crane function on level 2 All functions that are displayed next to the buttons are on level 2.

The functions are only displayed if the crane is equipped with them.

Storage, maintenance and care of the wireless system

Cleaning and care Maintain and treat the units carefully to ensure perfect function during their entire product life.

Keep the wireless equipment and its components clean and avoid any contamination.

Clean contaminated components carefully with a wet cloth and mild cleaning agent (e.g. detergent).

Never: • dip the wireless equipment or its components into liquids, • clean the wireless equipment or its components under high pressure; • use aggressive solvents for cleaning; • clean the wireless equipment or its components with compressed air; • or apply to much pressure when wiping the display clean. This could cause scratches.

Maintenance Ensure that: • Damaged gaskets are replaced immediately (humidity). • Damaged operating elements (e.g. keys, buttons, levers) are replaced immediately. • Every time servicing is carried out the RC console is checked as well to make sure it is working

properly.

62


Service All service work must be carried out by PALFINGER service partners in compliance with the PALFINGER training documents and service records. Non-compliance results in loss of any warranty and liability.

Every service and repair must be recorded in the service manual and signed or stamped by a PALFINGER service partner.

Repairs • 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.

Disposal Electronic components are problematic waste. This is in particular applicable to the batteries. Defective batteries may not be disposed of in the environment.

All parts of the remote control must be disposed of in accordance with the national laws and regulations.

63

Chapter 7

In this chapter

Watch out for faults before and during operation ...................................... 67 Working range .......................................................................................... 68 Starting the crane ..................................................................................... 69 Preparing for remote operation ................................................................. 69 Vehicle inclination ..................................................................................... 71 Supporting the vehicle .............................................................................. 72 Pulling outrigger beams out manually ....................................................... 75 Stabilizer cylinders .................................................................................... 76 Bringing the load arm to working position ................................................. 76 Daily function check of safety equipment .................................................. 78

C H A P T E R 7

Preparing for crane operation

65

Chapter 7 Preparing for crane operation

Watch out for faults before and during operation

Danger! Observe all equipment for damage and malfunctions during operation. If damage or malfunctions are found during operation and operation is not stopped immediately, there is an acute risk of fatal injury to the operators and others.

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. • Unserviceable bearings. • Damage to the hydraulic system (leakage, unusually high temperatures etc.). • Unserviceable safety devices. • Loose threaded connections. • Insufficiently secured pins. • Hose winding malfunctions in the hose drum or the hose tray. • Abnormal noises. • Unusually quick or slow working movements. • Failure of the control system. • Operating levers are difficult to operate and/or do not return to neutral position. • Poor rope guidance, rope run out off the guide pulleys and / or guide rollers. • Damaged winch components such as deflection and/or guide pulleys. • Damaged rope.

Restarting the unit is only allowed after corrective measures have been taken and safe operation is guaranteed again.

Operating stands, steps and platforms

Warning! Soiled, icy, snow-covered signs, operating elements, operating stands, steps, platforms, booms, etc. increase the risk of accidents. There is then a severe risk of fatality for the operator and others.

Operating elements, operating stands, steps, platforms, boom etc. must be free of snow, ice, soiling (oil, grease etc.). Operating symbols, information and warning signs must be recognizable. No objects must be left on operating stands, steps, platforms etc.

67


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. If this is impossible the operator must be aided by a qualified signaller.

• Plan in sufficient clearance for crane operation and support. Crane movements may not be obstructed by lines, masts, trees, buildings or other objects.

• The entire working range of the crane is a danger zone. • No other work may be carried out within the working range. • Streets, path ways, bicycle lanes or sidewalks etc. that cross the working area must be blocked

during the entire crane operation.

• The entire working range must be lit during twilight or darkness so that the work can be carried out

safely.

Danger! In case of insufficient visibility stop work immediately.

68


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. • Only one person shall operate the crane at a time.

At ambient temperatures below freezing point • Let the pump run for a few minutes before operating any crane function.

Additionally in remote control mode

Note! After having started up the crane the green flashing warning light (see illustration) starts flashing. This indicates any third persons that the crane may start to move any time.

Preparing for remote operation

Caution! The radio remote control needs to be checked for any malfunctions every time before starting to work, failure to do so may result in severe risk of fatality for the operator and others.

Carefully check the wireless remote control system before starting work every day. Check for: • Self-return of the buttons. • There are no missing or damaged components.

Any defects must be remedied before using the wireless remote control system.

Battery: • Always handle batteries with care. • Only start working with the crane with fully charged battery.

69


Start remote control console: 1. Press the STOP-button and hold it down. 2. Press the function key FN and let both buttons go. 3. As soon as the status LED is on, the unit is ready for operation.

The console is ready for operation.

Caution! In the event of any malfunctions during crane operation and unless the work is interrupted immediately, there is an acute danger of accident.

Warning! Whenever the remote control console is not being used or there is no visual contact with the crane, the console must always be switched off. After finishing work always secure the unit against unauthorized use.

If malfunctions occur, let all buttons go immediately and push the STOP-button. The remote control console may only be used once the malfunction has been corrected by a PALFINGER service partner.

The remote control operation stops automatically if: • There is no radio connection. • The battery is empty. • Any crane function was not operated for more than 5 minutes. A PALFINGER service partner can

individually set the period.

To be able to continue working, the remote control handset must be restarted.

No wireless connection

Possible causes: • Transmitter out of reach. Reduce the distance between transmitter and receiver. • Receiver not switched on. Check if receiver is on, if not switch it on. • No valid (paired) receiver. • Defective radio components. Contact your PALFINGER partner.

Have any defective remote control handset immediately replaced by a PALFINGER service partner.

70


Vehicle inclination Only after having supported and levelled the vehicle properly it is allowed to operate the crane.

Declination indicator

5°

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° and 5°.

Work up to 60° boom position Level the vehicle as horizontal as possible, however within 3° inclination.

Working above 60° boom position (refer to chapter 8, "Crane working position").

Level the vehicle exactly. The air bubble is in the inner circle.

Danger! Vehicle inclination of more than 1° reduces the guide function of the extension booms and leads to side loading of the boom system. There is an acute danger of accident.

Vehicle inclination must not exceed 1° in any direction.

71


Supporting the vehicle

Danger! If the vehicle is not properly supported it may tip over. Working without proper support is prohibited. This creates an acute risk of fatal injury.

The crane must not be moved in working position until the vehicle has been properly supported.

Note! The parking brake must be pulled all the time when supporting the vehicle and during loading. Braked wheels need sufficient ground contact.

Danger! If the additional support of a vehicle is not extended the vehicle may tip over. This creates an acute risk of fatal injury.

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 soil for the following: • Stability. • Hollows (manhole covers, pipelines, etc.). • Sufficient distance to any drop offs, holes, ditches, etc. • Ground inclination 5° maximum in all directions.

Increase the support area according to the ground conditions (refer to table) or find a suitable support area.

Max 5°

72


Ground pressure Ground pressure by support jacks max. 400 N/cm² (58 psi).

Permissible ground pressure under DIN 1054 Heaped up soil, that was not stabilized artificially. 0 - 10 N/cm² (0-14.5 psi)

Asphalt 20 N/cm² (29 psi)

Grown, obviously untouched soil.

1. Mud, turf, marsh 0 N/cm² (0 psi)

2. Incohesive soils:

Fine sand to medium sand 15 N/cm² (21.75 psi)

Coarse sand to gravel 20 N/cm² (29 psi)

Compacted gravel 25 N/cm² (36.25 psi)

3. Cohesive soils: Mushy 0 N/cm² (0 psi) Soft 4 N/cm² (5.8 psi) Stiff 10 N/cm² (14.5 psi)

Semisolid 20 N/cm² (29 psi)

Hard (solid) 30 N/cm² (43.5 psi)

4. Rock:

Weathered 100 N/cm² (145 psi)

Determining necessary support area (use metric or imperial consistently):

Support area A [cm² or in²] = Supporting force F [N or lbs]

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.

Caution! 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.

73


When supporting the crane choose an operating station from where you may view the complete support movement range. Always keep moving crane components in view. No persons and objects are allowed to be in the movement area of the stabilizer outriggers / stabilizer cylinders.

The outrigger beams and stabilizer cylinders need to be operated separately on both sides. To do so, alternately use both operator stations.

Fully extend the outrigger beams (mark must be visible).

Stabilizing sequence The crane stabilizers are designed for absorbing only the crane load! If the vehicle is lifted completely during crane operation, the crane support can fail.

Danger! If the vehicle is lifted partly or completely when on the stabilizers the stabilizing system will be under significantly higher load. This may lead to damage and the vehicle may tip over when the crane is being operated. This creates an acute risk of fatality for the operator and others. Never lift up the vehicle!

It is prohibited to lift the vehicle until the wheels are unloaded. This overloads the support system and reduces the braking effect.

74


In order to ensure safe operation follow the below sequence of stabilizing your vehicle:

Note! Depending on the equipment available on your vehicle like front stabilizer, rear stabilizers or additional stabilizers one or several points may not apply to your model.

3

3

2

1

Extend the stabilizers until they have firm ground contact (support pad). 1. Extend and support the additional stabilizers (left / right). 2. Extend and support the crane stabilizers (left / right). 3. Extend and support the front and rear stabilizers (left /

right).

In general it is only permitted to operate the crane with all stabilizer cylinders being on the ground.

Exception: If the crane is equipped with HPSC stability control (refer to ‘Safety equipment, HPSC stability control’).

Working position stabilizers monitoring In order to lift loads, the stabilizers of cranes with "working position stabilizers monitoring" must be fully extended.

Pulling outrigger beams out manually No persons or objects are allowed to be in the movement area of the outrigger beams. • Lift und unlock the locking shackle. • Move cam lock to the left. • Pull out the stabilizers completely. • Move interlock to the right. Check whether the primary lock has engaged by attempting to move

the outrigger beam in and out.

• Fix the stabilizer extension in the appropriate position and secure the connection pin with linch pin.

75


Stabilizer cylinders Hydraulic stabilizers

Operator station:

Radio-controlled operation:

• Then pull out the stabilizer cylinders one after the other so that you may view the danger zone.

Crank-down stabilizers If the crane is equipped with crank-down stabilizers, crank down the stabilizer extensions until the support jacks have firm ground contact.

If the vehicle is equipped with additional stabilizers proceed as described above.

Bringing the load arm to working position Prerequisites for unfolding the crane

Caution! If the manual extension booms are not properly pinned and secured, they will slide out of the extension booms when unfolding the crane. This creates a severe risk of fatality for the operator and others.

• Extension booms are pinned and secured. • Vehicle is properly supported. • No bystanders or obstacles are in the movement range of the crane.

76


Caution! Not maintaining the minimum distances creates an acute risk of fatality for the operator and others.

• The operator must have full view of all crane movements.


Caution! Extending the extension booms before the main boom is in nearly vertical position causes acute risk of fatality for the operator.

Only extend the extension booms when the main boom has been raised to a near-vertical position. See ‘Unfolding the crane’. • Move the main boom out of its transport position into working position. • Make sure that all mechanically actuated functions are properly secured with connection pin and

lynch pin.

Unfolding the crane

Operator station:


Lift the main boom.

Extend the extension booms.

• The crane is ready for operation.

77


Daily function check of safety equipment Carry out the function check without load and with all extension booms retracted.

Emergency cut-off function check

Danger! If the crane doesn’t stop after pressing the emergency cut-off button or if other crane movements are still possible there is acute danger to life.

Working with a defective emergency cut-off button is grossly negligent. Do not operate the crane and contact a PALFINGER service partner. • Operate any crane function. The crane must move perfectly in all directions. • Press the emergency cut-off button while the crane is moving. The crane must come to a stop. • Again, operate any crane function.

The crane must not move. • Release the emergency cut-off button; The crane should move perfectly in all directions.

Refer also to chapter 5, "Emergency cut-off button".

Functional check of OS hydraulic overload protection

Always carry out a functional check without load before starting work: • Raise the main boom up to the limit stop at maximum speed. The overload protection system must

respond when the limit stop is reached (avoid this test position in working operation). • The movements indicated above must be blocked.

Danger! If the overload protection system does not respond stop the crane IMMEDIATELY, otherwise there is an acute risk of fatal injury.

• Briefly operate the touch valve and lower the main boom.

78

Chapter 8

In this chapter

Load limits ................................................................................................ 81 Working position of the crane ................................................................... 81 Loads ....................................................................................................... 84 Working with loads ................................................................................... 85

C H A P T E R 8

Crane operation

79

Chapter 8 Crane operation

Load limits

Caution! 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. There is severe danger to life for the operator and others.

Load capacity label:

1. Maximum load capacity of the crane. 2. Number of extended extension booms and extensions. 3. Maximum load capacities at the respective outreach.

For load capacity chart refer to chapter 13, 'Technical description'.

If required by national regulations and laws the installer should enclose load capacity charts for additional load ranges (ISC, SHB) in chapter 13.

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; • the component wear increases.

The crane must always be in an optimum working position for the task at hand.

81

Crane operation

Working range Optimum working range:

XX°

B

A

XX° = optimum angle of main boom (between 15° and 30°, dependent on crane type).

When the main boom is below the horizontal the maximum lifting moment cannot be reached, therefore you should avoid this position.

Refer to load capacity chart attached to the crane.

Lower range limit:

Danger! Any working position with main boom completely lowered is prohibited. In this position the crane may be overloaded. Consequently the load may fall down. This creates an acute risk of fatality for the operator and others.

82


Load handling close to the crane using 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.

Upper limit range:

Boom system between 60° and 70° • Working with boom system higher than 60° is only allowed when the outrigger beams are fully

extended.

Danger! At a boom position higher than 60° • Abrupt crane movements may lead to an excessive side

loading of the boom system. Consequently the load may fall down. This creates an acute risk of fatality for the operator and others. When working above 60°, pay particular attention to the stated load limits.

Increasing the lift angle and height may result in side loading of the boom system. The overload protection system is unable to monitor this type of loading.

Therefore pay particular attention to • working within the range shown in the load capacity chart; • smooth crane operation.

83

Crane operation

Working with loads in an operating range over 80° is prohibited.

60°70°

Loads Before loading/unloading • Before lifting any loads check if the load lifting gear is used correctly. • Observe special instructions about load handling and/or lifting gear (e.g. lifting points, center of

gravity, orientation, etc.) • Secure the load.

• The weight of the load must be known. If information about the weight is not available, it has to be

calculated or estimated. • Make sure the load is free to move and not anchored, iced or otherwise attached to the ground. • Before lifting, remove ice or snow from the load. Wet or icy loads may slip off. • Lift the load only above its center of gravity.

84


Working with loads

Caution! There is acute danger to life for operators and others in the entire working range of the crane.

• Notes in chapter 7 'Working range' shall be observed. • Every time before moving the crane, make sure that there are no persons in the

working range of the crane (danger zone). • Stop moving the crane immediately when a person steps into the working range. Restart crane

operation only after all persons have left the working range.

Local regulations regarding loading crane operation shall be observed.

All safety notes of chapter 2 shall be observed. • Before starting to work with the crane the operator has to plan the operation (lift plan). • Any assistants, signalers and bystanders must be informed about the planned operation. • The operator must have full view of the crane, the load and their paths at all times. • If any part of the crane or load path is out of the operator's view it is necessary to involve a

signaller. • Working with a signaller:

• Operator and signaller must be familiar with locally understood signals.

• The signaller must be clearly identified. Only one signaller can give signals at a time to the operator.

• The operator must not be otherwise occupied while operating the crane (e.g. making phone calls, etc.).

• In the case of remote control operation the operator is not allowed to give the handset away. • It may become necessary to relocate or retract the stabilizer cylinders to prevent overloading the

stabilizers during loading/unloading. Relocating the stabilizers is only allowed: • Without load. • With extension booms retracted. • With the load arm secured on the vehicle platform or in transport position.

85

Crane operation

Attaching / detaching loads

• Position the load arm as required. Stop the crane movements.

Caution! When the load is attached or detached by the operator while the crane is still in operation this creates

• through unauthorized crane operation, • by unintended actuation of control equipment on the

operator station or handset of the remote control acute danger to life for the operator and others.

Load attached / detached by assistants:

• Assistant may enter the crane's danger zone only after the operator has given permission. • Only attach/detach loads with permission from the operator and when the crane has stopped

completely. • The assistant must leave the working area when attaching/detaching is completed.

After the assistant has left the danger zone, crane movements may be carried out again.

Load attached / detached by the operator:

In order to attach or detach the load, the operator may need to enter the working area. • Turn off the crane on the crane’s operator station or on the remote control. • Attach / detach the load. • Exit the danger zone. • Turn on the crane.

Lifting / moving loads

Warning! If loads, load handling attachment or ancillary equipment rub against the load arm they may get damaged.

Load, load handling attachment or ancillary equipment must not rub against the load arm. Minimum distance between all crane components and load 0.5m.

86


Caution! 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.

Caution! Abrupt crane movements can make the load swing. Consequently the load may fall down. This creates an acute risk of fatality for the operator and others.

Carry out all crane movements smoothly. • Grasp the operating lever of the crane function firmly. • Press the lever slowly until the crane responds. • Monitor the overload capacity indicator (refer to chapter 5, 'Overload display'). • If the yellow range is reached, reduce the working speed. • Lift the load a little and check whether it is correctly attached and stays in the intended position.

Caution! Operating crane functions at full working speed to the cylinder stop:

• increases the wear of components and reduces the life of the crane;

• the load may fall down. This creates an acute risk of fatality for the operator and others.

• It is prohibited to operate crane functions (with/without load) at full speed to the cylinder stop.

Caution! Releasing the operating levers suddenly can cause the load to swing uncontrollably. Consequently the load may fall down. This creates an acute risk of fatality for the operator and others.

• Finish crane movements slowly and smoothly by releasing the operating levers carefully. • It is possible to operate several crane functions at a time.

This may reduce the speed of the already actuated crane movements.

Warning! If several crane functions are used at a time and one or more are stopped, the remaining active function(s) may increase in speed.

• If crane functions are used simultaneously (combined crane movements create a different load path), reduce the speed of the individual functions accordingly.

In the event of sudden danger In case of an emergency, stop all crane movements immediately (see also 'Emergency cut-off button‘, chapter 5).

87

Crane operation

Lowering the load

Caution! In cranes without overload protection system, the load lowers uncontrollably when the permissible load moment is exceeded.

Refer to chapter 5, 'Capacity indicator'.

Don't increase the outreach when lowering the load.

If you increase the outreach when lowering the load, the load may lower uncontrollably.

Monitor the capacity indicator.

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.

Warning! If the load on the main boom is relieved suddenly, bulk materials are emptied quickly (grab application) or the load is put down quickly with the cable winch, the main boom may snap upwards. Always put loads down slowly.

• Before detaching the load handling attachment make sure the load sits properly and stable. Work interruptions

If it is necessary to leave the crane unattended: • Land the load. • Put down the load arm properly. • Turn off the crane. • Secure the crane against unauthorized use.

Resuming work • If crane has been left unattended, check whether the crane has been tampered with before

resuming crane operation. Ensure secure crane operation.

If the crane has been tampered with by unauthorized persons: • (Refer to chapter 7 'Preparing for crane operation'). Carry out all function checks described in

chapter 7.

In devices with remote control it is additionally necessary to: • check that the appropriate device control panel (control handset) is used (as indicated) before

resuming crane operation.

88


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.

89

Chapter 9

In this chapter

Bringing the crane into transport position .................................................. 93 Retracting the stabilizers .......................................................................... 94 Ending radio remote control operation ...................................................... 97 Before driving ........................................................................................... 97

C H A P T E R 9

Ending operation

91

Chapter 9 Ending operation

Bringing the crane into transport position All safety notes of chapter 2 shall be observed.

Caution! If the manual extension booms are not properly pinned and secured, they will slide out of the extension booms when folding the crane. This creates a severe risk of fatality for the operator and others.

Before folding the crane push in the mechanical extensions and secure them properly with connection pin and lynch pin.

Caution! Not maintaining the minimum distances creates an acute risk of fatality for the operator and others.

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 removed and/or secured, refer to chapter 6.

The operator must have full view of all crane movements.

Operator station:


Retract the hydraulic extension booms

Move the main boom to transport position.

93

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.

Secure the boom system sufficiently against side movements.

When the boom rests on the vehicle platform the vehicle's total height may change.

Note! If the crane is equipped with a transport position indicator, monitor the signal.

Retracting the stabilizers

Danger! If the load arm is not in transport position while retracting the 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.


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.

94


When retracting the supports choose an operating station from where you may view the complete support movement range. Always keep moving supports in view. No persons and objects are allowed to be in the movement area of the outrigger beam / stabilizer cylinders.

The outrigger beams and stabilizer cylinders need to be operated separately on both sides. Change the operating station.

Danger! Incompletely retracted and/or unsecured stabilizer cylinders and outrigger beams create an acute risk of fatality for the operator and others. Inadequate or lack of securing of stabilizer cylinders and/or outrigger beams is prohibited. There is an acute risk of fatality for the operator and others.

Retract the stabilizer cylinder completely.

Push in all manual outrigger beams completely, lock and secure them.

Danger! Not maintaining the minimum distances given in chapter 2 creates an acute risk of fatality for the operator and others.

95

Ending operation

Retract stabilizer cylinder

Operator station:


• Retract the stabilizer cylinders separately to always have full view of the danger zone.

Warning! When retracting the opposite stabilizer cylinders the operator must always have full view of these cylinders.

If the crane is equipped with crank-down stabilizers, wind in the stabilizer extensions completely.

96


Ending radio remote control operation

• Push the stop button. • Charge the battery. • Secure the remote control console against unauthorized use.

After finishing all crane movements • Turn off the crane. • Secure the crane against unauthorized use. • Stop the vehicle motor. • Pull the ignition key. • Lock the driver's cab.

Before driving

Caution! 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.

Every time before starting to drive check that: • the crane has not been tampered with by unauthorized persons; • the stabilizer outrigger beams and stabilizer cylinders are completely retracted and properly

secured; • the crane (hydraulic pump) is off; • the crane is secured for transport and side movement is not possible.

Caution! Any winch components, load handling attachment, etc. protruding over the vehicle width create an acute danger of accident and danger of life.

• Remove any winch components, load handling attachments, lifting gear, ancillary equipment, etc. that protrude over the vehicle width in transport position or are loose or unsecured and store them before starting to drive.

• The load is properly secured according to the local regulations and laws.

97

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 the transport position").

Note! If the crane is equipped with a transport position indicator, monitor the signal.

98

Chapter 10

In this chapter

General .................................................................................................. 101 Operating hours counter ......................................................................... 102 Maintenance ........................................................................................... 103 Cleaning ................................................................................................. 104 Visual inspection .................................................................................... 105 Machine lubrication ................................................................................. 107 Hydraulic oil change ............................................................................... 112 Paint repair ............................................................................................. 115

C H A P T E R 1 0

Maintenance

99

Chapter 10 Maintenance

General Reliability, safety and service life of an equipment item are extremely dependent on maintenance and servicing. Maintenance and service are therefore not a recommendation - the company operating the equipment must carry out the work (or have it carried out by a third party).

The company operating the equipment must ensure that all maintenance work is carried out in compliance with these operating instructions and national law.

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.

When replacing device components during repair or warranty use exclusively PALFINGER spare parts. Any damages to the device or accidents because of different parts are not covered by the liability of PALFINGER.

For further information, please refer to service manual (supplied with crane).

Keep all service records. Every service and repair must be recorded in the service manual and signed and stamped by a person authorized by PALFINGER.

Note! Absolutely comply with the PALFINGER maintenance guidelines and intervals. Non-compliance results in loss of any warranty and liability.

Arranged by Executed by

Maintenance Operating company Operating company / operator / PALFINGER partner

Service Operating company PALFINGER partner

Refer also to chapter 2 'Safety for individuals'.

Note! Use the consumables recommended by PALFINGER. PALFINGER will not assume liability for any damages caused by applying wrong consumables.

Use only original PALFINGER lubricants or lubricants that correspond with the lubricant specification given in this chapter.

Replacing hydraulic components

Warning! Despite pressure relief in the hydraulic system there might still be residual pressure. While opening the hydraulic system there is danger to the operator and others due to the residual pressure and/or hot hydraulic oil.

If it is necessary to replace hydraulic components contact your PALFINGER service center.

101

Maintenance

Relieving the pressure of the hydraulic system: • The unit must be switched off and the power supply disconnected. • Secure the unit against being switched on unintentionally. • Push all operating levers in both switching positions several times.

The pressure in the hydraulic system is relieved apart from possible residual pressures.

Warning! Let the hydraulic oil cool down sufficiently to prevent scalding.

Operating hours counter The counter’s display shows the total number of operating hours, the number of hours until the next service and the number of hours until the next scheduled maintenance.

-1100

12

1 Display starts blinking when it gets down to 100 hours of use.

2 Solid red light stays on from 0 hours of use.

The operating hours counter counts down from 500 to 0. As of 100, the display starts to flash. From 0 the solid red light comes on and stays on.

Using the minus sign, the counter then counts up from 0 (-1, -2, -3 etc.).

After the crane is turned on (power supply), its total operating hours are shown on the display for 10 seconds.

After this period, the display shows the number of operating hours until the next service.

The service must be carried out by a PALFINGER service workshop at around 0 hours and logged accordingly in the service manual.

If the crane is used for less than 500 hours a year, a service must be arranged at least once annually.

After the service has been done, the service workshop resets the operating hours counter to 500 hours.

102


Maintenance

Note! Have only qualified personnel carry out maintenance.

Maintenance and servicing recommendations in these operating instructions are of general nature and apply to several PALFINGER products.

Maintenance has to be carried out after every 50 operating hours.

However, the maintenance intervals depend also on application, duty cycle and environmental conditions. Road salt, sand, etc. are especially aggressive and speed up corrosion and wear. Therefore maintenance may be required in even shorter intervals.

Maintenance and service may only be carried out while the unit is out of operation (hydraulic and electric power turned off).

Correct order of maintenance tasks 1. Clean the unit thoroughly.

2. Visual inspection.

3. Lubricate the unit.

Before longer downtimes of the device

Before longer downtimes complete maintenance has to be carried out on the unit. All blank metal parts must be protected using an anti-corrosion preservative (except the extension system, refer to ‘Device lubrication’ in chapter 10). Retract all hydraulic cylinders completely.

After device downtimes (longer than 3 weeks)

After downtimes the device must be lubricated (refer to ‘Device lubrication’ in chapter 10).

103

Maintenance

Cleaning

Note! Thorough cleaning increases the reliability and the service life of the unit.

Use only environmentally friendly, pH neutral and skin-friendly cleaning agents. This protects the environment and avoids oxidations on the unit.

Warning! Oil and grease must not be released into the environment.

Clean the device only in suitable places (oil separator).

Do not use abrasive rags, brushes, etc.

Cleaning procedure

Warning! Wet or damp electric parts may cause short circuits in the electronic system or other malfunctions of the unit.

• Carry out cleaning work only when the unit is turned off. • Secure the unit against being switched on unintentionally. • Keep the working environment clean.

Warning! Contaminations, especially oil or other lubricants must be cleaned off immediately as a precaution against slipping.

Using high-pressure cleaning equipment:

Warning! Failure to comply with the following steps may result in damage to the unit.

• The operating instructions of the high-pressure cleaning equipment shall be observed. • Never exceed the water temperature / cleaning agent temperature of 60° C. • Always ensure that there is sufficient distance between the nozzle and the unit.

• Never point the water jet directly at: • Electric and electronic parts (water penetration); • Plastic parts (deformation, breakage); • Bearings or bearing points (forces dirt into and lubricant out of

the bearing); • Signs (can become detached or unrecognizable);

104


Visual inspection

Danger! Missing equipment, damage, cracks on crane components, ancillary equipment or load lifting gear creates an acute risk of fatality to the operator and others.

Note! Determine the cause of any damage to prevent reoccurrence. Replace any missing, worn out or damaged components immediately.

Check the crane and its attached parts as follows:

Fasteners and other hardware • Check completeness and function of bolts, screws, pins and locking devices; check pins for any

deformation and sufficient security (e. g. lynch pins). • Tighten any loose bolts/nuts to appropriate torque specification. Contact a PALFINGER partner for

additional information as needed.

Immediately replace any missing or inoperative hardware.

Steel parts • Cracks on components, specifically on welds and bending edges. • Deformations. • Corrosion.

Hydraulic system • Entire hydraulic system (fittings, pipes, hoses, valves, cylinders, etc.) for leaking or loose

connections; • Hydraulic pipes for deformations and cracks; • Hoses for cuts, abrasions, cracks, porosity, etc.; • Cable/hose protection for incompleteness and damage, etc.; • Hydraulic fluid level (unsupported and in transport position); • Absence of load-holding valve seals.

Electric system • Cables for unwinding, abrasions, cracks, etc.; • Cable/hose protection for incompleteness and damage, etc.; • Sockets, switches, display elements, sensors for improper attachment, damage, etc.

Covers • Completeness of all covers. • Covers for damages.

105

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'.

Danger! Damaged ropes can break during rope winch operation. There is an acute danger of accident.

Unwind the rope while keeping it tight and check for: • Contamination; • Insufficient lubrication; • Corrosion. • Damaged rope clamps; • Broken strands, broken wires, grinding points, abrasion, bird caging, constrictions, necking, kinks

etc.

Rope discarding:

If a rope is so damaged that it can be no longer used it must be discarded.

The rope must be discarded if a defined number of broken wires can be detected in the outer braid strands.

Check the rope in the location where the most damage has occurred.

Controlled length Number of visible wire breaks

6 x rope diameter 5

30 x rope diameter 10

30 x d6 x d

d

In the case of permanent deformations such as worn or flat spots, bird caging, kinks, necking (rope diameter reduced by more than 10%), etc. the rope must also be discarded.

Rewind the rope under tension.

106


Labels Check for legibility and completeness.

Check the load lifting gear • Hooks for cracks, deformations and wear. • Sensor unit of manual extension booms for cracks,

deformation, leaks and wear. Mark (A) must not be visible. • Safety latch for proper function.

Check of safety devices Refer to 'Daily function check of the safety equipment' chapter 7.

Machine lubrication

Caution! If lubricant gets into your eyes, rinse with fresh water immediately and consult a doctor or a hospital! If lubricant comes into contact with the skin, clean surface of skin with fresh water.

Lubricant specification

Note! PALFINGER recommends using biodegradable grease. Do not mix incompatible lubricants. Even biodegradable grease must not be released into the environment. 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.

107

Maintenance

Grease: Available from most PALFINGER partners according to national guidelines under Order no. EZ982 – 5 kg (11 lb) can Order no. EZ1432 – 50 kg (110 lb) barrel

Technical data Tested according to

Structure smooth

Consistency (NLGI) 2 DIN 51818

Indication code KP2K-35 DIN 51502

Dropping point °C 150 ISO 2176

Worked penetration 265/295 1/10 mm ISO 2137

Oxidation stability 100h/100°C max. 0.2bar DIN 51808

Basic oil viscosity at 40° C > 80 mm²/s

Behavior in water Assessment level 0/90 DIN 51807-1

Rope grease: Available from most PALFINGER partners according to national guidelines under Order no. W10008415

Teflon® spray: Available from most PALFINGER partners according to national guidelines under Order no. EZ2807

Maintenance symbols

Rope grease

Teflon® spray

Grease

Greasing prohibited *

108


Maintenance (operating company, operator) every 50 hours or after downtimes lasting more than 3 months.

1 Operating levers, control rods 2 Stabilizer outrigger slide surface 3 Cam lock (outrigger safety mechanism) 4 Pin bushings 5 Jordal rails*) 6 Hydraulic extension booms, mechanical extension booms 7 Lubricate column bearing 8 Crank of stabilizer 9 Rope winch (limit switch, rope)

10 Hook

*) Lubrication points indicated by this symbol must never be lubricated with grease. If lubricating is necessary (chattering, creaking), only use PALFINGER Teflon® spray.

109

Maintenance

The illustrated crane is an example and shows components which may be optional on your unit, depending on model and version.

110


Lubrication

Danger! Unintended crane movement during lubrication creates an acute risk of fatality for the operator and others.

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:

Warning! Dirt in the bearing may cause damage to the unit and increase repair cost and downtime.

• Remove all old, dirty grease and other contamination from the lubricating point. Otherwise dirt in old grease will be pressed into the bearing point.

• Press the grease into the bearing point. • Move the components. This distributes the grease in the bearing. • Press more grease into the grease nipple.

• Repeat this until fresh grease begins to come out of the bearing point.

Warning! Excess grease at lubricating points and bearing points increase the risk of accident and are a danger to the environment.

• After lubricating remove any excess grease. • Do not use excess grease again. • Dispose of excess grease in accordance with the applicable national legislation!

Grease all lubricating points on the unit.

Rope grease

Warning! Sticking out strands can cause severe hand injuries when you lubricate the load rope.

Therefore always wear appropriate gloves when lubricating the load rope.

111

Maintenance

1. Unwind the load rope under tension. 2. Turn off the crane. 3. Apply rope grease over the entire rope length using a cloth or brush. 4. Turn the crane on and wind up the load rope under tension.

Note! Ensure that the load rope is wound up properly, otherwise damages may occur under load.

Hydraulic oil change Hydraulic oil change, hydraulic oil maintenance

Hydraulic oil change Hydraulic oil needs to be changed after every 500 operating hours or once every year.

Information! Oil maintenance on a yearly basis significantly increases the oil change intervals. For the operating company this means cost saving and also a reduced quantity of discarded oil and therefore a less pollution. Have oil maintenance carried out by a PALFINGER partner on a yearly basis.

Hydraulic oil maintenance Oil maintenance includes the following actions: • Oil filtration. • Water separation. • Check of oil purity. • Filter change.

112


Hydraulic oil

Note! PALFINGER recommends the use of biodegradable oil. Even biodegradable oil must not be released into the environment.

Required characteristics

Hydraulic oil Operating temperature Synthetic ester (biologically degradable): approx. -30 to +80ºC (-22°F to +176°F) Mineral oil (not biologically degradable): approx. -30 to +80ºC (-22°F to +176°F)

Use either synthetic ester (biologically degradable) or mineral oil (not biologically degradable).

The hydraulic fluid has a working range of between -30° and 80°C (-22°F and +176F), depending on the outside temperature.

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. • Good thermal and mechanical properties; • Considerable ageing resistance. • Good corrosion protection; • Sufficient cold flow behavior. • Good air release capability. • Excellent foam behavior; • Does not attack seals and hydraulic hoses.

113

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 °CA

B

C

A Viscosity mm²/s or cSt

B ISO reference temperature in °Celsius

C Recommended range

High temperature range: 10 cSt Cold start limit: 1000 cSt Purity class: 17/15/12 (in accordance with ISO 4406)

114


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 caused by bird dropping, salt water or similar immediately. Protects the unit against corrosion.

Refer to PALFINGER repair instructions.

115

Chapter 11

In this chapter

General .................................................................................................. 119 Check of threaded fasteners ................................................................... 119 Initial servicing after 50 operating hours ................................................. 121 Initial servicing after one year ................................................................. 121 After every 500 operating hours or once every year ............................... 121 After every 3000 working hours or once every three years ..................... 122 Every 6 years ......................................................................................... 122 Gear oil ................................................................................................... 122 Check of control equipment .................................................................... 123 Protective hoses ..................................................................................... 123 Repairs ................................................................................................... 123 Lowering rate .......................................................................................... 123

C H A P T E R 1 1

Service

117

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.

The operating company must arrange a service when the operating hour counter indicates it. For further information, please refer to service manual (supplied with crane).

Keep all service records. Every service and repair must be recorded in the service manual and signed or stamped by a PALFINGER service partner.

Preparing for service:

1. Clean the device (refer to 'Cleaning' in chapter 10).

2. Make a visual check (refer to 'Visual inspection' in chapter 10).

Check of threaded fasteners

Caution! Loose, damaged or over-tightened threaded connections can 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% Screws: DIN EN ISO 4762, 4014 Nuts: DIN EN ISO 4032 Washers: DIN EN ISO 7090

119

Service

Thread: Stability: 5.6 Stability: 6.8 Stability: 8.8 Stability: 10.9 Stability: 12.9 M03 0.7 (0.6) 0.9 (0.7) 1.2 (0.9) 1.5 (1.2) M04 1.7 (1.3) 2.1 (1.6) 2.6 (2) 3.9 (2.9) 4.5 (3.4)

M05 3.4 (2.6) 4.3 (3.2) 5.2 (3.9) 7.6 (5.7) 8.9 (6.6)

M06 5.9 (4.4) 7.3 (5.4) 9 (6.7) 13,2 (9,8) 15.4 (12)

M08 21.6 (16) 31.8 (24) 37.2 (28)

M10 43 (32) 63 (47) 73 (54)

M12 73 (54) 108 (80) 126 (93)

M14 117 (87) 172 (127) 201 (149)

M16 180 (133) 264 (195) 309 (228)

M18 259 (292) 369 (273) 432 (319)

M20 363 (268) 517 (382) 605 (447)

M22 495 (366) 704 (520) 824 (608)

M24 625 (461) 890 (657) 1041 (768)

Tightening torques for Bride screws in Nm (ft.lbs): Tolerance range +/- 10%

Thread: Material: 42 Cr Mo 4v M 20 x 1.5 210 (155)

Service symbols

Functional check

Change

Visual check

Check bolts for tightness

Teflon® spray

Grease

Low-viscosity grease EZ5511 / 1kg can

Rope grease

120

Chapter 11 Service

Initial servicing after 50 operating hours Description Activity Oil filter package

Worm slewing drive (check level - lower worm must run in grease)

Hydraulic fluid level (unsupported and in transport position)

Tighten hydraulic lines / hoses, screw joints

Crane base fixing

Initial servicing after one year

Description Activity

Rope winch - gear oil (see ‘Gear oil’, chapter 11)

After every 500 operating hours or once every year Description Activity Oil filter package - hydraulic oil

Worm slewing drive (check level - lower worm must run in grease)

Crane base fixing

Extension booms Hydraulic lines / hoses, screw joints

End position switch All safety devices

Ancillary equipment

Pump performance – speed

Operating levers, control rods

Load attachment Crane column bearing clearance: see training documentation.

121

Service

After every 3000 working hours or once every three years


Rope winch - gear oil (see ‘Gear oil’, chapter 11)

Every 6 years


Hydraulic hoses

Gear oil The gear oil must be replaced during the first annual service. And after that after every 3000 working hours or once every three years, whichever comes first.

Only the PALFINGER approved gear oil PALFINGER GEAR GUARD must be used.

Property Unit Density at 15°C [kg/m³] 900 Flashpoint (CoC) [°C] 205 Viscosity class [SAE J 306]

[ISO VG] 8W-90

150 Viscosity at 40°C Viscosity at 100°C [mm²/s] 159

15.6 Brookfield viscosity at -26°C [mPa*s] 128.000 Pour point [°C] < -30

Available from most PALFINGER partners according to national guidelines under Order no. EZ6311 – 4 l can Order no. EZ6312 – 20 l can

122

Chapter 11 Service

Check of control equipment

Note! The entire safety equipment must be checked during servicing (overload test, HPSC test, etc.).

Protective hoses

During servicing, check protective hoses, covers etc. and replace damaged and missing parts.

Repairs • 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.

123

Chapter 12

In this chapter

Decommissioning and disposal guidelines.............................................. 127

C H A P T E R 1 2

Decommissioning and disposal

125

Chapter 12 Decommissioning and disposal

Decommissioning and disposal guidelines Properly disassemble the unit.

Warning! 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. Comply with the locally applicable laws when disposing of the unit's single parts and consumables.

• Clean all oily and greasy parts. • Dispose of the components according to their nature (steel, plastic, electric and electronic parts,

etc.). • Dispose of all consumables - even biodegradable ones - in an environmentally friendly way. • Contact your PALFINGER partner regarding the purchase of a new unit.

127

Index

A Additionally in remote control mode • 69 Adverse working conditions • 12 After every 3000 working hours or once

every three years • 122 After every 500 operating hours or once

every year • 121 After maintenance, service and repairs •

18 Ancillary equipment • 47, 51 B Before driving • 97 Bringing the crane into transport position

• 93 Bringing the load arm to working position

• 76 C Capacity indicator • 42 CE symbol • 21 Check of control equipment • 123 Check of threaded fasteners • 119 Cleaning • 104 Components • 59 Components of the remote control • 58 Crane control systems • 58 Crane operation • 79 D Daily function check of safety equipment

• 78 Danger from power lines • 16 Danger of getting crushed • 13 Dangers caused by exhaust • 16

Decommissioning and disposal • 125 Decommissioning and disposal

guidelines • 127 Device and function • 23 E Emergency cut-off button / push-button •

41, 61 Emergency cut-off function check • 78 Emergency operation after remote

control failure • 44 Ending operation • 91 Ending radio remote control operation •

97 Every 6 years • 122 F Function labels • 27 Functional check of OS hydraulic

overload protection • 78 G Gear oil • 122 General • 19, 41, 49, 58, 101, 119 Government regulations and standards

for operating the unit • 12 Graphics and pictures • 5 Guidelines to prevent dangers • 58 H Hook • 50 Hydraulic oil • 113 Hydraulic oil change • 112 Hydraulic oil change, hydraulic oil

maintenance • 112 Hydraulic overload protection • 43

Index

129

Index

I Initial servicing after 50 operating hours •

121 Initial servicing after one year • 121 L Labels for North America • 34 Load limits • 81 Loads • 84 Lowering rate • 123 Lubricant specification • 107 Lubrication • 111 M Machine lubrication • 107 Main components • 25 Maintenance • 99, 103 Mechanical extension booms • 57 Modifications to unit • 22 N Noise emission • 15 Notes regarding the operating

instructions • 1 O Operating hours counter • 102 Operating instructions • 3 Operating levers • 60 Operators • 22 Overload protection in radio remote

control operation • 43 Overview of labels • 30 P Paint repair • 115 Preparing for crane operation • 65 Preparing for remote operation • 61, 69 Protective hoses • 123 Pulling outrigger beams out manually •

75 R Remote control • 58 Repairs • 123 Residual risks • 11 Retract stabilizer cylinder • 96 Retracting the stabilizers • 94 Risk of burns • 15 Risk of falling • 13 Rope grease • 111 Rope winch • 51 S Safety and Health Standards • 7

Safety equipment • 39 Safety for individuals • 9 Service • 117 Slingers, other attachments to lift the

load • 50 Stabilizer cylinders • 76 Stabilizing sequence • 74 Starting the crane • 69 Storage, maintenance and care of the

wireless system • 62 Structure of system • 21 Supporting the vehicle • 72 Symbols • 5 Symbols of remote control console • 28 T Technical description • 131 Terms • 4 Transport position monitoring system •

44 U Use for intended purpose / limits of the

device • 10 V Validity of operating instructions • 3 Vehicle inclination • 71 Visual inspection • 105 W Watch out for faults before and during

operation • 67 Working position of the crane • 81 Working range • 68 Working with loads • 85

130

Chapter 13

C H A P T E R 1 3

Technical description

131

132

132

Technical SpecificationPC 3800 JI(S026-ST-A)

Edition 03/2015 ENPALFINGER AG

5101 Bergheim / AustriaLamprechtshausener Bundesstraße 8

www.palfinger.com

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PC 3800 JI 0.01000

03/2015

Signs and symbols - abbreviation

Limitation of rotation over FLLimitation of rotation, main boom over ILimitation of rotation over IIS001Limitation of rotation IIS

Crane with 9 hydraulic extension boomsCrane with 8 hydraulic extension boomsCrane with 7 hydraulic extension boomsCrane with 6 hydraulic extension boomsCrane with 5 hydraulic extension boomsCrane with 4 hydraulic extension boomsCrane with 3 hydraulic extension boomsCrane with 2 hydraulic extension boomsCrane with one hydraulic extension boom

HGFEDCBA()Hydraulic extensionsHYA, PJHY

SHPLSEHPLSHigh Power Lifting SystemHPLS

Cross lever controlKK1Linear lever controlKL0Top seat - controlHOST

with control valveHEC02Rear-stabilizerHEC

EINS Pull-in part

Integrated baseEGGSemi-trailer installationSATMounting LKWLKWType - crane BaseGRA

IS003IS002

manually High Power Lifting System

Radio remote controlFFSTRemote controlFERN

Dual Power System PlusDual Power SystemDPS

Support controllable from top seatSR.Both side extension box - hydraulicalBoth side extension box - extendedExtension box telescopicBoth side extension box - extendedBoth side extension boxOne side extension box

R.XR4R3R2R1R0

without extension boxR

-->123456789123456789-->

Page-A

ABST Support

Counter control sideControl valve side

Valid from crane numberValid to crane number

Page-B

MHPLSSuper High Power Lifting SystemHigh Power Lifting System

DPSP,DPS+

with IS002, IG001IK006with IS001, IG001IK004without IS001, with IG001IK002Standing platform FFSTIKONS

2 portIG0023 portIG001RailingIG

Standard seatHS012Tiltable seatHS005Top seat - standardHSITZ

Folding seat with heaterHK004Seat with heaterHK003Tiltable seatHK002Standard seatHK001Top seat FFSTHKONS

Pull-in part (J103E01SA)EIN...

Installation width with hose-equipment2, 4, 2/4Installation width without hose-equipmentX

Rear module

Hydraulically tiltable stabilizer cylinder

HEM Standard

CWC Comfort Winch Control RTC Rope Tension ControlSRC Synchronized Rope Control

HSTZY

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PC 3800 JI0.02000

03/2015


STU03Stabilizer ram -150mm

IH Top seat

Emergency control - crane column, double circulitEmergency control - crane column

NK2K

Floor controlHigh stand platform

NK

FLControl - crane

SOSTZ

Quick-coupling, crane + PJQuick-coupling, PJQuick-coupling, crane

MULTI3MULTI2MULTI1Quick-couplingSKUPP

with 2 pressure ranges + jumper with one pressure range

SHB07SHB01Slew angle dependent capacity limitationSHB

Power link rope winch (hydraulic tiltable at main boom)SHEKSKESK

with limiting switch - outer boomwithout limiting switch - outer boomwith limiting switch - main boomSHE

Rope winchS

PJV see V

Variable displacement pumpFixed displacement pump

PU003PU002Type - pumpPUMPE

Fly-JibPJ

Paltronic 150PT150Paltronic 50PT050

1 Auxiliary equipment - hose drum (inside)T4I 2 Auxiliary equipments - hose drum (inside)

2 Auxiliary equipmentsJ041 Auxiliary equipmentJ02Hose-equipment PJ PJKSL

see HYAHydraulic extensionsPJHY

PaltronicPAL

Oil cooler 10.5kW, mountedOil cooler 20kW, looseOil cooler 20kW, mountedOil cooler 8.5kW, looseOil cooler 10.5kW, looseOil cooler 8.5kW, mounted

ÖLK07ÖLK05ÖLK04ÖLK03ÖLK02ÖLK01Oil coolerOELKU

2 1 Auxiliary equipment - hose tray4 2 Auxiliary equipments - hose trayT2 1 Auxiliary equipment - hose drum

Multifaster

Hose-equipment SL

JV...

MHEH

Combustion motorElectric motor

2 Auxiliary equipments - hose drumT2I

Fly-Jib

T4

Extension

without limiting switch - main boomSH

STU01Separate-stabilizer

STGA

Stabilizer ram -100mm

ISC Integrated Stability Control ISC01 Support control+SHBISC-S ISC standardISC-L ISC light+SHBHPSC-L High Performance Stability Control lightHPSC continuous High Performance Stability Control

HF Top seat - ground control

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PC 3800 JI 0.03000

03/2015


AUSG

Extension 100mm

4 4 strand

KT... Crane tank ...l

STEIL Monitoring the steep position STEIL1 Monitoring the steep positionSTEIL2 Monitoring the steep position - Fly-Jib

STT Stabilizer plates Std Standard100

WALVOIL SDM081SALAMI VDM07

NORDHYDRAULIK RSQ240NORDHYDRAULIK RS220NORDHYDRAULIK RS210DANFOSS PVG32REXROTH M4-12

VDM07SDM081RSQ240RS220RS210PVG32M4-12Control valveTSCH,TSTB

Unreeve the rope

Auxiliary tank ...lTL...Auxiliary tankTKLO

Crane tankTKKR

4,5t3,5t2,5t1,5t

4,53,52,51,5Max. rope winch capacity:SWK

2GETR 2-Slewing gear1-Slewing gear1GETRSlewing systemSWERK

Page-A= STZY3 B= STZS3Page-A= STZS3 B= STZY3Hydraulically tiltable stabilizer cylinderStabilizer ram - slewableStabilizer ram - rigidType without support

STZYS3STZS3YSTZYSTZY3STZS3STZOStabilizer ramSTZ

Transport position rope

Extension 200mm

TOT Dead center TOWI Dead center over balanceTOQU Dead center over transverse sparSE continuous

TSEIL

200

DNCE50 DINOIL DNCE50

2 strand1 1 strand2

Rope winch, strandSTRAN

DN46 DINOIL DN46

EING Reeve the rope

V,PJV Extensions V...() ...Extensions by HYA()V...A ...Extensions by HYAAV...B ...Extensions by HYABV...C ...Extensions by HYACV...D ...Extensions by HYADV...E ...Extensions by HYAEV...F ...Extensions by HYAFV...G ...Extensions by HYAGV...H ...Extensions by HYAH

Attachment part

VBH Crane height 180cm180cmSpecial overall height

ZUBA BRI-4 4x BoltsBRI-8 8x BoltsBRI-4B 4x Bolts coatedBRI-8B 8x Bolts coated

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PC 3800 JI

03/2015

Table of Contents

0 PREFACE 0.01000 Signs and symbols - abbreviation

0.02000 Signs and symbols - abbreviation

0.03000 Signs and symbols - abbreviation

010 SPECIFICATIONS 010.01100 Specifications

010.01110 Crane weight

010.01120 Extension

010.02100 Transport position

010.02110 Transport position SH,SHE

010.03100 Working positions

010.04100 Rope winch SH,SHE 0.8t

010.05100 Control stand

010.05110 Counter control

010.05120 Radio remote control

010.06100 Stationary mounting

020 LIFTING CAPACITY DIAGRAM 020.01100JI Lifting capacity diagram PC 3800 A

020.02100JI Lifting capacity diagram PC 3800 B

Page

H1/B2 EN12999

[26,920 ft.lb]3,7 mt (36,5 kNm)

[4,400 lb]2000 kg

[16' 50"]5,0 m

325

[2,730 ft.lb]0,4 mt (3,7 kNm)

[3,190 psi]22.0 MPa (220 bar)

[3.2 US gpm]12 l/min

[31,710 ft.lb]4,4 mt (43,0 kNm)

[2,950 ft.lb]0,4 mt (4,0 kNm)

[12' 20"]3,7 m

HYA A

[16' 50"]5,0 m

HYA B

[4.0 US gpm]15 l/min

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PC 3800 JI 010.01100

03/2015

Specifications

Rope winch

Pump capacity:

Slewing area:

Operating pressure:

Max. hydraulic outreach:

Slewing torque:

Torsional moment (dynamic)

Subject to change, production tolerances have to be taken into account.

Pump capacity:

Max. hydraulic outreach:

Crane moment (dynamic)

Max. lifting capacity:

Basic data

Classification:

Max. lifting moment:

FL

HYA A

25 kg[55 lb]

6 kg[55 lb]

FFST50 kg[110 lb]

SH 0.8t SHE 0.8t

[570 lb]258 kg

40 kg[88 lb]

43 kg[95 lb]

STRAN2 32 kg[71 lb]

HYA B [624 lb]283 kg

STRAN120 kg[44 lb]

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PC 3800 JI010.01110

03/2015

Crane weight

Control system

Rope winch

Additional weight


All weights are without accessories, auxiliary equipment and oil.

Crane weight

Control stand Counter control

m [ft]

DT_S026-AS.ASMS026-AS_SKEL_AUS

Ansicht NEW_VIEW_9Vereinfachte Darstellung: S026-STA_V2B_AUSSnapshot/Explosion: S026-STA_V2B_AUS

HYA A

HYA B

HYA A

HYA B

HYA A

HYA B

7,1 m[23 ft]

11 kg[24 lb]

[1,433 lb]650 kg

[1,280 lb]580 kg

7,1 m[23 ft] [617 lb]

280 kg

V1

kg[lb]

V1 V2

V1 V2

5,0 m[16 ft]

15 kg[33 lb]

6,0 m[20 ft]

18 kg[40 lb]

15 kg[33 lb]

5,0 m[16 ft]

6,0 m[20 ft] [1,280 lb]

580 kg

6,0 m[20 ft]

V1 V2

6,0 m[20 ft]

V2

kg[lb] kg

[lb]

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PC 3800 JI 010.01120

03/2015

Extension

Max. outreach

Weight

Load capacity


1675

[65.

94]

1018 [40.08] PC 3800 V2B

779 [30.65] PC 3800 A,V1A,B153 [6.04]

360 [14.17]

220 [8.66]

min. 15

R158

[6.2

1]

169

[6.6

3]

180[7.09]

360 [14.17]

445 [17.52]

131

[5.1

6]

1630

[64.

17]

177

[6.9

5]

134

[5.2

8]

S026-STA_SKEL_LADE

Ansicht NEW_VIEW_1Vereinfachte Darstellung: S025-STASnapshot/Explosion: S026-STA_ZUS Ansicht NEW_VIEW_3Vereinfachte Darstellung: S026-STASnapshot/Explosion: S026-STA_ZUS2

Ansicht NEW_VIEW_4Vereinfachte Darstellung: S026-STA_ZUS_R�KANSICHTSnapshot/Explosion: S026-STA_ZUS_R�KANSICHT

325

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PC 3800 JI010.02100

03/2015

Transport positionSubject to change, production tolerances have to be taken into account.

R245

[9.65

]

SH

300

[11.

81]

SHE

317

[12.

48]

197

[7.7

6]

1285

[50.

59]

224 [8.82]

A 931 [36.67] V1A,B 981 [38.63]

V2A,V1B 1024 [40.33]

32

A111

[4.3

6]V1

A,B

60 [2

.36]

V2A,

V1B

3[.1

3]

605

[23.

82]

206 [8.11]

1710

[67.

32]

129 [5.10]

180[7.09]

360 [14.17]

445 [17.52]

220 [8.66]

360 [14.17]

Seilwinden konstruktionsbedingt unterdr�kt!Im Modell zur�kholen: S026H02KA.ASMKMT067KA.ASM>Gruppe Rollenkopf

S026-STA_SKEL_SW

Ansicht NEW_VIEW_1Vereinfachte Darstellung: S026-STA_SW_KOMPLETTSnapshot/Explosion: S026-STA_SW

EP 984 SHEP 979 SHE

UR316

325

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PC 3800 JI 010.02110

03/2015

Transport position SH,SHESubject to change, production tolerances have to be taken into account.

1339

[52.

72]

1690 [66.54]1447 [56.97]

70 [2.76]140 [5.51]210 [8.27]

1908

[75.

11]

1601

[63.

02]

153 [6.04]

R1782 [70.15]

3290

[129

.53]

372 [14.63]

1575

[62.

01]

75


S025-STA_SKEL_LADE

Ansicht NEW_VIEW_1Vereinfachte Darstellung: S026-STA_SWSnapshot/Explosion: S026-STA_HOR Ansicht NEW_VIEW_3Vereinfachte Darstellung: S026-STASnapshot/Explosion: S026-STA_ZUS

Ansicht NEW_VIEW_2Vereinfachte Darstellung: S026-STASnapshot/Explosion: S026-STA_LADE

www.palfinger.com

PC 3800 JI010.03100

03/2015

Working positionsSubject to change, production tolerances have to be taken into account.

569 [22.40]

123 [4.84]

720 [28.35]

266

[10.

49]

197 [7.76]

SH 300 [11.81]SHE 317 [12.48]


DT_S026-AS.ASMS026-AS_SKEL_EINAnsicht NEW_VIEW_1Vereinfachte Darstellung: S026-STA_HOR_SW1STRANG_EINSnapshot/Explosion: S026-STA_HOR_SW1STRANG_EIN

Ansicht NEW_VIEW_9Modellname: DT_UL175AM.ASMAnsicht NEW_VIEW_3Vereinfachte Darstellung: S026-STA_HOR_SW2STRANG_EINSnapshot/Explosion: S026-STA_HOR_SW2STRANG_EIN

Ansicht NEW_VIEW_2Modellname: DT_KUR070-BA.ASM

2STRANUL085

HIS 329EQ 042

EQ 042

HHK 400

UR316

HI 042 PC 3800 A, V1A,V2A,B,V1B

KUR057-BB

EQ 042

HHK 400

UR316

HI 042

PC 3800 A, B

EP 979 SHEEP 984 SH

X

UL175A1STRAN

X

4xES 032

8xEK1108

HXE3505

8xEK1108

4xEM 021

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PC 3800 JI 010.04100

03/2015

Rope winch SH,SHE 0.8tSubject to change, production tolerances have to be taken into account.

295 [11.60]

385

[15.

17]

450

[17.

71]

106 [4.17]

212 [8.35]

428

[16.

85]

478 [18.83]

250 [9.85]

161 [6.34]

9 [.35]

3[.1

2]

Modell: DT_S026BF01A.ASM

X

X

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PC 3800 JI010.05100

03/2015

Control stand Subject to change, production tolerances have to be taken into account.

385 [15.16]

123

[4.8

4]

174 [6.85]

110 [4.31]

374

[14.

74]

330 [12.99]

9[.35]

35[1

.38]

Modellname: DT_HXE-3725_MONT.ASM

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PC 3800 JI 010.05110

03/2015

Counter controlSubject to change, production tolerances have to be taken into account.

127

[5.0

0]

607 [23.90]

8[.32]

234

[9.2

1]

244

[9.6

0]

571 [22.48]

328

[12.

91]

364

[14.

31]

Modellname: DT_S025FS01A.ASM

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PC 3800 JI010.05120

03/2015

Radio remote controlSubject to change, production tolerances have to be taken into account.

150

[5.9

1]

300

[11.

81]

190 [7.48]

300 [11.81]

21 [.83]

d l

ES 1398 (KMG02436A) M20 80 mm[3.15"]

462 Nm[340 ft.lb]

S026-STA_SKEL_LADE

Ansicht NEW_VIEW_1Vereinfachte Darstellung: S026-STA_GG_BRI4 Ansicht NEW_VIEW_2Vereinfachte Darstellung: S026-STA_GG

X

4xES 1398

4xEK 176

4xHT9430

4xEK 176

4xEM 029

X

KMG

0243

6A

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PC 3800 JI 010.06100

03/2015

Stationary mounting

Tightening torque


Fixation

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PC 3800 JI020.01100JI

04/2015

Lifting capacity diagram PC 3800 A

-12ft

0m 1m 2m 3m 4m 5m-2m

-4ft-1m

0m0ft

1m2200lbs

4ft 3200lbs 1000kg1440kg

-15°

2m4400lbs 3100lbs 2150lbs2000kg 1420kg 980kg

8ft

3050lbs4400lbs 1380kg 3m2000kg

15° 2100lbs3050lbs960kg1380kg12ft

4m3150lbs

30°1420kg 2100lbs960kg

3450lbs1560kg

16ft 4000lbs 5m45°1820kg 2150lbs980kg

60°71° 2350lbs

1060kg 6m2750lbs20ft1240kg

max 4400lbsmax 2000kg

7m

0ft 4ft 8ft 12ft 16ft


www.palfinger.com

PC 3800 JI 020.02100JI

04/2015

Lifting capacity diagram PC 3800 B

0m 1m 2m 3m 4m 5m 6m-2m

-4ft-1m

0m0ft

1650lbs2150lbs 1m740kg960kg4ft -15°3050lbs

1380kg

2m4400lbs 3000lbs 2100lbs 1600lbs2000kg 1360kg 940kg 720kg

8ft

2950lbs3m1340kg4400lbs 2050lbs

2000kg 920kg2950lbs

12ft 1340kg 15° 1550lbs700kg 4m

2050lbs3050lbs 920kg1380kg

3350lbs1520kg16ft 30°3950lbs 5m2100lbs 1550lbs

1800kg 950kg 700kg

2300lbs1030kg 45° 6m1600lbs2700lbs20ft 720kg1220kg

60°1740lbs71° 7m790kg

2050lbs24ft max 4400lbs920kgmax 2000kg

8m

0ft 4ft 8ft 12ft 16ft


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Documents

Operating Manual Hydraulic Crane