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Safety and Health Standards

Required minimum distances

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

Crushing points

Possible crushing points.

More crushing points may result from your installation and use.

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Summary of Contents for PC 3800

Page 1: ...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 ...

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Page 3: ...t 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...

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Page 5: ... 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 ...

Page 6: ...ng 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 ho...

Page 7: ...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 ...

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Page 9: ... 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 ...

Page 10: ...cillary 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 ran...

Page 11: ... 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 l...

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Page 13: ... 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 ...

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Page 15: ...e 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...

Page 16: ...rating 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 ...

Page 17: ...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 part...

Page 18: ...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 ...

Page 19: ...n 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 spec...

Page 20: ...ve 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 ...

Page 21: ...icle 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 loa...

Page 22: ...d 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 li...

Page 23: ...ient 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 do...

Page 24: ...lth Standards After maintenance service and repairs Note Every time after maintenance repair or service it is absolutely necessary to check the function of all safety equipment on the device stand ard and optional 18 ...

Page 25: ...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 ...

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Page 27: ...y 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 contro...

Page 28: ... 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 operat...

Page 29: ...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 ...

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Page 31: ...ponents 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 8 7 19 15 11 13 16 14 1 6 5 3 17 18 20 Find the names of the main components on the next page 25 ...

Page 32: ...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 ...

Page 33: ... 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 ...

Page 34: ... 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 ...

Page 35: ...Chapter 4 Device and function Rotator clockwise right Warning horn Working light on off Motor start Motor stop Increase engine RPM Reduce increase speed 29 ...

Page 36: ...ct 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 ...

Page 37: ...ely 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 range...

Page 38: ...ng 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...

Page 39: ...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 ...

Page 40: ...r 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 ho...

Page 41: ... 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 ...

Page 42: ... 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 Risk if ignored Death or serious injury Manual extension bo...

Page 43: ...ation 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 ...

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Page 45: ...tton 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 ...

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Page 47: ... 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 wit...

Page 48: ...llow 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 prohibi...

Page 49: ...s 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...

Page 50: ...y 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 an...

Page 51: ...port 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 a...

Page 52: ...ne 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 ...

Page 53: ...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 ...

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Page 55: ...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 ...

Page 56: ...t 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...

Page 57: ...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 co...

Page 58: ...n 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...

Page 59: ...osite 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 1 2 Rope deflecting angle Note I...

Page 60: ...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 ...

Page 61: ...ions 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 ...

Page 62: ... 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 th...

Page 63: ...ification 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 connec...

Page 64: ...m 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 ...

Page 65: ...Chapter 6 Ancillary equipment Components Remote control console Receiver Charging cable Accessories Carrying strap Magnet antenna Charger optional 59 ...

Page 66: ...he 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 1 2 3 4 6 5 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 leve...

Page 67: ...onsole 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 le...

Page 68: ...splayed 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 th...

Page 69: ...amped 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 ...

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Page 71: ...ing 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 ...

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Page 73: ...nding 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 ...

Page 74: ... 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 cra...

Page 75: ... 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 C...

Page 76: ...ur 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 b...

Page 77: ... 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 ...

Page 78: ...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 follow...

Page 79: ... 36 25 psi 3 Cohesive soils Mushy 0 N cm 0 psi Soft 4 N cm 5 8 psi Stiff 10 N cm 14 5 psi Semisolid 20 N cm 29 psi Hard solid 30 N cm 43 5 psi 4 Rock Weathered 100 N cm 145 psi Determining necessary support area use metric or imperial consistently Support area A cm or in Supporting force F N or lbs Load capacity of the soil N cm or psi The supporting force values are specified in chapter 13 Techni...

Page 80: ...gger 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...

Page 81: ...d 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...

Page 82: ...rt 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 ot...

Page 83: ...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 ...

Page 84: ...hile 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...

Page 85: ...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 ...

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Page 87: ... 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 bearing...

Page 88: ... 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 ...

Page 89: ...ed 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 prot...

Page 90: ...ing 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...

Page 91: ...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 sig...

Page 92: ...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 statio...

Page 93: ...top 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...

Page 94: ...ed 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 S...

Page 95: ...on 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 ...

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Page 97: ...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 ...

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Page 99: ...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 op...

Page 100: ... 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 additiona...

Page 101: ...es 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 ou...

Page 102: ... 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 ...

Page 103: ... 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 cr...

Page 104: ...t 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 ...

Page 105: ... 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 ...

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Page 107: ...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 p...

Page 108: ...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 ...

Page 109: ...equired 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 ...

Page 110: ... 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 shal...

Page 111: ...ntact 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 ...

Page 112: ...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 occurre...

Page 113: ...ricant 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 n...

Page 114: ...t 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 mm 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...

Page 115: ... 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 ...

Page 116: ...Maintenance The illustrated crane is an example and shows components which may be optional on your unit depending on model and version 110 ...

Page 117: ...erwise 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 env...

Page 118: ...intenance 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 yea...

Page 119: ...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 Favorab...

Page 120: ...ing an oil Note Please contact the PALFINGER partner when selecting the recommended hydraulic oils and oil filters 0 C A B C A Viscosity mm 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 ...

Page 121: ...er 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 ...

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Page 123: ...g 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 ...

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Page 125: ...ied 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 lo...

Page 126: ... 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 t...

Page 127: ...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 Ope...

Page 128: ...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 m 900 Flashpoint CoC C 205 Viscosity class SAE J 306 ISO VG 8W 90 150 Viscosity at 40 C Viscosity at 100 C mm s 159 15 6 Brookfield viscosity at 26 C mPa s 128 000 Pour point C 30 Available from most PALFINGER partners according ...

Page 129: ...icing 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 ...

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Page 131: ...Chapter 12 In this chapter Decommissioning and disposal guidelines 127 C H A P T E R 1 2 Decommissioning and disposal 125 ...

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Page 133: ...ALFINGER 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...

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Page 135: ... 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 ...

Page 136: ...s 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...

Page 137: ...Chapter 13 C H A P T E R 1 3 Technical description 131 ...

Page 138: ...132 132 ...

Page 139: ...Technical Specification PC 3800 JI S026 ST A Edition 03 2015 EN PALFINGER AG 5101 Bergheim Austria Lamprechtshausener Bundesstraße 8 www palfinger com ...

Page 140: ... control FFST Remote control FERN Dual Power System Plus Dual Power System DPS Support controllable from top seat SR Both side extension box hydraulical Both side extension box extended Extension box telescopic Both side extension box extended Both side extension box One side extension box R X R4 R3 R2 R1 R0 without extension box R 123456789 123456789 Page A ABST Support Counter control side Contr...

Page 141: ...150 Paltronic 50 PT050 1 Auxiliary equipment hose drum inside T4I 2 Auxiliary equipments hose drum inside 2 Auxiliary equipments J04 1 Auxiliary equipment J02 Hose equipment PJ PJKSL see HYA Hydraulic extensions PJHY Paltronic PAL Oil cooler 10 5kW mounted Oil cooler 20kW loose Oil cooler 20kW mounted Oil cooler 8 5kW loose Oil cooler 10 5kW loose Oil cooler 8 5kW mounted ÖLK07 ÖLK05 ÖLK04 ÖLK03 Ö...

Page 142: ...lewing system SWERK Page A STZY3 B STZS3 Page A STZS3 B STZY3 Hydraulically tiltable stabilizer cylinder Stabilizer ram slewable Stabilizer ram rigid Type without support STZYS3 STZS3Y STZY STZY3 STZS3 STZO Stabilizer ram STZ Transport position rope Extension 200mm TOT Dead center TOWI Dead center over balance TOQU Dead center over transverse spar SE continuous TSEIL 200 DNCE50 DINOIL DNCE50 2 str...

Page 143: ...fications 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 diagr...

Page 144: ...HYA A 16 50 5 0 m HYA B 4 0 US gpm 15 l min www palfinger com 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...

Page 145: ...lb HYA B 624 lb 283 kg STRAN1 20 kg 44 lb www palfinger com PC 3800 JI 010 01110 03 2015 Crane weight Control system Rope winch Additional weight Subject to change production tolerances have to be taken into account All weights are without accessories auxiliary equipment and oil Crane weight Control stand Counter control ...

Page 146: ...1 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 www palfinger com PC 3800 JI 010 01120 03 2015 Extension Max outreach Weight Load capacity Subject to change production tolerances have to be taken into account ...

Page 147: ...53 6 04 360 14 17 220 8 66 min 15 R 1 5 8 6 2 1 169 6 63 180 7 09 360 14 17 445 17 52 131 5 16 1630 64 17 177 6 95 134 5 28 325 www palfinger com PC 3800 JI 010 02100 03 2015 Transport position Subject to change production tolerances have to be taken into account ...

Page 148: ...24 40 33 32 A111 4 36 V1A B 60 2 36 V2A V1B 3 13 605 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 EP 984 SH EP 979 SHE UR316 325 www palfinger com PC 3800 JI 010 02110 03 2015 Transport position SH SHE Subject to change production tolerances have to be taken into account ...

Page 149: ... 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 www palfinger com PC 3800 JI 010 03100 03 2015 Working positions Subject to change production tolerances have to be taken into account ...

Page 150: ... 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 SHE EP 984 SH X UL175A 1STRAN X 4xES 032 8xEK1108 HXE3505 8xEK1108 4xEM 021 www palfinger com PC 3800 JI 010 04100 03 2015 Rope winch SH SHE 0 8t Subject to change production tolerances have to be taken into account ...

Page 151: ...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 12 X X www palfinger com PC 3800 JI 010 05100 03 2015 Control stand Subject to change production tolerances have to be taken into account ...

Page 152: ...85 15 16 123 4 84 174 6 85 110 4 31 374 14 74 330 12 99 9 3 5 35 1 38 www palfinger com PC 3800 JI 010 05110 03 2015 Counter control Subject to change production tolerances have to be taken into account ...

Page 153: ...5 00 607 23 90 8 32 234 9 21 244 9 60 571 22 48 328 12 91 364 14 31 www palfinger com PC 3800 JI 010 05120 03 2015 Radio remote control Subject to change production tolerances have to be taken into account ...

Page 154: ...2436A M20 80 mm 3 15 462 Nm 340 ft lb X 4xES 1398 4xEK 176 4xHT9430 4xEK 176 4xEM 029 X KMG02436A www palfinger com PC 3800 JI 010 06100 03 2015 Stationary mounting Tightening torque Subject to change production tolerances have to be taken into account Fixation ...

Page 155: ...0lbs 3100lbs 2150lbs 2000kg 1420kg 980kg 8ft 3050lbs 4400lbs 1380kg 3m 2000kg 15 2100lbs 3050lbs 960kg 1380kg 12ft 4m 3150lbs 30 1420kg 2100lbs 960kg 3450lbs 1560kg 16ft 4000lbs 5m 45 1820kg 2150lbs 980kg 60 71 2350lbs 1060kg 6m 2750lbs 20ft 1240kg max 4400lbs max 2000kg 7m 0ft 4ft 8ft 12ft 16ft Subject to change production tolerances have to be taken into account ...

Page 156: ...60kg 940kg 720kg 8ft 2950lbs 3m 1340kg 4400lbs 2050lbs 2000kg 920kg 2950lbs 12ft 1340kg 15 1550lbs 700kg 4m 2050lbs 3050lbs 920kg 1380kg 3350lbs 1520kg 16ft 30 3950lbs 5m 2100lbs 1550lbs 1800kg 950kg 700kg 2300lbs 1030kg 45 6m 1600lbs 2700lbs 20ft 720kg 1220kg 60 1740lbs 71 7m 790kg 2050lbs 24ft max 4400lbs 920kg max 2000kg 8m 0ft 4ft 8ft 12ft 16ft Subject to change production tolerances have to b...

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