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Original Operating Manual

Palfinger PK 34002-SH P7, Original Operating Manual

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Chapter 10

217

In this chapter

General .................................................................................................. 219
Operating hours counter ......................................................................... 220
Maintenance........................................................................................... 221
Cleaning ................................................................................................. 222
Visual inspection .................................................................................... 223
Machine lubrication................................................................................. 226
Hydraulic oil change, filter change .......................................................... 231
Paint repair ............................................................................................. 234

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H A P T E R

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Maintenance

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Summary of Contents for PK 34002-SH P7

Page 1: ......

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Page 3: ...tively over the long term x Please follow all safety instructions x Please maintain your PALFINGER unit in accordance with regulations x Please adhere to the prescribed maintenance intervals x The uni...

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Page 5: ...ol 21 Structure of system 21 Modifications to unit 22 Operators 22 Device and function 23 Main components 25 Remote control 27 Explanation of the operating labels 44 PALcom P7 menu 57 Meaning of the s...

Page 6: ...n 205 Retracting the stabilizers 207 Before driving 214 Maintenance 217 General 219 Operating hours counter 220 Maintenance 221 Cleaning 222 Visual inspection 223 Machine lubrication 226 Hydraulic oil...

Page 7: ...Chapter 1 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...

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Page 9: ...erman version of the present operating instructions shall prevail Note Enclosed in these operating instructions you will also find the PALFINGER DVD On the crane Changes since going to press PALFINGER...

Page 10: ...ncillary 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...

Page 11: ...s 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 op...

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Page 13: ...1 Government regulations and standards for operating the unit 11 Adverse working conditions 12 Risk of falling 12 Danger of getting crushed 13 Risk of burns 14 Noise emission 14 Dangers caused by exha...

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Page 15: ...ent 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...

Page 16: ...ing 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 x Load u...

Page 17: ...is known to be defective x Maintenance hast not been carried out or only insufficiently x Servicing has been carried out by a service workshop other than PALFINGER partner x Parts other than original...

Page 18: ...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 x When thunderstorms are approaching and during thunderstorms x At ambient temperatures...

Page 19: ...ing Operating situations in which the operators or other persons are at risk of crushing are prohibited Required minimum distances The crushing point for the parts of the body specified above are not...

Page 20: ...otor 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...

Page 21: ...d 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 nation...

Page 22: ...ient occurs Within the potential gradient there is acute danger to life x The minimum distance to the vehicle device load or broken power lines is 20 meters 66 feet potential gradient x Leave the dang...

Page 23: ...rsons out of the electric circuit turn off the life electric line After maintenance service and repairs Note Every time after maintenance repair or service it is absolutely necessary to check the func...

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Page 25: ...Chapter 3 19 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...

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Page 27: ...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 PALFINGE...

Page 28: ...e 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...

Page 29: ...this chapter Main components 25 Remote control 27 Explanation of the operating labels 44 PALcom P7 menu 57 Meaning of the symbols 57 Hazard warning symbols 58 Overview of labels 59 C H A P T E R 4 Dev...

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Page 31: ...ice and function 25 Main components The illustrated crane is an example and shows components which may be optional on your unit depending on model and version Find the names of the main components on...

Page 32: ...Endless slewing system with gear rim 8 Lifting cylinder 9 Emergency operator station on the crane column 10 Balance 11 Crane column 12 Linkage system 13 Main boom 14 Rope winch 15 Outer boom lift cyl...

Page 33: ...e starting the remote control console make sure that any operating lever is not actuated x Check the remote control console for proper functioning before starting work refer to Preparing for remote op...

Page 34: ...remote control console receiver charging unit and battery x indicate the serial number of the part and other information x serve to identify the system x are necessary for communication with PALFINGE...

Page 35: ...it and battery Battery x 2 pieces Charger x With indication of the various operating statuses Accessories Diverse accessories x Waist strap optionally diagonal strap x Magnet antenna x Cable for cable...

Page 36: ...number of proportional functions required to do this the remote control console s design may vary from the base version Remote control console size Large remote control console for a maximum of 9 pro...

Page 37: ...4 functions Joystick 4 functions 2 0 2 Linear lever 5 functions Joystick 6 functions 2 2 2 Linear lever 6 functions Joystick 6 functions 3 0 3 Linear lever 7 functions Joystick 7 functions 2 3 2 Line...

Page 38: ...ce and function 32 Small remote control console Linear lever 4 functions Joystick 4 functions 2 0 2 Linear lever 5 functions Joystick 6 functions 2 2 2 Linear lever 6 functions Joystick 6 functions 3...

Page 39: ...1 13 10 10 5 8 1 Rotary switch for speed pre selection always present cannot be changed 2 Status LED 3 Load indicator LEDs 4 Display for menu navigation refer to the Paltronic 150 control system in ch...

Page 40: ...e crane loading level dependent on the then applicable load limit between 60 and 100 4 Display x For the display menu navigation refer to the Paltronic 150 control system chapter x In order to save po...

Page 41: ...engine revs rpm 0 Auto Left position Engine revs permanent signal Right position Automatic signal when lever actuated 2 Engine start stop Switch for engine start and stop function Left position Engin...

Page 42: ...d A Stabilizer button quick access button for stabilizer operation opens the Stabilizer menu B MAOS button concrete bucket function if included otherwise has no function refer to AOS system in chapter...

Page 43: ...items x Switch on the display s background lighting if lighting is off x Switch over lever on Stabilizer menu for example joystick on RC console in the case of FFST8 switching from left to right Press...

Page 44: ...ol console 2 SEL Select equates to pressing the PALdrive on the remote control console 3 ESC Is the same as the ESC Escape button on the remote control console 4 DOWN Equates to rotating the PALdrive...

Page 45: ...ent display for status codes 2 Antenna plug connector 3 Connector for cable connection and programming 4 70 pin connector to the crane Usually an extension cable comes from the receiver port 3 to the...

Page 46: ...is correctly the following rules apply x The charger should ideally be fitted vertically x Shield from direct sunlight in excessive heat the charger works more slowly or not at all x Vertical air circ...

Page 47: ...ply the charger runs a system test The 3 LEDs on the operating panel light up one after the other in red green and orange Note An optional mains adapter for mains power supply 110 220V is available fr...

Page 48: ...into the vehicle x it should not be aborted as this will harm battery life x around 12 hours should be allowed for it to complete e g overnight or when the battery is not needed for such a period Batt...

Page 49: ...ed operating elements e g keys buttons levers are replaced immediately x Every time servicing is carried out the RC console is checked as well to make sure it is working properly Service All service w...

Page 50: ...miliarize yourself with the functions symbols and how they are arranged on your device remote control handset Operator station symbols Stabilizer outrigger on operator side Retract Extend Stabilizer c...

Page 51: ...Chapter 4 Device and function 45 Main boom Lower Lift hoist Outer boom Lower Lift hoist Boom extension Extend Retract Rotator Clockwise right Counter clockwise left...

Page 52: ...Device and function 46 Grab Open Close Rope winch Lift hoist Lower Fly jib main boom Lower Lift hoist Fly jib extension boom Extend Retract...

Page 53: ...he following hydraulic crane movements can be made by moving the levers joysticks and rotary levers in the direction of the arrow Slewing Clockwise Anticlockwise Anticlockwise Clockwise Clockwise Anti...

Page 54: ...Device and function 48 Boom extension Extend Retract Retract Extend Extend Retract Retract Extend Fly jib main boom Lower Lift hoist Lift hoist Lower...

Page 55: ...Chapter 4 Device and function 49 Fly jib extension boom Extend Retract Retract Extend Extend Retract Retract Extend Extend Retract Retract Extend...

Page 56: ...Device and function 50 Rotator Clockwise Anticlockwise Anticlockwise Clockwise Clockwise Anticlockwise Anticlockwise Clockwise Clockwise Anticlockwise Anticlockwise Clockwise...

Page 57: ...Chapter 4 Device and function 51 Grab Open Close Close Open Open Close Close Open Open Close Close Open...

Page 58: ...Device and function 52 Rope winch Lift hoist Lower Lower Lift hoist Lift hoist Lower Lower Lift hoist Alternating operation of fly jib or grab Lower open Lift hoist close Lift hoist open Lower close...

Page 59: ...tor Extend clockwise Retract anticlockwise Retract clockwise Extend anticlockwise Extend clockwise Retract anticlockwise Retract clockwise Extend anticlockwise Alternating operation of rope winch or r...

Page 60: ...rigger beam Retract stabilizer cylinder Stabilizer rear left Extend stabilizer outrigger beam Extend stabilizer cylinder Retract stabilizer outrigger beam Retract stabilizer cylinder Stabilizer front...

Page 61: ...ilizer outrigger beam Retract stabilizer cylinder Stabilizer left Extend stabilizer outrigger beam Extend stabilizer cylinder Retract stabilizer outrigger beam Retract stabilizer cylinder Stabilizer r...

Page 62: ...bilizer outrigger beam Extend stabilizer cylinder Retract stabilizer outrigger beam Retract stabilizer cylinder Crane support stabilization with joystick control and 8 functions only Extend stabilizer...

Page 63: ...c 150 control system PALcom P7 Meaning of the symbols On the crane Working light on off Warning horn OLP button Switch between rotator and fly jib main boom Switch between grab and fly jib extension P...

Page 64: ...Motor start stop Speed adjustment on vehicle engine Return oil utilization off on Manual AOS Warning horn Hazard warning symbols Check operating instructions Crane crushing hazard Stabilizer supports...

Page 65: ...y 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...

Page 66: ...Device and function 60 Overview of labels...

Page 67: ...to step under the suspended load Risk if ignored Risk of fatal injury by falling loads 4 Low maintenance extension system instruction label Position On outer boom Meaning Extension booms need no regul...

Page 68: ...ehicle stability may be reduced 8 Hazardous area Position On the outrigger box and extension cylinders Closes drilled assembly holes on stabilizer outriggers where there is increased danger of getting...

Page 69: ...m Meaning Controls order unfold fold crane Risk if ignored Damages to the crane and risk of fatal injury 12 Tiltable stabilizer cylinder instruction label Position On the stabilizer cylinders Meaning...

Page 70: ...be changed or removed Risk if ignored Damages to the crane and risk of fatal injury 15 Instruction label 360 Slewing during lubrication Position On the slewing ring near the grease nipples Meaning Ind...

Page 71: ...injury by the tilting up stabilizer 20 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 c...

Page 72: ...wer 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 o...

Page 73: ...ry 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 Pos...

Page 74: ...he 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...

Page 75: ...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 t...

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Page 77: ...ronic 150 safety equipment standard 100 HPSC stability control 108 Transport position monitoring system 114 Securing a person to a crane 114 Emergency operation after remote control failure 115 Emerge...

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Page 79: ...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 servi...

Page 80: ...of crane optionally stabilizers x Emergency operation crane operated from crane operating station Manual support operation left switch position Cranes with manual stabilization can be prepared for de...

Page 81: ...g operating situation However the display is always split into 4 sections which are illustrated below using two examples crane and stabilizer operation 1 Scroll bar To select the various menu items 2...

Page 82: ...pe winch Rope winch settings Set up Set up menu Example Switching over of the fly jib grab Information Error memory operating hours contact data oil status etc Optional Custom Provides special functio...

Page 83: ...EXS Extension Speed Switchable return oil utilization on EXP Extension Power Switchable return oil utilization off AOS Active Oscillation Suppression Vibration damping activated SRC Synchronised Rope...

Page 84: ...t colors on the joystick display are color coded with the respective function on the main display area Example Stabilizer rear left x Linear levers or joysticks with 2 and 3 functions may be shown Dis...

Page 85: ...nction connected 5 Fly jib load in 6 Additional mechanical extension function activated 7 Additional counter weight function activated 8 Additional function workman basket or personal fall protection...

Page 86: ...3 Crane overload status code 4 Movement arrow example Retraction of extension boom still possible Menu items Note The menu items can be selected from the scroll bar and contain different functions de...

Page 87: ...for switching general functions on and off Available functions if present Working light Switch working light on or off Press SELECT button Console lighting Switch console s background lighting on or o...

Page 88: ...ailable functions if present Active Oscillation System AOS Switch AOS off on Press SELECT button For how to operate AOS see AOS system in chapter 5 OLP function Deactivate OLP overload protection func...

Page 89: ...cess button To quit press the ESC button Respond to confirmation prompt when switching on and off by pressing OK Stabilization mode then gets graphically depicted example 1 Radio controlled support op...

Page 90: ...as follows x Scroll with the PALdrive in stabilization mode x Confirm selection with OK Support menu On the Support menu select rear stabilization if included and controllable via RC console Example d...

Page 91: ...ment 85 On the support menu select front stabilization if included and controllable via RC console Example depiction 5 Front supports display Depiction of the control levers for each front stabilizer...

Page 92: ...button The system does not function if the rope winch is switched off For how to operate the system refer to RTC Rope tension control chapter 5 Switch rope winch on or off In order to avoid incorrect...

Page 93: ...splay area in place of the rope winch Fold rope winch The Fold rope winch function is used to move the winch between transport position and working position The function is available only on cranes wi...

Page 94: ...e is equipped accordingly SRC AOS F1 Set up OFF x Switching over of a crane with fly jib to grab rotator operation instead of the fly jib The levers of the fly jib are then used to operate the grab an...

Page 95: ...e blocked This switchover is necessary as the crane s overload protection device makes other settings Switch over from fly jib to grab rotator operation x Crane in radio controlled mode x Make selecti...

Page 96: ...g moved the function gets shown on the main display area While the counter weight is moving no other crane movements are possible x By pressing the ESC button you can switch back to operating with the...

Page 97: ...ample 79 operating hours until next service Once a service interval of either crane or rope winch is exceeded this is automatically shown every time Paltronic is started to remind the operator of the...

Page 98: ...g Red folder icon with content At least 1 error is pending Quitting is possible Yellow folder icon with no content No errors pending There is therefore also no quitting necessary Note All pending erro...

Page 99: ...Oil temperature warning appears whenever the permitted top temperature is exceeded 75 C 2 Current oil temperature figure 3 Oil temperature graphic 4 Current fill level Graphic 5 Current fill level in...

Page 100: ...2 4 or 6 functions The displayed variants are only examples Depending on the custom configuration the presentation may vary on your model Example Large remote control console linear lever 7 functions...

Page 101: ...vailable etc Bar color Red Bar color Yellow Bar color Gray Delete pop up graphic by pressing ESC pop up graphic gets deleted Automatically after 10 seconds Automatically when the dangerous situation n...

Page 102: ...ange overload stability stabilization force etc All movements that would go further into the programmed area get blocked Remedy x Move out of the dangerous range Crane overload Gets shown if a crane c...

Page 103: ...it pop up if the error persists contact PALFINGER service partner Data bus fault Gets shown whenever a data bus fault occurs device fails to respond communication etc Example A CAN connection or devic...

Page 104: ...Oil status error Gets shown if the oil temperature or fill level is outside the specified warning limits Remedy x Check oil status and depending on display allow crane to cool down or top up oil x Qui...

Page 105: ...runs out Remedy x Charge battery insert charged reserve battery into RC console Function not available Gets shown if a desired function cannot be carried out in a given mode example an operator tries...

Page 106: ...ed and before approaching a programmed movement range for examples the cylinder s end positions one or several crane movements get smoothly slowed down until the limit is reached If several crane func...

Page 107: ...itoring system provides load dependent and load independent control of the boom system It measures the total of all boom angles of crane and fly jib if installed It is indicated on the Paltronic 150 d...

Page 108: ...ossible overstretching angle depends on the fly jib model As the outer boom angle increases load independent 30 to 70 the overstretching angle of the fly jib gradually reduces Function with fly jib x...

Page 109: ...that increase the outer boom angle are blocked x Extend extension booms function blocked x Display of status code Paltronic 003 008 Function with fly jib x Acoustic warning signal x Capacity indicator...

Page 110: ...when this takes place Jerky crane movements and load impacts from the suspended load are prevented The following crane movements are prevented by soft stop x Slewing only possible with slewing system...

Page 111: ...crane The Paltronic 150 contains two load limits that restrict the negative load of the boom system to a set limit These are one limit for the boom system of the crane and one for the outer boom syste...

Page 112: ...gain before the 30 seconds have elapsed the OLP timer appears and the remaining time is displayed OLP modes of operation The display shows the currently active operating mode 1 F1 function menu 2 OLP...

Page 113: ...f Right position Extension speed EXS Oil recovery on Warning horn Cranes that are operated by radio remote control and or have a range of more than 12 meters must be equipped with a warning horn in th...

Page 114: ...for the operator Note When equipped with HPSC loading cranes are stable even if the vehicle s stabilizer cylinders and outrigger beams are only partly or not extended used This makes it possible to wo...

Page 115: ...ximum possible support version Please note x Always extend all stabilizer cylinders for crane operation If not all stabilizer cylinders have ground contact this strongly reduces the lifting power of t...

Page 116: ...or even maximum lifting power on the working side optimally supported crane inappropriately supported crane The loading crane s lifting power on the working side is higher if the opposite side is also...

Page 117: ...crane HPSC in combination with Paltronic 150 Switch off in limit situations Upon reaching the safety limit allowable in the respective position due to high load moment the system switches off all cran...

Page 118: ...ating company on the LCA01 LCA02 LCA03 or a combination of these And an appropriate load capacity label needs to be produced and attached to every operator station on the device LCA01 Incorporating op...

Page 119: ...hus risk of fatal injury For LCA03 use only the ballast weight defined and calculated by the installer Combination of LCAs It is possible to combine various load capacity areas Example LCA01 in combin...

Page 120: ...ing x Alarm for positions of hydraulic stabilizer enlargement alarm for lock of manually operated stabilizer enlargement The acoustic alarm can be switched off by acknowledgment key or pressed down pa...

Page 121: ...operation Danger If the user cannot observe all stabilizer crane movements from the crane s emergency operation stand there is risk of fatal injury If it is not possible to fully observe all x stabili...

Page 122: ...ator station on the crane column The emergency operator station on the crane column that is shown in the following is an example The positions of the crane functions symbols can therefore differ on th...

Page 123: ...e location Keep a safe distance away from all moving parts of the crane and the load see Danger of getting crushed chapter 2 A slewing movement may make it necessary to change location to the opposite...

Page 124: ...will fail x Remove the seal 1 on the operating panel Open the cover 2 Switch to position 3 Emergency unit starts x Open the ball valve of the automatic leveling system so that the basket can be lowere...

Page 125: ...effective 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 Danfoss remote control va...

Page 126: ...load moment see Load limits loads chapter 8 x Move the crane in transport position as described in chapter 9 x Switching to HPCO support Turn bypass screw 180 to the left anticlockwise until it engag...

Page 127: ...Chapter 6 121 In this chapter General 123 Slingers other attachments to lift the load 124 Ancillary equipment 125 Additional crane equipment 150 C H A P T E R 6 Ancillary equipment...

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Page 129: ...f the model x Year of manufacture x Manufacturer x Serial number x Dead weight x Maximum permissible load capacity x Operating pressure x etc The operator must be trained on all the ancillary equipmen...

Page 130: ...risk of fatality for the operator and others x Use hook and shackle suitable for the weight of the load that is being lifted x Different hooks and shackles are provided for some crane models Depending...

Page 131: ...ting x Switch off the pump x Operate the levers in both switching positions Residual pressure is released x Make sure all operating levers are in neutral position x Remove the protective caps from the...

Page 132: ...pen the tightening lever 3 x Put the plug 4 on the coupling x Close the tightening lever 3 until the safety button locks Disconnecting x Switch to manual operation in case of Paltronic x Switch off th...

Page 133: ...chapter Technical Description Rope winch attached to the outer boom example Rope winch attached to the main boom example 1 2 3 5 4 1 Rope winch 2 Rope 3 Intermediate pulley 4 Pulley head 5 Lower load...

Page 134: ...ope winch in working position the rope winch and the crane will get damaged It is prohibited to fold the crane in transport position with the Power Link rope winch being in working position Move the r...

Page 135: ...e functions may be actuated unintendedly This poses risk of injury and severe risk of fatality for the operator and others Turn off the crane power between two assembly steps where crane movement is n...

Page 136: ...m 2 ft before the pulley head 2 Assembling the pulley head Note For the pulley head load capacity refer to Technical data A B C x Fasten and lock the connecting block A in the extension boom using pin...

Page 137: ...y will damage the components of the winch for instance by rubbing This represents a severe risk of injury and even fatality for the operator and others due to falling loads The rope should be reeved p...

Page 138: ...ediate pulleys may get damaged or damage other crane components When mounting the intermediate pulleys observe the correct fitting direction Variants of intermediate pulleys x Reeve the rope in the pu...

Page 139: ...nner 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 usin...

Page 140: ...ut of the back side of the outer boom Rope deflecting angle Note In order to keep the rope deflecting angle D as small as possible extend at least one extension boom before winch operation without fly...

Page 141: ...ith overload protection system The rope winch components are protected but this working position must generally be avoided If the device is equipped with synchronized rope control refer also to SRC Sy...

Page 142: ...st be moved to the transport position beforehand Working position If the pulley head is not in the working position during rope winch operation the load will rub against the outer boom The rope the pu...

Page 143: ...l off sufficient rope x Switch off crane x Disassemble the lower load block and store it properly x Unreeve the rope pin it to the storage point and secure it properly x Turn on the crane x Slowly and...

Page 144: ...rope is reeved in rope securing pin RTC operating modes The display shows the currently active operating mode 1 Rope winch menu item 2 RTC OFF 3 RTC ON Note If RTC is still active when the crane is t...

Page 145: ...pulleys and intermediate pulleys x Reeve and secure the rope in the rope securing pin Note Depending on the fly jib model the rope must be reeved appropriately Caution When the rope runs over the pul...

Page 146: ...ing and therefore a risk of injury x Switch RTC on x Retract the extension booms For the extensions choose a speed where RTC always winds the rope under tension x Move the Power Link rope winch if ava...

Page 147: ...ally when a lever is being deflected exception Slewing Do not reach into the rope s range There is an acute risk of crushing and therefore a risk of injury x Switch RTC on x Unfold the load arm into w...

Page 148: ...ly jib functions Caution When you select the wrong speed for the extension booms loops of slack rope may develop They may considerably damage the rope and the load may fall down There is risk of injur...

Page 149: ...of the load lifting gear and ancillary equipment require the use of special PALFINGER hardware More detailed information about the PALFINGER special load lug is available at all PALFINGER partners War...

Page 150: ...mum 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 Note Loads that are hea...

Page 151: ...and lynch 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 e...

Page 152: ...4 400 lbs Operating modes can be set up on the mode selector switch Warning If the position of the operating mode selector switch doesn t match the installation status the extension or the sensor unit...

Page 153: ...he electric cables must be connected when assembling the ancillary equipment Note When the cable drum s pretension doesn t match the specifications on the type plate then drum and cable may get damage...

Page 154: ...isconnect the cable from the parking position 2 Take the cable stopper unwind the cable and put the cable stopper in the provided holder 3 By pulling the spring loaded pulley or releasing the spring c...

Page 155: ...oscillations while hydraulic boom functions are being operated Manual AOS function damping of boom oscillations while any hydraulic boom function is not actuated Function Note AOS is only possible in...

Page 156: ...speed increase function is active or the engine is run at increased speed Whole body vibration The highest root mean square value of whole body vibrations in the workman basket is below the limit valu...

Page 157: ...remote operation 154 Cable operation 157 Working range 158 Starting the crane 159 Supporting the vehicle 160 Stabilizer outriggers 166 Stabilizer cylinder 167 Vehicle inclination 172 Unfolding the cra...

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Page 159: ...the hose tray x Abnormal noises x Unusually quick or slow working movements x Failure of the control system x Operating levers are difficult to operate and or do not return to neutral position x Defec...

Page 160: ...hers Carefully check the wireless remote control system before starting work every day Check that x The operating levers reset themselves into the neutral position x The switches buttons are mechanica...

Page 161: ...about 2 seconds until you hear a beep x Let the key go it reverts automatically to the ON position The transmitter now runs a system test and establishes the wireless connection with the receiver As...

Page 162: ...NGER service partner can individually set the period To be able to continue working the remote control handset must be restarted No wireless connection If it is not possible to establish a wireless co...

Page 163: ...een the remote control console and the receiver 1 Switch off the remote control console 2 Remove plug connectors protective caps and connect cable as shown 3 Restart console as for wireless mode Note...

Page 164: ...y a qualified signaller x Plan in sufficient clearance for crane operation and support Crane movements may not be obstructed by lines masts trees buildings or other objects x The entire working range...

Page 165: ...t idle and then select correct engine speed x Only one person shall operate the crane at a time At ambient temperatures below freezing point x Let the pump run for a few minutes before operating any c...

Page 166: ...Caution If the additional support of a vehicle is not extended the vehicle may tip over This creates an acute risk of fatal injury With stability control HPSC The load limits are adapted to the curren...

Page 167: ...4 Heaped up soil that was not stabilized artificially 0 10 N cm 0 14 5 psi Asphalt 20 N cm 29 psi Grown obviously untouched soil 1 Mud turf marsh 0 N cm 0 psi 2 Incohesive soils Fine to medium sand 15...

Page 168: ...operating station This prevents operation of the stabilizer outrigger beam on the opposite side that is out of view If the crane has a display at the side concerned the function key provided on the d...

Page 169: ...ne is equipped with a stability control system refer HPSC stability control chapter 5 Move tiltable stabilizer cylinders into their position only after extending the outrigger beam The safety distance...

Page 170: ...This overloads the support system and reduces the braking effect In order to ensure safe operation follow the below sequence of stabilizing your vehicle Note Depending on the equipment available on yo...

Page 171: ...go to the stabilization menu refer to Stabilization menu item chapter 5 Display menu navigation As soon as the stabilization menu was selected the warning signal sounds x Press the SELECT button on th...

Page 172: ...eption If equipped with stability control refer to chapter 5 Safety equipment Manually extendible 1 Open the secondary lock 2 Turn the primary lock handle to the stop 3 Pull the outrigger beam complet...

Page 173: ...tiltable stabilizer cylinders via operator station Moving the tiltable stabilizer cylinders in supporting position Firmly hold the stabilizer cylinder Open latch lever Slew stabilizer cylinder careful...

Page 174: ...lizer cylinders until the stabilizer cylinder is unlocked Extend the hydraulic outrigger beams completely Open latch lever of stabilizer cylinder Activate the function Extend stabilizer cylinder and t...

Page 175: ...tabilizer cylinders via radio remote control Moving the tiltable stabilizer cylinders in supporting position Firmly hold the stabilizer cylinder Open latch lever Slew stabilizer cylinder carefully int...

Page 176: ...er is unlocked Without HPSC Extend stabilizer outriggers completely With HPSC Extend stabilizer outriggers Extend the hydraulic outrigger beams completely Open latch lever of stabilizer cylinder Activ...

Page 177: ...nce between the support jack and the ground is too small to push in the supporting plate Only pull out the pin for the pivot rods when the stabilizer cylinder points downwards Note Once the pin for th...

Page 178: ...en 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...

Page 179: ...s properly supported x No bystanders or obstacles are in the movement range of the crane Danger Not maintaining the minimum distances creates an acute risk of fatality for the operator and others x Th...

Page 180: ...out in the given order Always carry out the steps in the correct order Move the main boom to a near vertical position Fold the outer boom completely Move extension boom out of suspension eye Unfold t...

Page 181: ...te any crane function The crane must move perfectly in all directions x Press the emergency cut off button while the crane is moving The crane must come to a stop Whenever the emergency cut off button...

Page 182: ......

Page 183: ...s chapter Load limits 179 Working position of the crane 180 Loads 182 Working with loads 183 SRC Synchronised rope control 189 Securing a person to a crane 192 Operation of AOS system 199 C H A P T E...

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Page 185: ...capacity label 1 Maximum load capacity of the crane 2 Number of extended extension booms 3 Maximum load capacities at the respective outreach 4 Note Displayed loads only with fully deployed crane sup...

Page 186: ...between 15 and 30 dependent on crane type Refer to load capacity chart attached to the crane The optimum angle is reached when the lift cylinder is vertical to the main boom or the linkage system dep...

Page 187: ...ction of the boom system to side and or rear 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 th...

Page 188: ...Before loading unloading x Before lifting any loads check if the load lifting gear is used correctly x Observe special instructions about load handling and or lifting gear e g lifting points center o...

Page 189: ...x Any assistants signalers and bystanders must be informed about the planned operation x The operator must have full view of the crane the load and their paths at all times x If any part of the crane...

Page 190: ...ching 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 n...

Page 191: ...in the intended position Caution If loads are not lifted from directly below the pulley head in rope winch operation x The load may swing uncontrollably x The rope the pulley head and the pulley can b...

Page 192: ...e 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...

Page 193: ...n slowly x Before detaching the load lifting gear make sure the load sits properly and stable Work interruptions If it is necessary to leave the crane unattended x Land the load x Secure the boom syst...

Page 194: ...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...

Page 195: ...unction The sensor unit in the pulley head monitors the rope being wound unwound and synchronises the rope winch SRC balances crane movements that elongate the rope and so ensures a stable distance be...

Page 196: ...ntrol is on it is not possible to activate SRC Requirements x Cable connected to pulley head x Rope winch is on To be activated via SELECT key in the rope winch menu Control characteristics Various fa...

Page 197: ...tored pulley x In order to prevent the rope from oscillating all intermediate pulleys must be mounted Control function gets disabled in the below situations and reactivated afterwards x While working...

Page 198: ...per of the industry group D A CH S Fall protection The present operating instructions contain extracts from this document Full up to date download on the website of Bauforumplus sub group D A CH S htt...

Page 199: ...ective communication must be ensured between the operator and the person secured Equipment needed x The loading crane must have a load moment of 10mt minimum x The carrier vehicle s permissible total...

Page 200: ...s for transporting materials Flow of protection operation Preparatory measures x Remove all ancillary equipment and attachment parts workman basket grab etc x Push in the mechanical extensions to the...

Page 201: ...ane s operator terminal the following message appears Remote control handset must be in cable operation mode The function is on but not active The symbol is shown in red See point Indication of the fu...

Page 202: ...his function x AOS will be deactivated x RTC will be deactivated x SRC will be deactivated x P FOLD cannot be activated x The stabilizing function cannot be activated x The fold rope winch function ca...

Page 203: ...ample peg hole in the extension boom x Attach the fall arrester to the crane s lifting gear shackle A Secure the fastener to a second independent securing point B for example hook A B x Attach the fal...

Page 204: ...vity of the person to be secured changes during work it is allowed to follow the person s movements To do so proceed as follows x Set the key switch to ON Caution When following the person with the cr...

Page 205: ...l fall protection mode at reduced speed Movements have to be coordinated by another person in visual and verbal contact with the operator and the person to be rescued Operation of AOS system Warning I...

Page 206: ...ing and lowering movements slowly x Slowly lift up and put down the loads The drop down point may shift during damping Then the load will not be put down in the proper place If the load must be put do...

Page 207: ...multi function wheel select F1 from the scroll bar 1 x Press Select AOS is highlighted yellow the slide button is in status ON 2 AOS is shown in the status bar 3 x Press Select The slide button is in...

Page 208: ......

Page 209: ...Chapter 9 203 In this chapter Folding the crane into transport position 205 Retracting the stabilizers 207 Before driving 214 C H A P T E R 9 Ending operation...

Page 210: ......

Page 211: ...he ground operator station opposite the boom support Remote control Danger When the operator is in the folding unfolding area of the crane there is an acute risk of fatal injury x Choose a position ou...

Page 212: ...set down position Lower the main boom The boom system rests in the intended support on the base For cranes with fly jib system refer to the fly jib operating instructions For cranes with rope winch se...

Page 213: ...position If the vehicle is equipped with additional supports they also must be retracted All safety notes of chapter 2 shall be observed Danger If the movement ranges of the supports are not completel...

Page 214: ...supports while controlling them x if the operator others or objects are in the slew range of the stabilizer cylinder there is a high risk of injury or even fatality for the operator and others Seriou...

Page 215: ...ods is not inserted the stabilizer cylinder can still lift and lower but not slew any more Warning Only push in the pin for the pivot rods with the stabilizer cylinder sufficiently extend and pointing...

Page 216: ...t position Retract the stabilizer cylinders completely Open latch lever of stabilizer cylinder Pivot stabilizer cylinder into transport position When the stabilizer cylinder is in transport position C...

Page 217: ...Stow supporting pads away in the correct way Retracting rigid stabilizer cylinders via radio remote control Retract the stabilizer cylinders completely Retracting manually tiltable stabilizer cylinde...

Page 218: ...inders via radio remote control Retract the stabilizer cylinders until the outrigger beams are unloaded Open latch lever of stabilizer cylinder Operate the function Retract stabilizer cylinder and til...

Page 219: ...and out 3 Close the secondary lock 1 2 3 Danger An unlocked and or unchecked outrigger beam creates a high risk of accident and danger to life 4 Check whether the beam locks have engaged properly by...

Page 220: ...cylinders are completely retracted and properly secured x the crane hydraulic pump is off x the crane is secured for transport and side movement is not possible Danger Any winch components load fixin...

Page 221: ...ight total width axle loads and gross vehicle weight including crane ancillary equipment and load and act accordingly refer to chapter 5 Monitoring systems for transport position Note If the crane is...

Page 222: ......

Page 223: ...n this chapter General 219 Operating hours counter 220 Maintenance 221 Cleaning 222 Visual inspection 223 Machine lubrication 226 Hydraulic oil change filter change 231 Paint repair 234 C H A P T E R...

Page 224: ......

Page 225: ...al 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 t...

Page 226: ...onic 150 control system contains an operating hours counter This provides information about the total number of operating hours and the number of operating hours that remain until the next service Fun...

Page 227: ...e 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 Cle...

Page 228: ...t against being switched on unintentionally x Keep the working environment clean Warning Contaminations especially oil or other lubricants must be cleaned off immediately as a precaution against slipp...

Page 229: ...ALFINGER partner for additional information as needed Immediately replace any missing or inoperative hardware Steel parts x Cracks on components specifically on welds and bending edges x Deformations...

Page 230: ...ient lubrication x Corrosion x Damaged rope clamps x Broken strands broken wires grinding points abrasion bird caging constrictions necking kinks etc Rope discarding If a rope is so damaged that it ca...

Page 231: ...ad lifting gear x Hooks for cracks deformations and wear x Sensor unit of manual extension booms for cracks deformation leaks and wear Mark A must not be visible x Safety latch for proper function Che...

Page 232: ...hite 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 Grease Available fr...

Page 233: ...Greasing prohibited Maintenance operating company operator every 50 hours or after downtimes lasting more than 3 months 1 Operating levers control rods 2 Stabilizer outrigger sliding surface tiltable...

Page 234: ...Maintenance 228 The illustrated crane is an example and shows components which may be optional on your unit depending on model and version...

Page 235: ...x Remove all old dirty grease and other contamination from the lubricating point Otherwise dirt in old grease will be pressed into the bearing point x Press the grease into the bearing point x Move t...

Page 236: ...can sometimes be necessary to spray in some Palfinger Teflon Spray to assist the build up of this layer It is also possible that in process blank spots may arise on the gliding surface Prior to any r...

Page 237: ...whichever comes first Hydraulic oil change hydraulic oil maintenance Hydraulic oil change Hydraulic oil needs to be changed after every 1000 operating hours or once every year Note Oil maintenance on...

Page 238: ...lic 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 60 C 86 F and 140 F Alw...

Page 239: ...en choosing 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 Re...

Page 240: ...ids Reasons for not mixing different oils x Reduces service life x Mixtures of synthetic esters and mineral oils are no longer biodegradable x etc Paint repair Note Repair paint damage caused by bird...

Page 241: ...one year 239 After every 1000 operating hours or once every year 240 After every 3000 working hours or once every three years 240 Every 6 years 241 Hook and shackle 241 Slewing ring bolts initial ser...

Page 242: ......

Page 243: ...pplied 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...

Page 244: ...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 Tighteni...

Page 245: ...ity Oil filter package Slewing system slewing gear Hydraulic fluid level unsupported and in transport position Inner and outer slewing ring bolts refer to slewing ring bolt service Tighten hydraulic l...

Page 246: ...raulic lines hoses screw joints Rope winch limit switch Rope winch transmission oil Remote control All control equipment Central lubrication Ancillary equipment Pump performance speed Operating levers...

Page 247: ...c material are allowed The following points must be checked at regular intervals for x Deformations decrease of diameter elongation cuts notches cracks heavy corrosion discoloration by heat or other e...

Page 248: ...e detected by the operator operating company contact the nearest service partner immediately Continuing to work is not permitted Caution There is acute risk of fatal injury loose slewing ring bolts or...

Page 249: ...possible x Release the emergency cut off button Repeat the inspection until you have checked all inside slewing ring bolts After this Check the outside slewing ring bolts x Press the emergency cut of...

Page 250: ...C 30 Available from most PALFINGER partners according to national guidelines under Order no EZ6311 4 l can Order no EZ6312 20 l can Check of control equipment Note The entire safety equipment must be...

Page 251: ...Chapter 12 245 In this chapter Decommissioning and disposal guidelines 247 C H A P T E R 1 2 Decommissioning and disposal...

Page 252: ......

Page 253: ...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 th...

Page 254: ......

Page 255: ...77 Crane operation with activated AOS P3 200 D Daily function check of safety equipment 175 Danger from power lines 15 Danger of getting crushed 13 Dangers caused by exhaust 15 Deactivating AOS system...

Page 256: ...14 Notes regarding the operating instructions 1 O On the crane 57 On the remote control console 58 Operating hours counter 220 Operating instructions 3 Operation 109 Operation of AOS system 199 Operat...

Page 257: ...the vehicle 160 Symbols 5 Symbols of remote control console 47 T Technical description 253 Terms 4 Transport position monitoring system 114 Type plate with CE symbol 28 U Unfolding the crane 173 Use...

Page 258: ......

Page 259: ...Chapter 13 253 C H A P T E R 1 3 Technical description...

Page 260: ...254...

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