Operators Manual Hydraulic Crane

PK xxx M PK x80 M

Crane number:

CPDB0001 Version: 08/2005

DANGER ATTENTION: Indicates situations of severe danger which may cause great risks for health and safety of the operating personnel if handled without care.

ATTENTION TIP: Indicates that a proper conduct is required so that health and safety of the operating personnel are not put at risk and no economic damages are caused.

IMPORTANT: Indicates technical information of particular importance which should not be ignored.

Dear Customer

Many thanks for choosing to a CRANE POWER / PALFINGER MARINE product. We have done everything to ensure optimal and safe operation in the design and production of your crane.

To ensure that your crane works reliably and economically for many years, please observe the following:

Observe the safety instruction (possible dangers). Maintain your crane regularly in accordance with the instructions. Keep your crane clean. Dirt increases wear on the cylinders and

bearings. Leaking oil or other lubricants are a major source of accidents.

Follow the instructions of this manual.

We wish you all the best!

CRANE POWER / PALFINGER MARINE

by CRANE POWER

Safety instructions

1 It is also in your own interest to observe these instructions very carefully.

Before operation of the crane

2 This chapter provides you with important safety instructions which must be followed each time before starting operation.

Start operation of the crane

3 This chapter gives you all the necessary information to properly start operation of your crane.

Crane operation

4 This chapter provides you with the necessary information to properly operate your crane.

After crane operation

5 This chapter provides you with a summary of the necessary instructions to safely finish work with your crane.

Maintenance and service

6 This chapter provides you with the necessary information to properly maintain and service your crane.

Appendix

7 EEx - Crane

Safety instructions Chapter 1

1 Safety instructions

CONTENTS

1.1 AN OVERVIEW OF THE DANGERS

1.1-1 RULES FOR THE AVOIDANCE OF DANGERS

1.2 PREREQUISITES

1.2-1 CE-SYMBOL

1.2-2 ASSEMBLY, ACCEPTANCE AND REGULAR INSPECTION OF THE CRANE UNIT

1.2-3 REQUIREMENTS FOR THE OPERATING PERSONNEL

1.2-4 SAFETY DEVICES NOT TO BE TAMPERED WITH

1.2-5 CRANE OPERATION IN ADVERSE OPERATING CONDITIONS

1.2-6 INTENDED USE

1.3 DURING CRANE OPERATION

1.3-1 AVOID DANGER OF CRUSHING

1.3-2 DANGER OF BURN INJURIES

1.3-3 KEEP DISTANCE FROM POWER LINES

1.3-4 ACTION IN THE EVENT OF FLASHOVER

1.3-5 ACTION IN THE EVENT OF DEFECTS

An overview of the dangers 1.1-1

1.1 An overview of the dangers

1.1-1 Rules for the avoidance of dangers

1. General safety instructions

Operation only by trained personnel. Safety devices not to be tampered with. Prescribed safe distances to be maintained. Safe distances from electric power lines to be maintained. Be alert to faults during crane operation.

2. Prior to crane operation

Pay attention to effluent hydraulic oil. Make a visual inspection. Check the safety devices before start-up.

3. On start-up

Use the right hydraulic fluid for the temperatures. Check the heel / load diagram. Remove the extensions before unfolding.

4. During crane operation

Ensure the crane is used according to the specifications. Keep an eye on the working area. Do not stay in the danger area of the crane. Safeguard the working area. Select the right control stand. Pick up and secure loads in the due and proper manner. Use of load lifting gear and ancillary equipment supplied by CRANE POWER / PALFINGER MARINE Secure attachment of ancillary equipment. Adherence to the max. lifting capacity of the crane, ancillary equipment and load lifting gear. No load moment increase when lowering the load.

5. After crane operation

Secure crane in transport position. Switch off hydraulic pump. Observe maximum head room on bridges, etc.

6. On maintenance and lubrication

Carry out maintenance work only when the machine is inoperative. Keep steps, standing areas and handles clean.

1.2-1 Prerequisites 1.2 Prerequisites

1.2-1 CE-Symbol If your crane is marked with a CE symbol it meets the requirements of the machine directive of the EEA (European Economic Area).

This symbol is only valid in connection with a conformity declaration issued for your crane.

The firm mounting the crane on the ship must issue a conformity declaration. If constructional changes are made to the crane (e.g. mounting of a rope winch, remote control, raised stand or raised seat, etc.) the CE symbol must be re-issued by the firm mounting the equipment (new conformity declaration).

If the crane bears a CE symbol, it must be fitted with an overload safety device.

Ancillary equipment must bear its own CE symbol.

In the EEA and certain other countries the crane may only be operated if it has a valid CE symbol and valid conformity declaration.

1.2-2 Assembly, acceptance and regular inspection of the crane unit The crane must be assembled according to the valid assembly rules of CRANE POWER / PALFINGER MARINE.

In addition, national regulations and guide-lines regarding installation must be observed and the official acceptance must proceed according to the regulations in force.

The firm responsible for assembly must on handing over the crane instruct the crane operator in the operation of the crane and point out to the crane operator all possible dangers and risks of injury.

On handover of the crane the customer is to be given the maintenance manual, operating instructions (including assembly-related additions), and the conformity declaration for the EEA.

The firm operating the crane is responsible for ensuring that the regular inspections required by law are carried out.

Any use other than the one intended by the company CRANE POWER / PALFINGER MARINE as well as constructional changes that affect the stability of load-bearing components need to be approved by the manufacturer.

Prerequisites 1.2-3

1.2-3 Requirements for the operating personnel

Operation of the crane requires skill, ability and experience. Therefore only entrust persons with the operation of the crane:

who are physically and mentally suitable for this (not tired, and not under the influence of alcohol,

drugs or medication).

who handle the crane responsibly and reliably. who have the right qualifications (training, crane operators license). who can prove that they have been instructed on how to operate the unit described here and who

are familiar with the content of these operating instructions. This also applies to the operating instructions for ancillary equipment used on the crane.

If the crane is operated by a person without crane operators license and training on this machine there is acute danger of accident.

Observe the regulations valid in your country!

1.2-4 Safety devices not to be tampered with Safety devices serve to protect you and were developed to avoid accidents and make your work safer. On delivery safety devices such as Emergency Off, load holding valve, pressure relief valve, etc. are adjusted to ensure safe crane operation (4.2). They must on no account be interfered with or rendered inoperative.

Caution:

If safety devices are tampered with or if lead seals are damaged, any warranty on the part of the manufacturer will cease to apply!

If safety devices are tampered with you put yourself and other persons at risk of fatal injury.

1.2-5 Crane operation in adverse operating conditions Safe operation of the crane can no longer be assured if winds are in excess of 50 km/h. If the wind exceeds this speed, the crane must not be put into operation or operation must stop. Our cranes may be used at ambient temperatures ranging from -30 C to +50 C. If the temperature drops below or exceeds these limits, operation must be discontinued as it can lead to damage to the hydraulic components.

1.2-6 Intended use Use the crane only for handling loads; mechanical interventions (pushing or driving against obstacles), fastening of loads at points other than those provided for this purpose, pulling of loads, etc. are prohibited. Manufacturer will accept no liability for damage caused by doing so.

1.3-1 During crane operation 1.3 During crane operation

1.3-1 Avoid danger of crushing

Avoid operating situations in which there is a risk of you or bystanders being crushed by the crane, or load.

The crush point is not regarded as a danger point for the body parts stated if the safety distances highlighted below are complied with and it is ensured that the next-biggest body part cannot penetrate.

Required minimum distances:

Body Leg Foot Arm Hand Finger

500 mm 180 mm 120 mm 100 mm 25 mm

If the distances are not complied with there is danger of injury and even death.

1.3-2 Danger of burn injuries Through the flow of oil in the hydraulic unit the hydraulic oil and therefore all components in the hydraulic unit are heated. The control valve, all other valves, hydraulic lines and hoses, hose couplings, hydraulic cylinders etc. can become so hot that they can cause burns if touched. Always therefore be careful of their temperature before touching hydraulic components.

1.3-3 Keep distance from power lines Keep the required minimum distances away from power lines. If this is not possible because of the particular work being carried out the lines must be disconnected (switched off).

The appearance and height of electric power lines gives no indication of their voltage.

In the case of lines where the voltage is not known a distance of at least 5 metres between the crane and the line must be maintained. This also applies to all load lifting gear and ancillary equipment attached to the crane.

Take into account that in a wind a power line can sway out or the load arm of the crane can be caused to swing by sudden movements (also upwards). Even unintentional approaching can lead to flashover.

Flashover can occur even on just approaching a power line. This entails the risk of fatal injury for the crane operator and auxiliary personnel.

During crane operation 1.3-4

For overhead power lines and contact lines of electric railways the following minimum distances apply:

A up to....... 1.500 V..... 1,0 m =

DC

~AC

over........ 1.500 V..... 1,5 m up to....... 1.000 V..... 1,0 m over........ 1.000 V..... 1,5 m

B up to ............ 1.000 V ...........1,0 m 1.000 ........... 110.000 V .......3,0 m 110.000 ....... 220.000 V .......4,0 m 220.000 ....... 380.000 V .......5,0 m unknown voltage ..................5,0 m

1.3-4 Action in the event of flashover If the crane touches a power line only your correct reaction can prevent a serious accident. If you touch the crane, ship, load or if you try to leave your location you will put yourself in acute danger of fatal injury.

Stay calm. Persons in the vicinity must keep a distance of at least 10 metres from the ship, crane and load

(resistance area).

If the power line has been cut and is touching the ground a distance of at least 10 metres must likewise be maintained (resistance area).

If there is a person within this 10 metre area this person may leave the danger area only by hopping with legs tight together (step voltage).

Do not touch the crane, ship or load. Warn bystanders not to touch the ship, crane or load and not to approach. Do not attempt to leave the operating stand; and do not touch any metal parts there. Indicate that the power lines must be disconnected. If you are on the loading area or in the operators cab of the ship, do not leave this location. It is

essential you remain where you are.

If someone is in the electric circuit the power line must be disconnected before this person can be removed; if you approach the person before the power is switched off you will put yourself in danger of fatal injury.

1.3-5 During crane operation

1.3-5 Action in the event of defects Observe the crane during operation for any sudden signs of any defects.

If you discover the following damage or defects to the crane, ancillary equipment, load lifting gear or fixing from the crane you must stop crane operation immediately:

Damages or cracks on load-bearing parts. Defect bearings. Defects in the hydraulic unit or safety devices. Loose screwed connections. Inadequately secured bolt connections. Leaks on hydraulic components or connections. Unusual noises. Unusually quick or slow working movements. Functional errors in the control system. Unusually high temperature of hydraulic components.

In the case of the above-mentioned damage or defects safe crane operation is no longer ensured. There is acute danger of accident and thus of fatal injury.

The crane may only return to service when the defects have been removed and safe working is once again assured.

Before operation of the crane Chapter 2

2 Before operation of the crane

Contents

2.1 CHECKS

2.1-1 DAILY VISUAL INSPECTION

Checks 2.1-1 2.1 Checks

2.1-1 Daily visual inspection Check the crane and its mounting once daily for visible defects, damages or alterations.

The man-riding basket has to be maintained and protected against corrosion on a regular basis. This action is absolutely necessary as corrosion may lead to a wall thickness reduction (3 mm).

Carry out this inspection very carefully every time: alterations or damages not detected because of carelessness or old habits are a major source of accidents.

Carefully check:

Screw fittings, connections, and other parts of the hydraulic system for damages or oil leaks.

Leaks of hydraulic oil may lead to dangerous accidents and cause considerable environmental damage and pollution.

Whether bolts and screw fittings are properly fixed. For defective bolt connections. The smoothness and the return motion of hand levers. Load bearing parts, accessories, load holding attachments

(grab, winch, etc.) for cracks and damages.

Defects in paintwork. Corrosion.

When such defects are detected, immediately cease operation of the crane.

If your crane is equipped with safety devices such as an emergency CUT-OFF, an overload protection system or a rope winch limit stop, always carry out a function test on them before operation.

Proceed as described in chapter 4. Always pay attention to the safety instructions!

If the safety devices do not work, operation of the crane is strictly prohibited.

Carry out this inspection very carefully every time: carelessness and old habits are a major source of accident.

Start operation of the crane Chapter 3

3 Start operation of the crane

CONTENTS

3.1 AN OVERVIEW OF THE CRANE

3.1-1 DESIGN ( PK 32080 M)3.1-2 DESIGN (PK 32002 M )3.1-3 OPERATING ELEMENTS

3.2 PREPARING FOR CRANE OPERATION

3.2-1 COLD START IN LOW OUTSIDE TEMPERATURES

3.2-2 PUTTING CRANE INTO OPERATING POSITION

An overview of the crane 3.1-1 3.1 An overview of the crane

3.1-1 Design ( PK 32080 M)

Crane base Outer boom ram 1 7 Limited slewing system Lever 2 8 Crane column Outer boom 3 9 Slewing gear Boom extension ram 4 10 Main boom Boom extension 5 11 Lifting cylinder Mechanical extension 6 12

3.1-2 An overview of the crane

3.1-2 Design (PK 32002 M )

Crane base Main boom 1 8 Turntable Outer boom ram 2 9 Crane column Outer boom 3 10 Slewing gear Boom extension ram 4 11 Emergency control stand (optional) Boom extension 5 12 Lifting cylinder Mechanical extension 6 13 Lever 7

An overview of the crane 3.1-3

3.1-3 Operating elements The symbols of the operating elements are explained here. The order of crane functions (symbols) as available on the emergency stand or on the remote control panel may differ from the displayed example. Therefore, always pay attention to the way the symbols (crane functions) are arranged on the control stand of your crane or on the remote control panel.

Slew Main boom Outer boom Extension booms

clockwise / counter clockwise lower / lift lower / lift extend / retract

Rotator Grab Rope winch

clockwise / counter clockwise open / close unwind / wind

3.2-1 Preparing for crane operation3.2 Preparing for crane operation

3.2-1 Cold start in low outside temperatures In outside temperatures below freezing:

Check the oil level.

0

40302010

-10-20-30

Switch on the pump assembly at lowest engine speed. Let the oil pump around without pressure for a few minutes so that it

warms up a little.

You can accelerate warming up of the oil by moving a hydraulic cylinder to the end stop.

At temperatures below 0 C make sure that your crane is being operated with a hydraulic fluid which is suitable for such temperatures.

3.2-2 Putting crane into operating position When unfolding the crane makes sure the mechanic extensions and the pulley head are completely in and fixed and secured properly (see also chapter 4).

If the extensions, the pulley head or a fly jib are not fixed and secured properly they may slide out of the hydraulic extendable arms when unfolding the crane and this means a high risk of accident for your and others.

Crane with remote control radio:

In cranes with remote control radio make sure not to bin the area of the rising main boom. Choose a posoutside of the cranes danger zone (see also chapter 4).

eition

Emergency control panel:

Never unfold the crane when operating from the emergency control panel. It serves to finish the loading works in case of a remote control system failure. Then put the crane in transport position and contact an authorized service workshop (see chapter 4).

Preparing for crane operation 3.2-2

Extending the crane:

PK xxx M:

Observe every safety instruction mentioned in chapter 1. Briefly press the function Fold-in outer boom to lift the knuckle boom from its support at the

crane post.

Then press the function Retract boom extensions one time briefly. Lift main boom Move the main boom in a near-vertical position using the function . Anyway,

avoid moving the main boom up to the top end.

Then unfold the knuckle boom with the function "Unfold outer boom" until it reaches a horizontal position.

The crane is now ready for operation. Without rope winch

With rope winch

3.2-2 Preparing for crane operation

PK x80 M:

Observe every safety instruction mentioned in chapter 1. Briefly press the function Fold-in outer boom to lift the knuckle boom from its support at the

crane post.

Lift main boom Move the main boom in a near-vertical position using the function . Anyway, avoid moving the main boom up to the top end.

Then unfold the knuckle boom with the function "Unfold outer boom" until it reaches a horizontal position.

The crane is now ready for operation. Without rope winch

With rope winch

Crane operation Chapter 4

4 Crane operation

CONTENTS

4.1 DURING CRANE OPERATION

4.1-1 KEEP THE WORKING RANGE IN VIEW

4.1-2 LOADING ACTIVITY

4.1-3 OBSERVE LOAD LIMITS

4.2 SAFETY DEVICES

4.2-1 EMERGENCY OFF BUTTON

4.2-2 HPLS SYSTEM

4.2-3 OVERLOAD PROTECTION SYSTEM

4.2-4 MANUAL PUMP EMERGENCY OPERATION (OPTION)

4.3 ADDITIONAL EQUIPMENT

4.3-1 LOAD HOLDING ATTACHMENTS AND ACCESSORIES

4.3-2 GRAB AND ROTATOR

4.3-3 ROPE WINCH

4.3-4 STANDING PLATFORM, TOP SEAT, CABIN, PROTECTION COVER

4.3-5 REMOTE CONTROL

4.3-6 EMERGENCY OPERATION FOLLOWING FAILURE OF THE REMOTE CONTROL CONSOLE

During crane operation 4.1-1 4.1 During crane operation

4.1-1 Keep the working range in view

Always keep a close eye on the suspended load, especially during slewing motions.

Ensure there is sufficient light on the working site.

The crane must be operated by no more than one operator at a time.

During loading activities, the crane operator must always have the hand levers at his fingertips.

As long as a load is suspended, the operator must remain in contact with the control levers.

If the possibility exists that objects could fall off onto the ground, the danger zone must be protected by road blocks or warning posts.

Standing within the danger zone is strictly prohibited, especially under the suspended load or close to moving crane components. Always choose the best working position which has the best view on the job being done and does not endanger other bystanders. Accidents may prove fatal.

In a case where it is not be possible for the operator to oversee the complete danger zone, a qualified person must guide the crane operator via hand signals. Use the hand signals legally accepted in your country.

Both the crane operator and the guiding person must master the hand signals.

The guiding person must always be exactly informed about the work being performed.

Only one person shall give instructions.

The instructor in a working group needs to be clearly indicated (signal flag, hard head in different color, etc.)

If there is a danger that parts of the load might drop during working with the crane the entire working area must be closed off and secured by a warning post.

Clean all steps, control units (standing areas) and moving parts of the crane of ice and snow, if necessary, before beginning work.

Whenever a raised load is hanging from the crane, the crane operator must not leave the current operating stand nor put the control console down; the crane operation must not be stopped, even temporarily.

4.1-2 During crane operation

4.1-2 Loading activity Only use the crane for lifting loads and never for freeing, hitting, pulling (dragging) loads, pressing or driving against solid obstacles or for towing. Any angled hoisting is prohibited.

The transportation of persons is only permissible in workman baskets specially constructed for the purpose.

The regulations specific to each country must be adhered to.

Always lift loads from above their center of gravity. Ensure the load will not slip.

When operating with a grab, always encompass the load fully before lifting.

Handle wet or icy loads with care; there is a danger of slippage! If there is so much ice or snow on the load which is to be lifted that safe lifting cannot be guaranteed, the ice or snow must be removed from the load before it is lifted.

When you activate a crane function grip the operating lever completely and press it until the crane responds. You can then increase the speed of the crane function by further slow and even pressing of the operating lever.

Likewise stop the crane movements slowly and evenly.

Operate the crane so that it performs gentle movements.

Abrupt crane movements, such as quick pressing through or momentary stopping of a crane function can cause the load to swing and drop. There is danger of an accident.

Move the raised load gently enough that it does not bump against the crane or other obstacles.

During crane operation 4.1-2

Loads must only be attached and removed when the crane is completely at a standstill. Before moving the load arm ensures that the person who has attached or removed the load is no longer in the danger area of the crane.

If persons are in the area of the moving load arm (danger area) they are in acute accident danger.

Do not move the crane at full working speed to the stop, this increases wear and shortens service life. You can operate several functions at the same time, i.e. carry out several movements at the same time.

If the crane is operated with several functions at the same time it must be ensured that if one function is switched off the working speed of the other functions can increase.

A

B When it is below the horizontal line (range A) the main boom is not able to reach the maximum lift moment; therefore this position should be avoided. If you work in this boom position anyway particularly bear in mind that it is not possible to use the maximum lift moment of the crane. Therefore work with the knuckle boom in these load ranges. In some crane types it is possible to unfold the knuckle boom beyond the main boom angle. In the upper movement range (range B from ca. 60 to maximum main boom angle) it is not allowed to use this knuckle boom position as working position.

With heavy loads there is risk of excessive heel! Therefore: Observe the inclination and load diagrams!

4.1-3 During crane operation

At load (100%):

5 Heel 2 Trim A = Inclination B = Lifting moment C = Slew load D = Hold load

When working with a load, do not lower the main boom to full retraction since the overload protection system does not function in that boom configuration.

If loading operations have to be interrupted, lay the booms down, turn the hydraulic pump off and ensure unauthorized persons cannot operate.

In order to resume work safely after a break, you must check whether anybody has manipulated the crane in the meantime.

4.1-3 Observe load limits

Never exceed the load moment permitted for the crane. This may cause uncontrolled sinking of the load or breaking (crack) of elements. The permissible load capacities and the maximum load are given on the load capacity label. By working with an overhang as low as possible you increase the safety and live of your crane.

During crane operation 4.1-3

Lowering a heavy load from an extended boom configuration must be performed without increasing the outreach, otherwise the admissible load limit may be exceeded. For cranes with no overload protection or fitted with an overload indicator only, this causes the booms to lower uncontrollably. For cranes with an overload protection, the resulting sudden stop puts unnecessary stress on the crane and may cause the load to slip out. For a description of safety devices see Chapter 4.2.

Load lifting material (hook, lifting slings, chains, etc.) and attachments such as grabs, rotators and manual extensions must be accounted for when calculating the overall load.

Never exceed the load limit indicated on accessories or lifting material. Pay attention to and observe the load charts of the manufacturer when using slings, ropes, chains or any other lifting material.

When working with manual extensions, the admissible load of the manual extensions determines the overall admissible load of the whole crane (see load chart), and that, even if they are fully retracted.

Therefore always hook up your load on the manual extension best suited for the job or on a hydraulic extension boom.

Load capacity label for a crane:

1. Angle specification for ideal main boom position

2. Range of coverage specification

3. Load capacity values

4.2-1 Safety devices4.2 Safety devices

Using safety devices can avoid accidents. They are for your protection therefore you should make sure which of the below safety devices are available on your crane.

4.2-1 Emergency off button The emergency CUT-OFF button is a safety device wwhen pressed, brings the crane to an immediate stop. Allcrane functions remain locked until the CUT-OFF buttois de-activated.

hich,

n

On the transmission console of the remote control system: (see also Chapter 4.3 Remote Control)

If an unexpected hazardous situation occurs during crane operation, release all of the operating levers immediately and press the emergency off switch until it clicks. All of the crane functions will then be blocked. If the emergency off switch was pressed because of an emergency situation, it must not be released until safe crane operation has been guaranteed.

If, during operation, the CUT-OFF valve is activated because of a power supply failure, you can bring the crane back into transport position with the following procedure:

Dispose of the lead seal and the spacer on the valve. Turn in the knurled thumb screw.

After this procedure, the CUT-OFF button is out of order and must be repaired as soon as possible at your service workshop.

Safety devices 4.2-2

Test the function of the CUT-OFF button every time before working:

Actuate a crane function and simultaneously press the CUT-OFF button: the crane should im-mediately come to stop.

Crane movements should no longer be possible.

If the crane motions do not stop IMMEDIATELY, then cease operation of the crane!

4.2-2 HPLS System Your crane may be equipped with an HPLS system, which can be switched on as needed by using the pushbutton. When the HPLS system is switched on, your crane has greater lifting power due to a reduction in the crane speed.

4.2-3 Overload protection system

The may can be equipped with an overload protection. The overload protection of the crane will react when the crane (main boom, knuckle boom, extendable arms) is in the overload range.

OAS (Hydraulic overload protection system with blocked outer boom motions):

An overload protection system is supposed to prevent a load moment which is too high on the crane before the overload becomes dangerous by turning off the movements which increase the load moment. Before the load becomes dangerous means before the load holding valve is activated, this would cause the crane to begin to drop the load uncontrollably. The pressure from the lifting cylinder is used to activate the system. If the pressure set for the overload valve is exceeded, all of the movements in the tank increasing the load moment are shut down; they are combined in one block.

The following functions will be disabled if your crane reaches the overload range:

Main boom ........................................................................................ lower Outer boom ....................................................................................... lift / lower Extension .......................................................................................... extend Rope winch ....................................................................................... hoisting

When the crane is in overload it is only possible to execute movements that reduce the load-moment. As long as the pressure in the lifting cylinder falls below the pressure specified for the overload protection.

These functions will only enable after reducing the load moment. This is achieved by retracting the extendable arms or lowering the rope winch.

4.2-3 Safety devices

Pressure peak button:

Lifting the lift cylinders up to the stop activates the overload protection. Reason for this is a pressure peak in the lifting cylinder which develops when running to the stop end (with our without load).

Lower main boomIt is impossible to release this pressure peak as the function is blocked and the pressure in the lifting cylinder cannot be reduced by movements that reduce the load moment. In order to lower the main boom from this position, the pressure peak button must be pressed briefly several times. This will cause the pressure in the system to be released into the tank and the overload valve will switch back to normal crane operation. This will not work when the crane is actually in overload as in such a case it is impossible to reduce the pressure in the lifting cylinder.

Checking the overload protection system:

Before start working with the crane, the overload protection system must be checked.

How to do:

To check the overload protection system, no load is necessary. The only one thing to do is to move the main boom on top position with maximum speed. In this case a peak pressure raises in the main boom cylinder and activates the OAS system.

The following movements must be blocked:

Main boom......................................................................................... lower Outer boom........................................................................................ lift / lower Extension........................................................................................... extend Rope winch........................................................................................ hoisting

To switch back the overload system it is necessary to push the peak pressure button a few seconds.

If this test is not OK, it is not allowed to work with the crane!

Briefly press the release valve and lower the main boom.

Safety devices 4.2-4

4.2-4 Manual pump emergency operation (option)

Emergency operation following a power failure or defect in the electric system of the crane.

If your crane stops due to a defect in the electric system of the crane or because of a complete power failure then you can bring the crane in an emergency operation status (emergency operation). When the crane is in emergency operation it is possible to move it in transport position. (After this see a CRANE POWER / PALFINGER MARINE authorized repair centre immediately). The device (by-pass screw) that allows you to bring your crane in emergency operation is always on the emergency off magnet valve. Depending on the crane model it is either on the control valve or on the high-pressure filter.

Operating the manual pump in emergency operation:

Block the EMREGENCY-OFF magnet valve (1) manually using the by-pass screw. Close the control line with the hand lever (2).

Operate the necessary functions on the control valve (3) and at the same time pump with the hand pump (4) to move the crane into transport position.

The hand pump is assembled to the hydraulic aggregate or to the side of the raised stand.

The working speed is very low when controlling the crane with the hand pump.

4.3-1 Additional equipment4.3 Additional equipment

4.3-1 Load holding attachments and accessories You may operate the crane with a number of different load fixing tools such as grab, rotator, extensions, pallet fork, belts, ropes, manipulators, a second knuckle system, etc. In addition to the cranes operating instructions refer to the operating instructions for the load fixing tool or accessory you are using. For some accessories, a special suspension from CRANE POWER / PALFINGER MARINE must be employed and mounted according to the following sketch. Otherwise, damages to the attachment are possible and such a case is not covered by the warranty. For more details, simply ask your CRANE POWER / PALFINGER MARINE service workshop.

For cranes with extensions a CE sign is NOT possible!

Please observe the following in connection with load lifting gear:

The weights of the load lifting gear and accessory equipment count as part of the load. The load lifting gear must be matched to the crane in terms of size and lifting capacity. A type plate must be attached to the load lifting gear showing details such as manufacturer, type

designation, manufacture number, weight, operating pressure, capacity, maximum permissible lifting capacity and year of manufacture.

The maximum lifting capacity of your crane is always determined by the weakest unit of load lifting gear used. Please therefore always observe the lifting capacities stated on the load lifting gear.

Familiarize yourself with the content of the operating instructions of the respective load carrying equipments.

Hook:

On your crane only use load hooks which match your crane and the load to be lifted.

The lifting capacity of the load hook and the shackle must correspond to the maximum lifting capacity of the crane.

Fasten and secure the load hook properly. Ensure that the safety catch closes again by spring pressure after the load has

been hooked.

Additional equipment 4.3-1

Working with mechanical extensions:

Put the load arm in horizontal position. Extend the extendable arms. Lower the crane boom far enough that you can remove the spring cotter and the securing bolt

with which the mechanical extension is secured. Always stand to the side, never in front of the crane boom.

Mechanical extensions can slide out of the boom extension after removal of the securing bolt owing to the inclined position of the boom extension. Therefore always take up a position to the side of the boom extension, otherwise there is a danger of fatal injury.

Remove the spring cotter from the securing bolt and pull the bolt out. Pull out the mechanical extensions so far until you can secure them with the bolt again in the

extendable arm. It is prohibited to let the extensions fall out of the load arm by placing it in a steep position.

Secure the bolt again with the spring cotter. The maximum permissible load capacity of the used extension (see model label or side label on

the extension) must not be exceeded. This is even applicable when the extension is completely retracted and secured.

Inadequately secured mechanical extensions pose a potentially frisk for you and others. Always use only bolts and cotters recommended by CRANE POWER / PALFINGER MARINE.

atal

ock

The maximum load capacity of the crane is always determined by the weakest load taking element. Therefore, always observe the load-carrying capacities specified on the load taking elements.

When you are working with load carrying equipment or accessories such as load hooks, mechanical extensions, winch components, etc. always make sure that the equipment has been properly secured.

Always use the proper bolts and securing elements (cotter pins, lnuts, etc.) for the load carrying equipment or accessories.

4.3-1 Additional equipment

Working with hydraulic ancillary equipment:

A range of ancillary equipment (grab, rotator etc.) is operated hydraulically. The hydraulic system of the crane must be connected to the hydraulic system of the ancillary equipment with screw couplings. When using quick couplings, make sure they are clean (use dust caps). Once the screw couplings are connected, screw down the dust caps as well.

Connecting screw couplings:

Switch off pump. Remove pressure from the lines by operating the control levers in both switching positions. Remove dust caps from the couplings. Screw couplings until tight. Connect dust caps.

Couplings, hoses or leaking oil can become so hot from the heated oil that there is a risk of burns. Carelessly screwed couplings can result in oil leakage and the consequent pollution of the environment. The loss of pressure impairs the function of the ancillary device or causes it to fail completely.

Separating screw couplings:

Switch off pump. Remove pressure from the lines by operating the control levers in both switching positions. Separate dust caps. Separate screw couplings. Screw on dust caps and stow the hoses properly in the hose boxes.

Additional equipment 4.3-2

4.3-2 Grab and Rotator Grabs should be used exclusively for moving loose materials such as sand, gravel, soil etc. Never use the grab to pull (out) or drag objects (masts, trees, etc.), or to press or hit, as this can result in damage to the crane, the load suspension, rotator or the grab itself.

Installation of rotator and grab see operating instructions for the grab.

Your crane should be equipped with an adequately sized tank and/or oil cooler (oil temperature) for grab operation. However, you should monitor the oil temperature constantly during grab operation.

4.3-3 Rope winch For rope winch operation only use CRANE POWER / PALFINGER MARINE rope winches, pulleys, pulley heads, etc. Mount the winch components (intermediate pulleys, pulley heads) as shown in the technical sheet. Use the correct bolts and bolt locks for each of the pulleys. Observe the maximum load values of the rope winch which you find on the type plate of the rope winch. Rope, insert, pulley head and bottom flanges are parts of the load. By single rope use, put the rope trough the trolley head and but the pin trough the rope head and the load attachment of the crane hook.

By two way rope use put also the rope trough the trolley head and the trough the bottom sheave and fix it then at the trolley head by a pin.

1. Rope winch

2. Rope

3. Reversing pulley

4. Pull-in part

5. Trolley head

6. Bottom sheave (Hook)

Furthermore there is danger of the rope being torn up, because it will shorten if the knuckle boom is unfolded with the rope winch being assembled to the main boom. So always pay careful attention during rope winch operation that enough rope is pulled off the drum during these crane movements.

It is prohibited to use damaged, worn or too weak ropes!

4.3-3 Additional equipment

When working with the rope winch it has to be ensured that:

Movements which cause the load to rotate about the axis of the rope should be avoided!

The lifting capacity may not be increased or modified in any way. The rope winch is not overloaded with the lifting capacity of the crane. When extracting the extendable arms or lifting the knuckle boom make

sure that this will not shorten the rope to the extant that it tears up.

Crane components such as hydraulic extendable arms, mechanical extensions and pulleys etc. are not overloaded with the lifting capacity of the rope winch.

If the rope winch does not have a safety device it must be ensured when winding off the rope that at least 3 turns remain on the drum.

If during working with the rope winch the rope is wound off to less than three full turns the rope may be pulled out of its fastening in the rope drum. This will cause the load to drop, which means an acute accident danger for you and other persons.

On a rope winch with safety device it is ensured that when the rope is wound off at least 3 turns

remain on the drum and that the rope is not snapped by unintentional shortening (extending the extendable arms).

The pulley heads, pulleys and intermediate pulleys are to be mounted and used in accordance with the technical information sheets.

To prevent slack the rope must be kept tight when being wound onto the rope drum (not with the hands).

If the lower rope layers on the drum are hardly used or not used at all they are to be wound off the drum from time to time and rewound with pretensioning.

Additional equipment 4.3-3

Controlling winch functions

If a winch is used infrequently, a full operational check is required at least once a year. The winch as well as the braking system must be tested under full load conditions.

To check the multiple disk brakes, stop the winch action while operating the winch under conditions of full load. The load should come to a complete stop and remain suspended at rest. No lowering of the load should occur.

If the load continues to lower even only slowly the rope winch break will be not fully functional. Stop rope winch operation immediately and contact your service centre. Do not continue using the winch under any circumstances!

Loading and unloading work in rope pulley operation (observe load limits):

Always work with the lowest possible load moment in rope pulley operation as well. You will increase the safety of the loading or unloading procedure and the useful lifetime of your crane.

If the load-bearing arm is in a near-vertical position, the extendable arms must be retracted as far as possible during loading and unloading. If the load-bearing arm of the crane is in a near-vertical position, retract the hydraulic extendable arms before picking up or setting down the load. Lift the load without extending the extendable arms. Lift the load only far enough so that it does not bump against the load-bearing arm.

Slowly lower the load-bearing arm to about 60.

4.3-4 Additional equipment

Now you may, if necessary, extend the hydraulic extendable arms. Pay special attention to ensure that the necessary length of rope always unwinds when extending the hydraulic extendable arms.

Pay special attention to the load during this procedure. It must not hit the load-bearing arm or rub against it if its position is too steep. Slewing movements must be performed slowly and gently so that the load does not begin to swing back and forth.

When work is done with a fully extended hydraulic extendable arm and the load-bearing arm in a near-vertical position, the load-bearing arm may swing to the side, especially during slewing motions of the crane. This can cause the load to fall. Do not work in rope winch operation in this work position. If the extended load-bearing arm is in a steep position (more than 60), do not extend the hydraulic extendable arms by more than 2/3 of the possible distance.

4.3-4 Standing platform, Top seat, Cabin, Protection cover Use the railings, ladder or handles to climb onto the standing platform or the top seat. Be

extremely careful not to touch any operating elements.

Handles, step treads and standing spaces must at all times be clear from dirt, oil or ice. Clean if necessary.

After taking place on the operating stand, use the protection safety belts or cables provided. While working on the valve box, make sure that you are never in the danger zone of the crane in particular below the lift load or below or near any moving parts of the crane. Therefore, observe the required safety distance to load and crane components while running the crane movements. If it is insufficient this means acute risk of fatality for you!

Additional equipment 4.3-4

Description of the operating elements

1. Manometer

2. Emergency-off button

3. Switch for remote control radio operation manual operation

4. Pressure peak button

5. Capacity shield (Crane)

6. Operation symbol

7. Capacity shield (Rope winch)

8. Lever

4.3-5 Additional equipment

4.3-5 Remote control

In order to be able to make smooth precise crane movements during remote-controlled operation the carry belt for the transmitter panel must be used.

The remote control unit is ready for operation as soon as the start button is pressed. All operating levers must be in neutral position. It is impossible to start the unit if the emergency CUT-OFF button is pressed. For information about the crane operation via remote control radio see the delivered separate operating instructions. To prevent unforeseen interruptions and downtimes due to empty accumulators always keep a charged reserve accumulator with you. A sealing of the valve plug is not necessary, as the outputs of the receiver are intrinsically safe. The plug has not been secured to the valve by a screw. Dont take the plug away from the valve when the valve is under voltage! The screw tightening has to be checked regularly.

Observe all instructions in the remote control operator's manual delivered with each unit. The selection switch remote control / valve control is fitted on the control panel.

Additional equipment 4.3-6

4.3-6 Emergency operation following failure of the remote control console Following failure of the remote control console, the crane must be operated using the emergency control unit (emergency control). This is located on the crane post and may be operated only for the purpose of putting the crane into transport position. Contact a CRANE POWER / PALFINGER MARINE authorized service centre immediately.

Move crane into transport position using the emergency control console:

Select a safe place to stand at the emergency control unit (standing area and handles should in any case be provided by the assembler) from which you can easily reach the operating elements of the emergency control unit.

Then proceed as follows:

Remove the operating lever (1) and screw it onto the control valve on the crane function Slew. Pay attention to the arrangement of the crane functions on the emergency control unit!

Then put the crane into transport position and contact a CRANE POWER / PALFINGER MARINE authorized service centre to repair the operational disruption.

1. Operation symbol

2. Lever

3. Emergency-off button

4. Switch for remote control radio operation manual o

Capacity sh

peration

5. ield

When operating the emergency control unit (emergency operation),

ng

6. Pressure peak button

make sure that you always maintain an adequate distance to all moving crane parts and the load. There is an acute danger of beicrushed (risk of fatality). Also make sure that you have a secure place to stand (danger of falling).

After crane operation Chapter 5

5 After crane operation

CONTENTS

5.1 ENDING CRANE OPERATION

5.1-1 PUTTING CRANE IN TRANSPORT POSITION

5.2 AFTER CRANE OPERATION

5.2-1 SECURING AND TRANSPORTING THE LOAD

Ending crane operation 5.1-1 5.1 Ending crane operation

5.1-1 Putting crane in transport position In your activity observe all the safety instructions in Chapter 1.

Cranes with remote control operation:

On cranes with radio remote control make sure that you are not in the area of the slewing or descending boom. Select a standing place outside of the crane danger area (see also Chapter4).

Retracting the crane:

Push the extensions in and secure them as described in Chapter 4.

If mechanical extensions are not properly retracted and secured they can slide out of the hydraulic extendable arms and then represent a high risk of accident for you and others.

When retracting the crane please ensure to have all crane movements within your field of vision.

PK xxx M:

Lift main boom Move the main boom in a near-vertical position using the function . Anyway, avoid moving the main boom up to the top end.

Retract boom extension

Fully retract the boom extensions using the function . Fold in outer boom Now fold in the outer boom completely using the function .

Retract boom extension Retract the boom extensions using the function until the transport hook is securely fixed in the eye.

Left, right slew Slew the crane into transport position using the function and observe the fold-in arrows on crane column and crane base.

Move the main boom in its support position using the function Lower main boom. The support console for the load-bearing booms has to be assembled by the crane assembler (see also assembly instructions). On request there is a support for cranes larger than 30 mt.

5.1-1 Ending crane operation

Without rope winch

With rope winch

Winch

operation only in this position!

Ending crane operation 5.1-1

PK x80 M:

Lift main boom Move the main boom in a near-vertical position using the function . Anyway, avoid moving the main boom up to the top end.

Fold in outer boom

Now fold in the outer boom completely using the function . Retract boom extension Retract the boom extensions using the function .

Left, right slew Slew the crane into transport position using the function and observe the fold-in arrows on crane column and crane base.

Lower main Move the main boom in its support position using the function boom. The support console for the load-bearing booms has to be assembled by the crane assembler.

Without rope winch

With rope winch

5.2-1 After crane operation

If, during transport, the crane booms are not folded in this position but rest on the platform or on the driver's cabin, ensure that they are properly secured against sideways motions.

If the crane is not properly secured against sideways motion or not completely folded, there is a great risk of accident.

5.2 After crane operation

5.2-1 Securing and transporting the load

Secure the load in accordance with the regulations before starting the trip.

Before starting the trip check that the hydraulic pump is switched off.

It is necessary to operate the main switch for remote control radio to interrupt power supply (24 V) to the remote control.

Maintenance and service Chapter 6

6 Maintenance and service

CONTENTS

6.1 MAINTENANCE

6.1-1 WARRANTY PROVISIONS

6.1-2 SCHEDULE OF MAINTENANCE

6.1-3 PLANE OF MAINTENANCE ( PK 32080 M)6.1-4 PLANE OF MAINTENANCE (PK 32002 M )6.1-5 LUBRICATION

6.1-6 HYDRAULIC OILS

6.1-7 OIL CHANGE / OIL MAINTENANCE

6.2 CLEANING THE PLANT

6.2-1 CLEANING AGENTS AND EQUIPMENT

6.2-2 REPAIRING PAINT DAMAGE

6.2-3 REMOVAL FROM SERVICE AND DISPOSAL

Maintenance 6.1-1 6.1 Maintenance

6.1-1 Warranty provisions

Regrettably, during servicing, we have noticed repeatedly that our recommendations for maintenance and lubrication of the crane have been ignored. We are not liable for any costs for damage resulting from insufficient maintenance and lubrication. It is in your own interest to carry out the maintenance and lubrication of your work platform regularly and in accordance with the instructions. Only use lubricants and hydraulic oil of sufficient quality. Using poor quality products represents a false economy. Guarantee and service work must only be carried out at one of our authorised customer service centres (see Maintenance Handbook). The conditions of the guarantee are stated in the guarantee booklet.

6.1-2 Schedule of Maintenance

When working on hydraulic equipment, make sure that the hsystem is not still under pressure!

ydraulic

after the first 50 hours

1st service Oil filter change

every 20 hours / smallest once a week

Column bearing (slew 360 degrees) 2 Rotary distributor (slew 360 degrees) 12

6.1-2 Maintenance

every 50 hours / smallest once a month

Fixation of crane base 1 Slewing rack (slew 360 degrees) 3 Main boom cylinder pivot, Outer boom cylinder pivot 4 Continuous rotation 5 Thrust bearing 5 Gear oil (inspection glass- fuel lever plunger) 5 Main boom pivot 6 Power link pivot 7 Outer boom pivot 8 Boom extension rams - guide parts, pivot guide 9 Extension booms - guide blocks 10 Mechanical extensions 11 Turntable (slew 360 degrees) 13 Thrust turntable 13 Rope winch Rope Load hook Tighten up, fittings, pipes and hoses Repairing paint damage

every 1000 hours / smallest once a year

Oil filter, hydraulic oil change Rope winch hydraulic oil (see data sheet) Slewing system gear oil

Rope grease Grease SAE 90Oil spray Screw Machinery oil Visual check

Maintenance 6.1-3

6.1-3 Plane of maintenance ( PK 32080 M)

PK X080 Serie

8

9

9

10

11

3

4

2

5

1

4

8

7 6

4

6.1-4 Maintenance

6.1-4 Plane of maintenance (PK 32002 M )

Maintenance 6.1-5 6.1-5 Lubrication

The following maintenance and care instructions apply to all CRANE POWER / PALFINGER MARINE cranes. Therefore this chapter includes also hints which do not refer to your crane.

Deficient or incorrect lubrication causes increased wear out and consequently unnecessary repairs (downtimes) of the crane. Therefore, make sure that bearings, hydraulic extendable arms and mechanic support arms are always sufficiently lubricated and that only those lubricants are used which are included in the specification below or correspond with them.

Lubricant to be used:

To lubricate the bearings only use solid-free grease without any graphite, MoS2, etc. Using different greases quickly leads to bdamages on the crane.

earing

Bearing:

Inspected according Technical Data to:

Structure smoothConsistence (NLGI) 2 DIN 51818

Designation KP2K-35 DIN 51502

Dropping point C 150 DIN ISO 2176

Worked penetration 265/295 1/10 mm DIN ISO 2137

Oxidation stability 100 h / 100 C max. 0,2 bar DIN 51808

Basic oil viscosity at 40 >80 mm/s

Behaviour in water Water resistant DIN 51807-1

Boom extensions / mechanic extensions, etc:

Inspected Technical Data according to:

Type designation OMV whiteplex 1 (EZ 739) Thickener type Al-Komplex

Temperature range -30 C to +190 C

Consistence (NLGI) 1 DIN 51818

Specification K 1 R-30 DIN 51825

Dropping point C 240 DIN ISO 2176

Worked penetration 300 mm/10 DIN ISO 2137

Flow pressure at -15 C - hPa DIN 51805

Flow pressure at -25 C 500 hPa Flow pressure at -30 C 900 hPa

Basic oil viscosity at 40 220 mm/s

Behaviour in water Water resistant DIN 51807-1

6.1-5 Maintenance

How to grease the bearings on the crane correctly:

Before greasing clean the spot thoroughly, yet dirt that gets into the bearing hole together with the grease causes quick wear-out of the bearing.

Then press fresh grease into the bearing on the intended grease spots (oil holes etc.) until it comes out off the bearing.

After greasing it is necessary to clean off any excess grease from the bearing.

Grease the column bearing properly (rack track, thrust washer)

Before greasing the column bearing extract the main boom completely (outer boom remains folded) so that the grease may distribute evenly in the column bearings. The column bearing has to be lubricated on the grease spots intended for this by CRANE POWER / PALFINGER MARINE. If you lubricate via central lubrication make sure that sufficient lubrication is provided anyway.

After having pressed grease into all grease spots for the first time, slew the crane round its whole slew area. Then repeat this process until the grease comes out between crane column and crane base.

How to grease the hydraulic boom extensions on the crane correctly:

Extract the hydraulic boom extensions completely and then place the load-bearing arm on a piece of wood.

Before lubricating clean the grease spots off any old and dirty grease and other dirt.

Then apply the grease on the bottom of the hydraulic boom extension using a suitable tool (brush or similar).

Retract the hydraulic boom extensions while applying light pressure (lower main

boom).

Then remove the excess grease.

Because of danger of slipping excess grease is a safety hazard and must not get into the environment.

Maintenance 6.1-6

If the crane has not been used for a period of time, the complete crane system must be lubricated according to the lubrication plan. Each exposed metal part must be protected with an anti-rust agent. All of the hydraulic cylinders must be retrieved as far as possible. The cable winch and cable must be protected with an anti-rust agent. For continuous swivelling equipment the gear drive, pinion and all exposed metal parts must be especially protected against corrosion.

As grease is lost at most lubrication points on the work platform (grease is consumed or goes into the environment), we recommend the use of biodegradable greases.

Care of extendable cylinder piston rods:

If the extendable arms are never completely retracted to the transport position the extendable cylinder piston rods may suffer oxidation. The extendable cylinders (extendable arms) must therefore be completely retracted once a month.

6.1-6 Hydraulic oils When choosing the hydraulic oil, you should consult your service representative.

HLP / ISO hydraulic oils should be used with the following properties:

Reasonable viscosity / temperature properties. Good thermal and mechanical resistance. Significant ageing resistance. Good corrosion protection properties. Adequate cold-flow properties. Adequate lubrication effect at the lubrication limits. Good air-separation properties. Perfect foaming behaviour. Neutral with respect to seals and hydraulic hoses.

6.1-6 Maintenance

As the viscosity of hydraulic oils is strongly influenced by temperature changes, compromises during their selection cannot be avoided. The following limiting values are valid for your CRANE POWER / PALFINGER MARINE work platform:

Ope

ratin

g lim

its

Rec

omm

ende

d ra

nge

ISO Reference temperature Temperature C

High temperature range:............... ........................................................... 10 cSt Cold start limit: .............................. ........................................................... 1000 cSt Cleanness class: .......................... ........................................................... 15/12 (according to ISO 4406)

The working temperatures differ according to the different product bases:

Mineral oil based oils: ................... ........................................................... approx. -30 C to +80 C Biodegradable oils: .......................Fully synthetic esters:......................... approx. -30 C to +80 C Biodegradable oils: .......................Natural esters:.................................... approx. -20 C to +80 C Biodegradable oils: .......................Oils on the basis of rapeseed oil:....... approx. -20 C to +65 C

Rape-seed oil and Class HLP 22 oil must not be used. Rape-seed oil causes the valves to stick!

The ideal working temperature for hydraulic oil lies between 30C and 60C. If these temperatures are frequently exceeded when using the work platform, consult your service representative with regard to the installation of oil cooler or a larger oil tank.

Maintenance 6.1-6

Biodegradable oils are better for the environment than conventional hydraulic oils. Anyway, even these oils must not be disposed into nature.

Releasing oils (including biodegradable oils) into the natural environment is not permitted!

The hydraulic oils listed in our recommendations may be blended together but must not be mixed with other fluids.

Note the following disadvantages:

Shortening of service life, Mineral-oil mixtures are not biodegradable. Reduced permitted operational temperature for mixtures with rapeseed oil or native ester.

Hydraulic oils

Manufacturer: Mineral oils: Biodegradable oils: Gear oils: Toothed wheel Lubricating grease: grease: Rope:

AGIP Arnica32 Arnica S Blasia 150 Grease 33 FD FIN 332 / F

ARAL Vitam VF 32 Vitam EHF 46 Degol BG 150 Langzeitfett H Sinit FZZ

Avia Synthofluid 46 N

Avia Gear RSX 150

Avia Aluplex 0 RHS AVIA Avia Fluid HVI 32 Avia TAC BB 21

Castrol Grease CL CASTROL Hyspin AWH 32 Carelube HES Alpha SP 150

Spectron ZFK EPO DEA Astron HVLP 32 Econa E 46 Falcon CLP 150 Caron WAW EP 2

Biohydran TMP 32 FINA Hydran TSX 32 Giran L 150 Merkan DT 95 Cabline MGR

Plantohyd Super S FUCHS Renolin B HVI 32 Renolin CLP 150 Almetyn 2 Ceplatyn 300

Mobilgear OGL 007 MOBIL Mobil DTE 13 M Mobil UF 46 Mobilgear 629 Mobilgrease HP

OMV HLP M 32 Biohyd MS 46 Gear HST 150 OMV Fett ZMO OMV Fett ZFK

SHELL Tellus T 32 Naturell HF E 46 Omala Oil 150 Retinax HD 2 Shell Kuggfett

TEXACO Rando HDZ 32 Meropa 150 FM Novatex EP 1

TOTAL Equivis ZS 32 Hydrobio 46 Charter EP 150 Multis 2 Multis WR 2

Ultramax HVLP 32 VALVOLINE Ultrasyn HE 46 EPG 150 Val Plex EP 2 MP Molly Grease

WINTERSHALL Wiolan HVG 32 Wiolan HE 46 Ersolan 150 Wiolub LDF

6.1-7 Maintenance6.1-7 Oil change / oil maintenance

The annual maintenance of oil can significantly increase its working life. Apart from the saving in costs, this means a drastically reduced amount of waste oil and less contamination of the environment.

All rams must be fully retracted when changing the oil or topping up the hydraulic oil.

Oil maintenance means:

Filtration, dewatering and testing of the oil purity which you have carried out in an authorised workshop.

Life in years:

Oil type Oil maintenance

without with

Mineral oils 1 2

Biodegradable oils

Natural esters 1 2

Fully synthetic esters 1 2

The relevant local laws, regulations and guidelines apply to the disposal of wastes, residues or used materials!

Maintenance 6.1-7

The following nomogram gives the service life of the fully synthetic ester oils:

Max. oil temperature

Service life in years

Working hours

per year

6.2-1 Cleaning the plant 6.2 Cleaning the plant

6.2-1 Cleaning agents and equipment Regular expert care will serve to preserve the value of your crane. How often the crane needs to be washed depends on how frequently it is used, the season, weather influences and so on. Road salt, oils, dust, etc. attack the paintwork of your crane and an increased corrosion of the crane components can occur.

Only wash the crane when the electrical unit is switched off.

Cleaning agents:

For the care of your crane use only pH-neutral cleaning agents to avoid oxidation on chrome parts. When selecting cleaning agents please ensure that you only use environment-friendly products.

Some cleaning agents are harmful to the skin. Be informed about your cleaning agent and protect yourself accordingly before sthe cleaning work.

tarting

Cleaning equipment:

When using high-pressure cleaning equipment there must always be enough distance between the nozzle and the crane being cleaned as otherwise damage can be caused by the high water pressure.

Electronic components, plastic components, signs and bearings must not be cleaned using high-pressure cleaning equipment.

Therefore ensure that:

Lubricant is washed out of the bearings. Adhesive signs are not loosened from the crane by sideways or excessively long spraying. Plastic parts are not damaged by excessively high water temperature or high pressure. Crane parts containing electronic components (control valve, electronics boxes, etc.) or electronic

components themselves must never be sprayed directly with high-pressure cleaning equipment. If water gets into these parts, it can lead to a malfunction of the crane or to short circuits in the electrical system.

Areas which have been marked with the warning sign High-pressure cleaning prohibited must also not be cleaned with high-pressure cleaning equipment.

When using high-pressure cleaning equipment, the water (cleaning agent) must not exceed a temperature of 60 C.

Cleaning the plant 6.2-2

6.2-2 Repairing paint damage If you discover paint damage on your crane, you must take care of it immediately. Damaged places must be sanded off and coated with a primer before painting.

Repair damaged paint to avoid corrosion!

Degrease damaged paint. Apply primer. Apply top coat.

6.2-3 Removal from service and disposal

If the crane is taken out of service and dismantled from the vehicle its parts must be disposed of properly. Bear in mind that many crane components are contaminated with grease and oil which on no account must be allowed to discharge into the environment. Biodegradable oils and greases should not be allowed to discharge into the environment either.

Therefore dispose of the parts separately according to their nature (steel, plastic, electrical components, oils, greases, etc.) and in accordance with the respective statutory regulations in your country.

Appendix Chapter 7

7. Appendix

CONTENTS

7.1 EEX CRANE MODELS

7.1-1 GENERAL INFORMATION

7.1-2 TECHNICAL INFORMATION

7.1-3 INFORMATION ON SAFETY

7.1-4 INFORMATION ON SAFETY SPECIFIC TO THE CRANE

EEx Crane Models 7.1-1 7.1 EEx Crane Models

7.1-1 General Information

Objective of the Manual

This manual has been prepared by the machine manufacturer with the aim of providing information about safe operation of the equipment to the people who are authorized to carry out work procedures for transport, handling, installation, servicing, repair, disassembly and disposal of the crane.

Failure to observe the information can result in risks to the health and safety of people and in property damage.

This documentation should be given to a conscientious person for use as intended and for safekeeping at an appropriate location so that it is always available for reference and maintained in good condition.

If this documentation should be lost or damaged, request a replacement directly from your dealer, giving the identification code of the current manual.

The manufacturer retains the right to insert modifications, integrated material or improvements in the manual at any time; said insertions will not cause this publication to become unusable.

Symbols have been used to call your attention to especially important items in the text; their meaning is explained below.

SYMBOLS

DANGER ATTENTION: Indicates highly hazardous situations which could pose great risks to the health and safety of personnel if they do not exercise care in their actions.

CAUTION NOTE: Indicates that reasonable caution is necessary to avoid risk to the health and safety of personnel and the possibility of material damage.

IMPORTANT: Indicates especially important technical information which should not be ignored.

References marked by these symbols refer solely to machines in conformity with the ATEX Directive 94/9/CE. The work marked by this symbol must be carried out by qualified specialists who have the necessary skills for working in potentially explosive atmospheres. Failure to observe this note will result in serious safety risks for people and environment.

7.1-1 EEx Crane Models

Labelling of the Product

Additional Plate for Cranes and Accessories with ATEX Option (Example)

Legibility of the Type Plate

All of the information shown on the type plate must be clearly legible at all times, so the plate should be cleaned regularly.

Identification data on the type plate should always be given when making enquiries to the dealer such as requests for spare parts, information or customer service.

Glossary and Terminology

The terms used most frequently in this manual are explained below so that their meaning is clearly defined.

Scheduled Service

All of the work required to maintain the operational capability and efficiency of the crane. The work is normally stipulated by the manufacturer, who also determines the skills required and the type of intervention.

Unscheduled Service

All of the work required to maintain the operational capability and efficiency of the crane. This work is not stipulated by the manufacturer and must be performed by experience maintenance personnel.

Experienced Service Specialist

Authorized technician who is selected from among the people who have the necessary training, the necessary competence and the skills in the areas of mechanics and electrical equipment to perform unscheduled service on cranes.

EEx Crane Models 7.1-1

Overhaul

An overhaul comprises replacement of bearings and/or other mechanical components which display so much wear and tear that the operation of the crane is adversely affected. In addition, an overhaul includes a check of all of the crane components (gaskets, washers, deaeration valves, etc.). These materials must be disposed of in conformity with applicable environmental protection laws.

Requesting Customer Service

Whenever you require technical customer service of any kind, please contact the manufacturers sales network directly, providing the data shown on the type plate, the approximate number of operating hours of the equipment and a description of the malfunction which has occurred.

Responsibilities of the Manufacturer

The manufacturer refuses to accept any responsibility whatsoever in the following cases:

Use of the crane in violation of national laws for safety and accident prevention Incorrect installation, non-observance or erroneous observance of the instructions included in this

manual

Damage to the power supply or damage to the hydraulic supply Modifications performed or damage caused by the customer himself Work performance by untrained or unauthorized personnel

Safe operation of the crane also depends on strict observance of the regulations contained in this manual. They include:

Use of the crane within its operational limits Regular performance of proper maintenance Assignment of personnel for inspections and servicing trained for this purpose Exclusive use of original spare parts

Any configurations other than those shown the crane catalogue is prohibited.

Not using the crane contrary to the given instructions. The instructions in this manual are intended solely as a supplement to, not

as a substitute for, the applicable legal safety regulations.

7.1-2 EEx Crane Models

7.1-2 Technical Information

Description of the Crane

Safety Data for Cranes Conforming to Directive 94/9/CE

As a precaution, make selection with service factor Use only synthetic lubricants (oil and grease). Use washers made of VITON, for example, original Crane Power spare

parts.

Mount deaeration screws with spring return valve (e.g., for gear box). The oil drain screws are made of steel. The oil wiper rings have a dust protection lip. Remove metal elements which could rub against the exterior surfaces of

the crane.

Do not use any plastic parts which could become electrostatically charged, or insulate them appropriately.

Declaration of Conformity

Our cranes have been developed so that they are in conformity with the most important relevant safety guidelines and the Machine Directive 98/37/CE; on request, they can also be certified by a manufacturers declaration Appendix IIB, in combination with the Directive itself.

Cranes intended for use in potentially explosive atmospheres are in conformity with the most important safety requirements of Appendix II of the "ATEX" Directive 94/9/CE and satisfy the following classifications:

Machine Group: II Category: 3G Zone: Gas 2 Max. surface temperature: Temperature Class T4 for 3G (135 C)

Operational Limitations and Conditions

Modifications of the design or the mounting position (e.g., of accessories) are permissible only after previous consultation with and approval by the technical customer service at CRANE POWER. If this approval has not been granted, the ATEX homologation expires.

EEx Crane Models 7.1-3

Ambient Conditions

The use of the crane in potentially explosive atmospheres or in areas where the use of components protected from explosion is mandatory is prohibited, unless expressly stated otherwise.

The data shown on the type plate regarding the maximum surface temperature refers to measurements taken under normal ambient conditions and at a standard installation. Even the smallest variations in these conditions (e.g., smaller installation areas) may have significant effects on heat development.

Lighting When performing service work in poorly lighted areas, use additional lamps so that the work can be carried out under safe conditions and in accordance with the guidelines stipulated by applicable laws.

7.1-3 Information on Safety

Safety Standards

Read the instructions contained in this manual carefully and apply them as appropriate directly to the crane. Pay special attention to the safety instructions!

The service personnel for the crane must have the precise technical competence, special skills and the necessary recognized experience in this special sector as well as the required equipment and suitable personal protection, and know how to use it, for the entire service life of the crane. If these conditions are not met, safety of operation may be reduced, leading to risks to the health of the personnel.

Use the crane only for the purposes intended by the manufacturer. Using it for unintended purposes may result in risks to safe operation and the health of the personnel and may also cause economic losses.

The manufacturers intended purpose is of industrial origin and is what the crane was designed to do.

Servicing the equipment at the stipulated intervals secures maximum efficiency of the crane.

Correct maintenance means best performance, long service life and long life of the safety features.

When maintenance work is performed in areas which are difficult to access or dangerous, the necessary safety conditions conforming to legal provisions regarding occupational safety must be provided for the specialists doing the servicing and other personnel.

7.1-4 EEx Crane Models

Maintenance, service and repair work may be carried out solely by experienced service personnel who are aware of any hazards which may exist. Precautionary measures which will intervene in the event of a dangerous situation and eliminate the risk must be taken for the equipment as a whole. The experienced maintenance personnel must always proceed with the greatest caution and attention and strictly observe all safety standards.

During the operation phase, use only protective clothing and/or protective equipment which is indicated in the operating instructions provided by the manufacturer and which is required by current laws regarding occupational safety.

Replace all of the worn parts with original spare parts. Use only the oils and greases recommended by the manufacturer.

Dispose of pollutant materials in conformity with applicable laws. Observe applicable waste disposal laws during disposal.

Clean the surface of the crane and the steps in the working area after applying any lubricants.

When working on cranes which are used in potentially explosive atmospheres, the repair personnel must without fail turn off the power supply to the crane by switching it to out of service before commencing work. Avoid any circumstances which could lead to an unwanted restart or even to certain parts of the crane beginning to move. In addition, all of the additional necessary precautions for environmental protection must be taken (e.g., elimination of rgas, residual powder, etc.).

esidual

7.1-4 Information on Safety Specific to the Crane

Opening of EEx Protected Parts

Do NOT open ANY switch cabinets, power packs, electrical motors or other components which are labelled EEx or protected on the crane without the supervision of a professionally competent supervisor or monitor.

Danger from sparking!

Waiting time before opening

Any waiting time stipulated by the operating instructions for individual components (electrical motor, etc.) must be observed to prevent unexpected heat escape or sparking; if no waiting time has been stipulated, wait a minimum of 5 hours.

The equipment must NOT be opened in a potentially explosive atmosphere before the expiration of this stipulated waiting time.

EEx Crane Models 7.1-4

Sliding Points

Gliding points must be thoroughly lubricated at specific intervals to avoid electrostatic build-up. This is especially the case for bearing points of plastic bearings (e.g., sleeve pack on the boom extension).

Before Starting Up the Crane

Every time the crane is started up, a thorough visual inspection must first be conducted to ensure safe operation (e.g., damage to paint, damage to coated load attachments, hooks, etc.).

No modification of EEx protected components

Generally speaking, mounted parts (radio control units, switch cabinets, electrical outlets, etc.) may not be modified. This includes, for example, painting over defined gaps or the replacement of original screws, etc. Moreover, it is prohibited to modify parts in such a manner that the protection from penetration by dust, vapours, etc., is removed.

Winch

Special attention must be paid to winches (incl. rollers, intermediate rollers, bottom sheaves, etc.).

Danger from sparking! From collision of the bottom sheaves with crane components in the upright position! Strong rocking or oscillation of the bottom sheaves! Poor winding or guiding of the cable! Worn or breaking disc springs on the extension stop!

These parts should be monitored and/or serviced specifically before every start-up and as necessary

ealed or corrected to prevent sparking, or the cable guide

during operation to exclude these risks. For example, the disc springs could be scould be corrected by an authorized service centre.

7.1-4 EEx Crane Models

Hydraulic Components

Care must be taken that hydraulic components such as pumps do not run hot during operation as defined by the temperature classes (T1 ... T6), or that these parts (including control valves, valves) remain about 20 C below the maximum temperature permitted by the temperature class.

Classification of the Surface Temperature for Equipment in Group II G

Temperature Class Max. Surface Temperature in [C] 450 T1 300 T2 200 T3 135 T4 100 T5 85 T6

Impacts

Danger from sparking! Impacts or jerky motions with the crane should be avoided!

aterial CombinationsM

el (Fe) with aluminium (Al), m (Ti) must be avoided.

Danger from sparking! Correct such situations r.

wn Cr

Combinations of rusty stemagnesium (Mg) or titaniu

immediately, i.e., contact the contractual partneSuspend crane operation!

ane OperationShutting Do

Since there is a boom support on the crane column on

anger from sparking! Electrostatic build-up!

every crane, the crane must be moved at an appropriately slow speed with the extension system into this boom support.

D

EEx Crane Models 7.1-4

Crane Settings

None of the crane settings may be modified. With the company Crane Power the changes must be co-ordinated.

Danger from sparking! Speeds which are set too high (e.g., for the winch) are likely to cause a collision!

General

Normally the cranes are classified as EEx II 3G T3 (T4). The classification of the electrical

therwise, operation is to be conducted in accordance with EN 13463 (cleaning, etc.).

components is EEx II 2G d IIB (T4). O

pc_pk_pkm_ps_psm_ptm-k1-GB.pdf1 Safety instructions1.1 An overview of the dangers1.1-1 Rules for the avoidance of dangers

1.2 Prerequisites1.3 During crane operation

pc_pk_pkm_ps_psm_ptm-k2-GB.pdf2 Before operation of the crane2.1 Checks2.1-1 Daily visual inspection

pkxxxm-k3-GB.pdf3 Start operation of the crane3.1 An overview of the crane3.1-1 Design (( PK 32080 M)3.1-2 Design (PK 32002 M ()3.1-3 Operating elements

3.2 Preparing for crane operation

pkxxxm-k4-GB.pdf4 Crane operation4.1 During crane operation4.1-1 Keep the working range in view4.1-2 Loading activity4.1-3 Observe load limits

4.2 Safety devices4.3 Additional equipment

pkxxxm-k5-GB.pdf5 After crane operation5.1 Ending crane operation5.1-1 Putting crane in transport position

5.2 After crane operation

pkxxxm-k6-GB.pdf6 Maintenance and service6.1 Maintenance6.1-1 Warranty provisions6.1-2 Schedule of Maintenance6.1-3 Plane of maintenance (( PK 32080 M)6.1-4 Plane of maintenance (PK 32002 M ()6.1-5 Lubrication6.1-6 Hydraulic oils6.1-7 Oil change / oil maintenance

6.2 Cleaning the plant

pc_pk_pkm_ps_psm_ptm-k7-GB.pdf7. Appendix7.1 EEx Crane Models