Palfinger Clocktower PK2400 TK Operating instructions

1
Translation of the original Operation Instruction
Operating and maintenance manual
Clocktower PK2400 TK
Edition 08-2015

Dear customer,
thank you for purchasing and putting your faith in a quality product from
PALFINGER. During the development and manufacture of your unit,
everything was done to ensure that the equipment operates reliably and
safely.
Please note the information that follows so that you can work with your
PALFINGER product reliably and cost-effectively over the long term.
Please follow all safety instructions.
Please maintain your PALFINGER unit in accordance with regulations.
Please adhere to the prescribed maintenance intervals.
The unit must be cleaned at regular intervals, since dirt increases the
amount of wear.
Contamination by grease and oil increases the risk of accidents.
All prohibitions and notes in these operating instructions must be
complied with, since they protect your life and the lives of other persons.
We wish you great success with your PALFINGER product!

Contents
Notes regarding the operating instructions .........................................................1
Operating instructions.......................................................................................................3
Validity of operating instructions.......................................................................................3
Terms ...............................................................................................................................4
Symbols............................................................................................................................5
Graphics and pictures.......................................................................................................5
Safety and Health Standards..................................................................................7
Safety for individuals ........................................................................................................9
Use for intended purpose / limits of the device...............................................................10
Residual risks.................................................................................................................11
Government regulations and standards for operating the unit........................................11
Adverse working conditions............................................................................................12
Risk of falling..................................................................................................................12
Danger of getting crushed.............................................................................................. 12
Risk of burns...................................................................................................................13
Noise emission...............................................................................................................13
After maintenance, service and repairs..........................................................................13
General ...................................................................................................................15
CE symbol......................................................................................................................17
Structure of system.........................................................................................................17
Modifications to unit........................................................................................................18
Operators........................................................................................................................18
Device and function ..............................................................................................19
Main components...........................................................................................................21
Remote control...............................................................................................................24
Overview of operator station...........................................................................................29
Hazard warning symbols................................................................................................30
Remote control console - main functions........................................................................31
Overview of labels..........................................................................................................36
Safety equipment...................................................................................................41
General...........................................................................................................................43
Emergency cut-off button ...............................................................................................43
Paltronic 150 control system...........................................................................................44
Menu and function overview...........................................................................................49
Paltronic 150 safety equipment standard .......................................................................58
Emergency operation after remote control failure...........................................................62
Failure of electric system................................................................................................63
Failure of electric system................................................................................................63
Emergency operation in case of a power failure.............................................................63
Ancillary equipment ..............................................................................................65
General...........................................................................................................................67
Slingers, other attachments to lift the load......................................................................67
Preparing for crane operation..............................................................................69
Use for intended purpose / limits of the device...............................................................71
Watch out for faults before and during operation............................................................73
Preparing for remote operation.......................................................................................74
Contents

Contents
Remote control safety shutdown ....................................................................................74
Cable operation..............................................................................................................74
Working range................................................................................................................75
Starting the crane...........................................................................................................76
Unfolding the crane ........................................................................................................78
Daily function check of safety equipment........................................................................80
Crane operation .................................................................................................... 81
Load limits ......................................................................................................................83
Working position of the crane.........................................................................................83
Loads..............................................................................................................................85
Working with loads .........................................................................................................86
Workman basket.............................................................................................................91
Ending operation .................................................................................................. 99
Folding the crane into transport position.......................................................................100
Before driving ...............................................................................................................102
Rope winch.......................................................................................................... 103
Rope winch at winding device ......................................................................................104
Maintenance........................................................................................................ 109
Decommissioning and disposal........................................................................ 111
Decommissioning and disposal guidelines...................................................................113
Index..................................................................................................................... 115
Technical description......................................................................................... 117

Chapter 1
1
In this chapter
Operating instructions................................................................................. 3
Validity of operating instructions................................................................. 3
Terms.........................................................................................................4
Symbols .....................................................................................................5
Graphics and pictures.................................................................................5
CH A P T E R 1
Notes regarding the operating
instructions

Chapter 1 Notes regarding the operating instructions
3
Operating instructions
The operating instructions have been prepared to explain operation of the unit.
The operating instructions are part of the unit.
Always keep the operating instructions with the unit.
Note! In case of damage or loss of these operating instructions
please contact your PALFINGER partner and request a new copy.
Neither the operating instructions nor the annexed Technical Sheets replace proper operator training.
Please contact your PALFINGER partner immediately if there is anything in this operating instruction
which requires explanation. We appreciate any suggestions received from our customers; they help us
to make the operating instructions ever more user friendly. PALFINGER assume no responsibility for
the translation. In case of faulty or inaccurate translations the German version of the present operating
instructions shall prevail.
Note! Enclosed in these operating instructions you will also find the
PALFINGER DVD 'On the crane'.
Changes since going to press
PALFINGER is anxious to apply the latest and most advanced technology in their devices by further
development. This may result in deviations between operating instructions and the actual unit.
Please contact your PALFINGER partner immediately if any function in this operating instruction is
described insufficiently or incorrectly.
The specifications, pictures and descriptions shown in these operating instructions do not qualify for
any legal claims.
© Copyright by PALFINGER
Copying (even in extracts) only permitted on written approval
by:
PALFINGER AG
Franz-Wolfram-Scherer-Straße 24
5020 Salzburg / Austria
Validity of operating instructions
These operating instructions are only valid for the equipment shown on the front page. They are only
applicable in conjunction with the operating instructions from all other auxiliary equipment that is used
on the equipment/vehicle.

Notes regarding the operating instructions
4
Terms
Operating company
The owner, lessee, renter of the unit, uses the unit, operates the unit either himself or
entrusts a third party with the operation.
Operator
Anyone who starts up the unit.
Start-up
Switch unit on, irrespective of purpose (operation, maintenance, service etc.)
Assistant
Provides assistance but does not operate the unit.
Installer
Fits the unit to the building.
Service partner
Authorized by PALFINGER.
Expert
Someone with sufficient knowledge of loading cranes due to their technical training and
experience who is familiar with the relevant government laws and regulations to the
extent that they can assess whether the equipment is safe for operation.
Properly
A person who observes and complies with all duties of care that his work involves acts
properly.
Negligent
A person who disregards the duties that his work involves acts (grossly) negligently.
(Grossly) negligent
Who fails to observe what should be obvious to anybody under the respective
circumstances.
Load moment
The moment that is exerted by the load, ancillary equipment, lifting devices, etc. that
are hanging on a hook.
Inherent moment
The moment that is exerted by the dead weight of the boom system.
Lifting capacity
Consists of the load moment and the inherent moment
Lifting power
The force needed to lift an object.
Overload situation
Reaching of the maximum permissible load for the current working position.
Working position
Crane position.
Working range
The area that is required to carry out the work.
Movement range
The area within which the crane can be moved.
Load range
The range within which the respective crane can handle loads.
Load path
The course of the path that is taken by the moved load.
Hold load
Holding the lifted load under the supervision of the operator whilst the crane safety
systems are activated.
Setup status
Crane that has been prepared for the respective work.
EU
European Union.
CE marking
Shows that the unit has been manufactured in accordance with the EU directives.
Operating instruction
Produced in addition to these operating instructions by the operating company for
special operating conditions.
Emergency operation
Operating mode that is not for normal crane operation. Used to put the crane into
transport position after a failure of the electrical system and /or the safety equipment.

Chapter 1 Notes regarding the operating instructions
5
Symbols
The layout of the operating instructions is designed to make important notes, instructions or warnings
particularly clear by using symbols and signaling words.
Danger!
These symbols and the Danger! signal word are used for immediately
threatening dangers of fatal injury.
Ignoring this instruction will result in death or serious injury for
operator and others.
Warning!
These symbols and the Warning! signal word are used for immediately
threatening dangers.
Ignoring this instruction could result in death or serious injury for
operator and others. Damage to the unit or property can also result.
Note!
The symbol and signal word are used for particularly important notes
which make working with the unit easier.
Symbol for operating lever:
In neutral position
Operated
Graphics and pictures
Note!
Some of the pictures (for instance of the crane) in these instructions
are symbolic representations and for illustration only.

Chapter 2
7
In this chapter
Safety for individuals ..................................................................................9
Use for intended purpose / limits of the device ......................................... 10
Residual risks........................................................................................... 11
Government regulations and standards for operating the unit...................11
Adverse working conditions...................................................................... 12
Risk of falling............................................................................................12
Danger of getting crushed ........................................................................12
Risk of burns ............................................................................................13
Noise emission......................................................................................... 13
After maintenance, service and repairs..................................................... 13
CH A P T E R 2
Safety and Health Standards

Chapter 2 Safety and Health Standards
9
Safety for individuals
This unit is an item of working machinery. It has been constructed and built in accordance with
prevailing EU standards, guidelines and safety provisions. During use, maintenance or servicing
unforeseen risks to individuals, the device or other objects may nevertheless arise.
The safety of the operators and other persons must be top priority.
Operating situations in which the operators or other persons are in danger are prohibited.
If used incorrectly or negligently and/or operated wrongly the unit can potentially be extremely
dangerous.
In the event of manipulation or commissioning of the unit, the operator must ensure that neither he nor
any other person is in the danger area!
The operator must recognize and understand all safety instructions in the operating instructions and
the meaning of all signs.
Safety clothing
During any work on the unit such as:
Cleaning and maintenance
Setting up
All sorts of checks
Operation
Service and repairs
safety clothing that is suitable for the respective danger must be worn.
Before putting on the safety clothing, remove jewelry (example: rings, chains, bracelets etc.).
Personal safety equipment:
Operation: safety clothing, work gloves, hard-capped boots, helmet.
Other activities: depending on the type of danger (example: hearing protection in case of increased
noise emission, safety goggles, work gloves, safety belt).

Safety and Health Standards
10
Use for intended purpose / limits of the device
Use the crane only within the load limits shown on the load capacity chart to lift, move, carry and set
down loads. For load capacity chart refer to chapter 13, 'Technical description'.
Danger!
Improper use endangers people and causes damages to the crane and
loss of warranty and liability.
If the operating instructions of any ancillary equipment or instructions prepared by the operating
company allow other use (for instance excavating or diagonal pull), which contradict these operating
instructions, then the crane's operating instructions shall have priority.
It is allowed to:
Lift and move loads at or down from large heights;
Lift loads up to a specific height and hold them in this height for assembly works (e.g. rafters, steel
girders, etc.)
Material basket
Workman basket
Danger!
If the device is used against orders there is severe risk of fatal injury
to the operator and others.

Chapter 2 Safety and Health Standards
11
What is not allowed:
To use the device for other purposes than the ones specified above;
To push against obstacles or loads;
To pull, to pull things loose, any diagonal pull;
Abrupt release of boom system load;
To attach loads to other positions on the crane than the intended ones;
To transport persons;
Exception: Transporting persons in the PALFINGER workman basket, only on specially equipped
cranes. National laws, regulations and standards must be complied with.
Accidents caused by incorrect use are grossly negligent if:
The device is not used as intended.
The device is started and used by untrained, unqualified individuals.
The present operating instructions are neglected.
The device is started up after it is known to be defective.
Maintenance hast not been carried out or only insufficiently.
Servicing has been carried out by a service workshop other than PALFINGER partner.
Parts other than original PALFINGER spare parts have been installed.
Residual risks
The present operating instructions are meant as a guideline. With their help qualified operators will be
able to operate the device safely. During operation, however, dangerous situations may develop which
are unforeseeable for PALFINGER. Therefore, PALFINGER cannot include such hazardous situations
in these operating instructions.
When such hazardous situations occur the operator has to act responsibly, with foresight and safety-
awareness, yet he is responsible for the safety of all people and others involved.
The safety of people always must be of top priority.
Government regulations and standards for operating the unit
The operator must know about and follow the national regulations, standards and safety provisions for
operating the unit.
If the operating instructions contain regulations and safety provisions that contradict the national laws
and regulations, the national laws and regulations have priority.

Safety and Health Standards
12
Adverse working conditions
Do not operate the crane
at wind speeds from 10 m/s (22.4 mph).
Wind speed in
Beaufort
Description
m/s
km/h
mph
5
Larger branches and trees
begin to sway, whitecaps
on lakes.
8.0 to <10.8
29 - 38
18.4 to <25.3
When thunderstorms are approaching.
At ambient temperatures below +5ºC (41°F) or above +50ºC (122°F). Average ambient
temperature must not exceed +40°C (104°F) during operation.
Danger! Ignoring these instructions on working conditions may lead
to risk of fatal injury for the operator and others and/or to damages to
the crane.
Risk of falling
Warning!
Climbing up on the unit can lead to the individual falling or the unit
being damaged. There is an acute danger of accident.
Climbing on the unit is prohibited.
Exception: Climbing to the emergency operator station at the crane column (see 'Emergency control
operation after remote control failure', chapter 5).
Cables, sensors, sensor attachment lugs, drivers for sensors etc. may not be used as steps and / or
handles.
Warning!
If you need to climb up the machine for instance for visual checks,
maintenance and servicing absolutely use a climbing aid (e.g. ladder).
Danger of getting crushed
Danger!
If the minimum distances specified below are undershot, there is an
acute risk of crushing.
Operating situations in which the operators or other persons are at risk of crushing are prohibited!

Chapter 2 Safety and Health Standards
13
Required minimum distances
The crushing point for the parts of the body specified above are not considered to be dangerous
locations provided that the specified safety distances are not undershot. It must also be ensured that
the next biggest part of the body cannot get into the crushing point.
Risk of burns
Some components can become extremely hot during operation (lines, hoses, valves, valve operating
levers, hose connections, hydraulic cylinders, oil motors, pumps etc.).
Contact with these parts can cause burns!
Risk of scalding if oil escapes!
No smoking!
No naked flame!
Noise emission
Warning! Permanent low or short high noise emission levels
endanger the health of operators and bystanders.
Main source of noise:
Power unit
Protective measures:
Ear protection.
Operators have to comply with the relevant national noise control standards and laws.
After maintenance, service and repairs
Note!
Every time after maintenance, repair or service it is absolutely
necessary to check the function of all safety equipment on the device
(stand ard and optional)!