Palfinger PC 3800 User manual

1
Operating Manual
Hydraulic Crane
PC 3800
Serial number:
DB1140+NAEN
Edition: 11/2016
Palfinger North America
7942 Dorchester Rd.
Niagara Falls, ON L2G 7W7
www.palfinger.com

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

Contents
Notes regarding the operating instructions .........................................................1
Operating instructions.......................................................................................................3
Validity of operating instructions.......................................................................................3
Terms ...............................................................................................................................4
Symbols............................................................................................................................5
Graphics and pictures.......................................................................................................5
Safety and Health Standards..................................................................................7
Safety for individuals ........................................................................................................9
Use for intended purpose / limits of the device...............................................................10
Residual risks.................................................................................................................11
Government regulations and standards for operating the unit........................................12
Adverse working conditions............................................................................................12
Risk of falling..................................................................................................................13
Danger of getting crushed..............................................................................................13
Risk of burns...................................................................................................................15
Noise emission...............................................................................................................15
Dangers caused by exhaust...........................................................................................16
Danger from power lines ................................................................................................16
After maintenance, service and repairs..........................................................................18
General ...................................................................................................................19
CE symbol......................................................................................................................21
Structure of system.........................................................................................................21
Modifications to unit........................................................................................................22
Operators........................................................................................................................22
Device and function ..............................................................................................23
Main components...........................................................................................................25
Function labels ...............................................................................................................27
Overview of labels..........................................................................................................30
Safety equipment...................................................................................................39
General...........................................................................................................................41
Emergency cut-off button / push-button..........................................................................41
Capacity indicator...........................................................................................................42
Hydraulic overload protection.........................................................................................43
Overload protection in radio remote control operation.................................................... 43
Transport position monitoring system.............................................................................44
Emergency operation after remote control failure...........................................................44
Ancillary equipment ..............................................................................................47
General...........................................................................................................................49
Slingers, other attachments to lift the load......................................................................50
Ancillary equipment........................................................................................................51
Remote control...............................................................................................................58
Preparing for crane operation..............................................................................65
Watch out for faults before and during operation............................................................67
Working range................................................................................................................68
Starting the crane...........................................................................................................69
Preparing for remote operation.......................................................................................69
Contents

Contents
Vehicle inclination...........................................................................................................71
Supporting the vehicle....................................................................................................72
Pulling outrigger beams out manually.............................................................................75
Stabilizer cylinders..........................................................................................................76
Bringing the load arm to working position.......................................................................76
Daily function check of safety equipment........................................................................78
Crane operation .................................................................................................... 79
Load limits ......................................................................................................................81
Working position of the crane.........................................................................................81
Loads..............................................................................................................................84
Working with loads .........................................................................................................85
Ending operation .................................................................................................. 91
Bringing the crane into transport position.......................................................................93
Retracting the stabilizers ................................................................................................94
Ending radio remote control operation............................................................................97
Before driving .................................................................................................................97
Maintenance.......................................................................................................... 99
General.........................................................................................................................101
Operating hours counter...............................................................................................102
Maintenance.................................................................................................................103
Cleaning .......................................................................................................................104
Visual inspection...........................................................................................................105
Machine lubrication.......................................................................................................107
Hydraulic oil change.....................................................................................................112
Paint repair...................................................................................................................115
Service................................................................................................................. 117
General.........................................................................................................................119
Check of threaded fasteners.........................................................................................119
Initial servicing after 50 operating hours.......................................................................121
Initial servicing after one year.......................................................................................121
After every 500 operating hours or once every year.....................................................121
After every 3000 working hours or once every three years ..........................................122
Every 6 years................................................................................................................122
Gear oil.........................................................................................................................122
Check of control equipment..........................................................................................123
Protective hoses...........................................................................................................123
Repairs.........................................................................................................................123
Lowering rate................................................................................................................123
Decommissioning and disposal........................................................................ 125
Decommissioning and disposal guidelines...................................................................127
Index..................................................................................................................... 129
Technical description......................................................................................... 131

Chapter 1
In this chapter
Operating instructions.................................................................................3
Validity of operating instructions.................................................................3
Terms.........................................................................................................4
Symbols .....................................................................................................5
Graphics and pictures.................................................................................5
CHAPTER 1
Notes regarding the operating
instructions
1

Chapter 1 Notes regarding the operating instructions
Operating instructions
The operating instructions have been prepared to explain operation of the unit.
The operating instructions are part of the unit.
Always keep the operating instructions with the unit (driver’s cab).
Note! In case of damage or loss of these operating instructions
please contact your PALFINGER partner and request a new copy.
Neither the operating instructions nor the annexed Technical Sheets replace proper operator training.
Please contact your PALFINGER partner immediately if there is anything in this operating instruction
which requires explanation. We appreciate any suggestions received from our customers; they help us
to make the operating instructions ever more user friendly. PALFINGER assume no responsibility for
the translation. In case of faulty or inaccurate translations the German version of the present operating
instructions shall prevail.
Changes since going to press
PALFINGER is anxious to apply the latest and most advanced technology in their devices by further
development. This may result in deviations between operating instructions and the actual unit.
Please contact your PALFINGER partner immediately if any function in this operating instruction is
described insufficiently or incorrectly.
The specifications, pictures and descriptions shown in these operating instructions do not qualify for
any legal claims.
© Copyright by PALFINGER Copying (even in extracts) only permitted with written
approval from:
PALFINGER AG
Lamprechtshausener Bundesstraße 8
A-5101 Bergheim near Salzburg
Validity of operating instructions
These operating instructions are only valid for the equipment shown on the front page. They are only
applicable in conjunction with the operating instructions from all other auxiliary equipment that is used
on the equipment/vehicle.
3

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

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

Chapter 2
In this chapter
Safety for individuals ..................................................................................9
Use for intended purpose / limits of the device .........................................10
Residual risks...........................................................................................11
Government regulations and standards for operating the unit................... 12
Adverse working conditions......................................................................12
Risk of falling............................................................................................13
Danger of getting crushed ........................................................................13
Risk of burns ............................................................................................15
Noise emission.........................................................................................15
Dangers caused by exhaust .....................................................................16
Danger from power lines...........................................................................16
After maintenance, service and repairs.....................................................18
CHAPTER 2
Safety and Health Standards
7

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

Safety and Health Standards
Use for intended purpose / limits of the device
Use the crane only within the load limits shown on the load capacity chart to lift, move, carry and set
down loads. For load capacity chart refer to chapter 13, 'Technical description'.
Caution!
Improper use endangers people and causes damages to the crane and
loss of warranty and liability.
If the operating instructions of any ancillary equipment or instructions prepared by the operating
company allow other use (for instance excavating or diagonal pull), which contradict these operating
instructions, then the crane's operating instructions shall have priority.
It is allowed to:
•Load/unload your own vehicle or another vehicle;
•Lift and move loads at or down from large heights;
•Lift and move loads below ground level;
•Lift loads up to a specific height and hold them in this height for assembly works (e.g. rafters, steel
girders, etc.)
•Occasional grab application for lifting and moving bulk materials such as loose sand, gravel etc.
Caution!
If the device is used against orders there is severe risk of fatal injury
to the operator and others.
10

Chapter 2 Safety and Health Standards
It is not allowed:
•To use the device for other purposes than the ones specified above;
•To use the device for logging and scrap application;
•To push against obstacles or loads;
•To pull, to pull things loose, any diagonal pull;
•Abrupt release of boom system load;
•To attach loads to other positions on the crane than the intended ones;
•To move dangerous loads (e.g. molten material).
•Any excavating work with the grab (refer to 'Grab', chapter 6 'Ancillary equipment’);
•To transport persons;
Exception: Transporting persons in the PALFINGER workman basket, only on specially equipped
cranes. National laws, regulations and standards must be complied with.
Note!
Matching workman baskets are available from all PALFINGER
partners.
Accidents caused by incorrect use are grossly negligent if:
•The device is not used as intended.
•The device is started and used by untrained, unqualified individuals.
•The present operating instructions are neglected.
•The device is started up after it is known to be defective.
•Maintenance hast not been carried out or only insufficiently.
•Servicing has been carried out by a service workshop other than PALFINGER partner.
•Parts other than original PALFINGER spare parts have been installed.
Residual risks
The present operating instructions are meant as a guideline. With their help qualified operators will be
able to operate the device safely. During operation, however, dangerous situations may develop which
are unforeseeable for PALFINGER. Therefore, PALFINGER cannot include such hazardous situations
in these operating instructions.
When such hazardous situations occur the operator has to act responsibly, with foresight and safety-
awareness, yet he is responsible for the safety of all people and others involved.
The safety of people always must be of top priority.
11

Safety and Health Standards
Government regulations and standards for operating the unit
The operator must know about and follow the national regulations, standards and safety provisions for
operating the unit.
If the operating instructions contain regulations and safety provisions that contradict the national laws
and regulations, the national laws and regulations have priority.
Adverse working conditions
Do not operate the crane
•at wind speeds of 50 km/h (30 mph) and above;
•at wind speeds from 34 km/h (20 mph) when lifting bulky loads or working in near vertical position;
Wind speed in
Beaufort Description m/s km/h mph
0 -2 Wind can be felt on the
face or exposed skin. Tree
leaves rustle. max. 3.4 max. 11 max. 8.1
3 Leaves and twigs are in
constant motion while the
wind will extend light flags. 3.4 to <5.5 12 - 19 8.1 to <12.7
4 Branches are in motion,
the wind will raise dust,
leaves, and loose paper. 5.5 to < 8.0 20 - 28 12.7 to <18.4
5 Larger branches and trees begin to sway, whitecaps
on lakes. 8.0 to <10.8 29 - 38 18.4 to <25.3
6 Large tree branches are in
motion, the wind whistles
in overhead wires. 10.8 to <13.9 39 - 49 25.3 to <32.2
7
Whole trees are moving in
the wind while walking
becomes affected by the
wind.
13.9 to <17.2 50 - 61 32.2 to <39.1
•When thunderstorms are approaching and during thunderstorms.
•At ambient temperatures below -30ºC (-22°F) or above +50ºC (122°F). Average ambient
temperature must not exceed +40°C (104°F) during operation.
Danger!
Ignoring these instructions on working conditions may lead to risk of
fatal injury for the operator and others and/or to damages to the crane.
12

Chapter 2 Safety and Health Standards
Risk of falling
Warning!
Climbing up on the unit can lead to the individual falling or the unit
being damaged. There is an acute danger of accident.
Climbing on the unit is prohibited.
Exception: Climbing up to operating stands using climbing aids (see ‘High stand, top seat’, Chapter 6)
or climbing to the emergency operator station at the crane column (see ‘Emergency control operation
after remote control failure’, Chapter 5).
Cables, sensors, sensor attachment lugs, drivers for sensors etc. may not be used as steps and / or
handles.
Warning!
If you need to climb up the machine for instance for visual checks,
maintenance and servicing absolutely use a climbing aid (e.g. ladder).
Danger of getting crushed
Caution!
If the minimum distances specified below are undershot, there is
acute risk of crushing.
Operating situations in which the operators or other persons are at risk of crushing are prohibited!
13

Safety and Health Standards
Required minimum distances
The crushing point for the parts of the body specified above are not considered to be dangerous
locations provided that the specified safety distances are not undershot. It must also be ensured that
the next biggest part of the body cannot get into the crushing point.
Crushing points
Possible crushing points.
More crushing points may result from your installation and use.
14