Palfinger PK 23002 User manual

Dear customer.
Many thanks for choosing a PALFINGER product. We
have done everything to ensure optimal and safe opera-
tion in the design and production of your crane.
To ensure that your crane works reliably and economi-
cally for many years, please observe the following:
•Observe the safety instructions (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!
PALFINGER
© by PALFINGER

Inhalt

Contents
Inhalt
1 Safety Instructions
It is also in your own interest to observe these instructions
very carefully.
2 Before Crane Operation
This chapter provides you with important safety instructions
which must be followed each time before starting an
operation.
3 Running a Crane
/ Starting Crane
Operation
This chapter gives you all the necessary information to
properly start operation of your crane.
4 Crane Operation
This chapter provides you with the necessary information to
properly operate your crane.
5 Ending Crane Operation
This chapter provides you with a summary of the necessary
instructions to safely finish working with your crane.
6 Maintenance and Service
This chapter provides you with the necessary information to
properly maintain and service your crane.
7 Technical Description
This chapter provides you with the specific data of your
crane version and its accessories.

Inhalt

CONTENTS
1.1. OVERVIEW OF 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 NOISE EMISSION
1.3-4 KEEP DISTANCE FROM POWER LINES
1.3-5 ACTION IN THE EVENT OF FLASHOVER
1.3-6 ACTION IN THE EVENT OF DEFECTS
Safety Instructions Chapter 1

1.1-1 Overview of dangers

Overview of dangers 1.1-1
1.1. Overview of 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 adequate hydraulic fluid according to the temperatures.
The slope of the vehicle must not exceed 3° in any direction.
Outriggers must be fully extended.
When extending outriggers and stabilizer cylinder observe the safety distances.
If necessary, enlarge the support surface according to the condition of the ground.
The vehicle must not be raised using the support.
Lock manually extendable outriggers properly.
Prevent the support from sinking into the ground.
Adjust the support when loading and unloading.
Before unfolding the crane mechanical extensions have be secured properly.
Cranes with floor control stand unfold from side A (Control valve side).
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 adequate control stand.
Pick up and secure loads in the due and proper manner.
Use of load lifting gear and ancillary equipment supplied by PALFINGER.
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.
Observe safety distances when retracting the outriggers and stabilizer cylinder.
Lock the manually retractable outriggers in the retracted position.
Check the outrigger locking device before every trip.
Switch off hydro pump.
Observe maximum head room on bridges and tunnels.
6. 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 company mounting the crane on the truck 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 company 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 PALFINGER. The valid
Installation Instructions may be obtained from the responsible general representative. After
successful crane mounting the vehicle still has to be stable throughout the entire working area of the
crane.
In addition, country-specific assembly regulations, provisions and rules as well as provisions and
rules of the truck manufacturer are to be observed. The acceptance procedure required by law must
be carried out.
The company responsible for assembly must instruct the crane operator in the operation of the crane
and point out to the crane on handing over 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.
Approval from the Palfinger company is required:
If the crane is used for other operations than those intended by the PALFINGER company.
In case of structural modifications to all load-bearing components.
In case of structural modifications which affect the stability.
In case of structural modifications which obstruct the accessibility of the operating elements.
In case of structural modifications which do no longer ensure a safe crane operation.

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 (not tired, and not under the influence of alcohol, drugs
or medication).
•who handle the crane responsibly and reliably.
•who have the correct qualifications (training, crane operator’s license).
•who can prove that they have been instructed 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 used by persons without training or crane operator’s
license there is a high risk of injury.
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 render your work
safer.
On delivery safety devices such as Emergency Off, overload safety device, load holding valve,
pressure relief valve, etc. are adjusted to ensure safe crane operation (4.2).
They must by no means be interfered with or rendered inoperative.
Caution:
If safety devices are tampered with or if 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 wind speed exceeds 50 km/h. If the wind
exceeds this speed, the crane must not be put into operation or operation must stop.
If a thunderstorm is approaching, 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 of the
hydraulic components.

1.2-6 During crane operation
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.
Lifting persons is only allowed in specifically produced workman baskets. In addition, national
regulations and laws regarding the transport of persons have to be observed. In order to ensure
optimum operation you should operate the crane using a PALFINGER workman basket.
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,
the support system 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 risk of injury and
even death.
1.3-2 Danger of burn injuries
Because of 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.
Therefore always be careful of their temperature before touching hydraulic components.
1.3-3 Noise emission
Main source of noise: the vehicle motor
Protective measures: Wear ear protectors.
High noise pollution puts health at risk. The crane operator is obliged to observe the noise protection
standards applicable in the specific country.

During crane operation 1.3-4
1.3-4 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).
Neither the appearance nor the height of electric power lines indicates their voltage.
In 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.
In addition, always observe national standards because they may differ from those given in this
operating manual.
Take into account that in wind weather 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 by just approaching a power line. This
entails the risk of fatal injury for the crane operator and auxiliary
personnel.
For overhead power lines and contact lines of electric railways the following minimum
distances apply:
A up to à 1500V….1,0 m
over à1500V…. 1,5 m
up to à1000V….1,0 m
over à1000V.... 1,5m
B
up to..............................à
1000V .............................1,0m
1000V-10000V ...............3,0m
110000V-220000V .........4,0m
220000V-380000V .........5,0m
unknown tension ............5,0m
The crane operator is obliged to observe any additional national standards, yet country-
specific minimum distances to circuit lines may differ from those given here.
A B
=
DC
~
AC

1.3-5 During crane operation
1.3-5 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, vehicle or load or if you try to leave your location you will put youself in acute danger
of fatal injury.
•Stay calm.
•Persons nearby must keep a distance of at least 10 metres from the vehicle, 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, vehicle or load.
•Warn bystanders not to touch the vehicle, 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 operator’s cab of the vehicle, 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
risk of fatal injury.

During crane operation 1.3-6
1.3-6 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 the carrier vehicle you must stop crane operation immediately:
•Defects, damage 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 risk of accident and
thus of fatal injury.
The crane may only return to service when the defects have been removed and safe working is
accurd once again.

1.3-6 During crane operation

CONTENTS
2.1. CHECKS
2.1-1 DAILY VISUAL INSPECTION AND FUNCTIONAL CHECK
Before crane operation Chapter 2

2.1-1 Checks

Checks 2.1-1
2.1. Checks
2.1-1 Daily visual inspection and functional check
Check the crane and its assembly daily for externally visible defects, damage and changes.
Conduct this inspection carefully each time; routine and habit represent a major source of danger
because changes are difficult to recognise.
Check:
•Bolted connections, hose connections and elements of the hydraulic unit for damage or escaping
hydraulic fluid.
Escaping hydraulic fluid represents risk of accidents and causes
serious and costly environmental damage.
•Easy movement and self-return of the controls.
•Load-bearing parts, ancillary equipment, lifting hooks, hook securing devices, load lifting gear
(ropes, etc.) for any cracks, damage and for easy movement.
If such defects occur the crane must not be started up.
If your crane is fitted with safety devices such as Emergency Off, overload safety device, etc. check
that they are functioning every time before starting work.
Proceed as described in Chapter 4. Follow any safety instructions!
If the safety equipment fails to respond the crane must not be started
up.
Carry out this inspection carefully every time; as mentioned above, routine and habit represent a major
source of danger here.
After repair works and additions inspect the crane as described above.

2.1-1 Checks