Palfinger PK9001-EH User manual

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.
xPlease follow all safety instructions.
xPlease maintain your PALFINGER unit in accordance with regulations.
xPlease adhere to the prescribed maintenance intervals.
xThe unit must be cleaned at regular intervals, since dirt increases the
amount of wear.
xContamination by grease and oil increases the risk of accidents.
xAll 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
Foreseeable misuse of the device .................................................................................. 10
Residual risks ................................................................................................................. 10
Government regulations and standards for operating the unit........................................ 11
Adverse working conditions............................................................................................ 11
Risk of falling .................................................................................................................. 12
Danger of getting crushed .............................................................................................. 13
Risk of burns...................................................................................................................14
Noise emission ............................................................................................................... 14
Dangers caused by exhaust ........................................................................................... 15
Danger from power lines ................................................................................................ 15
After maintenance, service and repairs .......................................................................... 17
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
Switches / buttons .......................................................................................................... 30
Hazard warning symbols ................................................................................................ 31
Overview of labels .......................................................................................................... 31
Crane control systems..........................................................................................43
General........................................................................................................................... 45
Emergency cut-off button ............................................................................................... 45
Capacity indicator ........................................................................................................... 46
Paltronic 50 Control System ........................................................................................... 47
Stability control (ISC - S) ................................................................................................ 53
HPSC stability control..................................................................................................... 55
HPSC-L stability control.................................................................................................. 61
High stand slewing limiter IS........................................................................................... 62
Geometry monitoring ...................................................................................................... 63
Steep position monitoring ............................................................................................... 66
Steep position monitoring system up to 5+ extension + fly jib ........................................ 67
OSK overload protection system .................................................................................... 67
Transport position monitoring system............................................................................. 68
Emergency operation after remote control failure........................................................... 69
Failure of electric system................................................................................................ 70
Contents

Contents
Ancillary equipment ............................................................................................. 73
General........................................................................................................................... 75
Slingers, other attachments to lift the load...................................................................... 77
Ancillary equipment ........................................................................................................ 78
Additional crane equipment ............................................................................................ 90
Preparing for crane operation ............................................................................. 97
Use for intended purpose / limits of the device ............................................................... 99
Watch out for faults before and during operation.......................................................... 100
Working range .............................................................................................................. 101
Starting the crane ......................................................................................................... 102
Supporting the vehicle .................................................................................................. 102
Stabilizer outriggers...................................................................................................... 107
Stabilizer cylinder ......................................................................................................... 108
Vehicle inclination......................................................................................................... 110
Unfolding the crane ...................................................................................................... 111
Daily function check of control systems........................................................................ 114
Crane operation .................................................................................................. 117
Load limits .................................................................................................................... 119
Working position of the crane ....................................................................................... 120
Loads............................................................................................................................ 122
Working with loads ....................................................................................................... 123
Ending operation ................................................................................................ 129
Folding the crane into transport position....................................................................... 131
Retracting the stabilizers .............................................................................................. 135
Before driving ............................................................................................................... 140
Maintenance ........................................................................................................ 143
General......................................................................................................................... 145
Operating hours counter............................................................................................... 146
Maintenance ................................................................................................................. 147
Cleaning ....................................................................................................................... 148
Visual inspection........................................................................................................... 149
Machine lubrication....................................................................................................... 152
Hydraulic oil change, filter change................................................................................ 157
Paint repair ................................................................................................................... 160
Service ................................................................................................................. 161
General......................................................................................................................... 163
Threaded fasteners ...................................................................................................... 164
Initial servicing after 50 operating hours ....................................................................... 166
After every 1000 operating hours or once every year................................................... 167
Every 6 years................................................................................................................ 167
Hook and shackle ......................................................................................................... 168
Check of control equipment.......................................................................................... 169
Protective hoses ........................................................................................................... 169
Repairs ......................................................................................................................... 169
Lowering rate................................................................................................................ 169
Decommissioning and disposal........................................................................ 171
Decommissioning and disposal guidelines ................................................................... 173
Index..................................................................................................................... 175
Technical description......................................................................................... 177

Chapter 1
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

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 (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 unaccurate 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 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.

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
Foreseeable misuse of the device ...............................................10
Residual risks ..............................................................................10
Government regulations and standards for operating the unit......11
Adverse working conditions .........................................................11
Risk of falling ...............................................................................12
Danger of getting crushed ...........................................................13
Risk of burns ...............................................................................14
Noise emission ............................................................................14
Dangers caused by exhaust ........................................................15
Danger from power lines..............................................................15
After maintenance, service and repairs........................................17
CHAPTER 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 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:
xCleaning and maintenance
xSetting up
xAll sorts of checks
xOperation
xService 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
Foreseeable misuse of the device
Danger! If the device is foreseeably misused there is severe risk of
fatal injury to the operator and others.
Accidents caused by foreseeable misuse are grossly negligent if:
xThe device is not used as intended.
xThe device is started and used by untrained, unqualified individuals.
xAll safety instructions and hazard statements in these operating instructions are neglected.
xThe device is started up after it is known to be defective.
xMaintenance and / or servicing have not been carried our or only insufficiently.
xDifferent parts have been used for replacement.
xParts 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.

Chapter 2 Safety and Health Standards
11
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
xat wind speeds of 50 km/h (30 mph) and above;
xat 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
xWhen thunderstorms are approaching.
xAt 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.

Safety and Health Standards
12
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.
Exceptions: Climbing up to operating stands using climbing aids (see "High stand, high 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).

Chapter 2 Safety and Health Standards
13
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!
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.

Safety and Health Standards
14
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!
In order to avoid burns, the exhaust system of the vehicle must be covered in the operating area, or a
safe distance must be maintained.
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: Vehicle motor.
Protective measures: Ear protection.
Operators have to comply with the relevant national noise control standards and laws.
Measuring values
On operating stands of loading cranes which are mounted to Diesel motor vehicles (also in case of
remote control operation within 1 m from the vehicle) the sound pressure level depends on vehicle
model, status of operation (idling speed, full load) and crane installation, so the following values can be
reached:
xAt low or high idling speed of the vehicle engine 72 to 84 dB(A)
xIn crane operation 79 to 86 dB(A)
xThe sound power level is between 92 and 100 dB(A).
Information! In order to reduce noise exposure it is recommended
to maintain a low idling speed and use the remote control at a
distance from the vehicle motor greater than 1 m.