Palfinger PSM Series User manual
Operators Manual
PSM
Hydraulic Crane
Translation of the original Operator Manual
Equipment number :
CPDB0009
Version : 2011/10
PALFINGER AG
Franz-Wolfram-Scherer-Straße 24
5020 Salzburg / Austria
www.palfinger.com
DANGER –ATTENTION: Indicates situations of severe danger
which may cause great risks for health and safety of the
operating personnel if handled without care.
ATTENTION –TIP: Indicates that a proper conduct is required
so that health and safety of the operating personnel are not put
at risk and no economic damages are caused.
IMPORTANT: Indicates technical information of particular
importance which should not be ignored.
Dear Customer
Many thanks for choosing to a PALFINGER MARINE product. We have
done everything to ensure optimal and safe operation in the design and
production of your crane.
To ensure that your crane works reliably and economically for many
years, please observe the following:
Observe the safety instruction (possible dangers).
Maintain your crane regularly in accordance with the instructions.
Keep your crane clean. Dirt increases wear on the cylinders and
bearings. Leaking oil or other lubricants are a major source of
accidents.
Follow the instructions of this manual.
We wish you all the best!
PALFINGER MARINE
© by PALFINGER MARINE GMBH
1
Safety instructions
It is also in your own interest to observe these instructions
very carefully.
2
Before operation of the crane
This chapter provides you with important safety instructions
which must be followed each time before starting operation.
3
Start operation of the crane
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
After crane operation
This chapter provides you with a summary of the necessary
instructions to safely finish work with your crane.
6
Maintenance and service
This chapter provides you with the necessary information to
properly maintain and service your crane.
7
Appendix
EEx - Crane
Safety instructions Chapter 1
1 Safety instructions
CONTENTS
1.1 AN OVERVIEW OF THE DANGERS
1.1-1 RULES FOR THE AVOIDANCE OF DANGERS
1.2 PREREQUISITES
1.2-1 CE-SYMBOL
1.2-2 ASSEMBLY,ACCEPTANCE AND REGULAR INSPECTION OF THE CRANE UNIT
1.2-3 REQUIREMENTS FOR THE OPERATING PERSONNEL
1.2-4 SAFETY DEVICES NOT TO BE TAMPERED WITH
1.2-5 CRANE OPERATION IN ADVERSE OPERATING CONDITIONS
1.2-6 INTENDED USE
1.3 DURING CRANE OPERATION
1.3-1 AVOID DANGER OF CRUSHING
1.3-2 DANGER OF BURN INJURIES
1.3-3 KEEP DISTANCE FROM POWER LINES
1.3-4 ACTION IN THE EVENT OF FLASHOVER
1.3-5 ACTION IN THE EVENT OF DEFECTS
An overview of the dangers 1.1-1
1.1 An overview of the dangers
1.1-1 Rules for the avoidance of dangers
1. General safety instructions
Operation only by trained personnel.
Safety devices not to be tampered with.
Prescribed safe distances to be maintained.
Safe distances from electric power lines to be maintained.
Be alert to faults during crane operation.
2. Prior to crane operation
Pay attention to effluent hydraulic oil.
Make a visual inspection.
Check the safety devices before start-up.
3. On start-up
Use the right hydraulic fluid for the temperatures.
Check the heel / load diagram.
Remove the extensions before unfolding.
4. During crane operation
Ensure the crane is used according to the specifications.
Keep an eye on the working area.
Do not stay in the danger area of the crane.
Safeguard the working area.
Select the right control stand.
Pick up and secure loads in the due and proper manner.
Use of load lifting gear and ancillary equipment supplied by PALFINGER MARINE
Secure attachment of ancillary equipment.
Adherence to the max. lifting capacity of the crane, ancillary equipment and load lifting gear.
No load moment increase when lowering the load.
5. After crane operation
Secure crane in transport position.
Switch off hydraulic pump.
Observe maximum head room on bridges, etc.
6. On maintenance and lubrication
Carry out maintenance work only when the machine is inoperative.
Keep steps, standing areas and handles clean.
1.2-1 Prerequisites
1.2 Prerequisites
1.2-1 CE-Symbol
If your crane is marked with a CE symbol it meets the requirements of the machine directive of the
EEA (European Economic Area).
This symbol is only valid in connection with a conformity declaration issued for your crane.
The firm mounting the crane on the ship must issue a conformity declaration. If constructional changes
are made to the crane (e.g. mounting of a rope winch, remote control, raised stand or raised seat, etc.)
the CE symbol must be re-issued by the firm mounting the equipment (new conformity declaration).
If the crane bears a CE symbol, it must be fitted with an overload safety device.
Ancillary equipment must bear its own CE symbol.
In the EEA and certain other countries the crane may only be operated if it has a valid CE symbol and
valid conformity declaration.
1.2-2 Assembly, acceptance and regular inspection of the crane unit
The crane must be assembled according to the valid assembly rules of PALFINGER MARINE.
In addition, national regulations and guide-lines regarding installation must be observed and the
official acceptance must proceed according to the regulations in force.
The firm responsible for assembly must on handing over the crane instruct the crane operator in the
operation of the crane and point out to the crane operator all possible dangers and risks of injury.
On handover of the crane the customer is to be given the maintenance manual, operating instructions
(including assembly-related additions), and the conformity declaration for the EEA.
The firm operating the crane is responsible for ensuring that the regular inspections required by law
are carried out.
Any use other than the one intended by the company PALFINGER MARINE as well as constructional
changes that affect the stability of load-bearing components need to be approved by the manufacturer.
Prerequisites 1.2-3
1.2-3 Requirements for the operating personnel
Operation of the crane requires skill, ability and experience.
Therefore only entrust persons with the operation of the crane:
who are physically and mentally suitable for this (not tired, and not under the influence of alcohol,
drugs or medication).
who handle the crane responsibly and reliably.
who have the right qualifications (training, crane operator’s license).
who can prove that they have been instructed on how to operate the unit described here and who
are familiar with the content of these operating instructions. This also applies to the operating
instructions for ancillary equipment used on the crane.
If the crane is operated by a person without crane operator’s license
and training on this machine there is acute danger of accident.
Observe the regulations valid in your country!
1.2-4 Safety devices not to be tampered with
Safety devices serve to protect you and were developed to avoid accidents and make your work safer.
On delivery safety devices such as Emergency Off, load holding valve, pressure relief valve, etc. are
adjusted to ensure safe crane operation (4.2).
They must on no account be interfered with or rendered inoperative.
Caution:
If safety devices are tampered with or if lead seals are damaged, any warranty on the part of the
manufacturer will cease to apply!
If safety devices are tampered with you put yourself and other
persons at risk of fatal injury.
1.2-5 Crane operation in adverse operating conditions
Safe operation of the crane can no longer be assured if winds are in excess of 50 km/h. If the wind
exceeds this speed, the crane must not be put into operation or operation must stop.
Our cranes may be used at ambient temperatures ranging from -30º C to +50º C. If the temperature
drops below or exceeds these limits, operation must be discontinued as it can lead to damage to the
hydraulic components.
1.2-6 Intended use
Use the crane only for handling loads; mechanical interventions (pushing or driving against obstacles),
fastening of loads at points other than those provided for this purpose, pulling of loads, etc. are
prohibited. Manufacturer will accept no liability for damage caused by doing so.
1.3-1 During crane operation
1.3 During crane operation
1.3-1 Avoid danger of crushing
Avoid operating situations in which there is a risk of you or bystanders being crushed by the crane, or
load.
The crush point is not regarded as a danger point for the body parts stated if the safety distances
highlighted below are complied with and it is ensured that the next-biggest body part cannot penetrate.
Required minimum distances:
Body Leg Foot Arm Hand Finger
If the distances are not complied with there is danger of injury and
even death.
1.3-2 Danger of burn injuries
Through the flow of oil in the hydraulic unit the hydraulic oil and therefore all components in the
hydraulic unit are heated. The control valve, all other valves, hydraulic lines and hoses, hose
couplings, hydraulic cylinders etc. can become so hot that they can cause burns if touched. Always
therefore be careful of their temperature before touching hydraulic components.
1.3-3 Keep distance from power lines
Keep the required minimum distances away from power lines. If this is not possible because of the
particular work being carried out the lines must be disconnected (switched off).
The appearance and height of electric power lines gives no indication of their voltage.
In the case of lines where the voltage is not known a distance of at least 5 metres between the crane
and the line must be maintained. This also applies to all load lifting gear and ancillary equipment
attached to the crane.
Take into account that in a wind a power line can sway out or the load arm of the crane can be caused
to swing by sudden movements (also upwards). Even unintentional approaching can lead to flashover.
Flashover can occur even on just approaching a power line. This
entails the risk of fatal injury for the crane operator and auxiliary
personnel.
500 mm 180 mm 120 mm 100 mm 25 mm
During crane operation 1.3-4
For overhead power lines and contact lines of electric railways the following minimum
distances apply:
A up to.......à 1.500 V.....1,0 m
over........à 1.500 V.....1,5 m
up to.......à 1.000 V.....1,0 m
over........à 1.000 V.....1,5 m
B
up to ............1.000 V ...........1,0 m
1.000 ...........110.000 V .......3,0 m
110.000 .......220.000 V .......4,0 m
220.000 .......380.000 V .......5,0 m
unknown voltage ..................5,0 m
1.3-4 Action in the event of flashover
If the crane touches a power line only your correct reaction can prevent a serious accident. If you
touch the crane, ship, load or if you try to leave your location you will put yourself in acute danger of
fatal injury.
Stay calm.
Persons in the vicinity must keep a distance of at least 10 metres from the ship, crane and load
(resistance area).
If the power line has been cut and is touching the ground a distance of at least 10 metres must
likewise be maintained (resistance area).
If there is a person within this 10 metre area this person may leave the danger area only by
hopping with legs tight together (step voltage).
Do not touch the crane, ship or load.
Warn bystanders not to touch the ship, crane or load and not to approach.
Do not attempt to leave the operating stand; and do not touch any metal parts there.
Indicate that the power lines must be disconnected.
If you are on the loading area or in the operator’s cab of the ship, do not leave this location. It is
essential you remain where you are.
If someone is in the electric circuit the power line must be disconnected before this person can be
removed; if you approach the person before the power is switched off you will put yourself in
danger of fatal injury.
=
DC
~
AC
1.3-5 During crane operation
1.3-5 Action in the event of defects
Observe the crane during operation for any sudden signs of any defects.
If you discover the following damage or defects to the crane, ancillary equipment, load lifting
gear or fixing from the crane you must stop crane operation immediately:
Damages or cracks on load-bearing parts.
Defect bearings.
Defects in the hydraulic unit or safety devices.
Loose screwed connections.
Inadequately secured bolt connections.
Leaks on hydraulic components or connections.
Unusual noises.
Unusually quick or slow working movements.
Functional errors in the control system.
Unusually high temperature of hydraulic components.
In the case of the above-mentioned damage or defects safe crane
operation is no longer ensured. There is acute danger of accident
and thus of fatal injury.
The crane may only return to service when the defects have been removed and safe working is once
again assured.
Checks 2.1-1
2.1 Checks
2.1-1 Daily visual inspection
Check the crane and its mounting once daily for visible defects, damages or alterations.
The “man-riding” basket has to be maintained and protected against corrosion on a regular basis. This
action is absolutely necessary as corrosion may lead to a wall thickness reduction (3 mm).
Carry out this inspection very carefully every time: alterations or damages not detected because of
carelessness or old habits are a major source of accidents.
Carefully check:
Screw fittings, connections, and other parts of the hydraulic system for damages or oil leaks.
Leaks of hydraulic oil may lead to dangerous accidents and cause
considerable environmental damage and pollution.
Whether bolts and screw fittings are properly fixed.
For defective bolt connections.
The smoothness and the return motion of hand levers.
Load bearing parts, accessories, load holding attachments
(grab, winch, etc.) for cracks and damages.
Defects in paintwork.
Corrosion.
When such defects are detected, immediately cease operation of the
crane.
If your crane is equipped with safety devices such as an emergency CUT-OFF, an overload protection
system or a rope winch limit stop, always carry out a function test on them before operation.
Proceed as described in chapter 4. Always pay attention to the safety instructions!
If the safety devices do not work, operation of the crane is strictly
prohibited.
Carry out this inspection very carefully every time: carelessness and old habits are a major source of
accident.
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