Palfinger PSM400-16 User manual

2021-11-15 Rev.03 / NOV
PALFINGER AG
Franz-Wolfram-Scherer-Straße 245020 Salzburg / Austria
LIFETIME EXCELLENCE
Installation Manual
PSM400-16
Taiko Trading Co. Ltd.
OA100082338 & OA100084986
Equipment number: 1100013705 - 1100014330

Content
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 withyour
PALFINGER product reliably and cost-effectively over the longterm.
•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 good luck using your PALFINGER product!

Content
CONTENT
General ..................................................................... 1
Symbols ...................................................... 2
Safety for individuals.................................. 3
General....................................................... 4
Installing company ..................................... 4
Crane installer ............................................ 4
Control of delivery .................................................... 5
Overview component transport................. 6
Visual check for transport damages........... 6
Control of delivery...................................... 6
Overview of tools..................................................... 7
General....................................................... 8
Check of threaded fasteners ...................... 9
Crane handling........................................................ 12
Crane handling ......................................... 13
Storage ..................................................... 16
Set-Up..................................................................... 17
Main components .................................... 18
Crane Mounting ....................................... 20
Preparation for base assembly................. 22
Process of tightening................................23
Preserving the screw joints ...................... 24
Hydraulic system................................................... 28
Cleanness during assembly ...................... 29
Hydraulic circuit diagram ......................... 30
Electric system ....................................................... 30
Connecting the electric motor ..................31
Venting and cooling the electric motor.... 31
Electric circuit diagram............................. 32
Power Pack............................................................. 34
Filling the power pack tank ...................... 35
Start-Up ..................................................................36
Checklist before start-up.......................... 37
Start-up .................................................... 37
Bringing the crane into parking position.. 39
Checklist after start-up............................. 40
Post-assembly check..............................................41
Post-assembly check ................................ 42
Commissioning....................................................... 43
Commissioning ......................................... 44
Term Definitions....................................... 44

CHAPTER 1
1
CHAPTER 1
General
In this chapter
Symbols ...................................................... 2
Safety for individuals.................................. 3
General....................................................... 4
Installing company ..................................... 4
Crane installer ............................................ 4

CHAPTER 1
2
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 words 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 words 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.

CHAPTER 1
3
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 in the unit such as:
•Cleaning and maintenance
•Setting up
•Check before starting to work
•Operation
•Service and repairs
Safety clothing that is suitable for the respective danger must be worn.
Before putting on the safety clothing, remove jewellery (example: rings, chains, bracelets etc.).
Personal safety equipment:
Operation: Safety clothing, work gloves, hard-capped boots, helmet, safety belt
Other activities: depending on the type of danger (example: hearing protection in case of increased
noise emission, safety goggles, work gloves).
Personal protective equipment:
Operation: Safety clothing, work gloves, hard-capped boots, helmet, safety belt
Other activities: depending on the type of danger (example: hearing protection in case of increased
noise exposure, safety goggles, work gloves).

CHAPTER 1
4
General
The present installation guideline is an instruction and technical demand for companies that carry out
crane installations and it applies to PALFINGER MARINE PSM-cranes for the Taiko Trading Co. Ltd.
Project.
PALFINGER cannot be held liable for the consequences/influence of deviations from this instruction.
Installing company
The installing company is responsible to observe the following issues:
•Nationally applicable law and regulations.
•Regulations of the customer, owner or the shipyard.
•Operational and traffic safety.
•Classification in the correct lift group.
•Responsible to complete the crane documentation (crane book)
In case of any deviations or special assembly the crane must be re-classified (modification of the
loads).
In case the crane classification changes it is required to contact PALFINGER MARINE.
Crane installer
The crane installer is additionally responsible for:
•Compliance with and proper installation according to the assembly instructions.
•Stability reserve in the entire working range.
•Possibility to carry out maintenance on the crane at the place of installation.
•Stability of the crane during installation (e.g., support it by another crane if it has not
beenfastened and secured yet)
•Observance of safety regulations and provisions.
•Observance of corrosion protection according to PALFINGER regulations and provisions
Danger! Improper use leads to premature wearing and overloading
of components.

CHAPTER 2
5
CHAPTER 2
Control of delivery
In this chapter
Visual check for transport damages........... 6
Control of delivery...................................... 6

CHAPTER 2
6
Overview component transport
Visual check for transport damages
Check the delivery for any damages (for instance scratches) and report them to the shipping agency
immediately, to be entitled to damage claims later.
Crane serial number is stated at the type shield (Placed at the rear of the crane column).
Control of delivery
Before starting to install the crane check the delivery for completeness. To do this, use the pack list and
delivery note supplied on delivery. Otherwise, it will not be possible to take subsequent deliveries into
account in the scope of supply.

CHAPTER 3
7
CHAPTER 3
Overview of tools
In this chapter
General....................................................... 8
Check of threaded fasteners ...................... 9

CHAPTER 3
8
General
The following tools are needed to transport and mount this crane model (PSM1200):
1. Set of wrenches:
•Set of hexagonal recess wrenches (6mm, 8mm, 10mm, 16mm, 20mm).
•Set of ratchets including socket wrench (17mm, 19mm, 22mm, 24mm, 27mm, 32mm, 36mm, 41mm).
•Open-end and box wrench (17mm, 19mm, 22mm, 24mm, 27mm, 32mm, 36mm, 41mm).
2. Torque spanner for tightening torques according to table (next page).
3. Voltmeter for voltage checks.
4. Manometer (pressure range 400 bar), recommended for trouble shooting.
5. Grease gut to lubricate the system. Grease nipples according to DIN 71412.
6. Various tools:
•Set of open-end wrenches.
•Set of box wrenches.
•Sets of both slotted and Phillips screwdrivers.
•500 g hammer.
•10 kg hammer.
•Set of power tools.
•2 brushes or paint-roller.
•Spatula.
7. Appropriate lifting equipment (mobile loader crane) and various lifting straps.
8. Grease for crane lubrication paint:
•Primer code
•Top paint
9. Wax for preventive measures

CHAPTER 3
9
Check of threaded fasteners
Tightening torques [Nm] (not oiled, not lubricated).
Values are valid for screws WITHOUT finish (NOT oiled) and with the surface GEOMET 500A or equivalent
(maximum tightening torques).
(µ = 0.12...... 0.18)
Screw
diameter
Drill diameter
Hydraulic MD
torque
wrench
MD torque wrench
Hydraulic MD
torque
wrench
MD torque wrench
DIN / ISO 273 8.8 8.8 10.9 10.9
M12 14 79 75 110 105
M14 16 126 120 176 168
M16 17.5 194 185 271 258
M18 20 268 255 374 356
M20 22 378 360 530 505
M24 26 651 620 919 875
M27 30 971 925 1361 1296
M30 33 1313 1250 1848 1760
Screw
diameter
Drill diameter
Hydraulic MD
torque
wrench
MD torque wrench
Hydraulic MD
torque
wrench
MD torque wrench
Grade 5 Grade 5 Grade 8 Grade 8
UNC 5/8" - 11 18 175 167 252 240
UNC 3/4" - 10 21 310 295 452 430
UNC 7/8" - 9 25 509 485 714 680
UNC 1" - 8 27.5 756 720 1103 1050
UNC 1 1/8" - 7 32 950 905 1523 1450
UNC 1 1/4" - 7 35 1339 1275 2142 2040
Caution!
Loose, damaged or over-tightened threaded connections can break under load.
There is risk of fatal injury.
Note!
Tighten the screws only using the torque wrench and applying the prescribed
tightening torque.

CHAPTER 3
10
Screw
diameter
Drill diameter
Hydraulic MD
torque
wrench
MD torque wrench
Hydraulic MD
torque
wrench
MD torque wrench
Grade 5 Grade 5 Grade 8 Grade 8
UNF 5/8" - 11 18 205 195 284 270
UNF 3/4" - 10 21 352 335 499 475
UNF 7/8" - 9 25 572 545 798 760
UNF 1" - 8 27.5 845 805 1181 1125
UNF 1 1/8" - 7 32 1076 1025 1733 1650
UNF 1 1/4" - 7 35 1496 1425 2394 2280
Note: Use the screw in the status as delivered!
If the screws are slightly oiled (threading & contact area) then the values specified in the table must be
reduced as follows (attention - only typical values for guidance):

CHAPTER 3
11
(µ=0,06...... 0.1)
Screw diameter Hydraulic MD torque
wrench MD torque wrench Hydraulic MD torque wrench MD torque wrench
8.8 8.8 10.9 10.9
M12 -25%...-30% -25%...-30% -25%...-30% -25%...-30%
M14 -25%...-30% -25%...-30% -25%...-30% -25%...-30%
M16 -28%...-32% -28%...-32% -28%...-32% -28%...-32%
M18 -28%...-32% -28%...-32% -28%...-32% -28%...-32%
M20 -30%...-34% -30%...-34% -30%...-34% -30%...-34%
M24 -30%...-34% -30%...-34% -30%...-34% -30%...-34%
M27 -30%...-34% -30%...-34% -30%...-34% -30%...-34%
M30 -30%...-34% -30%...-34% -30%...-34% -30%...-34%
The reduced values depend on lubrication and other influencing factors.
If you intend to avoid exceeding 90% of the screws’ yield point deduct half of the tolerance width of the used
pretension measuring device or torque tool from the specified values.
Maximum permissible initial tensions [kN]:
Screw diameter Initial tension [kN] Initial tension [kN]
8.8 10.9
M12 33.4 47
M14 45.5 64.6
M16 63.2 93.3
M18 76.8 110
M20 100 145
M24 142.3 210
M27 190 273
M30 230 320
Please note: The minimum screw length must be guaranteed.
Furthermore, the contact areas (between screw head and HV disk and between the components) must not be
painted or oiled. Status: Blank!
Regarding possible exceptions, please, contact your PALFINGER MARINE partner.

CHAPTER 4
12
CHAPTER 4
Crane handling
In this chapter
Crane handling ......................................... 13
Storage ..................................................... 16

CHAPTER 4
13
Crane handling
Fasten the crane according to the following picture and bear in mind that the crane components should be
lifted only in horizontal position.
Load arm:
•Weight (1) c. 1,607 kg*.
•Use lugs (2) for attaching the unit.
•Connect lifting cylinder with boom (3).
* Actual weights will be mentioned on the delivery documents
* Illustration may differ from this project crane

CHAPTER 4
14
Crane column, mounting base and high stand
•Weight - hydraulic oil not included c. 2,650 kg*.
•Diameter of lifting lugs - 33mm.
* Actual weights will be mentioned on the delivery documents
1630mm
* Illustration may differ from this project crane
Transport on forklift is permitted in the indicated directions only.
75

CHAPTER 4
15
Make sure that the crane including pallet is always placed on an even surface.
It is prohibited to drag and tug it!

CHAPTER 4
16
Storage
General
Cranes, crane components, and accessories must be placed in a suitable
storage room in their original package. The storage room must be clean, dry, and
ventilated.Corrosive gases, dust, shocks, and vibrations are not permitted. Components
must be protected against insects and other small animals and rodents. The ambient
temperature must be between -20°C and +50°C with a maximum of 75% relative humidity.
Important:
- ETB must be stored inside storage (storage room must be dry, 30-50%humidity)
- Levelling Ring must also be stored inside storage (storage room must be dry, max. 75%
humidity)
Short term storage (max. 2 months)
Cranes not installed immediately are not allowed to be stored without protective measures.
For temporary outdoor storage (maximum 2 months) the crane / crane components must be
covered with weatherproof tarpaulins. Accessories are not allowed to be
stored outside. Open bearing points and flanges must be protected and covered with wax
against corrosion.
Storage beyond 2 months
In addition to the measures for short-term storage, the following measures are necessary:
• Cranes are to be completed according to the assembly instructions (assembly).
• When working in the surrounding area, the crane must be protected against dust, blasting
material and grinding chips.
• The storage condition (protective measures) must be checked monthly. Corrosion must be
removed immediately. Maintenance must be carried out according to the maintenance
guidelines.
• Open bearing points and flanges must be protected and covered with wax against corrosion.

CHAPTER 5
17
CHAPTER 5
Set-Up
In this chapter
Main components .................................... 18
Crane Mounting ....................................... 20
Preparation for base assembly................. 22
Process of tightening................................23
Preserving the screw joints ...................... 24