Operators Manual

Hydraulic Crane

PK xxx M
PK x80 M
Crane number:

CPDB0001
Version: 08/2005

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 CRANE POWER / 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!

CRANE POWER / PALFINGER MARINE

by CRANE POWER

1
2
3
4
5
6
7

Safety instructions
It is also in your own interest to observe these instructions
very carefully.

Before operation of the crane

This chapter provides you with important safety instructions
which must be followed each time before starting operation.

Start operation of the crane

This chapter gives you all the necessary information to
properly start operation of your crane.

Crane operation
This chapter provides you with the necessary information to
properly operate your crane.

After crane operation

This chapter provides you with a summary of the necessary
instructions to safely finish work with your crane.

Maintenance and service

This chapter provides you with the necessary information to
properly maintain and service your crane.

Appendix
EEx - Crane

Safety instructions
1

Chapter 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

An overview of the dangers

1.1-1

Rules for the avoidance of dangers

1.1-1

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 CRANE POWER / 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 CRANE POWER /
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 CRANE POWER / 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 operators 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 operators 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 -30 C to +50 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

500 mm

Foot

180 mm

Arm
120 mm

Hand
100 mm

Finger
25 mm

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.

During crane operation

1.3-4

For overhead power lines and contact lines of electric railways the following minimum
distances apply:
A

=
DC

up to....... 1.500 V ..... 1,0 m

over........ 1.500 V ..... 1,5 m

~
AC

up to....... 1.000 V ..... 1,0 m

over........ 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 operators 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.

1.3-5
1.3-5

During crane operation

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.

Before operation of the crane

2

Before operation of the crane

Contents
2.1

CHECKS

2.1-1

DAILY VISUAL INSPECTION

Chapter 2

Checks
2.1

2.1-1

2.1-1

Checks

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.

Start operation of the crane

3

Start operation of the crane

CONTENTS
3.1

AN OVERVIEW OF THE CRANE

3.1-1

DESIGN ( PK 32080 M)

3.1-2

DESIGN (PK 32002 M )

3.1-3

OPERATING ELEMENTS

3.2

PREPARING FOR CRANE OPERATION

3.2-1

COLD START IN LOW OUTSIDE TEMPERATURES

3.2-2

PUTTING CRANE INTO OPERATING POSITION

Chapter 3

An overview of the crane

3.1

An overview of the crane

3.1-1

Design ( PK 32080 M)

3.1-1

Crane base

Outer boom ram

Limited slewing system

Lever

Crane column

Outer boom

Slewing gear

10

Boom extension ram

Main boom

11

Boom extension

Lifting cylinder

12

Mechanical extension

3.1-2
3.1-2

An overview of the crane

Design (PK 32002 M )

Crane base

Main boom

Turntable

Outer boom ram

Crane column

10

Outer boom

Slewing gear

11

Boom extension ram

Emergency control stand (optional)

12

Boom extension

Lifting cylinder

13

Mechanical extension

Lever

An overview of the crane

3.1-3

3.1-3

Operating elements
The symbols of the operating elements are explained here. The order of crane functions (symbols) as
available on the emergency stand or on the remote control panel may differ from the displayed
example. Therefore, always pay attention to the way the symbols (crane functions) are arranged on
the control stand of your crane or on the remote control panel.

Slew

Main boom

Outer boom

Extension booms

clockwise / counter clockwise

lower / lift

lower / lift

extend / retract

Rotator

Grab

Rope winch

clockwise / counter clockwise

open / close

unwind / wind

3.2-1

Preparing for crane operation

3.2

Preparing for crane operation

3.2-1

Cold start in low outside temperatures

In outside temperatures below freezing:

40
30
20
10
0
-10
-20
-30

Check the oil level.

Switch on the pump assembly at lowest engine speed.

Let the oil pump around without pressure for a few minutes so that it
warms up a little.

You can accelerate warming up of the oil by moving a hydraulic cylinder

to the end stop.

At temperatures below 0 C make sure that your crane is being

operated with a hydraulic fluid which is suitable for such
temperatures.

3.2-2

Putting crane into operating position

When unfolding the crane makes sure the mechanic extensions and the pulley head are completely in
and fixed and secured properly (see also chapter 4).
If the extensions, the pulley head or a fly jib are not fixed and
secured properly they may slide out of the hydraulic extendable
arms when unfolding the crane and this means a high risk of
accident for your and others.

Crane with remote control radio:

In cranes with remote control radio make sure not to be
in the area of the rising main boom. Choose a position
outside of the cranes danger zone (see also chapter
4).

Emergency control panel:

Never unfold the crane when operating from the
emergency control panel. It serves to finish the loading
works in case of a remote control system failure. Then
put the crane in transport position and contact an
authorized service workshop (see chapter 4).

Preparing for crane operation

3.2-2

Extending the crane:

PK xxx M:

Observe every safety instruction mentioned in chapter 1.

Briefly press the function Fold-in outer boom to lift the knuckle boom from its support at the
crane post.

Then press the function Retract boom extensions one time briefly.

Move the main boom in a near-vertical position using the function Lift main boom. Anyway,
avoid moving the main boom up to the top end.

Then unfold the knuckle boom with the function "Unfold outer boom" until it reaches a horizontal
position.

The crane is now ready for operation.

Without rope winch

With rope winch

3.2-2

Preparing for crane operation

PK x80 M:

Observe every safety instruction mentioned in chapter 1.

Briefly press the function Fold-in outer boom to lift the knuckle boom from its support at the
crane post.

Move the main boom in a near-vertical position using the function Lift main boom. Anyway,
avoid moving the main boom up to the top end.

Then unfold the knuckle boom with the function "Unfold outer boom" until it reaches a horizontal
position.

The crane is now ready for operation.

Without rope winch

With rope winch

Crane operation
4

Chapter 4

Crane operation

CONTENTS
4.1

DURING CRANE OPERATION

4.1-1

KEEP THE WORKING RANGE IN VIEW

4.1-2

LOADING ACTIVITY

4.1-3

OBSERVE LOAD LIMITS

4.2

SAFETY DEVICES

4.2-1

EMERGENCY OFF BUTTON

4.2-2

HPLS SYSTEM

4.2-3

OVERLOAD PROTECTION SYSTEM

4.2-4

MANUAL PUMP EMERGENCY OPERATION (OPTION)

4.3

ADDITIONAL EQUIPMENT

4.3-1

LOAD HOLDING ATTACHMENTS AND ACCESSORIES

4.3-2

GRAB AND ROTATOR

4.3-3

ROPE WINCH

4.3-4

STANDING PLATFORM, TOP SEAT, CABIN, PROTECTION COVER

4.3-5

REMOTE CONTROL

4.3-6

EMERGENCY OPERATION FOLLOWING FAILURE OF THE REMOTE CONTROL

CONSOLE

During crane operation

4.1

4.1-1

During crane operation

4.1-1

Keep the working range in view

Always keep a close eye on the suspended load, especially during slewing motions.
Ensure there is sufficient light on the working site.
The crane must be operated by no more than one operator at a time.
During loading activities, the crane operator must always have the hand levers at his fingertips.
As long as a load is suspended, the operator must remain in contact with the control levers.
If the possibility exists that objects could fall off onto the ground, the danger zone must be protected
by road blocks or warning posts.
Standing within the danger zone is strictly prohibited, especially
under the suspended load or close to moving crane components.
Always choose the best working position which has the best view
on the job being done and does not endanger other bystanders.
Accidents may prove fatal.

In a case where it is not be possible for the operator to oversee the complete danger zone, a qualified
person must guide the crane operator via hand signals. Use the hand signals legally accepted in your
country.
Both the crane operator and the guiding person must master the hand signals.

The guiding person must always be exactly informed about the work being performed.
Only one person shall give instructions.
The instructor in a working group needs to be clearly indicated (signal flag, hard head in different
color, etc.)
If there is a danger that parts of the load might drop during working with the crane the entire working
area must be closed off and secured by a warning post.
Clean all steps, control units (standing areas) and moving parts of
the crane of ice and snow, if necessary, before beginning work.
Whenever a raised load is hanging from the crane, the crane
operator must not leave the current operating stand nor put the
control console down; the crane operation must not be stopped,
even temporarily.

4.1-2
4.1-2

During crane operation

Loading activity
Only use the crane for lifting loads and never for freeing, hitting, pulling (dragging) loads, pressing or
driving against solid obstacles or for towing. Any angled hoisting is prohibited.

The transportation of persons is only permissible in workman baskets specially constructed for the
purpose.
The regulations specific to each country must be adhered to.
Always lift loads from above their center of gravity. Ensure the load will not slip.
When operating with a grab, always encompass the load fully before lifting.
Handle wet or icy loads with care; there is a danger of slippage! If
there is so much ice or snow on the load which is to be lifted that
safe lifting cannot be guaranteed, the ice or snow must be removed
from the load before it is lifted.
When you activate a crane function grip the operating lever completely and press it until the crane
responds. You can then increase the speed of the crane function by further slow and even pressing of
the operating lever.
Likewise stop the crane movements slowly and evenly.
Operate the crane so that it performs gentle movements.

Abrupt crane movements, such as quick pressing through or

momentary stopping of a crane function can cause the load to
swing and drop. There is danger of an accident.

Move the raised load gently enough that it does not bump against the crane or other obstacles.

During crane operation

4.1-2

Loads must only be attached and removed when the crane is completely at a standstill. Before moving
the load arm ensures that the person who has attached or removed the load is no longer in the danger
area of the crane.

If persons are in the area of the moving load arm (danger area) they
are in acute accident danger.

Do not move the crane at full working speed to the stop, this increases wear and shortens service life.
You can operate several functions at the same time, i.e. carry out several movements at the same
time.
If the crane is operated with several functions at the same time it
must be ensured that if one function is switched off the working
speed of the other functions can increase.

When it is below the horizontal line (range A) the main boom is not able
to reach the maximum lift moment; therefore this position should be
avoided. If you work in this boom position anyway particularly bear in
mind that it is not possible to use the maximum lift moment of the
crane.
Therefore work with the knuckle boom in these load ranges.
In some crane types it is possible to unfold the knuckle boom beyond
the main boom angle. In the upper movement range (range B from ca.
60 to maximum main boom angle) it is not allowed to use this knuckle
boom position as working position.

With heavy loads there is risk of excessive heel!

Therefore: Observe the inclination and load diagrams!

4.1-3

During crane operation

At load (100%):
5 Heel
2 Trim

A = Inclination
B = Lifting moment
C = Slew load
D = Hold load

When working with a load, do not lower the main boom to full
retraction since the overload protection system does not function in
that boom configuration.

If loading operations have to be interrupted, lay the booms down, turn the
hydraulic pump off and ensure unauthorized persons cannot operate.
In order to resume work safely after a break, you must check whether anybody
has manipulated the crane in the meantime.

4.1-3

Observe load limits

Never exceed the load moment permitted for the crane. This may cause
uncontrolled sinking of the load or breaking (crack) of elements.
The permissible load capacities and the maximum load are given on the
load capacity label.
By working with an overhang as low as possible you increase the safety
and live of your crane.

During crane operation

4.1-3

Lowering a heavy load from an extended boom configuration must

be performed without increasing the outreach, otherwise the
admissible load limit may be exceeded. For cranes with no overload
protection or fitted with an overload indicator only, this causes the
booms to lower uncontrollably. For cranes with an overload
protection, the resulting sudden stop puts unnecessary stress on
the crane and may cause the load to slip out. For a description of
safety devices see Chapter 4.2.
Load lifting material (hook, lifting slings, chains, etc.) and attachments such as grabs, rotators and
manual extensions must be accounted for when calculating the overall load.
Never exceed the load limit indicated on accessories or lifting material. Pay attention to and observe
the load charts of the manufacturer when using slings, ropes, chains or any other lifting material.

When working with manual extensions, the admissible load of the

manual extensions determines the overall admissible load of the
whole crane (see load chart), and that, even if they are fully
retracted.

Therefore always hook up your load on the manual extension best suited for the job or on a hydraulic
extension boom.

Load capacity label for a crane:

1. Angle specification for ideal main
boom position
2. Range of coverage specification
3. Load capacity values

4.2-1
4.2

Safety devices

Safety devices

Using safety devices can avoid accidents. They are for your protection therefore you should make
sure which of the below safety devices are available on your crane.

4.2-1

Emergency off button

The emergency CUT-OFF button is a safety device which,

when pressed, brings the crane to an immediate stop. All
crane functions remain locked until the CUT-OFF button
is de-activated.

On the transmission console of the remote control system: (see also Chapter 4.3 Remote
Control)

If an unexpected hazardous situation occurs during crane

operation, release all of the operating levers immediately and press
the emergency off switch until it clicks. All of the crane functions
will then be blocked. If the emergency off switch was pressed
because of an emergency situation, it must not be released until
safe crane operation has been guaranteed.
If, during operation, the CUT-OFF valve is activated because of a power supply failure, you can bring
the crane back into transport position with the following procedure:

Dispose of the lead seal and the spacer on the valve.

Turn in the knurled thumb screw.

After this procedure, the CUT-OFF button is out of order and must
be repaired as soon as possible at your service workshop.

Safety devices

4.2-2

Test the function of the CUT-OFF button every time before working:

Actuate a crane function and simultaneously press the CUT-OFF button: the crane should immediately come to stop.

Crane movements should no longer be possible.

If the crane motions do not stop IMMEDIATELY, then cease

operation of the crane!

4.2-2

HPLS System
Your crane may be equipped with an HPLS system, which can be
switched on as needed by using the pushbutton. When the HPLS
system is switched on, your crane has greater lifting power due to a
reduction in the crane speed.

4.2-3

Overload protection system

The may can be equipped with an overload protection. The overload protection of the crane will react
when the crane (main boom, knuckle boom, extendable arms) is in the overload range.
OAS (Hydraulic overload protection system with blocked outer boom motions):
An overload protection system is supposed to prevent a load moment which is too high on the crane
before the overload becomes dangerous by turning off the movements which increase the load
moment.
Before the load becomes dangerous means before the load holding valve is activated, this would
cause the crane to begin to drop the load uncontrollably.
The pressure from the lifting cylinder is used to activate the system.
If the pressure set for the overload valve is exceeded, all of the movements in the tank increasing the
load moment are shut down; they are combined in one block.
The following functions will be disabled if your crane reaches the overload range:
Main boom ........................................................................................ lower
Outer boom ....................................................................................... lift / lower
Extension .......................................................................................... extend
Rope winch ....................................................................................... hoisting
When the crane is in overload it is only possible to execute movements that reduce the load-moment.
As long as the pressure in the lifting cylinder falls below the pressure specified for the overload
protection.
These functions will only enable after reducing the load moment. This is achieved by retracting the
extendable arms or lowering the rope winch.

4.2-3

Safety devices
Pressure peak button:
Lifting the lift cylinders up to the stop activates the overload protection. Reason for this is a pressure
peak in the lifting cylinder which develops when running to the stop end (with our without load).
It is impossible to release this pressure peak as the function Lower main boom is blocked and the
pressure in the lifting cylinder cannot be reduced by movements that reduce the load moment.
In order to lower the main boom from this position, the pressure peak button must be pressed briefly
several times. This will cause the pressure in the system to be released into the tank and the overload
valve will switch back to normal crane operation.
This will not work when the crane is actually in overload as in such a case it is impossible to reduce
the pressure in the lifting cylinder.

Checking the overload protection system:

Before start working with the crane, the overload protection system must be checked.
How to do:
To check the overload protection system, no load is necessary. The only one thing to do is to move
the main boom on top position with maximum speed. In this case a peak pressure raises in the main
boom cylinder and activates the OAS system.
The following movements must be blocked:
Main boom ......................................................................................... lower
Outer boom........................................................................................ lift / lower
Extension ........................................................................................... extend
Rope winch........................................................................................ hoisting
To switch back the overload system it is necessary to push the peak pressure button a few seconds.

If this test is not OK, it is not allowed to work with the crane!

Briefly press the release valve and lower the main boom.

Safety devices
4.2-4

4.2-4

Manual pump emergency operation (option)

Emergency operation following a power failure or defect in the electric system of the crane.
If your crane stops due to a defect in the electric system of the crane or because of a complete power
failure then you can bring the crane in an emergency operation status (emergency operation). When
the crane is in emergency operation it is possible to move it in transport position. (After this see a
CRANE POWER / PALFINGER MARINE authorized repair centre immediately). The device (by-pass
screw) that allows you to bring your crane in emergency operation is always on the emergency off
magnet valve. Depending on the crane model it is either on the control valve or on the high-pressure
filter.

Operating the manual pump in emergency operation:

Block the EMREGENCY-OFF magnet valve (1)

manually using the by-pass screw.
Close the control line with the hand lever (2).

Operate the necessary functions

on the control valve (3) and at the
same time pump with the hand
pump (4) to move the crane into
transport position.

The hand pump is assembled to the hydraulic aggregate or to the side

of the raised stand.

The working speed is very low when controlling the crane with the hand pump.

4.3-1
4.3

Additional equipment

Additional equipment

4.3-1

Load holding attachments and accessories

You may operate the crane with a number of different load fixing tools such as
grab, rotator, extensions, pallet fork, belts, ropes, manipulators, a second
knuckle system, etc. In addition to the cranes operating instructions refer to the
operating instructions for the load fixing tool or accessory you are using.
For some accessories, a special suspension from CRANE POWER /
PALFINGER MARINE must be employed and mounted according to the
following sketch. Otherwise, damages to the attachment are possible and such a
case is not covered by the warranty.
For more details, simply ask your CRANE POWER / PALFINGER MARINE
service workshop.
For cranes with extensions a CE sign is NOT possible!

Please observe the following in connection with load lifting gear:

The weights of the load lifting gear and accessory equipment count as part of the load.

The load lifting gear must be matched to the crane in terms of size and lifting capacity.

A type plate must be attached to the load lifting gear showing details such as manufacturer, type
designation, manufacture number, weight, operating pressure, capacity, maximum permissible
lifting capacity and year of manufacture.

The maximum lifting capacity of your crane is always determined by the weakest unit of load lifting
gear used. Please therefore always observe the lifting capacities stated on the load lifting gear.

Familiarize yourself with the content of the operating instructions of the respective load carrying
equipments.

Hook:

On your crane only use load hooks which match your crane and the load to be
lifted.

The lifting capacity of the load hook and the shackle must correspond to the
maximum lifting capacity of the crane.

Fasten and secure the load hook properly.

Ensure that the safety catch closes again by spring pressure after the load has
been hooked.

Additional equipment

4.3-1

Working with mechanical extensions:

Put the load arm in horizontal position.

Extend the extendable arms.

Lower the crane boom far enough that you can remove the spring cotter and the securing bolt
with which the mechanical extension is secured. Always stand to the side, never in front of the
crane boom.

Mechanical extensions can slide out of the boom extension after

removal of the securing bolt owing to the inclined position of the
boom extension. Therefore always take up a position to the side of
the boom extension, otherwise there is a danger of fatal injury.

Remove the spring cotter from the securing bolt and pull the bolt out.

Pull out the mechanical extensions so far until you can secure them with the bolt again in the
extendable arm. It is prohibited to let the extensions fall out of the load arm by placing it in a steep
position.

Secure the bolt again with the spring cotter.

The maximum permissible load capacity of the used extension (see model label or side label on
the extension) must not be exceeded. This is even applicable when the extension is completely
retracted and secured.
Inadequately secured mechanical extensions pose a potentially fatal
risk for you and others. Always use only bolts and cotters
recommended by CRANE POWER / PALFINGER MARINE.

The maximum load capacity of the crane is always determined by the weakest load taking element.
Therefore, always observe the load-carrying capacities specified on the load taking elements.
When you are working with load carrying equipment or accessories
such as load hooks, mechanical extensions, winch components,
etc. always make sure that the equipment has been properly
secured.
Always use the proper bolts and securing elements (cotter pins, lock
nuts, etc.) for the load carrying equipment or accessories.

4.3-1

Additional equipment
Working with hydraulic ancillary equipment:
A range of ancillary equipment (grab, rotator etc.) is operated hydraulically. The hydraulic system of
the crane must be connected to the hydraulic system of the ancillary equipment with screw couplings.
When using quick couplings, make sure they are clean (use dust caps). Once the screw couplings are
connected, screw down the dust caps as well.
Connecting screw couplings:

Switch off pump.

Remove pressure from the lines by operating the control levers in both switching positions.

Remove dust caps from the couplings.

Screw couplings until tight.

Connect dust caps.

Couplings, hoses or leaking oil can become so hot from the heated
oil that there is a risk of burns. Carelessly screwed couplings can
result in oil leakage and the consequent pollution of the
environment. The loss of pressure impairs the function of the
ancillary device or causes it to fail completely.

Separating screw couplings:

Switch off pump.

Remove pressure from the lines by operating the control levers in both switching positions.

Separate dust caps.

Separate screw couplings.

Screw on dust caps and stow the hoses properly in the hose boxes.

Additional equipment
4.3-2

4.3-2

Grab and Rotator

Grabs should be used exclusively for moving loose materials such as sand, gravel, soil etc. Never use
the grab to pull (out) or drag objects (masts, trees, etc.), or to press or hit, as this can result in damage
to the crane, the load suspension, rotator or the grab itself.
Installation of rotator and grab see operating instructions for the grab.
Your crane should be equipped with an adequately sized tank and/or oil cooler (oil temperature) for
grab operation. However, you should monitor the oil temperature constantly during grab operation.

4.3-3

Rope winch
For rope winch operation only use CRANE POWER / PALFINGER MARINE rope winches, pulleys,
pulley heads, etc.
Mount the winch components (intermediate pulleys, pulley heads) as shown in the technical sheet.
Use the correct bolts and bolt locks for each of the pulleys.
Observe the maximum load values of the rope winch which you find on the type plate of the rope
winch. Rope, insert, pulley head and bottom flanges are parts of the load.
By single rope use, put the rope trough the trolley head and but the pin trough the rope head and the
load attachment of the crane hook.
By two way rope use put also the rope trough the trolley head and the trough the bottom sheave and
fix it then at the trolley head by a pin.

1. Rope winch
2. Rope
3. Reversing pulley
4. Pull-in part
5. Trolley head
6. Bottom sheave (Hook)

Furthermore there is danger of the rope being torn up, because it will shorten if the knuckle boom is
unfolded with the rope winch being assembled to the main boom. So always pay careful attention
during rope winch operation that enough rope is pulled off the drum during these crane movements.

It is prohibited to use damaged, worn or too weak ropes!

4.3-3

Additional equipment
When working with the rope winch it has to be ensured that:

Movements which cause the load to rotate about the axis of the rope
should be avoided!

The lifting capacity may not be increased or modified in any way.

The rope winch is not overloaded with the lifting capacity of the crane.

When extracting the extendable arms or lifting the knuckle boom make
sure that this will not shorten the rope to the extant that it
tears up.

Crane components such as hydraulic extendable arms,

mechanical extensions and pulleys etc. are not overloaded
with the lifting capacity of the rope winch.

If the rope winch does not have a safety device it must be

ensured when winding off the rope that at least 3 turns
remain on the drum.
If during working with the rope winch the rope is wound off to less
than three full turns the rope may be pulled out of its fastening in
the rope drum. This will cause the load to drop, which means an
acute accident danger for you and other persons.

On a rope winch with safety device it is ensured that when the rope is wound off at least 3 turns
remain on the drum and that the rope is not snapped by unintentional shortening (extending the
extendable arms).

The pulley heads, pulleys and intermediate pulleys are to be mounted and used in accordance
with the technical information sheets.

To prevent slack the rope must be kept tight when being wound onto the rope drum (not with the
hands).

If the lower rope layers on the drum are hardly used or not used at all they are to be wound off the
drum from time to time and rewound with pretensioning.

Additional equipment

4.3-3

Controlling winch functions

If a winch is used infrequently, a full operational check is required at least once a year. The winch as
well as the braking system must be tested under full load conditions.
To check the multiple disk brakes, stop the winch action while operating the winch under conditions of
full load. The load should come to a complete stop and remain suspended at rest. No lowering of the
load should occur.
If the load continues to lower even only slowly the rope winch break
will be not fully functional. Stop rope winch operation immediately
and contact your service centre. Do not continue using the winch
under any circumstances!

Loading and unloading work in rope pulley operation (observe load limits):
Always work with the lowest possible load moment in rope pulley operation as well. You will increase
the safety of the loading or unloading procedure and the useful lifetime of your crane.
If the load-bearing arm is in a near-vertical position, the extendable arms must be
retracted as far as possible during loading and unloading.

If the load-bearing arm of the crane is in a near-vertical position, retract the hydraulic
extendable arms before picking up or setting down the load.

Lift the load without extending the extendable arms. Lift the load only far enough so that
it does not bump against the load-bearing arm.

Slowly lower the load-bearing arm to about 60.

4.3-4

Additional equipment
Now you may, if necessary, extend the hydraulic extendable arms. Pay special
attention to ensure that the necessary length of rope always unwinds when
extending the hydraulic extendable arms.
Pay special attention to the load during this procedure. It must not hit the loadbearing arm or rub against it if its position is too steep. Slewing movements must
be performed slowly and gently so that the load does not begin to swing back and
forth.
When work is done with a fully extended hydraulic
extendable arm and the load-bearing arm in a nearvertical position, the load-bearing arm may swing to the
side, especially during slewing motions of the crane. This
can cause the load to fall. Do not work in rope winch
operation in this work position. If the extended loadbearing arm is in a steep position (more than 60), do not extend the
hydraulic extendable arms by more than 2/3 of the possible
distance.

4.3-4

Standing platform, Top seat, Cabin, Protection cover

Use the railings, ladder or handles to climb onto the standing platform or the top seat. Be
extremely careful not to touch any operating elements.

Handles, step treads and standing spaces must at all times be clear from dirt, oil or ice. Clean if
necessary.

After taking place on the operating stand, use the protection safety belts or cables provided.
While working on the valve box, make sure that you are never in the
danger zone of the crane in particular below the lift load or below
or near any moving parts of the crane. Therefore, observe the
required safety distance to load and crane components while
running the crane movements. If it is insufficient this means acute
risk of fatality for you!

Additional equipment

4.3-4

Description of the operating elements

1. Manometer
2. Emergency-off button
3. Switch for remote control radio operation
manual operation
4. Pressure peak button
5. Capacity shield (Crane)
6. Operation symbol
7. Capacity shield (Rope winch)
8. Lever

4.3-5
4.3-5

Additional equipment
Remote control
In order to be able to make smooth precise crane movements
during remote-controlled operation the carry belt for the transmitter
panel must be used.

The remote control unit is ready for operation as soon as the start button is pressed. All operating
levers must be in neutral position. It is impossible to start the unit if the emergency CUT-OFF button is
pressed.
For information about the crane operation via remote control radio see the delivered separate
operating instructions.
To prevent unforeseen interruptions and downtimes due to empty accumulators always keep a
charged reserve accumulator with you.
A sealing of the valve plug is not necessary, as the outputs of the receiver are intrinsically safe. The
plug has not been secured to the valve by a screw. Dont take the plug away from the valve when
the valve is under voltage! The screw tightening has to be checked regularly.

Observe all instructions in the remote control operator's manual

delivered with each unit. The selection switch remote control / valve
control is fitted on the control panel.

Additional equipment
4.3-6

4.3-6

Emergency operation following failure of the remote control console

Following failure of the remote control console, the crane must be operated using the emergency
control unit (emergency control). This is located on the crane post and may be operated only for the
purpose of putting the crane into transport position. Contact a CRANE POWER / PALFINGER
MARINE authorized service centre immediately.
Move crane into transport position using the emergency control console:
Select a safe place to stand at the emergency control unit (standing area and handles should in any
case be provided by the assembler) from which you can easily reach the operating elements of the
emergency control unit.
Then proceed as follows:

Remove the operating lever (1) and screw it onto the control valve on the crane function Slew.

Pay attention to the arrangement of the crane functions on the emergency control unit!
Then put the crane into transport position and contact a CRANE POWER / PALFINGER MARINE
authorized service centre to repair the operational disruption.

1.

Operation symbol

2.

Lever

3.

Emergency-off button

4.

Switch for remote control radio operation manual operation

5.

Capacity shield

6.

Pressure peak button

When operating the emergency control unit (emergency operation),

make sure that you always maintain an adequate distance to all
moving crane parts and the load. There is an acute danger of being
crushed (risk of fatality). Also make sure that you have a secure
place to stand (danger of falling).

After crane operation

5

After crane operation

CONTENTS
5.1

ENDING CRANE OPERATION

5.1-1

PUTTING CRANE IN TRANSPORT POSITION

5.2

AFTER CRANE OPERATION

5.2-1

SECURING AND TRANSPORTING THE LOAD

Chapter 5

Ending crane operation

5.1

5.1-1

Ending crane operation

5.1-1

Putting crane in transport position

In your activity observe all the safety instructions in Chapter 1.
Cranes with remote control operation:
On cranes with radio remote control make sure that you are not in the area of the slewing or
descending boom. Select a standing place outside of the crane danger area (see also Chapter4).
Retracting the crane:

Push the extensions in and secure them as described in Chapter 4.

If mechanical extensions are not properly retracted and secured

they can slide out of the hydraulic extendable arms and then
represent a high risk of accident for you and others.

When retracting the crane please ensure to have all crane movements within your field of vision.
PK xxx M:

Move the main boom in a near-vertical position using the function Lift main boom. Anyway,
avoid moving the main boom up to the top end.

Fully retract the boom extensions using the function Retract boom extension.

Now fold in the outer boom completely using the function Fold in outer boom.

Retract the boom extensions using the function Retract boom extension until
the transport hook is securely fixed in the eye.

Slew the crane into transport position using the function Left, right slew and
observe the fold-in arrows on crane column and crane base.

Move the main boom in its support position

using the function Lower main boom.
The support console for the load-bearing
booms has to be assembled by the crane
assembler (see also assembly instructions).
On request there is a support for cranes
larger than 30 mt.

5.1-1

Ending crane operation

Without rope winch

With rope winch

Winch
operation only
in this position!

Ending crane operation

5.1-1

PK x80 M:

Move the main boom in a near-vertical position using the function Lift main boom. Anyway,
avoid moving the main boom up to the top end.

Now fold in the outer boom completely using the function Fold in outer boom.

Retract the boom extensions using the function Retract boom extension.

Slew the crane into transport position using the function Left, right slew and
observe the fold-in arrows on crane column and crane base.

Move the main boom in its support position using the function Lower main
boom. The support console for the load-bearing booms has to be assembled by
the crane assembler.

Without rope winch

With rope winch

5.2-1

After crane operation

If, during transport, the crane booms are not folded in this position but rest on the platform or on the
driver's cabin, ensure that they are properly secured against sideways motions.

If the crane is not properly secured against sideways motion or not

completely folded, there is a great risk of accident.
5.2

After crane operation

5.2-1

Securing and transporting the load

Secure the load in accordance with the regulations before starting the trip.
Before starting the trip check that the hydraulic pump is switched off.
It is necessary to operate the main switch for remote control radio to interrupt power supply (24 V) to
the remote control.

Maintenance and service

6

Maintenance and service

CONTENTS
6.1

MAINTENANCE

6.1-1

WARRANTY PROVISIONS

6.1-2

SCHEDULE OF MAINTENANCE

6.1-3

PLANE OF MAINTENANCE ( PK 32080 M)

6.1-4

PLANE OF MAINTENANCE (PK 32002 M )

6.1-5

LUBRICATION

6.1-6

HYDRAULIC OILS

6.1-7

OIL CHANGE / OIL MAINTENANCE

6.2

CLEANING THE PLANT

6.2-1

CLEANING AGENTS AND EQUIPMENT

6.2-2

REPAIRING PAINT DAMAGE

6.2-3

REMOVAL FROM SERVICE AND DISPOSAL

Chapter 6

Maintenance
6.1

6.1-1

Maintenance

6.1-1

Warranty provisions
Regrettably, during servicing, we have noticed repeatedly that our recommendations
for maintenance and lubrication of the crane have been ignored.
We are not liable for any costs for damage resulting from insufficient maintenance
and lubrication. It is in your own interest to carry out the maintenance and lubrication
of your work platform regularly and in accordance with the instructions.
Only use lubricants and hydraulic oil of sufficient quality. Using poor quality products
represents a false economy.
Guarantee and service work must only be carried out at one of our authorised
customer service centres (see Maintenance Handbook).
The conditions of the guarantee are stated in the guarantee booklet.

6.1-2

Schedule of Maintenance
When working on hydraulic equipment, make sure that the hydraulic
system is not still under pressure!

after the first 50 hours

1st service
Oil filter
every 20 hours / smallest once a week
2

Column bearing (slew 360 degrees)

12

Rotary distributor (slew 360 degrees)

change

6.1-2

Maintenance
every 50 hours / smallest once a month
1

Fixation of crane base

Slewing rack (slew 360 degrees)

Main boom cylinder pivot, Outer boom cylinder pivot

Continuous rotation

Thrust bearing

Gear oil (inspection glass- fuel lever plunger)

Main boom pivot

Power link pivot

Outer boom pivot

Boom extension rams - guide parts, pivot guide

10

Extension booms - guide blocks

11

Mechanical extensions

13

Turntable (slew 360 degrees)

13

Thrust turntable
Rope winch
Rope
Load hook
Tighten up, fittings, pipes and hoses
Repairing paint damage

every 1000 hours / smallest once a year

Oil filter, hydraulic oil

change

Rope winch hydraulic oil (see data sheet)

Slewing system gear oil

Visual check

Grease

Oil spray

Rope
grease

Screw

Machinery oil

SAE 90

Maintenance
6.1-3

6.1-3

Plane of maintenance ( PK 32080 M)

8
9
8

PK X080
Serie

6
4
10
11

5
4
2

6.1-4
6.1-4

Maintenance
Plane of maintenance (PK 32002 M )

Maintenance
6.1-5

6.1-5

Lubrication
The following maintenance and care instructions apply to all CRANE POWER / PALFINGER MARINE
cranes. Therefore this chapter includes also hints which do not refer to your crane.
Deficient or incorrect lubrication causes increased wear out and consequently unnecessary repairs
(downtimes) of the crane. Therefore, make sure that bearings, hydraulic extendable arms and
mechanic support arms are always sufficiently lubricated and that only those lubricants are used which
are included in the specification below or correspond with them.
Lubricant to be used:

To lubricate the bearings only use solid-free grease without any

graphite, MoS2, etc. Using different greases quickly leads to bearing
damages on the crane.

Bearing:
Inspected according
to:

Technical Data
Structure

smooth

Consistence (NLGI)
Designation
Dropping point C
Worked penetration
Oxidation stability 100 h / 100 C
Basic oil viscosity at 40

DIN 51818

KP2K-35

DIN 51502

150

DIN ISO 2176

265/295 1/10 mm

DIN ISO 2137

max. 0,2 bar

DIN 51808

>80 mm/s

Behaviour in water

Water resistant

DIN 51807-1

Boom extensions / mechanic extensions, etc:

Inspected
according to:

Technical Data
Type designation
Thickener type

OMV whiteplex 1 (EZ 739)

Al-Komplex

Temperature range

-30 C to +190 C

Consistence (NLGI)

DIN 51818

K 1 R-30

DIN 51825

240

DIN ISO 2176

300 mm/10

DIN ISO 2137

Flow pressure at -15 C

Flow pressure at -25 C
Flow pressure at -30 C

- hPa
500 hPa
900 hPa

DIN 51805

Basic oil viscosity at 40

220 mm/s

Specification
Dropping point C
Worked penetration

Behaviour in water

Water resistant

DIN 51807-1

6.1-5

Maintenance
How to grease the bearings on the crane correctly:

Before greasing clean the spot thoroughly, yet dirt

that gets into the bearing hole together with the
grease causes quick wear-out of the bearing.

Then press fresh grease into the bearing on the

intended grease spots (oil holes etc.) until it comes
out off the bearing.

After greasing it is necessary to clean off any excess

grease from the bearing.

Grease the column bearing properly (rack track, thrust washer)

Before greasing the column bearing extract the main boom completely (outer boom remains
folded) so that the grease may distribute evenly in the column bearings. The column bearing has
to be lubricated on the grease spots intended for this by CRANE POWER / PALFINGER
MARINE. If you lubricate via central lubrication make sure that sufficient lubrication is provided
anyway.

After having pressed grease into all grease spots for the first time, slew the crane round its whole
slew area. Then repeat this process until the grease comes out between crane column and crane
base.

How to grease the hydraulic boom extensions on the crane correctly:

Extract the hydraulic boom extensions completely and then place the load-bearing arm on a piece
of wood.

Before lubricating clean the grease spots off any old and dirty grease and other dirt.

Then apply the grease on the bottom of the hydraulic boom extension using a
suitable tool (brush or similar).

Retract the hydraulic boom extensions while applying light pressure (lower main
boom).

Then remove the excess grease.

Because of danger of slipping excess grease is a safety hazard and

must not get into the environment.

Maintenance

6.1-6
If the crane has not been used for a period of time, the complete
crane system must be lubricated according to the lubrication plan.
Each exposed metal part must be protected with an anti-rust agent.
All of the hydraulic cylinders must be retrieved as far as possible.
The cable winch and cable must be protected with an anti-rust
agent. For continuous swivelling equipment the gear drive, pinion
and all exposed metal parts must be especially protected against
corrosion.

As grease is lost at most lubrication points on the work platform (grease is consumed
or goes into the environment), we recommend the use of biodegradable greases.

Care of extendable cylinder piston rods:

If the extendable arms are never completely retracted to the transport
position the extendable cylinder piston rods may suffer oxidation. The
extendable cylinders (extendable arms) must therefore be completely
retracted once a month.

6.1-6

Hydraulic oils
When choosing the hydraulic oil, you should consult your service representative.
HLP / ISO hydraulic oils should be used with the following properties:

Reasonable viscosity / temperature properties.

Good thermal and mechanical resistance.

Significant ageing resistance.

Good corrosion protection properties.

Adequate cold-flow properties.

Adequate lubrication effect at the lubrication limits.

Good air-separation properties.

Perfect foaming behaviour.

Neutral with respect to seals and hydraulic hoses.

6.1-6

Maintenance

Recommended
range

Operating limits

As the viscosity of hydraulic oils is strongly influenced by temperature changes, compromises during
their selection cannot be avoided. The following limiting values are valid for your CRANE POWER /
PALFINGER MARINE work platform:

ISO Reference
temperature

Temperature C

High temperature range:............... ........................................................... 10 cSt

Cold start limit:.............................. ........................................................... 1000 cSt
Cleanness class: .......................... ........................................................... 15/12 (according to ISO 4406)
The working temperatures differ according to the different product bases:
Mineral oil based oils: ................... ........................................................... approx. -30 C to +80 C
Biodegradable oils: .......................Fully synthetic esters:......................... approx. -30 C to +80 C
Biodegradable oils: .......................Natural esters:.................................... approx. -20 C to +80 C
Biodegradable oils: .......................Oils on the basis of rapeseed oil:....... approx. -20 C to +65 C

Rape-seed oil and Class HLP 22 oil must not be used. Rape-seed oil
causes the valves to stick!

The ideal working temperature for hydraulic oil lies between 30C and 60C.
If these temperatures are frequently exceeded when using the work platform, consult your service
representative with regard to the installation of oil cooler or a larger oil tank.

Maintenance

6.1-6

Biodegradable oils are better for the environment than conventional hydraulic oils.
Anyway, even these oils must not be disposed into nature.

Releasing oils (including biodegradable oils) into the natural

environment is not permitted!

The hydraulic oils listed in our recommendations may be blended together but must not be mixed with
other fluids.
Note the following disadvantages:

Shortening of service life,

Mineral-oil mixtures are not biodegradable.

Reduced permitted operational temperature for mixtures with rapeseed oil or native ester.

Hydraulic oils
Manufacturer:

Mineral oils:

Biodegradable
oils:

Gear oils:

Lubricating
grease:

Toothed wheel
grease:
Rope:

AGIP

Arnica32

Arnica S

Blasia 150

Grease 33 FD

FIN 332 / F

ARAL

Vitam VF 32

Vitam EHF 46

Degol BG 150

Langzeitfett H

Sinit FZZ

AVIA

Avia Fluid HVI 32

Avia Synthofluid
46 N

Avia Gear RSX

150

Avia TAC BB 21

Avia Aluplex 0
RHS

CASTROL

Hyspin AWH 32

Carelube HES

Alpha SP 150

Castrol Grease
CL

DEA

Astron HVLP 32

Econa E 46

Falcon CLP 150

Caron WAW EP 2

Spectron ZFK
EPO

FINA

Hydran TSX 32

Giran L 150

Merkan DT 95

Cabline MGR

FUCHS

Renolin B HVI 32

Renolin CLP 150

Almetyn 2

Ceplatyn 300

MOBIL

Mobil DTE 13 M

Mobil UF 46

Mobilgear 629

Mobilgrease HP

Mobilgear OGL
007

OMV

HLP M 32

Biohyd MS 46

Gear HST 150

OMV Fett ZMO

OMV Fett ZFK

SHELL

Tellus T 32

Naturell HF E 46

Omala Oil 150

Retinax HD 2

Shell Kuggfett

TEXACO

Rando HDZ 32

Meropa 150 FM

Novatex EP 1

TOTAL

Equivis ZS 32

Hydrobio 46

Charter EP 150

Multis 2

Multis WR 2

VALVOLINE

Ultramax HVLP
32

Ultrasyn HE 46

EPG 150

Val Plex EP 2

MP Molly Grease

WINTERSHALL

Wiolan HVG 32

Wiolan HE 46

Ersolan 150

Wiolub LDF

Biohydran TMP
32
Plantohyd Super
S

6.1-7
6.1-7

Maintenance
Oil change / oil maintenance
The annual maintenance of oil can significantly increase its working life. Apart from the saving in
costs, this means a drastically reduced amount of waste oil and less contamination of the
environment.

All rams must be fully retracted when changing the oil or topping up
the hydraulic oil.

Oil maintenance means:

Filtration, dewatering and testing of the oil purity which you have carried out in an authorised
workshop.
Life in years:
Oil type

Oil maintenance
without

with

Natural esters

Fully synthetic esters

Mineral oils

Biodegradable oils

The relevant local laws, regulations and guidelines apply to the

disposal of wastes, residues or used materials!

Maintenance

6.1-7

The following nomogram gives the service life of the fully synthetic ester oils:

Service life in
years
Working hours
per year

Max. oil
temperature

6.2-1
6.2

Cleaning the plant

Cleaning the plant

6.2-1

Cleaning agents and equipment

Regular expert care will serve to preserve the value of your crane. How often the crane needs to be
washed depends on how frequently it is used, the season, weather influences and so on. Road salt,
oils, dust, etc. attack the paintwork of your crane and an increased corrosion of the crane components
can occur.

Only wash the crane when the electrical unit is switched off.

Cleaning agents:
For the care of your crane use only pH-neutral cleaning agents to avoid oxidation on chrome parts.
When selecting cleaning agents please ensure that you only use environment-friendly products.

Some cleaning agents are harmful to the skin. Be informed about

your cleaning agent and protect yourself accordingly before starting
the cleaning work.

Cleaning equipment:
When using high-pressure cleaning equipment there must always be enough distance between the
nozzle and the crane being cleaned as otherwise damage can be caused by the high water pressure.
Electronic components, plastic components, signs and bearings must not be cleaned using highpressure cleaning equipment.
Therefore ensure that:

Lubricant is washed out of the bearings.

Adhesive signs are not loosened from the crane by sideways or excessively long spraying.

Plastic parts are not damaged by excessively high water temperature or high pressure.

Crane parts containing electronic components (control valve, electronics boxes, etc.) or electronic
components themselves must never be sprayed directly with high-pressure cleaning equipment. If
water gets into these parts, it can lead to a malfunction of the crane or to short circuits in the
electrical system.

Areas which have been marked with the warning sign High-pressure cleaning
prohibited must also not be cleaned with high-pressure cleaning equipment.

When using high-pressure cleaning equipment, the water (cleaning

agent) must not exceed a temperature of 60 C.

Cleaning the plant

6.2-2

6.2-2

Repairing paint damage

If you discover paint damage on your crane, you must take care of it immediately. Damaged places
must be sanded off and coated with a primer before painting.
Repair damaged paint to avoid corrosion!

6.2-3

Degrease damaged paint.

Apply primer.

Apply top coat.

Removal from service and disposal

If the crane is taken out of service and dismantled from the vehicle its parts must be disposed of
properly. Bear in mind that many crane components are contaminated with grease and oil which on no
account must be allowed to discharge into the environment. Biodegradable oils and greases should
not be allowed to discharge into the environment either.
Therefore dispose of the parts separately according to their nature (steel, plastic, electrical
components, oils, greases, etc.) and in accordance with the respective statutory regulations in your
country.

Appendix
7.

Chapter 7

Appendix

CONTENTS
7.1

EEX CRANE MODELS

7.1-1

GENERAL INFORMATION

7.1-2

TECHNICAL INFORMATION

7.1-3

INFORMATION ON SAFETY

7.1-4

INFORMATION ON SAFETY SPECIFIC TO THE CRANE

EEx Crane Models

7.1

7.1-1

7.1-1

EEx Crane Models

General Information
Objective of the Manual
This manual has been prepared by the machine manufacturer with the aim of providing information
about safe operation of the equipment to the people who are authorized to carry out work procedures
for transport, handling, installation, servicing, repair, disassembly and disposal of the crane.
Failure to observe the information can result in risks to the health and safety of people and in property
damage.
This documentation should be given to a conscientious person for use as intended and for
safekeeping at an appropriate location so that it is always available for reference and maintained in
good condition.
If this documentation should be lost or damaged, request a replacement directly from your dealer,
giving the identification code of the current manual.
The manufacturer retains the right to insert modifications, integrated material or improvements in the
manual at any time; said insertions will not cause this publication to become unusable.
Symbols have been used to call your attention to especially important items in the text; their meaning
is explained below.
SYMBOLS

DANGER ATTENTION: Indicates highly hazardous situations

which could pose great risks to the health and safety of personnel if
they do not exercise care in their actions.

CAUTION NOTE: Indicates that reasonable caution is necessary to

avoid risk to the health and safety of personnel and the possibility
of material damage.

IMPORTANT: Indicates especially important technical information

which should not be ignored.

References marked by these symbols refer solely to machines in

conformity with the ATEX Directive 94/9/CE. The work marked
by this symbol must be carried out by qualified specialists who
have the necessary skills for working in potentially explosive
atmospheres. Failure to observe this note will result in serious
safety risks for people and environment.

7.1-1

EEx Crane Models

Labelling of the Product
Additional Plate for Cranes and Accessories with ATEX Option (Example)

Legibility of the Type Plate

All of the information shown on the type plate must be clearly legible at all times, so the plate should
be cleaned regularly.

Identification data on the type plate should always be given when making enquiries to the
dealer such as requests for spare parts, information or customer service.

Glossary and Terminology

The terms used most frequently in this manual are explained below so that their meaning is clearly
defined.
Scheduled Service
All of the work required to maintain the operational capability and efficiency of the crane. The work is
normally stipulated by the manufacturer, who also determines the skills required and the type of
intervention.
Unscheduled Service
All of the work required to maintain the operational capability and efficiency of the crane. This work is
not stipulated by the manufacturer and must be performed by experience maintenance personnel.
Experienced Service Specialist
Authorized technician who is selected from among the people who have the necessary training, the
necessary competence and the skills in the areas of mechanics and electrical equipment to perform
unscheduled service on cranes.

EEx Crane Models

7.1-1

Overhaul
An overhaul comprises replacement of bearings and/or other mechanical components which display
so much wear and tear that the operation of the crane is adversely affected. In addition, an overhaul
includes a check of all of the crane components (gaskets, washers, deaeration valves, etc.). These
materials must be disposed of in conformity with applicable environmental protection laws.
Requesting Customer Service
Whenever you require technical customer service of any kind, please contact the manufacturers sales
network directly, providing the data shown on the type plate, the approximate number of operating
hours of the equipment and a description of the malfunction which has occurred.
Responsibilities of the Manufacturer
The manufacturer refuses to accept any responsibility whatsoever in the following cases:

Use of the crane in violation of national laws for safety and accident prevention

Incorrect installation, non-observance or erroneous observance of the instructions included in this

manual

Damage to the power supply or damage to the hydraulic supply

Modifications performed or damage caused by the customer himself

Work performance by untrained or unauthorized personnel

Safe operation of the crane also depends on strict observance of the regulations contained in this
manual. They include:

Use of the crane within its operational limits

Regular performance of proper maintenance

Assignment of personnel for inspections and servicing trained for this purpose

Exclusive use of original spare parts

Any configurations other than those shown the crane catalogue is

prohibited.

Not using the crane contrary to the given instructions.

The instructions in this manual are intended solely as a supplement to, not
as a substitute for, the applicable legal safety regulations.

7.1-2
7.1-2

EEx Crane Models

Technical Information
Description of the Crane
Safety Data for Cranes Conforming to Directive 94/9/CE

As a precaution, make selection with service factor

Use only synthetic lubricants (oil and grease).

Use washers made of VITON, for example, original Crane Power spare
parts.

Mount deaeration screws with spring return valve (e.g., for gear box).

The oil drain screws are made of steel.

The oil wiper rings have a dust protection lip.

Remove metal elements which could rub against the exterior surfaces of
the crane.

Do not use any plastic parts which could become electrostatically charged,
or insulate them appropriately.

Declaration of Conformity
Our cranes have been developed so that they are in conformity with the most important relevant safety
guidelines and the Machine Directive 98/37/CE; on request, they can also be certified by a
manufacturers declaration Appendix IIB, in combination with the Directive itself.

Cranes intended for use in potentially explosive atmospheres are

in conformity with the most important safety requirements of
Appendix II of the "ATEX" Directive 94/9/CE and satisfy the
following classifications:

Machine Group:

II

Category:

3G

Zone:

Gas 2

Max. surface temperature:

Temperature Class T4 for 3G (135 C)

Operational Limitations and Conditions

Modifications of the design or the mounting position
(e.g., of accessories) are permissible only after
previous consultation with and approval by the
technical customer service at CRANE POWER. If this
approval has not been granted, the ATEX
homologation expires.

EEx Crane Models

7.1-3

Ambient Conditions

The use of the crane in potentially explosive atmospheres or in areas where the use of
components protected from explosion is mandatory is prohibited, unless expressly stated
otherwise.
The data shown on the type plate regarding the
maximum surface temperature refers to
measurements taken under normal ambient
conditions and at a standard installation. Even the
smallest variations in these conditions (e.g., smaller
installation areas) may have significant effects on
heat development.

Lighting
When performing service work in poorly lighted areas, use
additional lamps so that the work can be carried out under safe
conditions and in accordance with the guidelines stipulated by
applicable laws.

7.1-3

Information on Safety
Safety Standards

Read the instructions contained in this manual carefully and apply them as appropriate directly to
the crane. Pay special attention to the safety instructions!

The service personnel for the crane must have the precise technical competence, special skills
and the necessary recognized experience in this special sector as well as the required equipment
and suitable personal protection, and know how to use it, for the entire service life of the crane. If
these conditions are not met, safety of operation may be reduced, leading to risks to the health of
the personnel.

Use the crane only for the purposes intended by the manufacturer. Using it for unintended
purposes may result in risks to safe operation and the health of the personnel and may also cause
economic losses.

The manufacturers intended purpose is of industrial

origin and is what the crane was designed to do.

Servicing the equipment at the stipulated intervals secures maximum efficiency of the crane.
Correct maintenance means best performance, long service life and long life of the safety
features.

When maintenance work is performed in areas which are difficult to access or dangerous, the
necessary safety conditions conforming to legal provisions regarding occupational safety must be
provided for the specialists doing the servicing and other personnel.

7.1-4

EEx Crane Models

Maintenance, service and repair work may be carried out solely by experienced service personnel
who are aware of any hazards which may exist. Precautionary measures which will intervene in
the event of a dangerous situation and eliminate the risk must be taken for the equipment as a
whole. The experienced maintenance personnel must always proceed with the greatest caution
and attention and strictly observe all safety standards.

During the operation phase, use only protective clothing and/or protective equipment which is
indicated in the operating instructions provided by the manufacturer and which is required by
current laws regarding occupational safety.

Replace all of the worn parts with original spare parts. Use only the oils and greases
recommended by the manufacturer.

Dispose of pollutant materials in conformity with applicable laws. Observe applicable waste
disposal laws during disposal.

Clean the surface of the crane and the steps in the working area after applying any lubricants.

When working on cranes which are used in potentially explosive

atmospheres, the repair personnel must without fail turn off the
power supply to the crane by switching it to out of service before
commencing work. Avoid any circumstances which could lead to an
unwanted restart or even to certain parts of the crane beginning to
move. In addition, all of the additional necessary precautions for
environmental protection must be taken (e.g., elimination of residual
gas, residual powder, etc.).

7.1-4

Information on Safety Specific to the Crane

Opening of EEx Protected Parts
Do NOT open ANY switch cabinets, power packs, electrical motors or other
components which are labelled EEx or protected on the crane without the
supervision of a professionally competent supervisor or monitor.

Danger from sparking!

Waiting time before opening

Any waiting time stipulated by the operating instructions for individual
components (electrical motor, etc.) must be observed to prevent
unexpected heat escape or sparking; if no waiting time has been
stipulated, wait a minimum of 5 hours.

The equipment must NOT be opened in a potentially

explosive atmosphere before the expiration of this
stipulated waiting time.

EEx Crane Models

7.1-4

Sliding Points
Gliding points must be thoroughly lubricated at specific intervals to
avoid electrostatic build-up. This is especially the case for bearing
points of plastic bearings (e.g., sleeve pack on the boom
extension).
Before Starting Up the Crane
Every time the crane is started up, a thorough visual inspection must first be conducted to ensure safe
operation (e.g., damage to paint, damage to coated load attachments, hooks, etc.).
No modification of EEx protected components

Generally speaking, mounted parts (radio control units, switch

cabinets, electrical outlets, etc.) may not be modified. This includes,
for example, painting over defined gaps or the replacement of original
screws, etc.
Moreover, it is prohibited to modify parts in such a manner that the
protection from penetration by dust, vapours, etc., is removed.

Winch
Special attention must be paid to winches (incl. rollers, intermediate rollers, bottom sheaves, etc.).
Danger from sparking! From collision of the bottom
sheaves with crane components in the upright
position! Strong rocking or oscillation of the bottom
sheaves! Poor winding or guiding of the cable! Worn
or breaking disc springs on the extension stop!

These parts should be monitored and/or serviced specifically before every start-up and as necessary
during operation to exclude these risks.
For example, the disc springs could be sealed or corrected to prevent sparking, or the cable guide
could be corrected by an authorized service centre.

7.1-4

EEx Crane Models

Hydraulic Components
Care must be taken that hydraulic components such as pumps do not run hot during operation as
defined by the temperature classes (T1 ... T6), or that these parts (including control valves, valves)
remain about 20 C below the maximum temperature permitted by the temperature class.
Classification of the Surface Temperature for Equipment in Group II G
Temperature Class
T1
T2
T3
T4
T5
T6

Max. Surface Temperature in [C]

450
300
200
135
100
85

Impacts

Danger from sparking! Impacts or jerky

motions with the crane should be avoided!

Material Combinations
Combinations of rusty steel (Fe) with aluminium (Al),
magnesium (Mg) or titanium (Ti) must be avoided.

Danger from sparking! Correct such situations

immediately, i.e., contact the contractual partner.
Suspend crane operation!
Shutting Down Crane Operation
Since there is a boom support on the crane column on
every crane, the crane must be moved at an
appropriately slow speed with the extension system
into this boom support.

Danger from sparking! Electrostatic build-up!

EEx Crane Models

Crane Settings
None of the crane settings may be modified.
With the company Crane Power the changes
must be co-ordinated.

Danger from sparking! Speeds which are set too high

(e.g., for the winch) are likely to cause a collision!

General
Normally the cranes are classified as EEx II 3G T3 (T4). The classification of the electrical
components is EEx II 2G d IIB (T4).
Otherwise, operation is to be conducted in accordance with EN 13463 (cleaning, etc.).

7.1-4