Safety instructions

1 It is also in your own interest to observe these instructions

very carefully.

Before operation of the crane

2 This chapter provides you with important safety instructions

which must be followed each time before starting operation.

Start operation of the crane

3 This chapter gives you all the necessary information to

properly start operation of your crane.

Crane operation

4 This chapter provides you with the necessary information to

properly operate your crane.

After crane operation

5 This chapter provides you with a summary of the necessary

instructions to safely finish work with your crane.

Maintenance and service

6 This chapter provides you with the necessary information to

properly maintain and service your crane.

Appendix

7 EEx - Crane
Safety instructions Chapter 1
1 Safety instructions

CONTENTS

1.1 AN OVERVIEW OF THE DANGERS

1.1-1 RULES FOR THE AVOIDANCE OF DANGERS

1.2 PREREQUISITES
1.2-1 CE-SYMBOL

1.2-2 ASSEMBLY, ACCEPTANCE AND REGULAR INSPECTION OF THE CRANE UNIT

1.2-3 REQUIREMENTS FOR THE OPERATING PERSONNEL

1.2-4 SAFETY DEVICES NOT TO BE TAMPERED WITH

1.2-5 CRANE OPERATION IN ADVERSE OPERATING CONDITIONS

1.2-6 INTENDED USE

1.3 DURING CRANE OPERATION

1.3-1 AVOID DANGER OF CRUSHING

1.3-2 DANGER OF BURN INJURIES

1.3-3 KEEP DISTANCE FROM POWER LINES

1.3-4 ACTION IN THE EVENT OF FLASHOVER

1.3-5 ACTION IN THE EVENT OF DEFECTS

An overview of the dangers 1.1-1
1.1 An overview of the dangers

1.1-1 Rules for the avoidance of dangers

1. General safety instructions

Operation only by trained personnel.

Safety devices not to be tampered with.
Prescribed safe distances to be maintained.
Safe distances from electric power lines to be maintained.
Be alert to faults during crane operation.

2. Prior to crane operation

Pay attention to effluent hydraulic oil.

Make a visual inspection.
Check the safety devices before start-up.

3. On start-up

Use the right hydraulic fluid for the temperatures.

Check the heel / load diagram.
Remove the extensions before unfolding.

4. During crane operation

Ensure the crane is used according to the specifications.

Keep an eye on the working area.
Do not stay in the danger area of the crane.
Safeguard the working area.
Select the right control stand.
Pick up and secure loads in the due and proper manner.
Use of load lifting gear and ancillary equipment supplied by PALFINGER MARINE
Secure attachment of ancillary equipment.
Adherence to the max. lifting capacity of the crane, ancillary equipment and load lifting gear.
No load moment increase when lowering the load.

5. After crane operation

Secure crane in transport position.

Switch off hydraulic pump.
Observe maximum head room on bridges, etc.

6. On maintenance and lubrication

Carry out maintenance work only when the machine is inoperative.

Keep steps, standing areas and handles clean.
1.2-1 Prerequisites
1.2 Prerequisites

1.2-1 CE-Symbol
If your crane is marked with a CE symbol it meets the requirements of the machine directive of the
EEA (European Economic Area).

This symbol is only valid in connection with a conformity declaration issued for your crane.

The firm mounting the crane on the ship must issue a conformity declaration. If constructional changes
are made to the crane (e.g. mounting of a rope winch, remote control, raised stand or raised seat, etc.)
the CE symbol must be re-issued by the firm mounting the equipment (new conformity declaration).

If the crane bears a CE symbol, it must be fitted with an overload safety device.

Ancillary equipment must bear its own CE symbol.

In the EEA and certain other countries the crane may only be operated if it has a valid CE symbol and
valid conformity declaration.

1.2-2 Assembly, acceptance and regular inspection of the crane unit

The crane must be assembled according to the valid assembly rules of PALFINGER MARINE.

In addition, national regulations and guide-lines regarding installation must be observed and the
official acceptance must proceed according to the regulations in force.

The firm responsible for assembly must on handing over the crane instruct the crane operator in the
operation of the crane and point out to the crane operator all possible dangers and risks of injury.

On handover of the crane the customer is to be given the maintenance manual, operating instructions
(including assembly-related additions), and the conformity declaration for the EEA.

The firm operating the crane is responsible for ensuring that the regular inspections required by law
are carried out.

Any use other than the one intended by the company PALFINGER MARINE as well as constructional
changes that affect the stability of load-bearing components need to be approved by the manufacturer.
Prerequisites 1.2-3

1.2-3 Requirements for the operating personnel

Operation of the crane requires skill, ability and experience.

Therefore only entrust persons with the operation of the crane:

who are physically and mentally suitable for this (not tired, and not under the influence of alcohol,
drugs or medication).
who handle the crane responsibly and reliably.
who have the right qualifications (training, crane operator’s license).
who can prove that they have been instructed on how to operate the unit described here and who
are familiar with the content of these operating instructions. This also applies to the operating
instructions for ancillary equipment used on the crane.

If the crane is operated by a person without crane operator’s license

and training on this machine there is acute danger of accident.

Observe the regulations valid in your country!

1.2-4 Safety devices not to be tampered with

Safety devices serve to protect you and were developed to avoid accidents and make your work safer.
On delivery safety devices such as Emergency Off, load holding valve, pressure relief valve, etc. are
adjusted to ensure safe crane operation (4.2).
They must on no account be interfered with or rendered inoperative.

Caution:

If safety devices are tampered with or if lead seals are damaged, any warranty on the part of the
manufacturer will cease to apply!

If safety devices are tampered with you put yourself and other
persons at risk of fatal injury.

1.2-5 Crane operation in adverse operating conditions

Safe operation of the crane can no longer be assured if winds are in excess of 50 km/h. If the wind
exceeds this speed, the crane must not be put into operation or operation must stop.
Our cranes may be used at ambient temperatures ranging from -30º C to +50º C. If the temperature
drops below or exceeds these limits, operation must be discontinued as it can lead to damage to the
hydraulic components.

1.2-6 Intended use

Use the crane only for handling loads; mechanical interventions (pushing or driving against obstacles),
fastening of loads at points other than those provided for this purpose, pulling of loads, etc. are
prohibited. Manufacturer will accept no liability for damage caused by doing so.
1.3-1 During crane operation
1.3 During crane operation

1.3-1 Avoid danger of crushing

Avoid operating situations in which there is a risk of you or bystanders being crushed by the crane, or
load.

The crush point is not regarded as a danger point for the body parts stated if the safety distances
highlighted below are complied with and it is ensured that the next-biggest body part cannot penetrate.

Required minimum distances:

Body Leg Foot Arm Hand Finger

500 mm 180 mm 120 mm 100 mm 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
= up to .......à 1.500 V ..... 1,0 m
DC over ........à 1.500 V ..... 1,5 m

~ up to .......à 1.000 V ..... 1,0 m

AC over ........à 1.000 V ..... 1,5 m

B
up to ............ 1.000 V ........... 1,0 m
1.000 ........... 110.000 V ....... 3,0 m
110.000 ....... 220.000 V ....... 4,0 m
220.000 ....... 380.000 V ....... 5,0 m
unknown voltage .................. 5,0 m

1.3-4 Action in the event of flashover

If the crane touches a power line only your correct reaction can prevent a serious accident. If you
touch the crane, ship, load or if you try to leave your location you will put yourself in acute danger of
fatal injury.

Stay calm.
Persons in the vicinity must keep a distance of at least 10 metres from the ship, crane and load
(resistance area).
If the power line has been cut and is touching the ground a distance of at least 10 metres must
likewise be maintained (resistance area).
If there is a person within this 10 metre area this person may leave the danger area only by
hopping with legs tight together (step voltage).
Do not touch the crane, ship or load.
Warn bystanders not to touch the ship, crane or load and not to approach.
Do not attempt to leave the operating stand; and do not touch any metal parts there.
Indicate that the power lines must be disconnected.
If you are on the loading area or in the operator’s cab of the ship, do not leave this location. It is
essential you remain where you are.
If someone is in the electric circuit the power line must be disconnected before this person can be
removed; if you approach the person before the power is switched off you will put yourself in
danger of fatal injury.
1.3-5 During crane operation

1.3-5 Action in the event of defects

Observe the crane during operation for any sudden signs of any defects.

If you discover the following damage or defects to the crane, ancillary equipment, load lifting
gear or fixing from the crane you must stop crane operation immediately:

Damages or cracks on load-bearing parts.

Defect bearings.
Defects in the hydraulic unit or safety devices.
Loose screwed connections.
Inadequately secured bolt connections.
Leaks on hydraulic components or connections.
Unusual noises.
Unusually quick or slow working movements.
Functional errors in the control system.
Unusually high temperature of hydraulic components.

In the case of the above-mentioned damage or defects safe crane

operation is no longer ensured. There is acute danger of accident
and thus of fatal injury.

The crane may only return to service when the defects have been removed and safe working is once
again assured.
Before operation of the crane Chapter 2
2 Before operation of the crane

Contents

2.1 CHECKS

2.1-1 DAILY VISUAL INSPECTION

Checks 2.1-1

2.1 Checks

2.1-1 Daily visual inspection

Check the crane and its mounting once daily for visible defects, damages or alterations.

The “man-riding” basket has to be maintained and protected against corrosion on a regular basis. This
action is absolutely necessary as corrosion may lead to a wall thickness reduction (3 mm).

Carry out this inspection very carefully every time: alterations or damages not detected because of
carelessness or old habits are a major source of accidents.

Carefully check:

Screw fittings, connections, and other parts of the hydraulic system for damages or oil leaks.

Leaks of hydraulic oil may lead to dangerous accidents and cause

considerable environmental damage and pollution.

Whether bolts and screw fittings are properly fixed.

For defective bolt connections.
The smoothness and the return motion of hand levers.
Load bearing parts, accessories, load holding attachments
(grab, winch, etc.) for cracks and damages.
Defects in paintwork.
Corrosion.

When such defects are detected, immediately cease operation of the

crane.

If your crane is equipped with safety devices such as an emergency CUT-OFF, an overload protection
system or a rope winch limit stop, always carry out a function test on them before operation.

Proceed as described in chapter 4. Always pay attention to the safety instructions!

If the safety devices do not work, operation of the crane is strictly

prohibited.

Carry out this inspection very carefully every time: carelessness and old habits are a major source of
accident.
Start operation of the crane Chapter 3
3 Start operation of the crane

CONTENTS

3.1 AN OVERVIEW OF THE CRANE

3.1-1 DESIGN (PTM XXX)

3.1-2 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

An overview of the crane 3.1-1
3.1 An overview of the crane

3.1-1 Design (PTM xxx)

3.1-1 An overview of the crane

1 Base 13 Boom extension

2 Turntable 14 Boom extension ram
3 Crane column 15 Filler filter, ventilation filter
4 Slewing gear 16 Engine
5 Lifting cylinder 17 Pump
6 Main boom 18 Slip ring body
7 Rope winch 19 Bore hole for oil drain (2x)
8 Rope 20 Glass gauges (min., max.)
9 Pulley head 21 Switch cabinet
10 Load attachment Oil cooler
11 Standing platform Oil heating
12 Cab
An overview of the crane 3.1-2

3.1-2 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 Extension booms Rope winch

clockwise / counter clockwise lower / lift extend / retract unwind / wind

Rotator Grab
clockwise / counter clockwise open / close
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:

Check the oil level.

Switch on the pump assembly at lowest engine speed.
40
30 Let the oil pump around without pressure for a few minutes so that it
20
10 warms up a little.
0
-10
-20
-30
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

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 crane’s 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:

PTM xxx:

Observe every safety instruction mentioned in chapter 1.

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.

The crane is now ready for operation.

Crane operation Chapter 4
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 ROPE WINCH

4.3-3 STANDING PLATFORM, TOP SEAT, CABIN, PROTECTION COVER

4.3-4 REMOTE CONTROL

4.3-5 EMERGENCY OPERATION FOLLOWING FAILURE OF THE REMOTE CONTROL

CONSOLE
During crane operation 4.1-1
4.1 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 During crane operation

4.1-2 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.

With heavy loads there is risk of excessive heel!

Therefore: Observe the inclination and load diagrams!

At load (100%): At load (80%):

max. 5° Heel max. 15° Heel
max. 2° Trim max. 2° Trim

A = Inclination
B = Lifting moment
C = Slew load
D = Hold load
4.1-3 During crane operation

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.

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.

Load capacity label for a crane:

1. Angle specification for ideal main

boom position
2. Range of coverage specification
3. Load capacity values
Safety devices 4.2-1
4.2 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.
4.2-2 Safety devices
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 im-
mediately 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

Extension boom ................................................................................. 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.
Safety devices 4.2-3
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

Extension boom ................................................................................ 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.

During the lowest main boom position (lifting cylinder fully retracted) the overload protection system is
deactivated, since the lifting cylinder is on mechanical stop. Raise therefore main boom absolutely
somewhat.
4.2-4 Safety devices

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
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.
Additional equipment 4.3-1
4.3 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 crane’s operating instructions refer to the
operating instructions for the load fixing tool or accessory you are using.

For some accessories, a special suspension from 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 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.

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.
4.3-2 Additional equipment

4.3-2 Rope winch

For rope winch operation only use 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)

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

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.
Additional equipment 4.3-2

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.

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!
4.3-2 Additional equipment
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°.

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 load-
bearing 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.
Additional equipment 4.3-3
When work is done with a fully extended hydraulic extendable arm
and the load-bearing arm in a near-vertical 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 load-
bearing 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.

4.3-3 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!
4.3-3 Additional equipment

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
Additional equipment 4.3-4

4.3-4 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. Don’t 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.
4.3-5 Additional equipment

4.3-5 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 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 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 Chapter 5
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
Ending crane operation 5.1-1
5.1 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:

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

PTM xxx:

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”.
Then wind up the rope using the function „Wind rope winch“ until the load suspension is sitting
tightly on the pulley head.

Slew the crane into transport position using the function „Left, right slew“.
5.2-1 After crane operation
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).

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 Chapter 6
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 (PTM XXX)

6.1-4 LUBRICATION

6.1-5 HYDRAULIC OILS

6.1-6 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

Maintenance 6.1-1
6.1 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 every 50 operating hours or once every year

1st service
Oil filter change

After every 50 operating hours or once every year

Rotary distributor (slew 360 degrees)

6.1-2 Maintenance
After every 50 operating hours or once every year

1 Turntable (360° slew)

2 Continuous rotation
2 Thrust bearing
2 Gear oil (inspection glass, fuel lever plunger)
3 Main boom cylinder pivot
4 Main boom pivot
5 Rope winch
6 Rope
7 Pulley head
8 Load hook, function control of safety flap
9 Thrust turntable
10 Fixation of crane base
11 Cab rotating
12 Boom extension rams - guide parts, pivot guide
13 Extension booms - guide blocks
14 Guide pulley
Tighten up, fittings, pipes and hoses
Repairing paint damage

After every 50 operating hours or once every year

Oil filter, hydraulic oil change

Rope winch – hydraulic oil (see data sheet)
Slewing system – gear oil

Rope
Visual check Grease Oil spray Screw Machinery oil SAE 90
grease
Maintenance 6.1-3

6.1-3 Plane of maintenance (PTM xxx)

6.1-4 Maintenance
6.1-4 Lubrication
The following maintenance and care instructions apply to all 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
Technical Data
to:
Structure smooth
Consistence (NLGI) 2 DIN 51818
Designation KP2K-35 DIN 51502
Dropping point °C 150 DIN ISO 2176
Worked penetration 265/295 1/10 mm DIN ISO 2137
Oxidation stability 100 h / 100 °C max. 0,2 bar DIN 51808
Basic oil viscosity at 40° >80 mm²/s
Behaviour in water Water resistant DIN 51807-1

Boom extensions / mechanic extensions, etc:

Inspected
Technical Data
according to:
Type designation OMV whiteplex 1 (EZ 739)
Thickener type Al-Komplex
Temperature range -30° C to +190° C
Consistence (NLGI) 1 DIN 51818
Specification K 1 R-30 DIN 51825
Dropping point °C 240 DIN ISO 2176
Worked penetration 300 mm/10 DIN ISO 2137
Flow pressure at -15° C - hPa
Flow pressure at -25° C 500 hPa DIN 51805
Flow pressure at -30° C 900 hPa
Basic oil viscosity at 40° 220 mm²/s
Behaviour in water Water resistant DIN 51807-1
Maintenance 6.1-4
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.

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.

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.
6.1-5 Maintenance

6.1-5 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.
Maintenance 6.1-5
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 PALFINGER
MARINE work platform:
Operating limits

Recommended
range
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 30°C and 60°C.

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.
6.1-5 Maintenance
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
Toothed wheel
Biodegradable Lubricating
Manufacturer: Mineral oils: Gear oils: grease:
oils: 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 Synthofluid Avia Gear RSX Avia Aluplex 0
AVIA Avia Fluid HVI 32 Avia TAC BB 21
46 N 150 RHS
Castrol Grease
CASTROL Hyspin AWH 32 Carelube HES Alpha SP 150
CL
Spectron ZFK
DEA Astron HVLP 32 Econa E 46 Falcon CLP 150 Caron WAW EP 2
EPO
Biohydran TMP
FINA Hydran TSX 32 Giran L 150 Merkan DT 95 Cabline MGR
32
Plantohyd Super
FUCHS Renolin B HVI 32 Renolin CLP 150 Almetyn 2 Ceplatyn 300
S
Mobilgear OGL
MOBIL Mobil DTE 13 M Mobil UF 46 Mobilgear 629 Mobilgrease HP
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

Ultramax HVLP
VALVOLINE Ultrasyn HE 46 EPG 150 Val – Plex EP 2 MP Molly Grease
32
WINTERSHALL Wiolan HVG 32 Wiolan HE 46 Ersolan 150 Wiolub LDF
Maintenance 6.1-6
6.1-6 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
Mineral oils 1 2

Biodegradable oils

Natural esters 1 2

Fully synthetic esters 1 2

The relevant local laws, regulations and guidelines apply to the

disposal of wastes, residues or used materials!
6.1-6 Maintenance
The following nomogram gives the service life of the fully synthetic ester oils:

Max. oil
Service life in temperature
years

Working hours
per year

The hydraulic oil service should be performed before each cold weather period, or at least once a
year. The complete hydraulic system and the hydraulic oil tank must be thoroughly clean before filling
them with new oil. Please observe that it must be filled only with clean, filtered hydraulic oil.

Instructions:

• Move crane into transport position.

• Remove the filling socket with coarse filter (A)
and flange plate.
• Discharge the old oil through the oil drain (B).
• Suck out the oil residues absolutely thoroughly.
• Clean the filling socket (A) and its surrounding.
• Reassemble the filling socket with the coarse
filter (A) and flange plate.
• Fill clean oil in the tank up to the upper mark.

A = filling socket, coarse filter

B = oil drain
Maintenance 6.1-6
Tank volume:

PTM 190 140 litres

PTM 330 280 litres
PTM 580 420 litres
PTM 850 600 litres
PTM 1100 800 litres
PTM 1700 1000 litres

Power supply:

The oil supply for the hydraulic system is completely integrated in the crane column. The pump
enclosure is located in the lower part of the crane column and is totally separated from the tank. A
large removable plate beside the control stand enables access to this area.

The following elements are in the pump room:

Hydraulic pump
Shut-off cock for the suction line (A)
Shut-off cock for the drain line (B)

A
B
6.1-6 Maintenance
Water trap:

Major fluctuations of oil temperature -25 deg to +60 deg may occur during operation of the crane, all
depending on location and weather conditions. Condensation in the oil tank is therefore unavoidable.
In order to protect against damages due to frost, a drain fitted beside the control stand which allows to
be drained accumulated condensation water.

A = Water trap
Cleaning the plant 6.2-1
6.2 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 high-
pressure 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.
6.2-2 Cleaning the plant

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!

Degrease damaged paint.

Apply primer.
Apply top coat.

6.2-3 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 Chapter 7
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 7.1-1
7.1 EEx – Crane Models

7.1-1 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 manufacturer’s 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 EEx – Crane Models

7.1-2 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 PALFINGER MARINE
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
manufacturer’s 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 PALFINGER MARINE. 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 manufacturer’s 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 Max. Surface Temperature in [°C]

T1 450
T2 300
T3 200
T4 135
T5 100
T6 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 7.1-4
Crane Settings

None of the crane settings may be modified.

With the company PALFINGER MARINE 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.).

 Supplement
Original operating manual
Hydraulic Marine Crane

PTM1800

Valid for serial number 510007119

Edition 01/2018
Palfinger Marine GmbH
Franz-Wolfram-Scherer-Straße 24
5020 Salzburg / Austria
www.palfingermarine.com
Dear customer,
thank you for purchasing and putting your faith in a quality product from
PALFINGER. During the development and manufacture of your unit,
everything was done to ensure that the equipment operates reliably and
safely.
Please note the information that follows so that you can work with your
PALFINGER product reliably and cost-effectively over the long term.
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 great success with your PALFINGER product!
 Contents

Contents

Notes regarding the operating instructions .........................................................1

Supplement to the operating instructions ......................................................................... 3
Operating instructions....................................................................................................... 3
Validity of operating instructions ....................................................................................... 4
Symbols ............................................................................................................................ 4
Graphics and pictures....................................................................................................... 5
Supplement to equipment number 510007119-21 ................................................7
Main components ............................................................................................................. 9
Operating panel .............................................................................................................. 13
General ........................................................................................................................... 24
PALOPS system ............................................................................................................. 25
Signal column ................................................................................................................. 27
Slewing ranges ............................................................................................................... 28
Control box main operation / emergency operation ........................................................ 30
Failure of electric system ................................................................................................ 32
Index .......................................................................................................................35
 Chapter 1

CHAPTER 1

Notes regarding the operating

instructions

In this chapter
Supplement to the operating instructions .................................................... 3
Operating instructions ................................................................................. 3
Validity of operating instructions ................................................................. 4
Symbols ..................................................................................................... 4
Graphics and pictures ................................................................................. 5

1
 Chapter 1 Notes regarding the operating instructions

Supplement to the operating instructions

These operation instructions supplement the standard operating instructions.
The special functions described in these operating instructions,
are not included in the standard operating instructions.
they replace the respective functions in the standard operating instructions.

Operating instructions
The operating instructions have been prepared to explain operation of the unit.
The operating instructions are part of the unit.
Always keep the operating instructions with the unit (operator station).

Note!
In case of damage or loss of these operating instructions please
contact your PALFINGER MARINE partner and request a new copy.

Neither the operating instructions nor the technical sheets replace proper operator training.
Please contact your PALFINGER MARINE partner immediately if there is anything in this operating
instruction which requires explanation. We appreciate any suggestions received from our customers;
they help us to make the operating instructions ever more user friendly.
PALFINGER assume no responsibility for the translation. In case of faulty or inaccurate translations the
German version of the present operating instructions shall prevail.

Changes since going to press

PALFINGER is anxious to apply the latest and most advanced technology in their devices by further
development. This may result in deviations between operating instructions and the actual unit.
Please contact your PALFINGER MARINE partner immediately if any function in this operating
instruction is described insufficiently or incorrectly.
The specifications, pictures and descriptions shown in these operating instructions do not qualify for
any legal claims against operating company, operator or PALFINGER MARINE partner.

Copying (even in extracts) only permitted with written

approval from:
© Copyright by PALFINGER MARINE PALFINGER MARINE GmbH
GmbH Franz Wolfram Scherer Straße 24
A - 5020 Salzburg / Austria
www.palfingermarine.com

3
Notes regarding the operating instructions

Validity of operating instructions

These operating instructions are only valid for the equipment shown on the front page. They are only
applicable in conjunction with the operating instructions from all other auxiliary equipment that is used
on the equipment/vehicle.

Symbols
The layout of the operating instructions is designed to make important notes, instructions or warnings
particularly clear by using symbols and signaling words.

Danger!
These symbols and the Danger! signal word are used for immediately
threatening dangers of fatal injury.
Ignoring this instruction will result in death or serious injury for
operator and others.

Warning!
These symbols and the Warning! signal word are used for immediately
threatening dangers.
Ignoring this instruction could result in death or serious injury for
operator and others. Damage to the unit or property can also result.

Note!
The symbol and signal word are used for particularly important notes
which make working with the unit easier.

Symbol for operating lever:

In neutral position Operated

4
 Chapter 1 Notes regarding the operating instructions

Graphics and pictures

Note!
Some of the pictures (for instance of the crane) in these instructions
are symbolic representations and for illustration only.

5
 Chapter 2

CHAPTER 2

Supplement to equipment number

510007119-21

In this chapter
Main components ....................................................................................... 9
Operating panel ........................................................................................ 13
General .................................................................................................... 24
PALOPS system ....................................................................................... 25
Signal column ........................................................................................... 27
Slewing ranges ......................................................................................... 28
Control box main operation / emergency operation................................... 30
Failure of electric system .......................................................................... 32

7
 Chapter 2 Supplement to equipment number 510007119-21

Main components
The illustrated crane is an example and shows components which may be optional on your unit,
depending on model and version.

9 29 21 14

11 15
16

8
13

21

27

23
12

19

20

7 26 1

9
Supplement to equipment number 510007119-21

10 6

22

24

28
17

3
18
5
4

25

Find the names of the main components on the next page.

10
 Chapter 2 Supplement to equipment number 510007119-21

Designations of the main components:

1 Mounting base with flange

2 Ball slewing ring

3 Crane column

4 Slewing gear

5 Hydraulic motor for rotary actuator

6 Main boom

7 Lifting cylinder

8 Extension booms

9 Extension cylinders for extension booms

10 Rope winch with cover

11 Lightning conductor

12 Load rope

13 Load cell

14 Pulley head

15 Top stop

16 Single-strand load attachment

17 Filler filter, ventilation filter

18 Emergency power unit

19 High stand

20 Ladder

21 Lighting system for aviation

22 Wind sensor

23 Signal column

24 Cable drum

25 Maintenance window

26 Rotation limiter (inside)

27 Advantech display

28 Platform for rope winch

29 Working lights

11
Supplement to equipment number 510007119-21

Radio remote control

Arrangement of keys and buttons on remote control handset. See also operating instructions for radio
remote control.

3 4 5 6 7 8 9 10 11 12

1 1

13

18 17 16 15 14
1 Operating lever for crane functions 10 Emergency-stop button
2 Connector for cable operation 11 Not used!
Parking position button - not used! /
3 Platform / OLP button - not used! 12
Working lights
Key switch for radio remote control
4 Override of rotation limiter 13
ON / OFF
5 Speed rotary control 14 Warning horn
Crane operation: Push-button
6 SWH 1.5 mode of operation 15
START
7 SWH 2.5 mode of operation 16 Not used!
Battery capacity / radio signal status
8 Not used! 17
indicator
9 LED indicator 18 Not used!

12
 Chapter 2 Supplement to equipment number 510007119-21

Operating panel
The operating panel enables crane operation from the operator station in combination with the control
valve levers for the respective crane functions.
The panel is equipped with switches, buttons and indicator lights that indicate the status of the unit.

1 Emergency-stop button

2 Warning horn button

'Crane operator station / radio remote

3 control' mode selector button

1 4 ‘Platform' mode selector button

F1 function key
5 'SWH 1.5 mode of operation'
F2 function key
60 70 80 90 100
6 'SWH 2.5 mode of operation'
12
F3 function key
2 13 7 Override of rotation limiter

14 'CT Constant rope tension' mode of

3 8 operation button
RESET

15 Not used!
4
9 Confirmation button
6
5 'Cargo / man-riding' mode of
7 10 operation key switch Inactive!
8 'Man-riding' indicator light active
16 11 Not used!
9
CARGO MANRIDING
12 60...100% capacity indicator LED
10 'Rope winch overloaded'
17 13 indicator light
11 MR
ACTIVE 14 'Crane overloaded' indicator light

OLP button.
15 Not used!
Parking position button
16 Not used!

17 MOPS button

13
Supplement to equipment number 510007119-21

Note!
After having switched on the unit, all indicator lights on the panel and
the warning horn activate for a short time.
This is for the operator to check that all indicator lights and the
warning horn function properly.
If any defect occurs, contact a PALFINGER MARINE partner.

All the functions of the various buttons, switches and indicators are described below.
For the control system functions refer to the 'Shipboard control system' operating instructions.

1. Emergency-stop button
The device is equipped with an electrical emergency-stop button.
The emergency-stop button stops all crane functions within 0.5 seconds (500 ms) after activation in an
emergency situation.
Located on every operating station.

1. In dangerous situations let go all operating levers immediately.

2. Press the emergency-stop button until it locks.
All crane functions stop.

Caution!
Releasing the emergency-stop button before ensuring safe crane
operation leads to acute risk of fatal injury.

Release the emergency-stop button only in safe working conditions.

14
 Chapter 2 Supplement to equipment number 510007119-21

2. Warning horn button

With the horn people that are about to enter the working/danger area can be
warned of the danger.

The audible alarm (a signal the operator can hear) gets activated:
If the constant rope tension operating mode (8) or MOPS (17) buttons have been actuated.
60% / 100% capacity indicator LED - When the crane reaches the 90% capacity limit, an
intermittent audible warning sounds.
60% / 100% capacity indicator LED - When the crane reaches the 100% capacity limit, a
continuous audible warning sounds. Only those movements are permissible that reduce the load
torque.

3. 'Crane operator station / radio remote control' mode of operation button

1. Press the 'Crane operator station / radio remote control'

mode of operation button (A).
2. The indicator lights (B) and (C) are flashing.
3. Shortly after press the confirmation button (D) - otherwise
the selection will be stopped.
4. The modes of operation 'Crane operator station' or 'Radio
remote control' are active.
Solid light in light indicator (B) = 'Radio remote control' mode
of operation is active.
Indicator light (B) is off = 'Crane operator station' mode of
operation is active.

Note!
After having switched on the crane, the 'Crane operator station' mode
of operation is always active.

15
Supplement to equipment number 510007119-21

4. ‘Platform' mode selector button

Working conditions may vary greatly, for instance
Working on a platform
Working on a platform while loading and unloading a supply vessel
Therefore it is necessary to adjust the load capacity to the current working conditions (wave height,
wind speed).

Caution!
It is only allowed to change the operating mode when there is no load
on the crane. The load or workman basket may fall down, and this
poses an acute risk of fatality for the operator and others.

Note!
After having turned on the crane it is always necessary to activate the
required mode of operation. The indicator light of the required mode
of operation must be on.
'Platform' mode of operation
F1 function for SWH 1.5
F2 function for SWH 2.5

B 1. Press the button for 'Platform' mode of operation (A).

2. Indicator lights (B) and (C) flashing.
A 3. Shortly after press the confirmation button (D) - otherwise
the selection will be stopped.
4. 'Platform' mode of operation is active.
Solid light in light indicator (B) = 'Platform' mode of operation
C is active.
Indicator light (B) is off = 'Platform' mode of operation is
inactive.
D

1. Press function key F1 or F2 for the required mode of

operation - 'SWH 1.5' (F1) or 'SWH 2.5' (F2).
B 2. The respective indicator lights (B) and (C) start flashing.
3. Shortly after press the confirmation button (D) - otherwise
the selection will be stopped.
A The selected function is active.
All indicator lights (B) are off - both functions F1 and F2 for the
C modes 'SWH 1.5 or 2.5' are inactive.
Solid light in one of the indicator lights (B) - the function
indicated by F1, or F2 for the respective mode of operation
D 'SWH 1.5 or 2.5' is active.

16
 Chapter 2 Supplement to equipment number 510007119-21

Note!
Load capacities and the maximum wave heights defined for the
modes of operation are shown on the load capacity label.

Warning!
The operator is responsible for selecting the correct mode of
operation!
When you choose the necessary mode of operation take into account:
Place of use and purpose.
Environmental conditions (swell, wind speed).
Load capacity chart, associated operating manuals.

5. F1 function key
Refer to 'Platform' mode selector button (Page 16).

6. F2 function key
Refer to 'Platform' mode selector button (Page 16).

7. F3 function key for overriding the rotation limiter

Caution!
If the load arm remains in the blocked range after crane work has been
finished there is severe risk of accident and danger of injury.

Overriding the rotation limiter:

1. Slew the crane until it stops moving. The factory set end position has been reached.
2. Before slewing the unit into the blocked range the operator must always make sure that the crane
will not collide with any obstacle.

17
Supplement to equipment number 510007119-21

3. Press and hold F3 function key (A).

B 4. Indicator light (B) is on.
5. F3 function is active as long as the key is being
A held.
No light in indicator light (B) = F3 function inactive.
Solid light in light indicator (B) = F3 function active.

6. Crane can be rotated further.

Letting the F3 key go deactivates overriding immediately. The audible warning signal stops. The crane
cannot be rotated any further.
After finishing crane work slew the crane to the permitted range and set it down on the boom support, if
available.

8. Rope tensioning operating mode button

Button not used!

9. Confirmation button
The Confirmation button is a security prompt that needs to be confirmed every time
the operator changes the mode of operation.
The flashing light indicator (LED) indicates that the security prompt is active.

Note!
Simultaneously the light indicator (LED) of the selected mode of
operation is flashing. If you do not confirm the selection within 5
seconds, it will be stopped.

18
 Chapter 2 Supplement to equipment number 510007119-21

10. 'Cargo / man-riding' operating mode key switch

The 'cargo / man-riding' operating mode key switch is inactive. Although a key is in the operating panel
it is not possible to use it for selecting an operating mode.

Note!
Although the key switch is inactive the 'Cargo' operating mode must
be selected.

11. 'Man-riding active' indicator light active

The crane is not equipped with a man-riding rope winch. The light indicator is not used!

12. 60%....100% capacity LED

The crane can optionally be equipped with a capacity indicator and acoustic warning. The capacity
indicator and the acoustic warning do not protect the crane from overloading.

Option 1, visually:

Capacity indicator LED:

1 2 3

1 Green (< 90%)

2 Yellow (90% - 100%) Reduce operating speed

3 Red (> 100%) Reduce load torque immediately

Always pay attention to the capacity indicator while working with the crane.

Note!
When an emergency-stop button has been pressed, this is indicated
by all LEDs flashing on the operating panel.

19
Supplement to equipment number 510007119-21

Option 2, visually + acoustically:

Green + ---
1
(< 90%)

Yellow + intermittent warning sound

2 Reduce operating speed
(90% - 100%)

Red + continuous sound

3 Reduce load torque immediately
(> 100%)

Always pay attention to the overload indicator and the acoustic signal while working with the crane.

Caution!
If the load torque is not reduced immediately upon reaching the red
overload range and/or when continuous tone sounds, the crane gets
overloaded. The load may sink uncontrollably. There is severe risk of
fatal injury!

It is prohibited to work in the red range and with continuous sound.

While working in the limit range, do not increase

the horizontal reach any further when lowering
the load.

20
 Chapter 2 Supplement to equipment number 510007119-21

13. 'Rope winch overload' indicator light

Hydraulic overload protection:

If crane movements that increase the load torque are not possible because of the rope winch (cut-off),
take the following steps to release the crane functions:

Movements that increase the load torque will then be blocked:

Rope winch Lift (hoist)

Main boom Lower / raise

Extension boom Extend

The crane functions will only be released when the load torque has been reduced.

Land the load.

All crane functions are operable again.

21
Supplement to equipment number 510007119-21

14. ‘Crane overload’ indicator light

Hydraulic overload protection:

When the crane reaches the overload range all functions that increase the load moment get blocked,
only those functions are still enabled that reduce the load moment.

Movements that increase the load moment will then be blocked:

Main boom Lower

Extension boom Extend

Rope winch Lift (hoist)

The crane functions will only be released when the load moment has been reduced.

Press the lever 'Retract extension booms' until

all crane functions are released.

or

Land the load.

All crane functions are operable again.

Warning!
The load moment increases while the main boom is being lowered
above the horizontal.

15. OLP button

Button not used!

16. Parking position button

Button not used!

22
 Chapter 2 Supplement to equipment number 510007119-21

17. MOPS button (option)

The MOPS safety system (manual overload protection system) is necessary for instance when the load
or hook tangles up on the vessel or drifts away from the crane.

On pressing the MOPS button a continuous warning tone sounds and

the brake of the rope winch releases. The load rope gets unwound
with low resistance.
By letting the MOPS button go, you deactivate the function.

Caution!
If the MOPS button is activated while a load is hanging on the hook,
the load will immediately fall down uncontrollably. This represents an
acute risk of fatal injury for everybody near the load.
Additionally this may cause severe damage to the vessel or platform,
etc.

Note!
In man-riding operating mode it is not possible to activate the MOPS
button.

23
Supplement to equipment number 510007119-21

General
PALFINGER MARINE has developed safety systems that protect the operator and the unit in order to
guarantee safe operation.
Safety systems are adjusted before delivery of the unit to the operating company/operator.

Caution!
Any unauthorized manipulation to the safety equipment leads to
danger of fatal injury.

Only PALFINGER MARINE service partners are allowed to set up and adjust the safety equipment.
Manipulating or inactivating the safety equipment is not allowed.

Note!
Any warranty and liability of the manufacturer will expire if
unauthorized persons manipulate the safety equipment or seals are
broken.

On the operating company's/operator’s request the PALFINGER MARINE service partner has to
replace any missing or damaged seals immediately.

24
 Chapter 2 Supplement to equipment number 510007119-21

PALOPS system
The PALOPS safety equipment must be used, when the hook or load of a stationary platform-crane got
entangled with the vessel and the vessel is drifting away from the crane. PALOPS prevents the crane
from getting damaged or torn off the platform when the distance between vessel and crane increases.
On activating PALOPS (either by hand or automatically) rope gets unwound from the drum long
enough to prevent any damage to the crane.
PALOPS consists of two safety systems:
MOPS - Manual overload protection system
Is generally required on platform-cranes.
AOPS - Automatic overload protection system
Is required on platform-cranes in regions with short waves like for instance in the North Sea.

MOPS - Manual overload protection system

Caution!
If MOPS is activated while a load is hanging on the hook, the load will
immediately fall down uncontrollably. This represents an acute risk of
fatal injury for everybody near the load. Additionally this may cause
severe damage to the vessel.

The MOPS button is on the operating panel at the high stand.

To prevent MOPS from being activated inadvertently, the ON/OFF button is covered by a safety lid.

Caution!
If the safety lid does not return into its covering position after letting
go, there is serious risk of fatal injury for everybody near the load.
Additionally this may cause severe damage to the vessel.

As the lid is a safety element it must automatically return into its covering position after letting go. If the
safety lid does not return into its covering position automatically after letting go, repair it immediately.

25
Supplement to equipment number 510007119-21

Activating MOPS:
Open and keep open the safety lid.
Press and hold the MOPS button. A continuous warning tone sounds, the brake of the rope winch
releases.
The rope automatically unwinds from the drum under load. When the maximum capacity is
exceeded by 20% the lower load block will drop down.
Deactivating MOPS:
Le the MOPS button go.
Close the safety lid.
You may continue working with the rope winch.

AOPS - Automatic overload protection system

Caution!
It is impossible to activate AOPS by hand.

AOPS activates automatically:

When the crane is in offshore mode.
When the load arm is above water.
When a certain pressure has been exceeded in the load holding valve.
The safety system is setup in a way that AOPS only activates when the load arm is above water. If the
load arm is above the platform AOPS will not activate.

Caution!
When AOPS gets activated the load sinks uncontrollably. Then there
is serious risk of fatal injury for everybody near the load. Additionally
this may cause severe damage to the vessel.

Before lifting a load make sure that there is nobody near the load to be lifted.
AOS gets activated:
An acoustic warning signal will sound and the signal column is flashing red.
Under load the rope automatically unwinds from the drum.
AOS gets deactivated:
The pressure in the load holding valve is back in the normal range.
The audible warning signal stops and the signal column stops flashing.
You may continue working with the rope winch.

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 Chapter 2 Supplement to equipment number 510007119-21

Signal column
The signal column indicates the current status of the crane via various light signals and colors.

Color Lighting mode Meaning

red Solid light 100% crane utilization reached
red Flashing AOPS active

orange Solid light 90% crane utilization reached

orange Flashing MOPS active

Crane in normal operating mode (can be
green Solid light
operated from the operator station on the crane)
green Flashing Crane in radio remote control operation

blue Solid light Low oil level

blue Flashing System error

Note!
Watch the signal column while operating the crane.

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Supplement to equipment number 510007119-21

Slewing ranges
The safety and control system divides the entire slewing angle in three different sectors. The purpose
is to adjust the unit's slewing range to the space currently available.

Caution!
Failing to observe all safety instructions in this operating manual with
the slewing range adjusted, will cause serious danger to life.

Even when the slewing range has been adjusted, the crane may only be moved after all persons have
left the danger zone and working range.

m
,5
3 10

2
3

1 White slewing range - normal working range.

Gray slewing range - this working range must be confirmed via 'Override rotation
2 limiter' button before you can work in this range.
Red slewing range - this working range must be confirmed via ‘Override rotation
limiter' button before you can work in this range. Additionally, the main boom must
3 be 2 m above the helideck (cross-hatched area). Only then 'Override rotation limiter'
activates and the crane can be moved further.

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 Chapter 2 Supplement to equipment number 510007119-21

Caution!
In the red slewing range the distance from the helideck must be kept
all the time.
When the rotation limiter activates:
Lift up the main boom and increase the distance to the helideck.
Crane operation will be enabled.

Changing the parameters of the slewing ranges

Note!
If the operating company / operator changes the parameters of the
slewing range he will be fully responsible / liable for the
consequences.

For changing the slewing limitation refer to the Advantech company operating instructions.

After power failure

After power failure the crane must be in the same slewing position like before the power failure.
Regarding slewing the crane in case of electric power failure refer to section 'Failure of electric system'.
If the crane has left his initial slewing angle position after a power failure, the rotary encoder of the
slewing angle measuring system no longer matches the actual slewing angle. In such a case contact
your PALFINGER MARINE partner.

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Supplement to equipment number 510007119-21

Control box main operation / emergency operation

4 5

6 7

8 9

1 2
1 Main ON / OFF switch 6 Button to start auxiliary motor
2 Emergency-stop button 7 Button to stop auxiliary motor
Power supply selector switch: Main Control lamp - Performance available for
3 8
supply / emergency supply engine
4 Button to start main motor 9 Low oil pressure
5 Button to stop main motor

Operation:
1. Set main switch (1) to position ON.
2. Select power supply (3) (main supply / emergency supply).
3. Check whether there is power for the engine.
Control lamp (8) in solid white.
4. Make sure the emergency-stop button (2) is unlocked (if not the engine will not start).
5. Start the motor you selected via START button (4 or 6).
The control lamp in the button is green.
6. Motor is running, crane can be operated.
7. After finishing crane operation switch off the selected motor via STOP button (5 or 7).
8. Set main switch (1) to position OFF.

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 Chapter 2 Supplement to equipment number 510007119-21

Caution!
In emergency operation mode all safety equipment such as
emergency-stop button, load torque restricting systems, etc. is
ineffective.
Immediately reduce the load torque in emergency operation.
In emergency operation mode, put down the load or basket
immediately.
If you continue working you put yourself and others at risk of fatality.
Immediately end loading operations.

Note!
While operating the crane with the emergency drive the working
speeds are very low.

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Supplement to equipment number 510007119-21

Failure of electric system

If the crane stops because of a fault in the electrical or electronic systems:
Check the power supply (fuse).

Caution!
In emergency operation mode all safety equipment such as
emergency-stop button, load torque restricting systems, etc. is
ineffective.
Immediately reduce the load torque in emergency operation.
In emergency operation mode, put down the load or basket
immediately.
If you continue working you put yourself and others at risk of fatality.
Immediately end loading operations.

If the fault cannot be remedied use the emergency operation mode as described in the two cases
below to bring the crane into parking position.

1. Remove the cover from the high stand.

2. Set the crane to emergency operation (refer to below instructions: situation A or B).
3. Bridging the emergency stop valve:
Actuate the bridging valve by pressing the button (see picture) and at the same time
activating the required crane function via lever.
4. Put the load down without increasing the load torque.
5. Bring the crane in parking position (refer to 'Bringing the crane into parking position' in
chapter 9).
6. Contact your PALFINGER MARINE partner.

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 Chapter 2 Supplement to equipment number 510007119-21

Situation A:
If the main motor is defective:
(The control lamp 'Performance available for motor’ (white) must still be illuminated).
1. Select the 'Start auxiliary motor' button (6) on the control box.
2. The two indicator lights 'Start auxiliary motor' (6 - green) and 'Performance available for motor'
(8) must be on.

Situation B:
If the main power supply is defective:
(The control lamp 'Performance available for main motor' (white) is off).
1. On the control box set the power supply selector switch (3) to emergency supply.
2. Select the 'Start auxiliary motor' button (6) on the control box.
3. The two indicator lights 'Start auxiliary motor' (6 - green) and 'Performance available for motor'
(8) must be on.
For button assignment in the control box see Main components of control box. (see "Control box
main operation / emergency operation" Page 30)

33
 Index

Index

C
Control box main operation / emergency
operation • 30, 33
F
Failure of electric system • 32
G
General • 24
Graphics and pictures • 5
M
Main components • 9
N
Notes regarding the operating
instructions • 1
O
Operating instructions • 3
Operating panel • 13
P
PALOPS system • 25
R
Radio remote control • 12
S
Signal column • 27
Slewing ranges • 28
Supplement to equipment number
510007119-21 • 7
Supplement to the operating instructions
•3
Symbols • 4
V
Validity of operating instructions • 4

35
.