Original operating manual

Workman basket
BB015AM

Edition 01/2018 EN
Palfinger Marine GmbH
Franz-Wolfram-Scherer-Straße 24
5020 Salzburg / Austria
www.palfingermarine.com
001
001.09 Operation Manual EN
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
Operating instructions..............................................................................................................................3
Validity of operating instructions.............................................................................................................. 3
Symbols...................................................................................................................................................4
Terms.......................................................................................................................................................5
Graphics and pictures..............................................................................................................................6
Safety and health protection..................................................................................................................... 7
Safety for individuals................................................................................................................................9
Personal fall protection.......................................................................................................................... 10
Intended use / Limits of the workman basket.........................................................................................11
Foreseeable misuse of the device......................................................................................................... 11
Residual risks........................................................................................................................................ 12
Government regulations and standards for operating the unit.............................................................. 13
Unauthorized use...................................................................................................................................13
Adverse working conditions...................................................................................................................13
Risk of falling......................................................................................................................................... 18
Danger of getting crushed..................................................................................................................... 18
Hazardous substances.......................................................................................................................... 19
Risk of burns..........................................................................................................................................19
Noise exposure......................................................................................................................................20
Vibration, whole-body vibration..............................................................................................................20
Danger from power lines........................................................................................................................21
After maintenance, service and repairs................................................................................................. 22
General...................................................................................................................................................... 23
Type plate.............................................................................................................................................. 25
System assembly...................................................................................................................................26
Modifications to unit...............................................................................................................................26
Operating personnel.............................................................................................................................. 27
Device and function..................................................................................................................................29
Main components.................................................................................................................................. 31
Explanation of the operating labels........................................................................................................34
Meaning of the symbols.........................................................................................................................35
Hazard warning symbols....................................................................................................................... 35
Overview of labels................................................................................................................................. 36
Safety equipment......................................................................................................................................39
General..................................................................................................................................................41
Emergency-stop button..........................................................................................................................42
Capacity utilization indicator.................................................................................................................. 43
Preparing for crane operation with workman basket............................................................................45
Prerequisites for workman basket operation......................................................................................... 47
Watch out for faults before and during operation...................................................................................48
Ship tilt...................................................................................................................................................49
Daily function check of safety equipment.............................................................................................. 50
Workman basket operation......................................................................................................................55
Start working..........................................................................................................................................57
Workman basket leveling.......................................................................................................................58
Payload..................................................................................................................................................58
Emergency operation.............................................................................................................................59
 Contents

Finishing work with workman basket..................................................................................................... 63

Bringing the workman basket in parking position.................................................................................. 65
Preparing for hook operation................................................................................................................. 66
Maintenance.............................................................................................................................................. 69
General..................................................................................................................................................71
Maintenance.......................................................................................................................................... 73
Cleaning.................................................................................................................................................74
Visual inspection ...................................................................................................................................76
Machine lubrication................................................................................................................................78
Paint repair............................................................................................................................................ 81
Service....................................................................................................................................................... 83
General..................................................................................................................................................85
Tightening torques / testing torques...................................................................................................... 87
Check of safety equipment.................................................................................................................... 89
Protective hoses.................................................................................................................................... 89
Repairs.................................................................................................................................................. 89
Decommissioning and disposal..............................................................................................................91
Decommissioning and disposal guidelines............................................................................................93
Index.......................................................................................................................................................... 95
 Chapter 1 Notes regarding the operating instructions

Chapter 1

Notes regarding the operating

instructions

In this chapter
Operating instructions............................................................................................ 3
Validity of operating instructions.............................................................................3
Symbols..................................................................................................................4
Terms......................................................................................................................5
Graphics and pictures............................................................................................ 6

1
 Chapter 1 Notes regarding the 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

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.

3
Notes regarding the operating instructions

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

Terms
Working range The area that is required to carry out the work.

Working position Optimal working position for the crane.

Assembler Fits the unit.

Operator Anyone who starts up the unit.

The owner, lessee, renter of the unit, uses the unit, operates the unit
Operating company
either himself or entrusts a third party with the operation.

Produced in addition to these operating instructions by the operating

Operating instruction
company for special operating conditions.

Movement range The area within which the crane can be moved.

Shows that the unit has been manufactured in accordance with the
CE-marking
EU directives.

EU European Union.

A person who does not observe and comply with all duties of care
Negligent
that his work involves acts negligently.

A person who grossly fails to operate the crane with due care and
(Grossly) negligent ignores what would be apparent to everyone in the given
circumstances, acts grossly negligently.

Assistant Provides assistance but does not operate the unit.

Lifting power The force needed to lift an object.

Switch unit on, irrespective of purpose (operation, maintenance,

Start-up
service etc.)

Holding the lifted load under the supervision of the operator whilst the
Hold load
crane safety systems are activated.

Load range The range within which the crane can handle loads.

The torque that is exerted by the load, ancillary equipment, lifting

Load torque
devices, etc. that are hanging on a hook.

Operating mode that is not for normal crane operation. Is used to put
Emergency operation the crane into parking position after a failure of the electrical system
and/or the safety equipment.

A person who observes and complies with the duties of care that his
Properly
work involves acts properly.

5
Notes regarding the operating instructions

Setup status Crane that has been prepared for the respective work.

Someone with sufficient knowledge of marine cranes due to their

technical training and experience who is familiar with the relevant
Expert government laws and regulations to the extent that they can assess
whether the equipment is safe for operation. This applies also to a
marine crane with (class) acceptance.

Service partner Authorized by PALFINGER MARINE.

Reaching of the maximum permissible load for the current working

Overload situation
position.

Graphics and pictures

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

6
 Chapter 2 Safety and health protection

Chapter 2

Safety and health protection

In this chapter
Safety for individuals.............................................................................................. 9
Personal fall protection.........................................................................................10
Intended use / Limits of the workman basket....................................................... 11
Foreseeable misuse of the device........................................................................11
Residual risks....................................................................................................... 12
Government regulations and standards for operating the unit............................. 13
Unauthorized use................................................................................................. 13
Adverse working conditions..................................................................................13
Risk of falling........................................................................................................ 18
Danger of getting crushed.................................................................................... 18
Hazardous substances.........................................................................................19
Risk of burns........................................................................................................ 19
Noise exposure.................................................................................................... 20
Vibration, whole-body vibration............................................................................ 20
Danger from power lines...................................................................................... 21
After maintenance, service and repairs................................................................22

7
 Chapter 2 Safety and health protection

Safety for individuals

This unit is an item of working machinery. It has been constructed and built in accordance with
prevailing EU standards, guidelines and safety provisions. During use, maintenance or servicing
unforeseen risks to individuals, the device or other things may nevertheless arise.
The safety of the operators and other persons must be top priority.
Operating situations in which the operators or other persons are in danger are prohibited.
If used incorrectly or negligently and/or operated wrongly the unit can potentially be extremely
dangerous.
In the event of manipulation or commissioning of the unit, the operator must ensure that neither he nor
any other person is in the danger area!
The operator must recognize and understand all safety instructions in the operating instructions and
the meaning of all signs.

Safety clothing
During any work on the unit such as:
• Cleaning and maintenance
• Setting up
• All sorts of checks
• Operation
• Service and repairs
safety clothing that is suitable for the respective danger must be worn.
Before putting on the safety clothing, remove jewelry (example: rings, chains, bracelets etc.).

Personal safety equipment:

Operation: safety clothing, work gloves, hard-capped boots, helmet.
Other activities: depending on the type of danger (example: hearing protection in case of increased
noise exposure, safety goggles, work gloves, safety belt).

9
Safety and health protection

Personal fall protection

Every person in the workman basket must be secured by its personal protective equipment and
restraint system.
There are two eye bolts in the workman basket. Maximum one person may be secured on one eye
bolt.

Danger of falling because of improper use of restraint system:

• Persons may fall down.

There is severe risk of fatal injury!
The restraint system must always be secured to an eye bolt in the
workman basket.
Comply with the manufacturer’s instructions on how to correctly use
the restraint system.

Workman basket:
1. Eye bolt
2. Label - Attachment point in the
workman basket

10
 Chapter 2 Safety and health protection

Intended use / Limits of the workman basket

The workman basket may only be used by qualified people for making work safer.
The workman basket’s permitted load capacity must not be exceeded.

Improper use endangers people and causes damages to the device

and loss of warranty and liability.

It is allowed that:
• people use the workman basket for work.

If the device is used against orders there is severe risk of fatal injury
to the operator and others.

It is not allowed to:

• Transport people, i.e. people do not enter / exit the workman basket at the entrance.
• Make fun rides (during parties or fun fairs, etc.).
• Push against obstacles or loads.
• Pull loads.
• Attach loads to the workman basket.
• Transport loads in the workman basket.
• Overload the workman basket.
National laws, regulations and standards must be complied with.

Foreseeable misuse of the device

Caution!
If the device is foreseeably misused there is severe risk of fatal injury
to the operator and others.

Accidents caused by foreseeable misuse are grossly negligent if:

• The device is not used as intended.
• The device is started and used by untrained, unqualified individuals.
• All safety instructions and hazard statements in these operating instructions are neglected.
• The device is started up after it is known to be defective.
• Maintenance hast not been carried out or only insufficiently.
• Servicing has been carried out by a service workshop other than PALFINGER MARINE partner.
• Parts other than original PALFINGER spare parts have been installed.

11
Safety and health protection

Residual risks
The present operating instructions are meant as a guideline. With their help qualified operators will be
able to operate the device safely. During operation, however, dangerous situations may develop which
are unforeseeable for PALFINGER MARINE. Therefore, PALFINGER MARINE cannot include such
hazardous situations in these operating instructions.
When such hazardous situations occur the operator has to act responsibly, with foresight and safety-
awareness, yet he is responsible for the safety of all people and others involved.
The safety of people always must be of top priority.

Safety instructions on the most frequent dangers

The below table shows an overview of the most frequent dangers in crane operation. This list does not
replace reading and understanding the operating instructions properly.

Danger Actions

• Setup-works to be carried out only by qualified

Faulty installation of ancillary equipment (e.g. staff.
pulley head or workman basket).
• Wear the required protective equipment (work
gloves, safety gloves).

• Observe maximum permissible wind speeds

Dangers because of environmental conditions: and wave heights.

• Wind and waves or ice may cause • Remove the ice.

mechanical overload or the load may sway.
• No operation before or during thunderstorms.
• Lightning.
• Maintain the intervals for maintenance and
• Corrosion due to seawater. servicing.

• Operator training is mandatory.

• Operation only by trained operators.

Unauthorized operation. • No access to the working area for unauthorized

individuals.

• Turn off the main switch.

Incorrect load attachment, parts of the lifted

load drop down. • Operator training is mandatory.

Prohibited use / misuse of crane with workman

basket:
• Pulling. • Any misuse of the crane is prohibited.

• Pushing. • Operator training is mandatory.

• Transporting loads.

12
 Chapter 2 Safety and health protection

Government regulations and standards for operating the unit

The operator must know about and follow the national regulations, standards and safety provisions for
operating the unit.
If the operating instructions contain regulations and safety provisions that contradict the national laws
and regulations, the national laws and regulations have priority.

Unauthorized use
Only authorized persons shall operate the crane.
When leaving the crane, even for a short time, the operator must switch off the crane and secure it, if
possible, against unauthorized use.

Secure the crane against unauthorized use.

Lock any lockable main switches with padlocks.

Adverse working conditions

Do not operate the crane
• At wind speeds of 36 km/h (22.4 mph) and above.
Other values may apply depending on the conditions of use.
See chapter 6 - Ship tilt

Note!
It is in the responsibility of the operating company to provide the
operator with the opportunity to inform himself of current wind
speeds.

• When thunderstorms are approaching and during thunderstorms.

• At ambient temperatures below -30ºC (-22°F) or above +50ºC (122°F). Average ambient
temperature must not exceed +40°C (104°F) during operation.

Ignoring these instructions on working conditions may lead to risk of

fatal injury for the operator and others and/or to damages to the crane.

13
Safety and health protection

Beaufort scale, description and wave height

Wind force in
Description Probable wave height * in meters
Beaufort

0 Calm ---

1 Light air 0.1 (0.1)

2 Light breeze 0.2 (0.3)

3 Gentle breeze 0.6 (1)

4 Moderate breeze 1 (1.5)

5 Fresh breeze 2 (2.5)

6 Strong breeze 3 (4)

7 Near gale 4 (5.5)

8 Gale 5.5 (7.5)

9 Strong gale 7 (10)

10 Storm 9 (12.5)

11 Violent storm 11.5 (16)

12 Hurricane 14 (---)

14
 Chapter 2 Safety and health protection

Beaufort scale, wind speed

Average wind speed at 10 meters above free ground

Wind force in Average wind speed in

m/s km/h mph
Beaufort knots

0 <1 0 - 0.2 1 <1

1 1-3 0.3 - 1.5 1-5 1-3

2 4-6 1.6 - 3.3 6 - 11 4-7

3 7 - 10 3.4 – 5.4 12 - 19 8 - 12

4 11 - 16 5.5 - 7.9 20 - 28 13 - 18

5 17 - 21 8.0 - 10.7 29 - 38 19 - 24

6 22 - 27 10.8 - 13.8 39 - 49 25 - 31

7 28 - 33 13.9 - 17.1 50 - 61 32 - 38

8 34 - 40 17.2 - 20.7 62 - 74 39 - 46

9 41 - 47 20.8 - 24.4 75 - 88 47 - 54

10 48 - 55 24.5 - 28.4 89 - 102 55 - 63

11 55 - 63 28.5 -32.6 103 - 117 64 - 72

12 64 and above 32.7 and above 118 and above 73 and above

15
Safety and health protection

Beaufort scale, sea

Wind force in
Sea conditions
Beaufort

0 Flat sea

1 Ripples without crests

2 Small wavelets. Crests of glassy appearance, not breaking.

Large wavelets. Crests begin to break; foam of glassy appearance, scattered

3
whitecaps.

4 Small waves with breaking crests. Fairly frequent whitecaps.

5 Moderate waves of some length. Many whitecaps. Small amounts of spray.

Long waves begin to form. White foam crests are very frequent. Some airborne
6
spray is present.

Sea heaps up. Some foam from breaking waves is blown into streaks along
7
wind direction.

Moderately high waves with breaking crests forming spindrift. Well-marked

8
streaks of foam are blown along wind direction.

High waves whose crests sometimes roll over. Dense foam is blown along wind
9
direction. Large amounts of airborne spray may begin to reduce visibility.

Very high waves with overhanging crests. Large patches of foam from wave
10 crests give the sea a white appearance. Considerable tumbling of waves with
heavy impact. Large amounts of airborne spray reduce visibility.

Exceptionally high waves. (Small and mid size vessels may temporarily
disappear from view.) Very large patches of foam, driven before the wind, cover
11
much of the sea surface. Very large amounts of airborne spray severely reduce
visibility.

Huge waves. Sea is completely white with foam and spray. Air is filled with
12
driving spray, greatly reducing visibility.

16
 Chapter 2 Safety and health protection

Beaufort scale, land and coast

Wind force in
Land Coast
Beaufort

0 Calm. Smoke rises vertically. Calm

Smoke drift indicates wind direction. Leaves

1 Calm, rippled sea
and wind vanes are stationary.

Wind felt on exposed skin. Leaves rustle. Wind

2 Smooth wavelets, 1 to 2 knots
vanes begin to move.

Leaves and small twigs constantly moving, light

3 Smooth wavelets, 3 to 4 knots
flags extended.

Dust and loose paper raised. Small branches

4 Slight sea
begin to move.

Small trees in leaf begin to sway. Whitecaps

5 Moderate sea
form on inland lakes.

Large branches in motion. Whistling heard in

6 Rough sea
overhead wires. Umbrella use becomes difficult.

Whole trees in motion. Effort needed to walk

7 Very rough sea
against the wind.

Some twigs broken from trees. Progress on foot

8 High sea
is seriously impeded.

Small damages to buildings, roof tiles and

9 ---
chimney cowls get blown off.

Rarely occurs in inland areas, trees get

10 ---
uprooted, considerable damages to buildings.

11 Very rare, severe widespread damage. ---

12 --- ---

World Meteorological Organization (WMO); Manual on Codes, International Codes, Volume I.1, Part A,
Alphanumeric Codes, 1995

17
Safety and health protection

Risk of falling
Risk of falling caused by:

• Climbing out of the basket

• Leaning out of the basket
Use personal protective equipment and restraint system. Do not exit
the workman basket.

Climbing on and out of the device is prohibited.

Cables, sensors, sensor attachment lugs, drivers for sensors etc. may not be used as steps and / or
handles.

Danger of getting crushed

Caution!
If the minimum distances specified below are undershot, there is
acute risk of crushing.

Operating situations in which the operators or other persons are at risk of crushing are prohibited!

Required minimum distances

The crushing point for the parts of the body specified above are not considered to be dangerous
locations provided that the specified safety distances are not undershot. It must also be ensured that
the next biggest part of the body cannot get into the crushing point.

18
 Chapter 2 Safety and health protection

Hazardous substances
Hydraulic oil, lubricating oil and grease used on the crane are hazardous substances.
Do not release these hazardous substances into the environment, avoid direct contact. While working
with hazardous substances for instance during maintenance and servicing, wear personal protective
equipment, refer to section 'Safety for individuals' (Page 9).

If you come in contact with hazardous substances anyway, take first aid measures immediately (see
safety datasheet about relevant hazardous substances):

General advice First aiders must provide for self-protection.

After eye contact, wash affected eye under running water with
Eye contact eyelids held open, or thoroughly wash with eyewash bottle. If
symptoms persist, consult an eye doctor.

After vapors or oil mist have been inhaled, get the persons
Inhalation
affected into fresh air.

Wash affected areas of the body thoroughly with soap and water,
Skin contact take polluted clothes off immediately and replace with clean
clothes.

On suspicion of swallowed or deeply inhaled substances

If substances are swallowed
(vomiting, coughing, shortness of breath) consult a doctor. Do not
or enter the lungs.
induce vomiting. Consult a doctor immediately.

Risk of burns
Some components can become extremely hot during operation (lines, hoses, valves, valve operating
levers, hose connections, hydraulic cylinders, oil motors, pumps etc.).
Contact with these parts can cause burns!
Risk of scalding if oil escapes!

No smoking!
No naked flame!

Note!
If the unit is equipped with a fire-extinguisher it must be inspected
and replaced, if necessary, according to local regulations.

19
Safety and health protection

Noise exposure
Permanent low or short high noise emission levels endanger the
health of operators and bystanders, therefore all of them must wear
ear protectors!

Possible sources of noise: Hydraulic unit, auxiliary engines, etc.

Protective measure: Ear protectors.
The operator has to comply with the relevant national noise control standards and laws.

Vibration, whole-body vibration

The highest root mean square value of whole-body vibrations in the workman basket is below the limit
value of 0.5 m/s².
Consequently, there is no limitation of the permissible exposure time in the basket.

20
 Chapter 2 Safety and health protection

Danger from power lines

The basket is not insulated. The whole system is not suited for working on live lines. For safety
reasons, the minimum distance from power lines must be observed at all times. If this is impossible due
to the workflow, these lines must be de-energized (switched off) before starting to work.

Severe risk to life because of electric shock!

• Even approaching a power line may lead to voltage

flashover.
Keep the required minimum distances.

Condition and height of power lines do not say anything about their voltage.
If the voltage is unknown, minimum distance from line 5 meters.

Note!
The national minimum distances from live power lines may differ from
the minimum distances specified in this document. The operator is
therefore obliged to comply with the respective national regulations.

• The minimum distance from power lines must be observed at all times.
• Working above power lines is prohibited.
• Before starting work, obtain information about the voltage of the lines from the line operator.
• If you need to be closer than the minimum distance for work reasons, the lines must be switched
off. Being closer than the minimum distance without switching off the lines is grossly negligent and
potentially fatal!
• Only carry out work close to the line after the line operator has de-energized the line and permitted
the work to be done.
Also to be considered:
• Power lines move in the wind.
• Power lines can also be out of the operator's view.
• The workman basket can swing because of a jerky movement. This unwanted movement may
mean that you get closer to a power line. And this triggers an electric flashover.

Minimum distances from live lines

Voltage Minimum distance

up to 1,000 volts 1.0 meter

unknown or over 1,000 volts 5.0 meters

21
Safety and health protection

Actions to take in the event of flashover

Note!
An accident with severe consequences can only be prevented by the
correct response.

• Stay calm, do not move.

• Warn persons standing in the vicinity and direct them to observe the safety distance.

Upon contact with a live electric line with the ground, a potential
gradient occurs. Within the potential gradient there is acute danger to
life.

• The minimum distance to the device or broken power line is 20 meters (potential gradient).
• Leave the danger zone of potential gradient only by jumping with both feet. Keep your legs closed
because of the step voltage.
• Under no circumstances you should leave the device, operator station, high stand or workman
basket; stay where you are and don't touch anything (levers, etc.).
• Do not touch the device or the broken lines.
• Immediately arrange the switch-off of the live electric line.

Approaching any persons or devices situated inside the electric

circuit creates acute danger to life.

• Before rescuing any persons out of the electric circuit turn off the life electric line.

After maintenance, service and repairs

Note!
Every time after maintenance, repair or service it is absolutely
necessary to check the function of all safety equipment on the device
(stand ard and optional)!

22
 Chapter 3 General

Chapter 3

General

In this chapter
Type plate.............................................................................................................25
System assembly................................................................................................. 26
Modifications to unit..............................................................................................26
Operating personnel.............................................................................................27

23
 Chapter 3 General

Type plate
In the EU and in certain countries, the unit may only be operated with
• A valid CE symbol for device and superstructure.
• A valid conformity declaration for the unit and the superstructure.
EU requirements are thus fulfilled.
CE marking: Shows that the unit has been manufactured in accordance with the EU directives.
Type: ___________ Year: _______
max. wind speed: 10 m/s
Dead weight: XXX kg I max. load: _____ kg
max. 2 Persons mixed with safety belts

F. W. Scherer Strasse 24
5020 Salzburg / Austria
EB-12430

(symbolic illustration)
The type plate is attached to the workman basket. The product name, year built and company name
must be specified on the type plate.

Note!
• Do not remove the type plate.
• In case of any constructional changes made to the
workman basket the assembler must issue a new CE
marking (new declaration of conformity).
• The workman basket must not be taken into operation
without a valid type plate.

25
General

System assembly
The unit has to be installed according to the valid assembly instructions issued by PALFINGER
MARINE.
Carry out any legally required acceptance.
In case your model is not assembled as intended, the load values may differ. Therefore the assembler
should enclose load capacity charts for additional load ranges. If you need any further information
please contact your PALFINGER MARINE partner.

Crane delivery to operating company / operator

• Comprehensive training in how to operate the equipment and accessories.
• Note concerning any dangers and residual risks.
• Explanation of all safety equipment.
• Delivery of service manual, operating instructions (including any additions required by installation)
and declarations of conformity for the crane and ancillary equipment.
• Confirmation of any legally required acceptance.
• Registration: Warranty / liability.

The company operating the equipment has to initiate any legally required periodic inspections.

Modifications to unit
Note!
The operating company or operator are not allowed to modify the unit
and to remove any protective devices!
Exception: Corrosion protection and maintenance works, refer to
chapter 'Maintenance' (Page 69).

Caution!
If operating company or operator modify the unit or remove protective
devices this may create severe risk of fatal injury!

Modifications to the unit may only be made by PALFINGER MARINE service partners or following
previous agreement with PALFINGER MARINE customer service.
In case of substantial modifications the manufacturer may withdraw from his responsibility regarding
product liability for the modified machine (e.g. crane, etc.). Should said modifications have effects on
the entire machine, the manufacturer's product liability will become void.
Essential modifications mean changes to the machine's functionality (e.g. customer installs a rope
winch, modifications to set pressures, etc.).

26
 Chapter 3 General

Operating personnel
The workman basket may only be started up by persons who meet the requirements specified below.

Risk of fatal injury because of:

• Operating errors.
• Deficient knowledge of the device.
• Lacking or deficient personal protective equipment.
The operator must be trained on the device.
All specifications of the operating instructions must be observed.

Note!
The operating company must provide operators with comprehensive
training or have such training carried out. These operators must meet
all of the requirements mentioned in this document.

The following is required of the operator when operating this unit:

• Physical and mental fitness for the job.
• Be in no way incapacitated by alcohol, drugs or medication.
• Comprehensive training on this unit.
• Be familiar with the contents of these operating instructions.
• Have understood the training and the operating instructions.
• Be familiar with the respective national regulations, standards and laws concerning the operation
of this unit and all auxiliary devices that are used.
• Knowledge of regulations and norms of insurance and acceptance companies, if they have been
specified for operating the device.
• Be responsible, reliable and able to concentrate.
• The legally required training (pay attention to national laws).
• Fulfill the minimum age requirement (pay attention to national laws).

27
 Chapter 4 Device and function

Chapter 4

Device and function

In this chapter
Main components................................................................................................. 31
Explanation of the operating labels...................................................................... 34
Meaning of the symbols....................................................................................... 35
Hazard warning symbols...................................................................................... 35
Overview of labels................................................................................................ 36

29
 Chapter 4 Device and function

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

1 2 3 4

10
5

9 8

31
Device and function

1 Insert 6 Switch valve (leveling system)

2 Hydraulic connection from crane to 7 Retaining rail

workman basket

3 Electrical connection from crane to 8 Static lifting points for personal

workman basket protection

4 Fork 9 Workman basket

5 Slewing gear (leveling) 10 Radio remote control

Operating levers and indicators

Operating levers and status indicators in the workman basket
Switch valve:

The switch valve switches between

• Working mode:
Workman basket is hydraulically leveled.
• Transport position:
Workman basket is balanced by gravity.

Working mode

Transport position

Risk of falling if switch position is wrong!

• Use the workman basket only in working mode.

Otherwise there is an acute risk of fatality for the operator and others.

32
 Chapter 4 Device and function

Radio remote control operation with connecting cable

The workman basket is designed for operating cranes via radio remote control. While the workman
basket is being operated the crane must be controlled via radio remote control.
1. Fasten the radio remote control to the proved holder in the workman basket.
2. Connect the connector in the workman basket to the radio remote control.
3. Power supply comes from the remote control handset’s battery. A second, fully charged battery must
be kept at hand in the workman basket.
As soon as the radio remote control handset is connected via connector, the crane’s speed reduces
automatically according to the applicable standards and regulations.
Only in this mode it is permitted to operate the unit.

Remote control handset on the workman basket

If the workman basket is equipped with its own remote control handset, it must be used to operate the
crane in workman basket mode. When the remote control handset is used, the crane’s speed reduces
automatically according to the applicable standards and regulations.
Only in case of failure of the workman basket’s remote control handset it is permitted to use the crane’s
radio remote control handset.

Risk of falling due to jerky crane movements!

• Carry out only those movements with the workman

basket that are necessary to exit it safely.
Otherwise there is an acute risk of fatality for the operator and others.

In case of failure of the workman basket’s remote control handset it is not permitted to continue
working with the workman basket.
Do not operate the workman basket and contact a PALFINGER MARINE service partner.

33
Device and function

Explanation of the operating labels

The order of the functions (symbols) may be different on your operating station (crane or remote
control handset) from the examples shown below. It is therefore absolutely essential to familiarize
yourself with the functions (symbols) and how they are arranged on your device / remote control
handset.

Slewing

Clockwise
(right)
Counter-clockwise
(left)

Main boom

Lower
Lift (hoist)

Outer boom

Lower
Lift (hoist)

Boom extension

Extend
Retract

34
 Chapter 4 Device and function

Meaning of the symbols

On operator station.

Push the electrical emergency-stop button only in a dangerous

situation. To resume work, unlock the emergency-stop button by
turning it clockwise.

Hazard warning symbols

Check operating instructions

Crane crushing hazard

No high pressure water jet cleaning

35
Device and function

Overview of labels
The labels are part of the unit, they serve to protect the operator and others and facilitate correct crane
operation.

Caution!
Missing, damaged or illegible labels increase the risk of accidents!

Missing, damaged or illegible labels lead to operating errors and mistakes during crane operation; they
must be replaced immediately.
Instruction label - Read the operating instructions!

Position:
Meaning:
Near to the hand pump of hydraulic unit,
First read the operating instructions!
operator station (FLVK) or high stand.

Risk if ignored:
Damages to the crane and risk of fatal injury for the operator and others due to ignorance or
operating errors.

Crane functions operation labels

Meaning:
Position: Operation labels for crane functions (see
Operator station. chapter 4 'Device and function', section
'Explanation of the operation labels').

36
 Chapter 4 Device and function

SWL label on the workman basket

(symbolic representation)

Position:
Meaning:
Workman basket (to the
Safe Working Load lettering. Max. permissible load.
side on the fork)

Instruction label - Personal fall protection

Position:
Meaning:
In the workman basket
Static lifting point for personal fall protection.
(twice)

37
Device and function

Instruction label - Basket leveling system

Position: Meaning:
Workman basket Switching between working position and transport position.

38
 Chapter 5 Safety equipment

Chapter 5

Safety equipment

In this chapter
General.................................................................................................................41
Emergency-stop button........................................................................................ 42
Capacity utilization indicator.................................................................................43

39
 Chapter 5 Safety equipment

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.

Caution!
In case of failure of any protective device, stop operating the unit
immediately and contact your PALFINGER MARINE partner. There is
severe risk of fatal injury!

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.

41
Safety equipment

Emergency-stop button
The device is equipped with an emergency-stop button.
The emergency-stop button stops all crane functions within 0.5 seconds (500 ms) after activation in an
emergency situation.
The switch is on the radio remote control handset.

Electrical design

Locked when actuated

Unlocked by turning clockwise

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

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

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.

42
 Chapter 5 Safety equipment

Capacity utilization indicator

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

Visually:
Capacity utilization indicator

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.

43
 Chapter 6 Preparing for crane operation with workman basket

Chapter 6

Preparing for crane operation with

workman basket

In this chapter
Prerequisites for workman basket operation........................................................ 47
Watch out for faults before and during operation................................................. 48
Ship tilt..................................................................................................................49
Daily function check of safety equipment............................................................. 50

45
 Chapter 6 Preparing for crane operation with workman basket

Prerequisites for workman basket operation

The crane operator is responsible for properly operating the crane with workman basket.
Two people are required to operate the crane in workman basket mode. The first one (crane operator)
is in the basket and controls the crane via radio remote control handset. The second one remains near
the crane (crane operator station), and in case of any technical defect such as failure of the remote
control, power failure, empty fuel tank etc. or if the basket operator faints he/she lowers the crane using
the emergency lowering mechanism. In addition to that this second person must prevent that anybody
unauthorized operates the operating levers on the crane.
All connections must be established:

• Mechanical connection
• Electrical connection
• Hydraulic connection

Risk of getting injured by crane movements!

• The person on the crane operator station must stay

outside the danger zone!
• Any other persons are not allowed to step into the
danger zone.

The crane must be controlled from the workman basket via radio remote control handset. Before
starting work, secure the operating levers on the crane operator station against unauthorized operation.
The crane operator must take a position where he/she is able to view the entire working area. Light up
the working area sufficiently if light is insufficient (sufficient hand lamp in workman basket).
From a working height of 20 meters voice communication must be possible via radio or phone between
crane operator and the person at the crane operator station.

Operating stands, steps and platforms

Warning!
Soiled, icy, snow-covered signs, operating elements, operating
stands, steps, platforms, booms, etc. increase the risk of accidents.
There is then a severe risk of fatality for the operator and others.

Operating elements, operating stands, steps, platforms, boom etc. must be free of snow, ice, soiling
(oil, grease etc.). Operating symbols, information and warning signs must be recognizable. No objects
must be left on operating stands, steps, platforms etc.

47
Preparing for crane operation with workman basket

Watch out for faults before and during operation

Acute danger to life for the operator and others!

• Caused by damage to the device.

• Caused by device malfunction.
If damage or malfunctions are found during operation, operation must
be stopped immediately!

If the following damage or faults are found on the unit do not start operation or stop operation
immediately and contact your PALFINGER MARINE partner:
• Lack of lubrication.
• Corrosion.
• Damage or cracks on load-bearing components / weld seams.
• Unserviceable bearings.
• Damage to the hydraulic system (leakage, unusually high temperatures etc.).
• Unserviceable safety equipment.
• Loose threaded connections.
• Insufficiently secured pins.
• Hose winding malfunctions in the hose drum or the hose tray.
• Unusual noises.
• Unusually fast or slow operating movements.
• Failure of the control system.
• Check that the controls move easily and reset themselves automatically.
Restarting the unit is only allowed after corrective measures have been taken and safe operation is
guaranteed again.

48
 Chapter 6 Preparing for crane operation with workman basket

Ship tilt
Working with crane is only permitted unless the permissible ship tilt is exceeded.

Tilt indicator (option)

There is a tilt indicator on the operator station.

When the air bubble is in the middle, the crane is levelled.

When the air bubble is between the two circles, the crane inclination is between
5° 0° and 5°.

Risk of accident due to excessive ship tilt:

• reduced guiding of extension boom sections cause the

load arm to move to the side.
Observe the tilt diagram and load capacity chart!

For the tilt diagram refer to the technical datasheets relating to the crane.
The tilt must not be exceeded in any direction (heel 5°, trim 2°).
Depending on the conditions of use other values may be specified by PALFINGER MARINE.

See chapter 8 'Crane operation', section 'Working position of the crane'.

Risk of accident due to excessive ship tilt:

reduced guiding of extension boom sections cause the load arm to
move to the side.

49
Preparing for crane operation with workman basket

Daily function check of safety equipment

Emergency stop function check

Caution!
If the crane doesn’t stop after pressing the emergency stop button or
if other crane movements are still possible there is severe danger to
life.

Function checks must always be carried out without load.

Working with a defective emergency stop button is grossly negligent. Do not operate the crane and
contact a PALFINGER MARINE service partner.

Functional check
• Operate any crane function. The crane must move perfectly in all directions.
• Press the emergency stop button while the crane is moving.
The crane must come to a stop.
• Again, operate any crane function.
The crane must not move.
• Unlock the emergency stop button.
The crane should move perfectly in all directions.
See section 'Emergency-stop button'.

Functional check of retaining rail

Risk of falling due to open retaining rail!

• During operation the retaining rail must always remain

closed!
If the retaining rail cannot be closed or the sensor is unable to detect
that, it is no longer permitted to work with the workman basket.
Contact your PALFINGER MARINE partner.

Carry out the functional check before using the workman basket.
Operating the workman basket with defective retaining rail is grossly negligent. Do not operate the
workman basket and contact a PALFINGER MARINE service partner.

50
 Chapter 6 Preparing for crane operation with workman basket

Picking up the workman basket

• Set the switch valve to transport position (release).

• Remove the pin and hook from the last extension boom.

• On cranes with rope winch it is necessary to

• dismount the insert / pulley head / lower load block and
• to secure the rope in the provided fixture.
• Remove the mechanical extensions, if available.

Note!
• Do not fasten the workman basket to the
mechanical extensions.
• Workman basket operation with mechanical
extensions is not permitted!

51
Preparing for crane operation with workman basket

Risk of injury (risk of crushing, fatal injury) for persons and

risk of material damage.

• Caused by improper disassembly (rope winch,

hook, etc.)
• Caused by incorrect assembly of insert and
workman basket
Assemble the workman basket properly!
When assembling the workman basket touch only the forks.

• Push in the insert, lock it with the threaded bolt and secure it using only original PALFINGER
safety elements (castle nut, washer and spring cotter).

1. Insert
1 2. Threaded bolt
3. Castle nut with washer
4. Spring cotter

3
2

52
 Chapter 6 Preparing for crane operation with workman basket

• Connect hydraulic and electrical supply lines.

• Set the switch valve to automatic leveling (workman basket mode).

Now the workman basket is ready.

53
 Chapter 7 Workman basket operation

Chapter 7

Workman basket operation

In this chapter
Start working........................................................................................................ 57
Workman basket leveling..................................................................................... 58
Payload................................................................................................................ 58
Emergency operation........................................................................................... 59

55
 Chapter 7 Workman basket operation

Start working
The workman basket may only be entered or exited when standing on the ground. Maximum 2 persons
are allowed to be in the workman basket.
1. Open the guard rails.
2. Enter the workman basket and secure yourself with the restraint system.
3. Close the guard rails. The guard rails must be closed all the time during operation.
4. Check if the switch valve is set to automatic leveling. If necessary, set the it to automatic leveling.
5. Check if the radio remote control handset has been properly connected.
The crane driver can now control the workman basket via radio remote control handset.

Risk of falling caused by:

• Improper use of restraint system.

• Objects such as ladders or boxes in the basket
used to take a higher stand.
• Wrong position of switch valve.
• Climbing the guard rails.
• Leaning out of the basket.
Refrain from all actions with risk of falling!

Steer the workman basket smoothly and evenly to

a position where you can carry out the planned
work.
The automatic leveling system keeps the workman
basket in a horizontal position as soon as the crane
driver carries out any movement with the crane.

57
Workman basket operation

Workman basket leveling

The gradual balancing movements may cause the workman basket to
move jerkily!

Before starting tilt compensation, the persons and payload

must be distributed evenly in the workman basket.
Otherwise it might be impossible to level out the workman
basket horizontally.
1. Set the switch valve to transport position.
2. The workman basket levels out.
3.
Once the workman basket has leveled out,
set the switch valve to automatic leveling.
Workman basket operation is possible again.

Payload
Irrespective of their weight, maximum 2 people are allowed in the workman basket. The maximum
payload of the workman basket is 280 kg (617.29 lb) and must not be exceeded.
Depending on the ambient conditions (e.g. swell) the maximum payload may be lower.
The payload includes the persons with their protective equipment, tools and materials for work.

58
 Chapter 7 Workman basket operation

Emergency operation
Risk of falling caused by tilt, overload and danger of collision

• In emergency operation mode all safety equipment is

ineffective.
• The emergency-stop button is ineffective.
• Automatic basket levelling is ineffective.
Carry out only crane movements that reduce the outreach and land the
workman basket immediately.

To lower the workman basket after a failure (e.g. failure of radio remote control or hydraulic pump) the crane must be
equipped either with an emergency drive or a hand pump.

Failure of electric system - Emergency lowering via hand pump

If the crane stops because of a fault in the electrical or electronic systems:
• Check the power supply (fuse).
If the fault cannot be remedied, the emergency operation mode must be used to bring the crane into
parking position.

Note!
The hand pump is located either at the side of the hydraulic unit or on
the high stand.

59
Workman basket operation

1. Remove the seal from the yellow by-pass screw (on the
control valve).
2. Tighten the by-pass screw (A) as far as it will go and screw
it back two or three turns.
3. If available:
Fully tighten the screw (B) on the overload valve (see
picture).
4. Actuate the necessary crane movements on the control
valve and simultaneously pump with the hand pump.
5. Land the workman basket.
6. Bring the crane into parking position as described in chapter
8, ‘Finishing work with workman basket’.
7. Screw out the by-pass screw (A).
8. Contact PALFINGER MARINE service partner immediately.

60
 Chapter 7 Workman basket operation

Failure of hydraulic system - Emergency lowering via emergency drive

In case of hydraulic system failure, it is possible to lower the workman basket via electrically driven emergency unit.
• It is activated manually on the control box of the unit.
• Now, the workman basket can be lowered via radio remote control handset or by hand on the
main control stand.

Note!
The emergency drive is located at the side of the hydraulic unit.

Note!
After having used the emergency mode, the crane must be checked
by a PALFINGER MARINE partner!
It is prohibited to continue work!

61
 Chapter 8 Finishing work with workman basket

Chapter 8

Finishing work with workman

basket

In this chapter
Bringing the workman basket in parking position................................................. 65
Preparing for hook operation................................................................................66

63
 Chapter 8 Finishing work with workman basket

Bringing the workman basket in parking position

After ending work, put the workman basket on the ground.
The workman basket may only be exited when standing on the ground.

Damages to the workman basket caused by:

• Jerky lowering.
• Obstacles in the lowering range.

1. Put the workman basket on the ground.

2. Exit the workman basket.
3. Set the switch valve to transport position (unlock).
4. Move the workman basket in parking position.
5. Properly secure the workman basket and load arm.

65
Finishing work with workman basket

Preparing for hook operation

Removing the workman basket

Risk of injury (risk of crushing) for persons and risk of

material damage.

• Caused by improper disassembly

• Caused by incorrect assembly of hook (wrong
bolt, safety catch)
Use only original PALFINGER bolts for assembling the hook.
When disassembling the workman basket touch only the fork.

• Lower and land the workman basket.

• Set the switch valve to transport position (unlock).

• Disconnect the electrical and hydraulic supply lines.

• Disassemble the threaded bolt.
• Pull the insert out of the extension boom.

1. Insert
2. Threaded bolt
3. Castle nut with washer
4 4. Spring cotter

3
2

66
 Chapter 8 Finishing work with workman basket

• Mount the hook to the extension boom using original PALFINGER bolt.

The crane is now ready for operation.

67
 Chapter 9 Maintenance

Chapter 9

Maintenance

In this chapter
General.................................................................................................................71
Maintenance.........................................................................................................73
Cleaning............................................................................................................... 74
Visual inspection ................................................................................................. 76
Machine lubrication.............................................................................................. 78
Paint repair........................................................................................................... 81

69
 Chapter 9 Maintenance

General
Reliability, safety and service life of an equipment item are extremely dependent on maintenance and
servicing. Maintenance and service are therefore not a recommendation - the company operating the
equipment must carry out the work (or have it carried out by a third party).
The company operating the equipment must ensure that all maintenance work is carried out in
compliance with these operating instructions and national law.
No costs will be accepted by PALFINGER MARINE for damage to the equipment or accidents caused
by failure to carry out maintenance work or service work properly, or by non-compliance with national
law.
When replacing device components during repair or warranty use exclusively PALFINGER MARINE
spare parts. Any damages to the device or accidents because of different parts are not covered by the
liability of PALFINGER MARINE.
For further information, please refer to service manual (supplied with crane).
Keep all service records. Every service and repair must be recorded in the service manual and signed
and stamped by a person authorized by PALFINGER MARINE.

Note!
Absolutely comply with the PALFINGER MARINE maintenance
guidelines and intervals. Non-compliance results in loss of liability,
guarantee and warranty.

Arranged by Executed by

Operating company / Operator / PALFINGER MARINE

Maintenance Operating company
partner

Service Operating company PALFINGER MARINE partner

Note!
Use the consumables recommended by PALFINGER MARINE.
PALFINGER MARINE will not assume liability for any damages
caused by applying wrong consumables.

Use only original PALFINGER MARINE lubricants or lubricants that correspond with the lubricant
specification given in this chapter.

71
Maintenance

Replacing hydraulic components

Warning!
Despite pressure relief in the hydraulic system there might still be
residual pressure. While opening the hydraulic system there is danger
to the operator and others due to the residual pressure and/or hot
hydraulic oil.

If it is necessary to replace hydraulic components contact your PALFINGER MARINE partner.

Relieving the pressure of the hydraulic system:
• The unit must be switched off and the power supply disconnected.
• Secure the unit against being switched on unintentionally.
• Push all operating levers in both switching positions several times. The pressure in the hydraulic
system is relieved apart from possible residual pressures.

Warning!
Let the hydraulic oil cool down sufficiently to prevent scalding.

72
 Chapter 9 Maintenance

Maintenance
Note!
Have only qualified personnel carry out maintenance.

Maintenance and servicing recommendations in these operating instructions are of general nature and
apply to several PALFINGER MARINE products.
Maintenance has to be carried out after every 20 / 50 operating hours.
However, the maintenance intervals depend also on application, duty cycle and environmental
conditions. Sea water, sea air, etc. are especially aggressive and speed up corrosion and wear.
Therefore maintenance may be required in even shorter intervals.

Note!
Maintenance and service may only be carried out while the unit is out
of operation (hydraulic unit and electric power turned off).

Correct order of maintenance tasks

1. Clean the unit thoroughly.

2. Visual inspection.
3. Lubricate the unit.

Before longer downtimes of the device:

Before longer downtimes the entire crane unit must be treated accordingly following the lubrication
schedule. All blank metal parts such as slewing rack, gear rim, pinion, rope winch, load rope, hydraulic
cylinder rods, etc., (if available) must be protected using a rust protecting preservative. Retract all
hydraulic cylinders as far as possible.

After device downtimes (longer than 3 months):

After downtimes the device must be lubricated, see subchapter 'Device lubrication' (Page 78).

73
Maintenance

Cleaning

Note!
Thorough cleaning increases the reliability and the service life of the
unit.

Cleaning interval according to maintenance schedule.

Use only environmentally friendly, pH neutral and skin-friendly cleaning agents. This protects the
environment and avoids oxidations on the unit.
Do not use abrasive rags, brushes, etc.

Warning!
Oil and grease must not be released into the environment.

Cleaning procedure

Warning!
Wet or damp electric parts may cause short circuits in the electronic
system or other malfunctions of the unit.

• Carry out cleaning work only when the unit is turned off.
• Secure the unit against being switched on unintentionally.
• Keep the working environment clean.

Warning!
Contaminations, especially oil or other lubricants must be cleaned off
immediately as a precaution against slipping.

74
 Chapter 9 Maintenance

Cleaning with high-pressure cleaning equipment:

Warning!
Failure to comply with the following steps may result in damage to the
unit.

• The operating instructions of the high-pressure cleaning equipment shall be observed.

• Never exceed the water temperature / cleaning agent temperature of 60°C.
• Always ensure that there is sufficient distance between the nozzle and the unit.
•
Never point the water jet directly at:
• Electric and electronic parts (water penetration);
• Plastic parts (deformation, breakage);
• Bearings or bearing points (forces dirt into and lubricant out of
the bearing);
• Signs (can become detached or unrecognizable);

75
Maintenance

Visual inspection
Missing safety equipment, damage and cracks on crane components
or load handling attachment can result in severe accidents.

Note!
Determine the cause of any damage to prevent reoccurrence.
Replace any missing, worn out or damaged components immediately.

Check the crane and its attached parts as follows:

Fasteners and other hardware

• Check completeness and function of bolts, screws, pins and locking devices; check pins for any
deformation and sufficient security (e. g. lynch pins).
• Re-tighten loose bolts / nuts. Contact a PALFINGER MARINE partner for additional information as
needed.
Immediately replace any missing or inoperative hardware.

Steel parts
• Cracks on components, specifically on welds and bending edges.
• Deformations.
• Corrosion.

Hydraulic system
• Entire hydraulic system (fittings, pipes, hoses, valves, cylinders, etc.) for leaking or loose
connections.
• Hydraulic pipes for deformations and cracks.
• Hoses for being unwound, rub marks, squeezing points, cracks, porosity, etc.
• Cable/hose protection for incompleteness, being unwound and damaged, etc.
• Hydraulic oil level (crane in parking position).
• Absence/damages of load-holding valve seals.

Electric system
• Cables for being unwound, rub marks, squeezing points, etc.
• Cable/hose protection for incompleteness, being unwound and damaged, etc.
• Sockets, switches, display elements, sensors for improper attachment, damage, etc.
• All electric connections (connectors, clamp connections, etc.)

Covers
• Completeness of all covers.
• Covers for damages.

Labels
Check for legibility and completeness.

76
 Chapter 9 Maintenance

Checking the load handling attachment

• Hooks for cracks, deformations and wear.
• Safety latch for proper function.

Check of safety equipment

See also chapter 7 'Preparing for crane operation', subchapter 'Daily function check of safety
equipment'.

77
Maintenance

Machine lubrication

Caution!
If lubricant gets into your eyes, rinse with fresh water immediately and
consult a doctor or a hospital! If lubricant comes into contact with the
skin, clean surface of skin with fresh water.

78
 Chapter 9 Maintenance

Lubricant specification

Note!
PALFINGER MARINE recommends the use of biodegradable grease.
Do not mix incompatible lubricants.
Even biodegradable grease must not be released into the
environment.
Lubricants must be free of solids. Don’t use any graphite lubricants.

Warning!
Use of incorrect lubricants, failure to follow maintenance intervals or
lack of lubrication may cause damage to the unit and increase repair
cost and downtime.

Grease:
Available from most PALFINGER MARINE partners according to national guidelines under

Order no. EZ 982 – 5 kg (11 lb) can

Order no. EZ1432 - 50 kg (110 lb) barrel
Order no. EZ6327 - 500 g cartridge
Order no. EZ6328 - 400 g cartridge
Order no. CPET1271 - 500 g grease gun

Technical data Tested according to

Structure smooth

Consistency (NLGI) 2 DIN 51818

Indication code KP2K-35 DIN 51502

Dropping point °C 150 ISO 2176

Walk penetration 265/295 1/10 mm ISO 2137

Oxidation stability
max. 0.2 bar DIN 51808
100h/100°C
Basic oil viscosity at
> 80 mm²/s
40° C

Behavior in water Assessment level 0/90 DIN 51807-1

79
Maintenance

Lubrication

Unintended crane movement during lubrication creates an acute risk

of fatality for the operator and others.

Turn off the crane every time before lubricating.

Grease nipples must take grease easily. Replace any damaged or seized grease nipples. If it is
impossible to press in grease even after replacing the nipple, contact your PALFINGER MARINE
partner.

Lubricating:

Dirt in the bearing may cause damage to the unit and increase repair
cost and downtime.

• Remove all old, dirty grease and other contamination from the lubricating point. Otherwise dirt in
old grease will be pressed into the bearing point.
• Press the grease into the bearing point.
• Move the components. This distributes the grease in the bearing.
• Press more grease into the grease nipple.
• Repeat this until fresh grease begins to come out of the bearing point.

Excess grease at lubricating points and bearing points increases the

risk of accident and is a danger to the environment.

• After lubricating remove any excess grease.

• Do not use excess grease again.
• Dispose of excess grease in accordance with the applicable local laws!
Grease all lubricating points on the unit.

Note!
In order to allow the lubricant to evenly distribute in the bearing
points it is necessary to run each crane movement once completely
after finishing lubrication.

80
 Chapter 9 Maintenance

Paint repair

Note!
Paint protects the unit against corrosion. Repair paint damage
immediately.

1. Prepare (grind and clean) damaged areas.

2. Prime and paint damaged areas.

81
 Chapter 10 Service

Chapter 10

Service

In this chapter
General.................................................................................................................85
Tightening torques / testing torques..................................................................... 87
Check of safety equipment...................................................................................89
Protective hoses...................................................................................................89
Repairs................................................................................................................. 89

83
 Chapter 10 Service

General

Note!
All service work must be carried out by PALFINGER MARINE service
partners. Non-compliance results in loss of any warranty and liability.

Service intervals
Service symbols

Functional check

Change

Visual inspection

Check bolts for tightness

Correct testing torque of the screws, see section 'Tightening torques / testing
torques’, table 2.

Initial servicing after 50 operating hours

Designation Activity

Hydraulic lines, hydraulic hoses, screw joints

After every 1000 operating hours or once every year

Designation Activity

Hydraulic lines, hydraulic hoses, screw joints

For the testing torques of all high-tensile pre-stressed screw joints (HV
screws) on the device see chapter 11 'Service', section 'Tightening torques /
testing torques', table 2.

Paint

Operating levers

Basket leveling system

Radio remote control

85
Service

Every 6 years

Description Activity

Hydraulic hoses

86
 Chapter 10 Service

Tightening torques / testing torques

Loose, damaged or over-tightened threaded connections can break
under load. There is risk of fatal injury.

Note!
Tighten bolts only using a torque wrench and by applying the
prescribed tightening torque.

Insert:
1. High-tensile bolts

87
Service

Table 1:

TIGHTENING TORQUES
ISO bolts in Nm:
(not oiled, not greased and dry, friction coefficient µ = 0.12 - 0.18)

Screws: DIN EN ISO 4762, 4014

Nuts: DIN EN ISO 4032

Washers: DIN EN ISO 7090

Thread: Strength: 8.8 Strength: 10.9

M 12 75 105

M 14 120 168

M 16 185 258

M 18 255 356

M 20 360 505

M 24 620 875

M 27 925 1296

M 30 1250 1760

High-strength bolting assemblies for preloading (high tensile

prestressed bolts) must be replaced by new original PALFINGER
MARINE high tensile prestressed bolts when having been loosened or
undone.
Reuse of old high-tensile bolts is prohibited!

Note!
When tightening high-tensile bolts, do not apply tightening torques,
but apply test torques (table 2).

88
 Chapter 10 Service

Table 2:

TEST TORQUES for high-tensile prestressed bolts

ISO bolts in Nm:
(not oiled, not greased and dry, friction coefficient µ = 0.12 - 0.18)

Screws: DIN EN ISO 4762, 4014

Nuts: DIN EN ISO 4032

Washers: DIN EN ISO 7090

Thread: Strength: 8.8 Strength: 10.9

M 12 64 89

M 14 102 143

M 16 157 219

M 18 217 303

M 20 306 429

M 24 527 744

M 27 786 1102

M 30 1063 1496

Check of safety equipment

Note!
The entire safety equipment must be checked during servicing
(overload test, etc.).

Protective hoses
During servicing, check protective hoses, covers etc. or replace damaged and missing parts.

Repairs
• Damages to the unit must be repaired immediately by a PALFINGER MARINE partner.
• Repairs have to be recorded in the service manual.
• If a repair is not carried out by a PALFINGER MARINE partner warranty will become void.

89
 Chapter 11 Decommissioning and disposal

Chapter 11

Decommissioning and disposal

In this chapter
Decommissioning and disposal guidelines...........................................................93

91
 Chapter 11 Decommissioning and disposal

Decommissioning and disposal guidelines

Properly disassemble the unit.

Warning!
Improper disassembly can cause an increased danger of accident.

• National regulations, standards and safety provisions must be complied with.

• Contact your PALFINGER MARINE partner for proper disassembly of the unit.
• Disassemble the unit into single parts according to the instructions of your PALFINGER MARINE
partner.
• Use the personal protective equipment.
• The unit must be switched off and the power supply disconnected.
• Secure the unit against being switched on unintentionally.
• Components must be secured with suitable equipment before and when being dismounted.

Disposal

Warning!
Clean all oily and greasy parts before disposal. Hydraulic oil and
grease must not be released into the environment.
Comply with the locally applicable laws when disposing of the unit's
single parts and consumables.

• National regulations, standards and safety provisions must be complied with.

• Clean all oily and greasy parts.
• Dispose of the device components according to their nature (steel, plastic, electric and electronic
parts, etc.).
• Dispose of hydraulic oils and grease - even biodegradable ones - in an environmentally friendly
manner.
• Contact your PALFINGER partner regarding the purchase of a new unit.

93
Index
Instruction label - Basket leveling system • 38
A Instruction label - Personal fall protection • 37
Adverse working conditions • 13 Instruction label - Read the operating
After every 1000 operating hours or once instructions! • 36
every year • 85 Intended use / Limits of the workman basket •
After maintenance, service and repairs • 22 11
B L
Bringing the workman basket in parking Lubricant specification • 79
position • 65 Lubrication • 80
C M
Capacity utilization indicator • 43 Machine lubrication • 78
Check of safety equipment • 89 Main components • 31
Cleaning • 74 Maintenance • 69, 73
Crane functions operation labels • 36 Meaning of the symbols • 35
D Modifications to unit • 26
Daily function check of safety equipment • 50 N
Danger from power lines • 21 Noise exposure • 20
Danger of getting crushed • 18 Notes regarding the operating instructions • 1
Decommissioning and disposal • 91
Decommissioning and disposal guidelines • 93 O
Device and function • 29 On operator station. • 35
Operating instructions • 3
E Operating levers and indicators • 32
Emergency operation • 59 Operating personnel • 27
Emergency stop function check • 50 Overview of labels • 36
Emergency-stop button • 42
Every 6 years • 86 P
Explanation of the operating labels • 34 Paint repair • 81
Payload • 58
F Personal fall protection • 10
Failure of electric system - Emergency Preparing for crane operation with workman
lowering via hand pump • 59 basket • 45
Failure of hydraulic system - Emergency Preparing for hook operation • 66
lowering via emergency drive • 61 Prerequisites for workman basket operation •
Finishing work with workman basket • 63 47
Foreseeable misuse of the device • 11 Protective hoses • 89
Functional check of retaining rail • 50
R
G Radio remote control operation with
General • 41, 23, 85, 71 connecting cable • 33
Government regulations and standards for Remote control handset on the workman
operating the unit • 13 basket • 33
Graphics and pictures • 6 Repairs • 89
H Residual risks • 12
Hazard warning symbols • 35 Risk of burns • 19
Hazardous substances • 19 Risk of falling • 18
I S
Initial servicing after 50 operating hours • 85 Safety and health protection • 7
Safety equipment • 39
Safety for individuals • 9
Service • 83
Service intervals • 85
Service symbols • 85
Ship tilt • 49
Start working • 57
SWL label on the workman basket • 37
Symbols • 4
System assembly • 26
T
Terms • 5
Tightening torques / testing torques • 87
Type plate • 25
U
Unauthorized use • 13
V
Validity of operating instructions • 3
Vibration, whole-body vibration • 20
Visual inspection • 76
W
Watch out for faults before and during
operation • 48
Workman basket leveling • 58
Workman basket operation • 55
Th
is
pa
ge
is
in
te
nt
io
na
lly
le
ft
bl
an
k
.