This document is an operating and maintenance manual for the Palfinger Clocktower PK2400 TK, a crane system designed for lifting, moving, carrying, and setting down loads. It emphasizes safe and reliable operation, adherence to maintenance schedules, and compliance with safety regulations.
Function Description:
The Palfinger Clocktower PK2400 TK is a working machine equipped with an electronic crane control system, Paltronic 150, which manages all safety systems during crane operation. It is primarily operated via a wireless remote control system, though a wired remote control option is available for situations with radio interference or when the radio remote control is disabled. The crane is designed to handle loads within specified limits, with a focus on safe working positions to minimize stress on components and prevent overload. It features a rope winch for load handling and can be equipped with ancillary equipment such as a workman basket.
Important Technical Specifications:
- Control System: Paltronic 150 electronic crane control system.
- Operation Modes: Basket operation (workman basket/material basket), crane remote control operation, manual emergency operation.
- Remote Control Battery Life: An undamaged, fully charged battery operates for about 4 hours, with a charging time of 3 hours.
- Wind Speed Limits: Maximum wind speed for working in and with the basket is 10 m/s. A warning horn activates at 8 m/s (intermittent alarm) and 10 m/s (continuous alarm).
- Temperature Limits: Operation is not recommended at ambient temperatures below +5ºC (41°F) or above +50ºC (122°F), with an average ambient temperature not exceeding +40°C (104°F) during operation.
- Safety Features: Emergency cut-off button, Paltronic 150 control system with HPLS (High Performance Lifting System) for speed and lifting force control, load-dependent geometry monitoring, soft stop function, negative load limits, and OLP (Overload Protection) function.
- Rope Tension Control (RTC): Allows folding/unfolding cranes with the rope reeved, maintaining rope tension via the rope winch during geometry changes.
- Frequency Switch: The system has 12 programmed frequencies, starting with the original frequency.
Usage Features:
- Remote Control: The primary method of operation, with distinct buttons and symbols for slewing, main boom lift/lower, extension boom extend/retract, rope winch raise/lower, outer boom lift/lower, rope protection cylinder extend/retract, and crane interlock lock/unlock. It also includes motor start/stop, deadman buttons, warning horn, and crane speed adjustment.
- Operator Station: Provides a key switch for selecting operating modes (workman basket, remote control, manual emergency operation) and an emergency cut-off. Manual levers are available for emergency control.
- Display Unit: The Paltronic 150 display shows status indicators (AOS, HPLS, RTC), selected crane speed, and graphical representations of operating status, including capacity indicators for the main crane and second fly jib, battery charge status, and radio signal strength. It also displays fault indicators with error codes for various limit conditions or errors.
- Load Handling: Cranes are to be used only within specified load limits. Special attention is given to load handling close to the crane using the rope winch or long lifting gear, emphasizing smooth movements and avoiding overstretching.
- Workman Basket Operation: Requires two operators (one in the basket with remote control, one at the crane control station), visual inspections, safety equipment checks, and adherence to specific safety guidelines regarding wind speed, crushing points, and communication.
- Emergency Procedures: Detailed instructions for emergency cut-off, emergency operation after remote control failure (connecting a wired handset or using the emergency operator station), and handling electric or hydraulic system failures.
Maintenance Features:
- Regular Cleaning: The unit must be cleaned at regular intervals to prevent increased wear due to dirt.
- Maintenance Intervals: Adherence to prescribed maintenance intervals is crucial for long-term reliability and cost-effectiveness.
- Safety Equipment Checks: Function checks of all safety equipment (standard and optional) are absolutely necessary after every maintenance, repair, or service.
- Remote Control Care: Keep the remote control clean, protect it from moisture, replace damaged gaskets and operating elements immediately, and have it checked for proper operation during servicing.
- Battery Management: Batteries should always be fully charged and discharged to maximize service life. Defective batteries must be replaced and disposed of according to local regulations.
- Modifications: Only PALFINGER service partners are allowed to modify the unit or remove protective devices.
- Disassembly and Disposal: Proper disassembly and disposal of the unit and its components (oily parts, steel, plastic, electric, electronic parts, consumables) must follow local regulations and be carried out by authorized PALFINGER partners.
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