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Palfinger PC 3800 User Manual

Palfinger PC 3800
158 pages
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1
Operating Manual
Hydraulic Crane
PC 3800
Serial number:
DB1140+NAEN
Edition: 11/2016
Palfinger North America
7942 Dorchester Rd.
Niagara Falls, ON L2G 7W7
www.palfinger.com

Table of Contents

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Palfinger PC 3800 Specifications

General IconGeneral
BrandPalfinger
ModelPC 3800
CategoryConstruction Equipment
LanguageEnglish

Summary

Operating Manual Hydraulic Crane PC 3800

Notes Regarding Operating Instructions

Operating Instructions Overview

Explains the purpose and validity of the operating instructions.

Terms and Definitions

Defines key terms used throughout the operating manual for clarity.

Symbols and Graphics

Explains the meaning of symbols and the use of graphics in the manual.

Safety and Health Standards

Safety for Individuals

Ensures operator and bystander safety with guidelines on protective clothing.

Intended Use and Device Limits

Defines the proper usage and limitations of the crane to prevent hazards.

Residual Risks

Addresses unforeseen hazards and the operator's responsibility for safety.

Adverse Working Conditions

Specifies conditions like wind and temperature that prohibit crane operation.

Risk of Falling

Highlights the dangers of climbing on the unit and prohibited actions.

Danger of Getting Crushed

Details minimum safety distances to prevent crushing hazards.

Risk of Burns

Warns about hot components and the risk of burns from hot surfaces.

Noise Emission

Advises on noise levels and the use of hearing protection.

Dangers Caused by Exhaust

Discusses hazards from vehicle exhaust fumes during operation.

Danger from Power Lines

Outlines safety measures and minimum distances when working near power lines.

After Maintenance, Service and Repairs

Emphasizes checking safety equipment after any maintenance or repair.

General Information

CE Symbol and Declarations

Explains the CE marking and its significance for unit operation.

System Structure and Delivery

Details system installation and the delivery process to the operator.

Modifications to Unit

Prohibits unauthorized modifications and specifies who can perform them.

Operator Requirements

Lists qualifications and conditions required for crane operators.

Device and Function

Main Components Overview

Illustrates and lists the main components of the crane.

Function Labels

Explains the symbols on control levers for various crane functions.

Remote Control Console Symbols

Details the functions assigned to buttons on the remote control console.

Overview of Labels

Identifies and locates various labels and their importance on the crane.

Labels for North America

Specific labels used in USA and Canada concerning safety and operation.

Hazard Labels

Describes hazard labels related to boom, operator training, conditions, and overload.

Danger of Moving Stabilizer

Warns about the risks associated with moving stabilizers and required checks.

Crane Mounting and Inspections

Highlights the importance of correct mounting and regular inspections.

Rotating Shaft and Power Take Off

Safety precautions regarding rotating drive shafts and power take-off.

Manual Extension Booms Safety

Safety information for operating manual boom extensions.

Winch and Falling Load Hazards

Safety warnings for winch operations and avoiding two-block situations.

Electrocution Hazard Remote Control

Safety warning regarding power lines and remote control operation.

Safety Equipment

General Safety Systems

Overview of PALFINGER's safety systems and prohibitions on manipulation.

Emergency Cut-off Button

Details the function and operation of the emergency stop button.

Capacity Indicator

Explains the three-color scale of the capacity indicator and its limitations.

Hydraulic Overload Protection

Describes how the system prevents overload by blocking movements.

Overload Protection in Radio Remote Operation

How overload protection functions in remote control operation.

Transport Position Monitoring

Details optional systems for monitoring transport position.

Emergency Operation After Remote Control Failure

Procedures for operating the crane in emergency mode after control failure.

Setting Crane to Emergency Mode

Step-by-step guide to activate emergency mode on the control box.

Ancillary Equipment

General Ancillary Equipment Use

Guidelines for using suitable accessories and training for operators.

Slingers and Load Lifting Attachments

Safety precautions for using hooks, shackles, and other lifting gear.

Rope Winch Operation

Instructions for assembling and operating the rope winch safely.

Winch Components and Pulley Heads

Details on composite pulleys, rope deflection, and safe usage.

Rope Winding and Tension

Guidelines for winding the rope, preventing damage, and maintaining tension.

Mechanical Extension Booms

Safety warnings and procedures for extending and securing mechanical booms.

Remote Control System

General information, safety features, and components of the remote control.

Operating Levers on Remote Console

Explanation of buttons, LEDs, and function levels on the remote control console.

Preparing for Crane Operation

Fault Checks Before and During Operation

Procedures for identifying and reporting equipment faults.

Working Range Safety

Defines the working range as a danger zone and safety requirements.

Starting the Crane

Steps for starting the crane, including PTO engagement and operator limits.

Preparing for Remote Operation

Checks and precautions for the wireless remote control system.

Vehicle Inclination Limits

Specifies acceptable vehicle inclination angles for safe operation.

Supporting the Vehicle

Critical steps and safety notes for properly supporting the vehicle.

Ground Condition Assessment

Checks for soil stability, hollows, and inclination before supporting.

Stabilizing Sequence

Procedure for extending stabilizers and warnings about lifting the vehicle.

Pulling Outrigger Beams Manually

Step-by-step guide for manually extending and securing outrigger beams.

Bringing Load Arm to Working Position

Prerequisites for unfolding the crane and safety checks.

Daily Function Check of Safety Equipment

Procedures for checking the emergency cut-off and overload protection systems.

Crane Operation

Load Limits and Capacity Charts

Information on load limits, labels, and capacity charts for safe lifting.

Working Position of the Crane

Impact of working position on load capacity and component wear.

Working Range and Boom Angles

Defines optimal working range and prohibits fully lowered boom positions.

Load Handling Close to Crane

Guidelines for lifting loads with extension booms and boom system angles.

Loads: Preparation and Handling

Checks for load lifting gear, securing loads, and handling procedures.

Working with Loads Safety

Safety notes for operators and signalers when handling loads.

Attaching and Detaching Loads

Procedures and safety warnings for attaching/detaching loads.

Lifting and Moving Loads

Warning about loads rubbing against the load arm and minimum distances.

Crane Control Operation Hazards

Hazards associated with control operation, abrupt movements, and cylinder stops.

Lowering the Load

Precautions when lowering loads, especially without overload protection.

Landing the Load Safely

Guidelines for safe load landing and avoiding sudden boom snap-up.

Work Interruptions and Resuming Work

Procedures for leaving the crane unattended and resuming operation.

Ending Operation

Bringing Crane into Transport Position

Steps to safely fold and secure the crane for transport.

Resting Boom on Vehicle Platform

Securing the boom system and monitoring vehicle height.

Retracting Stabilizers

Procedures and safety warnings for retracting stabilizers.

Ending Radio Remote Control Operation

Steps to safely end remote control operation and secure the console.

Before Driving Checks

Essential checks before driving to ensure the crane is secured.

Maintenance

General Maintenance Guidelines

Emphasizes qualified personnel, compliance with guidelines, and spare parts.

Operating Hours Counter

Explanation of the operating hours counter display and service scheduling.

Maintenance Tasks Order

Specifies the correct sequence for maintenance tasks: cleaning, inspection, lubrication.

Cleaning Procedures

Instructions for cleaning the unit using environmentally friendly agents.

Visual Inspection Checklist

Detailed checks for fasteners, steel parts, hydraulic and electric systems.

Rope Winch Components Inspection

Inspection of rope winch components and visual check of the rope.

Machine Lubrication Guidelines

Information on lubricant types, specifications, and safe application.

Hydraulic Oil Change and Maintenance

Schedule and actions for hydraulic oil change and maintenance.

Hydraulic Oil Specifications

Required characteristics and operating temperatures for hydraulic oils.

Paint Repair

Instructions for repairing paint damage to prevent corrosion.

Service Intervals and Procedures

General Service Requirements

All service work must be performed by PALFINGER partners.

Check of Threaded Fasteners

Ensures proper tightening of fasteners to prevent failures.

Initial Servicing Schedule

Defines tasks for initial servicing at 50 operating hours and one year.

Regular Servicing Schedule

Tasks for servicing after 500 operating hours or annually.

Extended Service Schedule

Tasks for servicing every 3000 hours/3 years and every 6 years.

Gear Oil Replacement

Schedule and specifications for gear oil replacement.

Check of Control Equipment

Ensures all safety equipment is checked during servicing.

Protective Hoses Inspection

Check and replacement of protective hoses and covers.

Repairs and Warranty

Procedure for repairs and the effect of non-authorized repairs on warranty.

Lowering Rate Specification

Maximum permissible lowering rate for safe operation.

Decommissioning and Disposal

Disassembly and Disposal Guidelines

Instructions for proper unit disassembly and environmentally friendly disposal.

Technical Description

Basic Data and Specifications

Key specifications including lifting moment, capacity, outreach, and pressure.

Crane Weight Configurations

Details weight specifications for different crane configurations and accessories.

Extension Specifications

Information on maximum outreach, weight, and load capacity for extensions.

Transport Position Dimensions

Diagrams showing crane dimensions in transport position.

Working Position Diagrams

Illustrations of crane configurations in various working positions.

Rope Winch and Component Dimensions

Dimensions and specifications for rope winch and related components.

Control Stand and Counter Control Dimensions

Diagrams and dimensions for control stand and counter control units.

Radio Remote Control Unit Dimensions

Diagrams and dimensions for the radio remote control unit.

Stationary Mounting Specifications

Details for stationary mounting, including fixation and torque specifications.

Lifting Capacity Diagram PC 3800 A

Load capacity chart for PC 3800 A configuration.

Lifting Capacity Diagram PC 3800 B

Load capacity chart for PC 3800 B configuration.

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