PC 3800

Operating Manual
Hydraulic Crane
PC 3800
Serial number:
DB1140+NAEN
Edition: 11/2016
Palfinger North America

7942 Dorchester Rd.
Niagara Falls, ON L2G 7W7 1
www.palfinger.com
Dear customer,
thank you for purchasing and putting your faith in a quality product from
PALFINGER. During the development and manufacture of your unit,
everything was done to ensure that the equipment operates reliably and
safely.
Please note the information that follows so that you can work with your
PALFINGER product reliably and cost-effectively over the long term.
• Please follow all safety instructions.
• Please maintain your PALFINGER unit in accordance with regulations.
• Please adhere to the prescribed maintenance intervals.
• The unit must be cleaned at regular intervals, since dirt increases the
amount of wear.
• Contamination by grease and oil increases the risk of accidents.
• All prohibitions and notes in these operating instructions must be
complied with, since they protect your life and the lives of other persons.
We wish you great success with your PALFINGER product!
Contents
Contents
Notes regarding the operating instructions .........................................................1

Operating instructions....................................................................................................... 3
Validity of operating instructions ....................................................................................... 3
Terms ............................................................................................................................... 4
Symbols ............................................................................................................................ 5
Graphics and pictures....................................................................................................... 5
Safety and Health Standards ..................................................................................7
Safety for individuals ........................................................................................................ 9
Use for intended purpose / limits of the device ............................................................... 10
Residual risks ................................................................................................................. 11
Government regulations and standards for operating the unit ........................................ 12
Adverse working conditions ............................................................................................ 12
Risk of falling .................................................................................................................. 13
Danger of getting crushed .............................................................................................. 13
Risk of burns................................................................................................................... 15
Noise emission ............................................................................................................... 15
Dangers caused by exhaust ........................................................................................... 16
Danger from power lines ................................................................................................ 16
After maintenance, service and repairs .......................................................................... 18
General ...................................................................................................................19
CE symbol ...................................................................................................................... 21
Structure of system......................................................................................................... 21
Modifications to unit ........................................................................................................ 22
Operators........................................................................................................................ 22
Device and function ..............................................................................................23
Main components ........................................................................................................... 25
Function labels ............................................................................................................... 27
Overview of labels .......................................................................................................... 30
Safety equipment ...................................................................................................39
General ........................................................................................................................... 41
Emergency cut-off button / push-button .......................................................................... 41
Capacity indicator ........................................................................................................... 42
Hydraulic overload protection ......................................................................................... 43
Overload protection in radio remote control operation .................................................... 43
Transport position monitoring system ............................................................................. 44
Emergency operation after remote control failure ........................................................... 44
Ancillary equipment ..............................................................................................47
General ........................................................................................................................... 49
Slingers, other attachments to lift the load ...................................................................... 50
Ancillary equipment ........................................................................................................ 51
Remote control ............................................................................................................... 58
Preparing for crane operation ..............................................................................65
Watch out for faults before and during operation ............................................................ 67
Working range ................................................................................................................ 68
Starting the crane ........................................................................................................... 69
Preparing for remote operation ....................................................................................... 69
Contents
Vehicle inclination ........................................................................................................... 71

Supporting the vehicle .................................................................................................... 72
Pulling outrigger beams out manually ............................................................................. 75
Stabilizer cylinders .......................................................................................................... 76
Bringing the load arm to working position ....................................................................... 76
Daily function check of safety equipment........................................................................ 78
Crane operation .................................................................................................... 79
Load limits ...................................................................................................................... 81
Working position of the crane ......................................................................................... 81
Loads .............................................................................................................................. 84
Working with loads ......................................................................................................... 85
Ending operation .................................................................................................. 91
Bringing the crane into transport position ....................................................................... 93
Retracting the stabilizers ................................................................................................ 94
Ending radio remote control operation ............................................................................ 97
Before driving ................................................................................................................. 97
Maintenance .......................................................................................................... 99
General ......................................................................................................................... 101
Operating hours counter ............................................................................................... 102
Maintenance ................................................................................................................. 103
Cleaning ....................................................................................................................... 104
Visual inspection........................................................................................................... 105
Machine lubrication ....................................................................................................... 107
Hydraulic oil change ..................................................................................................... 112
Paint repair ................................................................................................................... 115
Service ................................................................................................................. 117
General ......................................................................................................................... 119
Check of threaded fasteners......................................................................................... 119
Initial servicing after 50 operating hours ....................................................................... 121
Initial servicing after one year ....................................................................................... 121
After every 500 operating hours or once every year ..................................................... 121
After every 3000 working hours or once every three years .......................................... 122
Every 6 years................................................................................................................ 122
Gear oil ......................................................................................................................... 122
Check of control equipment .......................................................................................... 123
Protective hoses ........................................................................................................... 123
Repairs ......................................................................................................................... 123
Lowering rate ................................................................................................................ 123
Decommissioning and disposal ........................................................................ 125
Decommissioning and disposal guidelines ................................................................... 127
Index..................................................................................................................... 129
Technical description ......................................................................................... 131
Chapter 1
CHAPTER 1
Notes regarding the operating

instructions
In this chapter
Operating instructions ................................................................................. 3
Validity of operating instructions ................................................................. 3
Terms ......................................................................................................... 4
Symbols ..................................................................................................... 5
Graphics and pictures ................................................................................. 5
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 (driver’s cab).
Note! In case of damage or loss of these operating instructions

please contact your PALFINGER partner and request a new copy.
Neither the operating instructions nor the annexed Technical Sheets replace proper operator training.
Please contact your PALFINGER 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 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.
© Copyright by PALFINGER Copying (even in extracts) only permitted with written

approval from:
PALFINGER AG
Lamprechtshausener Bundesstraße 8
A-5101 Bergheim near Salzburg
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
Terms
Operating company The owner, lessee, renter of the unit, uses the unit, operates the unit either himself or
entrusts a third party with the operation.
Operator Anyone who starts up the unit.
Start Switch unit on, irrespective of purpose (operation, maintenance, service etc.)
Assistant Provides assistance but does not operate the unit.
Installer Fits the unit to the vehicle.
Service partner Authorized by PALFINGER.
Expert Someone with sufficient knowledge of loading cranes due to their technical training and
experience who is familiar with the relevant government laws and regulations to the
extent that they can assess whether the equipment is safe for operation.
Properly A person who observes and complies with all duties of care that his work involves acts
properly.
Negligent A person who disregards the duties that his work involves acts (grossly) negligently.
(Grossly) negligent Who fails to observe what should be obvious to anybody under the respective
circumstances.
Load moment The moment that is exerted by the load, ancillary equipment, lifting devices, etc. that
are hanging on a hook.
Inherent moment The moment that is exerted by the dead weight of the boom system.
Lifting capacity Consists of the load moment and the inherent moment
Lifting power The force needed to lift an object.
Overload situation Reaching of the maximum permissible load for the current working position.
Working position Crane position.
Working range The area that is required to carry out the work.
Movement range The area within which the crane can be moved.
Load range The range within which the respective crane can handle loads.
Load path The course of the path that is taken my the moved load.
Hold load Holding the lifted load under the supervision of the operator whilst the crane safety
systems are activated.
Setup status Crane that has been prepared for the respective work.
EU European Union.
CE marking Shows that the unit has been manufactured in accordance with the EU directives.
Operating instruction Produced in addition to these operating instructions by the operating company for
special operating conditions.
Emergency operation Operating mode that is not for normal crane operation. Used to put the crane into
transport position after a failure of the electrical system and/or the safety equipment.
4
Chapter 1 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
Graphics and pictures
Note!
Some of the pictures (for instance of the crane) in these instructions
are symbolic representations and for illustration only.
5
Chapter 2
CHAPTER 2
Safety and Health Standards
In this chapter
Safety for individuals .................................................................................. 9
Use for intended purpose / limits of the device ......................................... 10
Residual risks ........................................................................................... 11
Government regulations and standards for operating the unit ................... 12
Adverse working conditions ...................................................................... 12
Risk of falling ............................................................................................ 13
Danger of getting crushed ........................................................................ 13
Risk of burns ............................................................................................ 15
Noise emission ......................................................................................... 15
Dangers caused by exhaust ..................................................................... 16
Danger from power lines........................................................................... 16
After maintenance, service and repairs..................................................... 18
7
Chapter 2 Safety and Health Standards
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
Use for intended purpose / limits of the device

Use the crane only within the load limits shown on the load capacity chart to lift, move, carry and set
down loads. For load capacity chart refer to chapter 13, 'Technical description'.
Caution!
Improper use endangers people and causes damages to the crane and
loss of warranty and liability.
If the operating instructions of any ancillary equipment or instructions prepared by the operating
company allow other use (for instance excavating or diagonal pull), which contradict these operating
instructions, then the crane's operating instructions shall have priority.
It is allowed to:
• Load/unload your own vehicle or another vehicle;
• Lift and move loads at or down from large heights;
• Lift and move loads below ground level;
• Lift loads up to a specific height and hold them in this height for assembly works (e.g. rafters, steel
girders, etc.)
• Occasional grab application for lifting and moving bulk materials such as loose sand, gravel etc.
Caution!
If the device is used against orders there is severe risk of fatal injury
to the operator and others.
10
It is not allowed:
• To use the device for other purposes than the ones specified above;
• To use the device for logging and scrap application;
• To push against obstacles or loads;
• To pull, to pull things loose, any diagonal pull;
• Abrupt release of boom system load;
• To attach loads to other positions on the crane than the intended ones;
• To move dangerous loads (e.g. molten material).
• Any excavating work with the grab (refer to 'Grab', chapter 6 'Ancillary equipment’);
• To transport persons;
Exception: Transporting persons in the PALFINGER workman basket, only on specially equipped
cranes. National laws, regulations and standards must be complied with.
Note!
Matching workman baskets are available from all PALFINGER
partners.
Accidents caused by incorrect use are grossly negligent if:

• The device is not used as intended.
• The device is started and used by untrained, unqualified individuals.
• The present 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 partner.
• Parts other than original PALFINGER spare parts have been installed.
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. Therefore, PALFINGER 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.
11
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.
Adverse working conditions

Do not operate the crane
• at wind speeds of 50 km/h (30 mph) and above;
• at wind speeds from 34 km/h (20 mph) when lifting bulky loads or working in near vertical position;
Wind speed in
Description m/s km/h mph
Beaufort
Wind can be felt on the
0 -2 face or exposed skin. Tree max. 3.4 max. 11 max. 8.1
leaves rustle.
Leaves and twigs are in
3 constant motion while the 3.4 to <5.5 12 - 19 8.1 to <12.7
wind will extend light flags.
Branches are in motion,
4 the wind will raise dust, 5.5 to < 8.0 20 - 28 12.7 to <18.4
leaves, and loose paper.
Larger branches and trees
5 begin to sway, whitecaps 8.0 to <10.8 29 - 38 18.4 to <25.3
on lakes.
Large tree branches are in
6 motion, the wind whistles 10.8 to <13.9 39 - 49 25.3 to <32.2
in overhead wires.
Whole trees are moving in
the wind while walking
7 13.9 to <17.2 50 - 61 32.2 to <39.1
becomes affected by the
wind.
• 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.
Danger!
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.
12
Risk of falling
Warning!
Climbing up on the unit can lead to the individual falling or the unit
being damaged. There is an acute danger of accident.
Climbing on the unit is prohibited.

Exception: Climbing up to operating stands using climbing aids (see ‘High stand, top seat’, Chapter 6)
or climbing to the emergency operator station at the crane column (see ‘Emergency control operation
after remote control failure’, Chapter 5).
Cables, sensors, sensor attachment lugs, drivers for sensors etc. may not be used as steps and / or
handles.
Warning!
If you need to climb up the machine for instance for visual checks,
maintenance and servicing absolutely use a climbing aid (e.g. ladder).
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!
13
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.
Crushing points
Possible crushing points.
More crushing points may result from your installation and use.
14
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!
In order to avoid burns, the exhaust system of the vehicle must be covered in the operating area, or a
safe distance must be maintained.
No smoking!
No naked flame!
Noise emission
Warning!
Permanent low or short high noise emission levels endanger the
health of operators and bystanders.
Main source of noise: Vehicle motor.
Protective measures: Ear protection.
Operators have to comply with the relevant national noise control standards and laws.
Measuring values
Near operating stands of loading cranes which are mounted to Diesel motor vehicles (also in case of
remote control operation within 1 m (3,3 feet) from the vehicle) the sound pressure level depends on
vehicle model, status of operation (idling speed, full load) and crane installation, so the following values
can be reached:
• At low or high idling speed of the vehicle engine 72 to 84 dB(A)
• In crane operation 79 to 86 dB(A)
• The sound power level is between 92 and 100 dB(A).
Note!
In order to reduce noise exposure it is recommended to maintain a
low idling speed and use the remote control at a distance from the
vehicle motor greater than 1 m (3,3 feet).
15
Dangers caused by exhaust

Exhaust components such as carbon monoxide, nitrous oxides or diesel soot can put the operator on
the operator station at risk.
It must therefore be ensured that:
• the vehicle exhaust does not flow into the vicinity of operating stands.
• when working in closed rooms, the vehicle exhaust must be led outside using suitable auxiliary
materials.
Danger from power lines

Caution! Even approaching a power line may lead to an electric
shock. The operator will receive a fatal electric shock.
Condition and height of power lines do not say anything about their voltage.
If the voltage is unknown, the minimum distance from lines is 5 meters (16.5 feet). This applies to the
crane, ancillary equipment, rope winch, rope, load handling attachment and load.
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!
Also to be considered: Power lines move in the wind. Power lines can also be out of the operator's
view.
The main boom of the crane or the load can swing because of a jerky movement (including up and
down). This unwanted movement may mean that you get closer to power line. The crane, ancillary
devices, the load handling attachment or the load may be electrified.
16
Minimum distances from live lines
Voltage Minimum distance
up to 1,000 Volts 1.0 meter (3.3 feet)
unknown or over 1,000 Volts 5.0 meters (16.5 feet)
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.
Danger!
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 vehicle, device, load or broken power lines is 20 meters / 66 feet
(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 high stand, top seat, driver's cab, truck bed or
workman basket; stay where you are and don't touch anything.
• Do not touch the device, the load or the broken lines.
• Immediately arrange the switch-off of the live electric line.
Danger!
Approaching any persons, devices or loads 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.
17
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)!
18
Chapter 3
CHAPTER 3
General
In this chapter
CE symbol ................................................................................................ 21
Structure of system................................................................................... 21
Modifications to unit .................................................................................. 22
Operators ................................................................................................. 22
19
Chapter 3 General
CE symbol
In the EU and in certain countries, the unit may only be operated with
• A valid CE symbol for the unit and the 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.
Auxiliary devices require their own CE markings and their own conformity declaration.
Structure of system
Through a PALFINGER partner in compliance with the Palfinger installation guidelines.
Carry out any legally required acceptance.
If the design differs from that of a truck loading crane (example: stationary installation) the load values
may change. If you need any further information please contact your PALFINGER 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 control equipment.
• Delivery of maintenance manual, operating instructions (including any additions required by
installation) and declarations of conformity for vehicle, crane and ancillary equipment, etc.
• Confirmation of any legally required acceptance.
• Registration: Warranty.
The company operating the equipment has to initiate any legally required periodic inspections.
21
General
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 according to chapter
'Maintenance'.
Danger!
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 service partners.
Operators
This system is a working machine that can be extremely dangerous to the operator and other persons
if it is operated incorrectly or improperly. For this reason, the unit may only be started up by persons
who meet all of the conditions specified below.
Caution!
If the unit is operated without training and/or knowledge of these
operating instructions, there is an acute risk of fatal injury for
operators and other persons.
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:

• 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 contents of the operating instructions of all additional equipment used.
• Be familiar with the respective national regulations, standards and laws concerning the operation
of this unit and all auxiliary devices that are used.
• Physical and mental fitness for the job.
• Be responsible, reliable and able to concentrate.
• The legally required training (pay attention to national laws).
• Be in no way incapacitated by alcohol, drugs or medication.
• Fulfill the minimum age requirement (pay attention to national laws).
22
Chapter 4
CHAPTER 4
Device and function
In this chapter
Main components ..................................................................................... 25
Function labels ......................................................................................... 27
Overview of labels .................................................................................... 30
23
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.
5 6 7 8 19 20
10
16 1
2
11
13
14
12 15 17 18
Find the names of the main components on the next page.
25
Device and function
1 Crane base
2 Assembly frame
3 High-tensile, high-alloy bolts
4 Swivel motor
5 Crane column
6 Lifting cylinder
7 Main boom
8 Extension cylinder
9 Hydraulic extension booms
10 Mechanical extension boom
11 Stabilizer outriggers
12 Cam lock
13 Stabilizer cylinders
14 Crank-down stabilizer
15 Hydraulic oil tank
16 Operator station
17 Rope winch
18 Pulley head
19 Hook
20 Radio remote control
26
Function labels
The function labels are explained below. The order of functions (symbols) may be different on your
operator station from the example shown below. Therefore it is absolutely essential to familiarize
yourself with the symbols and how they are arranged on your device.
Stabilizer cylinder
Retract
Extend
Slewing
Clockwise (right)
Counter-clockwise (left)
Main boom
Lower
Lift (hoist)
Extension boom
Extend
Retract
27
Device and function
Symbols of remote control console

Depending on the labelling of the panel buttons (levels 1 and 2) the following functions are enabled by
pushing the buttons:
Slew clockwise (right)
Slew counter-clockwise (left)
Lower main boom
Lift main boom
Extend extension boom
Retract extension boom
Lower rope winch
Raise rope winch
Extend outrigger beam
Retract outrigger beam
Extend stabilizer cylinder
Retract stabilizer cylinder
Open grab
Close grab
Rotator counter-clockwise (left)
28
Rotator clockwise (right)
Warning horn
Working light on / off
Motor start
Motor stop
Increase engine RPM
Reduce / increase speed
29
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.
Danger! 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.
Overview of labels:
30
1.
1. Company name label
Position:
Both sides on main boom and fly-jib
2. Crane model label

Position:
Both sides of main boom.
Meaning:
Product title.
3. Indication for completely extended outrigger beam

Position:
On the outrigger beam.
Meaning:
Outrigger beam completely extended.
Risk if ignored:
If outrigger beam is not completely extended the vehicle stability
may be reduced.
4. Type plate
Position: On the crane column.
Meaning: Information about
1 Machine type
2 Internal code
3 Serial number
4 Year built
5 Company address
The identification plate may not be changed or removed.
5. Load capacity label

Position:
Operating stand.
Meaning:
Specification of loads, load ranges and ranges.
Risk if ignored:
Overloading the crane, danger of the vehicle tipping over.
31
Device and function
6. Identification plate for manual boom extensions

Position:
On manual extensions.
Meaning:
Information about year built, device type, maximum capacity.
Risk if ignored:
Damages to the crane and risk of fatal injury.
7. Operating lever instruction label

Position:
On operating stand.
Meaning:
Indicates the functions of the operating levers.
Risk if ignored:
Risk of unintended crane operations and danger to life.
8. Warning sign 'Keep out from under suspended loads'.

Position:
On both sides of outer boom or main boom.
Meaning:
It is prohibited to step under the suspended load.
Risk if ignored:
Risk of fatal injury by falling loads.
9. Pulley head identification plate

Position:
On the pulley head.
Meaning:
Information about year built, device type, technical data. The
identification plate may not be changed or removed.
Risk if ignored:
Damages to the crane and risk of fatal injury.
32
10. Functional label / covering film

Position:
Covers drilled holes and cut-outs on the device (in or near the
operating area) where there is increased risk of getting crushed,
cut or injured by shearing. Position on the overview of labels meant
as example. Depending on crane design the position may vary.
Meaning:
Serves to exclude the danger of getting crushed, cut and injured by
shearing.
Risk if ignored:
If this label is missing or damaged there is danger of getting
crushed, cut or injured by shearing.
33
Device and function
Labels for North America

Following labels are only used in USA and Canada. Operators have to read and understand all
additional labels.
Electrocution hazard (manual or manual / RRC control)

Position: Near the operator station.
Meaning: Shows minimum required distances to live electrical
power lines; remote control not insulated.
Risk if ignored: Death or serious injury.
Electrocution hazard
Position: On 4 sides of the vehicle.
Meaning: Bystanders keep distance from the crane/vehicle in case
of flash over.
Never ride the boom or hoist people

Meaning: Under no circumstances shall any personnel be
transported on a boom, hook, load, or any device
attached to the crane, boom or load line.
34
Stay clear of the boom

Meaning: Stand on the side opposite the boom when folding or
stowing the crane. Stay clear of the boom when
operating or servicing the crane.
Well trained operator

Meaning: Only well trained operators must operate the crane.
Operating conditions and requirements

Meaning: Observe all operating conditions and requirements.
Overload hazard
Meaning: Don't exceed loads, work areas, ratings.
35
Device and function
Danger of moving stabilizer

Position: On every stabilizer cylinder.
Meaning: Do not operate any stabilizer unless you or a signal
person can see that all personnel are clear of the
stabilizer and its ground contact point.
Risk if ignored: Serious crushing injury.
Crane mounting and prescribed inspections

Meaning: Do all prescribed inspections and maintenance practices.
Keep clear or rotating drive shaft, power take off

Position: On both sides of the vehicle.
Meaning: Keep clear of rotating drive shaft. Never work on or near
an installed power take off or drive line with the engine
running.
Manual extension booms (if equipped)

Meaning: How to operate manual boom extensions.
36
Winch / falling load hazard (if equipped)

Meaning: Avoid two-block situation.
Electrocution hazard remote control (if equipped)

Position: On the RRC handset.
Meaning: Shows minimum required distances to live electrical
power lines; remote control not insulated.
37
Chapter 5
CHAPTER 5
Safety equipment
In this chapter
General .................................................................................................... 41
Emergency cut-off button / push-button .................................................... 41
Capacity indicator ..................................................................................... 42
Hydraulic overload protection ................................................................... 43
Overload protection in radio remote control operation .............................. 43
Transport position monitoring system ....................................................... 44
Emergency operation after remote control failure ..................................... 44
39
Chapter 5 Safety equipment
General
PALFINGER 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.
Danger!
Any unauthorized manipulation to the safety devices leads to danger
of fatal injury.
Only PALFINGER service partners are allowed to set up and adjust the safety equipment.
Manipulating or inactivating these safety features is not allowed.
Danger!
In case of failure of any protective device, stop operating the unit
immediately and contact your PALFINGER partner. There is severe
risk of fatal injury!
Note!
Any warranty and liability of the manufacturer will expire if
unauthorized persons manipulate the safety features or seals are
broken.
On the operating company's/operator’s request the PALFINGER service partner has to replace any
missing or damaged seals immediately.
Emergency cut-off button / push-button

The emergency cut-off button / push-button stops all crane functions within 0.5 seconds (500 ms) after
activation in an emergency situation.
An emergency cut-off button can be found at every operating station and on the radio remote control
handset.
1. In a dangerous situation let go all operating elements immediately.

2. Actuate the emergency cut-off.
All crane functions stop.
Caution!
Releasing the emergency cut-off button before ensuring safe crane
operation leads to acute risk of fatal injury.
41
Safety equipment
Release the emergency cut-off button only in safe working conditions.
Capacity indicator
If the crane is equipped with a capacity indicator, it shows the current load status on a three-color
scale. The capacity indicator does not protect the crane from overloading.
2
1 3
Color Crane utilization

1 = green: Working range
2 = yellow: Limit range Lower operating speed.
3 = Red: Overload range Reduce load moment immediately.
Watch de capacity indicator while operating the crane.
Danger! If the load moment is not reduced immediately upon

reaching the overload range (example: retract extension booms) the
crane will be overloaded or become unstable. The load may sink
uncontrollably. This creates an acute risk of fatal injury.
It is prohibited to work in the red range.

While working in the limit range, do not increase the horizontal
reach any further when lowering the load.
42
Hydraulic overload protection

When the crane reaches the overload range the locking cylinders push the hand levers that increase
the load moment back into neutral positions.
The following movements will then be blocked:

Lower main boom
Extend extension boom
The hand levers will only be released when the load moment has been reduced.
If possible, reduce the load moment by operating

the ‘Retract extension boom’ function. After this all
crane functions will be operable.
No movements possible:
If crane movements that reduce the load moment are not possible because of the crane position (all
extension booms retracted), take the following steps to unlock the crane functions:
If the main boom is locked in the upper stop,

actuate the touch valve and
lower the main boom until the hand levers

(operating levers) are released.
Warning! The load moment briefly increases while the main boom is
being lowered above the horizontal.
All crane functions are operable again.
Overload protection in radio remote control operation

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

• Raise / lower main boom.
• Extend the extension boom.
• Raise rope winch.
The crane functions will only be released when the load moment has been reduced. Example: Retract
extension boom.
If crane movements that increase the load moment are not possible because of the rope winch (cut-
off), actuate ‘Lower the rope winch’ and land the load.
43
Safety equipment
Transport position monitoring system

The following systems are optionally available:
Main boom in horizontal position - maximum 0° (height warning) - legally required in Europe
(EN12999).
Monitoring of the manual outrigger beams (interlock) – legally required in Europe (EN 12999).
Usually the installer connects all above mentioned systems to a warning light and buzzer, as well as
immobilizer, etc. in the driver's cab.
Emergency operation after remote control failure

Small handset (P4):
Remove the battery and insert the charged spare battery. Charge the battery you removed
immediately.
If the crane movements are still not possible even via radio remote control:
Caution!
In emergency operation mode all safety devices such as emergency
cut-off button, transport position monitoring and all load moment
restricting systems, etc. are ineffective.
Immediately reduce the load moment in emergency operation.
If you continue working you put yourself and others at risk of fatality.
Immediately end loading operations.
Caution!
Emergency operation may only be used to move the crane to the
transport position.
After this contact a PALFINGER partner immediately to get the crane
repaired.
If you continue working you put yourself and others at risk of fatality.
Immediately end loading operations.
44
Set the crane to emergency mode.

Remove the cover of the control box.
Crane with PTO (power-take-
off)
Equipped with power pack

(electric motor):
For sending the external signal
to the power pack it is
necessary to press also button
B in addition to the procedure
described below.
1. Remove the seal from the override button A.

2. Press the override button to its stop.
3. Turn it counter-clockwise by 180°.
4. Then let the override button go.
The crane is now in emergency mode.
Moving the crane into transport position in emergency mode:

Operate the crane from the emergency operator station.
• If a load has been raised, put it down without increasing the load moment.
• To put down the load you may perform only those crane movements that reduce the load moment.
Before starting to operate the crane, familiarize with the arrangement of the control symbols on the
emergency operator station.
Keep a safe distance away from all moving parts of the crane and the load (see 'Minimum distances'
Chapter 2).
• After having put down the load move the crane in transport position (refer to 'Moving the crane in
transport position' in chapter 9).
Continuing to work is not permitted!
• Contact a PALFINGER partner immediately to get the crane repaired.
45
Safety equipment
Caution!
If the operator cannot observe all support/crane movements or the
lifted load from the crane's emergency operator station, there is risk of
fatal injury.
If it is not possible to fully observe all

• stabilization components;
• crane movements and the resulting load path;
• loads;
from the emergency operator station during support and/or crane operation, the operator must be given
signals by a qualified signaller.
46
Chapter 6
CHAPTER 6
Ancillary equipment
In this chapter
General .................................................................................................... 49
Slingers, other attachments to lift the load ................................................ 50
Ancillary equipment .................................................................................. 51
Remote control ......................................................................................... 58
47
Chapter 6 Ancillary equipment
General
Note! Use only accessories that are suitable for use on the relevant
loader crane.
Note! Matching ancillary equipment and load lifting gear are

available from all PALFINGER partners.
Any damages or accidents caused by the use of unsuited ancillary equipment and/or load lifting gear
are not covered by the PALFINGER warranty.
The crane can be operated with a number of different ancillary equipment and load lifting gear.
Example of ancillary equipment: Example of load lifting gear and lifting equipment:
Rope winch, grab, rotator, manual extension, Hooks, ropes, chains, belts, shackles, palette forks, etc.
hydraulic palette forks, auger, etc.
Depending on the type of equipment, a plate might be attached informing about:

• Name of the model
• Year of manufacture
• Manufacturer
• Serial number
• Dead weight
• Maximum permissible load capacity
• Operating pressure
• etc.
.
The operator must be trained on all the ancillary equipment, load lifting gear and lifting equipment used
and has to understand the relevant operating instructions.
Danger! There is acute danger of fatal injury if

1. the crane is overloaded by ancillary equipment and/or
load lifting gear;
2. ancillary equipment, load lifting gear and/or lifting devices
are overloaded using the crane.
Observe the load capacities of ancillary equipment, load lifting gear and lifting equipment.
Observe the maximum permissible angle of inclination for lifting devices.
The maximum load capacity is defined by the weakest load lifting gear used.
Load lifting gear and ancillary equipment:
• Are always considered as part of the load (except rope winch and fly-jib).
• Always attach and secure them using original PALFINGER bolts and securing devices.
Danger! Depending on the type of ancillary equipment, the crane
has to be turned off before attaching the device. Follow the relevant
instructions. Keep the minimum distances (see chapter 2).
49
Ancillary equipment
Carry out any necessary steps for attachment

• before starting to operate the crane,
• when the device is turned off.
• Let only professional operators or trained personnel
carry out and complete assembly works.
Slingers, other attachments to lift the load

Hook
Danger!
Undersized, incorrectly attached, defective or unsecured crane hooks
or shackles may cause the load to drop. This creates an acute risk of
fatality for the operator and others.
• Use hook and shackle suitable for the weight of the load that is being lifted.
• Different hooks and shackles are provided for some crane models. Depending on the load, the
relevant PALFINGER hook and shackle with bolt must be used on the associated lifting gear
.
• Observe the load capacity given on the load lifting gear.
• The safety latch of the hook must close by means of spring pressure after the load has been
attached.
• Secure the shackle pin with the linchpin. Use only the original pin for the shackle!
• Have any damaged safety latch or linch pin immediately replaced by a PALFINGER partner.
Warning!
When attaching and detaching loads, be aware of increased risk of
crushing.
Keep the required minimum distances to all crushing points (refer 'Danger of getting crushed' in
chapter 2).
50
Ancillary equipment
Rope winch
Use the rope winch only to lift loads vertically. Any other use is prohibited.
Use only PALFINGER rope winches, ropes and winch components (pulley heads, attaching and safety
material, etc.) for rope winch operation.
Note! For assembly, weight and use of winch components such as

pulley head, rope, rope diameter, etc. refer to chapter 13 "Technical
Description".
Ropes must be in good condition (see 'Rope discarding', in the maintenance chapter 10).
Assemble the rope winch components before starting work (boom in working position):
Danger! Failure to maintain the minimum distances represents an

acute risk of fatality for the operator and others.
Keep the required minimum distances to all crushing points (refer 'Danger of getting crushed' in
chapter 2).
For the position of the pulley head and rope refer to the "Technical Description" in chapter 13.
Carry out and complete any necessary assembly works before starting to operate the crane.
Warning! Turn off the crane power during assembly steps, where
crane movement is not required. Failure to do this will result in an
acute risk of injury (potentially fatal).
Structure:
1. Rope winch
2. Pulley head
3. Lower load block
51
Ancillary equipment
Assembling the pulley head:

• Extend the extension booms until approx. 50 cm (2 ft) before the pulley head.
1. Insert connecting block into extension boom and secure with pin.
2. Secure pin with spring cotter.
3. Lower extension boom until lifting gear fits onto pulley head, and secure with pin.
4. Secure pin with a linch pin.
5. Rotate the pulley head upwards, until it can be secured with the connecting block.
• Reel off sufficient rope.

• Switch off crane.
• Reeve the rope.
• Assemble the lower load block.
• Check rope guidance and rope.
• While operating the winch the rope must run over all of the pulleys (additional rollers etc.).
Danger! If the rope is not properly reeved, this may lead to

damages. There is risk of injury or even fatal injury.
Example:
• Move the load arm to a working position.
Warning! When mounting or dismounting the crane and while

moving it in transport or working position there is serious risk of
getting crushed!
52
Observe the safe distances given in

chapter 2 during all works you carry out
on the pulley head.
Winch components with composite pulleys
Danger! When using composite pulleys exclusively, the inner braid

strands may break before the outer braid strands after longer periods
of use. This may lead to unexpected rope failure and falling down
loads.
At least one steel pulley must be used. When using composite pulleys exclusively, the inner braid
strands may break before the outer braid strands after longer periods of use. Therefore rope breakage
may not be detected during normal inspection.
Single-strand winch operation with composite pulley head (1) is prohibited. The lower load block must
be equipped with a steel pulley (2). Single-strand winch operation is not permitted.
1
2
Rope deflecting angle

Note! In order to keep the rope deflecting angle (α) as small as
possible, extend at least one extension boom completely before
winch operation.
Purpose:
• This will lead to better rope winding behavior.
• Small entry angle into rope pulleys.
53
Ancillary equipment
Warning! If the rope rubs against crane components it gets

damaged. The rope may tear, and this creates risk of fatality for the
The rope should run smoothly over the pulleys and not rub anywhere.
Rope winch operation examples
For one-strand rope winch operation
For two-strand rope winch operation:

1. Fit additional pulley head for extending to two-
strand operation in pulley head.
2. Secure with pin.
4. Insert clamping sleeve.
Extend/retract extension booms in winch operation
Danger! Rope is shortened when extension booms are extended. If

the unwound rope is too short the lower load block will be pulled to
the pulley head at full force (two-blocking).
In case of rope winches without overload protection system:
Rope may break if not unspooled enough. This may lead to
unexpected rope failure and falling down loads.
In case of rope winches with overload protection system:
The rope winch components are protected, but this working position
must generally be avoided.
54
Ensure there is enough distance (A) between pulley head and lower load block during all winch
operations.
Winding up the rope:
Warning! Injuries can result, if rope is tightened by hand.
• Never tighten the rope by hand.

• Use a weight when winding up the rope (1).
• Prevent rope kinks (2) and slack rope (3).
If the lower rope layers are rarely or never used, unwind the rope after every 100 working hours and
wind it up again while tightening it.
55
Ancillary equipment
Crane without overload protection device
• Do not overload the crane • Do not overload the rope winch

components/accessory equipment with the lifting power of the crane.
such as hydraulic extendible booms,
manual extensions, etc. using the
lifting power of the rope winch.
Danger! Rope might be pulled off the drum if there are too few rope
wraps left on the drum. This may lead to unexpected rope failure and
falling down loads.
• At least three wraps of rope must be left on the drum.
Ending rope winch operation (load-arm still in working position)
Warning! The crane must be switched off between the individual

disassembly steps. Failure to do this will result in an acute risk of
injury (potentially fatal).
If disassembly of winch components is necessary:
• Lower the load arm boom (to carry out the following work)
• Reel off sufficient rope.
• Disassemble the lower load block and store it properly.
• Unreeve the rope, pin it to the storage point and secure it properly.
• Turn on the crane.
• Slowly and carefully operate the winch to tighten the rope.

• Disassemble and store the winch components properly (pulley head etc.).
56
Mechanical extension booms

Danger! If extensions are overloaded with the lifting power of the
crane, the load may fall down. This creates an acute risk of fatality for
the operator and others.
After pulling out the manual extension you can read the maximum load capacity on both sides. The
maximum load capacity is also printed on the identification plate of the manual extension. This may not
be exceeded, even if the manual extension has been fully pushed in and secured.
Information! Loads that are heavier than the maximum load

capacity of the manual extension boom must be attached to the last
hydraulic extension boom.
XXXX KG XXXX KG
The maximum load capacity of the manual extensions must be written on both sides of the extension
by the installer. If this specification is missing, contact your PALFINGER partner.
Pulling out/pushing in mechanical manual extensions
Danger! Always secure mechanical manual extensions properly.

Inadequately securing manual extensions, or failing to secure them, is
grossly negligent. This creates an acute risk of fatal injury.
Manual extension booms that are extended/retracted must be properly secured using original
PALFINGER connection pins and linch pins.
Danger! People standing in front of the crane boom while the

manual extension booms are extended are in acute danger to life.
The operator must stand to the side of the boom system when extending or retracting the manual
extension boom.
• Make sure that all manual extension booms are secured properly.
• Move the load arm to the set-up position.
• Turn off the crane.
• Remove the linch pin from the connecting pin, pull out connecting pin.
• Pull out the manual extension boom to the securing position.
• Put in the connection pin and secure it with the linch pin.
57
Ancillary equipment
Remote control
Note!
The wireless remote control system (remote control console,
receiver) complies with the applicable EMV directive. So the unit will
as far as possible not interfere with other systems or get interfered by
them at the place of application.
General
All safety regulations included in the operating instructions of the crane must be observed.
Crane control systems

Safety features serve to protect the operator, so it is not allowed to manipulate or inactivate them.
Guarantee and warranty immediately expire when any manipulations to the radio remote control
system (remote control console and receiver) become obvious.
Components of the remote control

Only original PALFINGER components must be used to operate the remote control system.
Guidelines to prevent dangers

• Make sure not to actuate any operating elements before starting the remote control console.
• If dangers occur push the STOP button.
• Have defective components (remote control console, receiver, accessories) immediately repaired
or replaced at a PALFINGER service partner.
• Immediately stop crane operation in the event of any malfunctions.
• Always fully charge the battery.
• Do not operate any crane functions while attaching and detaching loads.
• The position of the operator must always be outside the danger zone of the crane.
• The operator must have full view of the crane movements and the working range.
58
Components
Remote control console
Receiver
Charging cable
Accessories • Carrying strap

• Magnet antenna
• Charger (optional)
59
Ancillary equipment
Operating levers
The remote control console shown is an example of a standard version and is shown with the functions
preset by PALFINGER.
Note!
The assignment of functions to the buttons can, if desired by the
customer, partly be changed by authorized PALFINGER service
partners.
Prior to the remote control console being used for the first time, every operator must be trained by an
authorized PALFINGER service partner. Operators must familiarize themselves with the functions
assigned to their console's buttons.
5 6
4 8
3 9
2 1
1 STOP-button
2 Function key FN
3 Key for functions
4 Status LED
5 Indicator LED
6 Battery status indicator
7 Additional indicator LED
8 Crane function on level 1 (example: counter-clockwise slewing)
9 Crane function on level 2 (example: lifting the stabilizer cylinder)
60
1. STOP-button
The emergency-stop button switches the remote control console off and hence stops all crane
functions.
For how to operate it refer to Emergency cut-off button/ push-button (see "Emergency cut-off
button / push-button" Page 41).
2. Function key FN
The FN function key switches the remote control console on and is used to select the crane functions
(levels 1 and 2).
1. Press the STOP-button and hold it down.
Start remote control console 2. Press the function key FN and let both
See also Preparing for remote operation buttons go.
(Page 69). The remote control console is switched on.
Note!
The level that is active gets shown on the display.
Changing levels (1/2) • Function key FN is not pressed.

Level 1 is active. Example: counter-clockwise
1 slewing.
• Function key FN is pressed.
Level 2 is active. Example: Lift up the stabilizer
2 cylinder.
3. Buttons for crane functions

The crane functions’ buttons are proportional push-buttons for which double assignment is possible
(levels 1 and 2, see above). The depth of button operation corresponds to the movement speed of the
function that is activated.
4. Status LED
The red LED indicates whether the remote control console is on or off.
LED off: Remote control console is off.
LED on: Remote control console is on.
5. Indicator LED
Indicates the currently active level of the buttons for crane functions.
1. - Level 1
2. - Level 2
61
Ancillary equipment
6. Battery status indicator

The status indicator has two LEDs that show the remaining battery capacity (high / low).
While charging via cable (cigarette lighter) it furthermore indicates when charging is completed.
LED is flashing: Remote control console is being
charged.
LED is illuminated: Remote control console is fully
charged.
7. Additional indicator LED

LED is illuminated: During start-up as soon as the
STOP-button is pressed
Remaining For PALFINGER partner.
functions:
8. Crane function on level 1

All functions that are displayed on the buttons are on level 1.
The functions are only displayed if the crane is equipped with them.
9. Crane function on level 2

All functions that are displayed next to the buttons are on level 2.
The functions are only displayed if the crane is equipped with them.
Storage, maintenance and care of the wireless system

Cleaning and care
Maintain and treat the units carefully to ensure perfect function during their entire product life.
Keep the wireless equipment and its components clean and avoid any contamination.
Clean contaminated components carefully with a wet cloth and mild cleaning agent (e.g. detergent).
Never:
• dip the wireless equipment or its components into liquids,
• clean the wireless equipment or its components under high pressure;
• use aggressive solvents for cleaning;
• clean the wireless equipment or its components with compressed air;
• or apply to much pressure when wiping the display clean. This could cause scratches.
Maintenance
Ensure that:
• Damaged gaskets are replaced immediately (humidity).
• Damaged operating elements (e.g. keys, buttons, levers) are replaced immediately.
• Every time servicing is carried out the RC console is checked as well to make sure it is working
properly.
62
Service
All service work must be carried out by PALFINGER service partners in compliance with the
PALFINGER training documents and service records. Non-compliance results in loss of any warranty
and liability.
Every service and repair must be recorded in the service manual and signed or stamped by a
PALFINGER service partner.
Repairs
• Damages to the unit must be repaired immediately by a PALFINGER partner.
• Repairs have to be recorded in the service manual.
• If a repair is not carried out by a PALFINGER partner warranty will become void.
Disposal
Electronic components are problematic waste. This is in particular applicable to the batteries. Defective
batteries may not be disposed of in the environment.
All parts of the remote control must be disposed of in accordance with the national laws and
regulations.
63
Chapter 7
CHAPTER 7
Preparing for crane operation
In this chapter
Watch out for faults before and during operation ...................................... 67
Working range .......................................................................................... 68
Starting the crane ..................................................................................... 69
Preparing for remote operation ................................................................. 69
Vehicle inclination ..................................................................................... 71
Supporting the vehicle .............................................................................. 72
Pulling outrigger beams out manually ....................................................... 75
Stabilizer cylinders.................................................................................... 76
Bringing the load arm to working position ................................................. 76
Daily function check of safety equipment .................................................. 78
65
Chapter 7 Preparing for crane operation
Watch out for faults before and during operation

Danger!
Observe all equipment for damage and malfunctions during operation.
If damage or malfunctions are found during operation and operation is
not stopped immediately, there is an acute risk of fatal injury to the
operators and others.
If the following damage or faults are found on the unit, auxiliary equipment, load-bearing equipment or
vehicle, do not start operation or stop operation immediately and contact your PALFINGER partner:
• Lack of lubrication.
• Damage to or cracks in components/weld seams.
• Unserviceable bearings.
• Damage to the hydraulic system (leakage, unusually high temperatures etc.).
• Unserviceable safety devices.
• Loose threaded connections.
• Insufficiently secured pins.
• Hose winding malfunctions in the hose drum or the hose tray.
• Abnormal noises.
• Unusually quick or slow working movements.
• Failure of the control system.
• Operating levers are difficult to operate and/or do not return to neutral position.
• Poor rope guidance, rope run out off the guide pulleys and / or guide rollers.
• Damaged winch components such as deflection and/or guide pulleys.
• Damaged rope.
Restarting the unit is only allowed after corrective measures have been taken and safe operation is
guaranteed again.
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.
67
Working range
Danger! There is acute danger to life for operators and others in the
entire working range of the crane (slewing range and under
suspended loads). Allowing bystanders in the working range is
grossly negligent.
• The operator must have full view of the crane movements and the loading/unloading point. If this is
impossible the operator must be aided by a qualified signaller.
• Plan in sufficient clearance for crane operation and support. Crane movements may not be
obstructed by lines, masts, trees, buildings or other objects.
• The entire working range of the crane is a danger zone.
• No other work may be carried out within the working range.
• Streets, path ways, bicycle lanes or sidewalks etc. that cross the working area must be blocked
during the entire crane operation.
• The entire working range must be lit during twilight or darkness so that the work can be carried out
safely.
Danger! In case of insufficient visibility stop work immediately.
68
Starting the crane

• Park the vehicle as close as possible to the loading place.
Note! Working at shorter outreach generally increases the crane
lifetime.
• Engage the parking brake.
• Air suspension axles must be inactive during crane operation.
• Engage the PTO at idle and then select correct engine speed.
• Only one person shall operate the crane at a time.
At ambient temperatures below freezing point

• Let the pump run for a few minutes before operating any crane function.
Additionally in remote control mode
Note!
After having started up the crane the green flashing warning light
(see illustration) starts flashing. This indicates any third persons that
the crane may start to move any time.
Preparing for remote operation

Caution!
The radio remote control needs to be checked for any malfunctions
every time before starting to work, failure to do so may result in
severe risk of fatality for the operator and others.
Carefully check the wireless remote control system before starting work every day.
Check for:
• Self-return of the buttons.
• There are no missing or damaged components.
Any defects must be remedied before using the wireless remote control system.
Battery:
• Always handle batteries with care.
• Only start working with the crane with fully charged battery.
69
Start remote control console:

1. Press the STOP-button and hold it down.
2. Press the function key FN and let both buttons go.
3. As soon as the status LED is on, the unit is ready for operation.
The console is ready for operation.
Caution!
In the event of any malfunctions during crane operation and unless
the work is interrupted immediately, there is an acute danger of
accident.
Warning!
Whenever the remote control console is not being used or there is no
visual contact with the crane, the console must always be switched
off. After finishing work always secure the unit against unauthorized
use.
If malfunctions occur, let all buttons go immediately and push the STOP-button. The remote control
console may only be used once the malfunction has been corrected by a PALFINGER service partner.
The remote control operation stops automatically if:

• There is no radio connection.
• The battery is empty.
• Any crane function was not operated for more than 5 minutes. A PALFINGER service partner can
individually set the period.
To be able to continue working, the remote control handset must be restarted.
No wireless connection
Possible causes: • Transmitter out of reach.
Reduce the distance between transmitter and receiver.
• Receiver not switched on.
Check if receiver is on, if not switch it on.
• No valid (paired) receiver.
• Defective radio components.
Contact your PALFINGER partner.
Have any defective remote control handset immediately replaced by a PALFINGER service partner.
70
Vehicle inclination
Only after having supported and levelled the vehicle properly it is allowed to operate the crane.
Declination indicator
When the air bubble is in the middle, the vehicle is levelled.
When the air bubble is between the two circles, the vehicle inclination is
between 0° and 5°.
5°
Work up to 60° boom position

Level the vehicle as horizontal as possible, however within 3° inclination.
Working above 60° boom position

(refer to chapter 8, "Crane working position").
Level the vehicle exactly. The air bubble is in the inner circle.
Danger! Vehicle inclination of more than 1° reduces the guide

function of the extension booms and leads to side loading of the boom
system. There is an acute danger of accident.
Vehicle inclination must not exceed 1° in any direction.
71
Supporting the vehicle

Danger!
If the vehicle is not properly supported it may tip over. Working
without proper support is prohibited. This creates an acute risk of fatal
injury.
The crane must not be moved in working position until the vehicle has been properly supported.
Note!
The parking brake must be pulled all the time when supporting the
vehicle and during loading. Braked wheels need sufficient ground
contact.
Danger!
If the additional support of a vehicle is not extended the vehicle may
tip over. This creates an acute risk of fatal injury.
If the vehicle is equipped with additional supports, they must be extended as described below. The
vehicle is only stable with the supports fully extended (crane support and additional support if present).
All safety notes of chapter 2 shall be observed.
Ground condition
Check the soil for the following:
• Stability.
• Hollows (manhole covers, pipelines, etc.).
• Sufficient distance to any drop offs, holes, ditches, etc.
• Ground inclination 5° maximum in all directions.
Increase the support area according to the ground conditions (refer to table) or find a suitable support
area.
Max 5°
72
Ground pressure
Ground pressure by support jacks max. 400 N/cm² (58 psi).
Permissible ground pressure under DIN 1054
Heaped up soil, that was not stabilized artificially. 0 - 10 N/cm² (0-14.5 psi)
Asphalt 20 N/cm² (29 psi)
Grown, obviously untouched soil.
1. Mud, turf, marsh 0 N/cm² (0 psi)
2. Incohesive soils:
Fine sand to medium sand 15 N/cm² (21.75 psi)
Coarse sand to gravel 20 N/cm² (29 psi)
Compacted gravel 25 N/cm² (36.25 psi)
3. Cohesive soils:
Mushy 0 N/cm² (0 psi)
Soft 4 N/cm² (5.8 psi)
Stiff 10 N/cm² (14.5 psi)
Semisolid 20 N/cm² (29 psi)
Hard (solid) 30 N/cm² (43.5 psi)
4. Rock:
Weathered 100 N/cm² (145 psi)
Determining necessary support area (use metric or imperial consistently):

Supporting force F [N or lbs]
Support area A [cm² or in²] =
Load capacity of the soil [N/cm² or psi]
The supporting force values are specified in chapter 13, ‘Technical Sheets’.
Note! High-quality supporting pads are available from all

PALFINGER partners.
Caution! If the movement ranges of the supports are not completely

in view of the operator there is an acute risk of accident and danger to
life.
73
When supporting the crane choose an operating station from where you may view the complete
support movement range. Always keep moving crane components in view. No persons and objects are
allowed to be in the movement area of the stabilizer outriggers / stabilizer cylinders.
The outrigger beams and stabilizer cylinders need to be operated separately on both sides. To do so,
alternately use both operator stations.
Fully extend the outrigger beams (mark must be visible).
Stabilizing sequence
The crane stabilizers are designed for absorbing only the crane load! If the vehicle is lifted completely
during crane operation, the crane support can fail.
Danger!
If the vehicle is lifted partly or completely when on the stabilizers the
stabilizing system will be under significantly higher load. This may
lead to damage and the vehicle may tip over when the crane is being
operated.
This creates an acute risk of fatality for the operator and others.
Never lift up the vehicle!
It is prohibited to lift the vehicle until the wheels are

unloaded. This overloads the support system and
reduces the braking effect.
74
In order to ensure safe operation follow the below sequence of stabilizing your vehicle:
Note!
Depending on the equipment available on your vehicle like front
stabilizer, rear stabilizers or additional stabilizers one or several
points may not apply to your model.
Extend the stabilizers until they have firm ground contact

3 (support pad).
2 1. Extend and support the additional stabilizers (left / right).
2. Extend and support the crane stabilizers (left / right).

1
3. Extend and support the front and rear stabilizers (left /
right).
3
In general it is only permitted to operate the crane with all stabilizer cylinders being on the ground.
Exception: If the crane is equipped with HPSC stability control (refer to ‘Safety equipment, HPSC
stability control’).
Working position stabilizers monitoring

In order to lift loads, the stabilizers of cranes with "working position stabilizers monitoring" must be fully
extended.
Pulling outrigger beams out manually

No persons or objects are allowed to be in the movement area of the outrigger beams.
• Lift und unlock the locking shackle.
• Move cam lock to the left.
• Pull out the stabilizers completely.
• Move interlock to the right. Check whether the primary lock has engaged by attempting to move
the outrigger beam in and out.
• Fix the stabilizer extension in the appropriate position and secure the connection pin with linch pin.
75
Stabilizer cylinders
Hydraulic stabilizers
Operator station: Radio-controlled • Then pull out the stabilizer cylinders one after the
operation: other so that you may view the danger zone.
Crank-down stabilizers
If the crane is equipped with crank-down stabilizers, crank down the stabilizer extensions until the
support jacks have firm ground contact.
If the vehicle is equipped with additional stabilizers proceed as described above.
Bringing the load arm to working position

Prerequisites for unfolding the crane
Caution! If the manual extension booms are not properly pinned and
secured, they will slide out of the extension booms when unfolding
the crane. This creates a severe risk of fatality for the operator and
others.
• Extension booms are pinned and secured.
• Vehicle is properly supported.
• No bystanders or obstacles are in the movement range of the crane.
76
Caution! Not maintaining the minimum distances creates an acute

risk of fatality for the operator and others.
• The operator must have full view of all crane movements.
Caution! Extending the extension booms before the main boom is in

nearly vertical position causes acute risk of fatality for the operator.
Only extend the extension booms when the main boom has been raised to a near-vertical position. See
‘Unfolding the crane’.
• Move the main boom out of its transport position into working position.
• Make sure that all mechanically actuated functions are properly secured with connection pin and
lynch pin.
Unfolding the crane

Operator station: Radio-controlled Lift the main boom.
operation:
Extend the
extension booms.
• The crane is ready for operation.
77
Daily function check of safety equipment

Carry out the function check without load and with all extension booms retracted.
Emergency cut-off function check
Danger!
If the crane doesn’t stop after pressing the emergency cut-off button
or if other crane movements are still possible there is acute danger to
life.
Working with a defective emergency cut-off button is grossly negligent. Do not operate the crane and
contact a PALFINGER service partner.
• Operate any crane function. The crane must move perfectly in all directions.
• Press the emergency cut-off button while the crane is moving. The crane must come to a stop.
• Again, operate any crane function.
The crane must not move.
• Release the emergency cut-off button; The crane should move perfectly in all directions.
Refer also to chapter 5, "Emergency cut-off button".
Functional check of OS hydraulic overload protection

Always carry out a functional check without load before starting work:
• Raise the main boom up to the limit stop at maximum speed. The overload protection system must
respond when the limit stop is reached (avoid this test position in working operation).
• The movements indicated above must be blocked.
Danger! If the overload protection system does not respond stop the
crane IMMEDIATELY, otherwise there is an acute risk of fatal injury.
• Briefly operate the touch valve and lower the main boom.
78
Chapter 8
CHAPTER 8
Crane operation
In this chapter
Load limits ................................................................................................ 81
Working position of the crane ................................................................... 81
Loads ....................................................................................................... 84
Working with loads ................................................................................... 85
79
Chapter 8 Crane operation
Load limits
Caution! Exceeding the permissible ranges, load capacities and/or
maximum load may affect the vehicle stability and/or cause the crane
components to break; it is therefore prohibited. There is severe
danger to life for the operator and others.
Load capacity label:
1. Maximum load capacity of the crane.

2. Number of extended extension booms and extensions.
3. Maximum load capacities at the respective outreach.
For load capacity chart refer to chapter 13, 'Technical description'.
If required by national regulations and laws the installer should enclose load capacity charts for
additional load ranges (ISC, SHB) in chapter 13.
Working position of the crane

Load capacity, component wear, and working life of the crane are among others dependent on the
working position.
In adverse working positions:
• the bearings, joints and crane components are under higher stress and therefore wear out quicker;
• the specified load may not be reached;
• the component wear increases.
The crane must always be in an optimum working position for the task at hand.
81
Crane operation
Working range
Optimum working range:
XX°
XX° = optimum angle of main boom (between 15° and 30°, dependent on crane type).
When the main boom is below the horizontal the maximum lifting moment cannot be reached, therefore
you should avoid this position.
Refer to load capacity chart attached to the crane.
Lower range limit:
Danger! Any working position with main boom completely lowered

is prohibited. In this position the crane may be overloaded.
Consequently the load may fall down. This creates an acute risk of
82
Load handling close to the crane using long lifting gear

• Lift the load with the extension booms as far as possible retracted (1, 2).
• Lower the load arm to 60°.
• If necessary extend the hydraulic extension booms.
Upper limit range:

Boom system between 60° and 70°
• Working with boom system higher than 60° is only allowed when the outrigger beams are fully
extended.
Danger! At a boom position higher than 60°

• Abrupt crane movements may lead to an excessive side
loading of the boom system.
When working above 60°, pay particular attention to the stated load limits.
Increasing the lift angle and height may result in side loading of the boom system. The overload
protection system is unable to monitor this type of loading.
Therefore pay particular attention to
• working within the range shown in the load capacity chart;
• smooth crane operation.
83
Crane operation
Working with loads in an operating range over 80° is prohibited.

70°
60°
Loads
Before loading/unloading
• Before lifting any loads check if the load lifting gear is used correctly.
• Observe special instructions about load handling and/or lifting gear (e.g. lifting points, center of
gravity, orientation, etc.)
• Secure the load.
• The weight of the load must be known. If information about the weight is not available, it has to be
calculated or estimated.
• Make sure the load is free to move and not anchored, iced or otherwise attached to the ground.
• Before lifting, remove ice or snow from the load. Wet or icy loads may slip off.
• Lift the load only above its center of gravity.
84
Working with loads

Caution! There is acute danger to life for operators and others in the
entire working range of the crane.
• Notes in chapter 7 'Working range' shall be observed.
• Every time before moving the crane, make sure that there are no persons in the
working range of the crane (danger zone).
• Stop moving the crane immediately when a person steps into the working range. Restart crane
operation only after all persons have left the working range.
Local regulations regarding loading crane operation shall be observed.
• Before starting to work with the crane the operator has to plan the operation (lift plan).
• Any assistants, signalers and bystanders must be informed about the planned operation.
• The operator must have full view of the crane, the load and their paths at all times.
• If any part of the crane or load path is out of the operator's view it is necessary to involve a
signaller.
• Working with a signaller:
• Operator and signaller must be familiar with locally understood
signals.
• The signaller must be clearly identified. Only one signaller
can give signals at a time to the operator.
• The operator must not be otherwise occupied while operating the crane (e.g. making phone calls,
etc.).
• In the case of remote control operation the operator is not allowed to give the handset away.
• It may become necessary to relocate or retract the stabilizer cylinders to prevent overloading the
stabilizers during loading/unloading. Relocating the stabilizers is only allowed:
• Without load.
• With extension booms retracted.
• With the load arm secured on the vehicle platform or in transport position.
85
Crane operation
Attaching / detaching loads

• Position the load arm as required. Stop the crane movements.
Caution! When the load is attached or detached by the operator

while the crane is still in operation this creates
• through unauthorized crane operation,
• by unintended actuation of control equipment on the
operator station or handset of the remote control
acute danger to life for the operator and others.
Load attached / detached by assistants:

• Assistant may enter the crane's danger zone only after the operator has given permission.
• Only attach/detach loads with permission from the operator and when the crane has stopped
completely.
• The assistant must leave the working area when attaching/detaching is completed.
After the assistant has left the danger zone, crane movements may be carried out again.
Load attached / detached by the operator:
In order to attach or detach the load, the operator may need to enter the working area.
• Turn off the crane on the crane’s operator station or on the remote control.
• Attach / detach the load.
• Exit the danger zone.
Lifting / moving loads
Warning! If loads, load handling attachment or ancillary equipment

rub against the load arm they may get damaged.
Load, load handling attachment or ancillary equipment must not rub against the load arm. Minimum
distance between all crane components and load 0.5m.
86
Caution! If controls are unintentionally operated with the load and/or

crane components, there is an acute risk of fatal injury to the operator
and others.
During all crane operations, maintain an adequate distance between the load, crane components and
controls.
Caution! Abrupt crane movements can make the load swing.

Carry out all crane movements smoothly.

• Grasp the operating lever of the crane function firmly.
• Press the lever slowly until the crane responds.
• Monitor the overload capacity indicator (refer to chapter 5, 'Overload display').
• If the yellow range is reached, reduce the working speed.
• Lift the load a little and check whether it is correctly attached and stays in the intended position.
Caution! Operating crane functions at full working speed to the

cylinder stop:
• increases the wear of components and reduces the life of
the crane;
• the load may fall down.
• It is prohibited to operate crane functions (with/without load) at full speed to the cylinder stop.
Caution! Releasing the operating levers suddenly can cause the

load to swing uncontrollably. Consequently the load may fall down.
• Finish crane movements slowly and smoothly by releasing the operating levers carefully.
• It is possible to operate several crane functions at a time.
This may reduce the speed of the already actuated crane movements.
Warning! If several crane functions are used at a time and one or

more are stopped, the remaining active function(s) may increase in
speed.
• If crane functions are used simultaneously (combined crane movements create a different load
path), reduce the speed of the individual functions accordingly.
In the event of sudden danger

In case of an emergency, stop all crane movements immediately (see also 'Emergency cut-off button‘,
chapter 5).
87
Crane operation
Lowering the load
Caution! In cranes without overload protection system, the load

lowers uncontrollably when the permissible load moment is exceeded.
Refer to chapter 5, 'Capacity indicator'.

Don't increase the outreach when lowering the load.
If you increase the outreach when lowering the load, the load may lower uncontrollably.
Monitor the capacity indicator.
Landing the load

• The landing area must be free of obstacles.
• Don't land the load on ice or snow.
• Don't land the load on drop offs, bumps, slopes, holes, ditches, etc.
• Land the load only on solid level ground; if necessary use suitable blocks or boards.
• When the load is put down, the load on the main boom must not be relieved suddenly.
Warning! If the load on the main boom is relieved suddenly, bulk

materials are emptied quickly (grab application) or the load is put
down quickly with the cable winch, the main boom may snap upwards.
Always put loads down slowly.
• Before detaching the load handling attachment make sure the load sits properly and stable.
Work interruptions
If it is necessary to leave the crane unattended:
• Land the load.
• Put down the load arm properly.
• Secure the crane against unauthorized use.
Resuming work
• If crane has been left unattended, check whether the crane has been tampered with before
resuming crane operation. Ensure secure crane operation.
If the crane has been tampered with by unauthorized persons:
• (Refer to chapter 7 'Preparing for crane operation'). Carry out all function checks described in
chapter 7.
In devices with remote control it is additionally necessary to:
• check that the appropriate device control panel (control handset) is used (as indicated) before
resuming crane operation.
88
Loading of the rope
Moving the load at the acute angle (A) places less load on the
rope than moving it at the obtuse angle (B). This protects the
rope.
Higher load on the rope (B) puts strain on the rope and
causes quicker wear.
89
Chapter 9
CHAPTER 9
Ending operation
In this chapter
Bringing the crane into transport position .................................................. 93
Retracting the stabilizers .......................................................................... 94
Ending radio remote control operation ...................................................... 97
Before driving ........................................................................................... 97
91
Chapter 9 Ending operation
Bringing the crane into transport position

Caution! If the manual extension booms are not properly pinned and
secured, they will slide out of the extension booms when folding the
crane. This creates a severe risk of fatality for the operator and others.
Before folding the crane push in the mechanical extensions and secure them properly with connection pin and lynch
pin.
Caution! Not maintaining the minimum distances creates an acute

Prerequisites for folding the crane

• Extension booms are retracted, pinned and secured.
• No bystanders or obstacles are in the movement range of the crane.
• Ancillary equipment is removed and/or secured, refer to chapter 6.
The operator must have full view of all crane movements.
Operator station: Radio-controlled Retract the hydraulic
operation: extension booms
Move the main boom

to transport position.
93
Ending operation
Resting the boom on the vehicle platform or boom support
Danger!
If the boom system is not secured against any side movements this
creates an acute danger to life of all road users.
Not knowing the vehicle's total height and not observing the clearance
heights creates an acute risk of fatal injury.
Secure the boom system sufficiently against side movements.
When the boom rests on the vehicle platform the vehicle's total height may change.
Note!
If the crane is equipped with a transport position indicator, monitor
the signal.
Retracting the stabilizers

Danger! If the load arm is not in transport position while retracting
the supports the vehicle may tip over. This creates an acute risk of
fatal injury.
Retract the supports only when the boom system is in transport position.
If the vehicle is equipped with additional supports, they also must be retracted.
Danger! If the movement ranges of the supports are not completely

in view of the operator there is an acute risk of accident and danger to
life.
94
When retracting the supports choose an operating station from where you may view the complete
support movement range. Always keep moving supports in view. No persons and objects are allowed
to be in the movement area of the outrigger beam / stabilizer cylinders.
The outrigger beams and stabilizer cylinders need to be operated separately on both sides. Change
the operating station.
Danger! Incompletely retracted and/or unsecured stabilizer cylinders

and outrigger beams create an acute risk of fatality for the operator
and others.
Inadequate or lack of securing of stabilizer cylinders and/or outrigger
beams is prohibited. There is an acute risk of fatality for the operator
and others.
Retract the stabilizer cylinder completely.

Push in all manual outrigger beams completely, lock and secure them.
Danger! Not maintaining the minimum distances given in chapter 2

creates an acute risk of fatality for the operator and others.
95
Ending operation
Retract stabilizer cylinder

Operator station: Radio-controlled • Retract the stabilizer cylinders separately to
operation: always have full view of the danger zone.
Warning!
When retracting the opposite stabilizer cylinders the operator must
always have full view of these cylinders.
If the crane is equipped with crank-down stabilizers, wind in the stabilizer extensions completely.
96
Ending radio remote control operation

• Push the stop button.
• Charge the battery.
• Secure the remote control console against unauthorized use.
After finishing all crane movements

• Secure the crane against unauthorized use.
• Stop the vehicle motor.
• Pull the ignition key.
• Lock the driver's cab.
Before driving
Caution! Incompletely retracted stabilizer cylinders create an acute
Starting to drive without securing the crane and supports properly is prohibited.
Every time before starting to drive check that:

• the crane has not been tampered with by unauthorized persons;
• the stabilizer outrigger beams and stabilizer cylinders are completely retracted and properly
secured;
• the crane (hydraulic pump) is off;
• the crane is secured for transport and side movement is not possible.
Caution! Any winch components, load handling attachment, etc.

protruding over the vehicle width create an acute danger of accident
and danger of life.
• Remove any winch components, load handling attachments, lifting gear, ancillary equipment,
etc. that protrude over the vehicle width in transport position
or are loose or unsecured
and store them before starting to drive.
• The load is properly secured according to the local regulations and laws.
97
Ending operation
The driver must know the total height, total width, axle loads and gross vehicle weight (including crane,
ancillary equipment and load) and act accordingly (refer to chapter 5 "Monitoring the transport
position").
Note! If the crane is equipped with a transport position indicator,

monitor the signal.
98
Chapter 10
CHAPTER 10
Maintenance
In this chapter
General .................................................................................................. 101
Operating hours counter ......................................................................... 102
Maintenance ........................................................................................... 103
Cleaning ................................................................................................. 104
Visual inspection .................................................................................... 105
Machine lubrication................................................................................. 107
Hydraulic oil change ............................................................................... 112
Paint repair ............................................................................................. 115
99
Chapter 10 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 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 spare parts.
Any damages to the device or accidents because of different parts are not covered by the liability of
PALFINGER.
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.
Note!
Absolutely comply with the PALFINGER maintenance guidelines and
intervals. Non-compliance results in loss of any warranty and liability.
Arranged by Executed by
Maintenance Operating company Operating company / operator / PALFINGER partner
Service Operating company PALFINGER partner
Refer also to chapter 2 'Safety for individuals'.
Note!
Use the consumables recommended by PALFINGER. PALFINGER will
not assume liability for any damages caused by applying wrong
consumables.
Use only original PALFINGER lubricants or lubricants that correspond with the lubricant specification
given in this chapter.
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 service center.
101
Maintenance
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.
Operating hours counter

The counter’s display shows the total number of operating hours, the number of hours until the next
service and the number of hours until the next scheduled maintenance.
1 Display starts blinking when it gets down to
2 100 hours of use.
1 2 Solid red light stays on from 0 hours of use.
100 -1
The operating hours counter counts down from 500 to 0. As of 100, the display starts to flash. From 0
the solid red light comes on and stays on.
Using the minus sign, the counter then counts up from 0 (-1, -2, -3 etc.).
After the crane is turned on (power supply), its total operating hours are shown on the display for 10
seconds.
After this period, the display shows the number of operating hours until the next service.
The service must be carried out by a PALFINGER service workshop at around 0 hours and logged
accordingly in the service manual.
If the crane is used for less than 500 hours a year, a service must be arranged at least once annually.
After the service has been done, the service workshop resets the operating hours counter to 500
hours.
102
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 products.
Maintenance has to be carried out after every 50 operating hours.
However, the maintenance intervals depend also on application, duty cycle and environmental
conditions. Road salt, sand, etc. are especially aggressive and speed up corrosion and wear.
Therefore maintenance may be required in even shorter intervals.
Maintenance and service may only be carried out while the unit is out of operation (hydraulic 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 complete maintenance has to be carried out on the unit. All blank metal parts
must be protected using an anti-corrosion preservative (except the extension system, refer to ‘Device
lubrication’ in chapter 10). Retract all hydraulic cylinders completely.
After device downtimes (longer than 3 weeks)
After downtimes the device must be lubricated (refer to ‘Device lubrication’ in chapter 10).
103
Maintenance
Cleaning
Note!
Thorough cleaning increases the reliability and the service life of the
unit.
Use only environmentally friendly, pH neutral and skin-friendly cleaning agents. This protects the
environment and avoids oxidations on the unit.
Warning!
Oil and grease must not be released into the environment.
Clean the device only in suitable places (oil separator).

Do not use abrasive rags, brushes, etc.
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.
Using 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);
104
Visual inspection
Danger!
Missing equipment, damage, cracks on crane components, ancillary
equipment or load lifting gear creates an acute risk of fatality to the
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).
• Tighten any loose bolts/nuts to appropriate torque specification. Contact a PALFINGER 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 cuts, abrasions, cracks, porosity, etc.;
• Cable/hose protection for incompleteness and damage, etc.;
• Hydraulic fluid level (unsupported and in transport position);
• Absence of load-holding valve seals.
Electric system
• Cables for unwinding, abrasions, cracks, etc.;
• Cable/hose protection for incompleteness and damage, etc.;
• Sockets, switches, display elements, sensors for improper attachment, damage, etc.
Covers
• Completeness of all covers.
• Covers for damages.
105
Maintenance
Rope winch components

Refer also to chapter 13, 'Technical description'.
• Intermediate rollers for completeness and correct attachment.
• Pulley head, lower load block for functionality and correct attachment.
• All rope pulleys for damage, ease of movement and wear.
Visual inspection of rope

Refer also to chapter 6, 'Rope winch'.
Danger!
Damaged ropes can break during rope winch operation. There is an
acute danger of accident.
Unwind the rope while keeping it tight and check for:

• Contamination;
• Insufficient lubrication;
• Corrosion.
• Damaged rope clamps;
• Broken strands, broken wires, grinding points, abrasion, bird caging, constrictions, necking, kinks
etc.
Rope discarding:
If a rope is so damaged that it can be no longer used it must be discarded.
The rope must be discarded if a defined number of broken wires can be detected in the outer braid
strands.
Check the rope in the location where the most damage has occurred.
Controlled length Number of visible wire breaks
6 x rope diameter 5
30 x rope diameter 10
30 x d
6xd
In the case of permanent deformations such as worn or flat spots, bird caging, kinks, necking (rope
diameter reduced by more than 10%), etc. the rope must also be discarded.
Rewind the rope under tension.
106
Labels
Check for legibility and completeness.
Check the load lifting gear

• Hooks for cracks, deformations and wear.
• Sensor unit of manual extension booms for cracks,
deformation, leaks and wear. Mark (A) must not be visible.
• Safety latch for proper function.
Check of safety devices

Refer to 'Daily function check of the safety equipment' chapter 7.
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.
Lubricant specification
Note!
PALFINGER recommends using biodegradable grease. Do not mix
incompatible lubricants.
Even biodegradable grease must not be released into the
environment.
Lubricants must be free of solids. Do not use graphite lubricant.
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.
107
Maintenance
Grease:
Available from most PALFINGER partners according to national
guidelines under
Order no. EZ982 – 5 kg (11 lb) can
Order no. EZ1432 – 50 kg (110 lb) barrel
Tested according
Technical data
to
Structure smooth
Consistency (NLGI) 2 DIN 51818
Indication code KP2K-35 DIN 51502
Dropping point °C 150 ISO 2176
Worked penetration 265/295 1/10 mm ISO 2137
Oxidation stability 100h/100°C max. 0.2bar DIN 51808
Basic oil viscosity at 40° C > 80 mm²/s
Behavior in water Assessment level 0/90 DIN 51807-1
Rope grease:
guidelines under
Order no. W10008415
Teflon® spray:
guidelines under
Order no. EZ2807
Maintenance symbols
Rope grease
Teflon® spray
Grease
Greasing prohibited *
108
Maintenance (operating company, operator) every 50 hours or after downtimes lasting more than 3
months.
1 Operating levers, control rods

2 Stabilizer outrigger slide surface
3 Cam lock (outrigger safety mechanism)
4 Pin bushings
5 Jordal rails*)
6 Hydraulic extension booms, mechanical extension booms
7 Lubricate column bearing
8 Crank of stabilizer
9 Rope winch (limit switch, rope)
10 Hook
*) Lubrication points indicated by this symbol must never be lubricated with grease. If lubricating is
necessary (chattering, creaking), only use PALFINGER Teflon® spray.
109
Maintenance
The illustrated crane is an example and shows components which may be optional on your unit,
depending on model and version.
110
Lubrication
Danger! Unintended crane movement during lubrication creates an
acute risk of fatality for the operator and others.
Therefore 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 partner.
Lubricating:
Warning! 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.
Warning! Excess grease at lubricating points and bearing points

increase the risk of accident and are 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 national legislation!
Grease all lubricating points on the unit.
Rope grease
Warning!
Sticking out strands can cause severe hand injuries when you
lubricate the load rope.
Therefore always wear appropriate gloves when lubricating the load rope.
111
Maintenance
1. Unwind the load rope under tension.

2. Turn off the crane.
3. Apply rope grease over the entire rope length using a cloth or brush.
4. Turn the crane on and wind up the load rope under tension.
Note!
Ensure that the load rope is wound up properly, otherwise damages
may occur under load.
Hydraulic oil change

Hydraulic oil change, hydraulic oil maintenance
Hydraulic oil change

Hydraulic oil needs to be changed after every 500 operating hours or once every year.
Information! Oil maintenance on a yearly basis significantly

increases the oil change intervals.
For the operating company this means cost saving and also a
reduced quantity of discarded oil and therefore a less pollution.
Have oil maintenance carried out by a PALFINGER partner on a yearly
basis.
Hydraulic oil maintenance

Oil maintenance includes the following actions:
• Oil filtration.
• Water separation.
• Check of oil purity.
• Filter change.
112
Hydraulic oil
Note!
PALFINGER recommends the use of biodegradable oil. Even
biodegradable oil must not be released into the environment.
Required characteristics
Hydraulic oil Operating temperature
Synthetic ester (biologically degradable): approx. -30 to +80ºC (-22°F to +176°F)
Mineral oil (not biologically degradable): approx. -30 to +80ºC (-22°F to +176°F)
Use either synthetic ester (biologically degradable) or mineral oil (not biologically degradable).
The hydraulic fluid has a working range of between -30° and 80°C (-22°F and +176F), depending on
the outside temperature.
The ideal operating temperature of the hydraulic fluid is between + 30 and + 60ºC (+86°F and +140°F).
Always read off hydraulic fluid temperature after using the crane.
If this temperature range is exceeded frequently, please contact a PALFINGER service partner.
Recommended characteristics
• Favorable viscosity/temperature behavior.
• Good thermal and mechanical properties;
• Considerable ageing resistance.
• Good corrosion protection;
• Sufficient cold flow behavior.
• Good air release capability.
• Excellent foam behavior;
• Does not attack seals and hydraulic hoses.
113
Maintenance
Limits for oil selection

Please pay attention to the temperature dependence of the viscosity when choosing an oil.
Note!
Please contact the PALFINGER partner when selecting the
recommended hydraulic oils and oil filters.
A
0 °C
B
A Viscosity mm²/s or cSt
B ISO reference temperature in °Celsius
C Recommended range
High temperature range: 10 cSt

Cold start limit: 1000 cSt
Purity class: 17/15/12 (in accordance with ISO 4406)
114
Mixing capability
Note!
Hydraulic oils are intermixable. Hydraulic oils must not be mixed with
other fluids.
Reasons for not mixing different oils:

• Reduces service life.
• Mixtures of synthetic esters and mineral oils are no longer biodegradable.
• etc.
Paint repair
Note!
Repair paint damage caused by bird dropping, salt water or similar
immediately. Protects the unit against corrosion.
Refer to PALFINGER repair instructions.
115
Chapter 11
CHAPTER 11
Service
In this chapter
General .................................................................................................. 119
Check of threaded fasteners ................................................................... 119
Initial servicing after 50 operating hours ................................................. 121
Initial servicing after one year ................................................................. 121
After every 500 operating hours or once every year ............................... 121
After every 3000 working hours or once every three years ..................... 122
Every 6 years ......................................................................................... 122
Gear oil................................................................................................... 122
Check of control equipment .................................................................... 123
Protective hoses ..................................................................................... 123
Repairs ................................................................................................... 123
Lowering rate.......................................................................................... 123
117
Chapter 11 Service
General
Note!
All service work must be carried out by PALFINGER service partners
in compliance with the PALFINGER training documents and service
records. Non-compliance results in loss of any warranty and liability.
Time left until next service - refer to Operating hours counter.

The operating company must arrange a service when the operating hour counter indicates it. 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
or stamped by a PALFINGER service partner.
Preparing for service:
1. Clean the device (refer to 'Cleaning' in chapter 10).
2. Make a visual check (refer to 'Visual inspection' in chapter 10).
Check of threaded fasteners

Caution! Loose, damaged or over-tightened threaded connections
can break under load. There is risk of fatal injury.
Note! Tighten the screws only using the torque wrench and applying
the prescribed torque.
ISO bolt torques in Nm (ft.lbs): Tolerance range +/- 10%

Screws: DIN EN ISO 4762, 4014
Nuts: DIN EN ISO 4032
Washers: DIN EN ISO 7090
119
Service
Thread: Stability: 5.6 Stability: 6.8 Stability: 8.8 Stability: 10.9 Stability: 12.9
M03 0.7 (0.6) 0.9 (0.7) 1.2 (0.9) 1.5 (1.2)
M04 1.7 (1.3) 2.1 (1.6) 2.6 (2) 3.9 (2.9) 4.5 (3.4)
M05 3.4 (2.6) 4.3 (3.2) 5.2 (3.9) 7.6 (5.7) 8.9 (6.6)
M06 5.9 (4.4) 7.3 (5.4) 9 (6.7) 13,2 (9,8) 15.4 (12)
M08 21.6 (16) 31.8 (24) 37.2 (28)
M10 43 (32) 63 (47) 73 (54)
M12 73 (54) 108 (80) 126 (93)
M14 117 (87) 172 (127) 201 (149)
M16 180 (133) 264 (195) 309 (228)
M18 259 (292) 369 (273) 432 (319)
M20 363 (268) 517 (382) 605 (447)
M22 495 (366) 704 (520) 824 (608)
M24 625 (461) 890 (657) 1041 (768)
Tightening torques for Bride screws in Nm (ft.lbs): Tolerance range +/- 10%
Thread: Material: 42 Cr Mo 4v
M 20 x 1.5 210 (155)
Service symbols
Functional check
Change
Visual check
Check bolts for tightness
Teflon® spray
Grease
Low-viscosity grease EZ5511 / 1kg can
Rope grease
120
Chapter 11 Service
Initial servicing after 50 operating hours

Description Activity
Oil filter package
Worm slewing drive (check level - lower worm must run in grease)
Hydraulic fluid level (unsupported and in transport position)
Tighten hydraulic lines / hoses, screw joints
Crane base fixing
Initial servicing after one year

Rope winch - gear oil (see ‘Gear oil’, chapter 11)
After every 500 operating hours or once every year

Oil filter package - hydraulic oil
Worm slewing drive (check level - lower worm must run in grease)
Crane base fixing
Extension booms
Hydraulic lines / hoses, screw joints
End position switch

All safety devices
Ancillary equipment
Pump performance – speed
Operating levers, control rods
Load attachment
Crane column bearing clearance: see training documentation.
121
Service
After every 3000 working hours or once every three years

Rope winch - gear oil (see ‘Gear oil’, chapter 11)
Every 6 years
Hydraulic hoses
Gear oil
The gear oil must be replaced during the first annual service. And after that after every 3000 working
hours or once every three years, whichever comes first.
Only the PALFINGER approved gear oil PALFINGER GEAR GUARD must be used.
Property Unit
Density at 15°C [kg/m³] 900
Flashpoint (CoC) [°C] 205
Viscosity class [SAE J 306] 8W-90
[ISO VG] 150
Viscosity at 40°C 159
[mm²/s]
Viscosity at 100°C 15.6
Brookfield viscosity at -26°C [mPa*s] 128.000
Pour point [°C] < -30
guidelines under
Order no. EZ6311 – 4 l can
Order no. EZ6312 – 20 l can
122
Chapter 11 Service
Check of control equipment
Note!
The entire safety equipment must be checked during servicing
(overload test, HPSC test, etc.).
Protective hoses
During servicing, check protective hoses, covers etc. and replace damaged and missing parts.
Repairs
• Damages to the unit must be repaired immediately by a PALFINGER partner.
• Repairs have to be recorded in the service manual.
• If a repair is not carried out by a PALFINGER partner warranty will become void.
Lowering rate
The lowering rate must not exceed 0.2 % of the outreach per minute.
123
Chapter 12
CHAPTER 12
Decommissioning and disposal
In this chapter
Decommissioning and disposal guidelines.............................................. 127
125
Chapter 12 Decommissioning and disposal
Decommissioning and disposal guidelines

Properly disassemble the unit.
Warning! Improper disassembly can cause an increased danger of

accident.
• Contact your PALFINGER partner for proper disassembly of the unit.
• Disassemble the unit into single parts according to the instructions of your PALFINGER partner.
Disposal
Warning! Clean all oily and greasy parts before disposal. 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.
• Clean all oily and greasy parts.
• Dispose of the components according to their nature (steel, plastic, electric and electronic parts,
etc.).
• Dispose of all consumables - even biodegradable ones - in an environmentally friendly way.
• Contact your PALFINGER partner regarding the purchase of a new unit.
127
Index
Index
A Decommissioning and disposal • 125

Additionally in remote control mode • 69 Decommissioning and disposal
Adverse working conditions • 12 guidelines • 127
After every 3000 working hours or once Device and function • 23
every three years • 122 E
After every 500 operating hours or once Emergency cut-off button / push-button •
every year • 121 41, 61
After maintenance, service and repairs • Emergency cut-off function check • 78
18 Emergency operation after remote
Ancillary equipment • 47, 51 control failure • 44
B Ending operation • 91
Before driving • 97 Ending radio remote control operation •
Bringing the crane into transport position 97
• 93 Every 6 years • 122
Bringing the load arm to working position F
• 76 Function labels • 27
C Functional check of OS hydraulic
Capacity indicator • 42 overload protection • 78
CE symbol • 21 G
Check of control equipment • 123 Gear oil • 122
Check of threaded fasteners • 119 General • 19, 41, 49, 58, 101, 119
Cleaning • 104 Government regulations and standards
Components • 59 for operating the unit • 12
Components of the remote control • 58 Graphics and pictures • 5
Crane control systems • 58 Guidelines to prevent dangers • 58
Crane operation • 79 H
D Hook • 50
Daily function check of safety equipment Hydraulic oil • 113
• 78 Hydraulic oil change • 112
Danger from power lines • 16 Hydraulic oil change, hydraulic oil
Danger of getting crushed • 13 maintenance • 112
Dangers caused by exhaust • 16 Hydraulic overload protection • 43
129
Index
I Safety equipment • 39
Initial servicing after 50 operating hours • Safety for individuals • 9
121 Service • 117
Initial servicing after one year • 121 Slingers, other attachments to lift the
L load • 50
Labels for North America • 34 Stabilizer cylinders • 76
Load limits • 81 Stabilizing sequence • 74
Loads • 84 Starting the crane • 69
Lowering rate • 123 Storage, maintenance and care of the
Lubricant specification • 107 wireless system • 62
Lubrication • 111 Structure of system • 21
M Supporting the vehicle • 72
Machine lubrication • 107 Symbols • 5
Main components • 25 Symbols of remote control console • 28
Maintenance • 99, 103 T
Mechanical extension booms • 57 Technical description • 131
Modifications to unit • 22 Terms • 4
N Transport position monitoring system •
Noise emission • 15 44
Notes regarding the operating U
instructions • 1 Use for intended purpose / limits of the
O device • 10
Operating hours counter • 102 V
Operating instructions • 3 Validity of operating instructions • 3
Operating levers • 60 Vehicle inclination • 71
Operators • 22 Visual inspection • 105
Overload protection in radio remote W
control operation • 43 Watch out for faults before and during
Overview of labels • 30 operation • 67
P Working position of the crane • 81
Paint repair • 115 Working range • 68
Preparing for crane operation • 65 Working with loads • 85
Preparing for remote operation • 61, 69
Protective hoses • 123
Pulling outrigger beams out manually •
75
R
Remote control • 58
Repairs • 123
Residual risks • 11
Retract stabilizer cylinder • 96
Retracting the stabilizers • 94
Risk of burns • 15
Risk of falling • 13
Rope grease • 111
Rope winch • 51
S
Safety and Health Standards • 7
130
Chapter 13
CHAPTER 13
Technical description
131
132
Technical Specification
PC 3800 JI
(S026-ST-A)
Edition 03/2015 EN
PALFINGER AG
Lamprechtshausener Bundesstraße 8
5101 Bergheim / Austria
www.palfinger.com
PC 3800 JI 0.01000
Signs and symbols - abbreviation
-->123456789 Valid to crane number

123456789--> Valid from crane number
Page-A Control valve side
Page-B Counter control side
X Installation width without hose-equipment
2, 4, 2/4 Installation width with hose-equipment
ABST Support R without extension box

R0 One side extension box
R1 Both side extension box
R2 Both side extension box - extended
R3 Extension box telescopic
R4 Both side extension box - extended
R.X Both side extension box - hydraulical
SR. Support controllable from top seat
CWC Comfort Winch Control RTC Rope Tension Control

SRC Synchronized Rope Control
DPS Dual Power System DPSP,DPS+ Dual Power System Plus
EINS Pull-in part EIN... Pull-in part (J103E01SA)
FERN Remote control FFST Radio remote control
GRA Type - crane Base LKW Mounting LKW

SAT Semi-trailer installation
EGG Integrated base
HEC Rear-stabilizer HEC02 with control valve

HSTZY Hydraulically tiltable stabilizer cylinder
HEM Rear module Standard

HKONS Top seat FFST HK001 Standard seat
HK002 Tiltable seat
HK003 Seat with heater
HK004 Folding seat with heater
HOST Top seat - control KL0 Linear lever control

KK1 Cross lever control
HPLS High Power Lifting System EHPLS High Power Lifting System
SHPLS Super High Power Lifting System
MHPLS manually High Power Lifting System
HSITZ Top seat - standard HS005 Tiltable seat

HS012 Standard seat
HYA, PJHY Hydraulic extensions () Crane with one hydraulic extension boom
A Crane with 2 hydraulic extension booms
B Crane with 3 hydraulic extension booms
C Crane with 4 hydraulic extension booms
D Crane with 5 hydraulic extension booms
E Crane with 6 hydraulic extension booms
F Crane with 7 hydraulic extension booms
G Crane with 8 hydraulic extension booms
H Crane with 9 hydraulic extension booms
IG Railing IG001 3 port

IG002 2 port
IKONS Standing platform FFST IK002 without IS001, with IG001

IK004 with IS001, IG001
IK006 with IS002, IG001
IS Limitation of rotation I IS001 Limitation of rotation over I

IS002 Limitation of rotation, main boom over I
IS003 Limitation of rotation over FL
03/2015 www.palfinger.com
0.02000 PC 3800 JI
ISC Integrated Stability Control ISC01 Support control+SHB

ISC-S ISC standard
ISC-L ISC light+SHB
HPSC-L High Performance Stability Control light
HPSC continuous High Performance Stability Control
OELKU Oil cooler ÖLK01 Oil cooler 8.5kW, mounted

ÖLK02 Oil cooler 10.5kW, loose
ÖLK03 Oil cooler 8.5kW, loose
ÖLK04 Oil cooler 20kW, mounted
ÖLK05 Oil cooler 20kW, loose
ÖLK07 Oil cooler 10.5kW, mounted
PAL Paltronic PT050 Paltronic 50

PT150 Paltronic 150
PJ Fly-Jib Fly-Jib
PJHY Hydraulic extensions see HYA
PJKSL Hose-equipment PJ J02 1 Auxiliary equipment

J04 2 Auxiliary equipments
PJV Extension JV... see V
PUMPE Type - pump PU002 Fixed displacement pump

PU003 Variable displacement pump
MH Combustion motor
EH Electric motor
S Rope winch SH without limiting switch - main boom

SHE with limiting switch - main boom
SK without limiting switch - outer boom
SKE with limiting switch - outer boom
SHEK Power link rope winch (hydraulic tiltable at main boom)
SHB Slew angle dependent capacity limitation SHB01 with one pressure range
SHB07 with 2 pressure ranges + jumper
SKUPP Quick-coupling MULTI1 Quick-coupling, crane

Multifaster MULTI2 Quick-coupling, PJ
MULTI3 Quick-coupling, crane + PJ
SL Hose-equipment 2 1 Auxiliary equipment - hose tray

4 2 Auxiliary equipments - hose tray
T2 1 Auxiliary equipment - hose drum
T4 2 Auxiliary equipments - hose drum
T2I 1 Auxiliary equipment - hose drum (inside)
T4I 2 Auxiliary equipments - hose drum (inside)
SOSTZ Separate-stabilizer STU01 Stabilizer ram -150mm

STU03 Stabilizer ram -100mm
STGA Control - crane FL Floor control

I High stand platform
H Top seat
NK Emergency control - crane column
NK2K Emergency control - crane column, double circulit
HF Top seat - ground control
www.palfinger.com 03/2015
PC 3800 JI 0.03000
STRAN Rope winch, strand 1 1 strand

2 2 strand
4 4 strand
STEIL Monitoring the steep position STEIL1 Monitoring the steep position
STEIL2 Monitoring the steep position - Fly-Jib
STT Stabilizer plates Std Standard

100 Extension 100mm
200 Extension 200mm
STZ Stabilizer ram STZO Type without support

STZS3 Stabilizer ram - rigid
STZY3 Stabilizer ram - slewable
STZY Hydraulically tiltable stabilizer cylinder
STZS3Y Page-A= STZS3 B= STZY3
STZYS3 Page-A= STZY3 B= STZS3
SWERK Slewing system 1GETR 1-Slewing gear

2GETR 2-Slewing gear
SWK Max. rope winch capacity: 1,5 1,5t

2,5 2,5t
3,5 3,5t
4,5 4,5t
TKKR Crane tank KT... Crane tank ...l
TKLO Auxiliary tank TL... Auxiliary tank ...l
TOT Dead center TOWI Dead center over balance

TOQU Dead center over transverse spar
SE continuous
TSCH,TSTB Control valve M4-12 REXROTH M4-12

PVG32 DANFOSS PVG32
RS210 NORDHYDRAULIK RS210
RS220 NORDHYDRAULIK RS220
RSQ240 NORDHYDRAULIK RSQ240
SDM081 WALVOIL SDM081
VDM07 SALAMI VDM07
DNCE50 DINOIL DNCE50
DN46 DINOIL DN46
TSEIL Transport position rope AUSG Unreeve the rope

EING Reeve the rope
V,PJV Extensions V...() ...Extensions by HYA()

V...A ...Extensions by HYAA
V...B ...Extensions by HYAB
V...C ...Extensions by HYAC
V...D ...Extensions by HYAD
V...E ...Extensions by HYAE
V...F ...Extensions by HYAF
V...G ...Extensions by HYAG
V...H ...Extensions by HYAH
VBH Special overall height 180cm Crane height 180cm
ZUBA Attachment part BRI-4 4x Bolts

BRI-8 8x Bolts
BRI-4B 4x Bolts coated
BRI-8B 8x Bolts coated
PC 3800 JI
Table of Contents
Page
0 PREFACE
0.01000 Signs and symbols - abbreviation
010 SPECIFICATIONS
010.01100 Specifications
010.01110 Crane weight
010.01120 Extension
010.02100 Transport position
010.02110 Transport position SH,SHE
010.03100 Working positions
010.04100 Rope winch SH,SHE 0.8t
010.05100 Control stand
010.05110 Counter control
010.05120 Radio remote control
010.06100 Stationary mounting
020 LIFTING CAPACITY DIAGRAM

020.01100JI Lifting capacity diagram PC 3800 A
020.02100JI Lifting capacity diagram PC 3800 B
PC 3800 JI 010.01100
Specifications
Subject to change, production tolerances have to be taken into account.
Basic data
Classification: H1/B2 EN12999
3,7 mt (36,5 kNm)

Max. lifting moment: [26,920 ft.lb]
2000 kg
Max. lifting capacity: [4,400 lb]
5,0 m
Max. hydraulic outreach: [16' 50"]
Slewing area: 325
0,4 mt (3,7 kNm)

Slewing torque: [2,730 ft.lb]
22.0 MPa (220 bar)

Operating pressure: [3,190 psi]
12 l/min
Pump capacity: [3.2 US gpm]
15 l/min
Pump capacity: Rope winch [4.0 US gpm]
4,4 mt (43,0 kNm)

Crane moment (dynamic) [31,710 ft.lb]
0,4 mt (4,0 kNm)

Torsional moment (dynamic) [2,950 ft.lb]
Max. hydraulic outreach:
3,7 m
HYA A [12' 20"]
5,0 m
HYA B [16' 50"]
010.01110 PC 3800 JI
Crane weight
Crane weight FL
258 kg
HYA A [570 lb]
283 kg
HYA B [624 lb]
Additional weight
Control system Control stand Counter control FFST
25 kg 6 kg 50 kg
[55 lb] [55 lb] [110 lb]
Rope winch SH 0.8t SHE 0.8t STRAN1 STRAN2
40 kg 43 kg 20 kg 32 kg
[88 lb] [95 lb] [44 lb] [71 lb]
All weights are without accessories, auxiliary equipment and oil.
PC 3800 JI 010.01120
Extension
Max. outreach
V1 V2
5,0 m 6,0 m
HYA A [16 ft] [20 ft]
6,0 m 7,1 m
HYA B [20 ft] [23 ft]
Weight
V1 V2
18 kg 15 kg
HYA A [40 lb] [33 lb]
15 kg 11 kg
HYA B [33 lb] [24 lb]
Load capacity
V1 V2
5,0 m 650 kg 6,0 m 580 kg

HYA A [16 ft] [1,433 lb] [20 ft] [1,280 lb]
6,0 m 580 kg 7,1 m 280 kg

HYA B [20 ft] [1,280 lb] [23 ft] [617 lb]
m [ft]
V1 V2
kg kg
[lb] [lb] kg
[lb]
010.02100 PC 3800 JI
Transport position
1018 [40.08] PC 3800 V2B

779 [30.65] PC 3800 A,V1A,B
153 [6.04]
1675 [65.94]
1630 [64.17]
169 [6.63]
min. 15
220 [8.66] 180

360 [14.17] [7.09]
360 [14.17]
445 [17.52]
131 [5.16]
325
134 [5.28]
177 [6.95]
]1
8
[6.2
R15
PC 3800 JI 010.02110
Transport position SH,SHE
A 931 [36.67] 129 [5.10]

V1A,B 981 [38.63]
224 [8.82] V2A,V1B 1024 [40.33]
EP 984 SH
EP 979 SHE
1710 [67.32]
1285 [50.59]
206 [8.11]
32
605 [23.82]
V2A,V1B 3 [.13]
V1A,B 60 [2.36]
A111 [4.36]
220 [8.66] 180

[7.09]
UR316
360 [14.17] 360 [14.17]
445 [17.52]
325
197 [7.76]
SHE 317 [12.48]

SH 300 [11.81]
]
[9. 5
65
4
R2
010.03100 PC 3800 JI
Working positions
]
.15
[70
2
372 [14.63] 78
R1
3290 [129.53]
70 [2.76]
140 [5.51]
75 210 [8.27]
153 [6.04]
1908 [75.11]
1601 [63.02]
1575 [62.01]
1339 [52.72]
1447 [56.97]
1690 [66.54]
PC 3800 JI 010.04100
Rope winch SH,SHE 0.8t
HI 042 PC 3800 A, V1A,V2A,B,V1B

EQ 042
HHK 400
UR316
266 [10.49]
HIS 329
EQ 042
123 [4.84]
X
569 [22.40]
4xES 032
720 [28.35]
8xEK1108
UL175A
HXE3505
1STRAN
8xEK1108
4xEM 021
PC 3800 A, B
HI 042
EQ 042
HHK 400
EP 979 SHE
EP 984 SH
UR316 197 [7.76]
SH 300 [11.81]
KUR057-BB SHE 317 [12.48]
UL085
2STRAN
010.05100 PC 3800 JI
Control stand
295 [11.60]
478 [18.83]
161 [6.34]
450 [17.71]
385 [15.17]
106 [4.17] 250 [9.85]
212 [8.35]
X
9 [.35]
3 [.12]
428 [16.85]
PC 3800 JI 010.05110
Counter control
385 [15.16]
123 [4.84]
110 [4.31]
174 [6.85]
374 [14.74]
9
[.3
5]
330 [12.99]
35 [1.38]
010.05120 PC 3800 JI
Radio remote control
127 [5.00]
234 [9.21]
244 [9.60]
8
[.3
2]
607 [23.90] 328 [12.91]
364 [14.31]
571 [22.48]
PC 3800 JI 010.06100
Stationary mounting
4xES 1398
X 4xEK 176
KMG02436A
4xHT9430
4xEK 176
4xEM 029
300 [11.81]
190 [7.48]
300 [11.81]
150 [5.91]
]
[.83
21
Fixation d l Tightening torque
80 mm 462 Nm
ES 1398 (KMG02436A) M20
[3.15"] [340 ft.lb]
020.01100JI PC 3800 JI
Lifting capacity diagram PC 3800 A
0ft 4ft 8ft 12ft 16ft
7m
max 2000kg
max 4400lbs
1240kg
20ft 2750lbs
1060kg 6m
71° 2350lbs
60°
980kg
1820kg 2150lbs
45° 5m
4000lbs
16ft
1560kg
3450lbs
960kg
1420kg 2100lbs
30°
3150lbs
4m
12ft 1380kg 960kg
3050lbs
15° 2100lbs
2000kg
4400lbs 1380kg 3m
3050lbs
8ft
2000kg 1420kg 980kg
4400lbs 3100lbs 2150lbs
2m
-15°
1440kg
4ft 3200lbs 1000kg
2200lbs
1m
0ft 0m
-1m
-4ft
-2m
0m 1m 2m 3m 4m 5m
PC 3800 JI 020.02100JI
Lifting capacity diagram PC 3800 B
0ft 4ft 8ft 12ft 16ft
8m
max 2000kg
920kg max 4400lbs
24ft 2050lbs
790kg 7m
71° 1740lbs
60°
1220kg 720kg
20ft 2700lbs 1600lbs 6m
1030kg 45°
2300lbs
1800kg 950kg 700kg

3950lbs 2100lbs 30° 1550lbs 5m
16ft 1520kg
3350lbs
1380kg
920kg
3050lbs
2050lbs
700kg 4m
12ft 1340kg 15° 1550lbs
2950lbs
920kg
2000kg
2050lbs
4400lbs 1340kg 3m
2950lbs
8ft
2000kg 1360kg 940kg 720kg
4400lbs 3000lbs 2100lbs 1600lbs
2m
1380kg
4ft 3050lbs -15°
960kg
2150lbs 740kg 1m
1650lbs
0ft 0m
-1m
-4ft
-2m
0m 1m 2m 3m 4m 5m 6m
.

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Operating Manual

Palfinger North America

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

Vehicle inclination ........................................................................................................... 71

Notes regarding the operating

Note! In case of damage or loss of these operating instructions

Changes since going to press

© Copyright by PALFINGER Copying (even in extracts) only permitted with written

Validity of operating instructions

Symbol for operating lever:

Graphics and pictures

Safety and Health Standards

Safety for individuals

Personal safety equipment:

Use for intended purpose / limits of the device

Accidents caused by incorrect use are grossly negligent if:

Government regulations and standards for operating the unit

Adverse working conditions

Climbing on the unit is prohibited.

Danger of getting crushed

Required minimum distances

Main source of noise: Vehicle motor.

Protective measures: Ear protection.

Dangers caused by exhaust

Danger from power lines

Minimum distances from live lines

Voltage Minimum distance

up to 1,000 Volts 1.0 meter (3.3 feet)

unknown or over 1,000 Volts 5.0 meters (16.5 feet)

Actions to take in the event of flashover

After maintenance, service and repairs

Crane delivery to operating company / operator

Modifications to the unit may only be made by PALFINGER service partners.

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

Device and function

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

Symbols of remote control console

Slew clockwise (right)

Slew counter-clockwise (left)

Lower main boom

Lift main boom

Extend extension boom

Retract extension boom

Lower rope winch

Raise rope winch

Extend outrigger beam

Retract outrigger beam

Extend stabilizer cylinder

Retract stabilizer cylinder

Rotator counter-clockwise (left)

Rotator clockwise (right)

Working light on / off

Increase engine RPM

Reduce / increase speed

Danger! Missing, damaged or illegible labels increase the risk of

2. Crane model label

3. Indication for completely extended outrigger beam