Maintenance and service Chapter 6

6 Maintenance and service

CONTENTS

6.1 MAINTENANCE
6.1-1 WARRANTY PROVISIONS

6.1-2 SCHEDULE OF MAINTENANCE

6.1-3 PLANE OF MAINTENANCE (PTM XXX)

6.1-4 LUBRICATION

6.1-5 HYDRAULIC OILS

6.1-6 OIL CHANGE / OIL MAINTENANCE

6.2 CLEANING THE PLANT

6.2-1 CLEANING AGENTS AND EQUIPMENT

6.2-2 REPAIRING PAINT DAMAGE

6.2-3 REMOVAL FROM SERVICE AND DISPOSAL

Maintenance 6.1-1
6.1 Maintenance

6.1-1 Warranty provisions

Regrettably, during servicing, we have noticed repeatedly that our recommendations
for maintenance and lubrication of the crane have been ignored.

We are not liable for any costs for damage resulting from insufficient maintenance
and lubrication. It is in your own interest to carry out the maintenance and lubrication
of your work platform regularly and in accordance with the instructions.

Only use lubricants and hydraulic oil of sufficient quality. Using poor quality products
represents a false economy.

Guarantee and service work must only be carried out at one of our authorised
customer service centres (see Maintenance Handbook).

The conditions of the guarantee are stated in the guarantee booklet.

6.1-2 Schedule of Maintenance

When working on hydraulic equipment, make sure that the hydraulic

system is not still under pressure!

After every 50 operating hours or once every year

1st service
Oil filter change

After every 50 operating hours or once every year

Rotary distributor (slew 360 degrees)

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

1 Turntable (360° slew)

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

After every 50 operating hours or once every year

Oil filter, hydraulic oil change

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

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

6.1-3 Plane of maintenance (PTM xxx)

6.1-4 Maintenance
6.1-4 Lubrication
The following maintenance and care instructions apply to all PALFINGER MARINE cranes. Therefore
this chapter includes also hints which do not refer to your crane.

Deficient or incorrect lubrication causes increased wear out and consequently unnecessary repairs
(downtimes) of the crane. Therefore, make sure that bearings, hydraulic extendable arms and
mechanic support arms are always sufficiently lubricated and that only those lubricants are used which
are included in the specification below or correspond with them.

Lubricant to be used:

To lubricate the bearings only use solid-free grease without any

graphite, MoS2, etc. Using different greases quickly leads to bearing
damages on the crane.

Bearing:

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

Boom extensions / mechanic extensions, etc:

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

• Before greasing clean the spot thoroughly, yet dirt

that gets into the bearing hole together with the
grease causes quick wear-out of the bearing.
• Then press fresh grease into the bearing on the
intended grease spots (oil holes etc.) until it comes
out off the bearing.
• After greasing it is necessary to clean off any excess
grease from the bearing.

How to grease the hydraulic boom extensions on the crane correctly:

• Extract the hydraulic boom extensions completely and then place the load-bearing arm on a piece
of wood.
• Before lubricating clean the grease spots off any old and dirty grease and other dirt.
• Then apply the grease on the bottom of the hydraulic boom extension using a
suitable tool (brush or similar).
• Retract the hydraulic boom extensions while applying light pressure (lower main
boom).
• Then remove the excess grease.

Because of danger of slipping excess grease is a safety hazard and

must not get into the environment.

If the crane has not been used for a period of time, the complete
crane system must be lubricated according to the lubrication plan.
Each exposed metal part must be protected with an anti-rust agent.
All of the hydraulic cylinders must be retrieved as far as possible.
The cable winch and cable must be protected with an anti-rust
agent. For continuous swivelling equipment the gear drive, pinion
and all exposed metal parts must be especially protected against
corrosion.

As grease is lost at most lubrication points on the work platform (grease is consumed
or goes into the environment), we recommend the use of biodegradable greases.

Care of extendable cylinder piston rods:

If the extendable arms are never completely retracted to the transport

position the extendable cylinder piston rods may suffer oxidation. The
extendable cylinders (extendable arms) must therefore be completely
retracted once a month.
6.1-5 Maintenance

6.1-5 Hydraulic oils

When choosing the hydraulic oil, you should consult your service representative.

HLP / ISO hydraulic oils should be used with the following properties:

• Reasonable viscosity / temperature properties.

• Good thermal and mechanical resistance.
• Significant ageing resistance.
• Good corrosion protection properties.
• Adequate cold-flow properties.
• Adequate lubrication effect at the lubrication limits.
• Good air-separation properties.
• Perfect foaming behaviour.
• Neutral with respect to seals and hydraulic hoses.
Maintenance 6.1-5
As the viscosity of hydraulic oils is strongly influenced by temperature changes, compromises during
their selection cannot be avoided. The following limiting values are valid for your PALFINGER
MARINE work platform:
Operating limits

Recommended
range
ISO Reference
temperature Temperature °C

High temperature range: .............. ............................................................ 10 cSt

Cold start limit: ............................. ............................................................ 1000 cSt
Cleanness class: .......................... ............................................................ 15/12 (according to ISO 4406)

The working temperatures differ according to the different product bases:

Mineral oil based oils:................... ............................................................ approx. -30° C to +80° C

Biodegradable oils:....................... Fully synthetic esters: ......................... approx. -30° C to +80° C
Biodegradable oils:....................... Natural esters: .................................... approx. -20° C to +80° C
Biodegradable oils:....................... Oils on the basis of rapeseed oil: ....... approx. -20° C to +65° C

Rape-seed oil and Class HLP 22 oil must not be used. Rape-seed oil
causes the valves to stick!

The ideal working temperature for hydraulic oil lies between 30°C and 60°C.

If these temperatures are frequently exceeded when using the work platform, consult your service
representative with regard to the installation of oil cooler or a larger oil tank.
6.1-5 Maintenance
Biodegradable oils are better for the environment than conventional hydraulic oils.
Anyway, even these oils must not be disposed into nature.

Releasing oils (including biodegradable oils) into the natural

environment is not permitted!

The hydraulic oils listed in our recommendations may be blended together but must not be mixed with
other fluids.

Note the following disadvantages:

• Shortening of service life,

• Mineral-oil mixtures are not biodegradable.
• Reduced permitted operational temperature for mixtures with rapeseed oil or native ester.

Hydraulic oils
Toothed wheel
Biodegradable Lubricating
Manufacturer: Mineral oils: Gear oils: grease:
oils: grease:
Rope:
AGIP Arnica32 Arnica S Blasia 150 Grease 33 FD FIN 332 / F

ARAL Vitam VF 32 Vitam EHF 46 Degol BG 150 Langzeitfett H Sinit FZZ

Avia Synthofluid Avia Gear RSX Avia Aluplex 0
AVIA Avia Fluid HVI 32 Avia TAC BB 21
46 N 150 RHS
Castrol Grease
CASTROL Hyspin AWH 32 Carelube HES Alpha SP 150
CL
Spectron ZFK
DEA Astron HVLP 32 Econa E 46 Falcon CLP 150 Caron WAW EP 2
EPO
Biohydran TMP
FINA Hydran TSX 32 Giran L 150 Merkan DT 95 Cabline MGR
32
Plantohyd Super
FUCHS Renolin B HVI 32 Renolin CLP 150 Almetyn 2 Ceplatyn 300
S
Mobilgear OGL
MOBIL Mobil DTE 13 M Mobil UF 46 Mobilgear 629 Mobilgrease HP
007
OMV HLP M 32 Biohyd MS 46 Gear HST 150 OMV Fett ZMO OMV Fett ZFK

SHELL Tellus T 32 Naturell HF E 46 Omala Oil 150 Retinax HD 2 Shell Kuggfett

TEXACO Rando HDZ 32 Meropa 150 FM Novatex EP 1

TOTAL Equivis ZS 32 Hydrobio 46 Charter EP 150 Multis 2 Multis WR 2

Ultramax HVLP
VALVOLINE Ultrasyn HE 46 EPG 150 Val – Plex EP 2 MP Molly Grease
32
WINTERSHALL Wiolan HVG 32 Wiolan HE 46 Ersolan 150 Wiolub LDF
Maintenance 6.1-6
6.1-6 Oil change / oil maintenance

The annual maintenance of oil can significantly increase its working life. Apart from the saving in
costs, this means a drastically reduced amount of waste oil and less contamination of the
environment.

All rams must be fully retracted when changing the oil or topping up
the hydraulic oil.

Oil maintenance means:

Filtration, dewatering and testing of the oil purity which you have carried out in an authorised
workshop.

Life in years:

Oil type Oil maintenance

without with
Mineral oils 1 2

Biodegradable oils

Natural esters 1 2

Fully synthetic esters 1 2

The relevant local laws, regulations and guidelines apply to the

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

Max. oil
Service life in temperature
years

Working hours
per year

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

Instructions:

• Move crane into transport position.

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

A = filling socket, coarse filter

B = oil drain
Maintenance 6.1-6
Tank volume:

PTM 190 140 litres

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

Power supply:

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

The following elements are in the pump room:

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

A
B
6.1-6 Maintenance
Water trap:

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

A = Water trap
Cleaning the plant 6.2-1
6.2 Cleaning the plant

6.2-1 Cleaning agents and equipment

Regular expert care will serve to preserve the value of your crane. How often the crane needs to be
washed depends on how frequently it is used, the season, weather influences and so on. Road salt,
oils, dust, etc. attack the paintwork of your crane and an increased corrosion of the crane components
can occur.

Only wash the crane when the electrical unit is switched off.

Cleaning agents:

For the care of your crane use only pH-neutral cleaning agents to avoid oxidation on chrome parts.
When selecting cleaning agents please ensure that you only use environment-friendly products.

Some cleaning agents are harmful to the skin. Be informed about

your cleaning agent and protect yourself accordingly before starting
the cleaning work.

Cleaning equipment:

When using high-pressure cleaning equipment there must always be enough distance between the
nozzle and the crane being cleaned as otherwise damage can be caused by the high water pressure.

Electronic components, plastic components, signs and bearings must not be cleaned using high-
pressure cleaning equipment.

Therefore ensure that:

Lubricant is washed out of the bearings.

Adhesive signs are not loosened from the crane by sideways or excessively long spraying.
Plastic parts are not damaged by excessively high water temperature or high pressure.
Crane parts containing electronic components (control valve, electronics boxes, etc.) or electronic
components themselves must never be sprayed directly with high-pressure cleaning equipment. If
water gets into these parts, it can lead to a malfunction of the crane or to short circuits in the
electrical system.

Areas which have been marked with the warning sign “High-pressure cleaning
prohibited” must also not be cleaned with high-pressure cleaning equipment.

When using high-pressure cleaning equipment, the water (cleaning

agent) must not exceed a temperature of 60° C.
6.2-2 Cleaning the plant

6.2-2 Repairing paint damage

If you discover paint damage on your crane, you must take care of it immediately. Damaged places
must be sanded off and coated with a primer before painting.

Repair damaged paint to avoid corrosion!

Degrease damaged paint.

Apply primer.
Apply top coat.

6.2-3 Removal from service and disposal

If the crane is taken out of service and dismantled from the vehicle its parts must be disposed of
properly. Bear in mind that many crane components are contaminated with grease and oil which on no
account must be allowed to discharge into the environment. Biodegradable oils and greases should
not be allowed to discharge into the environment either.

Therefore dispose of the parts separately according to their nature (steel, plastic, electrical
components, oils, greases, etc.) and in accordance with the respective statutory regulations in your
country.