HIAB 335K HiPro CD CE, Operator'S Manual

Page 1: ...Operator s Manual GB HIAB 335K HiPro CD CE This operator s manual is an Original Instruction and applies for cranes from serial number 3350690 2015 06 ...

Page 2: ...ly and with full satisfaction Please read the complete manual It provides detailed information about the crane safety system and the practical management and maintenance of the crane We advise you to read it carefully and familiarize yourself with your crane before you start to use it Help us to improve this manual Please send your comments and suggestions to documentation hiab com 2 Operator s Ma...

Page 3: ...ing valves 14 2 7 Description of Hiab 335K HiPro CD 15 3 Safety precautions and warnings 16 3 1 Operating conditions 16 3 2 Definition of a HIAB loader crane 17 3 2 1 Noise declaration 18 3 2 2 Warning signs 19 3 2 3 Maximum load 19 3 2 4 Maximum load moment 22 3 3 Signals when using a crane 25 3 4 Wind speeds 29 3 5 Use of the crane 30 3 6 Use of lifting equipment 37 3 7 Use of dismountable crane...

Page 4: ... crane out of parked position 71 6 During operation 73 6 1 OLP Overload protection 73 7 Ending crane operation 78 7 1 Operate the crane to parking position 78 7 4 Placing the stabiliser extensions and legs in transport position 79 7 5 Switching off the safety system 80 7 6 Emergency operation Valve V91 80 7 7 TWI Transport warning interface option 81 8 Maintenance and Service 83 8 1 Service 83 8 2...

Page 5: ... the cartridge in the pressure reduction filter 93 8 5 4 Replacing the cartridge in high pressure filter option 94 8 5 5 Checking the oil tank level 94 8 5 6 Changing the hydraulic oil 94 8 5 7 Bleeding air from the hydraulic system 97 8 6 Troubleshooting 98 8 6 1 Main fuses 98 8 6 2 Faults in the HiPro crane 98 9 Decommissioning 102 9 1 Decommissioning a crane 102 10 Technical Data 104 10 1 Load ...

Page 6: ... Operator s Manual for your crane carefully it could lead to fatal accidents or serious damage Therefore you should Study the entire Operator s Manual carefully Study the operating manuals for other add on equipment if fitted Use the crane only after having done so Follow the directions for use operation and maintenance of the crane and add on equip ment exactly Store the Technical Data and manual...

Page 7: ... of Conformity delivered with the crane contains Business name and full address where the crane is manufactured Factory addresses Hiab Cranes S L U Pol Ind Malpica calle E 86 50016 Zaragoza Spain Cargotec Poland Sp z o o Ul Metalowa 2 73 110 Stargard Szczecinski Poland Description and identification of the loader crane Mark Type see chapter Identification of the crane Serial number Manufact year D...

Page 8: ...NG Danger of injury to yourself or to bystanders or danger of serious damage to the crane or other objects Follow the instructions carefully CAUTION Hazard for the crane or crane components Follow the instructions carefully Important If actions are numbered 1 Do this 2 Do that 3 4 5 you should carry them out in numerical order NOTE Extra information that can prevent problems TIP Tip to make the wo...

Page 9: ...eive instruc tion from an experienced person from your own company Only then should you operate your crane Ensure that you comply with the statutory requirements of the country in which you use the crane for example certificate obligatory safety helmet DANGER Carry out yourself only the service and maintenance work you have the requisite knowledge and experience of All other maintenance work may o...

Page 10: ...controller in water or other liquid This will make the controller unusable If your crane is equipped with add on lifting equipment hoist rotator etc The operation of the crane with add on lifting equipment can differ from the oper ation as described in this manual You should therefore study the Operating Manual for the add on equipment careful ly before you use the crane Take particular note when ...

Page 11: ... crane base column and the slewing sys tem consist of the following components Crane base with stabiliser beam column bearings and three point bridge Column this fitted to the crane base and turns in an upper and a lower bearing Slewing system 2 3 Boom system The boom system consists of the following components 1st boom 2nd boom Hydraulic extensions The extensions are operated by hydraulic cylinde...

Page 12: ...option Add on lifting accessories are placed between the boom tip and the load e g pallet fork grapple rotator Separate lifting accessories option Separate lifting accessories help to make or use a slinging device eye hooks shackles eye bolts etc 12 Operator s Manual GB ...

Page 13: ...cranes Stabiliser beam The stabiliser beam is a part of the crane base Stabiliser extensions The stabiliser exten sions are hydraulically slid out from the stabiliser beam Stabiliser legs Place the stabiliser legs on firm levelled ground to support the crane Stabiliser locking device Support plates The support plates are used under the stabiliser legs for additional sup port Operator s Manual GB 1...

Page 14: ...educers return filter pressure filter option 2 6 LHV Load holding valves All cylinders are equipped with load holding valves as a safety device After a crane move ment they hold the crane in position also in the unlikely event of a burst hose If there is a leak or a component fractures such as a pipe hose or a coupling the load holding valves will stop the booms from collapsing down even when the ...

Page 15: ...s class S2 according to EN13001 Lifting capacity HIAB 335K 28 9 tonne metres 208 672 6 ft lbs The cranes are supplied in a version HIAB 335K 4 reach 17 3 metres 56 9 ft The control valve V91 CombiDrive2 and the SPACE 5000 safety system are standard equip ment on the HIAB 335K HiPro CD The crane type and the manufacturer are marked on the serial number plate NOTE The exact technical information for...

Page 16: ...rox 29 7 mph the crane will behave unpredictably Never use the crane during a thunderstorm Never use the crane at temperatures below 40 C 40 F as the steel s properties deteriorate below this temperature WARNING At temperatures below 0 C 32 F Do not touch the operating levers during the first few minutes When starting in cold weather the wear on the hydraulic system is greater than at normal worki...

Page 17: ...e Lifting of loads from the ground vehicle to a higher place Installation work beams concrete plates windows in building constructions Lifting construction material wall boards bricks blocks on a pallet fork to a build ing taking the material from the vehicle on which the crane is mounted from another vehicle or from the ground Hoisting e g beams concrete plates and any other material and equipmen...

Page 18: ... specifically prepared for this Push pull with the boom system against any type of obstacle wall ground 3 2 1 Noise declaration The following values for emitted noise may be taken as general and conservative values for ordinary installations of loader cranes on normal diesel engine powered trucks Declared dual number noise emission values in accordance with ISO 4871 Emitted A weighted sound power ...

Page 19: ...kNm or tm This lifting capacity is also known as the load moment The lifting capacity is the payload at hook multiplied by the outreach in metres that the crane can operate at different positions The lifting capacity of your crane determines the maximum load your crane may lift within its working zone However take careful note the greater the operating radius of the crane the lower the lifting cap...

Page 20: ...vy Load plate You will find the load plate next to the control valve On the plate is the maximum weight that you may lift at a given reach with the 1st boom in the optimum position In chapter Technical Data in this manual you will find these values for your crane Optimum position The weight that your crane can lift will be determined by Stabilty test of your crane on vehicle Stabiliser extensions ...

Page 21: ... and height For a given maximum load the possible working zone is to the left of the load curve The lifting capacity for some cranes is limited in the high lifting area WARNING Care must be taken when handling loads in the high lifting area so the load tool does not come into contact with the boom system WARNING Never operate the hydraulic extensions against a solid objet when the first boom is co...

Page 22: ... then the following movements are locked first boom down up second boom down extension boom out If the second boom is down then the following movements are locked first boom up second boom up extension boom out first boom down certain crane types and cases Lifting the load You obtain the best from your crane in this way Ensure that you always have the work in clear view If you cannot see the load ...

Page 23: ...in accordance with the table Max angle to Mode factor Mode factor the vertical of two legged three and four any sling leg sling legged sling degrees 0 45 1 4 2 1 45 60 1 0 1 5 If the angle between the legs of the sling exceeds 90 the slings should not be hung directly on the hook but rather be slung from a ring that is hung on the hook Working close to the load Always try to lift the load with the...

Page 24: ...d plate on your crane DANGER Never exceed the maximum permissible load ing of the hook Heavy loads cannot be handled with the boom straight Set the second boom so there is an angle in relation to the first boom Loads at the extreme limit of the working zone Also in this case angle down the second boom somewhat Only use the first boom TIP Make smooth crane movements operate the crane with various f...

Page 25: ...low the instructions and signals given by a qualified person qualified The country specific regulations for crane operator signals are to be used Signals in this manual give a number of standard signals that can be used Lift Raised arm and index finger raised Circular motion with hand Lower Arm pointing downwards and index finger down Circular motion with hand Operator s Manual GB 25 ...

Page 26: ...s and the arms to an oblique angle Very short movement Place the hands a very short distance apart with the palms facing each other The hands may be held either horizontally or vertically The next movement may be Lift lower move the lifting gear change the reach or turn Change the reach Signal with your hands Sideways movement outwards with both hands Thumbs outwards Sideways movement inwards with...

Page 27: ...s 3 3 Turn in the direction indicated Indicate the direction with the hands Open the grapple Extend the arms at shoulder height with the palms facing downwards Close the grapple Move both hands close together Operator s Manual GB 27 ...

Page 28: ...grapple a little Extend both arms at shoulder height with the palms facing upwards Make vertical movements with both arms outstretched Keep the grapple in position briefly Raise the hand drooping slightly with the fist clenched 28 Operator s Manual GB ...

Page 29: ...ground Fairly strong wind Small leaved branches make swaying 5 8 0 10 7 movements crested waves form on lakes and canals Strong wind Large branches move you can hear the wind whistling in telephone wires 6 10 8 13 8 umbrellas can only be held with diffi culty Severe wind Entire trees move the wind causes 7 13 9 17 1 difficulty when you walk into it 8 17 2 20 7 Stormy wind Twigs break off walking i...

Page 30: ...ned Look out for sewers cellars excavations etc The stabiliser legs must not be able to sink in Use support plates that are large and firm enough for your crane The plates must not bend under load Check that the support plate as it comes under load is not pushed into the ground Ensure you can see the stabiliser legs and stabiliser extensions when you are operat ing them Do not lower the stabiliser...

Page 31: ...s a load WARNING Use low force when placing the stabiliser legs on the ground Do not raise the vehicle with the stabiliser legs if the crane is equiped with only two stabiliser legs If you raise the vehicle with the stabiliser legs this may damage the stabiliser legs Check that the add on lifting accessories and separate lifting accessories are in good order Add on lifting accessories are sometime...

Page 32: ... system when operating the crane out of parking position Preparations for use DANGER Ensure that there are no unauthorised persons within the operating range of your crane TIP Mark out the working range e g with cones Put on your vehicle s warning lights 32 Operator s Manual GB ...

Page 33: ...lated insulated con conductor ductor 500 V 0 5 m 2 m 500 40000 V 1 5 m 4 m 40000 V 2 0 m 6 m Voltages are found up to 500 V to buildings 500 40000 V trams trains over 40000V power transmisson Crane operation DANGER Your crane has a safety system The safety system will help you to work safely Nevertheless you remain responsible for safe use of the crane Therefore always work according to the oper a...

Page 34: ...f signals Make certain that you and the person assisting you know these signals Pay attention to the safety of the person giving the signals Never move the vehicle if you have a freely suspended load on the crane Never walk or stand under a suspended load During operation never stand below the boom system or load Do not slew the crane nor lift the first boom nor lift the second boom into their end...

Page 35: ...tricted spaces for example windows Check that the boom system can move up and down freely The boom system will bend somewhat when loading and unloading the crane If the boom system is in a high position first boom above 70 do not allow the boom to lower at full speed The crane could go into an uncontrolled movement Be careful if in particular the OLP gives an early warning When loading the vehicle...

Page 36: ...els etc Pay attention to overhead power lines Make sure that no part of the crane ever comes in contact with overhead power lines For further instructions see vehicle s manual s Ending crane operation DANGER Always end crane operation as follows After use always place the crane in the transport position Withdraw the stabiliser legs and stabiliser extensions Check that the locking mechanisms are pr...

Page 37: ...g accessories when you are working on the crane After the lifting accessories have been fitted 1 Check that the lifting accessories are securely fixed 2 Only after this should you use your crane WARNING Clean the couplings when connecting and disconnecting lifting accessories Dirt can damage the hydraulic system Take care that your fingers are not trapped 3 7 Use of dismountable cranes DANGER Ensu...

Page 38: ...Safety precautions and warnings 3 7 WARNING Take care when mounting dismounting the crane on off the vehicle Roughly handling can seriously damage the crane or the vehicle 38 Operator s Manual GB ...

Page 39: ... system HiPro CD V91 SPACE 5000 NOTE The safety system provides a large number of functions Certain functions are standard others are options If you do not use the system for 30 minutes it will switch itself off in order to prevent draining the truck battery This feature can be cancelled Contact your HIAB service workshop 4 2 How the safety system works The safety system works as follows On the cr...

Page 40: ...l be reduced When the fault is serious use of the crane is blocked completely DANGER Never try to repair the safety system yourself Repairs may only be made by a HIAB service workshop 4 3 Components of SPACE Safety System Main control valve The crane can be operated from the main control valve but as soon as you have selected remote control operation it is impos sible to operate the main control v...

Page 41: ...ontrol valve and the stabiliser control valve The dump valve 2 must be activated from the SPACE interface before the stabilis er system can be controlled Decoder Remote controller CombiDrive2 The controller is the device that the operator use to control the crane There is also an emergency stop button on the controller Selector valve cranes with top seat Select the oil flow towards either the cran...

Page 42: ...control CombiDrive2 with radio with cable connected 4 5 Main control valve The speed of a function corresponds to the extent of the lever movement regardless of the load and other functions as long as the oil flow is sufficient When the oil flow is insufficient one or more functions might reduce their speed When remote control is used the oil flow is allocated by means of PFD 42 Operator s Manual ...

Page 43: ...The Safety system 4 5 Main control valve lever function Operator s Manual GB 43 ...

Page 44: ...ol valve The stabiliser control valve is equipped with 2 levers on each side of the crane The levers have the functions Stabiliser leg upward downward Stabiliser extension out in The stop button affects the oil supply to this valve 44 Operator s Manual GB ...

Page 45: ...he functions Stabiliser leg upward downward Stabiliser extension out in Extra stabiliser leg upward downward Extra stabiliser extension out in The stop button affects the oil supply to this valve 4 8 Selector valve option Use lever to select Crane functions manual or remote Stabiliser system functions Operator s Manual GB 45 ...

Page 46: ... on equipment Joystick Second boom downward upward Add on equipment Pedal Extension boom out in Pedal Slew clockwise counterclockwise For safety reasons it is necessary to sit down on the seat to operate the controls DANGER Take care not to put your foot on the pedals when taking place in the high seat Uninten tional crane movements can occur Hydraulic stabiliser extensions and legs are con trolle...

Page 47: ...r stands while manually operating the crane 4 11 User panel SPACE 5000 Cranes with remote control type CombiDrive2 and control valve type V91 are equipped with user panel SPACE 5000 Functions Stop button When you push the stop button all crane movements are stopped immediately ON OFF button with the symbol to switch the safety system On Off Button with the symbol To switch on the remote control an...

Page 48: ...ror crane stops OLP Release Red light on OLP Red light blinking OLP release button has been pressed 5 sec to release OLP VSL Variable Green light on Full VSL stability Stability Limit Light off Vehicle has limited stability but crane capacity is not fully used Red light on VSL OLP Vehicle has reached a stability limit Also all the 1st boom diodes will light red Green light on Dump valve 1 activate...

Page 49: ...reen light on Remote control Good radio connec tion Green light blinking Stop button pressed no radio connection Red light blinking Radio interference Manual extensions Green light on Manual extension selected Green light blinking Manual extension selected and 1st manual extension out but 1st crane extension not out Manual control Green light on Manual control Stabiliser system Green light on The ...

Page 50: ...ovides information about which menu has been chosen as well as indicat ing the radio reception conditions battery status fault information micro ADC manual extension and so on The side displays show the symbol for the function which each lever activates in the chosen menu When the operator changes menu the symbols change to the functions that become active Via cable A four metre cable is supplied ...

Page 51: ...ed Alternating symbols will not be updated at tem peratures below freezing In order to prevent accidental menu shifts in cold weather below 10 C there will be a time delay before any menu button will react to a second depression In order to avoid this inconvenience HIAB recommends that whenever the controller is not in use it should be stored in a compart ment where the temperature exceeds 10 C Ce...

Page 52: ...e Indicates that the LSS V function is active shown enlarged for three seconds and then return to normal size MEWP Mobile Elevating Work Plat HDC form Indicates that the HDC function is active Indicates that MEWP if present is active Signal strength JDC The bars show the radio signal strength Indicates that the JDC function is active Five bars indicate optimum reception condi tions If the symbol f...

Page 53: ...Symbol appears enlarged in the center of the display After three seconds it returns to normal size and moves to the upper part of the display Critical error Symbol remains enlarged in the center of the display The crane stops Error code display The control system has the possibility to send error codes to the controller By pressing button on the left hand side below the display handle The centre d...

Page 54: ... Button CRANE menu Button EXTRA menu button ON OFF menu In each of the main menus the operator can step through submenus by pressing the same button repeatedly e g 1 2 3 and then back to 1 again The restriction is that one function is only present on a specific lever If a lever is faulty or deflected at startup the lever is disabled The other levers operate in the usual way With the 2 extra levers...

Page 55: ...y lever there is a correspond ing function which it controls This appears in the left or right display When the menu changes by pressing the button for CRANE menu the symbols change and the functions are activated in the current menu The symbols are stored in a symbol library and can be configured set via the terminal program for a CE crane Symbols for the 8 lever controller Centre Left side displ...

Page 56: ...1 2 3 The Safety system 4 13 Symbols for the 6 lever controller Left side display Centre Right side display display CRANE MENU 56 Operator s Manual GB ...

Page 57: ...ion to the lever The symbols are configured in the same way as for the CRANE menu The same method is used for stepping between the sub menus Left is defined as the side of the crane where the main control valve is normally placed The order of the levers is customized For the 6 lever controller If the crane has 1 stabiliser control valve the order of the levers should be Functions lever forward on ...

Page 58: ...leg down Menu 3 Lever Functions lever forward on the con troller 2 Right crane stabiliser extension out 3 Right crane stabiliser leg down 4 Right auxiliary stabiliser extension out 5 Right auxiliary stabiliser leg down For the 8 lever controller If the crane has 1 stabiliser control valve the order of the levers should be Lever Functions lever forward on the con troller 3 Left stabiliser extension...

Page 59: ... con troller 1 Left auxiliary stabiliser extension down 2 Left auxiliary stabiliser leg out 3 Left crane stabiliser extension down 4 Left crane stabiliser leg out 5 Right crane stabiliser extension out 6 Right crane stabiliser leg down 7 Right auxiliary stabiliser extension out 8 Right auxiliary stabiliser leg down Operator s Manual GB 59 ...

Page 60: ... entered directly into the window that corresponds to each function Only ordinary numerals and the letters of the English alphabet can be used For each sub menu four functions may be defined The functions are controlled by levers 2 5 A lever may be deflected in any direction in order to activate the corresponding function ON OFF MENU Left side display Centre display Right side display FRONT REAR P...

Page 61: ... battery is approximately 3 hours The battery charger is designed not to damage the battery even during long continuous charging Operating ambient temp Battery 0 to 45 C A charged battery The voltage level of a fully charged battery is approximately 8 4V and it provides about 5 8 hours working time Note that the battery voltage remains between 7 6V and 7 5V for a long time Therefore the battery vo...

Page 62: ...er and operating the crane Locking the controller 1 Press and hold button and while the stop button is pressed 2 Keep button and pressed while pulling out the stop button The centre display then shows a large locked padlock symbol Unlocking the controller 1 Press and hold button and while the stop button is pressed 2 Keep button and pressed while pulling out the stop button 3 Release button and Th...

Page 63: ... Automatic Speed Control The ASC function automatically provides the extra power by reducing the speed smoothly when working close to the rated capacity When the load decreases normal speed is restored ADC Automatic Duty Control The purpose of the ADC function is to increase the lifting capacity by 10 The first boom pressure sensors indicate if there is a positive or negative pressure on the first...

Page 64: ...vements are thus avoided smooth simultaneous operation is achieved Controlling crane speed Use the button to change resolution of the lever to 50 or 20 of normal speed VSL Variable Stability Limit The VSL function detects the position of the stabiliser extensions and that the stabiliser legs are pressed to the ground This optimize the crane lifting capacity in relation to the vehicle s stabil ity ...

Page 65: ...on When the bubble is between the two circles the crane inclination is between 0 and 5 If the slope exceeds the permitted inclination unintentional crane movements can occur Particular case Working with boom sys tem beyond 60 To avoid side deflection and in order to guarantee the safest operation when working with the boom system beyond 60º the vehicle has to be completely levelled in any directio...

Page 66: ... the vehicle s engine could stall The maximum rpm may depend upon a governor on your PTO combination CD2 Start the safety system The operating levers must be in neutral position before start up To activate the system press the On Off button on the user panel The LED above the button starts to blink The system will check itself 2 4 seconds The warning lamps option on the stabiliser legs light up 66...

Page 67: ...hts 3 To activate the controller pull out the stop button by turning it clockwise The radio starts to establish a link with the decoder Wait is displayed while radio contact is being established Decoder LED s colour green yellow red The decoder is powered on when remote control is chosen LED is lit The LED on the decoder starts to blink Radio link established When the radio link has been establish...

Page 68: ...value between one and thirty minutes The controller will always start in CRANE 1 menu regardless of which menu was active when the controller was stopped Operating the stabiliser system DANGER When you are operating the stabiliser exten sions Make sure that you have full view of the stabiliser extensions Do not stand in front of the stabiliser extensions Remote control manual controlled stabiliser...

Page 69: ...atically stopped when pressure to the ground is sufficient To operate the stabiliser legs further downward move the lever once again For cranes with VSL the stabiliser leg downward movement is automatically stopped at a pre given force level To exceed this pre given force level operate the stabiliser leg down once again WARNING Take care not to lower the stabiliser leg to your foot DANGER Check th...

Page 70: ...sion 3 Position the loose leg support plate if de livered onto the ground 4 Set the stabiliser leg to the ground Repeat for the stabiliser extension and leg on the other side of the vehicle When there is an additional set of stabiliser legs option Repeat the process for the 3rd and 4th stabiliser legs 70 Operator s Manual GB ...

Page 71: ...ating instruc tions for add on equipment carefully Once the stabiliser extensions and legs are ready you can start using the crane 1 If stabiliser system is under manual control push button on the user panel 2 If using remote control push button on the controller to change the menu into crane operation DANGER Always operate manually controlled crane from the position indicated Operator s Manual GB...

Page 72: ...ane position Operate the boom system 1 Raise the first boom 2 Slew the crane to the working position 3 Extend the hydraulic extensions The crane is now ready for use NOTE As soon as you have selected remote control operation it is impossible to operate the main control valve levers 72 Operator s Manual GB ...

Page 73: ... is given The warning lamps on the stabiliser legs double blink and the cylinder pressure LEDs flash red When 100 of the maximum permitted pressure is reached the OLP cuts in The display shows whether a particular motion is prohibited or if the crane is subject to OLP The warning lamps on the stabiliser legs will flash twice and the cylin der pressure LEDs will light continuously Operator s Manual...

Page 74: ...ll motions that would increase torque are blocked If the operator attempts to activate a blocked function the function symbol is replaced by a cross while the lever is deflected When the lever is returned to the neutral position the cross disappears and the information returns Operate permitted load reducing functions only NOTE Do not operate heavy loads with the extensions fully retracted In an O...

Page 75: ...s the stabiliser leg where the OLP occurs The VSL indicator LED light red on the user panel The crane stops The centre display on the controller shows 100 and the symbol for which leg has overload Move all the levers to neutral and operate permitted load reducing functions only The display symbol goes back to normal Operator s Manual GB 75 ...

Page 76: ...OLP CombiDrive2 In certain OLP situations the first and second booms can be locked It is then possible to release the OLP for approximately 5 seconds by pressing the button on the right hand side below the display handle There is a waiting time before the release operation can be activated again The time increase in three steps 30 60 and maximum 90 seconds the time starts to count down as you move...

Page 77: ...anual control If one prohibited movement is used all move ments will stop The crane will be fully opera tional as long as only allowed movements are used DANGER Only use the OLP override to get the crane out of a locked position Never use the OLP override to overload the crane deliberately Operator s Manual GB 77 ...

Page 78: ...the crane man ually from the position indicated in the figure 1 Slew the crane until the crane is parallel to the vehicle 2 Retract the extensions completely 3 Lower the boom system against the vehicle Do not extend the second boom cylinder fully Remote control manual controlled stabiliser extensions and legs Without selector valve Press the button and the button or Press the button for EXTRA menu...

Page 79: ... the stabiliser legs tilting area DANGER Always ensure that the stabiliser legs and the stabiliser extensions are in transport position and securely locked WARNING Do not put your foot on the support plate Operation with non tiltable stabiliser legs 1 If loose support plate delivered rectract a little the stabiliser leg if not go to step 3 2 Unlock the loose support plate 3 Retract the stabiliser ...

Page 80: ...ching off the safety system Push in the stop button and switch off the safety system Disengage the PTO 7 6 Emergency operation Valve V91 EMERGENCY operation to bring the crane to parking position Do like this On the main control valve 1 Break the security sealing on dump valve 1 on the inlet section 2 Press the dump valve button and turn 90 degrees until it is blocked 3 Operate the crane to parkin...

Page 81: ...abiliser control valve DANGER To operate the crane like this is HIGHLY DANGEROUS because during emergency op eration all crane security is disconnected Always go to contact a HIAB service work shop when the seal wire has been broken 7 7 TWI Transport warning inter face option WARNING If you switch off the safety system when manual operated stabiliser extensions tiltable stabiliser legs are not loc...

Page 82: ...nowledgement button option or by a signal indicating that the parking brake of the vehicle is engaged The vehicle must not be moved 1 Switch the system on put the crane into the transport position 2 Switch off the system The vehicle may be moved DANGER After use always put the crane into the transport position When you have to park the boom on the load space or over the load secure the boom and th...

Page 83: ...ourself Drill ing work on the crane may only be carried out by or in close consultation with a HIAB service workshop Never try to reinstall the crane Only a HIAB Dealer may reinstall the crane Before carrying out any welding on the vehi cle Disconnect the power between the vehicle and the crane Contact the vehicle manufacturer After welding on the vehicle Connect the power between the vehicle and ...

Page 84: ...een switched off Always contact a HIAB service workshop Deal with an oil leak as follows 1 Rest the crane on the floor or on the truck platform 2 Switch off the operating system 3 Disengage the PTO 4 Leaking coupling Tighten the coupling with a spanner If tightening does not help contact a HIAB service workshop 5 Small leak on a line or hose Determine if you can still park the crane If you can par...

Page 85: ...ly the service and maintenance work you have the requisite knowledge and experience of If the crane is not be used for 1 month or longer Lubricate the crane thoroughly according to the lubrication schedule Park the crane in the transport position Filters Replace the filter cartridge after the first 50 hours operation then after every 500 hours operation or at least twice a year Cleaning Clean your...

Page 86: ...Check that these are in good condition Levers Check that the levers operate smoothly Check that the levers return to the neutral position Electronic components Check that these are in good condition Crane structure Check for damage to the crane structure e g any formation of cracks DANGER In the event of damage that presents a safety risk Do not use the crane Have the damage repaired immediately b...

Page 87: ...etc according to the instructions supplied with it Oil tank level To check the level in the oil tank Place the vehicle on level ground with the crane in transport position If necessary top up Slewing housing oil level Check the oil level in the slewing housing If necessary top up 8 3 2 Monthly inspection and mainte nance In addition to the daily inspection carry out the following each month Piston...

Page 88: ...olts and screw fixings Check that bolt and screw fixings are tight ened Cables and sensors on the boom system Check that these are in good condition Lubrication schedule Carry out the lubrication according to the instructions Hydraulic system Check that the hydraulic pump attachment screws are tightened Check if the oil in the hydraulic system needs to be changed Add on equipment etc Maintain all ...

Page 89: ...es the oil might need to be changed more often Slewing housing Change oil in the slewing housing 8 4 Lubrication WARNING Follow the lubrication schedule exactly If you not do so there may be serious damage to the crane and to add on equipment Type of grease Use lithium based grease containing EP additives consistencies 2 and 3 are recommended depend ing on the climate Recommended greases BP LS EP ...

Page 90: ... B Internal guides See chapter of Slewing housing Lubrication 8 4 2 Lubrication of slide pads in boom system Rear upper slide pads Extend the extensions until you can see the slide pad through the hole Lubricate Retract the extensions Front upper slide pads Extend extensions with load in order to create enough clearance Lubricate 90 Operator s Manual GB ...

Page 91: ...er column bearing Niple For greasing three point bridge DANGER The upper column bearing must be lubricated while the crane is slewed If one person lubricates the upper column bearing while another is slewing the crane Take care that the person lubricating the bearing does not come into contact or get crushed by the crane If you are lubricating the upper column bear ing without help Lubricate the u...

Page 92: ...0 Changing oil in the slewing housing Change the oil in the slewing house yearly 1 Remove the hose coupling from the level glass 2 Remove the plug 3 The slewing housing contains about 13 litres 3 43 gallon Use a container with sufficient capacity to receive the oil Drain off the oil through the filling hose 4 Attach the hose coupling to the level glass 5 Refill through the filling hole with transm...

Page 93: ...he o rings and gaskets Replace if necessary 4 Fit the new cartridge 5 Replace the cover NOTE Check that the cover is properly fitted 8 5 3 Replacing the cartridge in the pressure reduction filter WARNING Dirt will damage the hydraulic system 1 Clean the immediate surroundings of the pressure filter 2 Dismantle the filter housing 3 Remove the cartridge 4 Clean the filter housing 5 Fit a new cartrid...

Page 94: ...ransport position 2 Place the vehicle on level ground 3 Check the oil level in the tank 4 Oil level too low Top up with hydraulic oil 8 5 6 Changing the hydraulic oil WARNING The oil can be hot and cause injury 1 Operate the crane for a while to warm the oil Place the crane in the parked position Take care that the temperature of the oil does not exceed the point where you can handle it safely If ...

Page 95: ... NOTE Ensure the waste oil is disposed of safely and inaccordance with local environmental regula tions 4 Change at the same time all filters 5 Refit the drain plug Filling the oil tank with hydraulic oil The oil used for filling must be clean Do not mix different oils Hydraulic oil that is approved for HIAB products must comply with one of the following standards or equivalents DIN 51524 part 3 S...

Page 96: ... recommend an oil working tem perature below 70 C If necessary consider an oil cooler or heater NOTE When working in artic condition consider an oil with lower viscosity than the 32 oil in the table above Environmentally Friendly Oil The environmentally friendly oils recommended for HIAB products are ester based synthetic hydraulic fluids synthetic ester NOTE Vegetable oils do not meet HIAB s requ...

Page 97: ...after working on the hydraulic system if your crane works slowly or jerkily WARNING Air in the hydraulic system can lead to faults and damage To bleed air from the hydraulic system pro ceed as follows Move each crane cylinder and each hydraulically operated piece of add on equipment at least twice to its end positions slowly Operator s Manual GB 97 ...

Page 98: ...panel bottom 2x15A The user panel cover 2x7 5A and 3x3A Check all cable connections and close the covers 8 6 2 Faults in the HiPro crane Faults in the crane must be rectified immediately DANGER Only correct yourself the faults that ac cording to the table you may rectify Follow the instructions exactly All other faults may be dealt with only by personnel in a HIAB service workshop Fault Probable c...

Page 99: ...r Clear the blockage or re a noise Three causes is blocked place the entire filler cap Warning Stop using the Oil level in the tank is too Top up the oil tank and crane immediately low bleed the hydraulic system The pump is faulty Go to a HIAB service work shop The stabiliser extensions do The extensions are still Unlock the extensions not slide out locked Hydraulic fault Go to a HIAB service work...

Page 100: ...ernal Display option Placing The unit shall be placed under the plastic cover together with the SPACE box where it is pro tected from direct water splash Start up The External display automatically starts when the SPACE system is started Operating modes The display has three basic operating modes 1 Use time mode default 2 Error display mode 3 Config mode Use time mode default By default the displa...

Page 101: ... The number of active errors and a dot Each active error in turn Blank display if no errors Start over Press the button again to return to Use time mode Example 3 active errors 003 014 and 028 Clear errors In Error display mode errors can be cleared as in SPACE terminal by pressing the button for 2 seconds until the clear errors symbol is shown in the display Operator s Manual GB 101 ...

Page 102: ...crane s raw materials can be recycled Follow the regulations of the local authorities Oil and grease must not be spilled on to the ground or released into the environment Drain the oil from hydraulic cylinders valves and hoses Sort the waste Deliver the metal parts for recycling for reuse as raw material These are load bearing struc tures manufactured from steel or cast iron hydraulic cylinders an...

Page 103: ...ydraulic cylinder seals lights small plastic and rubber parts Hazardous waste is delivered to a collection point for hazardous waste oils hydraulic oil transmission oil from the slewing system solid lubricants greases from the joints and journal bearings other waste containing oils and greases hy draulic oil filters Operator s Manual GB 103 ...

Page 104: ...ble The Installer must fill in the valid meters m and kilos kg in this table following instructions given in the Installation instructions The enclosed Technical Data must be stored together with this Operator s manual 104 Operator s Manual GB ...