HIAB 435K HiPro CD, Operator'S Manual

Page 1: ...Operator s Manual GB HIAB 435K HiPro CD This operator s manual is an Original Instruction and applies for cranes from serial number 4350030 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: ... warnings 15 3 1 Operating conditions 15 3 2 Definition of a HIAB loader crane 16 3 2 1 Noise declaration 17 3 2 2 Warning signs 18 3 2 3 Maximum load 18 3 2 4 Maximum load moment 21 3 3 Signals when using a crane 24 3 4 Wind speeds 28 3 5 Use of the crane 29 3 6 Use of lifting equipment 36 3 7 Use of dismountable cranes 36 4 The Safety system 38 4 1 Safety System SPACE 5000 with CombiDrive2 38 4 ...

Page 4: ...tion 76 7 4 Switching off the safety system 77 7 5 Emergency operation Valve V91 78 7 6 TWI Transport warning interface option 79 8 Maintenance and Service 81 8 1 Service 81 8 2 Warranty 82 8 3 Follow the maintenance instructions 83 8 3 1 Daily inspection 84 8 3 2 Monthly inspection and maintenance 85 8 3 3 Annual maintenance 87 8 4 Lubrication 87 8 4 1 Lubrication schedule 88 8 4 2 Lubrication of...

Page 5: ...ic oil 92 8 5 6 Bleeding air from the hydraulic system 95 8 6 Troubleshooting 96 8 6 1 Main fuses 96 8 6 2 Faults in the HiPro crane 96 9 Decommissioning 100 9 1 Decommissioning a crane 100 10 Technical Data 102 10 1 Documentation 102 10 2 Load plate table 103 Operator s Manual GB 5 ...

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: ...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 8: ...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 9: ...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 10: ... 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 1st boom hydraulic extensions 2nd boom 2nd boom hydraulic extensions The extensions are operated by ...

Page 11: ...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 Operator s Manual GB 11 ...

Page 12: ...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 12 Operator s Manual G...

Page 13: ...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 14: ...es 280 641 0 ft lbs The cranes are supplied in a version HIAB 435K 4 reach 23 2 metres 76 1 ft The control valve V91 CombiDrive2 and the SPACE 5000 safety system are standard equip ment on the HIAB 435K HiPro CD The crane type and the manufacturer are marked on the serial number plate NOTE The exact technical information for your crane is shown in the Technical Data 14 Operator s Manual GB ...

Page 15: ...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 16: ...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 17: ... 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 18: ... 7091 XXX X X XXXXX Safety precautions and warnings 3 2 2 Particular installations can be quieter in which case a post installation noise measurement in accordance with clause 6 3 of EN 12999 2011 may be used to prove this 3 2 2 Warning signs 3 2 3 Maximum load Lifting capacity 18 Operator s Manual GB ...

Page 19: ...agram on your crane show the maximum loads you may lift in the operating reach of your crane DANGER Overloading could result in damage to the crane or in the worst case personal injury or death Never increase a hanging load since that may cause a load holding valve to open and or the vehicle to turn over Never use the crane with the OLP system switched off NOTE The extra weight of the lifting acce...

Page 20: ...ever exceed the maximum weight on the load plate Load diagram The load diagrams are placed on the column and show the maximum loads your crane may lift in the entire working zone The load diagram draw ing will also be found in the enclosed Technical Data The white area is the working zone of the crane The load curves show the maximum load that may be lifted at a given reach and height For a given ...

Page 21: ...s when the first boom is fully lifted as this could cause damage to the first boom cylinder 3 2 4 Maximum load moment If your crane has reached the maximum load moment lifting capacity the OLP gives a warning and locks any crane movement that will increase the load moment This is known as an OLP situation If the second boom is raised then the following movements are locked first boom down up secon...

Page 22: ...en the legs of the sling must not exceed 120 The maximum working load usually known as the working load limit WLL in standards of a multilegged sling for general purposes is calculated by multiplying the WLL of a single leg by a mode factor 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...

Page 23: ...ngle to about 10 to 30 above the horizontal plane Heavy loads Lift heavy loads with the second boom in the optimum position in relation to the first boom For this see the load 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 ex...

Page 24: ...he load and the entire working area clearly the crane oper ator is obliged to follow 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 ...

Page 25: ...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 26: ...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 26 Operator s Manual GB ...

Page 27: ...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 Operator s Manual GB 27 ...

Page 28: ...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 29: ...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 30: ...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 31: ... 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 Operator s Manual GB 31 ...

Page 32: ...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 33: ...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 34: ...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 35: ...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 36: ...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 37: ...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 Operator s Manual GB 37 ...

Page 38: ... 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 39: ...ll 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 ...

Page 40: ... and legs only when this valve is activated The dump valve 2 will be placed between the main control 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 ...

Page 41: ... the lamps flash twice 4 4 Operating components main control valve V91 stabiliser control valve extra stabiliser control valve user panel SPACE 5000 remote 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 flo...

Page 42: ...The Safety system 4 5 Main control valve lever function 42 Operator s Manual GB ...

Page 43: ...this valve The stabiliser control valve can be operated manually or remotely 4 7 OPS Operator Protection System option OPS is a system that protects the operator from the boom system s movements when operating the crane The OPS system is integrated in the SPACE system and it uses a sensor on the rack and tilt indicators on the boom system to indicate the position of the crane It creates a virtual ...

Page 44: ...opped immediately ON OFF button with the symbol to switch the safety system On Off Button with the symbol To switch on the remote control and radio control Button with the symbol To select manual function Confirm view button with the symbol To confirm full view of operating the stabilis er extensions outward 4 8 1 Indicator lights on user panel SPACE 5000 Power On Green light on The system is on G...

Page 45: ... limited stability but crane option 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 Automatic duty Green light on control option Increased capacity ADC mode Hoist LED Not active Cylinder pressure Green light A on 50 of OLP pressure LED s Green light A B on 70 of OLP pressure Red light A C flashes 90 of OLP pressure R...

Page 46: ...vides 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 a...

Page 47: ...d 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 Cen...

Page 48: ...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 49: ...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 50: ... 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 51: ...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 52: ...1 2 3 The Safety system 4 10 Symbols for the 6 lever controller Left side display Centre Right side display display CRANE MENU 52 Operator s Manual GB ...

Page 53: ...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 54: ...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 55: ... 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 55 ...

Page 56: ... 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 57: ... 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 58: ...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 59: ... 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 60: ... or 20 of normal speed Slewing sector option Within slewing sector lifting capacity can be reduced due to stability The overload warning will be given at a lower load in the limited sector than outside the sector In case of an overload warning you may slew out of the sector but not further into it VSL Variable Stability Limit option The VSL function detects the stabiliser exten sions position and ...

Page 61: ...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 62: ... 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 62...

Page 63: ...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 64: ...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 65: ...fficient 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 that the support plates do not bend or sink into the...

Page 66: ...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 66 Operator s Manual GB ...

Page 67: ...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 68: ... 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 68 Operator s Manual GB ...

Page 69: ...ure LED s flash red The yellow lamp on the lamp pole option flashes and the cylinder pressure LED s 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 lamp option on the stabiliser leg will flash twice the red and the amber lamps on the lamp pole option will light ...

Page 70: ...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 71: ...ion towards the stabiliser leg where the OLP occurs The VSL indicator lamp light red on the user panel The crane stops The centre display is viewed 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 71 ...

Page 72: ...mbiDrive2 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 the l...

Page 73: ...tem in 2nd boom cylinder This logic system prevents to get OLP in the 2nd boom cylinder during normal operation of the crane Due to this When lifting the 2nd boom and if the angle between 1st boom and 2nd boom is less than a defined angle 15º approx by default the 2nd boom speed is reduced to 50 This works only when lifting the 2nd boom When lifting the 2nd boom and if the angle between 1st boom a...

Page 74: ...a above the same limit angle Above the limit angle ß there is no restriction on the 1st boom extension function Below the limit angle ß the 1st boom exten sion function can be operated only if the 1st boom pressure does not reach the limit pressure 85 of nominal working pressure If it does operating the control valve or remote control lever will not have any effect on the 1st boom extension cylind...

Page 75: ...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 76: ...ivate operation of stabiliser extensions and legs DANGER Do not stand in 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 76 Operator s Manual GB ...

Page 77: ...ly WARNING Risk of crushing injuries Always keep hands away from moving parts during operation 5 The catcher will lock the stabiliser exten sion 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 7 4 Switching off the safety system Push in the stop button and s...

Page 78: ...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 parking position using the levers on the main control valve 78 Operator s Manual GB ...

Page 79: ...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 6 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 80: ...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 81: ...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 82: ...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 83: ...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 84: ...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 85: ...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 86: ...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 87: ...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 88: ...ides 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 Front lower slide pads 88 Operator s Manual GB ...

Page 89: ...earing 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 upper bearin...

Page 90: ...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 91: ...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 92: ...Take care that the temperature of the oil does not exceed the point where you can handle it safely If this occurs allow the oil to cool before moving to the next step 2 Suitable eye and hand protection must be worn while carrying out this operation and if there is a risk for inhalation of oil mist a mask as well WARNING Inhalation of oil mist Contact a doctor Skin contact Remove polluted clothing ...

Page 93: ...lters 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 SS 15 54 34 ISO 11158 HV Suppliers of hydraulic oil must verify that the quality and performance of the oil complies with the above stand...

Page 94: ... 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 95: ...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 95 ...

Page 96: ...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 97: ...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 98: ...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 99: ...s 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 99 ...

Page 100: ...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 101: ...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 101 ...

Page 102: ...ion The Technical Data document shows diagrams and technical information about your specific crane The enclosed Technical Data printed out by the installer should be stored together with this Operator s manual 102 Operator s Manual GB ...

Page 103: ... 2 Load plate table When the crane has VSL option the Installer should fill in the valid meters m or feet ft and kilos kg or pounds lb in this table following instructions given in the Installation instructions Operator s Manual GB 103 ...

Page 104: ...This page is intentionally blank 104 Operator s Manual GB ...