HIAB X-HiPro 358-408-418 X4 Operator's Manual
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HIAB X-HiPro 358-408-418 X4 Operator's Manual

HIAB X-HiPro 358-408-418 X4 Operator's Manual

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Operator's Manual GB
HIAB X-HiPro 358-408-418
X4
This operator's manual is an Original Instruction
and applies to cranes with serial number from:
3580001, 4080001, 4180001
2018-01

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Summary of Contents for HIAB X-HiPro 358-408-418 X4

  • Page 1 Operator's Manual GB HIAB X-HiPro 358-408-418 This operator’s manual is an Original Instruction and applies to cranes with serial number from: 3580001, 4080001, 4180001 2018-01...
  • Page 2 However, note that some of the content included in the 'Hiab AR+ App' may differ from the actual configuration of your crane and is subject to updates and changes from Hiab without prior notice.

  • Page 3: Table Of Contents

    Table of Contents ..................Introduction ..This Operator's Manual is intended for operators of this HIAB crane..............Cleanliness certificate ..........Indications in the Operator’s Manual ............. Structure and parts of the HIAB crane ................Main groups ........Crane base with column and slewing system ................
  • Page 4 Table of Contents ............How the safety system works ............ Components of the HiPro system Standard symbols and functions of the crane and the stabiliser system ............... Main control valve ........... Different stabiliser control valves .................. User panel ..........4.7.1 Indicator LEDs on user panel ................
  • Page 5 Table of Contents ..6.1.2 Controlling the crane speed with the controller CombiDrive ............6.1.3 Supervision of spools ............. 6.1.4 APO Automatic power off ..........6.1.5 ADO Automatic dump function ..........6.1.6 ASC Automatic Speed Control ..........6.1.7 ADC Automatic Duty Control ..........
  • Page 6 Table of Contents ......... 8.4.4 Lubrication of bearing assemblies ......8.4.5 Lubrication of slide pads in the boom system ............. 8.4.6 Lubrication of the hooks ................Hydraulics ....... 8.5.1 Replacing the cartridge in return oil filter ... 8.5.2 Replacing the cartridge in pressure-reducer filter - V200 ..

  • Page 7: Introduction

    Introduction This Operator's Manual is in- tended for operators of this HIAB crane. This manual describes: • Operation • Safety precautions and warnings • The crane control system • Maintenance and troubleshooting Enclosed to this manual the Installer will provide: •...

  • Page 8: Cleanliness Certificate

    Introduction NOTE HIAB shall at all times have the right to: • install, maintain and dismantle automated re- mote diagnostics system or similar sensor- based system (the “System”) in and from the Equipment; and • access, send, receive, collect, store and use...
  • Page 9 Introduction DANGER Danger to life for yourself or to bystanders. Follow the instructions carefully! WARNING 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.
  • Page 10 • All other maintenance work may only be carried out by a HIAB service workshop. • Ensure that every defect is rectified imme- diately, according to the instructions. • Follow the instructions exactly! •...
  • Page 11 Introduction WARNING • Never clean the electronic system, plastic components, signs or bearings with a high- pressure jet cleaner. It could cause damage. • Never expose the electronic system to high electrical voltages. This could damage the control system. • Never immerse the controller in water or other liquid.

  • Page 12: Structure And Parts Of The Hiab Crane

    Structure and parts of the HIAB crane Main groups This HIAB crane consists of the following main groups: • Crane base with column and slewing system • Stabiliser system • Boom system • Operating system - hydraulic components Some accessories can be fitted depending on your crane configuration: •...

  • Page 13: Stabiliser System

    Structure and parts of the HIAB crane Stabiliser system Every HIAB crane is equiped with two stabiliser extensions and two stabiliser legs. Auxiliary stabiliser systems may be needed for heavy cranes. The stabiliser system consists of: ① Stabiliser beam ② Stabiliser extensions ③...

  • Page 14: Accessories On The Boom System

    Structure and parts of the HIAB crane Accessories on the boom system Manual extensions [option] Manual extension is slid by hand into the hydraulic extension. Hoist [option] The hoist is a crane accessory which permits load handling without any or only limited boom movement.
  • Page 15 Structure and parts of the HIAB crane JIB [option] The JIB is an additional, folding, lifting device that extends the crane boom. Use the JIB so as to be able to reach further. The JIB consists of the following components: •...
  • Page 16 Structure and parts of the HIAB crane 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...

  • Page 17: Operating System - Hydraulic Components

    Structure and parts of the HIAB crane Operating system - hydraulic components The operating system consists of the following hydraulic components: ① Oil tank ⑤ Stabiliser control valve ⑪ Return filter [option] ② Hydraulic pump ⑥ Hydraulic hoses and ⑫ Load holding valve lines ③...

  • Page 18: Lhv Load Holding Valves

    • HIAB X-HiPro 358/408 E-4 (reach 11.8 me- tres) to HIAB X-HiPro 358/408 E-8 (reach 21.8 metres) • HIAB X-HiPro 418 EP-2 (reach 8 metres) to HIAB X-HiPro 418 EP-5 (reach 15.1 metres) The control valve V200, a controller (Combi-...

  • Page 19: Accessories That Can Be Fitted In A X-Hipro 358-408-418

    Structure and parts of the HIAB crane Accessories that can be fitted in a X-HiPro 358-408-418 JIBS available in combinations: 358/408 E-5/6 + JIB70X-3/4 100X 358/408 E-4/5 + JIB 100X-2/3/4/5 Hoists available in combinations: 418 EP-2/3/4/5 + TC2 TC2L. Not compatible...

  • Page 20: Safety Precautions And Warnings

    Safety precautions and warnings Operating conditions You may only use the crane under the following conditions: • In the open air, or in spaces with sufficient ventilation. • With a mean wind velocity less than 13.3 m/sec (approx. 29.7 mph). See the wind speed table.

  • Page 21: Wind Speeds

    Safety precautions and warnings Wind speeds Wind speed averaged over 10 minutes at a height of 10 m Above flat ground Characteristics Wind Force Wind type Calm Calm, smoke rises vertically or nearly 0.0 - 0.2 vertically Slight breeze Wind direction recognisable from smoke plumes, the wind begins to be 0.3 - 1.5 noticeable on the face;...

  • Page 22: Definition Of A Hiab Loader Crane

    Definition of a HIAB loader crane Usage of the crane The HIAB loader crane is used to lift and move loads in the working area permitted by the load plate and the load diagram. The cranes are normally mounted on a vehicle but they can also be mounted on a fixed base plate.

  • Page 23: Noise Declaration

    3.3.1 Forbidden duties: • Crane mounted onboard ships or floating structures, only permitted in cases authorized by HIAB • Continuous use as a production crane in assembly lines, foundries…, except for cranes prepared for that purpose • Handle loads, work with submerge boom...

  • Page 24: Signs On The Crane

    XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXXX LOADER CRANE TYPE SERIAL NO MANUF . YEAR HIAB CRANES S. L. P . Malpica, E, 86 ZARAGOZA - SPAIN XXXX XXXX XXXX XXXX XXXX XXX XXX XXXX XXXX XXXX...

  • Page 25: Maximum Load [Ar+]

    Safety precautions and warnings 3.3.3 3.3.3 Maximum load [AR+] Lifting capacity Your crane has a certain lifting capacity, ex- pressed in 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.
  • Page 26 Safety precautions and warnings 3.3.3 Optimum position The weight that your crane can lift will be determined by: • stabiliser extensions positioned and legs pressed to ground. • The reach at which you are working and the optimum position of the boom. •...

  • Page 27: Maximum Load Moment

    Safety precautions and warnings 3.3.4 WARNING Never operate the hydraulic extensions against a solid objet when the first boom is completely lifted. Do not try to push or compress loads when the first boom is fully lifted, as this could cause damage to the first boom cylinder. 3.3.4 Maximum load moment If your crane has reached the maximum load moment (lifting capacity), the OLP gives a...
  • Page 28 Safety precautions and warnings 3.3.4 Sling length Always attach the load using the shortest possible sling. The angle between 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 >120º...

  • Page 29: Signals When Using A Crane [Ar+]

    Safety precautions and warnings 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.
  • Page 30 Safety precautions and warnings Lift Raised arm and index finger raised. Circular motion with hand. Lower Arm pointing downwards and index finger down. Circular motion with hand. Stop all crane movements Also: Hold the load in position. Raise the open hand, with the palm clearly visible, and arm at shoulder height.
  • Page 31 Safety precautions and warnings 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.
  • Page 32 Safety precautions and warnings Close the grapple Move both hands close together. Lift the open 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.

  • Page 33: Use Of The Crane

    Safety precautions and warnings Use of the crane Starting crane operation DANGER • Wear a safety helmet (compulsory in some countries!). • Check that the ground is sufficiently flat and firm. • To ensure that the vehicle stays in its position, always engage the parking brake and place chocks under the wheels.
  • Page 34 Safety precautions and warnings DANGER • Do not stand in front of the hydraulically operated stabiliser legs when you are oper- ating them! • Never use the stabiliser legs as a parking brake, since the vehicle could start to slide. •...

  • Page 35: Preparations For Use

    Safety precautions and warnings 3.5.1 3.5.1 Preparations for use DANGER Ensure that there are no unauthorised persons within the operating range of your crane! Mark out the working range, e.g. with cones. Put on your vehicle's warning lights. DANGER • If a part of the crane comes in contact with an electricity line, you will be electro- cuted! •...

  • Page 36: Crane Operation

    Safety precautions and warnings 3.5.2 3.5.2 Crane operation DANGER Your crane has a control system. The control system will help you to work safely. Nevertheless, you remain responsible for safe use of the crane! Therefore, always work according to the oper- ating instructions! In an emergency immediately switch off all crane movements!
  • Page 37 Safety precautions and warnings 3.5.2 WARNING • Never push a load along the ground, or the vehicle's load space, with the extension boom. This can cause damage to the boom system. This will lead to expensive repairs. • Never use the extension boom as a jack. This could damage the slewing bearings and the connection between the crane column and the crane base.

  • Page 38: Driving With The Crane

    Safety precautions and warnings 3.5.3 3.5.3 Driving with the crane DANGER • Never drive the vehicle if there is a load suspended from the crane. • Before you move the vehicle: Check that there is no pump flow to the main control valve.

  • Page 39: Use Of Lifting Equipment

    HIAB service workshop. • Never attempt to install add-on lifting accessories yourself! • Add-on lifting accessories may only be installed by an authorised HIAB service workshop. • When using lifting accessories, follow the instructions supplied with the equipment! • Watch out for hazards! •...

  • Page 40: Ending Crane Operation

    Safety precautions and warnings 3.5.6 WARNING Take care when mounting/demounting the crane on/off the vehicle. Roughly handling can seriously damage the crane or the vehicle. 3.5.6 Ending crane operation DANGER Always end crane operation as follows: • After use, always place the crane in the transport position! •...

  • Page 41: The Hipro System

    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. How the safety system works On the crane there are various sensors and indicators which send signals about the crane’s...
  • Page 42 When the fault is serious, use of the crane is blocked completely. DANGER Never try to repair the control system yourself. Repairs may only be made by a HIAB service workshop! Operator's Manual GB...

  • Page 43: Components Of The Hipro System

    The HiPro system Components of the HiPro system ① Main control valve ④ Dump valve 1 ⑦ Lamp pole [Option] ② Stabiliser control valve ⑤ Dump valve 2 ⑧ XSDrive controller [Option] ③ User panel SPACE X4-UI ⑥ Pressure-reduc- ⑨ CombiDrive controller er filter [Option] Operator's Manual GB...

  • Page 44: Standard Symbols And Functions Of The Crane And The Stabiliser System

    The HiPro system Standard symbols and functions of the crane and the stabiliser system These symbols can be shown: • On the plates. • On the control valve levers. • On the controller (If delivered). ! NOTE If you use a controller to operate your crane, you can read about the symbols displayed on it in the dedicated section of this operator’s manual.
  • Page 45 The HiPro system Accessories symbols and functions (if de- livered) SYMBOLS FUNCTIONS SYMBOLS FUNCTIONS Hoist JIB cylinder Rotation tool JIB extensions Tool 2 Stabiliser system symbols and functions (if delivered) SYMBOLS FUNCTIONS SYMBOLS FUNCTIONS Crane stabiliser ex- Crane stabiliser leg tension Auxiliary stabiliser Auxiliary stabiliser...

  • Page 46: Main Control Valve

    The HiPro 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 impossible to operate the main control valve levers. 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.

  • Page 47: User Panel

    The HiPro system User panel Buttons: • On/off button ① To switch the control system on and off. • Button ② is stabiliser operation activation to enable operation of stabiliser extensions. The driver must have full view when operating the stabiliser extensions outward.
  • Page 48 The HiPro system 4.7.1 Power on/off Green light on: The system is on. Green light blinking: System on and the stop button has been pressed. Green light flashing: APO emergency operation time running. Red light flashing: CAN communication has been lost/ APO override time running Stabiliser system Green light on: Stabiliser system active.

  • Page 49: Dump Valves

    The HiPro system Cylinder pressure 1 of 4 green light on: 50% pressure. 2 of 4 green light on: 70% pressure. 3 of 4 red blinking light: 90% pressure. 4 of 4 red light on: 100% pressure. 4 of 4 red running light: OLP release activated. LED test for the user panel, see Daily inspec- tion.

  • Page 50: Pressure-Reducer Filter

    The HiPro system Pressure-reducer filter Pressure-reducer filter integrated in the main control valve and in the supply valve [option]. The oil goes through the filter and then to the positioner(s). 4.10 Lamp pole [option] The lamp pole is equipped with 3 lamps. Flash- ing/light up: green, amber and red.

  • Page 51: Indicator Leds On Xsdrive Controller

    The HiPro system 4.11.1 WARNING When the controller is in use (stop button released), keep a distance of minimum 1 meter between the controller and the crane or truck because of possible electromagnetic interfer- ence. Cable connection [option] The cable ② is intended to be used for short-term operation and when pairing in conjunction with the replacement of controller or receiver.

  • Page 52: Buttons

    The HiPro system 4.11.2 ⑤ OLP Release Red light on: OLP Red light blinking: OLP Release. ⑥ Low speed Green light on: Reduced speed. For normal speed, see section “Buttons” ⑦ Cylinder pressure Lower LEDs green light on: 70% of maximum LEDs pressure Lower LEDs, red light flashing: 90% of maximum...

  • Page 53: Menus

    4. LED 1 comes on. (Start menu) 4.11.3 Menus The functions presented in each menu can be customized depending on crane configuration. It can be changed by a Hiab Authorized Workshop. The table below shows an example: Operator's Manual GB...
  • Page 54 The HiPro system 4.11.3 Menu 1 Slewing, first boom, second boom, extension boom, tools JIB, hoist, etc. Menu 2 [option] (If crane is equipped with extra remote controlled stabiliser system) Menu 3 [option] Slewing, attachment. (If crane is equipped with remote controlled stabiliser): left and right stabiliser extension, left and right stabiliser leg.

  • Page 55: Standard Functions And Symbols

    The HiPro system 4.11.4 4.11.4 Standard functions and symbols The function corresponding to each lever depends on the configuration of the specific crane. The table below shows examples: Controller XSDrive levers Controller XSDrive joystick 3-0-3 Controller XSDrive joystick 2-2-2 Controller XSDrive joystick 3-2-3 Operator's Manual GB...

  • Page 56: Battery And Battery Charger Xsdrive

    The HiPro system 4.11.5 4.11.5 Battery and battery charger XSDrive Battery A fully charged battery provides approximately 5-8 hours use (at 25 °C, 77 °F) and the voltage level is approximately 8,4V. When the battery is about to wear out an indicator LED on the controller burns steady red and the horn will sound twice.

  • Page 57: Combidrive Controller

    The HiPro system 4.12 4.12 CombiDrive controller The controller has either six or eight levers. Normally the controller operates wirelessly via radio but it can also be operated via cable. The controller is equipped with a menu selection system as standard. The displays continuously provide the operator with information.

  • Page 58: Displays

    The HiPro system 4.12.1 4.12.1 Displays The displays are of LCD-type and will perform best in temperatures above +10 °C. At 0 °C there is a delay in shifting symbols of approximately 1 sec. At -20 °C the delay will increase to approxi- mately 8 sec.
  • Page 59 The HiPro system 4.12.1 ② ② Micro ⑧ ⑧ Manual extension Indicates that micro operation has Manual extension is selected by been selected. Micro operation pressing the horn and release but- changes the sensitivity of the lev- tons at the same time. The control ers as follows: At full lever deflec- system acknowledges by showing tion, μ50% gives 50% and μ20%...

  • Page 60: Buttons

    The HiPro system 4.12.2 4.12.2 Buttons ON/OFF buttons [option] Micro mode The controller has four configur- Push to choose micro mode. Push able pushbuttons for controlling again to choose normal mode. on/off functions e.g. start/stop en- gine, increase/decrease rpm on the engine etc.
  • Page 61 The HiPro system 4.12.2 Locking of controller Error code display & See section “Locking and unlock- Push the button to display error ing the controller”. codes in the system. If there are more than six error codes at the same time, the six most recent ones sent from the control system, are shown.

  • Page 62: Menus, Standard Functions And Symbols

    When the operator pulls out the stop button on the controller, it always starts in CRANE 1 menu. The submenus in CRANE menu are configured in production but can be changed by HIAB service personnel. CRANE 1 Example of submenus for the 6 lever controller:...
  • Page 63 The HiPro system 4.12.3 Left side display Centre Right side display display "CRANE MENU" Example of submenus for the 8 lever controller: Operator's Manual GB...
  • Page 64 The HiPro system 4.12.3 Centre Left side display Right side display display "CRANE MENU" EXTRA menu, button ④ The EXTRA menu contains hydraulically propor- tional functions for example front and rear stabi- liser extensions and legs, boat supports, bunk shifting, etc EXTRA 2 Operator's Manual GB...
  • Page 65 The HiPro system 4.12.3 Symbols shown on the displays The order of the levers is customized. • Crane stabiliser leg ① down/up. • Crane stabiliser leg ② down/up. • Auxiliary stabiliser leg ③ down/up. • Auxiliary stabiliser leg ④ down/up. •...

  • Page 66: Battery And Battery Charger

    The HiPro system 4.12.4 4.12.4 Battery and battery charger 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 voltage cannot be used to estimate remaining hours of use.

  • Page 67: Starting Crane Operation

    Starting crane operation Starting operations [AR+] • General case: Place the vehicle on a flat, firm and stable surface. The vehicle inclination (α) during crane operation must not be more than 3º. If this value is exceed, unintentional crane movements can occur.
  • Page 68 Starting crane operation Engage the PTO Engage the PTO (Power Take Off) and bring the vehicle engine to the correct rpm. ! NOTE • Rpm too high: the oil in the hydraulic system might overheat. Rpm too low: during crane operation, the vehicle engine could stall.

  • Page 69: Set The Stabiliser System

    Starting crane operation Indications CombiDrive “Wait” is shown on the centre display while radio contact is being established. On the decoder LED ① is lit. LED ② starts to blink. When contact has been established CRANE 1 menu and signal strength are displayed on the controller.
  • Page 70 Starting crane operation Stability sector indication The operator must have a full view of the stabiliser system when operating it. To confirm a full view of the stabiliser system, button pushed on the user panel on the side where the stabiliser system is going to be operated.

  • Page 71: Stabiliser System And Ground Conditions

    Starting crane operation 5.2.1 5.2.1 Stabiliser system and ground conditions Always: • Make sure that the ground can support the load that the stabiliser leg imposes on the ground. (*) • Make sure that the ground is not undermined. • Use the extra support plates that are large and firm enough for your crane model.

  • Page 72: Activate The Stabiliser System

    Starting crane operation 5.2.2 5.2.2 Activate the stabiliser system Manually controlled stabiliser system: 1. Make sure manual control is active. If not, push the button on the user panel 2. Push the button to activate stabiliser system operation. Remote controlled stabiliser system: 1.

  • Page 73: Set The Stabiliser Legs [Ar+]

    Starting crane operation 5.2.4 Hydraulically controlled stabiliser extensions Unlock the Stabiliser locking device ② [option] and extend the stabiliser extensions with the levers on the valve or the control- ler depending on your crane configuration. DANGER Do not stand in front of the hydraulically operated stabiliser legs when you are operating them! 5.2.4 Set the stabiliser legs [AR+]...
  • Page 74 Starting crane operation 5.2.4 ! NOTE 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. DANGER Always ensure that the stabiliser legs and stabiliser extensions are in working position and securely locked.
  • Page 75 Starting crane operation 5.2.4 Manual tiltable stabiliser legs 1. Make sure the stabiliser extensions are ex- tended a little. 2. Unlock the stabiliser leg lock ②, that holds the stabiliser leg in the transport position. DANGER Do not stand in the stabiliser leg tilting area.
  • Page 76 Starting crane operation 5.2.4 Manually tiltable stabiliser legs with gas spring support 1. Make sure the stabiliser extension is ex- tended and the stabiliser leg can rotate freely of the vehicle. 2. Place your right hand on the handle ③ while unlocking the stabiliser leg ④...

  • Page 77: Operate The Boom System Out Of Transport Position

    Starting crane operation Operate the boom system out of transport position WARNING • A crane with add-on equipment can differ from the operations described in this sec- tion. For this reason, study the operating instructions for any add-on equipment carefully. •...
  • Page 78 Starting crane operation DANGER Always operate a manually controlled crane from the position shown in the image! 1. If the stabiliser system is manually con- trolled, push button on the user panel to activate remote control. 2. If using remote control, push button ① on the controller to change the menu into crane operation.

  • Page 79: Bda Boom Deployment Assistance [Ar+]

    Starting crane operation 5.3.1 5.3.1 BDA Boom Deployment Assis- tance [AR+] BDA is a safety function in SPACE that prevents the operator to move the second boom and extensions in the wrong direction when operating the crane in to or out of parking position. •...
  • Page 80 Starting crane operation 5.3.1 Operate the boom system • HIAB 358 / 408 / 418: 1. Turn the pin and pull it out ①. 2. Raise the first boom ② until BDA allows you to operate the second boom or β>135º.

  • Page 81: During Operation

    During operation Functions The control system provides a large number of functions. Certain functions are standard, others are options. 6.1.1 Controlling the crane speed with the controller XSDrive At start up, the system by default is set to full speed. To reduce the speed, push button once.

  • Page 82: Supervision Of Spools

    During operation 6.1.3 6.1.3 Supervision of spools If a valve spool movement is greater than the equivalent lever or joystick movement on the controller, a safety function is tripped, and all crane movements stops. This occurs if a control lever on the valve is moved while the remote control is engaged.

  • Page 83: Asc Automatic Speed Control

    During operation 6.1.6 6.1.6 ASC 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. 6.1.7 ADC Automatic Duty Control The purpose of the ADC function is to increase the lifting capacity by 10%.

  • Page 84: Slewing Sector [Option]

    During operation 6.1.9 6.1.9 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.

  • Page 85: Olp (Overload Protection)

    During operation OLP (Overload protection) OLP is a safety function that prevents overload- ing of the crane. With 90% of maximum permit- ted pressure the amber lamp on the lamp pole, if present, flashes. OLP boom system When 100% of the maximum permitted pressure is reached, OLP cuts in and stops all functions that increase the pressure.

  • Page 86: Olp - Indications On The Controller

    During operation OLP - indications on the control- 6.3.1 XSDrive OLP boom system: The cylinder LEDs indicate a percentage of maximum pressure: • 70% of maximum pressure reached - lower LED on each cylinder light green • 90% of maximum pressure reached - lower LED on each cylinder flash red •...

  • Page 87: To Release Olp

    During operation To release OLP If all functions have been blocked due to OLP it is possible to temporarily release OLP and oper- ate an appropriate crane function to correct the overload situation. OLP release is active in 5 second intervals. After each 5 second interval of OLP release there is a wait before the release operation can be activated again.

  • Page 88: Manual Extensions [Option]

    During operation OLP release on controller CombiDrive Push and hold the button ⑨ on the right hand side below the display handle. The unlocked padlock will appear in the centre display. On the user panel the cylinder pressure LEDs perform a running light.
  • Page 89 During operation To lift heavier loads than specified on the sign ③, the hook position must be moved to the nearest hydraulic extension, in accordance with the load plate on the crane. To retract the manual extensions 1. Locate the boom system as close as possible to the horizontal position, but low enough to reach the extension by hand.
  • Page 90 During operation Activate and de-activate OLP for manual ex- tensions on the XSDrive controller WARNING You must switch the OLP on and off manually for additional manual extensions! Activate: Push buttons on the controller. The manual extensions are now included in the OLP protection.
  • Page 91 During operation Activate and de-activate OLP for manual ex- tensions on the CombiDrive controller WARNING You must switch the OLP on and off manually for additional manual extensions! Activate: Push both button ① and ② until symbol the centre display is lit. (The lamp for manual extension is lit on the user panel.) The manual extensions are now included in the...

  • Page 92: Ending Crane Operation

    Ending crane operation Operate the boom system into transport position WARNING • A crane with add-on equipment can differ from the operations described in this sec- tion. • For this reason, study the operating in- structions for any add-on equipment care- fully.

  • Page 93: Operate The Boom System

    Ending crane operation 7.1.1 7.1.1 Operate the boom system • HIAB 358 / 408 / 418: 1. Retract the extensions completely ①. 2. Raise the first boom ② until BDA allows you to operate the second boom or β>135º. 3. Slew the crane to parking position. Check that arrows “A”...

  • Page 94: Placing The Stabiliser System In The Transport Position

    Ending crane operation Placing the stabiliser system in the transport position DANGER Do not stand in the stabiliser legs, tilting area. WARNING Do not put your foot on the support plate. Risk of crushing injuries. Always keep hands away from moving parts during operation.
  • Page 95 Ending crane operation Non-tiltable stabiliser legs 1. Raise the stabiliser leg. 2. Retract the stabiliser extension completely. DANGER Risk of crushing injuries. Always keep hands away from moving parts during operation. Operator's Manual GB...
  • Page 96 Ending crane operation Manual tiltable stabiliser legs 1. Raise the stabiliser leg completely. 2. Unlock the stabiliser leg lock ①. 3. Tilt the stabiliser leg manually. 4. Lock the stabiliser leg lock ①. 5. Retract the stabiliser extension completely. DANGER Risk of crushing injuries.
  • Page 97 Ending crane operation Manually tiltable stabiliser legs with gas spring support 1. Raise the stabiliser leg completely. 2. Place your right hand on the handle ③ while unlocking the stabiliser leg ④ with your left hand. 3. Gently pull the stabiliser leg upwards until it stops.

  • Page 98: Switching Off The Control System

    Ending crane operation Hydraulically controlled stabiliser extensions Retract the stabiliser extensions with the levers on the valve or the controller depend- ing on your crane configuration. Make sure that the stabiliser locking device ② [option] is securely locked. WARNING Always ensure that the stabiliser legs and stabiliser extensions are in transport position and securely locked.

  • Page 99: Emergency Operation Valve-V200

    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. 1. Engage the pump. 2. Break the security sealing on Dump valve 1 ①...

  • Page 100: Twi Transport Warning Interface [Option]

    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. 1. Follow actions 1-5 in previous section "EMERGENCY operation to bring the...
  • Page 101 Ending crane operation • A warning, visible and audible from the driving position for transport, indicates when the crane height exceeds a predetermined maximum and when the manual operated stabiliser extensions/tiltable stabiliser legs are not locked in the transport position. •...

  • Page 102: Maintenance And Service

    Welding work on the crane may only be carried out by, or in close consul- tation with, a HIAB service workshop. • Do not drill into the crane yourself. Drill- ing work on the crane may only be carried out by, or in close consultation with, a HIAB service workshop.

  • Page 103: Warranty

    Determine if you can still park the crane. If you can: park the crane and go to a HIAB service workshop. If you cannot: contact a HIAB service workshop. 6. In all other cases, contact a HIAB service workshop. Warranty HIAB only provides a warranty if: •...

  • Page 104: Follow The Maintenance Instructions

    • All security seal wires on the valves are still intact. Always use original HIAB parts and tools. Follow the maintenance instruc- tions! Take the crane, at least once a year, to a HIAB service workshop for inspection and maintenance. Maintain lifting accessories according to the supplier’s instructions. WARNING •...

  • Page 105: Daily Inspection

    Maintenance and Service 8.3.1 Cleaning Clean your crane and accessories regularly, but: • Do not use aggressive cleaning agents. • Never use a high pressure jet cleaner on electronic parts, plastic components, signs, bearings, control valves, cylinders or the oil tank.
  • Page 106 In the event of damage that presents a safety risk: • Do not use the crane. • Have the damage repaired immediately by a HIAB service workshop. Hooks Before every lift: • Check general condition of the hook, and parts of the hook ① for deformation and surface damages with significant depth.
  • Page 107 • Make sure that all security seal wires (Ex. LHV, dump valves, etc...) are not broken. Always go to/contact a HIAB service work- shop when the seal wire has been broken. • Check oil level in the tank. If necessary, fill to correct level.

  • Page 108: Monthly Inspection And Maintenance

    Bolts and screw fixings • Check that bolt and screw fixings are not loose. If loose contact a HIAB service work- shop Cables and sensors • Check that these are in good condition.

  • Page 109: Annual Maintenance

    • Maintain all add-on equipment, auxiliary equipment etc. according to the instructions supplied with it. 8.3.3 Annual maintenance Take the crane, at least once a year, to a HIAB service workshop for inspection and maintenance. Carry out the following maintenance at least once a year.

  • Page 110: Lubrication

    Maintenance and Service Lubrication WARNING Follow the lubrication schedule exactly. If you do not do so, you can cause 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).

  • Page 111: Lubrication Schedule [Ar+]

    Maintenance and Service 8.4.1 8.4.1 Lubrication schedule [AR+] Lubricate after every 16 hours of use. Lubricate after every 50 hours of use. Grease after every 50 hours of use. Operator's Manual GB...

  • Page 112: Lubrication Of The Gearbox

    Maintenance and Service 8.4.2 8.4.2 Lubrication of the gearbox An oil change must be carried out after approxi- mately 150 operating hours. Thereafter change should be repeated approx. every 2000 or 4000 operating hours depending on working condi- tions. Change the oil at least once a year. Refill with oil SAE 80W/90.

  • Page 113: Lubrication Of Bearing Assemblies

    Maintenance and Service 8.4.4 8.4.4 Lubrication of bearing assem- blies Aralub 248 K to 403 K HLP 2 (-25º to +130º) Aralub 248 K to 403 K MKA-Z 1 (-25º to +130º) Energrease 248 K to 403 K LS-EP-2 (-25º to +130º) Energrease 243 K to 433 K LC 3...
  • Page 114 Maintenance and Service 8.4.4 Shell Alvania 248 K to 403 K EP 2 (-25º to +130º) GREASE 253 K to 503 K S.8327 (-20º to +230º) Multifak 243 K to 403 K EP 2 (-30º to +130º) Spectron 253 K to 423 K ZKF-EP 0 (-20º...

  • Page 115: Lubrication Of Slide Pads In The Boom System

    Maintenance and Service 8.4.5 8.4.5 Lubrication of slide pads in the boom system Side slide pads • Extend all the extensions completely. • Lubricate through the holes. • Retract the extensions. Upper slide pads • Extend extensions with load in order to create enough clearance.

  • Page 116: Lubrication Of The Hooks

    When clogging indicator turns red or filter time is reached (whichever is the sooner), the cartridge must be replaced. If indicator is not fitted, replace the cartridge periodically as recom- mended by Hiab. WARNING Dirt will damage the hydraulic system Operator's Manual GB...

  • Page 117: Replacing The Cartridge In Pressure-Reducer Filter - V200

    Maintenance and Service 8.5.2 Make sure that the area around the filter is clean to prevent contamination of the hydraulic oil. 1. Switch off the hydraulic system and release the filter of pressure. 2. Clean the immediate surrounding area of the filter.

  • Page 118: Replacing The Cartridge In Pressure-Reducer Filter - V80R

    Maintenance and Service 8.5.3 WARNING Dirt will damage the hydraulic system It is not possible to clean the cartridge. It must always be replaced. 1. Switch off hydraulic system. Release filter from pressure. 2. Carefully clean the filter housing and the surrounding area on the housing.
  • Page 119 Maintenance and Service 8.5.3 WARNING Dirt will damage the hydraulic system It is not possible to clean the cartridge, it must always be replaced. 1. Switch off hydraulic system. Release filter from pressure. 2. Clean the immediate surrounding area of the filter.
  • Page 120 Maintenance and Service 8.5.3 V80R - Internal filter in the stabiliser control valve WARNING Dirt will damage the hydraulic system It is not possible to clean the cartridge, it must always be replaced. This filter is used only in V80R stabiliser control valves that are used together with a non-V80R main control valve.

  • Page 121: Replacing The Cartridge In High Pressure Filter

    Maintenance and Service 8.5.4 8.5.4 Replacing the cartridge in high pressure filter High pressure filter ① ① Optical indicator ② ② Cartridge ③ ③ WARNING Dirt will damage the hydraulic system Operator's Manual GB...
  • Page 122 (which ever is the sooner), the cartridge must be replaced. If indicator is not fitted, replace the cartridge periodically as recom- mended by Hiab. 1. Switch off hydraulic system. Release filter of pressure. 2. Clean the immediate surrounding area of the filter.

  • Page 123: Checking The Oil Tank Level

    Maintenance and Service 8.5.5 8.5.5 Checking the oil tank level 1. Place the crane and stabiliser legs in the transport 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.
  • Page 124 Hydraulic oils must have been dealt with accord- ing to cleanliness requirements ISO 4406: - /16/13. Hydraulic oil that is approved for HIAB products must comply with one of the following standards or equivalents: - ISO 11158 HV...
  • Page 125 -15°C to 90°C -5°C to 90°C The recommended viscosity during normal work- ing conditions is between 16 and 40cSt. HIAB strongly 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.

  • Page 126: Bleeding Air From The Hydraulic System

    Maintenance and Service 8.5.7 8.5.7 Bleeding air from the hydraulic system Bleed the air from the hydraulic system: • after changing the hydraulic oil • after working on the hydraulic system • if your crane works slowly or jerkily • if your crane has not been used for a long time WARNING Air in the hydraulic system can lead to faults...
  • Page 127 Maintenance and Service 8.6.1 Description Components Fuse Location System main fuse Relay Box, Standard 40 A Located on the vehicle, Box, Oil Cooler were the crane is mounted. Fuse for all components Hydraulic main control 15 A Located inside the relay controlled by the relay valve, stabiliser leg box ①.

  • Page 128: Faults On The Crane

    • Only correct yourself the faults that ac- cording to the table you may rectify. • Follow the instructions exactly! • All other faults must be corrected by personnel in a HIAB service workshop! Fault Probable cause Action Electronic system will not...
  • Page 129 Stabiliser extensions are still Unlock the stabiliser exten- locked. sions. Stabiliser extensions do not slide out. Go to a HIAB service work- Hydraulic fault. shop. The stabiliser extensions do Contact a HIAB service not slide out/in. (Chain-driv- Incorrect chain tension.
  • Page 130 Replace the pressure-reducer erating it with the controller clogged. filter. is unsatisfactory. Load holding valves on the Go to a HIAB service work- first boom or second boom Boom system cannot keep shop. damaged. the load height, and it goes down by itself.

  • Page 131: Display [Option]

    Add-on equipment does not connected. structions. work properly (rotator, hoist, etc.) Go to a HIAB service work- Other defect. shop. 8.6.3 Display [option] The display has three menu items: Error codes, Timers & Counters and VSL. These items are shown on the screen when the display is first engaged.
  • Page 132 Maintenance and Service 8.6.3 Timers & Counters When item is selected information is shown about: • Total time - Number of hours that the crane has been engaged • Use time – Number of hours that dump valve has been active •...

  • Page 133: Decommissioning

    Decommissioning Decommissioning a crane Cranes are designed and manufactured taking the environment into consideration. Environmental requirements and soundness have been considered when selecting the raw materials. The metal parts are designed to achieve a light and durable construction, this includes the selection of higher- quality grades of steel.
  • Page 134 Decommissioning Unsorted waste should be delivered to a landfill • drained hydraulic hoses, electrical wires, con- trol cables, seat, hydraulic 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 •...

  • Page 135: Technical Data

    10.2 Identification of the loader crane The information below is to be filled in by the installer. The same information will be found on the serial number plate on the crane: Mark: HIAB Type: ......Serial number: ......Manufact. year: ......

  • Page 136: Abbreviations

    Technical Data 10.3 10.3 Abbreviations • ADC - ('Automatic Duty Control') - Automatic Duty Control • ADO - ('Automatic Dumping of Oil') - Automatic Dumping of Oil • APO - ('Automatic Power Off') - Automatic Power Off • ASC - ('Automatic Speed Control') - Automatic Speed Control •...

  • Page 137: Daily Inspection Checklist To Photocopy

    2.5 Hydraulic system * If you find a fault that prevents you to operate the crane safely, contact to a Hiab authorized service workshop. Do not try to repair the fault, it can cause you injury or you can damage the equipment.
  • Page 138 This page is intentionally blank. Operator's Manual GB...

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