HIAB X-Duo 044 Operator's Manual
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HIAB X-Duo 044 Operator's Manual

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Operator's Manual GB
HIAB X-Duo
044/078/088/102/112
This operator's manual is an Original Instruction and applies to cranes with serial
number from:
BL044DO00001, BL078DU00001, BL088DO00001, BL102DU00001,
BL112DU00001
2018-01

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Summary of Contents for HIAB X-Duo 044

  • Page 1 Operator's Manual GB HIAB X-Duo 044/078/088/102/112 This operator’s manual is an Original Instruction and applies to cranes with serial number from: BL044DO00001, BL078DU00001, BL088DO00001, BL102DU00001, BL112DU00001 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 ................The Duo system ............How the safety system works ............Components of the Duo system Standard symbols and functions of the crane and the stabiliser system ............... Main control valve ........... Different stabiliser control valves .................. User panel ..........
  • Page 5 Table of Contents ....Placing the stabiliser system in the transport position [AR+] ........7.2.5 Retract the stabiliser extensions [AR+] ............ Switching off the control system ............ Emergency operation Valve-V30 ............ Emergency operation Valve-V80 ............ TWI Transport warning interface ..............Maintenance and Service ..................
  • Page 6 Table of Contents ................. Troubleshooting ................ 8.6.1 Main fuses ............. 8.6.2 Faults on the crane ..............8.6.3 Display [option] ................Decommissioning ............Decommissioning a crane .................. Technical Data ................10.1 Documentation ..........10.2 Identification of the loader crane ............10.3 Theoretical using time Hoist ..........

  • 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: Boom System

    Structure and parts of the HIAB crane Boom system The boom system consists of the following components: • ① 1st boom • ② 2nd boom • ③ Hydraulic extensions The length of the hydraulic extension depends on the type of crane.

  • Page 15: 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. Hooks [option] Different hooks can be mounted depending on the crane model. DANGER Never exceed the maximum permissible load- ing of the hook.
  • Page 16 Structure and parts of the HIAB crane Hoist [option] The hoist is a crane accessory which permits load handling without any or only limited boom movement. An obvious advantage is that the hoist makes it possible to handle loads far below ground level.

  • 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

    Structure and parts of the HIAB crane 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.

  • Page 19: 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 20: 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 21: 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 22 Safety precautions and warnings 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 23: Determination - Hoist

    Safety precautions and warnings 3.3.1 3.3.1 Determination - Hoist The TC hoists belong to the group of hoisting winches. The use as determined is hoisting and lowering of loads as specified for each hoist type and under the attention of the given installation regulations as well as of the safety notes.

  • Page 24: Signs On The Crane

    Safety precautions and warnings 3.3.3 3.3.3 Signs on the crane ADC kg 4800 3200 2180 1540 1180 4350 2900 1960 1380 1020 10.8 12.9 15.1 17.4 19.3 ADC kg 4800 3200 2180 1540 1180 4350 2900 1960 1380 1020 387 2531 3.3.4 Maximum load [AR+] Lifting capacity Your crane has a certain lifting capacity, ex-...
  • Page 25 Safety precautions and warnings 3.3.4 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.

  • Page 26: Maximum Load Moment

    Safety precautions and warnings 3.3.5 Load diagram The load diagrams are placed on the column and show the maximum loads your crane / JIB (if fitted) / hoist (if fitted) may lift in the entire working zone (manual extensions excluded). The load diagram drawing will also be found in the enclosed Technical Data.
  • Page 27 Safety precautions and warnings 3.3.5 • 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:...
  • Page 28 Safety precautions and warnings 3.3.5 Always try to lift the load with the extension boom retracted, however not completely. The crane then has the greatest lifting capacity. Place the vehicle as close as possible to the load. Working below ground level If you have to load or unload below the level of the ground: keep the first boom angle to about 10 to 30°...

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

    Safety precautions and warnings Signals when using a crane [AR+] DANGER • If it is not possible to see the 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.
  • Page 30 Safety precautions and warnings Emergency stop for all movements by the crane. Raise the hands 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.
  • Page 31 Safety precautions and warnings Open the grapple Extend the arms at shoulder height, with the palms facing downwards. 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.

  • Page 32: 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 33 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 34: 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 35: 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 36 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 37: Service Platform [Option]

    Safety precautions and warnings 3.5.3 3.5.3 Service platform [option] DANGER Never operate the crane while standing on the service platform. The platform is only to be used when performing maintenance on the crane. Operator's Manual GB...

  • Page 38: Driving With The Crane

    Safety precautions and warnings 3.5.4 3.5.4 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: Use Of Demountable Cranes

    Safety precautions and warnings 3.5.7 WARNING • Clean the couplings, when connecting and disconnecting lifting accessories. Dirt can damage the hydraulic system. • Take care that your fingers are not trapped 3.5.7 Use of demountable cranes DANGER • Ensure that there are no unauthorized persons in the immediate vicinity of the crane.

  • Page 41: Ending Crane Operation

    Safety precautions and warnings 3.5.8 3.5.8 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 properly locked.

  • Page 42: The Duo 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 43 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 44: Components Of The Duo System

    The Duo system Components of the Duo system ① Main control valve ② User panel - Microprocessor Operator's Manual GB...

  • Page 45: Standard Symbols And Functions Of The Crane And The Stabiliser System

    The Duo 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 46 The Duo 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 47: Main Control Valve

    The Duo system 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.

  • Page 48: User Panel

    The Duo system User panel Functions: ① ON/OFF button to switch the control system on and off. When you push the stop button, all crane movements are stopped immediately. ② Stabiliser activation enables operation of stabiliser extensions and legs. The driver must have full view when operating the stabiliser extensions outward.
  • Page 49 The Duo system 4.7.1 Stabiliser operation Green light on: Stabiliser operation active. activation Green light flashing: Leg extension is in locked position. OLP Release Red light blinking: OLP Release active (crane, VSL or stabiliser leg) Green light flashing: Critical error. Manual extensions Green light on: Manual extension mode is active.

  • Page 50: Control Platform [Option]

    The Duo system Control platform [option] The platform is placed on the left side of the crane, with perforated anti-slip plate. • For manually controlled cranes: The platform is equipped for using tools and operated using six levers with control valve on the top.
  • Page 51 The Duo system DANGER Take care not to put your foot on the pedals when taking place in the high seat. Uninten- tional crane movements can occur. For safety reasons, it is necessary to sit down on the seat to operate the controls. Operator's Manual GB...

  • Page 52: 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 53: Set The Stabiliser System

    Starting crane operation ! NOTE • Rpm too high: the oil in the hydraulic system might overheat. Rpm too low: during crane operation, the vehicle engine could stall. • The maximum rpm may depend upon a governor on your PTO combination. Start the control system The operating levers must be in neutral position before start up.
  • Page 54 Starting crane operation Stability sector indication The operator must have full view of the stabiliser system when operating it. To confirm full view of the stabiliser system, button is pressed on the user panel on the side where the stabiliser system is to be operated.

  • Page 55: Activate The Stabiliser System

    Starting crane operation 5.2.2 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 56: Extend The Stabiliser Extensions [Ar+]

    Starting crane operation 5.2.3 5.2.3 Extend the stabiliser extensions [AR+] The procedure of setting the stabiliser extensions differs depending on the type of stabiliser exten- sions. Repeat the instructions for the stabiliser extension on the other side of the vehicle. For auxiliary stabiliser system [option]: Repeat the process.

  • Page 57: Set The Stabiliser Legs [Ar+]

    Starting crane operation 5.2.4 5.2.4 Set the stabiliser legs [AR+] The procedure of setting the stabiliser system differs depending on the type of stabiliser system. Repeat the instructions for the stabiliser extension and leg on the other side of the vehicle. For auxiliary stabiliser system [option]: Repeat the process.
  • Page 58 Starting crane operation 5.2.4 Non-tiltable stabiliser legs 1. Make sure that the stabiliser extensions are extended. 2. Operate the stabiliser leg downwards until it is set to the ground. Manual tiltable stabiliser legs 1. Make sure the stabiliser extensions are ②...
  • Page 59 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 60: Operate The Boom System Out Of Transport Position

    Starting crane operation Mechanically controlled tiltable stabiliser legs 1. Make sure the stabiliser extension is ex- tended a little and the stabiliser leg can be rotated freely of the vehicle. 2. Unlock the stabiliser leg lock ①. 3. Use the stabiliser leg lever to tilt the stabilis- er leg.

  • Page 61: Bda Boom Deployment Assistance [Option] [Ar+]

    Starting crane operation 5.3.1 5.3.1 BDA Boom Deployment Assis- tance [option] [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 62 Starting crane operation 5.3.1 Operate the boom system 1. Operate the second boom fully against the underside of the first boom ①. 2. Raise the first boom ②. 3. As soon as the first boom is raised to an angle where the second boom can go free from the crane base, raise the second boom ③.

  • Page 63: During Operation

    During operation Functions The control system provides a large number of functions. Certain functions are standard, others are options. 6.1.1 OPS Operator Protection System [option] OPS is a system that protects the operator from the boom system's movements when operating the crane.

  • Page 64: Ado Automatic Dump Function

    During operation 6.1.3 6.1.3 ADO Automatic dump function If a lever is not moved for 3 seconds, this function diverts the oil to the tank, thereby preventing the oil from overheating. The next lever movement stops the dumping and it func- tions as normal.

  • Page 65: To Release Olp

    During operation 6.2.2 OLP boom system When 100% of the maximum permitted pressure is reached, OLP cuts in and stops all functions that increase the pressure. The pressure level in the first and second boom is indicated by the LEDs on the user interface: •...

  • Page 66: Olp Release On User Panel

    During operation 6.2.3 DANGER Only use the OLP release to get the crane out of a locked position. Never use the OLP release to overload the crane deliberately! 6.2.3 OLP release on user panel Push and hold button on the user panel when operating load reducing functions.
  • Page 67 During operation To extend 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. 2. Stop the crane, by pressing the stop button. 3. Remove the locking device ① and the locking pin ②.
  • Page 68 During operation Activate and de-activate OLP for manual ex- tensions WARNING You must switch the OLP on and off manually for additional manual extensions! Activate: Push button on the user interface. The manual extensions are now included in the OLP protection. The lifting capacity will be reduced automatically.

  • Page 69: Change From Hoist To Hook Operation

    During operation Change from hoist to hook oper- ation ➃ ➂ ➅ ➄ ➀ ➁ 1. Remove the counterweight: • Remove the locking pin ①, the nut ② and the pin ③. • Release the rope. 2. Remove the rope from the top roller: •...
  • Page 70 During operation 3. Remove the rope from the rope guides: ! NOTE How to remove the rope depends on the crane model. The design and the number of rope guides depends on how many extensions the crane is equipped with. ➃...
  • Page 71 During operation 4. Remove the rope guides ➁ ➂ ➀ ➃ ➄ 5. Remove the rope guide from the first extension: • Remove the locking pin ① and the clevis pin ②. 6. Remove the rope guide from the 4th exten- sion: •...
  • Page 72 During operation • Remove the locking pin ①, the nut ② and the shaft ③. • Put the hook in place and fit the shaft ④. • Tighten the nut ⑤. • Secure with the locking pin ⑥. Operator's Manual GB...

  • Page 73: 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 74 Ending crane operation 7.1.1 3. Operate the 2nd boom against the underside of the 1st boom, as shown in the image. Make sure the position of the 1st boom is sufficiently high to do so. 4. Cranes with S-boom: Start to lower the 1st boom until the 2nd boom is horizontal.

  • Page 75: Placing The Stabiliser System In The Transport Position [Ar+]

    Ending crane operation Placing the stabiliser system in the transport position [AR+] DANGER Do not stand in the stabiliser legs, tilting area. WARNING Do not put your foot on the support plate. The procedure of operating the stabiliser legs differs depending on the type of stabiliser leg. Repeat the instructions for the stabiliser extension and leg on the other side of the vehicle.
  • Page 76 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. Manual tiltable stabiliser legs 1. Raise the stabiliser leg completely. ②...
  • Page 77 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 78: Retract The Stabiliser Extensions [Ar+]

    Ending crane operation 7.2.5 7.2.5 Retract the stabiliser extensions [AR+] The procedure of retracting the stabiliser exten- sions differs depending on the type of stabiliser extensions. Repeat the instructions for the stabi- liser extension on the other side of the vehicle. For auxiliary stabiliser system [option]: Repeat the process.

  • Page 79: Switching Off The Control System

    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. Break the security sealing on the dump valve.

  • Page 80: Emergency Operation Valve-V80

    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 security seal wire has been broken. 1. Break the security seal wire and remove the cap on dump valve 1.
  • Page 81 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 security seal wire has been broken. 1. Break the security seal wire on dump valve 2.

  • Page 82: Twi Transport Warning Interface

    Ending crane operation TWI Transport warning inter- face WARNING If you switch off the control system when manual operated stabiliser extensions/tiltable stabiliser legs are not locked in the transport position, and/or if the first boom angle exceeds a certain specified angle, the indicator lamps for both the cylinders and the hoist will flash red for a while.

  • Page 83: 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 84: 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 85: 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 86: 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 87 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 88 Maintenance and Service 8.3.1 Add-on equipment and separate accessories (hoist etc.) • Check the cables, cable connections, the cable guides and the attachment points for the add- on equipment. • Maintain all add-on equipment, separate ac- cessories, auxiliary equipment etc. according to the instructions supplied with it.

  • Page 89: Monthly Inspection And Maintenance

    • 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. ! NOTE Always place the vehicle on level ground with the crane in transport position while checking the oil.
  • Page 90 Maintenance and Service 8.3.2 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. Lubrication schedule • Carry out the lubrication according to the instructions.

  • Page 91: Annual Maintenance

    Maintenance and Service 8.3.3 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. Hydraulic oil • Change the hydraulic oil.
  • Page 92 Maintenance and Service 8.3.4 Interval Action Operating material First change of gear oil After 100 oper- ating hours, lat- est after 6 months Gear oil SAE 80W- Gear oil control*** Every 3 months After 1000 op- Change of gear oil erating hours, latest after 1 year...

  • Page 93: Check Rope

    Maintenance and Service 8.3.5 8.3.5 Check rope WARNING As ropes undergo very heavy strain and are not of permanent durability, it is important for the safety of the hoist system and like this for their operating personnel, to carry out a thorough check-up and to renew the rope in time.

  • Page 94: Course And Requirements Of The Rope

    Course of the rope CW (clockwise) Course of the rope CC (counter clockwise) Rope requirements For the hoists we recommend a rotating resistant rope, cross lay to the right. Always use HIAB original rope. hoist rope Ø possible hoisting force...

  • Page 95: Change Of Rope

    ! NOTE ➁ ➀ ➂ Always use HIAB original rope. Old rope has to be discarded 1. Spool off the rope without load, until the last three safety windings are left. 2. Stop and turn the drum slowly until you have access to the rope pocket ①.
  • Page 96 Maintenance and Service 8.3.8 Install a new rope 1. Guide the rope through the top roller and ➂ ➁ ➀ the rope guide/s. 2. Insert the rope end through the rope inlet ③ into the rope wedge ②. Insert both in the rope pocket ①.

  • Page 97: Maintenance And Monitoring Of Rope End

    Maintenance and Service 8.3.9 8.3.9 Maintenance and monitoring of rope end Inspection of the wear pad ①. ➁ CAUTION In order to prevent possible damage to the rope, the wear pad ① ① must be replaced, before metal of the clamp ② ② or the screws ③...

  • Page 98: Lubrication Schedule

    Maintenance and Service 8.4.1 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 2, ESSO UNIWAY EP2 N, AGIP GR MU/EP3, NYNÄS UNIFETT EP. ! NOTE Avoid grease with graphite or molybdenum- disulphide additives.

  • Page 99: Lubrication Of The Upper Column Bearing

    Maintenance and Service 8.4.2 8.4.2 Lubrication of the upper column bearing 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! ! NOTE...

  • Page 100: Lubrication Of The Hooks

    Maintenance and Service 8.4.4 • Again lubricate with a little grease. Repeat, until the column has been slewed round completely. 8.4.4 Lubrication of the hooks • Hooks with plane bearing. If the hook cannot rotate easily without load: 1. Lubricate the plane bearing surfaces ①. Use a heavy duty penetrating spray grease, type "ZEP 2000"...

  • Page 101: Hydraulics

    Maintenance and Service Hydraulics 8.5.1 Slewing housing: checking the oil level/oil change Checking the oil level in slewing housing 1. Check if the oil level on the measuring stick is between the maximum and mini- mum levels. 2. If the oil level is below the minimum level: Top up through the hole for the measuring stick with transmission oil of type MIL-L- 2105C or API-GL-5, viscosity SAE-80W-...

  • Page 102: Changing The Hydraulic Oil

    Maintenance and Service 8.5.3 8.5.3 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.
  • Page 103 8.5.3 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 - DIN 51524 part 3 HVLP...
  • Page 104 -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 105: Bleeding Air From The Hydraulic System

    ! NOTE Only filter cartridges from Hiab must be used. If non-Hiab supplied cartridges are used, warranty claims will be void. • The hydraulic system must be switched off before any work is carried out on the filter.

  • Page 106: Replacing The Cartridge In High Pressure Filter

    Maintenance and Service 8.5.6 • When changing a filter cartridge, a high level of cleanliness must be observed. • Never unpack a new filter until just prior to the installation of the filter. • Replace the filter cartridges as recommended: After the first 50 operating hours.
  • Page 107 (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 108: Replacing The Cartridge In Return Oil Filter

    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 109: Check Gear Oil

    Maintenance and Service 8.5.8 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 110 Maintenance and Service 8.5.8 WARNING The gear oil must not be mixed with synthetic oil. Gear oil control ➁ The hoist should be in horizontal position • Turn the screw ① to check if oil is leaking. If no oil is leaking, corresponding oil has to be filled in through the filling screw ②.

  • Page 111: Change Of Gear Oil

    Maintenance and Service 8.5.9 8.5.9 Change of gear oil First change of gear oil: after 100 operating hours, latest after 6 months. The hoist should be in horizontal position Heat gear oil: if necesary, completely pay out and reel in rope once. Drain off the oil: Spool off the rope until there is access to the screw ②.

  • Page 112: Troubleshooting

    Maintenance and Service Troubleshooting 8.6.1 Main fuses If the microprocessor detects a fault, this must be rectified immediately. Fault Probable cause Action The control system does not Defective fuses. 1. Replace faulty fuses work at all. in the: The indicator light next to - vehicle On/Off button on the user - standard box...

  • Page 113: 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 114 The stabiliser extensions do Contact a HIAB service not slide out/in. (Chain-driv- Incorrect chain tension. workshop. en stabiliser system) Go to a HIAB service work- Check valve damaged. shop. Go to a HIAB service work- The stabiliser leg cylinder Cylinder internal leakage.
  • Page 115 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 116: Display [Option]

    Maintenance and Service 8.6.3 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. To be able to select an item press the menu toggle button or the OK button.
  • Page 117 Maintenance and Service 8.6.3 If this item is selected the truck slewing sector diagram is shown. The diagram shows six sectors surrounding the crane. In each sector a percentage of maximum lifting capacity available is shown. High stability in a sector will give a high percentage of lifting capacity.

  • Page 118: 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 119 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 120: 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 121: Performance Data Tc1, Rope Capacity

    Technical Data 10.4 CAUTION The operator has to arrange for the GÜ on basis of determination of the used share of the theoretical using time, respectively latest after 10 years of use. (See BGV D8, as well as FEM 9.755 latest editions).

  • Page 122: Abbreviations

    Technical Data 10.5 10.5 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 123: 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 124 This page is intentionally blank. Operator's Manual GB...

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